Symbols Page No 22 PDF

AN NEXURE-2
ENGINEERS FORMAT FOR COMMENTS

OF 6-68-0021
$1. gZIT 054-63
-- INDIA LIMITED
■
It
& COMPLIANCE SHEET
Page 1 of 1
Filled-up, signed & stamped compliance sheet shall accompany each re-submission of
civil-structural document/ drawing by the contractor:
Document No. : Rev. No.:
Date of Submission: Date of Review:
Review Code: ❑ 1 ❑2 ❑ 3 DR oV
Sl. Contractor's Response

Reference Clause PMC Comments
No.
1.
4.
5.
6.
7.
8.
9.
Review Code Legend:
Code 1 No comments.
Code 2 Proceed with manufacture/ fabrication as per commented document.

Revised document required.
Code 3 Document does not confirm to basic requirement as marked.

Resubmit for review.
R Retained for Records.
V Void.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 1146 of 2065

CHECKLIST FOR ANNEXURE-3
er ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
5tga tialer., INDIA LIMITED
NORMAL FOUNDATIONS Page 1 of 1
Project: Job No.:

Document No.: Rev. No.:
Document Title:
SR. Tick Mark

CHECK/ CONTROL POINTS
NO. as per Legend
Founding level/ depth of foundation with respect to HPP/ FGL/ NGL/ EGL/
1
FFL (strike out whichever is not applicable).
2 Requirement & Level of plinth/ tie beams.
3 Type, Shape & Dimensions of footing.
4 Adequacy of loading for foundation.
5 Correctness of the design forces as per analysis.
6 Selection of critical loading cases/ combinations.
7 Long/ short column effect for pedestal.
8 Size of pedestal:
a) type of anchor bolts
b) bolt spacing (with respect to clearance between the bolts)
C) edge distance of anchor bolts
d) depth of embedment of anchor bolts
9 Location co-ordinates & Orientation with respect to North direction.
10 Conformance to Geotechnical recommendations:
a) check for SBC at founding depth (w.r.t. settlement/ shear)
b) consideration of ground water table.
c) check for FOS against overturning, sliding
d) increase in SBC (limited to 25% for wind or seismic/ 100% for blast)
e) spacing of piles (within group & inter-group)
f) pile cut-off level
g) load check conforming to pile capacity
h) increase in pile capacities (limited to 50% for vertical & 25% for lateral
for wind/ seismic/ 50% for blast)
Projection of foundation outside battery limit is co-ordinated with Civil
11
Department for under-ground piping, etc.
12 Ductile detailing requirements for reinforcement, wherever applicable.
13 Internal co-ordination with all concerned departments.
Date: Name & Signature
Legend :
✓ : Check carried out and found OK

1,4 NA : Check carried out and found not applicable
Page 1147 of 2065

CHECK LIST FOR ANNEXURE-4
ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
INDIA LIMITED
Ik st g-aw FOUNDATION FOR
Page 1 of 1
ROTATING EQUIPMENTS
Project: Job No.:

Document Title:
SR. Tick Mark

CHECK/ CONTROL POINTS as per Legend
NO.
I Approved (at least review code 2) inputs available.
Complete loading data:
a) reference line of machine, base frame dimensions and suction side &
discharge side (for pumps)
b) size of block/ deck, pedestal above HPP
,-)- c) static/dynamic loads (or dynamic load factor) & their location of
application (as per vendor)
d) permissible limiting values of vibration parameters
e) pocket dimensions, locations
f) grout type & thickness
g) whether anti-vibration pads are provided
3 Founding level/ depth of foundation w.r.t. HPP/ FGL/ NGL/ EGL/ FFL
Value of C„ & net SBC from soil recommendations.
4
For pile foundations, the pile stiffness value.
5 Amplitude of vibration and resonance check in required modes.
6 No fouling with adjacent foundation as per equipment layout.
7 Check for limiting size of element(s).
Check for critical speed, whether the machine is variable speed or fixed
speed?
8 If variable speed motor is used, whether amplitude has been checked
considering the machine speed same as the natural frequency of the
foundation system.
9 Minimum reinforcement requirement as per IS:2974.
10 Specified number of construction joints & their details.
I1 Note for single pour.
Leeend :

✓ NA : Check carried out and found not applicable
Format No. 8-00-0001-F1 Rev. 0 Copyright El L — All rights reserved
Page 1148 of 2065

,:11ENGINEERS ANALYSIS & DESIGN OF
077
, ,- Ofirec, INDIA LIMITED LIQUID RETAINING
OF 6-68-0021
Page 1 of 1
STRUCTURES
Project: I Job No.:

Document No.: L Rev. No.:
Document Title:
SR. Tick Mark

NO. as per Legend
I Design method (cracked or un-cracked) to be identified for each element.
Check for stability & uplift as per respective structure/ pit/ tank w.r.t. water
- table at various stages of construction.
3 Requirement of minimum thickness & reinforcement.
4 Reinforcement provided on both faces (for slab & walls).
5 Treatment to be given on surfaces in contact with earth.
6 Anti-corrosive treatment for structures storing corrosive liquids.
Requirement of joints, water stops, puddle flanges, giving notes for
7
execution sequences.
Legend :
: Check carried out and found OK

Page 1149 of 2065

,31
`-tia_le-i ENGINEERS
ANALYSIS & DESIGN OF OF 6-68-0021
ogar laWeg INDIA LIMITEDIA Govt of Ind,. Undertaking, CONCRETE BUILDINGS Page 1 of 4
Project: Job No.:

Document Title:
SR. Tick Mark

NO.
1.0 Availability of Inputs
1.1 Approved Architecture drawings of building
1.1 Approved Plot Plan
1.3 Approved related Area Drawings
1.4 Contour plan
1.5 Approved Geotechnical Recommendation
1.6 Approved Electrical Drawings for Substation Building
1.7 Approved Instrumentation Drawings for Control Room Building
1.8 Vendor Inputs for:
a) Air Conditioning Equipments
b) Transformers etc.
c) Lift
2.0 Correctness of Inputs
2.1 With respect to Architecture Drawings:
a) Framing arrangement.
b) Level & Location:
i) Co-ordinate of building
ii) Finished Ground Level
iii) Finished Floor Level
iv) Approach Road Level
c) Brickwork arrangement
i) Length/ height of brickwork.
ii) Stability check for brickwork with Steel frame.
iii) Flushing of Brickwork with frame structure.
iv) Brick supporting arrangement for Rain water Pipe
encasing.
d) Requirement of expansion joints as per codal provisions.
e) Arrangement & levels of false flooring & false ceiling.
f) Clear height of floors.
g) Cross-checking of elevations at FFLs of Ground Floor, Upper
Floors, Roof etc., w.r.t. FGL, Approach Road Level.
h) Monorail location & extent of monorail beam for Substation
building.
2.2 With respect to Mechanical Drawings:
a) Lift Pit Size and loading available in Approved Mechanical/
Vendor Drawing.
b) Machine Room Details available in Approved Mechanical/
Vendor Drawing.
c) Cut-out details for duct in AC Plant room/ AHU rooms in
Approved Mechanical/ Vendor Drawing.
d) Details of pedestals for AC Plant/ AHU in Approved Mechanical/
Vendor drawing.
e) Monorail location & Capacity as per Approved Mechanical
drawing.
Page 1150 of 2065

el ENGINEERS
Ogar 2154--eg INDIA LIMITED ANALYSIS & DESIGN OF OF 6-68-0021
rtirefir ,iikairviati Jos., IA Ctoki of India Undertaking,
CONCRETE BUILDINGS Page 2 of 4
SR. Tick Mark

NO.
2.3 With respect to Electrical Drawings:
a) Transformer details.
b) LT-FIT Switch gear panel location.
c) Cable trench layout.
2.4 With respect to Instrumentation Drawings:
a) Panel resting arrangements.
b) Cable tray details.
c) Pipe sleeves details.
d) MCT location.
e) Cable tray in superstructure.
f) Cable trench layout.
2 .5 With respect to General Civil Area Drawings:
a) Co-ordinates of building
b) Orientation of building with respect to North direction.
c) Approach Road level/ Finished Ground Level.
d) Contour for NGL from Plot Plan.
e) Fouling with existing/ proposed facilities from Area/ Foundation
drawing.
0 Underground facilities from Area Drawing.
2.6 With respect to Geotechnical Recommendation:
a) Type of foundation (Shallow or Pile).
b) Depth of foundation.
c) Net Allowable SBC for foundation from Geotechnical Report.
d) Pile Capacity from Geotechnical Report.
e) Diameter of Pile & Spacing of Piles from Geotechnical Report.
f) Specification of Piling.
g) Drawing of Pile.
3.0 Design Aspects
3.1 Structure is analysed as 3D Framed Structure.
3.2 Uses of Codes as per approved EDB:
a) For Concrete (IS:456/ IS:13920)
b) For Steel (IS:800)
3.3 Grade of Material as per approved EDB:
a) Concrete
b) Reinforcement
c) Structural Steel
3.4 Covers as per approved EDB:
a) Foundation
b) Column
c) Beam
d) Slab
e) Wall
3.5 Checking of Minimum thickness as per approved EDB:
a) Foundation
b) Column
c) Beam
d) Slab
e) Wall
3.6 Loadings
Copyright EIL — All rights reserved

Format No. 8-00-0001-F1 Rev. 0
Page 1151 of 2065

~stn
5fga g
1731,PT,1
ENGINEERS
INDIA LIMITED
(A C.A uf Inclo lindenalng)
ANALYSIS & DESIGN OF
CONCRETE BUILDINGS
OF 6-68-0021
Page 3 of 4
SR. Tick Mark

NO.
3.6.1 Dead Load:
a) Self weight
b) Slab load
c) Brick load
d) Gutter/ Parapet load
3.6.2 Live/ Imposed load as per approved EDB for panels, ducts, cables etc. on
floor, roof canopy, passage, lobby & stair case:
a) Office Building
b) Administrative building
c) Substation building
d) Control room
3.6.3 Seismic Load as per approved EDB:
a) Method of Seismic Analysis (Seismic Coefficient/ Response
Spectra).
b) Importance factor (Mention Value).
c) Response reduction factor accordingly consideration of ductile
detailing (Mention Value).
d) Damping factor (Mention Value).
e) Type of soil.
f) Type of structure.
g) Time period for frame structure as per IS:1893.
3.6.4 Wind load for Shed type Building
a) Basic Wind Speed (Mention Value).
b) Probability Factor (k1) (Mention Value).
c) Terrain, Height, Structure Size Factor (k2) (Mention Value).
d) Topography Factor (k3 ) (Mention Value).
Blast load for Control Room shall be as per RRA report (Mention Blast
3.6.5
Pressure).
3.6.6 Load combination shall be as per approved EDB:
3.7 Design of concrete member of building shall be as per IS:456/ IS:13920.
3.8 Ductile detailing requirements for Reinforcement, wherever applicable.
3.9 Slenderness check for design of columns.
3.10 Crack width of beam/ slab.
3.11 Deflection of slab/ staircase.
3.12 Foundation design.
3.12.1 Fouling of under-ground cable trench with foundations/ plinth beams etc.
3.12.2 Alignment of plinth beams with brick walls.
3.12.3 Factor of safety against overturning & Sliding as per approved EDB.
Checking of SBC/ pile capacity as per approved Geotechnical
3.1—.4
Recommendation.
3.12.5 Maximum allowable settlement of soil as per approved EDB
3.12.6 Checking of modified pressure calculation in case of tension occurred.
3.12.7 Increase in stress shall be as per Geotechnical Recommendation.
3.12.8 Minimum percentage of reinforcement as per approved EDB
3.12.9 Minimum spacing of reinforcement bar as per approved EDB.
4.0 Internal coordination with other departments.

Page 1152 of 2065

ENGINEERS
dgar Hales INDIA LIMITED ANALYSIS & DESIGN OF OF 6-68-0021
ele,r.mr,nrd IA Govt of India Undenakinc0
CONCRETE BUILDINGS Page 4 of 4
SR. Tick Mark

NO, as per Legend
5.0 MTO for super structure & Substructure
a) Area of building
b) Concrete in foundation
c) Concrete in superstructure
d) Reinforcement in foundation
e) Reinforcement in superstructure
f) Reinforcement per Cu. M. of Concrete for foundation
g) Reinforcement per Cu. M. of Concrete for superstructure
Legend :

Page 1153 of 2065

.0'itia,z1e1. . ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
s- lgar tfil&,- INDIA LIMIT-ED
UndertA
SHED TYPE BUILDINGS Page 1 of 1
Project: Job No.:

Document Title:
SR. Tick Mark

NO.
A SUB-STRUCTURE
1 Refer separate checklist for foundation.
2 Check fouling with machine/equipment foundation.
B SUPER-STRUCTURE
1 Check the clear gap for isolation of rotating machine foundation.
/ Requirement of roof monitor, extent of side cladding & height of parapet
wall.
3 Identification of braced bay & maintenance bay.
4 Whether provision of extension of shed by one bay considered (for future).
Live loads & superimposed loads at various locations, including crane
5
loading & centerline distance between rails
6 Check the critical load combination for design.
7 Check the horizontal (transverse & longitudinal) deflections.
8 Check flooring details conforming to likely superimposed load.
9 Compatibility between pedestal level & anchor bolts with base plate details.
Check whether correct limiting values of slenderness ratios for structural
10
elements (columns, beams, bracings, etc.) used in design.
Check whether correct effective lengths of structural elements (columns,
11
beams, bracings, etc.) used in design.
Check whether minimum 90% mass participation achieved (in both
12
horizontal directions) for calculating seismic forces.
13 Check over-all compliance to approved Architectural drawings.
Legend :

Page 1154 of 2065

ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
51.4-4101g16.-; INDIA LIMITED
(;ost TECHNOLOGICAL/
Page 1 of 2
PROCESS STRUCTURES
Project: Job No.:

Document Title:
SR. Tick Mark

NO.
A SUB-STRUCTURE
2 Check fouling with equipment foundation.
B SUPER-STRUCTURE
Material of construction as per engineering design basis of the project and
1
departmental guidelines.
2 Check the application of equipment load (correction, magnitude & location).
Live load/ superimposed load considered for respective level/ floor, air-
' coolers, fire proofing load, etc. where applicable.
4 Whether loading due to one extra floor considered (for future expansion).
Check the estimation of seismic/ wind force to be applied at respective
5
level/ floor.
Check whether critical design forces from various likely load combinations
6
have been considered for the design of structural element/ foundation.
Identify critical areas where limiting beam sizes need to be provided for
avoiding any fouling.
Location of braced bay, co-ordinated with Piping. Bracing angle is within
8
30° & 60°. Plan bracing considered.
9 Check the horizontal (transverse & longitudinal) deflections.
Check the capacity of overhead mono-rails & its location with extent (in &
10
outside plan dimensions) w.r.t. the respective equipment.
Verify whether all vertical & horizontal piping loads have been correctly &
11
completely taken care.
Equipment supporting arrangement - check fouling with bottom nozzle or
12
hood.
Arrangement of intermediate/ secondary beams to clear opening
13
requirements.
14 Inter-connection with pipe rack.
Joint details:
16 a) reference standard no. is furnished
b) details for connections not available in standard are furnished
Compatibility between member sizes in General Arrangement &
17
Reinforcement Details (in drawing).
18 Whether integrated analysis done with equipment/ piping.
19
/0
1I Check whether minimum 90% mass participation achieved (in both
Page 1155 of 2065

ias eltq ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
Ogar taireg INDIA LIMITED
ttl, 01,13, t t mt. ll+.ertak,,,,p TECHNOLOGICAL/
Page 2 of 2
PROCESS STRUCTURES
SR. Tick Mark

NO.
Check requirement of ductile detailing for reinforcement (for concrete
?,-)
- elements).
23 Summation of applied forces matched with reactions.
Legend :
: Check carried out and found OK


Page 1156 of 2065

1cI Ei ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
,fit Ofireg ',pm, INDIA LIMITED
PIPE RACKS
Page 1 of 2
(UNIT/ OFFSITE)
Project: Job No.:

Document Title:
SR. Tick Mark

NO. as per Legend
A FOUNDATION
B SUPER-STRUCTURE
Layout and configuration of pipe rack conforming to piping inputs/
1
approved equipment layout.
Levels of pipe rack/ tiers conforming to piping inputs/ approved equipment
layout.
Whether load due to one extra tier considered (for future expansion) to be
3
confirmed by Piping/ PMC.
Location of expansion joints and braced bays coordinated with Piping
4
department.
Material of construction as per engineering design basis of the project,
including fire-proofing requirements.
Check the loading considered given by piping conforming to the
6
requirement of design basis, including for fire proofing where applicable.
Check consideration of friction/ anchor/ guide loads as per design basis and
7
as forwarded by piping.
Check the layout & loading of Air-coolers including supports required for
8
inlet & outlet piping.
Check the routing of electrical cable trays & instrument duct to be supported
9
on the pipe rack and their respective loading as per design basis.
i0 Check the horizontal & vertical clearances at road/ railway crossings.
Location and arrangement of vertical & horizontal bracing fulfilling design
I1
requirements and confirmed by piping
Check whether additional load due to extra length of pipes have been
12
considered or not at the location where pipes are rising or getting dropped.
Check the level at top of grout w.r.t. actual profile of ground levels for off-
13
site pipe rack.
14 Local design checks at junction locations
Whether any two-phase flow lines are there? If yes, have these been taken
15
care as per the Design basis.
Joint details:
17 a) reference standard no. is furnished
b) details for connections not available in standard are furnished
Compatibility between member sizes in General Arrangement &
18
Reinforcement Details (in drawing).
19 Transverse beams are designed for horizontal bending.
20 Tray support members are provided as per electrical guidelines.
21 Battery Limit platform & approach for the same.
22 Bracing angle is within 30° & 60°.
23 Inter-connection with technological structures.
Page 1157 of 2065

611faaeitAY16--
1% ENGINEERS ANALYSIS & DESIGN OF
IfgarttR.eg ' INDIA LIMITED OF 6-68-0021
PIPE RACKS
Page 2 of 2
(UNIT/ OFFSITE)
SR. Tick Mark

NO. as per Legend
24 Fouling of vertical bracing with anchor bolt in pedestal (in drawing).
15
16
Check whether minimum 90% mass participation achieved (in both
27
Check requirement of ductile detailing for reinforcement (for concrete
28
elements).
Legend :

Page 1158 of 2065

J1 el ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
Ogar ttfReg INDIA LIMITED
;A Go, ot LJrvIelokr-gj
TALL STRUCTURES
Page 1 of 1
(CONCRETE/ STEEL)
Project: Job No.:

Document Title:
SR. Tick Mark

NO. as per Legend
A SUB-STRUCTURE
B SUPER-STRUCTURE
1 Check wind & seismic parameters considered.
2 Check estimation of wind forces.
3 Check estimation of seismic loads.
4 Check structural configuration and bracing system (vertical & horizontal).
5 Check analysis corresponding to critical wind/ seismic direction.
6
Check whether critical maximum design forces have been considered from
8
various load combinations for the design of respective elements.
9 Check for permissible horizontal (transverse & longitudinal) deflections.
Legend :

Page 1159 of 2065

r31 ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
gZff la
51= INDIA LIMITED
CONVEYOR GALLERIES
Page 1 of 1
& TRESTLES
Project: Job No.:

Document Title:
SR. Tick Mark

NO.
A SUB-STRUCTURE
I Refer separate checklist for foundation.
B SUPER-STRUCTURE
Check the system stability & dynamic analysis as per design basis/Job
1
specification.
Check the correctness in estimation of wind pressure corresponding to right
2
- shape factor for exposed members.
3 Check the lateral load transfer from gallery to top of trestle.
Check the supporting arrangement of gallery for keeping proper provision
4
for expansion, check limiting vertical deflection.
5 The analysis & design shall conform to the erection scheme being adopted.
6 lnte nal co-ordination with all concerned departments.
Legend :

Page 1160 of 2065

51
1 fa_Je-1 ENGINEERS ANALYSIS & DESIGN OF
KR-e-g*iir). INDIA LIMITED OF 6-68-0021
■
H1,7, et,1 (o,1 inaxl FOUNDATION FOR
Page 1 of 1
STORAGE TANKS
Project: Job No.:

Document Title:
SR. Tick Mark

NO. as per Legend
Check equality of bottom pressure below ring wall and intermediate
I
compacted soil mass.
Check the detailing/ arrangement of ring wall w.r.t. anchor bolts and clean
- out drain, requirement of minimum edge clearance for Anchor Bolt.
, Check the thickness, size, shape and spacing of piers with protective
...)
coating/ lining for tanks storing corrosive liquid.
Check the special requirements/ consideration (size, solid concrete slab
4 below bottom plate, anchorage, counter weights etc.) for storage tanks
storing liquids at high pressure and/ or high/ low temperature.
5 Location co-ordinates & Orientation w.r.t. North direction.
Legend :

: Check carried out and found not applicable
Page 1161 of 2065

,46ilfazie-if-,, ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
5taar faiter; INDIA LIMITED
Go, , FOUNDATION FOR
Page 1 of 1
STATIC EQUIPMENTS
Project: Job No.:

Document Title:
SR. Tick Mark

NO. as per Legend
I Design loads as per approved data sheet.
Check the input files for:
a) depth of foundation
2 b) depth of water table
c) wind/ seismic load as per Design Basis
d) support details as per data sheet
Check the out-put file for:
, a) SBC conforming to Geo-Tech Recommendations
..)
b) FOS against overturning
c) size restriction for likely fouling
Legend :

Page 1162 of 2065

i~IGieiei ENGINEERS ANALYSIS & DESIGN OF OF 6-68-0021
0011, INDIA LIMITED
f.k.1 irxtii, FURNACE FOUNDATIONS Page 1 of 1
Project: Job No.:

Document Title:
SR. Tick Mark

NO. as per Legend
I Loading as per approved data sheet of equipment
2 Additional load due to supported ducts/ lining
3 Check for SBC at founding level and FOS against overturning
4 Size limitations if any to avoid fouling
Legend :

INA : Check carried out and found not applicable
Page 1163 of 2065

41 MD, ENGINEERS PREPARATION OF OF 6-68-0021
INDIA LIMITED
STRUCTURAL DRAWING Page 1 of 3
Project: Job No.:

Document Title:
SR. Tick Mark

NO,
1 GENERAL
a Drawing number is as per approved DCI
b Electronic file number is as per approved DCI
c Draughting is as per design requirements
d North line/ orientation as per input data
e Notes comply with Job Specifications and General Notes
f Field notes for specific instructions/ scope of work defined
Layout of grids and spacing/ dimensions/ equipment location, support,
g orientation etc. as per input data
h Referenced Drawings specified
i Referenced Standards specified
If not adequately clear in General Notes, grade of concrete and grade of
.1 reinforcement bars specified
k Bill of materials furnished (for the detailed portion)
Necessary internal co-ordination done with relevant departments as per
1
requirements
m Resolution/ incorporation of comments received
2 FOUNDATIONS
Coordinates/ location is as per input data, suction side & discharge side (for
a
pump foundations) as per layout drawing
Referenced level and elevations specified are as per approved General Civil/
b
Architectural drawings/ Piping GAD (viz. NGL/ FGL/ HPP)
c Elevation/ depth of foundation bottom furnished
d Fouling with surrounding foundations/ services cleared
e Any extra cover for rebar required and specified
f Any extra minimum cement content required and specified
g Thickness, projection and grade of lean concrete specified
Anchor bolt location and orientation specified
Adequacy of foundation depth checked to accommodate anchor bolt
assemblies
J Anchor bolt description (as per standard) specified
k Depth of pockets specified
1 Minimum cover on anchor bolts/ pockets checked
m Fouling between anchor bolt assembly and pedestal rebar checked
n Grout thickness specified
o Reinforcement provided as per design/ codal requirements
Page 1164 of 2065

mad ENGINEERS
Ogui tVe--E; INDIA LIMITED PREPARATION OF OF 6-.68-0021
,rtfia Undert*.)1
SR. Tick Mark

NO, as per Legend
p Links and ties detailed
q Dowel lengths for column rebars staggered and specified
r Depth of machine foundations with respect to building foundations checked
s Separation detail for machine foundations and pouring sequence given.

Requirement of water bars at construction joints for liquid retaining
t
structures furnished
u Requirement of protective painting
Field note for sequence of construction, if adjoining foundations are at
v
different level
For pump foundations, following field note shall compulsorily be added in
foundation drawings:
w "The pump discharge nozzle is facing towards North/East/West/South".
(appropriate direction shall be selected as per layout drawing, in case
discharge is upwards, direction of suction nozzle shall be specified)
3 SUPER STRUCTURE Reinforced Cement Concrete
a Layout is as per approved Piping GAD/ Architectural drawings
b Requirement of expansion/ separation joints checked
c Anchor bolt location and orientation specified
d Anchor bolt description (as per standard) specified
e Pockets for bolts located/oriented and specified
f Depth of pockets/ length of bolts in RCC members checked
g Minimum cover on anchor bolts/ pockets checked
h Fouling between anchor bolt assembly and rebar checked
i Grout thickness specified
j Reinforcement provided as per design/ codal requirements
k Cut-outs as per requirement provided with edge protection
1 Slope has been provided over RCC roof
m Curb around all openings

n Insert plates & pipe sleeves provided wherever required
o Extra reinforcement around cut-outs & openings
p Dowel bars for lap length & anchorage length
q Nominal links in column, stin-ups for beams & their arrangement
4 SUPER STRUCTURE Structural steel

a Layout is as per approved Piping GAD/ input drawings
b Requirement of expansion/ separation joints checked
c Bolting details for equipments specified
d Member sizing and connection details furnished
e Grating/ chequered plate requirements with supporting members furnished
f Welding requirements furnished
g Fire-proofing requirements furnished

Page 1165 of 2065

31 ENGINEERS
ligat rtA,PRI, INDIA LIMITED PREPARATION OF OF 6-68-0021
r;,:, 04 ,rea. Undertak.g,
SR. Tick Mark

NO. as per Legend
h Requirement of removable floor/ handrails checked
i Requirement of grouting holes in base plates specified
j Vertical & Horizontal bracings provided as per piping clearance
k Splicing location has been proposed/ suggested
I Approach staircase/ ladder provided with proper landing at entry point
m Toe plate around openings
n Stiffness/ diaphragm plates have been suitably provided
o Vertical clearance below monorail beam checked
Capacity of monorail specified & structurally stable cantilever projection
P given
Drawing issued through DCIM (Document Control Index Module)
Legend :

Page 1166 of 2065

Page 1167 of 2065
Page 1168 of 2065
Page 1169 of 2065
Page 1170 of 2065
0'AelSA-L000-00-8 ON Ietwoj
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REF. UNE GIVEN ON GEN.
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Page 1177 of 2065

REFERENCE POINT STAGGERED RUNGS
(REF. STD. 7-65-0211)
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• vvor BRICK MASONRY IN
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c) REINFORCEMENT STEEL BARS
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GEN. CIVIL PCC M20 PARTS SHALL BE PAINTED WITH TWO COATS OF APPROVED ANTICORROSIVE PAINT.
AREA DRGS.
CD 5. DESLUDGING SHALL BE DONE PERIODICALLY EVERY YEAR PREFERABLY
-7/ BY A PORTABLE NON CLOG. PUMP.
Naaa.go
v.'.7■
A AA
O
0150/0250 (RCC PIPE) 6. 075 C.I. VENT PIPE (AS PER IS:1729) SHALL BE 3.0M MINIMUM HEIGHT FOR SELF
1 STANDING VENT. INCASE SEPTIC TANK IS LOCATED WITHIN 20M RADIUS FROM
HABITABLE BUILDING VENT PIPE SHALL BE EXTENDED FROM SIDE OF
PLAN DETAIL-1 SEPTIC TANK & TO BE BROUGHT NEAR TO THE NEAREST COLUMN/ BUILDING
(VENT ON SIDE) AND SHALL BE TAKEN AT LEAST 2.0M ABOVE THE HIGHTEST POINT OF
10 @ 150 C/C BOTHWAYS AT BOTTOM THE BUILDING/STRUCTURE. HOWEVER, THERE SHALL BE ONLY ONE
075 C.I. VENT PIPE WITH COWEL (ALT-I) 075 C.I. VENT PIPE FROM THE SEPTIC TANK, NEAR INLET PIPE.
R.C.C. SLAB (REF. NOTE-6)
(SEE NOTE-2) MANHOLE COVER & FRAME MEDIUM DUTY AS PER IS: 1726 7. EXACT THICKNESS OF BRICK MASONRY WALL SHALL BE AS PER LOCALLY
/OF GRADE MD-10 CIRCULAR 0500 CLEAR OPENING AVAIBLE BRICKS. HERE WALL THICKNESS HAS BEEN GIVEN AS PER BRICK
I I II DETAIL-1 750 SIZE OF 250X125X75.
1:2 CEMENT MORTAR JOINT 8. PROPORTION FOR NOMINAL MIX CONCRETE SHALL BE AS PER
TABLE 9 OF IS:456.
CD F.G.L.
CD
075 C.I. VENT PIPE
0500 111
PIPE WITH COWEL (ALT-II)
(REF. NOTE -6) O FOR CLEAR COVER
CD
CO
13 THK. CEMENT PLASTER 1:3
0 SEE NOTE-2
GROUTING IN 1:2 CEM. MORTAR lir250 II WITH WATER PROOFING COMPOUND RECOMMENDED DIMENSIONS OF SEPTIC TANKS
SIZE OF OPENINGS OUTER DIA. OUTLET LEVEL
OF PIPE + 100 (SQUARE) NO. OF USERS TYPE LENGTH BREADTH DEPTH
r471 TO SOAK PIT L B D
CD
CD
CD
0150 C.I. PIPE
INLET PIPE 10 I 2000 900 1075
O
CD *A
l I
0150/0250 (RCC PIPE)
8 @ 150 CLC 20 II 2300 1100 1385
HWAYS
Px
r
INLET LEVEL
CD 16 THK. CEMENT PLASTER 30 III 4000 1400 1400
(AS GIVEN ON GEN. CIVIL CD
CD
CD
cr) 1:3 WITH WATER PROOFING COMPOUND
AREA DRG.) 50 IV 4650 2000 1440
/
V
13 THK. CEMENT PLASTER
E
CD
62 1:3 WITH WATER PROOFING COMPOUND
100 THK. BAFFLE CD
RCC SLAB (SEE NOTE-2 PCC M20 (SCREED)
T10 @ 150 C/C SLOPE 1:20 FOR R.C.C. GRADE

BOTHWAYS AT BOTTOM SEE NOTE-2
CD
CD
PCC 1:5:10
757
50 750 750 50
/ FOR CLEAR COVER

SEE NOTE-2
SECTION A-A
4 21.01.13 REVISED AND ISSUED AS STANDARD Anil An--' DM STANDARD No.

SO1ticfel ENGINEERS 3 15.05.07 REVISED AND ISSUED AS STANDARD MSR • VC SEPTIC TANK
INDIA LIMITED 7-65-0216 Rev. 4
Ifgai fa- e5 riocbit,cli51,3isr)+4) (A Govt of India Undertaking)
Rev.
Date Purpose
Prepared Checked 1 SNRtd;BCommittee GM(ENGG) Stds. Bureau
Convenor Chairman
TYPE-I, II, III AND IV
by by Page 1 of 1
No. Approved by
Format No. 8-00-0001-F5 Rev. 0 Copyright E IL - All rights reserved
Page 1178 of 2065

EARTH FILLING(COMPACTED)
BRICK BATS FILLING 40mm 13mm THICK PLASTER IN
STRAW FILLING
NOTES:-
TO 50mm SIZE 11:3 CEMENT MORTAR
1. ALL DIMENSIONS ARE IN MILLIMETRES UNLESS OTHERWISE SPECIFIED.
, .,. 100 (TYP)
2. THE FIWNG OF BRICK BATS IN SOAKPIT SHALL BE DONE SIMULTANEOUSLY WITH CONSTRUCTION OF BRICK WALL AS WORK PROGRESSES.
FINISHED GROUND LEVEL
3. THE BRICKS SHALL CONFORM TO IS: 1077 (CLASS 5.0 MINIMUM).
7 ='01=>C-1 C6 D2' .t:711> qQ7,77

iS.
' :c2;,1<,
,c3D,xV1
XDOI::7,C7,ca_q...0.P.> -==, ei■
-v
450
FROM SEPTIC TANK
4. EXACT THICKNESS OF BRICK MASONRY WALL SHALL BE AS PER LOCALLY AVAILABLE BRICKS (HERE WALL THICKNESS
HAS BEEN GIVEN AS PER BRICK SIZE OF 250 X 125 X 75).
BEND 0150/0200/0250mm Cl/HDPE PIPE 5. C.I PIPE SHALL CONFORM TO IS:3486.
7 BRICK MASONARY CHAMBER
WITH DRY JOINTS 0 6. THE TABLE FOR SOAK PIT IS "READY FOR USE", IF FOUND SUITABLE AS PER SPACE AVAILABILITY. HOWEVER DEPTH AND DIA
/ 0 LEVEL GIVEN ON
LAYOUT DRG
CAN BE SUITABLY ADJUSTED TO GIVE THE EQUIVALENT ABSORPTIVE AREA DEPENDING UPON THE SUB SOIL WATER TABLE,
cA
iD8 c1 / BUT H SHALL BE 1.0M.
thg,n
—461. GROUTING I 1:2 FREE FLOW
/ Ze'e. N 7. BOTTOM OF THE SOAK PIT SHOULD NOT BE LESS THAN 600mm ABOVE THE SUB SOIL WATER LEVEL. SUB SOIL WATER LEVEL
ati
cD
') 75
P !).14,. / CEMENT MO TAR TYP
30MMTHICK 1:2CEMM
cNo,
A
° ,;,. / MEANS HIGHEST OBSERVED SUB SOIL WATER LEVEL.
/ 8. AS PER MANUAL ON SEWERAGE AND SEWAGE TREATMENT, MINISTRY OF URBAN DEVELOPMENT, NEW DELHI, 1987,
LOCATION OF SOAK PIT SHOULD BE MORE THAN 20M AWAY FROM ANY WATER SOURCES LIKE TUBE WELL ETC. AND MINIMUM
/ / 7.0M AWAY FROM NEAREST HABITABLE BUILDING.
9. SOAK PITS ARE NOT SUITABLE FOR IMPERVIOUS SOIL SUCH AS DENSE CLAY OR ROCK. IT IS ALSO NOT SUITABLE
/_ / IF THE PERCOLATION RATE OF SOIL EXCEEDS 30 MINUTES FOR 25mm ABSORPTION AS PER APPENDIX-A OF
IS : 2470 (PART-2).
/ /
Dab00 00°'
.
v
C7 YD
qft,
/
(11()K10
,
417,07
,1( 4
iDd v
4Do
4
k.7§D
(14
'!/
pv
250 D 1250
TABLE FOR SOAK PIT
SECTION A-A DEPTH DIA AREA OF ABSORPTION
TYPE NO.OF USERS H(METRE) D(METRE) ADH+7V4 D2 (M2)
1 10 2.0 2.0 15
2 20 2.5 3.0 30
3 30 3.0 3.7 45
4 50 4.0 4.7 75
5 100 5.0 7.1 150
6 150 5.0 9.7 225
PLAN
REVISED AND ISSUED AS STD. Gaurav RKS Sc STANDARD No.

5 05.06.14
ENGINEERS REAFFIRMED AND ISSUED AS STANDARD SKP RKS NK ND
Ifgar faaes
(Wen. eierPlelTSTJLICD+0
INDIA LIMITED
(A Govt. of India Undertaking)
Rev.
No.
4 20.05.09
Date Purpose
Prepared
by
Checked
by
Stds. Committee Stds. Bureau
Convenor Chairman
Approved by
DETAIL OF SOAK PIT 7-65-0217 Rev. 5
Page 1 of 1
Copyright EIL - All rights reserved
Page 1179 of 2065
/avavavavav
•7••••
•••••
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Page 1180 of 2065

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-T1 A. GI _I
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-I : (7: 0
Fil.-1
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m 0 -1:/ 0-)
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o m i..n m rn a I =
z
m Ts
v ei) In rn
(")
ar ....... 0
7J = K = 7.' C) Cl
(15. C rn MI 0 -•
-.1 VI
co = F° co --1 Q1
.4:.
Zm PC = 2., r- = m
I- rn =I A A < 71 8 . s MI .n
.7. ....... >C ri I- RI F I CD CI1
VI -"I :-... o- 0 p
1
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Page 1181 of 2065

19.
0 IV
Cn —10'W
1.1) CD
23
rn
-11 C)
250 1000 (B) c->

-o 250 , 500 , 250 -73
C71
zz
z 0
0.Aobl 9J-1-000-00-9 ON leuiJoj

I IL
111111PIMO
O
0 MAIM
1103S z
N0
-
391
1
0
O
I•3
O
CY1
13A03
(11
C-) r
n
CO
VI 0
M C,
—4 O
C)
rn
3
1,
3.
3. 01
0 (471 r- 113
CO CO O
0
100
m (1) IV. -1
-E, x x m
0i (.11
150 150
rri
7o © xr ›. v)
..4
!../2 t n
. 2 m --i
0 m-I--......
0 -• rI (1) 00 00
m 0- 0 mm0AN co 00 00
o
0 --• cn
.-..,_. M Ok' orn 0
N -1 c - X 0 -1.
00 00
i13 > RIX3 0 M 00 00
0 r- _...
z F Mm m -, „. to 0 00 00
Z -ri CD 0 0
)100H ONILill
D --i 0 C) x 00 00,
M.>. 44. O
■ 1 J
,1 '61
V. 0 00 00
0 --. 03 X Cr
O
0 0- I 0
= 0
0 *
0 >
0
Z.
-15 0
m
C/)
21Y18011 1N31433
2 z -4
cri 0
(11 ()4 Iv •-• rri •
0 0 0 0 o o 73
o o CO 0 w
-T1
m cC
OF
a) -P. N o o 9.3 1"-) z

b b b i•.) Co :1:-
-11 0
0
M ..
CD
"a--I, r..
m " cC
2
3 0s'" '7
c73
REQUIRED
-,1 2 m
m -I rn >'
-*
111 ?
. r11
Cm
v C
r r1"'i7i' . .:
:
''''
v_.D-.ij' V
M
m
3>
r 1)8
r31 1x.
: -...
' -.' !
L
r -0
-13 -o m (A rn
-I 23 V) D V)
co = 13 z -0
-n 2 0 =1 >
I- 24 m 0 > < ,,
cr) 4a.• N o o 1'
1 > 0 .7,Z ,_ z
0 co r-
FILTER MEDIA MEDIA
b b b is.) Co 'co Cr Z
CA 0 > C7 (i)
Si S4 .,4 = -r1 -0 >. > rn
PROVIDED
I---I v) 0
OF FILTER
3. ,n 1 6- (.,/
i- = r_ co -'1
1- r- 3
z - I =: 1- Mr1 -I 0 M 5 co
m c, xi xi
Pl
Ca 73 0 >
[
r1 rn
m V)
-4 ra-I(./7
CD n, co cr,
.
m 0
-.1 > > 3 72
-I-I0
2 <
)). z
C) rri 0 m 1.7, * 7C 73 > (sr)
0 73
MIN. VOLUME ACTUAL VOL. BREDTH
1.0
b b b b b > 77 0 3. 92 =4 n u) rn 0
IN METRE
Co 0 m .7Z < Z
M S 0 m > 1 „„ !:) ,
'S381311111111 NI 321V SNOISN3WI0
C) O C
IM
M 23-,-
-1 ; rn CO
M
M m CD 0 z
SHALL CONFORM TO I.S. 3489.
-T1 </) > 1°

"1
1.3 1-
I.-
2
PI C11 cm — 1- --
I ›*
I -
ul oi .... if 0
0 -0 (J)
0
),‹ -0
1.0
O i..1 .1 iv b M
THE PERCOLATION RATE OF SOILIS MORE THAN
Z 0M -■ Z 2
cn m 1- M is.., M
IN METRE
O
83338 S13A31 183ANI
7q.
THE TABLE FOR UPFLOW ANAEROBIC FILTER IS "READY
- - .... - O
o o
iv s., is.) b
IN METRE
Cn
io coo
o o 0 Coo
LENGTH (L) DEPTH OF
TI
FILTER MEDIA (D)
Copyright EIL - All rightsreserved
Page 1182 of 2065

STANDARD No.
Et•IGINFERS
SEIMONDIA LIMITED
01111/1MOIMill1.0 (A Got of bidlo Unclarta!dip)
METAL INSERT PLATES 7-68-0056 Rev. 6
Page 1 of 7
GENERAL NOTES :-
1. ALL LUGS SHALL BE OF HIGH STRENGTH DEFORMED BARS OF
GRADE Fe500/Fe500D CONFORMING TO 15:1786 (WITH GUARANTEED WELDABILITY)
AND SHALL BE CONNECTED TO METAL INSERT PLATES BY 6 mm
FILLET WELDS AS SHOWN IN SKETCHES.
2. METAL INSERT PLATES SHALL BE CONFORMING TO IS:2062 (GR—A/B).
3. METAL INSERT PLATES MARKED ON DRAWING REFER AS UNDER
IP—(A) 0 (C)
IP = INSERT PLATE
A = TYPE OF INSERT PLATE
C = ELEVATION OF INSERT PLATE (TOP EDGE)
e.g IP—R9a 0 EL.110.300 MEANS INSERT PLATE TYPE R9a AT EL.110.300.
4. METAL INSERT PLATES SHALL BE KEPT FLUSH WITH CONCRETE SURFACE.

5. THE LONGER SIDE OF METAL INSERT PLATE SHALL BE KEPT VERTICAL
UNLESS SHOWN OTHERWISE.
6. METAL INSERT PLATE ON COLUMN OR BEAM SHALL BE KEPT SYMMETRICAL

ABOUT q.OF COLUMN OR BEAM, UNLESS SHOWN OTHERWISE.
Nie( Q/-
6 23.10.12 REVISED AND ISSUED AS STANDARD VPS P.K.MITTAL s OHATURVEDI VINAY KUMAR D MALHOTRA
5 09.10.07 REVISED AND ISSUED AS STANDARD VP$ P.K.MITTAL VINAY KUMAR V.CHATURVE)I
Prepared Checked Stds. Committee CGM(E) Stds. Bureau
Rev
Date Purpose Chairman
hairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
Page 1183 of 2065

STANDARD No.
a ENGINEERS
NDIA UMRH)
(A Gov! of Nick Uncla-taking)
METAL INSERT PLATES
(LUG BENDING DETAILS)
7-68-0056 Rev. 6
Page 2 of 7
M.I. PLATE
12 4 LUG (TYP)
METAL INSERT DETAIL METAL INSERT DETAIL

ON TOP OF SLAB ON BOTTOM OF SLAB
M.I.
R.C.C. BEAM
METAL INSERT DETAIL

ON SIDE OF BEAM VIEW 1 -1
80
200
121 LUG
w = THICKNESS
OF M.I.
PLATE
M.I.
z
I-
150(LW) 12 1 LUG
M.I. PLATE
METAL INSERT DETAIL METAL INSERT DETAIL

ON BOTTOM OF BEAM ON COLUMNS
(FOR ALTERNATE DETAIL REF. SHT. 7 OF 7)
A+B = LUG EMBEDMENT REQUIRED
AS PER SHT. 4,5,6 OF 7
\kV "-O 'er

6 23.10.12 REVISED AND REISSUED AS STANDARD WS P.KAHTTAL MRWDI VINAY KUMAR D MALNOTRA
5 09.10.07 REVISED AND REISSUED AS STANDARD VPS P.K.MITTAL VINAY KUWAR V.CMW WM
Rev. Prepared Checked Stds. Committee CGM(E) Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001+4 Rev.0 Copyright EIL - All rights reserved
Page 1184 of 2065

STANDARD No.
METAL INSERT PLATES 7-68-0056 Rev. 6

liganibM IE
LPMTIS ED
NIIIMMO09911.• (A Govt. of tncgo Undertaking)
Page 3 of 7
M.I. PLATE
LUG
0 = DIA OF LUG
LW = WELD LENGTH AVAILABLE
BENDING DIMENSIONS FOR 121 & 161 LUGS

(FOR SPACING OF LUGS > 190)
(NOT APPLICABLE FOR S1, 52, RI & PS1)
1mm GAP 5mm WELD
LUG
PLUG WELD
M.I. PLATE
WELD DETAIL OF 12 & 16 LUGS WITH M.I. PLATE

(FOR SPACING OF LUGS < 190)
(VALID FOR 51, 52 R1 & PS1)
BENDING DIMENSIONS FOR 121 & 161 LUGS

(VALID FOR R9, R10, R12, R13, R14, PS11, & P512)
41\7 1)/ Cc?)

, (\\
6 23.10.12 REVISED AND REISSUED AS STANDARD VpS P.K.MITTAL s WEEP VINAY KUMAR 0 MALHOTRA
5 09.10.07 REVISED AND REISSUED AS STANDARD VPS P.K.IMITAL VINAY KUMAR V.CHATURVEDI
Rev Prepared Checked Stds. Committee CGM(E) Stds. Bureau

Dale Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - At rights reserved
Page 1185 of 2065

STANDARD No.
METAL INSERT PLATES
Cry
PDIA 7-68-0056 Rev. 6
011107MIMERPOPO
UMMD
(A Go* of kt6Io UndeviokMg) (SIR DESIGNATES)
Page 4 of 7
TYPEOF INSERT ]
TYPEOFINSERT
THK. OFINSERT
DETAILS OF INSERT PLATE DETAILS OF INSERT PLATE
THK. OFINSERT
Le,
DIAOFLUGS
o
0
6 6 _.
Z PLAN CROSS SECTION Z "a- PLAN CROSS SECTION
vi vi 6
, . 195 195 .
11.1111=1.
S1a 12 12 57a 12 12
U
01 I . 1
% 7. 0
4—± -
j, 300
Sib b 16 16 1, 400 j,
SIZE 150x150 SIZE 450x450
ili,_tc*
i, ,R, n
S2a 12 12 R1a 12 12
.V. I I V-I
2. - 1 1 8. L
0 0'
1 ---t- % cl)
S2b 16 16 jr, 300 R1b 16 16 I, 300

,
irrsp, . 90
r
Nat
S3a 12 12 R2a 12 12
1
0 V 0
3. 9.
t—t-
Sib 16 16 I 300 1 R2b 16 16 1 300
120 120 1 1140

flail" jail
S4a 12 12 R3a 12 12 ?
1
,0
4. FvE 1 V V ,?; 10.
? ?
? II •
S4b 16 16 350 R3b 16 16 350
3 irso145f145te_jr) 1 140
1 li
S5a 12 12 -4)— 4- 1
R4a 12 12 11
0
0) 0
5. NJ 5 1 11.. a
f-)
S5b 16 16
1---dr-t- R4b 16 16
350 I,
/ 350
SIZE 350x350 n SIZE 200x400
1170 170 30 I 190

MIMI jai
S6a 12 12 RSa 12 12
1
o
4 -4 1
6. 12. 0
S6b 16 16 350 R5b 16 16 350

6 23.10 12 REVISED AND REISSUED AS STANDARD

.4`1V 6t,
P.K.MUTAL
a RWDI
Qrec--
VIN KUMAR
'--- -I
D MAU4OTRA
5 09.10 07 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL VIMAY KUMAR V.CHATURVEDI
Rev. Prepared Checked Stds. Committee CGM(E) Stds. Bureau

No. by by
Approved by
Format No. 8-00-0001+4 Rev.0 Copyright EIL - All rights reserved
Page 1186 of 2065

age..
STANDARD No.
METAL INSERT PLATES
7-68-0056 Rev. 6
Min Astr m0 to Goal of Odic Undertaking) (R DESIGNATES)
Page 5 of 7
THK. OFINSERT
TYPE OFINSERT
TYPE OF INSERT
DETAILS OF INSERT PLATE DETAILS OF INSERT PLATE
THK. OF INSERT
DIAOFLUGS
E
6 6
Z PLAN CROSS SECTION Z PLAN CROSS SECTION
N ..c
a
N
30{1451451130
R6a 12 12 R12a 12 12
o
0
5
13. 19. ,5
o
R 6b 16 16 ,9,1c j, 350 R12b 16 16 400

SIZE 250x400 SIZE 350x5b3
n, 30 14 45 30
feat
all
R7a 12 12 — R13a 12 12 0 — 0
I m 1
o I
a ----40 0
co
14. 20. 5
0
co 1 _
O t 5
R13b 16 16 Ila"■' 1
R7b 16 16 re' 400 400
SIZE 250x500 ,I,
SIZE 350x600
R8a 12 12
.4 240 ,
li mn u R14a 12 12
?frril
__ -
o 1 o ■
MN o
15. 5 21.
='11
Sig
° MI u.1
ft—
,...
R8b 16 16 I 350 R14b 16 16 1 400
y1 2o) 20fr0
I
R9a 12 12 gins.
o raj
16. ° Bann
o Ilarri
swi
.=== l
i, 5
R9b 16 16 400
SIZE 300x500
o 3942041204430
R10a 12 12 o .. 1
17. 1
R10b 16 16 5 400
SIZE 300x600
290
R11a 12 12
======
18. o
5
R11b 16 16 j, 350
SIZE 350x400
TA 43tzpar \0)`()% 2„.„.4___
6 23.10 12 REVISED AND ISSUED AS STANDARD P.K.MITTAL TU VI NAY KUMAR D MALHOTRA
5 09.10 07 REAFFIRMED AND ISSUED AS STANDARD VPS P.K ARTTAL VINAY KUMAR V.0 HAT URVED I

Rev
No. by by Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 1187 of 2065

STANDARD No.
ENGNEERS METAL INSERT PLATES
7-68-0056 Rev. 6
dignMell•DIA UMITED (A Govt. of India Undertaking) (PS DESIGNATES)
Page 6 of 7
DETAILS OF INSERT PLATE

TYPE DIA TH K.
S.NO. OF OF OF
INSERT LUGS INSERT PLAN CROSS SECTION
PS1 12 12 1011
1.
;250 (rY
—P)1 FOR 14 LUGS
PS2 16 16 SIZE 150x150 300 (TYP) FOR lel LUGS
aatri*-rr
PS3 12 12 1.
o_ Iil
2.
P54 16 16
SIZE '
225x225
3/11, 240 1
,430
PS5 12 12
Mal
3. all
am■
wasi
PS6 16 16
SIZE 300x300
3 200 1,1401
,30
PS7 12 12
°
_ -.-I"
4. o i 0
I 1 1 1 0
° t--4°■
4t 14- "
PS8 16 16 100, 200 1
SIZE 400x400
30 { 195 195 fro
PS9 12 12 Lo
— I I 1
5. Lo kitrk I
— _ 1
PS10 16 16
SIZE 450x450
30.11, 220 ir 220 1..30
PS11 12 12 II
PS12 16 16
SIZE 500x500
.uk,1‘ / n rpZ Pr \r,Arf)-
c.4,_.-f,
6 23.10.12 REVISED AND ISSUED AS STANDARD R. Al %CHAT KUMAR D IIALHOTRA
5 09.10.07 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.WITTAI. MAY KUMAR V.CHATURVEDI
Rev Prepared Checked Stds. Committee CGM(E) Stds. Bureau

No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright Ell - All rights reserved
Page 1188 of 2065

STANDARD No.
a ENGINEERS
LAMM
(A Govt. of kidlo UndertokIng)
METAL INSERT PLATES
(T DESIGNATES)
7-68-0056 Rev. 6
Page 7 of 7
w
30 250 ,, 30
71(—- i
w
{ 30 30
w
\ L
30 30 7
i
±r. k 250 A,
II
t---
i
t 0
=
TYPE T1 TYPE T2, T3 & T4 TYPE T5 & 16 TYPE T7
50 mm (MIN.)
SLAB
25 mm w
(MIN.) B
SECTION 1 —1
ii
TYPICAL FIXING DETAIL
TYPE WIDTH OF MAXIMUM LENGTH MAXIMUM THICKNESS TOTAL

S.NO. OF BEAM WIDTH OF OF PLATE OF PLATE ANCHORAGE
INSERT PLATE LENGTH
.L, 'b' . I,
'B' 'W' T
(mm) (mm) (mm) (mm) (mm) (mm)
1. T1 230 180 180 110 16 350
2. T2 300 220 250 110 20 350
3. T3 350 270 250 110 20 350
4. 14 400 320 250 110 20 350
5. 15 450 370 300 110 32 350
6. T6 500 420 300 110 32 350
7. 17 500 420 400 110 32 350
SeV cete
6 23.10.12 REVISED AND ISSUED AS STANDARD VPS P.K.M AL s vumvum MAY KUMAR D IIALHOTRA
5 09.10.07 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL vINAY KUMAR V.CHATURVEDI

Rev.
No. by by
Approved by
Format No. 8-00-0001+4 Rev.0 Copyright EL - All rights reserved
Page 1189 of 2065

STANDARD No.
ENGINEERS M.S. ANCHOR BOLT
51gu fê45
I alWrf ri.em2 057,isn.1)
INDIA LIMITED
IA Govt of India Undertakong) ASSEMBLIES
7-68-0417 Rev. 7
SHT. 1 of 7
GRADE BOLT DIMENSIONS BOLT DIA ( 0 ) IN MM

OF
CONC. TYPE MM 10 12 16 18 20 22 24 27 30 33 36 39
L 250 300 450 450 550 600 650 750 850 950 1000 1100
I E 95 115 155 170 190 210 230 255 285 315 345 370
8c
III TYPE —I 280 336 498 504 610 666 722 831 940 1049 1108 1217
H
TYPE —III 430 486 648 654 910 966 1022 1281 1390 1499 1558 1667
M20
L 200 200 300 350 400 450 450 550 600 700 700 800
II E 150 180 240 270 300 330 380 405 450 495 540 585
8c
IV TYPE —II 230 236 348 404 460 516 522 631 690 799 808 917
H
TYPE—IV 380 386 498 554 760 816 822 1081 1140 1249 1258 1367
L 200 250 400 400 450 550 550 650 700 800 850 950
I E 95 115 155 170 190 210 230 255 285 315 345 370
&
111 TYPE —1 230 286 448 454 510 616 622 731 790 899 958 1067
H
TYPE —III 380 436 598 604 810 916 922 1181 1240 1349 1408 1517
M25
L 150 150 250 250 300 350 350 450 500 550 600 650
II E 150 180 240 270 300 330 360 405 450 495 540 585
&
IV TYPE —II 180 186 298 304 360 416 422 531 590 649 708 767
H
TYPE —IV 330 336 440 454 660 716 722 981 1040 1099 1158 1217
L 180 220 315 335 390 445 470 550 600 680 735 815
1 E 95 115 155 170 190 210 230 255 285 315 345 370
8c
III TYPE —I 210 260 365 390 450 515 545 635 690 780 845 935
H
TYPE —III 360 410 515 540 750 815 845 1085 1140 1230 1295 1385
M30
L 150 150 200 200 250 275 300 350 375 425 450 500
II E 150 180 240 270 300 330 360 405 450 495 540 585
8c
IV TYPE—II 180 190 250 255 310 345 375 435 465 525 560 620
H
TYPE—IV 330 340 400 405 610 645 675 885 915 975 1010 1070
+9-4;
7 26.11.13 REVISED AND ISSUED AS STANDARD A. . SHARMA AMARJEET P.K.MITTAL S.CHATURVEDI S.CHANDA
6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL VINAY KUMAR N. DUARI
Rev. Prepared Checked Stds. Committee GM Stds. Bureau

No. by by
Format No. 8-00-0f0".-F4 Rev.0 Copyright EIL - All rights reserved
Page 1190 of 2065

STANDARD No.
Og-a OfZ5 2i2O5-feasl.smo.-0
INDIA LIMITED
IA Govt of Incha Undertaking) ASSEMBLIES
7-68-0417 Rev. 7
SHT. 2 of 7
GRADE BOLT DIMENSIONS BOLT DIA ( 0 ) IN MM

OF
CONC. TYPE MM 10 12 16 18 20 22 24 27 30 33 36 39
L 160 190 275 295 340 390 410 480 525 595 640 710
I E 95 115 155 170 190 210 230 255 285 315 345 370
8c
III TYPE —I 190 230 325 350 400 460 485 565 615 695 750 830
H
TYPE—III 340 380 475 500 700 760 785 1015 1065 1145 1200 1280
M35
L 150 150 150 150 180 225 225 275 300 350 350 400
II E 150 180 240 270 300 330 360 405 450 495 540 585
8c
IV TYPE—II 180 190 200 205 240 290 300 360 390 450 460 520
H
TYPE—IV 330 340 350 355 540 590 600 810 840 900 910 970
L 150 170 240 255 300 340 360 425 460 525 565 625
I E 95 115 155 170 190 210 230 255 285 315 345 370
&
III TYPE —I 180 210 290 310 360 410 435 510 550 625 675 745
H
TYPE—III 330 360 440 460 660 710 735 960 1000 1075 1125 1195
M 40
L 150 150 150 150 175 200 200 225 250 275 300 325
II E 150 180 240 270 300 330 360 405 450 495 540 585
&
IV TYPE—II 180 190 200 205 235 270 275 310 340 375 410 445
H
TYPE—IV 330 340 350 355 535 570 575 760 790 825 860 895
elie 0_
■ Ile■ t'4,».■
tata
il
TYPE — I TYPE — II
o I—
K (NOMINAL BORE) a.
0
TACK WELD
(TYP)
DETAIL—A
TYPE — III TYPE — IV (TYP)
YX1_ A1:4--
7 26.11.13 REVISED AND ISSUED AS STANDARD A.K: SHARMA AMARJEET .ANTTAL S.CHATURVEDI S.CHANDA
6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL V1NAY KUMAR N. DUARI

No. by by
Format No. 8-00-0001-F4 Rcv.0 Copyright EIL - All rights reserved
Page 1191 of 2065

STANDARD No.
IA Govt. of India Undertakingt ASSEMBLIES
SHT. 3 of 7
000r0000000>(>000
N II,
in in (1) o o co tO tri 0 .4.
r, oro ro ro o csi 0 rO rO 00 00 N
.-
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0 .- 0 (0 O O O O U") O tO tr) O O
00 0 co rO ro O o tO 0 co ro in rs. in -rr
to 0 N l*, ..- CO N Cf> .- >L") (0 N N
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(c) O ■,) N. et O in sl• 11, co N. et N O O
tr) co O N tn tt, N r... 0) N N CD N
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0 u, 0 >r) o o o 0 11, 0 tn 10 0 in
N >n r. <0 "zr in 0 ,4. Lf> N U:› •ct 1... 14, co
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0 000000010000010
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"Cr CD r. N O et N tn 10 N CO el• .-
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e> tn 0 0 ••It in N 0 >") in o O 0 N 0 C'') 11,
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ri) et .-- vi u, .-- (C) vi 1D .- in
o o o oo>no in O O Lf> O tn If>

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CO tn in (1) 1•••• 0 Ch 0 •-• 0 cn O •-
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0 0 If> 0 0 et ,-, u, 0 to o co
co it, tn if> P. tf> K> ..,,
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C) lf> Lf> sl• tn II, .- CO .- II, .- CO
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DOUBLE NUT
SINGLE NUT
DIMENSIONS
CD
t3
CD= 3 -:2-1-10CDM 3 -..J -J (,)

MM
THREADED (T)
LENGTH
SLEEVE
> -
> X
LLI > - = -
-
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0 >- 0>i 0 ck; > 6.3 > > > > >
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CO I- -
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GRADE
CONC.
C.1 1+->
= = O
OF
cS
r..1
ci 't
I.r> ckS i N N rf)
= = ck$
7 26.11.13 REVISED AND ISSUED AS STANDARD A.K. SHARMA AMARJECT P.K.MITTAL S.CHATURVEDI S.CHANDA
6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL V1NAY KUMAR N. DUARI
No. by by
Format No. 8 .00-0001-F4 Rev.0 Copyright EIL - All rights reserverI
Page 1192 of 2065

• - • 0
STANDARD No.
$'>gu2di
dg INDIA LIMITED 7-68-0417 Rev. 7
It~ rlecnft asidnenan IA Govt of India Undertakong) ASSEMBLIES
SHT. 4 of 7
FORGING. THE FORGING TEMPERATURE SHALL BE ABOVE 900* C BUT LOWER

o 0 0 t.,) U) 0 O 0 0 If) O 0 N O
,0
0.1 Iff tO met N t.') o
SHALL BE TACKWELDED
0 115 LD
r n, N 1,) CO CO N N .- .- N tO
•- .-
U) O tl, U) O O U) O O U) O N O a_
0 m
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co o ce> ■
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w wo
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ID
to N
O
0 el• .- if) u) .-
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(D ir) 0 0, N) N N N .- .- N CO
r•- •-• .- • m
= <
o o O o o O O O in o o O co 0 u_
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5. ANCHORBOLTSSHALLBESET ACCURATELYANDHELDIN
(4, r••• 0 N N U> N N .- - N el• cri I-
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COARSE CONFORMING TOIS:1 367

o o Ir) 0 0 0 0 V) II, 0 C) if) 0 Z N 0 Z
(;) 0 11) N l' O 0 0 0) N N) 0) N N Lf) •ct •-
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ch .- Vi L.,_ , ±-
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w
POSITION BY TEMPLATE BEFORE CONCRETING.

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00 0 0 N) •It 0 0 CO CO 0 N cl> N N if) w=U) u. W
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DIMENSIONS
Z CO
TYPE OF BOLT
LL
1-
t3
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U S 3 -2- --I - -1 (.) LL•I Y _I _I _I _I O

MM
Z
0
THREADED (T)
LAJ
LAJ LL
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LENGTH
Z < O o w ce
o 0 <
(7) a ZN Z
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M
< v)
V &VI
w ce
> — > _ >
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26.11.13 REVISED AND ISSUED AS STANDARD 4t7a
A.K. HA 1AA AMARJEET P.K.MITTAL S.CHATURVEDI S.CHANDA
6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL VINAY KUMAR N. DUARI

No. by by
Format No. 8-00-0001-F4 R.ev.0 Copyright EIL - A'l re3erved
Page 1193 of 2065

STANDARD No.
51gz-z Wes INDIA LIMITED 7-68-0417 Rev. 7
lafwnetravtasksvsnitt IA Govt of Indo Godeftakm9) ASSEMBLIES
SHT. 5 of 7
GAP BETWEEN
SLEEVE & BOLT
SHALL BE FILLED
WITH GROUT
TYPE - V TYPE - VI
lja
1E1
(NOMINAL BORE> (NOMINAL BORE>
10 IuI 10
lil
6 THK. 6 THK,
SQ, Ft_ 2 sQ. FL
6 WELD ALROUND
ON BOTH SIDES DF le
C>
Al LTY
P>
8 THK.
6 rnrn VELD
SQ. FL
—SQ. Ft_
TYPE - VII TYPE - VIII
TYPE - IX TYPE - XII
26.11.13 REVISED AND ISSUED AS STANDARD A.K: SHARMA AMARJE P.K.M AL S.CHATURVEDI S.CHANDA
6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITrAL VINAY KUMAR N. DUARI

No. by by
Format Nc. 8-00-0001-F4 Rev.0 Copyright FIL - Al
I rights reserved
Page 1194 of 2065

STANDARD No.
0:11fadj
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SHT. 6 of 7
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26.11.13 REVISED AND ISSUED AS STANDARD A. SHARMA AMARJEET P.K. AL S.CHATURVEDI S.CHANDA
6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.14ITTAL VINAY KUMAR N. DUARI

No. by by
Format No. 8-00-0001-F4 Rev C Copyright EIL - All rights reserved
Page 1195 of 2065
STANDARD No.
faffleg INDIA LIMITED 7-68-0417 Rev. 7
lai(2R oftmi2as7J,n.0 (A Govt. of India Uncleitaking) ASSEMBLIES
SHT. 7 of 7
NUT NUT
WASHER WASHER
BASE PLATE BASE PLATE
GRDUT GRDUT
CONC. TDP CDNC. TOP
SEE DETAIL Ol
SQ. PDCKET
BOX OF 16 GAUGE MS PLATE
ISMC
n
ISA--I
I I 1 I
11
11
(>
I
I
L_J 11. J
VIEW B - B
VIEW A — A
TYPE — X
(* AS PER DESIGN REQUIREMENT)
DETAIL - (i)
(FOR FORGED BOLT HEAD)
TYPE - XI
7 26.11.13 REVISED AND ISSUED AS STANDARD A.K. SHARMA AMARJE P.K.MITTAL S.CHATURVEDI S.CHANDA
6 26.03.09 REVISED AND ISSUED AS STANDARD VPS P.K.MITTAL VINAY KUMAR N. DUARI

No. by by
Page 1196 of 2065

STANDARD No.
je ENGINEERS HANDRAILS
IND!A LIMITED 7-68-0501 Rev. 7
(~1 232215W 051.344.1) (A Govt of !ndla Undertalong)
Page 1 of 8
NOTES:—
1. ALL HANDRAILS AND UPRIGHT SHALL BE AS PER RESPECTIVE TYPE.

2. ALL FILLET WELDS OF 3mm (MINIMUM) THICKNESS SHALL BE CONTINUOUS UNLESS NOTED OTHERWISE.
3. JOINTS IN HANDRAILS SHALL BE PROVIDED AT SUITABLE LOCATIONS, WELDED AND GROUND FLUSH.
4. FOR ADDITIONAL TYPE OF UPRIGHT FIXING DETAILS REFER EIL STD. 7-68-0061.
5. ALL M.S. TUBES SHALL CONFORM T0 IS:1239.
6. FABRICATION OF TOP RAIL, INTERMEDIATE FLAT AND TOE PLATE SHALL ONLY BE STARTED AFTER TAKING
ACTUAL DIMENSIONS AT SITE.
7. ADJUSTMENT IN SPACING OF VERTICAL POST SHALL BE DONE AT EITHER END OF PLATFORM.
/ „, •ki\-"(
7 16.12.2014 REVISED & ISSUED AS STANDARD V.P.SINGH V ,-GOEL PK MITTAL S CHANDA
6 29.01.2010 REVISED & ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
Prepared Checked Stds. Committee Stds. Bureau

Rev.
No. by by
Approved by
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Page 1197 of 2065

STANDARD No.
k31 ENGINEERS
$.7fg-a[OWg INDIA LIMITED HANDRAILS 7-68-0501 Rev. 7
1~, Cl~C11,14CM) IA Govl of Intlia Undertalong)
Page 2 of 8
TYPE -
14 0 HOLES FOR
200 I112 MEDIUM DUIT RUST PROOF
ANCHOR FASTNER
o
V)
0
8 THK.
VIEW 3-3 BASE PL.
r-91, TUBULAR HANDRAIL

POST VIEW 2-2
n,-11
V3 ho TUBULAR HANDRAIL
11 II POST
FINISHED
FLOOR V 2 II II 2N
LEVEL
5,
, II I
eiie Niim
12 LUG(2N0S)
FIXING DET OF TUB. POST .

WITH M.I.PLATE (ALT-I)
SLOPING HANDRAIL ON R.C.C. STAIR FIXING DET OF TUBULAR POST
CONCRETE DISCONTINUOUS WITH ANCHOR FASTNER
END OF HANDRAIL ALT-II
250 1500(MAX.) 1500(MAX.) POST SPACING
,2 (TYP)
1
P-
- ---(-P
R=100
32 NB(M) TUBE— o
o
R=100
100x5 TOE PLATE o

o
WHERE REQUIRED
TO BE WELDED
STRUCTURAL F.F.L.
CONC. LEVEL
If
HORIZONTAL HANDRAIL ON R.C.C. PLATFORM SEC. 1-1

t
7 16.12.2014 REVISED & ISSUED AS STANDARD V.P.SINGH V GOE L PK MITTAL S CHANDA

Rev.
No. by by
Approved by
Förmat Nn 8-na-nnnt-F4 RPV n r.nnvrinht FII - All rinhts rpsprvAri
Page 1198 of 2065

STANDARD No.
ENGINEERS
51g-a 02-eg
irrteR r-fecolrosi~f
INDIA LIMITED
IA Govt of Incha Undertakno)
HANDRAILS 7-68-0501 Rev. 7
Page 3 of 8
TYPE - II
CONC. / STEEL FACE-DISCONTINUOUS END OF HANDRAIL
25 1500(MAX.) 1500(MAX.)
250
(MA X.) (TYP) (TY P)
Ip
TOE PL. 100x5
[1=1oeu_.
HORIZONTAL HANDRAIL ON STEEL PLATFORM
32 NB(M) TUBE
o
o POST 32 NB(M) TUBE
in
32 NB(M) TUBE
o
o
TOE PL. 100x5
o 50x50x6 THK. PL.

o (TYP)
in
TOP OF GRATING
CHEQ. PL.
T.O.S.
v
5J
SECTION 4-4 VIEW 5-5 VIEW 6-6

(FOR DETAILOREFER PAGE 8 OF 8) (AT CORNER)
S
. \r
7 16.12.2014 REVISED dc ISSUED AS STANDARD V .P.SI GH V- GOEL PK MITTAL S CHANDA
6 29.01.2010 REVISED dc ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
Rev. Prepared Checked Stds. Committee Stds. Bureau

No. by by
Approved by
Förmat Nn R-no-rinn1-F4 RPV n r.nnvrinht Fll - All rinhts rpsp,rvpd
Page 1199 of 2065

STANDARD No.
ENGINEERS HAN DRAI LS
04-a(~,eanc,o51.3~0
r fafje5 INDIA LIMITED
(A Govl of India UndeflakIng)
7-68-0501 Rev. 7
Page 4 of 8
TYPE - II
PIPE SHALL BE
GROUND TO SHAPE
PLATE
50x50x6 THK.
VIEW 7-7
SLOPING HANDRAIL ON STEEL STAIR

WHEREVER HIGHER SIZE OF STRINGER BEAMS
ARE REQUIRED AS PER DESIGN SIMILAR G.A.
BE FOLLOWED FOR THE SAME.
7 16.12.2014 REVISED & ISSUED AS STANDARD V.P.SINGH 1

.-dL MITTAL S CHANDA

Rev.
No. by by
Approved by
Fnrmat Nn s-rin-n001-F4 RPV 0 C.nnvrinht Fll - All rinhts re.sprv<441
Page 1200 of 2065

STANDARD No.
ENGINEERS
raW5 INDIA LIMITED HANDRAILS 7-68-0501 Rev. 7
,
1,7~.11 IA Govt of Incha UnderlakIng)
Page 5 of 8
TYPE - III
32 NB(M) TUBULAR
HAND RAILING
SEE DETAIL VIEW 9-9
OF WALL PLATE
1500(MAX.)
LANDING
100
1500(MAX.)
14 0 HOLES
WALL
8mm THK. 12 0
PLATE EXPANSION
3mm MIN. FASTNERS
CONTINUOUS
FILLET WELD
120 0-8 THK.
WALL PLATE
VIEW 8-8
DETAIL OF WALL PLATE
ELEVATION
HANDRAIL FIXED TO WALL DIRECT
7 16.12.2014 REVISED dc ISSUED AS STANDARD

-a‘\■.<
V.P.SINGH
(Ari PK NITTAL S CHANDA
6 29.01.2010 REVISED dc ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI

No. by by
Approved by
Forrnat Nn R-nn-noni -F4 RPV C:nnvrinht Fll - All rinhts rAsrtnind
Page 1201 of 2065

STANDARD No.
ENGINEERS
HAN DRAI LS
$1gzx f812- g
2,1~,n1.549,4)
(w.-rt
INDIA LIMITED
(A Govt ot Inclia UndertakIngt
7-68-0501 Rev. 7
Page 6 of 8
TYPE - IV
1500 1500 1500 MAX.
o
o
u)
TOE PLATE — 25 THK.
100x5 THK. GRATING
1 Oj
HANDRAIL ON HORIZONTAL PLATFORM (STEEL)
SEC. 10-10
NOTE : HANDRAIL TYPE-IV SHALL BE USED OVER PIPE CROSS OVER AND LOW LEVEL PLATFORMS
SUCH AS FOR VALVE OPERATION ETC. AS MENTIONED IN STD 7-68-0562 & 0563.
(FOR DETAILSA
O REFER PAGE 8 OF 8)
7 16.12.2014 REVISED & ISSUED AS STANDARD V.P

V.P.. INGH V G EL PK MITTAL S CHANDA

No. by by
Approved by
Fnrmat Nn a-nn-nnni-F4 RPV fl r.nnvrinht Fll - All rinhts rps.rvpri
Page 1202 of 2065

STANDARD No.
ENGINEERS HAN DRAI LS
0 .-a.OW5*10 " INDIA LIMITED 7-68-0501 Rev. 7
r W.WaP,~71)
- IA Govt of India Undertaiong)
Page 7 of 8
TYPE - IV
32 0 NB M
TUBE
SLOPING HALF HANDRAIL ON STEEL STAIR
SEC. 1 1 -1 1 DETAIL - `®J
\;W\I•V G}K
7 16.12.2014 REVISED & ISSUED AS STANDARD V.P.SINGH GO L PK MITTAL S CHANDA
No. by by
Approved by
Förmat Nn fc-nn-rinni-F4 Revn nnnvrinht Fll - All rinhts rpsprvpri
Page 1203 of 2065

STANDARD No.
ENGINEERS HANDRAILS
Og-af OW5 d INDIA LIMITED 7-68-0501 Rev. 7
IswfT 2,REO2osisoomf IA Govt of India Undertakong)
Page 8 of 8
IIIV
■J I
irm
32 NB(M)
TUBE
4V
tn
II
o II
TOE PLATE
0.•
100x5 THK.
OUTSIDE EDGE
OF MEMBER
VIEW 12-12
VT2
50 SQ.
1—
6 THK. PL.
u)
DETAIL - (A)
CONNECTION DETAILS
(FOR TYPE II & IV)
NOTE : CHEQUERED PLATES / GRATINGS SHALL BE SUITABLY NOTCHED TO ACCOMMODATE THE TUBE
IN CASE OF BEAM MC100 OR MC125.
7 16.12.2014 REVISED & ISSUED AS STANDARD VXINGH ())/16CjL PK ITTAL S CHANDA

No. by by
Approved by
Fnrrnat Nn 8-nn-nn01-F4 RAV ennvrinht Fll - All rinhts rpsprvpri
Page 1204 of 2065

STANDARD No.
el ENGINEERS
$'2,fir 215tg INDIA LIMITED STEEL STAIRS 7-68-0506 REV. 6
lxvR2w, femi.-Tuqq) (A Govt of India Undertaking)
SHT. 1 of 6
30, - r 75x75x8
NOSING
IOW 71O-1=1-4111111111-11MFill..=. ■
-■
-1111M-0. =4
2 2
ESA_
.E
7•-•=-1.110 .1■
1142..1=-•■
-1=1,-C =04//104/000. 7•-•••••■
BRACING (REFER SHT- 5)

30 - NO. OF TREAD x 230 MIN. 750
NOSING j, STRINGER SPAN
4000 MAX. FOR MC150
6000 MAX. FOR MC200
PLAN AT EL. 'A'

O
O
c•J
C.)
0 Lai
-J O
5
0 CC
CNI
N
CC
W
O
O
ca
Nu, CC
X o
rn
3
1
CONCRETE
BASE
NO. OF TREAD x 230
PLAN AT EL. 'C' SECTION 4-4
NOTES :-
1. FOR STAIRWAY/TREAD USE ELECTROFORGED GRATING TYPE—II AS PER EIL STD NO 7-68-0697.
2. FOR CONNECTION DETAILS REFER SHEETS 3, 4, 5 AND 6.
3. STRINGER SHALL BE SUITABLY DESIGNED FOR OFFICE BUILDING, WARE HOUSES AND WORKSHOP.
4. FOR DETAIL OF INSERT PLATE `R1a° REFER EIL STD. NO. 7-68-0056.
6 18.09.13 REVISED AND ISSUED AS STANDARD VPS" PK MITTAL RVEDI D.‘a'"

MALHOTRA
5 09.06.08 REAFFIRMED AND ISSUED AS STANDARD SPJoshl P.K.MITTAL VINAYKUMAR V.CHATURVEDI
Prepared Checked Stds. Coimlittee GM Stds. Bureau

Rev.
No. by by
Approved by
Fnrrnat Nn a-nn-.0001-F4 RPV Cnnvrinht FII - All rinhts mso.rvpri
Page 1205 of 2065

STANDARD No.
0 el ENGINEERS
Ig.ZIfdOteg INDIA LIMITED STEEL STAIRS 7-68-0506 Rev. 6
I KUM' t7e41,
Tr' 111,T9',Fe4i tA Govt of India Undertaking)
SHT. 2 of 6
300
II II
_7::
EL. 'A'
II Ii T.O.G/CH. PL
4i J1
EL. `B'
T.O.G/CH. Pl.
r75x75x8
EL. 'C'
T.O.G/CH. PL/T.O.C.
1500
MAX.
STRINGER MC 150
R
OR MC 200
0
0
z
EL. TOP OF GROUT\Ir
REFERENCE EL.
17
FOR STRINGER MC 150 REFER DET. <
FOR STRINGER MC 200 REFER DET. (g.)
ON SHEET 6 OF 6
MAXIMUM RISER IS 200 HOWEVER IT
SECTION 1 -1 MAY BE REDUCED AND ADJUSTED AS
REQUIRED.
18.09.13 REVISED AND ISSUED AS STANDARD PK IA AL ctiATU RVIDI D. MALHOTRA
5 09.06.08 REAFFIRMED AND ISSUED AS STANDARD SPJoshl P.K.IAITTAL VINAYKUMAR V.CHATURVEDI

No. by by
Approved by
Format Nn R-0O-01101-F4 RPV nonvrinht F I I - All rinhts resprvprl
Page 1206 of 2065

STANDARD No.
60J:A ENGINEERS
Igai2Preg INDIA LIMITED
4-IreM 29-edifF C51.34,1,-A (A Govt of India Undertaking)
STEEL STAIRS 7-68-0506 Rev. 6
SHT. 3 of 6
235 230 230 230

MIN. MIN. MIN. MIN.
30 NOSING
R.C.C. KERB CLEAT
M
L-75x75x8-150 LG.
F
U)
CLEAT
O
—75x75x8-150 LG.
0
La
6 THK. STIFFN. PL.
IA V)
—J I-
0 E)l
= co INSERT PL.
Lo R1 a END FLAT
c_o MC150 OR MC200
SECTION 2-2 SECTION 2-2

(CONNECTION WITH CONCRETE BEAM) (CONNECTION WITH STEEL BEAM MC)
235 230 230 230

MIN. MIN.
5 1■■
1=1I NMI IN=

• • • MOMEM MIN 1■
•
MEM • WM OWN I■
1111•1114 IM1 •111111.11•11111111•MME
MOM. ••111111 IMMO 11■ 01111 MINIM 1.■
■ ■■ • IMII■1 MINI M.MIN == l■

■
I■ 1 ■ =MOM ■ •■ 111 MN= MIMI II•1= ■
gar
MI •
LX ■
MN NMI MIN MINIM MIN M ■ II■ l■ l■ l■
L.d =MI MI= OM

■■
i■ IIII■
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=MOM MOM Mae l■
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ET=
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MN 1MM l■ l■ i■
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■ ■ ■
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STRINGER BEAM STRINGER BEAM
CLEAT CLEAT MC
VIEW 5-5 VIEW 6-6

STRINGER BEAM
MC150 OR MC200
STRINGER BEAM
CC
0
230 75
17 MIN.
x-10
III II-11 I—
M16 BOLTS
I
1V
CLEAT —75x75x8-60 LG.

1-75x75x8
200 LG. INSERT L-75x75x8
INSERT PL. 1000 LG. FOR 750MM
`R1 WIDTH
LUG C1 0 300 c/c
° r
INSERT PL. 'R 1 a
SECTION 3-3 SECTION 3-3 (ALT.) VIEW 7-7
(CONNECTION WITH CONCRETE BEAM) (CONNECTION WITH CONCRETE BEAM)
(R.C.C. KERB NOT SHOWN FOR CLARITY) (R.C.C. KERB NOT SHOWN FOR C RITY)
6 18.09.13 REVISED AND ISSUED AS STANDARD VPS PK MITTAL 7MAARVEDI

ikD. MALHOTRA
5 09.0E.38 REAFFIRMED AND ISSUED AS STANDARD SPJoshI P.K.MITTAL VINAYKUMAR V.CHATURVEDI

No. by by
Approved by
Pnrmat Nn s-00-nnni-F4 R PV (1 r.nnvrinht Ell - All rinhts rPsprvprl
Page 1207 of 2065

STANDARD No.
ei ENGINEERS
5'gzil. itiMeg INDIA LIMITED STEEL STAIRS 7-68-0506 Rev. 6
elecrAtT2.17,71.1.1) (A Govt. of India Undertaking)
SHT. 4 of 6
230 230
(MIN.) (MIN.)
CC BEAM
O
0
230 230 30 NOSING Cs1
(MIN.)
vg MC150 OR MC200
0
evl
O
O
0.1
75x75x8
150 LG.
C:, 6 THK.
STIFFN. PL. CLEAT —75x75x8-60 LG.
MEMBER
REF DESIGN DWG
6 THK. STIFFN. PL.
MC150 OR MC200

(CONNECTION WITH STEEL BEAM ISMB) (CONNECTION WITH STEEL BEAM ISMB)
■ ■
■
lMO
OM il■
il
IMM ■
MIOMNIN INMME
■
=MN .M■ NM MIS
MILO 1 UMW
NIIIN WWI P■
MN1I ■ ■
MI MIN
■
■ ■
I■ 11■ M.IIIIM
l■ l■
■
■I■
l■Il
ENO
■
■
l=OM I■
1■■ 1NM
WW1
OMB MI=
ME =MY II'■JIM ■
I MN ■
i■
l■
l■ =MN NM IME I■ ■ 1■ 11111111■ MIMI=
-----
LIMIMN .■
: l■ I ■
.1111 ,MNM•
IMIIIIIIM
l■
l■
l■ ■
STRINGER STIFFN. PL. STIFFN. PL STRINGER

230 30 ANGLE CLEAT WELDED TO
230
STRINGER, BOLTED TO MB
(MIN.) (MIN.)
VIEW 8-8 VIEW 9-9
230
MIN.
---- MC150 OR
MORE
STRINGER
CLEAT L_-75x75x8-250 LG.
6 THK.
STIFFN. PL. CLEAT WELDED TO STRINGER
AND BOLTED TO MC
—TOE PLATE
SECTION 3-3
(CONNECTION WITH STEEL BEAM ISMC) VIEW 10-10
6 18.09.13 REVISED AND ISSUED AS STANDARD VPS PK MITTAL SC EDI D. MALHOTRA
39.06.08 REAFFIRMED AND ISSUED AS STANDARD SPJoshI P.K.MITTAL VINAYKUMAR V.CHATURVEDI

No. by by
Approved by
Format No Ft-nn-nnnt-F4 RPV nonvrinht Fll - All rinhts resprvPrl
Page 1208 of 2065

STANDARD No.
.e.] ENGINEERS
$1gar Ofgr'
eg INDIA LIMITED STEEL STAIRS 7-68-0506 Rev. 6
i-freR irreMIP 051 J40,
1 A Gout of India Undertaking)
SHT. 5 of 6
MC150 OR
MC200
—50x50x6 o ;i
SEC. 11-11
6 THK.
CHEQ. PL.
•
HANDRAILING
230
/
111111=11r
r'
BRACING STRINGER
L-50x50x6
(APPROX.)
T —50x50x6
ELEVATION SHOWING STRINGER BRACINGS TYP. DET. OF CHEQ. PL. STEP
L-50x50x6 STIFFENING
BRACING TO BE PROVIDED
FULL STRENGTH FOR STAIR WITH MORE
BUTT WELD FOR THAN 20 RISER
FLANGES
8 THK. PL.
DETAIL — A SEC. 13-13 VIEW 12-12
STAIR DETS WITH CHEQURED PLATE STEPS

,kifyv-st
6 18.09.13 REVISED AND ISSUED AS STANDARD vps NGH K S URVEDI D. MALHOTRA
5 09.06.08 REAFFIRMED AND ISSUED AS STANDARD SPJoshl P. .MITTAL VINAYKUMAR V.CHATURVEDI

Fnrmat Nn R-00-0001-F4 Rpv n Cnnvrinht Fll - All rinhts rPsPrvPri
Page 1209 of 2065

STANDARD No.
ENGINEERS
Ogar Orol- e-g INDIA LIMITED STEEL STAIRS 7-68-0506 Rev. 6
(11,„,J3re Govt of Ind. UntlertakIng)
c7,1,14[hii! (A
SHT. 6 of 6
230 229
7 135
L-75x75x8-120 LG.
60x60x6 THK. WASHER

WITH 22 0 HOLE AT CENTRE
_Ada
r4, W.P.
H
M20 BOLT
REFERENCE EL.
SLOTTED HOLE 22x50 LG. FOR FDN. DETS. REFER
IN ANGLE CLEAT EIL STD. 7-67-0008
150 160
DETAIL —
230 219
4o
L 75x75x8-120 LG.
60x60x6 THK. WASHER

WITH 22 0 HOLE AT CENTER
o •3.
W.P.
M20 BOLT
REFERENCE EL.
SLOTTED HOLE 22x50 LG. FOR FDN. DETS. REFER
IN ANGLE CLEAT EIL STD. 7-67-0008
100 255
DETAIL —
/11
6 18.09.13 REVISED AND ISSUED AS STANDARD \t/ CH PK MITTAL SW5

C RVEDI D. MALHOTRA
5 09.06.08 REAFFIRMED AND ISSUED AS STANDARD SPJoahI P.K.MITTAL VINAYKUMAR V.CHATURVEDI
Stds. Committee GM Stds. Bureau

Rev . Prepared Checked
No. by by
Approved by
Format Nn A-no-norm -F4 RPV n rnnvrinht Fit - All rinhts rpspnipel
Page 1210 of 2065

STANDARD No.
ENCJNEFRS DETAILS OF STEEL LADDER 7-68-0507 Rev. 7
INDIA IJMITED
IAIRII VIONAVIII104KI (A Govt. ot Indlo Undertoking)
Page 1 of 3
O è' INSULATION THICKNESS (50 mm UNLESS NOTED OTHERWISE)

1.‘ T" REFER SEC. 11-11 OF 7-68-0509 (SHT. 1 OF 3)
RUNG
I:24:2 \ DtLIS
INNNN
EL. TOP
SUPPORT RUNG
X1
MENSION BETWEEN SUPPORTS
O
O
O
LJ
1—
0
z
0
0
O
o
o OF RUNGS
EL.
re)
SUPPORT
X2 x
z
NOS.
N=
o
0
1,4)
EL.
SU P o
SAFETY CAGE O
LADDER HEAD O
AT SIDE
EL. --L—
SUPPORT o
X2 o
o
eouom
RUNG
(REFER SHT. 3 OF 3)
O
o LOWER OR
INTERNED
HOOPS
LADDER FOR SIDE ENTRY LADDER FOR SIDE ENTRY
*
VESSEL DIA (mm) DISTANCE `D' (mm) MC100 SHALL BE ADOPED FOR DISTANCE
MORE THAN 1350 UPTO 2000
UPTO 800 200 + e
> 800 < 3200 260 + e
> 3200 4 8000 275 + e
REVISED AND ISSUED AS STANDARD SIttiV

7 28.11.13 VPS A
AJmj P.K.MITTAL S.CHATURVEDI S.CHANDA
6 06.11.08 REAFFIRMED AND ISSUED AS STANDARD S.P.JOSH1 P.K.MITTAL VINAY KUMAR V. CHATURVEDI

Date Purpose Conver.ir Chairman
No. by by
Approved by
F -r:nAt Un a-on-0001-F4 rvrni Corwrinht Fll - All rinhts resprvgri
Page 1211 of 2065

STANDARD No.
ENGNEERS DETAILS OF STEEL LADDER 7-68-0507 Rev. 7
0111111~011111~111100 (A Govt. of Indlo UndertokIng)
Page 2 of 3
800 800
FLAT
75x10
0
0 TOP OF
14, GRATING/
CHEQ. PL.
EL. ON
SUPPORT
SECTION
MAX. HEIGHTWITHOUT SAFETY CAGE = 4500

NOS. OF RUNGS
NOS. OFRUNGS
O
O
o o
O O
re) re,
EL. ON x II
SUPPORT ZZ
SECTION3_
400/
TOE ANGLE/EDGE OF
PLATF RM MEMBER
0 LADDER FOR FRONT ENTRY
CD
CD REF. EL. REF. EL.
L()
TOP OF PEDESTAL/ " BOTTOM
CHEQ. PL /GRATING RUNG
AONL
TYPE OF ATTACHMENT DEPENDING
ON FLOORING TYPE. LADDER FOR FRONT ENTRY
(REF. SHT. 3 OF 3)
LADDER FOR SIDE ENTRY
NOTES :-
1. LADDER POSTS SHALL BE OF FLAT (75x10) UPTO 3.60m (MAX.) BETWEEN SUPPORTS AND ISMC 100 UPTO
7.0m (MAX.) BETWEEN SUPPORTS.
2. RUNGS SHALL BE 20 0.
3. SUPPORT TYPE X1' CORRESPONDS TO FIXED SUPPORT AND X2' CORRESPONDS TO SLIDING SUPPORT.
4. SUPPORT ELEVATION X1, X2 CORRESPOND TO CL OF BOLT HOLES.
5. SUPPORTS 'X1' IS CAPABLE TO SUSTAIN A LOAD FOR 9000 mm LONG LADDER ONLY.
6. LADDER SHALL BE GIVEN A SUITABLE SLOPE (MAX.6*),IF NECESSARY, TO AVIOD FOULING WITH ANCHOR CHAIRS.
7 28.11.13 REVISED AND ISSUED AS STANDARD vikft

VPS AJS P.K.MITTAL S.CHATURVEDI S.CHANDA
6 06.11.08 REAFFIRMED AND ISSUED AS STANDARD S.P.JOSHI P.K.MITTAL VINAY KUMAR V. CHATURVEDI

Date Purpose Convenor Cnairman
No. by by
Approved by
Fnrrnat Nn s-nn-nnni-F4 Rr.v Cnnvrinht Fii - All rinhts rpsprvpri
Page 1212 of 2065

STANDARD No.
ENGNEB5 DETAILS OF STEEL LADDER 7-68-0507 Rev. 7
NDIA UMITID
(A Govt. of Indlo UndortokIng)
Page 3 of 3
TYPE OF ATTACHMENT NATURE OF SUPPORT SECTION REMARKS

A1, A2 SITE WITHOUT PAVING
B1, B2 CONCRETE FLOOR A1, B1, C1, D1 : FIXED TYPE
C1, C2, D1, D2 CHEQUERED PLATE / GRATING FLOORING A2, B2, C2, D2 : SLIDING TYPE
REFERENCE
ELEVATION
(TYP)
M.S. GRATING
PLATE (1 20x1 20x6)
TYPE - Al TYPE - B1 TYPE - C1
WITHOUT
NUT
— Ll 00x1 00x8
(TYP)
BOTTOM _ff
NTGO M REFERENCE
ELEVATION
WITHOUT (TYP)
/ NUT 8 WITHOUT
GRATING
PLATE (1 20x1 20x6)
TYPE - A2 TYPE - B2 TYPE - C2
1
EL. X1
OR X2
CHEQ.
PLATE
11111 ,;;r
PLATE (1 20x1 20x6)
TYPE - D1 TYPE - D2
O
TYPE - E
NOTE (FREE)
100 IN CASE OF TOWERS BOTTOM RUNG SHALL
280 I, 280 BE 300 mm FROM FGL /HPP.
560 24 0 HOLES FOR
M20 BOLTS TYPE OF ATTACHMENT AT BASE
LADDER BOTTOM DETAILS
7 28.11.13 REVISED AND ISSUED AS STANDARD AJS P.K.MITTAL S.CHATURVEDI S.CHANDA

6 06.11.08 REAFFIRMED AND ISSUED AS STANDARD S.P.JOSHI P.K.MITTAL VINAY KUMAR V. CHATURVEDI

Date Purpose Convenor Chairmai
No. by by
Approved by
Förrnal• Nn R-00-01101-F4 RAV 0 rnnv-inht Fll - All rk-.nts rPsArvPrI
Page 1213 of 2065

STANDARD No.
ENGINEERS SKIRTING DETAIL
ter n s
(keen eiroverb7,1•Cnri)
INDIA LIMITED
(A Govt of India Undertaking)
(WITH BRICK WALL) 7-75-0002 Rev. 5
Page 1 of 1
BRICK WALL BRICK WALL
CEMENT PLASTER CEMENT PLASTER
GROOVE IN PLASTER
12 THICK CEMENT
MORTAR
TILE ADHESIVE (1 CEMENT : 3 SAND) z
0
(AS PER ITEM DESCRIPTION)

TILE SKIRTING
STONE SKIRTING
U
LA
Lai
RECESSED BRICK CI
RECESSED BRICK WALL AS REQUIRED C•I
I
WALL AS REQUIRED
STONE FLOOR FINISH
TILE FLOOR FINISH — FLOOR BASE
FLOOR BASE ta
CEMENT MORTAR — a_
TILE ADHESIVE — (1 CEMENT: 4 SAND)
FINISHED
FINISHED FLOOR LEVEL
FLOOR LEVEL
......
• . ' •
• • .
. „
SECTION A—A SECTION A—A

(TILE FLOORING–FLUSH SKIRTING) (STONE FLOORING–RAISED SKIRTING)
BRICK WALL RECESSED BRICK

WALL AS REQUIRED
STONE FLOOR FINISH —
FLOOR BASE
CEMENT MORTAR —
(1 CEMENT: 4 SAND)
FINISHED
FLOOR LEVEL
SKIRTING
PLAN SECTION A—A

NOTE: ALL DIMENSIONS ARE IN MM (STONE FLOORING–FLUSH SKIRTING)
5 07.11.16 REAFFIRMED & ISSUED AS STANDARD Dow' JS/J RAJANJI SRIVASTAVA R. KAMA
4 25.10.11 REVISED & REISSUED DK SD JKB D.IIALHOTRA

No. by by
Approved by
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Page 1214 of 2065

STANDARD No.
ki
r--Riaelei ENGINEERS SKIRTING DETAIL
Ift41014teg
larleff clecrAl =awns°
INDIA LIMITED (WITH R.C.C. COLUMN) 7-75-0003 Rev. 5
Govt of India Undertaking)
Page 1 of 1
RCC COLUMN
CEMENT PLASTER
TILE ADHESIVE
TILE SKIRTING 0
1-7
C•1
0
TILE SKIRTING
Id
RCC COLUMN TILE FLOOR FINISH
FLOOR BASE
Id
TILE ADHESIVE a.
= •
FINISHED
FLOOR LEVEL
•
• .
.•
• 4 ..• : . A • • .g
• A.
CHAMFER OF TILES • • •
AT 45' ANGLE
PLAN SECTION B-B

(TILE SKIRTING)
RCC COLUMN
CEMENT PLASTER
111 1/4.74.....:* 1 1
• . .
• •
12 THICK CEMENT
MORTAR
(1 CEMENT : 3 SAND) • 0
STONE SKIRTING
C)
STONE SKIRTING
0
RCC COLUMN
Id
STONE FLOOR FINISH
FLOOR BASE
I •
CEMENT MORTAR a.
(1 CEMENT: 4 SAND)
In
FINISHED
FLOOR LEVEL
•
CHAMFER OF STONE •• 4 . • :
AT 45' ANGLE
PLAN SECTION A-A

(STONE SKIRTING)
07.11.16
NOTE: ALL DIMENSIONS ARE IN MM
REAFFIRMED & ISSUED AS STANDARD

L
RAJANJI SRIVASTAVA
Imo'
R. PUMA
4 25.10.11 REVISED & REISSUED ok SD JKB D.MALIIOTRA

No. by by
Approved by
Fnrmat Nn 13-00-0001-F4 Rev 0 Convrinht Fll - All rinhts reserved
Page 1215 of 2065

STANDARD No.
ei ENGINEERS DADO DETAIL
ligar klf5teg
elecPle 051.340,41)
INDIA LIMITED (WITH BRICK WALL AND RCC COLUMN) 7-75-0004 Rev. 5
IA Govt of India Undertaking)
Page 1 of 1
BRICK WALL/RCC
COLUMN
CEMENT PLASTER
12 THICK
CEMENT MORTAR
(1 CEMENT : 3 SAND)/
TILE ADHESIVE FOR TILES
STONE/TILE DADO
PERDRAWING
STONE/TILE
FLOORING
FLOOR BASE
CEMENT MORTAR -
(1 CEM : 4 SAND)/
TILE ADHESIVE FOR
TILES
FINISHED
FLO VE
SECTION A-A
CHAMFER OF TILES/STONE
AT 45* ANGLE
/1/
CHAMFER OF TILES/STONE
AT 45* ANGLE
RCC COLUMN
BRICK WALL
STONE/TILE DADO
or"
PLAN PLAN
(DADO ON BRICK WALL) (DADO ON RCC COLUMN)

IrY
5 07.11.16 REAFFIRMED & ISSUED AS STANDARD Dio4v* RAJANJISRI
VBIRVA R. PANDA
25.10.11 REVISED & REISSUED DK

4 SO JKB D.MALHOTRA

No. by by
Approved by
Fnrmat No R-00-0001-F4 Rev n ennvrinht Fll - All rinhts reserved
Page 1216 of 2065

STANDARD No.
ei
ENGINEERS WOODEN FLUSH DOOR
Zigar 5leg INDIA LIMITED (WITH WOODEN FRAME) 7-75-0012 Rev. 5
lomewaxemJklam) Govt of India Undertaking)
Page 1 of 1
BRICK WALL
CEMENT PLASTER 25x6 MS HOLD FAST
BUTT HINGES EMBEDDED IN M-20 CONCRETE
BLOCK SIZE 350x100x100
TEAK WOOD LIPPING
50
—35 THICK FLUSH DOOR

SHUTTER
WOODEN FRAME
OUT OF 65x125
SECTIONAL PLAN 1-1

R.C.C. LINTEL
CEMENT
PLASTER
WOODEN
DOOR FRAME WOODEN FRAME
TOWER BOLT OUT OF 65x125
-e—o-
0
--o-
rr HOLD FAST
TEAK WOOD LIPPING
BUTT HINGE
0 600 MAXIMUM
4 THICK PLAIN GLASS
VISION PANEL WITH 35 THK.FLUSH
TEAK WOOD BEADING DOOR SHUTTER
_CAS PER DOOR PROFILE
)--
DRAWING)
0
cm 0
0 0
)—
I MORTICE LOCK WITH

HANDLE/ALDROP PLASTIC KICK
0
0 35 THICK FLUSH PLATE (ONLY FOR
0 DOOR SHUTTER TOILET DOOR)
0
I FINISHED FINISHED
FLOOR LEVEL
0
0
• •
780 TO 11804
ELEVATION SECTION 2-2

NOTE: 1. ALL DIMENSIONS ARE IN MM
2. DOOR HARDWARE SHALL BE AS/SPECIFICATION
11/`2‘"--
5 14.09.16 REAFFIRMED & ISSUED AS STANDARD DK,Pbt lJS/14"--- RAJANA SRIVASTAVA L MAMA
4 12.10.11 REVISED & REISSUED DK SO JKO D. IIALNOTRA

No. by by
Approved by
Format No R-00-0001-F4 RAV Convrinht Fll - All rinhts rasarvar
Page 1217 of 2065

STANDARD No.
0 el ENGINEERS
fgZIT tafileg INDIA LIMITED GLAZED ALUMINIUM DOOR 7-75-0014 Rev. 4
272x172 ,Tf?nvil (A Govl of mate Undeflaking)
Page 1 of 1
R.C.C. LINTEL/
BEAM
CEMENT PLASTER
F F F FiO 101.60x44.45x2 5
ALUMINIUM DOOR FRAME
Nr (SECTION No.20102)
I -.
ALUMINIUM GLAZING CLIP
(SECTION NO.19377)
GLASS
F I F
OPENABLE SHUTTER
SECTION 4-4
k] c DOOR HANDLE
F oom II O F
(SECTION NO.19377)-
101.60x44.45x2.5
) L.., ALUMINIUM DOOR FRAME
. C) (SECTION No.20102)
3
PIVOT 50x44.50x2.5
6 GAP PIVOT ALUMINIUM SHUTTER FRAME
(SECTION No.19554)
ELEVATION
(F—FIXED GLAZING)
ALUMINIUM BOTTOM RAIL
(SECTION NO.19584) ALUMINIUM GLAZING CLIP
(SECTION NO.19377)
101.60x44.45x2.5
ALUMINIUM DOOR FRAME GLASS
(SECTION NO.20102)
50x44.50x2.5 ALUMINIUM
RUBBER/EPDM GASKET
SECTION 5-5
SHUTTER FRAME
(SECTION No.19554)
PIVOT 100x44.45x2
GLASS ALUMINIUM LOCK RAIL
47.62X44.45X2.8 ALUMINIUM
SHUTTER FRAME (SECTION No.19564)
(SECTION No.19502)
SECTION 2-2
BRICK WALL/R.C.C. COLUMN
CEMENT PLASTER ALUMINIUM GLAZING CLIP
(SECTION NO.19377)
101.50x44.50x2.5 ALUMINIUM DOOR
FRAME (SECTION No.20102) FIXED WITH
ALUMINIUM LUGS/ANCHOR FASTENER
ALUMINIUM GLAZING CLIP (SECTION NO.19377) SECTION 6-6
GLASS
GLASS
(SECTION NO.19377)
GLASS
150x44.45x3.10
ALUMINIUM BOTTOM RAIL
101.60X44.45X2.5 (SECTION No.19584)
ALUMINIUM FRAME
(SECTION NO.20057)
SECTION 1 —1 SECTION 3-3 FINISHED FLOOR LEVEL
NOTES:
1. ALL DIMENSIONS ARE IN MM.
THE SECTION DESIGNATION NOS. PERTAIN TO EXTRUDED ALUMINIUM SECTIONS OF
"JINDAL ALUMINIUM LTD." AND ARE INDICATED FOR REFERENCE. EQUIVALANT SECTIONS
S ECTION 7-7
OF OTHER APPROVED MANUFACTURERS CAN ALSO BE USED.
FOR FINISHING OF ALUMINIUM SECTION (ANODISED/POWDER COATING) REFER BID/TEND ER.
RUBBER/EPDM GASKET SHALL BE USED FOR FIXING OF GLASS.
HARDWARE SHALL BE AS PER BID/TENDER.
4 27.03.12 REVISED & ISSUED AS STANDARD JKAFV" MAY KUMAR D.MALHOTRA
3 21.03.07 REVISED, ISSUED AS STANDARD AMARJIT JKB/SO WHO KUMAR V.CHATURVEDI
Rev. Prepared Checked Stds, Committee GM(E) Stds. Bureau

No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EL - All rights reserved
Page 1218 of 2065
STANDARD No.
ENGINEERS
INDIA LIMITED GLAZED ALUMINIUM WINDOW 7-75-0015 Rev. 4
/A Govt 01 Incha Undertaking}
Page 1 of 1
RCC BEAM/
LINTEL
CEMENT
F 0 PLASTER
SECTION 20919
SECTION 19428
r-
1
0
1
GLASS
0
F SH SH F SECTION 1 —1
-
GLASS
‘S
ELEVATION SECTION 19428

(F -FIX ED GLAZING)
(SH -SIDE HUNG SHUTTER) SECTION 20916
SECTION 20899
SECTION 20916 SECTION 19428
SECTION 20899
SECTION 19428
GLASS GLASS
SECTION 2-2
GLASS
INSIDE SECTION 19428

SECTION 20919
SECTION 6-6 SECTION 7-7 CEMENT
BRICK WALL GLASS
CEMENT PLASTER SECTION 19428 BRICK WALL —•sr.E
SECTION 20916
SECTION 20919
SECTION 19428 GLASS — SECTION 3-3
— GLASS
GLASS
SECTION 19428
SECTION 20916
SECTION 8-8 SECTION 9-9 SECTION 20899

23.00 SECTION 19428
t t
30.5 GLASS
0
0 In
N SECTION 4
GLASS
63.00 40.60 40.00 3 SECTION 20899
3 3 SECTION 19428
SECTION. SECTION. SECTION. SECTION.
NO.-20916 NO-20919 NO.-20899 NO.-19428
NOTE: 1. ALL DIMENSIONS ARE IN MM. SECTION 20919
THE SECTION DESIGNATION NOS. PERTAIN TO EXTRUDED ALUMINIUM
SECTIONS OF "JINDAL ALUMINIUM LTD." AND ARE INDICATED FOR
REFERENCE. EQUIVALANT SECTIONS OF OTHER APPROVED CEMENT
MANUFACTURERS CAN ALSO BE USED. PLASTER
FOR FINISHING OF ALUMINIUM SECTION (ANODISED/POWDER BRICK WALL
COATING SWING
RUBBER/EPDM GASKET SHALL BE USED FOR FIXING OF GLASS.
HARDWARE AND GLASS SHALL BE AS PER BID/TENDER.
4 27.03.12 REVISED, ISSUED AS STANDARD *LI JK VINAY KUMAR D.MALHOTRA
3 21.03.07 REVISED, ISSUED AS STANDARD AMARJIT JKB/SD ARVIND KUMAR V.CHATURVEDI
Rev. Prepared Checked Stds. Committee GM(E) Stds. Bureau

No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - At rights reserved
Page 1219 of 2065

STANDARD No.
oiraeitiiM ENGINEERS STEEL WINDOWS/VENTILATORS
Ifgai faf51--eg ITIWIF INDIA LIMITED 7-75-0027 Rev. 5
GENERAL SPECIFICATIONS
ROM vtroweasNosvi„A Govt of India Undertaking)
Page 1 of 1
SPECIFICATIONS: STEEL WINDOWS / VENTILATORS SHALL BE MANUFACTURED STRICTLY IN CONFORMITY

WITH IS:1036 AND IS:1361.
SECTION: BEST QUALITY HOT ROLLED MILD STEEL SECTION CONFORMING TO IS:7452 SHALL BE
USED.
CONSTRUCTION: SECTIONS SHALL BE CUT TO REQUIRED LENGTH. THE CORNERS OF THE WINDOW
SHALL BE ELECTRICALLY FLASH BUT WELDED AND MITRED TO FORM A SOLID
FUSED RIGHT ANGLE JOINT SO THAT ALL FRAME SHALL BE SQUARE AND FLAT.
SUB DIVIDING BARS OF THE UNIT SHALL BE TENDED AND RIVETED TO THE FRAMES.
FENESTRA JOINT: AT THE INTERSECTION OF TEE SECTIONS THE VERTICAL TEE SHALL BE BROACHED
AND THE HORIZONTAL TEE SHALL BE THREADED THROUGH IT. THE INTERSECTION
SHALL BE CLOSED BY HYDRAULIC PRESSURE.
HINGES: PRESSED STEEL (HEAVY DUTY) HINGES SHALL BE INSERTED IN THE SLOTS CUT IN
THE OUTER FRAME FROM INSIDE. SIDE HUNG WINDOWS SHALL BE FITTED WITH
PROJECTING HINGES WITH ELECTRO GALVANISED STEEL PINS AND WASHERS TO
FACILITATE CLEANING OF GLASS PANES. TOP HUNG VENTILATORS SHALL BE
PROVIDED WITH PRESSED STEEL BUTT HINGES RIVETED TO OPENING SHUTTER AND
WELDED TO THE OUTER FRAME CUTTING SLOT IN IT.
FITTINGS: SIDE HUNG WINDOWS SHALL BE PROVIDED WITH HANDLES AND PEG STAYS OF
STEEL.
HANDLES SHALL HAVE A TWO POINT NOSE WITH A MILD STEEL BEVELLED STRIKING
PLATE RIVETED TO THE FIXED FRAME.
PEG STAYS SHALL HAVE THREE / FOUR DIFFERENT HOLES TO KEEP THE WINDOW
OPEN IN DIFFERENT POSITIONS UP TO A MAXIMUM OF 90 DEGREE.
HANDLE PLATES STAY, PEG STAY RESTS AND LOCKING BRACKETS SHALL BE OF
PRESSED STEEL AND SHALL BE RIVETED TO THE FRAME.
TOP HUNG VENTILATORS SHALL BE PROVIDED WITH PEG STAYS OF BRASS OR STEEL.
COMPOSITES: WINDOWS / VENTILATORS FOR LARGE OPENINGS SHALL BE FORMED BY COUPLING

DIFFERENT UNITS WITH VERTICAL COUPLING MULLION (K118).
5 12.09.16 AFFIRMED & ISSUED AS STANDARD RAJANJI SRIVASTAVA R. SAWA
4 12.10.11 REVISED & REISSUED DK SD JKS D. MALHOTRA

No. by —in-- Approved by
Format Nn R-00-0001-F4 Rev 0 Convrinht Fll - All rinhts reserver
Page 1220 of 2065

STANDARD No.
0 el ENGINEERS
Igar fa5itg K.:1) INDIA LIMITED STEELUSE
laiTen 2i7E1512 ,613,05i1)
WINDOWS/VENTILATORS 7-75-0028 Rev. 5
OF SECTIONS
(A Govt of India Undertaking)
Page 1 of 1
PURPOSE OR RECOMMENDED USE OF SECTIONS
NOTE : DESIGNATION OF SECTIONS ARE AS/ IS 7452.
SR. NO. DESIGNATION USE

OF SECTION
1. F7D : WINDOWS / VENTILATORS OUTER AND SHUTTER FRAME.
2. F4B : CENTRAL MULLION (MEETING BAR FOR SHUTTERS) FOR WINDOWS /

VENTILATORS. SUB DIVIDING BARS FOR OPENABLE WINDOWS AND
TOP—HUNG VENTILATORS.
3. T2 : VERTICAL AND HORIZONTAL GLAZING BARS FOR SASHES, WINDOWS,

VENTILATORS, SUB DIVIDING BARS FOR FIXED—LIGHTS, SASH BARS
FOR WINDOWS AND VENTILATORS.
4. K11B : (A) VERTICAL COUPLING MULLION FOR WINDOWS / VENTILATORS.
(B) CAN BE USED AS HORIZONTAL COUPLING BAR WHEN OPNABLE

WINDOWS ARE TO BE COUPLED ABOVE FIXED ONES OR BETWEEN
TWO FIXED WINDOWS.
5 12.09.16 REAFFIRMED & ISSUED AS STANDARD DK eS.° JS/JKe LAVA R. BANDA
4 12.10.11 REVISED & REISSUED DK SD/JKB JKB D. tMU4OTRA

No. by by
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Page 1221 of 2065

STANDARD No.
ei ENGINEERS STEEL WINDOWS
ligar f8151-eu
Reen vileake wawa))
INDIA LIMITED
(A Govt. of India Undertaking) SECTION DETAILS
7-75-0029 Rev. 5
Page 1 of 1
SIDE HUNG GLAZED SHUTTER
r FIX GLAZED ,
I I I I
49,_ I I
I Nir I I
J L J
ELEVATION
GLASS AS
SPECIFIED
F4B
2 THICK MS SHEET 2 THICK WEATHER BAR
FABRICATED BOX
PUTTY SHUTTER FRAME F7D
PUTTY
GLASS AS GLASS AS SPECIFIED
SPECIFIED

SHUTTER
GLASS AS SPECIFIED FRAME F7D
SHUTTER FRAME F7D COUPLING
CENTRAL MULLION F4B MULLION K11B
SASH BAR T-2 GLASS AS
SPECIFIED
Ei
MS HINGE
a
r \‘‘‘N‘Sjr
A
PUTTY
SECTION 2-2 MS SCREW
MASTIC
100X15X6 MS GLASS AS
LUGS 0 750 C/C SPECIFIED
BRICK WALL CENTRAL
CEMENT PLASTER GLASS AS MULLION F4B
SPECIFIED
SHUTTER —PUTTY
FRAME F7D SHUTTER
MS HINGE FRAME F7D
WINDOW FRAME F7D
SECTION 1 -1
DESIGNATION OF SECTIONS ARE AS/ IS : 7452.
(v^›
5 12.09.16 REAFFIRMED & ISSUED AS STANDARD DK /141". RAJANJI SRIVASTAVA R. NANA
4 12.10.11 REVISED & REISSUED DK SD JKB D. MALNOTRA

No. by by
Approved by
Page 1222 of 2065

STANDARD No.
ENGINEERS STEEL WINDOWS
ligarfarkg INDIA LIMITED 7-75-0032 Rev. 5
wren 4513UMR IA Govt. of India Undertaking) FITTINGS AND FIXTURES
Page 1 of 1
STEEL FRAME
T
3 THICK MS FLAT
CUT/BENT TO SHAPE
NYLON WASHER 0
8 DIA MS BOLT 3 THICK BRASS—T

STRIKNGPLAE
—N—
DETAIL OF MS HINGE DETAIL AT A-A
3 THICK 10 PROJECTED STEEL FRAME

BRASS STRIKING PLATE
RIVETED TO WINDOW 4 DIA PIN
FRAME TO HOLD THE
HANDLE IN POSITION
10 DIA MS FIXING SCREW
3 THICK BRASS 3 THICK MS
STRIKING PLATE FABRICATED HANDLE
11 ROUND OR PVC WASHER

SQUARE HOLE
DETAIL OF HANDLE
73 ; so TO WE
30
2 THICK MS
4) rp- -+- Ri
FABRICATED STAY 8 DIA PIN
1 B
75
I 65
300
65 75
DETAIL OF PEG STAY

NOTE: 1. ALL DIMENSIONS ARE IN MM.
2. FOR ADDITIONAL DETAILS REFERENCE SHALL BE MADE TO IS:1038.
/ 14)1
5 12.09.16 REAFFIRMED k ISSUED AS STANDARD ,„ette, ism RAJAIMI SRIVASTAVA R. HAMM
4 23.04.12 REVISED & ISSUED AS STANDARD DR SD JKt D. MALHOTRA

Date Purpose by by Convenor Chairman
No.
Approved by
Format No 8-00-0001-F4 RAN/ 0 Convrinht Fll - All rinhts MISR rVI:Ki
Page 1223 of 2065

STANDARD No.
ENGINEERS PIPE HANDRAIL
Og-ar faWs INDIA LIMITED
IA Govt of Incha Undertak.g) WITH SQUARE UP RIGHT TYPE
7-75-0036 Rev. 5
Page 1 of 1
40x5mm MS
FLAT NOSING
TREAD FINISH
25x6mm, 250mm LONG MS

LUG WELDED TO NOSING FLAT
0 MIN. 500mm & EMBEDDED
IN RCC STEP
CEMENT MORTAR
32 0 N.B. (MEDIUM)
MS PIPE 12mm THICK CEMENT
WELDED PLASTER
TO BALUSTERS
25x25mm MS SQUARE
BAR BALUSTERS OVER
EACH STEP
SECTION A-A
(FOR CAST IN—SITU CONCRETE TREAD)
NOSING
CEMENT MORTAR
— KOTA/GRANITE/MARBLE STONE
FINISH
TREAD FINISH
CEMENT MORTAR
50x50x100mm POCKET
FOR FIXING MS FLAT 10MM
SHOE FILLED WITH MINIMUM
CEMENT CONCRETE (1:3:6)
40x40x6mm THK. MS
FLAT SHOE WELDED AT
BOTTOM OF BALUSTER &
INSERTED IN RCC STEP
SECTION A-A
12mm THICK (FOR STONE FINISHED TREAD)
CEMENT PLASTER
DETAIL OF HANDRAIL
NOTE: 1. ALL DIMENSIONS ARE IN MM.

2. RISER, TREAD AND SKIRTING SHALL BE OF SAME ,ifINISH
5 07.03.14 REVISED AND ISSUED AS STANDARD ;èSD JKB S.CHATURVEDI S. CHANDA
4 09.03.09 REVISED AND ISSUED AS STANDARD AG SD/JKB VINAY KUMAR N.DUARI
Rev. Date Purpose Prepared Checked Stds. Committee GM(CIVIL) Stds. Bureau
No. by by Convenor Chairman
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - AII rights reserved
Page 1224 of 2065

STANDARD No.
ENGINEERS FALSE CEILING DETAIL
IA Govt of India Undertaking) WITH ALUMINIUM GRID
Page 1 of 1
RCC SLAB
25x25x3 THICK
MS ANGLE FIXED
TO ROOF WITH
ANCHOR FASTENERS
@ 1200 C/C MAX.
6 DIA M S HANGER CEMENT

@1200 C/C BOTHWAYS PLASTER
BRICK WALL
10 110
LEVELING NUT
3 THICK MS
FLAT CLAMP
MS NUT WITH RETURN AIR GRILL

MMI 25 LONG BOLT
/ 11111111 10111
ALUMINIUM MAIN TEE
25 x 35 x 2.5 THICK
ALUMINIUM ANGLES
CEILING TILES
AS SPECIFIED
SECTION AT 1-1
Epp MAIN TEE ® 600 C/C

CROSS TEE @ 600 C/C
CEILING TILE
AS SPECIFIED
!PA
AI A V /
ALUMINIUM CROSS
RETURN AIR SLIT TEE 25x25
COVERED WITH
GRILL AS/SECTION 1-1
PLAN (PART) SECTION AT 2-2

(ELECTRICAL, A/C FIXTURE LOCATIONS SHALL BE AS PER DETAIL DRAWING)
NOTE: ALL DIMENSIONS ARE IN MILLIMETRES.
I.
Is 1.4 - OLD
5 02.03.16 REVISED & ISSUED AS STANDARD K ifilk/J B RAJANJI SRIVASTAVA S. CH NDA
4 31.08.10 REAFFIRMED & ISSUED AS STANDARD SANDHYA GB/JS JKB N. DUARI

No. by by
Approved by
Format Nn a_nn_onni-Ftt RPV n norwrinht Fll - All rinhts raaarvari
Page 1225 of 2065

STANDARD No.
ENGINEERS ALUMINIUM PANEL FALSE
$1ftl 0141 eg
Rivnefromen513,10511) IA Govt. of India Undertakindt , CEILING (TRAY TYPE)
Page 1 of 2
26 SWG GI
MAIN RUNNER ROOF SLAB
44
G I CEILING
,
HANGER (SLOTTED) FIXED TO
CEILING I WALL r /
A
H
CEMENT
) PLASTER / /
t
GI SUSPENSION
ANGLE
R ETURN / /
AIR GRILL
/ /
if SI
ALUMINIUM ALLOY
ALUMINIUM
CEILING PANEL ANGLES
ALUMINIUM
SECTION 1-1 HOLD ON HANGER
(HANGING/SUSPENSION ARRANGEMENT CAN VARY FROM VENDOR TO VENDOR)
ALUMINIUM ALLOY
CEILING PANEL
MAIN RUNNER
SIZE : 254/305x1264
OR AS/DRAWING
LIGHTING FIXTURE/DIFFUSER RETURN —

AIR SLIT COVERED
WITH GRILL AS PER
SECTION 1-1
REFLECTED CEILING PLAN (PART)

(LINEAR PANEL)
5 02.03.16 REVISED & ISSUED AS STANDARD "'SD/J RAJANJI AVA S. CHANDA
4 31.08.10 REVISED & ISSUED AS STANDARD SANDHYA GB/JS JKB N. DUARI

No. by by
Approved by
Format No R-00-0001-F4 RPV 0 Convrinht Fll - All rinhts rpsprvpri
Page 1226 of 2065

STANDARD No.
((ro) ENGINEERS ALUMINIUM PANEL FALSE
Ifear Elf5teg
(rte c'- ,e ebl3TIV41)
INDIA LIMITED
,,Go■ft. of lodilJnertakiN),, CEILING (TRAY TYPE)
7-75-0043 Rev. 5
Page 2 of 2
RAWL PLUG
'J' HOOK
GI ROD HANGER
AT 1200 C/C
HOLD ON CLAMP WITH WALL

CLIP AT 1200 C/C
CEMENT
PLASTER
RETURN
—CLIP IN PROFILE AIR GRILL
AT 600mm C/C
I'll
ALUMINIUM ALLOY ALUMINIUM ANGLES
CEILING PANEL
SECTION 1-1
(HANGING/SUSPENSION ARRANGEMENT CAN VARY FROM VENDOR TO VENDOR)
— MAIN RUNNER
ALUMINIUM ALLOY RETURN AIR SLIT
CEILING PANEL 600 COVERED WITH
f 17C • LfMLnn
JILL
• (TTY.) (KILL AS/StC. I ,
1 ii II 11 1
1 - II 11 ii 1
1 11 ii ii 1
1 II II II 1
0
.., iii I -ti I
II II
,.. N/11
1 i/.1 II 0 1
II 1 II 1, 1, II
ii ii 11 11
11 1 ii ii ii II
II II iiII II ,,\ 1, 11 II II II
II II II II II I I, I, II II II 1
,
LIGHTING FIXTURE/DIFFUSER
REFLECTED CEILING PLAN (PART)

(600mm X 600mm PANELS)
41_
5 02.03.16 REVISED Et ISSUED AS STANDARD 4/4-CK )(CfSD/JK8 RAJANJI SRIVASTAVA S. CHANDA
4 31.08.10 REVISED 11 ISSUED AS STANDARD SANDHYA GB/JS JKB N. DUARI

No. by by
Approved by
Format Nn s_nn_nnni-F4 RPV Cnnvrinht Fll - All rinhfc rpeprvprl
Page 1227 of 2065

STANDARD No.
ENGINEERS TRANSFORMER GATE DETAILS
(A Govt or India Undertaking) (UPTO 6000mm. WIDTH)
Sheet 1 of 2
50x50x8 GAUGE
R.C.0 COLUMN WELDED MESH
75X50,8 THK
M.S INSERT PLATE 25x25x3 M.S ANGLE
2 NOS. 6 THK. M.S.FLATS
WELDED TO INSERT PLATE
40x40x3.2 M.S. SQUARE
FABRICATED HINGE ASSEMBLY HOLLOW SECTION
AS/DETAIL DETAIL AT
2 NOS. 6 THK. M.S.FLATS
25x25x3 M.S ANGLE
WELDED TO FRAME
40x40x3.2 M.S. SQUARE 50x50x4.5 M.S SQUARE
HOLLOW SECTION HOLLOW SECTION FRAME
50x50x8 GAUGE —
WELDED MESH
75
12 DIA. HOLE
50x50x4.5 M.S SQUARE FOR LOCK
HOLLOW SECTION FRAME 40x40x6 M.S. ANGLE FOR
M.S HOLD FAST LOCKING ARRANGEMENT
25x6x200 LONG
DETAIL PLAN (PART SHOWING ONE SHUTTER)

40x40x6 M.S. ANGLE FOR
FABRICATED LOCKING ARRANGEMENT
HINGE ASSEMBLY
AS/DETAIL
25x25x3 M.S. ANGLE 12 DIA. HOLE FOR LOCK
50x50x8 GAUGE
WELDED MESH 50x50x4.5 M.S SQUARE
50x50x4.5 M.S SQUARE HOLLOW SECTION FRAME
HOLLOW SECTION FRAME
EQ EQ.
HOLLOW SECTION
DETAIL AT
•
1,
IIME• IMMO
:
IIIIIIII• I••• 50x50x4.5 M.S SQUARE
11111••
I. 11.11111
11•••
HOLLOW SECTION FRAME
. IIIC i . IIN IV.
. MN
NAOMI*
,,.•••••
1•••••11111. •••••
1••••••••
(I)
I-
L11 D
.-I 12 SQUARE 0
L
M.S BARS 50x50x8 GAUGE
EARTHING LUG (TYP.) WELDED MESH
(FOR DETAILS REFER
ELECTRICAL STD. NO. 7-51-0115)
HOLLOW SECTION
ELEVATION 25 DIA. 100 LONG
HOLE IN FLOOR 25x25x3 M.S ANGLE
20 DIA. M.S. BAR
TOWER BOLT 250 LONG

HOLLOW SECTION
RCC COLUMN
EARTHING LUG (TYP.)
AS PER (FOR DETAILS REFER
P ARCH. ELECTRICAL STD. NO.
DRAWINGS
7-51-0115)
EQUAL, / "EQUAL
I I
L_-- 3000 TO 6000 _J
PLAN
NOTE:
SECTION AT 0 -0
ALL STEEL MEMBERS SHALL CONFORM TO RELEVANT B.I.S. CODES AS4PPLICABLE. L
5 14.12.15 REVISED ft ISSUED AS STANDARD '1"4/'DK )1,4*[;/A&-- RAJANJI SdlatrAlq, S. CHANDA
4 13.10.10 REVISED ft ISSUED AS STANDARD SANDHYA GB/JS JKB N. DUARI

No. by by
Approved by
Format Nn 8-00-0001-F4 Rev Convrinht Fll - All rinhts reserved
Page 1228 of 2065

STANDARD No.
ENGINEERS TRANSFORMER GATE DETAILS
f:4U fe1156 INDIA LIMITED (U PTO 6000mm. WIDTH)
7-75-0051 Rev. 5
(lfl electoee(A.Agns0 (A Govt of India findetta(OV
Sheet 2 of 2
75 1 75
R.C.C. COLUMN
2 NOS. 6 THK. 50x50x4.5 M.S SQUARE
M.S.FLATS WELDED TO HOLLOW SECTION FRAME
INSERT PLATE
75X50,8 THK. HOLLOW SECTION
M.S INSERT PLATE
M.S HOLD FAST 50x50x8 GAUGE
25x6x200 LONG
4 WELDED MESH
FABRICATED HOLLOW
M.S CYLINDER MADE OF 2 NOS. 6 THK. M.S.FLATS
5 THK. M.S PLATE WITH WELDED TO FRAME
20 INTERNAL DIA.
FIXED TO SHUTTER 25x25X3 M.S. ANGLE
FABRICATED
HINGE ASSEMBLY
DETAIL AT
NMI
■ 49 AM/
25X25X3 M.S. ANGLE
50x50x8 GAUGE
■ AMP WELDED MESH

HOLLOW SECTION
25X25X3 M.S. ANGLE
► 12 SQUARE
4•\ \
M.S BARS
1111011
DETAIL AT
75
50x50x8 GAUGE
R.C.C. COLUMN WELDED MESH
75 25X25X3 M.S. ANGLE

•
WELD JOINT BETWEEN
VERTICAL Ft HORIZONTAL . 2 50 40x40x3.2 M.S. SQUARE
MEMBERS (TYP. FOR HOLLOW SECTION
ALL LOCATIONS)
111
50x50x4.5 M.S SQUARE

X.1.71‘,„ HOLLOW SECTION FRAME
2Nos. 50x100x6 THICK
M.S. FLAT WELDED TO FRAME EARTHING LUG (TYP.)
AND M.S. SQUARE BAR (FOR DETAILS REFER ELECTRICAL
F.F.L. STD. NO. 7-51-0115)
32 M.S SQUARE BAR WELDED
1 1 1 TO FRAME (MACHINE GRINDED
I I I TO ROUND SHAPE AT BOTTOM)
I I I I.,
60x60x125 M.S SOLID SECTION
WITH 100 DEEP CIRCULAR SLOT
I I I IV
FOR PIVOT ROD I LJI
L —
_160_1_
NOTE: DETAIL AT
ALL STEEL MEMBERS SHALL CONFORM TO RELEVANT B.I.S. CODES ASPPLICABLE.
5 14.12.15 REVISED Et ISSUED AS STANDARD ..466- SD/JKB RAJANJI SRIVASTAVA S. CHANDA

4 13.10.10 REVISED Et ISSUED AS STANDARD SANDHYA GB/JS JKB N. DUARI
No. by by
Approved by
Format No 8-00-0001-F4 RAV 0 Convrinht Fll - All rinhts rpsprver1
Page 1229 of 2065

STANDARD No.
0 el ENGINEERS TRANSFORMER GATE DETAILS
IfgarfEitigleg INDIA LIMITED 7-75-0052 Rev. 4
elvove .3413, 01 (A
(BEYOND 6000mm. WIDTH)
Govt of India Undertaking)
Sheet 1 of 1
132X132X5.4 M.S.
SQUARE BOX SECTION
4-16
BOLT
300X300, 12 THK.
M.S. BASE PLATE
CONC. BLOCK (M-25)/

50x50x4.5 M.S
STUB COLUMN AS PER
STRUCTURAL DETAILS. SQUARE HOLLOW
SECTION FRAME
ELEVATION 50X50X6 THK.
PLATE M.S ANGLE
65x65x6
132X132X5.4 M.S.
SQUARE BOX SECTION 40 DIA.3 THK.
• M.S HOLD FAST M.S WASHER
25x6x200 LONG 20 DIA.M.S BOLT
132X132X5.4 M.S.
65x65X6 Et
SQUARE BOX SECTION
50 LONG M.S
0
0 ANGLE HINGE
300X300, 12 THK.
M.S. BASE PLATE
HOLES IN BASE PLATE

FOR ANCHOR BOLTS 16 gl
PLAN DETAIL AT 0
FIXING DETAIL AT OA 25X25X3 M.S. ANGLE
FABRICATED HINGE 50x50x4.5 M.S SQUARE CAP PLATE
ASSEMBLY AS/DETAIL HOLLOW SECTION FRAME 6 THK.
40x40x3.2 M.S. SQUARE (TYP.)
50x50x8 GAUGE
WELDED MESH HOLLOW SECTION
IAN
I
1 C i -11
1 •X M•
1
1•11 /ter, la%
25 DIA. 100 LONG HOLE IN FLOOR

20 DIA. M.S. BAR
TOWER BOLT 250 LONG 12 SQUARE
200 LONG M.S. ALDROP M.S BARS
EARTHING LUG (TYP.) 25X25X3 M.S.
(FOR DETAILS REFER ELECTRICAL ANGLE
STD. NO. 7-51-0115)
ELEVATION
132X132X5.4 M.S.
SQUARE BOX SECTION
(REMOVABLE TYPE)
R.C.C. REMOVABLE FENCING
COLUMN
EQ. EQ. EQ. EQ.

AS PER
ERCH.
RAMP DRAWINGS
EQ.
1000
If EQ.
6000 TO 12000 OR AS PER ARCH. DRAWING

•
PLAN
NOTES:
1. FOR DETAILS0 Et°REFER STANDARD NO. 7-75-0051
2. ALL STEEL MEMBERS SHALL CONFORM TO RELEVANT B.I.S. COT. AS APPLICABLE.A
t
L lc,L j\/
4 14.12.15 REVISED & ISSUED AS STANDARD ,e-eir DK .W'"SD/JKT I.- RAJANJI SRIVASTAVA S. CHANDA
3 13.10.10 REVISED Et ISSUED AS STANDARD SANDHYA GB/JS JKB N. DUARI

Rev.
No. by by
Approved by
Format Nn 8-00-0001-F4 RAV 0 r.nnvrinht Fli - All rights rApArvpri
Page 1230 of 2065

STANDARD No.
0`11Relei ENGINEERS ORISSA PAN W.C.
Ogar faOleg ;fru INDIA LIMITED
MUT eirane• E1573,10.1)
)
(A Govt of India Undertaking) (FIXING DETAIL)

7-75-0060 Rev. 5
Page 1 of 2
/1,
DADO
DOOR CISTERN
BRACKET
(AS/ITEM DESCRIPTION)
BIB COCK
O FLUSH PIPE
O
FINISHED FLOOR
FLOOR FINISH ORISSA PAN WC LEVEL
SUNK BY
MINIMUM 10MM
FILLED UP MATERIAL
AS/ITEM DESCRIPTION
SLOPE TO MAIN HOLE
. • ' • . • . •
. v
„ •.
—.a a ' • ,* • .
CUT OUT IN WALL
SECTION A—A (FOR GROUND FLOOR)

(REFER SHEET 2 OF 2 FOR SECTION A—A APPLICABLE TO UPPER FLOORS WITH SUNK SLAB)
r BIB COCK
150
4%
6' 0
C====
S 0
O
10fr ORISSA PAN W
O
10MM DROP CISTERN

IN FLOOR
A STOP COCK
1200 MINIMUM
1
PLAN
NOTE: REFER SHEET 2 OF 2.
114
5 07.11.16 REVISED & REISSUED AS STANDARD. Dict"Y‘,°' JI sop RAJANJI SRIVASTAVA R. NANDA
4 09.11.11 REVISED & REISSUED OK SD JKB D.MALHOTRA

Convenor Chairman
No. by by
Approved by
Page 1231 of 2065
STANDARD No.
ENGINEERS ORISSA PAN W.C.
/Z4Z11 01:11 g INDIA LIMITED 7-75-0060 Rev. 5
Wren efeamennJodsn) IA Gov) of India Undertaking) (FIXING DETAIL)
Page 2 of 2
BRACKET
BIB COCK
FLUSH PIPE
FINISHED FLOOR
FLOOR FINISH — ORISSA PAN WC LEVEL
SUNK BY
MINIMUM 10MM VERTICAL PIPE
FILLED UP
MATERIAL AS PER
ITEM DESCRIPTION
CUT—OUT IN RCC
BEAM FOR PIPE
PENETRATION
SECTION A-A
(FOR UPPER FLOOR WITH SUNK SLAB)
(REFER SHEET 1 OF 2 FOR SECTION A—A APPUCABLE TO GROUND FLOOR)
NOTES:
1. ALL DIMENSIONS ARE IN MILLIMETRES.
2. ALL FLOOR FINISH LEVEL INSIDE THE W.C. CUBICLE SHALL
BE 10 TO 15MM LOWER THAN OUTSIDE.
3. PROVISION FOR NECCESSARY CUT—OUT IN THE R.C.C. STRUCTURAL
BEAM SHALL BE KEPT (FOR DISPOSAL PIPE PENETRATION). THE LOCATION
ANGLE, GRADIENT ETC. OF THE CUT—OUT SHALL BE AS PER SITE REQUIREMENTS.
4. REFER RELEVANT ARCHITECTURAL DRAWINGS FOR ACTUAL SIZE OF THE CUBICLE.
5 07.11.16 REVISED & REISSUED AS STANDARD /JO RAJANJI ASTAVA R. NANDA
4 09.11.11 REVISED & REISSUED DK SD JKB D.NIALHOTRA

Convenor Chairman
No. by by
Approved by
Page 1232 of 2065
STANDARD No.
ENGINEERS
feDI EUROPEAN TYPE WC
7-75-0062 Rev. 5
$iitaf 201-eg INDIA LIMITED (FIXING DETAIL)
laireK efeavIvrdnagasain (A Govt of India Undertaking)
Page 1 of 2
DADO
TOILET PAPER
HOLDER
CISTERN
EUROPEAN
TYPE WC
DOOR BIB COCK BRACKET

0 FLUSH PIPE WITH

0
BEND COMPLETE
FLOOR FINISH
SUNK BY S OR P TRAP
MINIMUM 10MM.
FLOOR TRAP SLOPE TO MAIN HOLE

COVERED WITH
GRATING
BRICK WALL
FILLED UP MATERIAL AS PER ITEM DESCRIPTION — CUT OUT IN WALL
SECTION A—A (FOR GROUND FLOOR

(REFER SHEET 2 OF 2 FOR SECTION A—A APPLICABLE TO UPPER FLOORS ITH SUNK SLAB)
FLOOR TRAP COVERED
WITH GRATING
SLOPE
BIB COCK
V0
4 0
e 200
(AS/ARCH. 'DRAWINGS)
10MM DROP
IN FLOOR EUROPEAN In
TYPE WC
CISTERN
STOP COCK
1300 MINIMUM
PLAN
NOTE: REFER SHEET 2 OF 2.
5 07.11.16 REVISED & REISSUED AS STANDARD JS/JKB AVA R. NANDA
4 09.11.11 REVISED & REISSUED DK SD JKB D.MAL/101RA

No. by by
Approved by
Fnrmat No A-00-0001-F4 RIAV Cnnvrinht Fll - All rinhts rPS440/Pri
Page 1233 of 2065

STANDARD No.
n~ie ENGINEERS EUROPEAN TYPE WC
7-75-0062 Rev. 5
lzgar Rift INDIA LIMITED
eiravran3denan IA Govt of India Undertaking)
(FIXING DETAIL)
Page 2 of 2
TOILET PAPER
HOLDER
CISTERN
I I VERTICAL PIPE
EUROPEAN I I
I I
TYPE WC I
DOOR I I
I I
BIB COCK BRACKET

FLUSH PIPE WITH

BEND COMPLETE
FLOOR FINISH
SUNK BY S OR P TRAP
MINIMUM 10MM.
FLOOR TRAP
COVERED WITH
GRATING CUT OUT IN RCC
BEAM FOR PIPE
RCC BEAM PENETRATION
N
FILLED UP MATERIAL AS PER ITEM DESCRIPTION
SECTION A-A
(FOR UPPER FLOOR WITH SUNK SLAB)
(REFER SHEET 1 OF 2 FOR SECTION A—A APPLICABLE TO GROUND FLOOR)
NOTES:
2. ALL FLOOR FINISH LEVEL INSIDE THE W.C. CUBICLE SHALL
BE 10 TO 15MM LOWER THAN OUTSIDE.
3. PROVISION FOR NECCESSARY CUT—OUT IN THE R.C.C. STRUCTURAL
BEAM SHALL BE KEPT (FOR DISPOSAL PIPE PENETRATION). THE LOCATION
ANGLE, GRADIENT ETC. OF THE CUT—OUT SHALL BE AS PER SITE REQUIREMENTS.
4. REFER RELEVANT ARCHITECTURAL DRAWINGS FOR ACTUAL SIZE OF THE CUBICLE.
5 07.11.16 REVISED & REISSUED AS STANDARD DoO"'" JS/J RAJANJI SRIVASTAVA R. MAMBA
4 09.11.11 REVISED & REISSUED DK SD JKB D.11AUCTRA

No. by by
Approved by
Format No A-00-0001-F4 RAV 0 Cnnvrinht Fll - All rinhts rpaprvarl
Page 1234 of 2065

STANDARD No.
ei ENGINEERS 7-75-0063 Rev. 5
5fgar fa5teg INDIA LIMITED URINALS FIXING DETAIL
=awn-
i➢eR rrecme 4U (A Goof of India Undertaking(
Page 1 of 1
CISTERN CISTERN (MOUNTED ON

WALL OR CONCEALED
TYPE)
FLUSH PIPE
CONCEALED TYPE
(CONNECTED TO
CISTERN OR O.H.
TANK)
TILES/WALL
FNISH
SENSOR
(APPLICABLE IF
SPECIFIED IN
TENDER ITEM)
URINAL PARTITION
(ALL EDGES
ROUNDED OFF)
SPREADER
LAT BACK
RINAL
i
9 LIIM OTTLE
RAP 1144
ij BOTTLE
TRAP
ro
OP OF
LATFORM
GRATING
L=
LOOR LEVEL URINAL
CI CX/ A TInkl
II TRAP
SIDE ELEVA ION

4
URINAL PARTITION (ALL EDGES ROUNDED OFF)
WASTE PIPE
9
0. 0,
11
0
0
co
EQ. EQ.
600 URINAL
(MINIMUM)
100 RAISED
PLATFORM
PLAN URINAL TRAP
NOTES:
2. THIS STANDARD IS INDICATIVE. TYPE AND NO. OF URINAL FIXTURES, FLUSHING ARRANGENT ETC.
SHALL BE AS PER ARCHITECTURAL DRAWINGS & TENDER ITEM.
3. SENSORS SHOWN SHALL BE PROVIDED ONLY IN CASE THE SAME E SPECIFIED IN T DER ITEM.
5 01.12.16 REVISED & REISSUED AS STANDARD RAJAHS A—
STAVA R. HANDS
4 09.11.11 REVISED & REISSUED DK SD JKI DMALINDIRA

No. by by
Approved by
Format No. 8 - 00 - 0001 - F4 Rev.O Copyright EIL - All rights reserved
Page 1235 of 2065

STANDARD No.
Or-Pei& Erf ENGINEERS
INDIA LIMITED WASH BASIN FIXING DETAIL
) 7-75-0064 Rev. 5
afge.a EPterg
Wen rirame c151,1,10.9) (A Goo. of India Undertaking)
Page 1 of 2
550
M NIMUM
DADO AS PER TENDER
ITEM / ARCH. DRAWINGS
0
MIRROR
0
GLASS SHELF
600MMx120MMx6MM THK
0
In FIXED BY 'D' OR 'F'
BRACKETS
SOAP CONTAINER
TOWEL RAIL
0
0 MANUALLY OPERATED
a)
PILLAR COCK OR
BATTERY OPERATED
FAUCET WITH SENSOR
0
BOTTLE TRAP
co
WASTE PIPE
EMBEDED IN WALL
GRATING
ELEVATION FLOOR TRAP
MS BRACKETS
IT A PA TAM W/
FLOOR TRAP
BELOW
WASH BASIN
TOWEL RAIL
PLAN
(FOR WALL HUNG TYPE WASH BASIN)
NOTES:-
1. ALL DIMENSIONS IN MILLIMETRES.
2. THE SIZE OF MIRROR SHOWN IS INDICATIVE. ACTUAL SIZE
SHALL BE AS PER ARCHITECTURAL DRAWINGS/ ITEMS DESCRIPTION.
3. THE ARRANGEMENT AND DETAIL OF WASH BASIN SHOWN (HERE AND IN SHEET-2) IS
TYPICAL. FOR 2 OR MORE WASH BASIN, REFER RELEVANT ARCHITECTURAL DRAWING
(FOR LOCATION & CONFIGURATION) WHICH SHALL BE READ IN CONJUNCTION WITH
THIS STANDARD.
4. LOCATION & TOWEL RAIL IS INDICATIVE. REFER RELEVANT ARCHITECTURAL DRAWING OR
EXACT LOCATION.
5 21.11.16 REVISED & REISSUED AS STANDARD MLT JS/JKB RAJAMJI ASTAVA R. NANDA
4 09.11.11 REVISED & REISSUED DK SD JK8 D.MALMOTRA
Rev. Prepared Chedced Stds. Committee Std.. Bureau

Date Purpose Convenor Chalet an
No. bY by Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - AI rights reamed
Page 1236 of 2065

STANDARD No.
ENGINEERS WASH BASIN FIXING DETAIL 7-75-0064 Rev. 5
INDIA LIMITED
IA Govt of India Undeitakingi
Page 2 of 2
1
550 DADO AS PER
TENDER ITEM /
ARCH DRAWINGS
•
0 MIRROR
0
o
co
SOAP CONTAINER
600
POLISHED STONE TO
COUNTER + FACIA
0 •
0 OVER R.C.C. SLAB
O
co
R.C.C. SLAB
0
o
co
BOTTLE TRA
•
MANUALLY OPERATED PILLAR
ELEVATION COCK OR BATTERY OPERATED
FAUCET WITH SENSOR
SECTION
AS PER ARCH. DRAWING
0
Ih
MIRRO
0
0 ROUND TYPE COUNTER TOP
WASH BASIN FITTED NEATLY IN
STONE COUNTER TOP AND RCC
SLAB UNDERNEATH.
(CUT NEATLY FOR EXACT SIZE
AND SHAPE OF WASIN BASIN).
TOWEL RAIL
PLAN
(FOR COUNTER TOP TYPE WASH BASIN)
NOTES:— REFER SHEET-1.
5 21.11.16 REVISED & REISSUED AS STANDARD MLT JS/JKi RAJANJI SRIVASTAVA R. BANDA
4 09.11.11 REVISED & REISSUED DK SD JKB D.IAALHOTRA

No. by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - AN rights reserved
Page 1237 of 2065
STANDARD No.
ENGINEE16 PLINTH PROTECTION
Otar 0151--e-g INDIA LIMITED 7-75-0065 Rev. 5
RireFleleMle ,613,1043) IA Govt of India Undertaking) (WITH BUILDING DRAIN)
Page 1 of 2
ROAD
BUILDING
0
0
0
ce BUILDING DRAIN
(TO BE CONNECTED TO MAIN STORM
WATER DRAINAGE SYSTEM AT
SUITABLE LOCATION AS PER STORM
I
WATER DRAINAGE SYSTEM DRAWING)
ROAD
1 1 i n
KEY PLAN
C/C OF COLUMNS
BUILDING DRAIN
(SLOPE 1:500)
COVERED WITH M.S.
GRATING
0
0
te) RWP EMBEDDED
IN CONCRETE
STRUCTURAL COLUMN
0 0
0 0
it)
EXTERNAL FACE
OF WALL
—RCC COLUMN RCC COLUMN
DRAIN BUILDING DRAIN

(SLOPE 1:500)
COVERED WITH M.S.
GRATING
45'
0 RWP EMBEDDED
0 IN CONCRETE
rn
RCC COLUMN
EXTERNAL FACE
OF WALL
PLAN (CASE 1, X<600)

NOTE: REFER SHEET 2 OF 2 FOR NOTES & DETAILS
5 09.11.16 REVISED AND REISSUED AS STANDARD 6/9IS/JKB RAJANJI SRNASTAVA R.NANDA
4 25.10.11 REVISED & REISSUED DK SD JKB D.MALHOTRA

No. by by
Approved by
Format No R-nn-nnni-F4 RPV n Convrinht Fll - All rinhts rpsarvAr
Page 1238 of 2065

STANDARD No.
0`10.1t4 ENGINEERS PLINTH PROTECTION
ligar 0151eg INDIA LIMITED 7-75-0065 Rev. 5
(oeff eivonvemanassn (A Goof of India Undertaking) (WITH BUILDING DRAIN)
Page 2 of 2
RCC COLUMN FACE LINE

II RAIN WATER PIPE
II M.S. GRATING COVER
II 15 THICK PLAIN CEMENT PLASTER
WITH NEAT CEMENT FINISH
900 M101111AU
Ir) II P
1 Ox1 0 FINISHED GROUND LEVEL
GROOVE I I
O
O
BRICK WORK
M20 CONC.
RAMMED EARTH
75 230 250 230 7

—RAMMED EARTH
PCC 1:2:4
SECTION A-A
600 MAX. (ONE PIECE)
137 r YiT P !CALL

0)(6 MS FLAT 40x6 MS FLAT
035 C/C
M.S. GRATING DETAIL

15THK CEMENT PLASTER
PCC (1:2:4)
40x6 MS FLAT
40x6 THICK MS
FLAT 0 35 C/C
15THK CEMENT PLASTER

50x50x6 MS ANGLE
PCC POCKET (1:3:6)
BRICK WALL
10 DIA MS BAR LUG
0 500 C/C WELDED
TO ANGLE AND
DETAIL EMBEDDED IN PCC DETAIL 0
(1:3:6)
NOTES:
2. WIDTH OF THE PLINTH PROTECTION SHALL BE MINIMUM 900mm AND X+300 MAXIMUM UNLESS OTHERWISE
MENTIONED IN BUILDING DRAWING.
3. PLINTH PROTECTION ALONG ANY PARTICULAR SIDE OF THE BUILDING SHALL BE OF CONSTANT WIDTH FOLLOWING
THE EXTERNAL WALL AUGNEMENT IF NOT SPECIFICALLY MENTIONED/INDICATED IN BUILDING DRAWING.
4. M.S. DRAIN COVER GRATING SHALL BE PROVIDED OVER BUILDING DRAIN AT ALL APPROACHES UNLESS OTHERWISE
MENTIONED/INDICATED IN BUILDING DRAWING.
AL
5 09.11.16 REVISED AND REISSUED AS STANDARD AIS/JKI\15P-'" RAJANJI SRIVASTAVA LNANDA
4 25.10.11 REVISED & REISSUED DK SD JKO DJAALHOTRA

No. by by
Approved by
Format No. 8 - 00 -0001 - F4 Rev.O Copyright EIL - All rights reserved
Page 1239 of 2065

STANDARD No.
101 e..1ENGINEERS WOODEN PANEL DOOR
Oge.ji EVleg INDIA LIMITED 7-75-0066 Rev. 5
1.14WR eleMIt' ,151,1,1(7.4) (A Goo of India Undedaking) (TOILET DOOR)
Page 1 of 1
RCC LINTEL
CEMENT PLASTER 10
A
L 750 TO 1000
f C
C
A
L
B
0
lN
— F0
P8
FINISHED
FLOOR LEVEL
M
(gt
ELEVATION SECTION 2-2
H
A
BRICK WORK
SECTIONAL PLAN 1 —1 CEMENT
LEGEND:
A: WOODEN FRAME OUT OF 125x65 H: TOILET DOOR LATCH
B: TEAK WOOD STYLE 100x35 J: TOWER BOLT
C: TEAK WOOD TOP RAIL 100x35 K: DOOR HANDLE
D: TEAK WOOD BOTTOM RAIL 200x35 L: COAT AND HAT HOOK
E: 12 THK. PARTICLE BOARD/MARINE PLY (INTERNAL SIDE OF THE DOOR)
INFILL PANEL WITH SPECIFIED FACING. M: ACRYLIC KICK PLATE 200X3 THICK.
F: 150 LONG BUTT HINGES N: TEAK WOOD LOCK RAIL 150x35
0 MAX. 600 C/C. P: TEAK WOOD BEADING
G: MS HOLD FAST
EMBEDDED IN CONCRETE
BLOCK 350x100x100
al
5 21.11.16 REAFFIRMED & ISSUED AS STANDARD iFspme RAJAN.II SRIVASTAVA R. NANDA
4 09.11.11 REVISED & REISSUED DK SO JKU DAIALNOTRA

No. by by
Approved by
Format No Ft - no - nom - Fa RAV n Convrinht Fit - All rinhts nAsAn/AvI
Page 1240 of 2065
STANDARD No.
ENGINEERS STEEL DOOR
s‘g-tirfaf5leg INDIA LIMITED (PRESSED STEEL) 7-75-0070 Rev. 4
IA Govt at India undertaking)
SINGLE SHUTTER Page 1 of 1
R.C.C. BEAM/
R.C.C. LINTEL
N li I 11
A 12X10 GROOVE IN
PLASTER FILLED WITH
POLYSULPHIDE SEALANT
B CEMENT PLASTER
C
SHUTTER
3 THICK MS FLAT
)— CONTINUOUS ALONG
VISION PANEL
18 SWG GI 'Z'
SECTION FIXED
0 TO FRAME
EPDM GASKET
ALL AROUND THE
GLASS
0
0 GLASS
II I
II I
II
II
I
I IF
SECTION 3-3
II
II II
II II
III II FINISHED
FLOOR LEVEL
20X20X3 MS ANGLE
880 TO 1180 WELDED TO BOTH
I FACES OF FRAME
ELEVATION SECTION 1 —1
12X10 GROOVE IN
PLASTER FILLED WITH
L BRICK WORK
0
10 79
A
tisivil 014 I I I L5
,.W '(?'
CEMENT
PLASTER
414 M
0
SECTION 2-2
LEGEND:
A: OVER HEAD HYDRAULIC DOOR CLOSER (HEAVY DUTY). H: 3 THICK MS FLAT CONTINUOUS ALONG
B. MS HOLD FAST 200x25x6THICK 0 MAXIMUM 600 C/C PERIMETER OF SHUTTER.
WELDED TO FRAME SPACER (L) 18 SWG GI VERTICAL STIFFNER 0 200 C/C
40 THICK (OVER ALL) 18 SWG GALVANIZED PRESSED (SPACING TO BE ADJUSTED FOR VISION PANEL).
STEEL SHUTTER FILLED WITH MINERAL WOOL (48Kg/cum). SPRING LOADED HEAVY DUTY DOOR STOPPER.
3 THICK MS FLAT SPACER WELDED TO FRAME
16 SWG GALVANIZED PRESSED STEEL FRAME OUT OF AT 0 500 C/C.
125X60 PROFILE FILLLED WITH CONCRETE (REBATE 40x150x3 THICK MS PAD WELDED TO FRAME
DIMENSION TO BE SUITABLY ADJUSTED FOR AT ALL HINGE & LOCK LOCATIONS.
ACCOMODATING GASKET FOR AIR TIGHT DOOR). N: SS 304 GRADE 19 DIA, 200 LONG HANDLE
VISION PANEL (AS/PROJECT DRAWING). ON BOTH SIDES.
100 LONG SS 304 GRADE HEAVY DUTY BALL BEARING 0: 18 SWG GI MORTAR GUARD AT THE BACK OF
HINGE 0 600 C/C MAXIMUM. HINGES & LOCK.
G: SS 304 GRADE 16 DIA 250 LONG ALDROP ON BOTH P: 10 DIA SS 304 TOWER BOLT (250 LONG FOR
SIDES. 2100 HT. & 600 LONG FOR 2500 HT.).
'D' PROFILE EPDM GASKET ALONG FRAME REBATE
NOTE: 1. ALL DIMENSIONS ARE IN MM (FOR AIR TIGHT DOOR ONLY).
(mom
4 09.04.12 REVISED & REISSUED err& a .111(C 16... PIA UMAR D.SAUK) TRA
CYK
3 21.03.07 REVISED, ISSUED AS STANDARD AMARJIT JKS/SD ARVIND KUMAR V.CHATURVEDI
Rev Prepared Checked Stds. Committee GM(E) Stds. Bureau

Format No 8-00 0001 F4 Rev .O Copyright Ell-All rights reserved
Page 1241 of 2065

STANDARD No.
A.11n ENGINEERS STEEL DOOR
aar Meg INDIA LIMITED (PRESSED STEEL) 7-75-0071 Rev. 4
DOUBLE SHUTTER
Greker teecran dnottaAl (A Gard or India Undertakrng)
Page 1 of 1
R
QC
—< FINISHED
K F BiR EVEL
ELEVATION
12X10 GROOVE IN
PLASTER FILLED WITH
BRICK WORK
D
10
}moo
z
La
ce
4354 CEMENT
104 M
PLASTER
0
SECTION 1 -1
LEGEND:
OVER HEAD HYDRAULIC DOOR CLOSER (HEAVY DUTY). 18 SWG GI VERTICAL STIFFNER 0 200 C/C
MS HOLDFAST 200x25x6 THICK 0 MAXIMUM 600 C/C (SPACING TO BE ADJUSTED FOR VISION PANEL).
WELDED TO FRAME SPACER (L). SPRING LOADED HEAVY DUTY DOOR STOPPER.
C. 40 THICK (OVER ALL) 18 SWG GALVANIZED PRESSED 3 THICK MS FLAT SPACER WELDED TO FRAME
STEEL SHUTTER FILLED WITH MINERAL WOOL (48Kg/cum). AT 0 500 C/C.
16 SWG GALVANIZED PRESSED STEEL FRAME OUT OF 40x150x3 THICK MS PAD WELDED TO FRAME
125X60 PROFILE FILLLED WITH CONCRETE (REBATE AT ALL HINGE & LOCK LOCATIONS.
DIMENSION TO BE SUITABLY ADJUSTED FOR ACCOMODATING N: SS 304 GRADE 19 DIA, 200 LONG HANDLE
GASKET FOR AIR TIGHT DOOR). ON BOTH SIDES.
VISION PANEL (AS/PROJECT DRAWING). 0: 18 SWG GI MORTAR GUARD AT THE BACK OF
100 LONG SS 304 GRADE HEAVY DUTY BALL BEARING HINGES & LOCK.
HINGE 0 600 C/C MAXIMUM. 10 DIA SS 304 TOWER BOLT (250 LONG FOR
SS 304 GRADE 16 DIA 300 LONG ALDROP ON BOTH SIDES. 2100 HT. & 600 LONG FOR 2500 HT.).
H: 3 THICK MS FLAT CONTINUOUS ALONG PERIMETER OF 'D' PROFILE EPDM GASKET ALONG FRAME REBATE
OF SHUTTER. (FOR AIR TIGHT DOOR ONLY).
R: 2 THICK 25X25 GI ANGLE (VERTICAL) EACH
NOTE: 1. ALL DIMENSIONS ARE IN MM WELDED TO ONE SHUTTER.
2. FOR OTHER DETAILS REFER STANDARD NO. 7-75-0070. • \Ot C\ WLsk
4 09.04.12 REVISED & REISSUED II" DK ?fKD (Nail'.
JK N AY KUMAR DUALH OTRA
3 21.03.07 REVISED, ISSUED AS STANDARD AMARJIT JKB/SD ARVIND KUMAR V.CHATURVEDI
Rev. Prepared Checked Stds. Committee GM(E) Stds. Bureau

No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright Et All rights reserved
Page 1242 of 2065

INSPECTION & TEST PLAN STANDARD SPECIFICATION No.
ENGINEERS FOR CIVIL,STRUCTURAL &
Ifgar faileg INDIA LIMITED 6-82-2700 Rev 2
Oren ei2M77 (A Govt of India Undertaking)
ARCHITECTURAL WORKS
(EPCC/LSTK CONTRACTS) Page 1 of 37
, nciLam'
itscom coma (it-flat-11/
vcotvc-i c61 tira4131-1)
1WtkEurr -titteTur
ei1.71 Outettft)
INSPECTION & TEST PLAN (ITP)

CIVIL, STRUCTURAL &
ARCHITECTURAL WORKS
(EPCC/LSTK CONTRACTS)
1A1-
2 19.02.2016 REVISED AND REISSUED
DJ AKM TKS SC
1 04.07.2011 REVISED AND REISSUED SM SM MKG DM
0 17.10.2005 ISSUED AS STANDARD SPECIFICATION MPJ SPS VNP VJN

Standards Standards
Committee Bureau
Rev. Prepared Checked
No by by
Approved by
Page 1243 of 2065

FOR CIVIL,STRUCTURAL & 6-82-2700 Rev 2
ARCHITECTURAL WORKS
Abbreviations:
AFC : Approved For Construction

BM : Bench Mark
CI : Cast Iron
CPT : Cone Penetration Test
GI : Galvanized Iron
IRC : Indian Road Congress
JB : Junction Box
MS : Mild Steel
MT : Magnetic Particle Testing
NDT : Non Destructive Testing
PCC : Plain Cement Concrete
PQR : Procedure Qualification Record
PT : Penetration Testing
PVC : Poly Vinyl Chloride
PWHT : Post Weld Heat Treatment
RCC : Reinforced Cement Concrete
RF : Reinforcement
SPT : Standard Penetration Test
U/G : Under Ground
WBM : Water Bound Macadam
WPS : Welding Procedure Specification
Construction Standards Committee
Convenor: Sh. T.K. Sen, ED (C)
Members: Sh. SN Bhatnagar, GM (Construction)

Sh. MK Garg, GM (Construction)
Sh. A K Mishra, GM (Construction)
Sh. Janak Kishore, DGM (Projects)
Sh. Rajeev Jain, DGM, (C&P)
Sh. Udayan Chakravarty, AGM (Piping)
Sh. Ravindra Kumar, AGM (Construction)
Sh. D Jana, AGM (Construction)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
Page 1244 of 2065

ARCHITECTURAL WORKS
CONTENTS
S. NO. DESCRIPTION DOCUMENT NO. PAGE NO.

ITPS FOR CIVIL WORKS
1. Land and Topographical Survey 2701 5
2. Soil Investigation 2702 6
3. Site Grading 2703 7
4. Excavation 2704 8
5. Backfilling 2705 9
6. Underground Piping (RCC/CI) 2706 10
7. WBM Roads 2707 11
Black Topping(Premix Carpeting) &
8. 2708 12
Bituminous Macadam (BM)
9. Tank Pads 2709 13
10. Micro Grading 2710 14
11. Under Ground Piping (Carbon Steel) 2740 15-18
Tie in joint for Underground Piping
12. 2740A 19
(Carbon Steel)
Mechanical Completion Record for
13. 2740B 20
Underground Piping (Carbon Steel)
ITPS FOR STRUCTURAL WORKS
14. Plain Cement Concrete 2741 21
15. RCC (Substructure) 2742 22
16. RCC (Super structure) 2743 23
17. Flooring/Pavement 2745 24
18. Brick Work 2746 25
19. Structural Works 2747 26
20. Piling Works 2748 27
ITPS FOR ARCHITECTURAL WORKS
21. Anti-termite Treatment 2771 28
22. Plastering 2772 29
23. Doors and Windows 2773 30
24. Painting (building works) 2774 31
25. Sanitary fittings 2775 32
26. Water proofing 2776 33
27. False Flooring and False ceiling 2777 34
28. Under Deck Insulation 2778 35
29. Roofing Accessories 2779 36
30. Lighting Works (Non-plant Buildings) 2799 37
Page 1245 of 2065

ARCHITECTURAL WORKS
GENERAL NOTE
The enclosed ITPs are indicative and shall be followed for developing the job specific ITP’s for the
works to be performed by the contractor. The provisions indicated for stage wise inspection by
EIL/Owner (For specific activities) are the minimum and the Engineer-In-Charge may decide to
increase Hold Points/ Witness Points while approving the job specific ITP’s. Activities for which
ITP’s are not provided in this specification contractor to develop and get the same approved by
EIL/Owner before start of the work. In general role of EIL has been specified in the document. The
role of owner to be specified during preparation of site specific ITPs
Contractor to submit job specific reporting formats with the aid of enclosed sample reporting
formats and job procedures for the jobs for which ITP’s are attached and submit to EIL/Owner for
approval, before commencement of the activity. If the contractor has to deviate from the given ITP
for a valid reason, he shall obtain prior written approval of EIL/Owner. Contractor to carry out
100% examination of all activities.
LEGEND
HP : Hold Point;
A point which requires witnessing/inspection/verification and acceptance by Owner/EIL

before any further processing is permitted.
The Contractor shall not process the activity/item beyond a Hold Point without written
approval by Owner/EIL except where prior written permission for further processing is
available.
W : Witness Point ;
An activity which requires witnessing/inspection/verification by Owner/EIL when the

activity is performed.
After proper notification has been provided (notification modalities and period shall be
finalized before hand), the Contractor is not obliged to hold further processing if
Owner/EIL is not available to witness the activity or does not provide comments before
the date notified. In such cases, basis of acceptance shall be review of Contractor
generated report/document as per relevant technical specification.
Rw : Review of Contractor’s documentation.
S : Surveillance Inspection by Owner/ EIL.

Monitoring or making observations to verify whether or not material/items or services
conform to specified requirements. Surveillance activities may include audit, inspections,
witness of testing, Review of quality documentation & records, personnel qualifications,
etc.
WC : 100% Supervision and Examination by Contractor.
Responsibility for execution of the inspection/testing is with the Contractor; Owner/EIL only
verifies examination or testing done by the Contractor at important stages
Page 1246 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2701
LAND & TOPOGRAPHICAL SURVEY
SL.
ACTIVITY CONTRACTOR EIL
NO.
Boundary markings and submission of

1. WC S
drgs./sketches
a) Availability of valid calibration certificates of
2. WC HP
instruments/ testing equipments
b) Field calibration, if any WC W

Block levels, contour plans, establishing
permanent bench marks with ref. to Survey of
3. WC S
India B.Ms. by check levels and submission of
relevant drgs. & records
Protection of control points, permanent bench
4. WC S
marks and regular rechecking
Submission of Master plan showing monuments,
structures exposed rocks, weirs, water works,
5. WC S
ponds, underground services if crossing that area,
etc.
INSPECTION & TEST DOCUMENTS
Review Test and Inspection Documents WC Rw
Page 1247 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2702
SOIL INVESTIGATION
SL.
NO.
1. Positioning of test location WC S

2. WC HP
b) Field calibration, if any WC W
3. Boring & sampling WC S
In-situ testing (SPT, CPT, Plate load test, Soil

4. WC S
Resistivity, Block vibration test, etc.)
5. Lab testing (as applicable) WC W/ Rw
6. Monitoring of water level WC S
Page 1248 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2703
SITE GRADING
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
Clearing and stripping of soil including disposal of
1. WC S -
unsuitable material
2. WC HP HP
b) Field calibration, if any WC S -
Taking and plotting of initial levels at specified

3. WC S* S*
intervals for cutting as well as filling areas
Classification (Levels of strata) and testing of
4. filling soil for suitability including preparation of WC S -
Lead Charts to filling/disposal areas.
Proper warning of explosions, misfires and storage
5. WC - S
of explosive materials (As applicable).
Breaking up of clods, lumps, etc. at the time of
6. WC S -
filling and compaction.
Identification and suitability of borrow areas for
7. filling soil/murrum including verification of WC Rw -
payments for royalty, etc.
Compaction test for earth filling in specified layers
8. WC Rw -
including finished areas.
9. Verification of final finished grade levels. WC S* S*
10. Computation of Earth works. WC Rw* Rw*

Record of tree cuttings, stacking of blasted rocks
11. and other quarry materials including handing over WC S S
to Owner
12. Preparation of “As built drawings WC Rw Rw
Removal of Surplus earth/excavated material and

13. WC S -
leveling in disposal areas.
Review Test and Inspection Documents WC Rw Rw
CAT B: All fillings

CAT C: All cuttings.
* In case quantum of earthwork is required to be certified by EIL then HP.
Page 1249 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2704
EXCAVATION
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT A CAT B CAT C
a) Availability of valid calibration
1. certificates of instruments/ testing WC HP HP RW
equipments
b) Field calibration, if any WC W S -
2. Layout checking WC S - -
3. Taking initial levels WC S - -

Slopes of excavation, benching, overburden,
4. shoring & strutting (in case of deep WC S S -
excavation)
Check for sub-soil water, dewatering
5. WC S S S
requirements as per specifications.
6. Bottom level of excavation and compaction WC S S S
7. Stacking of different type of soils separately WC S - -
List of obstacles encountered (cables, pipes,

8. WC S S -
conduits, etc)
Barricading of excavated pits for safety &
9. WC S S S
protection from rain
FOR HARD ROCK
Obtaining license from district authorities for

1 WC Rw Rw Rw
undertaking blasting operations
Storing of explosive materials as per explosive
2 WC S S S
rules
Prominent display of red flags around the area
3 WC S S S
to be blasted
4 Check the dimensions of bore holes WC S S S
Stacking of hard rock for useable/non useable

5 WC S S S
including handing over to owner
Review Test and Inspection Documents WC Rw Rw Rw
CAT A : Equipment foundations, Plant buildings, Technological structure, etc.

CAT B : Non Plant buildings, pipe racks, pipe culverts, bridges, etc.
CAT C : Boundary walls, wing walls, manholes, drains, etc
Page 1250 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2705
BACK FILLING
EIL
SL.
ACTIVITY CONTRACTOR
NO.
CAT A CAT B CAT C
1. Selection of materials/selected earth WC W S S
2. Check for treatment of soil, if any WC S S -
a) Availability of valid calibration certificates

3. WC HP HP HP
of instruments/ testing equipments
b) Field calibration, if any WC W S -
Filling in specified layers, consolidating,

4. WC S - -
watering.
5. Compaction tests for layers WC W S Rw
6. Filling to required levels WC S - -
CAT A: Equipment foundations, Plant buildings, Technological structure, etc.

CAT B: Non Plant buildings, pipe racks, pipe culverts, bridges, etc.
CAT C: Boundary walls, wing walls, manholes, drains, etc
Page 1251 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2706
UNDERGROUND PIPING (RCC/ CI)
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
1. Checking of material WC NOTE 1 NOTE 1
Adequate slope, benching in excavation for safety

2. WC S
purposes (if required)
3. Layout, line & level WC S -
4. Laying & jointing, grouting at manholes/chambers WC S -
5. Check for supports/ firm bed/ sub soil water level WC S -
6. Testing for leakages by blocking pipe ends WC W W
Hydro-testing and other tests, Removal of

7. WC W W
blockages, Cleaning & flushing of system
8. Backfilling in layers WC Rw Rw
Check for MS rungs in proper position, inlet/outlet

9. WC S S
pipe levels in manholes
10. Preparation of “As-built drawings” WC Rw Rw
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
CAT B: Main Plant Buildings, Utilities, Offsites etc.

CAT C: Non Plant Buildings, Technological Buildings, Admn. Buildings, Gate House, Security
Rooms, etc.
Page 1252 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2707
WBM ROADS
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
1. WC HP RW
b) Field calibration, if any WC S -
Layout checking including Road crossings and

2. WC S S
taking initial levels
Approval of source & checking/testing of
3. WC NOTE 1 NOTE 1
materials (wherever required)
Filling (if any), compaction, providing cambers
4. WC S S
in sub-base including levels
Spreading metal to required thickness, line &
5. levels, dry rolling including spreading of WC - -
screening material
6. Check for camber and levels over metalling WC S S
7. Spreading murrum/ sand, watering and rolling WC S -
Checking thickness after each layer and

8. WC S S
rectification thereof (if any)
Checking quantity of aggregate by excavation
9. WC W S
of trial pits as per IRC Code
CAT B: Roads subjected to heavy loading, connected to main highway, main plant roads
CAT C: Balance Roads
Page 1253 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2708
BLACK TOPPING (PREMIX CARPETING) &

BITUMINOUS MACADAM (BM)
SL.
NO.
1. Approval of source of materials WC Note 1

2. WC HP
b) Field calibration, if any WC S
3. Surface preparation & check for camber/level WC S
4. Checking/ testing of material wherever required WC W
5. Tack coat application WC -
6. Laying of Premix carpeting/ BM including rolling WC S
7. Application of Seal coat WC -
8. Check for camber and levels WC S
9. Check for bitumen temperature and consumption WC S
10. Thickness check of Premix carpet/ BM WC S
11. Removal of surplus earth WC -
12. Berm preparation WC -
13. Final Inspection WC W
Page 1254 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2709
TANK PADS
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT A CAT B
1. Approval of source of materials WC NOTE 1 NOTE 1
2. Stripping the area WC - -
3. WC HP RW
b) Field calibration, if any WC W S
4. Layout and marking of ground level WC S -
Excavation to required level, compaction of sub-
5. WC W S
base
6. Checking/ testing of materials WC W S
Filling selected materials in specified layers,
7. WC S -
rolling, watering
8. Compaction tests WC W Rw
Gravel filling under annular ring with compaction

9. WC W S
and adding graded filler material (As applicable)
10. Anti-corrosive layer, consolidation WC S -

11. Premix carpeting on side slopes WC S S
12. Preparation of “As-built drawing” for erection WC Rw Rw
Check for settlement of pads during hydro testing
13. WC W S
of tanks
CAT A: All Site fabricated steel storage tanks for process fluid/ Hydrocarbon, floating roof,
tanks having capacity 600cum or 10m dia. and 8 m height.
CAT B: Site fabricated steel storage tanks for Raw water, Fire water, waste water, DM water, etc.
and all tanks not covered under “CAT A”.
Page 1255 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2710
MICRO GRADING
SL.
NO.

1. WC RW
b) Field calibration, if any WC -
2. Taking initial levels WC S
Clearing/ Removal of extra soil, debris, etc.

3. WC -
from site by transportation
4. Taking final levels WC S
5. Verification of gradient of ground WC -
Finishing of ground surface by hand

6. WC S
compactor/ Roller (As applicable)
7. Final inspection WC W
Page 1256 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2740
FOR UNDERGROUND PIPING (CARBON STEEL)
SL. EIL
ACTIVITY CONTRACTOR
NO CAT B CAT C
A. PRIOR TO FABRICATION
1 Incoming materials WC NOTE 1 NOTE 1
2. Welding Filler Material Approval/Qualification

i) Review of Manufacturer's Test Certificates/
other documents WC RW RW
ii) Testing, if any WC Rw Rw
3. WPS/PQR
i) Review of proposed Procedure WC Rw Rw

ii) Welding of test coupon and subsequent
WC W W
Testing, if applicable
iii) Approval of Final WPS/PQR WC HP HP
4 Certification & approval of welders WC Rw Rw
5. NDT Procedure Qualification
i) Review of proposed Procedure WC Rw Rw
ii) Testing WC Rw Rw
iii) Approval of NDT procedure WC HP HP

Preparation of sketches from General
6. WC Rw -
Arrangement drawings
7. Joint numbering WC Rw -
8. Approval of colour coding scheme WC Rw -
9. Monitoring of colour coding on pipes & fittings WC S -
B. FABRICATION (SHOP & FIELD)

Material as per piping class (check w.r.t.
1. WC W
approved colour coding procedure)
i) Fit-up check WC S Rw
ii) Dimensional check WC S Rw
NOTE : 1) For incoming material inspection please refer ITP no: -6-82-1010.
CAT B : All pressure lines, Fire Water line, Cooling Water line, etc.
CAT C : Balance Works
Page 1257 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2740
SL. EIL
ACTIVITY CONTRACTOR
NO
CAT B CAT C
2. Pre-heat (if any) WC S -
Check for purity of purging/shielding Gas (if

3. WC S -
any)
4. Purging (if any) WC S -
5. Shielding rate (if any) WC S -
6. Baking of Electrodes WC S -
7. Inter-pass cleaning & Temperature check. WC S -
8. Visual check of completed welds WC S -
9. PT/MT WC S -
Radiography marking (for Random

10. WC W W
Radiography)
11. Radiography Interpretation WC W W
C. HYDROSTATIC/ PNEUMATIC TESTING
1. Procedure Review WC Rw Rw
2. Correctness of Testing arrangements WC S -
3. Calibration of Pressure Gauges WC - -
4. R.F. Pad testing, if any WC S -
Scrutiny of test packs for Mechanical & NDT

5. WC HP HP
Clearance (Refer UG-01)
6. Air/Water Flushing (preliminary) WC S S
Addition of corrosion inhibitors, if required –

6a. WC S S
Approval of make & quality
Page 1258 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2740
SL. EIL
ACTIVITY CONTRACTOR
NO CAT B CAT C
7. Pneumatic/ Hydrostatic testing WC S S
8. Draining of water & Air drying WC S S
D. LAYING
1. Trench excavation and levels WC S -
2. Cleaning of pipe surface WC S -
Approval of wrapping/coating material

3 WC Note 1 Note 1
manufacturers
4. Approval of agency for wrapping & coating WC Rw Rw
Sample test of coating materials in approved

5. WC Rw Rw
laboratory
6. Application of primer WC S S
7. Coal tar temperature WC S -
8. Coating & wrapping WC S S
9. Check Thickness of coating (if applicable) WC S -
10. Calibration of Holiday tester WC Rw Rw
11. Holiday testing WC W S
12. Peel test WC W Rw
Page 1259 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2740
SL. EIL
ACTIVITY CONTRACTOR
NO CAT B CAT C
14. Lifting arrangement WC S -
15. Lowering (levels & orientation of branches) WC S -

Checking of wrapping & coating for
16. damages during lowering, their repair, WC S S
Holiday Testing, etc.
17. Back filling & compaction WC S -
18. Location, Brickwork, plaster of valve pit WC - -
19. Top cover & Finish of valve pit WC S S
E. SYSTEM COMPLETION
Refer
1. Tie in joints WC Refer 2740A
2740A
Refer
2. Scrutiny of test packs for system testing WC Refer 2740B
2740B
3. System testing WC W Rw
Page 1260 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2740A
TIE IN JOINTS FOR UNDERGROUND PIPING (CARBON STEEL)
SL.
NO.
A. Fit up WC W
B. Root Run DP WC W
C. Final Run DP WC W
D. Radiograph Review WC HP
E. PWHT Hardness WC RW
F. RF Pad Testing WC HP
G. Cleaning & Priming WC S
H. Coating, Wrapping WC W
I. Peel Test WC HP
J. Holiday Testing WC HP
Checking For Any Damage In Wrapping &
K. Coating After Lowering, Their Repair Holiday WC W
Testing, Etc.
L Back Filling WC S
Page 1261 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2740B
MECHANICAL COMPLETION RECORD FOR

UNDERGROUND PIPING (CARBON STEEL)
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
1. Clearance for flushing & testing WC Rw Rw
Mechanical clearance
1a.
- Conformity with drawing HP Rw
WC
- Material as per Specification WC Rw Rw

Welding & NDT clearance
1b.
- Material as per Specification WC Rw Rw
- Fit-up check record WC Rw Rw
- Visual check of completed welds WC Rw -
- PT/MT WC Rw Rw
- Radiography WC Rw Rw
- PWHT & hardness WC Rw Rw
- RF pad testing WC Rw Rw
2. Flushing & Pressure testing WC W W
3. Coating & wrapping
- Surface preparation WC Rw -
- Primer application WC Rw Rw
- Coating, wrapping & peel test WC Rw -
- Holiday check WC Rw Rw
4. Laying
- Trench leveling WC Rw Rw
- Lowering & checking for damages in
wrapping & coating, their repair, WC Rw Rw
Holiday testing, etc.
- Backfilling WC Rw Rw
CAT C : Balance works
Page 1262 of 2065

ARCHITECTURAL WORKS
ITP NO : 2741
PLAIN CEMENT CONCRETE
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
1. certificates of instruments/ testing WC RW RW
equipments
b) Field calibration, if any WC S Rw
Checking of layout and materials,

2. WC S -
compaction of sub –grade
3. Mix proportion WC S -
4. Check for shuttering, dewatering if any. WC - -
5. Concreting with proper compaction WC - -
6. Checking of top level of PCC WC Rw -
7. Curing WC - -
CAT B : for filled-up area

CAT C : for cutting area
Page 1263 of 2065

ARCHITECTURAL WORKS
ITP NO : 2742
REINFORCED CEMENT CONCRETE (SUBSTRUCTURE)
SL. EIL
ACTIVITY CONTRACTOR
1 Approval of source of materials WC HP HP Rw
2. certificates of instruments/ testing WC HP HP HP
equipments
b) Field calibration, if any WC Rw Rw Rw
Checking of layout & condition of PCC/
3. WC S S -
leveling course
4. Incoming material checking WC NOTE 1 NOTE 1 NOTE 1
Design of mix &establishment of strength at
5. WC HP HP HP
site by trial mix
Check for line & level of shuttering
6. WC S S -
including its condition, quality and rigidity.
Check for sub-soil water & dewatering
7. WC S S -
arrangement, if any
8. Reinforcement & covers to reinforcement WC S S S
Inserts, Anchor bolts and pipe sleeves,
9. WC S S S
pockets, dowels, etc.
10. Pour Card WC W W Rw
Check for obstacles encountered (Electrical
11. WC S S -
conduits, pipe lines, etc.)
12. Concreting, testing, compaction & finishing WC W S Rw
13. Casting of cubes WC S S S
14. Curing WC S S -
15. Testing of cubes WC W W W
16. Removal of shuttering WC S - -
17. Check for water tightness, rendering, if any WC S S S
18. Preparation of As-built drawings WC Rw Rw Rw
CAT A: Critical foundations of equipments i.e. compressors, reactors, columns, stacks,

foundations subjected to dynamic loading and any other foundation with RCC Quantity >
250 Cum in single pour ,etc.
CAT B: Unit Pipe racks, plant buildings and other equipment foundations not covered in category
A, etc
CAT C: Non critical pipe racks (branch pipe, offsite pipe rack, etc.) non-plant buildings, pipe
sleepers, manhole, catch pit and balance works.
Page 1264 of 2065

ARCHITECTURAL WORKS
ITP NO : 2743
REINFORCED CEMENT CONCRETE (SUPER STRUCTURE)
SL. EIL
ACTIVITY CONTRACTOR
NO. CATA CATB CAT C
1 Approval of source of materials WC HP HP Rw
2. WC HP HP HP
of instruments/ testing equipment
b) Field calibration, if any WC Rw Rw Rw
3. Checking of layout WC S S -
4. Incoming material inspection WC Note 1 Note 1 Note 1
Design of mix &establishment of strength at
5. WC HP HP HP
site by trial mix
Check for line & level of shuttering and
6. scaffolding/ vertical bracing including hoisting WC S S -
arrangements.
7. Reinforcement & covers to reinforcement WC S S S
Inserts, bolts, pipe sleeves, MS rungs, concealed
8. electrical conduits, fan hooks, dowels, etc. WC S S -
including welding if any
9. Pockets/ openings WC S S -
10. Expansion joints, if any WC S S -
11. Check for water stops, slopes, stoppers, if any WC S S -
12. Pour Card WC W W Rw
13. Concreting, testing, compaction & finishing WC W S S
14. Casting of cubes WC S S S
15. Curing WC S S -
16. Testing of cubes WC W W W
17. Removal of formwork/ staging WC S - -
Verification of dimensions viz AFC drawings
18. WC S S S
and tolerances
19. Check for water tightness, rendering, if any WC S S -
20. Preparation of As built drawings. WC Rw Rw Rw
CAT A: Super structure of foundations for Critical equipments i.e. compressors, reactors,
columns, stacks, foundations subjected to dynamic loading and super structure of any
other foundation with RCC Quantity > 250 Cum. in single pour, Slabs of plant and non-
plant buildings, etc.
CAT B: Unit Pipe racks, plant buildings and super structure of other equipment not covered in
category A, etc
CAT C: Non critical pipe racks (branch pipe, offsite pipe rack, etc.) non-plant buildings, pipe
sleepers, manhole, catch pit and balance works.
Page 1265 of 2065

ARCHITECTURAL WORKS
ITP NO : 2745
RCC PAVEMENT/FLOORING
SL.
NO.
1. Approval of source of materials WC Rw

2. WC HP
b) Field calibration, if any WC S
3. Layout checking/ excavation of all new foundations WC -
4. Incoming material inspection WC NOTE 1

Design of mix &establishment of strength at site by trial
5. WC HP
mix
Check for proper back filling/compaction/ completion of
6. WC S
sub - Structure works
7. Check for edges of shuttering, alternate panels WC -
8. Check for slopes, thickness of flooring WC S
9. Shuttering, reinforcement (as applicable) WC -
10. Check for expansion joints/ Construction joints WC S
11. Check for concealed pipe embedment, earthing, if any WC -
12. Check for dividing strips, as applicable WC S
13. Concreting, finishing, etc WC S

Checking for line, levels, slopes, joints, thickness of
14. WC S
flooring viz. AFC drawings
15. Curing WC S
16. Grinding & polishing, as applicable WC S
17. Testing of concrete cubes (as applicable) WC W
18. Preparation of “As Built Drawings” WC Rw
Page 1266 of 2065

ARCHITECTURAL WORKS
ITP NO : 2746
BRICK MASONARY
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
1. WC RW RW
b) Field calibration, if any WC Rw Rw
2. Incoming material inspection WC Note 1 Note 1
3. Cleaning of surface WC - -
4. Wetting/soaking of bricks WC S S
5. Cement mortar proportion WC S S
6. Staging & scaffolding WC - -
7. Hacking of adjacent concrete surface WC S S
8. Check for bond/closers, thickness of joints WC S -
9. Line, level & plumb WC S S
10. Raking out joints, keys in brick work, if any WC S S

Check for placement of Reinforcement bars in
11. WC S S
case of partition brick work
12. Embedment of fixtures WC S S
13. Curing WC - -
14. Preparation of 'As Built' Drawings WC Rw Rw
CAT B : Load bearing walls

CAT C : Balance works
Page 1267 of 2065

ARCHITECTURAL WORKS
ITP NO : 2747
STRUCTURAL STEEL WORKS
S. CONTRA- EIL
ACTIVITY
NO CTOR CAT A CAT B CAT C
A PRE – FABRICATION ACTIVITIES
1. WC HP HP RW
b) Field calibration, if any WC S S Rw
3. Welding Filler material approval/ qualification
a) Manufacturing test certificates/ documents WC Rw Rw Rw
b) Testing, if any WC W W W
4. Approval of WPS/ PQR WC HP HP HP
5. Welders performance qualification WC W W Rw
6. Layout checking WC S - -
7. Welding equipment and accessories WC S - -
8. Preparation and approval of Fabrication drawings WC Rw Rw -
B FABRICATION ACTIVITIES
1. Materials as per design drawing WC Rw Rw Rw
2. Check straightness and non-warping of members WC S S -
Dimensional and fit-up checks including provision of
3. WC S S -
slopes for deflection wherever required
4. Visual check for welding WC S S -
Grinding including surface preparation for painting and
5. WC S S Rw
application of primer
6. Checking paint as per specs, shelf-life, etc. WC S S -
7. Application of specified paint, painting thickness, etc. WC S S -
C FIELD ERECTION ACTIVITIES
Lifting arrangements including test certificates of lifting
1. WC S S Rw
tackles
2. Correctness of location WC S - -
3. Orientation of bracing, lugs WC S - -
4. Alignment & levels WC S - -
5. Field welding (if any) WC S S -
6. Grouting WC S S -
7. Finishing coat of paint, thickness of paint etc. WC S S S
8. Preparation of As-built drawings WC Rw Rw Rw
CAT A: Steel structures pertaining to equipments i.e. compressors, reactors, columns, stacks,
Technological structures.
CAT B: Steel structures pertaining to Unit Pipe racks, and other equipments not covered in
category A, etc.
CAT C: Steel structures of Non critical pipe racks (branch pipe, offsite pipe rack, etc) plant
buildings and non-plant buildings, pipe sleepers, manhole, catch pit, walkways, platforms
at grade levels, etc.
Page 1268 of 2065

ARCHITECTURAL WORKS
ITP NO : 2748
PILING WORKS
SL. EIL
ACTIVITY CONTRACTOR
1. Approval of source of materials WC Rw Rw Rw
2. Layout and ground level WC S S -

Design of mix &establishment of strength
4. WC HP HP HP
at site by trial mix
5. Driving of piles & check for set point WC S S -
Check for depth of bore and lowering of
6. WC S - -
cage measuring
7. Pour Card WC HP HP Rw
8. Concreting, testing WC W S S
9. Casting of cubes/Testing WC W S/W S

Check for cut off level of concreting &
10. WC S - -
quantity of concrete poured
11. Lifting of casing pipe WC S S -
Pile load tests (lateral/vertical/cyclic/pull
12. WC W Rw Rw
out)
13. Submission of pile load test report WC Rw Rw Rw
CAT A: Critical foundations of equipments i.e. compressors, reactors, columns, stacks,

foundations subjected to dynamic loading and any other foundation with RCC Quantity
> 250 Cum in single pour ,Technological structures, etc.
CAT B: Unit Pipe racks, plant buildings and other equipment foundations not covered in category
A, etc.
CAT C: Non critical pipe racks(branch pipe, offsite pipe rack, etc.) non-plant buildings ,pipe
sleepers, manhole, catch pit, etc.
Page 1269 of 2065

ARCHITECTURAL WORKS
ITP NO : 2771
ANTI-TERMITE TREATMENT
SL.
NO.
Incoming material inspection & spraying devices

1. including personal protective equipments like facemask, WC HP & Note 1
gloves, shoes, etc.
Preparation of surface for taking dosage of emulsion by
2. ramming of each layer of soil by roding the earth at WC -
specified intervals
Backfilling and compaction in specified layers along with
3. application of emulsifier along the sides of masonry & WC S
RCC structures
Compaction of top surface for taking dosage of
4. emulsifier by roding the earth at specified intervals for WC -
the entire floor area before concreting
5. Check for consumption of emulsifier utilized WC S
Page 1270 of 2065

ARCHITECTURAL WORKS
ITP NO : 2772
PLASTERING
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
Check for completeness of all hidden jobs like piping,
1. WC - -
conduiting, etc.
2.. Check for grading of sand, Mix proportion WC S S
3. Sample preparation for finish and its approval WC W S
4. Neeru application on plaster (as applicable) WC S -
Hacking and cleaning the surface, removing loose

5. WC - -
particles, wetting the surface
6. Checking of plaster thickness, plumb & even surface WC S -
Check for grooves, openings, rounding off the corners,

7. WC - -
hollowness in plaster
8. Curing WC S -
CAT B: Area requiring special finish (e.g. pebble dash finish etc.)
CAT C: Balance works.
Page 1271 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2773
DOORS, WINDOWS AND VENTILATORS
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
2. Check for sections & dimensions WC S -
3. Line, level & plumb WC - -
4. Section joinery details WC Rw -
5 Grouting with lugs/ dash fasteners WC -
6 Check for fixtures & fittings WC S S
7 Check for thickness & type of glazing WC - -
8 Check for rubber gasket, anodizing (as applicable) WC - -
Brand/ shade of paints, no. of coats including

9 WC S Rw
surface preparation
CAT B: Main plant buildings

CAT C: Balance works
Page 1272 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2774
PAINTING (BUILDING WORKS)
EIL
SL.
ACTIVITY CONTRACTOR
NO.
CAT B CAT C
1. Completion of surface preparation WC - -
3. Confirmation of colour, shade & brand HP - -
4. Check for number of coats and thickness WC S -
5. Curing, if any WC S -

Page 1273 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2775
SANITARY FITTINGS
SL. EIL
NO. ACTIVITY CONTRACTOR CAT B CAT C
2. Checking of sample (as applicable) WC S -
Check completeness of finishing works w.r.t.

3. WC S -
line, level & position
Check proper fixing of the sanitary fittings to
4. WC S -
give aesthetic appeal
5. Check for leakage WC S Rw

Page 1274 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2776
WATER PROOFING (ROOF)
SL.
NO.
Surface preparation for screeding/ water proof

1. WC W
plastering
Mix proportion, thickness of screeding/
2. WC S
plastering & slope towards rain water pipes
Formation of groove at specified height on
3. WC -
parapet wall
Incoming material inspection, no. of coats,
4. WC S/Note 1
application procedure and consumption.
Termination of material in groove on vertical
5. WC S
plane
Check for hollowness, bubbles in water
6. WC S
proofing, if any
Conducting a sample of water proofing test by
7. flooding the area for specified interval (as WC S
applicable)
8. Cleaning of surface WC -
Submission of Guarantee in the requisite

9. WC Rw
Performa
Page 1275 of 2065

ARCHITECTURAL WORKS
ITP NO : 2777
FALSE FLOORING AND FALSE CEILING
SL.
NO.
FALSE FLOORING
1. Manufacturers Test Certificate WC Rw
2. Incoming material inspection WC Note 1
3. Cleaning base floor WC -
Painting base floor with Polyurethane based

4. WC S
paint (as specified)
5. Proper line, level & layout WC S
FALSE CEILING
1. Manufacturers Test Certificate WC Rw
2. Incoming material inspection WC Note 1
3. Surface preparation of panel boards WC -
4. Proper line, level & cut-outs WC S
5. Painting of panel boards WC S
Page 1276 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2778
UNDER DECK INSULATION
SL.
NO.
1. Incoming material checking including density WC Note 1
2. Checking of adhesive, fasteners for anchorage WC S
3. Fixing of scaffolding, ladders, platforms WC S
4. Fixing of under-deck insulation with adhesive WC -
5. Fixing of dash fasteners at defined spacing WC -
6. Finishing WC S
Page 1277 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2779
ROOFING ACCESSORIES
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
1. Incoming material inspection WC HP/Note 1 HP/Note 1
2. Check for mitring, overhang, laps, etc. WC S -

Slopes line, level of sheets, barge boards, ridges &
3. gutters, overhang WC S -
of sheets
Bolting by drilling only, length of bolts, nos.,
4. WC S -
anodizing and type of washers
Check for slopes of rain gutters, down take pipes,
5. WC S -
north lighting curves/ supports for gutters
6. Check for leakage/ passing of light WC S -
2) Fixing arrangement need to be reviewed with respect to contract specifications.
CAT B: Important structures (e.g. Compressor House, Warehouse and Pump House etc.)
CAT C: Balance works.
Page 1278 of 2065

ARCHITECTURAL WORKS
ITP NO. : 2799
LIGHTING WORKS (NON PLANT BUILDINGS)
SL.
NO.
Prepare detailed conduit layout diagram as

1. WC W
per the approved electrical drawing
Provide /PVC/GI sleeves in columns/beams
2. at identified locations to facilitate laying of WC S
conduit on later date.
Ensure conduit & accessories material is
3. WC W
inspected at site before using
Ensure that the conduit is laid in line with
4. execution drawings & provide pull-wires as WC S
per requirement.
5. Check correctness of drop/JB locations WC S
6. Check threaded joints are proper WC S
Ensure all JB/Fan box are properly stuffed
7. WC S
with jute
Ensure conduits are properly tied to
8. reinforcement bars to prevent floating WC S
during concrete
Ensure proper supporting of conduit lengths
9. WC S
wherever required
Ensure adequate chasing depth for conduit
10. WC S
portion coming inside brick walls
Check workmanship towards joints and
11. presence of any foreign material inside the WC S
conduits
Ensure wiring material is inspected at site
12. WC W
before use
Ensure correctness of lighting wire size and
13. no. of wires as per the drawing in each WC S
conduit portion
14. Preparation of "As Built" drgs. WC Rw
Page 1279 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 1 of 10
SCOPE OF WORK
FOR
ELECTRICAL WORKS
PROJECT: 2ND RAW WATER INTAKE PUMP

HOUSE & PIPELINE AT DAMANJODI,
NALCO.
CLIENT: NALCO.
B 20.12.2016 REVISED & ISSUED WITH BID PACKAGE CS MKS MKS
A 20.12.2016 ISSUED WITH BID PACKAGE JM MKS MKS

Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 1280 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 2 of 10
1.0 SCOPE OF WORK

1.1 General
The contractor’s Scope of work includes design, detail engineering, material supply,
preparation of detailed engineering drawings, getting statutory approvals, erection,
testing and commissioning of complete electrical power distribution, lighting, earthing
and lightning protection system as envisaged under this package.
1.2 Scope of Design and Detailed engineering:
The Contractor’s scope of work shall include the design and detail engineering
activities, including but not limited to the following:
1.2.1 Compilation of load data, its analysis and determination of sizes of various electrical
equipments.
1.2.2 Preparation of Overall Single Line Diagram.
1.2.3 Preparation of Protection cum metering single line diagram of each switchgear/power
distribution system in contractor’s scope.
1.2.4 Preparation of cabling, lighting, earthing, lightning protection layout drawings (earthing
for GTS s/s & cabling/earthing/lighting/lightning protection layout for new raw water
intake s/s) including associated documents like cable schedules, lighting/power panel
schedules etc.
1.2.5 Preparation of cable interconnection drawings.
1.2.6 Preparation of electrical equipment list and motor list.
1.2.7 Preparation of equipment layout of GTS s/s & new raw water intake s/s.
1.2.8 Preparation of sag-tension calculation chart at different locations of 11KV transmission
line showing that max. allowable sag at 70oC is with in 800mm. from lower phase
conductor.
1.2.9 Preparation of voltage drop calculation & motor starting study ensuring that minimum
voltage available at motor terminal located at new raw water intake substation is not
below 80% of rated value (6.6KV) during starting considering transmission line drop
over entire route length. Size of ACSR conductor, tap changer range along with
impedence voltage of isolation transformer (at GTS s/s) & 3-winding transformer (at
new intake s/s) shall be selected accordingly. System study in E-tap software shall be
carried out by contractor. All relevant data regarding 11KV existing system shall be
informed to contractor during detailed engineering stage.
1.2.10 11KV Transmission Line
 Preparation of 11KV new line survey report & installation/erection plan of new
transmission line.
 Detailed survey including route alignment, profiling, tower spotting, optimization of
tower location locations, soil resistivity measurement & geo technical investigations
(including special foundation locations/pile foundation locations)
 Right of way and way leave clearance including the payment of compensations (rail,
road, forest, line crossing and any other approval/permission requirement for
completion of job) shall be in the scope of work of contractor.
 Design/engineering, fabrication, factory testing, supply, installation of all type of
lattice structured poles as envisaged in MR.
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DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 3 of 10
 Supply & installation of all types of pole accessories such as phase plate, circuit
plate, number plate, danger board, anti climbing device, bird guard, earthing
arrangement etc.
 Supply & installation of various hardware fittings required for conductor.
 Design & construction of pole foundations/substation foundations as per guidelines
described in structural part of MR.
 Complete erection of poles, tack welding of bolts & nuts including supply and
application of zinc rich primer & two coats of enamel paint, pole earthing, fixing of
insulator string, stringing of conductors along with all line accessories.
 Complete painting of transmission line poles by anti rusting, anti corrosive paint
along with erection of span markers, warning lights (if required as per norms) and
stay set arrangements to neutralize the tension.
 Complete testing & commissioning of erected transmission line.
 All the raw materials like steel, zinc for galvanizing, reinforcement steel, cement,
sand, coarse & fine aggregates for pole foundations, coke & salt for earthing
purpose etc are included in contractor’s scope of work.
 Any other miscellaneous requirements/works required for successful commissioning
of entire transmission line which are not mentioned above.
1.2.11 Preparation of overall plot plan of entire 11KV transmission line (from refinery to new
raw water intake s/s & from 11KV tapping point to existing raw water intake s/s)
showing different type of poles as envisaged and its elevation/bending angles.
1.2.12 Preparation of GA drawing of different transmission line poles to be used for 11KV
transmission line along with its bill of quantity.
1.2.13 Preparation of detailed relay parameterization chart.
1.2.14 Preparation of testing and commissioning scheduled for various electrical equipments
in contractor’s scope.
1.2.15 Preparation of operation and maintenance manuals.
1.2.16 Preparation of bill of materials for cabling, lighting earthing and lightning protection
system.
1.2.17 Preparation of all final as built drawings.
1.3 Scope of Supply

Contractor shall supply all items / equipments required for work completion as listed
below. Except these listed equipments/items, if any other items are found necessary
during detailed engineering stage, same shall be supplied/installed/commissioned by
contractor with out any cost/time implication to owner.
1.3.1 8 Nos. Extensions to existing (HT-227A) Siemens make (model no. 8BK80)
11KV±10%, 1600A (single bus rating), 50±3%Hz, 3-phase, 40KA (1 sec.),
drawout type switchboard complete with horizontal and vertical busbars including all
interconnecting links, hardware, material and accessories as required for hooking-up of
extension panel with existing panel line-up, including VCB breaker, protection and
metering equipment/components/wiring as per attached hardwire data sheet (B001-
000-16-50-DS-9004/9007/9013). For detailed scope refer job specification.
1.3.2 11KV±10%, 630A (single bus rating), 50Hz±3%, 3 phase, 40KA (1 sec.), HV
switchboard as per attached data sheet (B001-000-16-50-DS-9007/9012/9013). Same
shall be located at new raw water intake s/s (refer key single line diagram) - 1 no.
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DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 4 of 10
1.3.3 6.6KV±10%, 630A (single bus rating), 50Hz±3%, 3 phase, 20KA (1 sec.), HV
switchboard as per attached data sheet (B001-000-16-50-DS-9005/9007/9013). Same
shall be located at new raw water intake s/s (refer key single line diagram) - 1 no.
1.3.4 415V±10%, 1250A (single bus rating), 50Hz±3%, TPN, 50KA (1 sec.), MV switchboard
as per attached data sheet (B001-000-16-50-DS-9006/9007/9013). Same shall be
located at new raw water intake s/s (refer key single line diagram) - 1 no.
1.3.5 One no. Oil filled 2-winding isolation transformer as per data sheet. B001-000-16-50-
DS-9001
1.3.6 Two nos. cast resin dry type 2-winding 11/6.9KV distribution transformers & 2 nos. cast
resin dry type 11/0.433 KV transformers of required ratings.
1.3.7 2 nos. Neutral grounding resistor as per data sheet. B001-000-16-50-DS-9003. For
details, refer key single line diagram.
1.3.8 One (1) no. 3-way outdoor type Ring Main Unit (RMU) having following as minimum:-
 Incomer shall have off-load isolator (Rating: 630A)
 O/G-1 having vacuum circuit breaker (rating:-630A) along with CT, PT & relay
 O/G-2 having vacuum circuit breaker (rating:-630A) along with CT, PT & relay
 Complete structural foundation along with shed for rain protection
 Earthing arrangement
1.3.9 11kV overhead line (ACSR conductor of suitable size preferably by PANTHER). Cross
section to be calculated by contractor as per cl. no. 1.2.8 above. Length of conductor
shall be calculated by contractor based on schematic arrangement drawing (B001-000-
11-42-3001) & line survey report. Per unit price of conductor shall also be furnished
along with lump sum price so that same can be applied at later date if addition quantity
is required.
1.3.10 4 Nos. 4 pole structures (at Kantabausuni temple for new water intake supply, 2 nos. at
old water intake substation, 1 no. at new water intake substation)
1.3.11 8m high, galvanized lattice structured poles (single pole with V-cross arm/double pole
with post insulator, gang operated isolator with earthing switch, conceal type box for
cable to conductor connection, lightning arrester/double pole with strain insulator/four
pole with strain insulator/single pole for 3-way 11KV connection) for carrying 11kV line
at a distance of approximately, every 50m, complete with insulators (pin/strain & post),
top/F- bracket, danger board & anti climbing device, cross arm for guard wire (required
at road crossings), guy wire with insulators (where required), necessary clamps, bolts
and fixing hardware/other structural items. Actual quantity to be calculated by
contractor after carrying out line survey report & sag-tension calculation. However, unit
price shall also be quoted so that if addition poles are required at later date, same can
be applied. (Refer typical pole GA drawing: B001-000-16-50-DS-4001A/B/C/D/E for
reference).
1.3.12 All HV motors and other field electrical devices.
1.3.13 110V DC system along with VRLA battery, dual redundant battery charger & DCDB.
Back up time shall be considered as 2 Hours.
1.3.14 Supply of following cables:-
1.3.13.1 11KV grade XLPE insulated armored Al cable (UE) of 3Cx300 sq.mm.size for following:
 From HT-227A in Existing GTS s/s to Four Pole structure located at Refinery
boundary limit. Approx. length = 7000M.
 From Four pole structure to HT-240 in new Intake well s/s. Approx. length = 100M.
Page 1283 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 5 of 10
 From Four pole structure to existing spare feeder of 11KV switchboard in existing
Intake well s/s. Approx. length = 100M.
 3-way point for bifurcation of line envisaged for existing intake well s/s. Approx
length = 100 mtr.
 Incoming Cable from HT 227 Pnl #34 (ABB make at GTS) to 7.5MVA Isolation
Transformer
 Outgoing Cable from 7.5MVA Isolation Transformer to HT#227A (Siemens make at
GTS)
 From HT-227A at GTS to CSS-07 (approx. length = 50M), From HT-227A at GTS
to CSS-08 (approx. length = 50M) including supply of 03 Nos of End Termination
Kits & 03 Nos of Straight Through jointing Kits. Cable size shall be 1 Run 3CX300
Sqmm.
 From HT-227A at GTS to new 4 pole structure at kantabausuni temple
 From new 4 pole structure to old 4 pole structure near old intake substation.
 From new 4 pole structure at old water intake substation to bridge crossing
 From 4 Pole structure at new Water Intake to 11 KV Switchboard (02 runs of cable
to be laid each from two different poles of the 4 pole structure.
 From 11 KV Switchboard at New Water Intake Sub Station to 04 nos of
Transformers
 From 4 pole Structure at Old Intake Sub Station (to be constructed) to existing
11KV Switchboard
 From existing Double Pole to 4 Pole (near existing water Intake Sub Station)
 From new 4 Pole (to be constructed) to existing 11KV Switchboard (Existing water
Intake)
Actual length is to be calculated by contractor based on requirement. Actual Run &
Length of cable to be calculated by the bidder based on requirement. Design
calculation of the cable to be submitted for review".
1.3.14.2 6.6KV grade XLPE insulated armored Al cable (UE) of 3Cx120 sq.mm. & 3Cx50
sq.mm. size. Length to be calculated by contractor based on actual requirement. Unit
price shall also be quoted.
1.3.14.3 1.1KV grade 415V PVC insulated armored Al/Cu cored power & control cables. Actual
length shall be calculated by contractor based on requirements. Unit price shall also be
quoted.
13.15 1 no. metering/alarm panel shall be considered in new raw water substation. Same
shall be located in operator room of new intake well substation. This panel shall have
Rittal make stainless steel enclosure having following indications/alarms:
 Run Indication of each pump
 Trip indication for each pump
 Ready to start indication for each pump
 Ammeter reaing for each pump
 Emergency Push button for each pump
 Hooter for pump tripped.
All necessary control cabling (supply, laying & termination) from starter panel to
control panel shall be in contractors scope.
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DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 6 of 10
1.3.15 Lighting fixtures suitable for indoor building lighting (for new raw water intake s/s
building), outdoor area lighting, flood lighting and high bay lighting etc. all weatherproof
to IP-55 as required for installation and use in dusty corrosive areas. All lighting fixture
shall have stainless steel reflector with cast iron body.
1.3.16 LED Lamps for all the lighting fixtures. Lighting fixture data sheet indicates
flouroscent/HPSV/HPMV/SON/GLS which are indicative only. Equivalent lumen output
LED lamps shall be provided. Company approval shall be obtained prior to
procurement of type of LED lighting fixtures.
1.3.17 Indoor and outdoor Lighting / power panels having IP-55 degree of protection.
1.3.18 Junction boxes, plugs, sockets, hand lamps and welding receptacles.
1.3.19 Local start/stop/metering control stations as required.
1.3.20 Suitable nos. of 415V, 3-ph. Welding Receptacles and 240V, 1-ph convenience outlet
in New Intake Well s/s and Pump house. One no. welding receiptacle shall be provided
in new transformer bay (7.5MVA). Suitable rated SFU feeder for the same shall be
provided by Owner from US-13 substation. However supply and laying of cable (approx
length 450m) on exsting cable trays shall be in contractors scope
1.3.21 30mtr. high flood light mast having 12 nos. of lighting fixture each having 2 nos. LED
lamps equivalent to 400watt. HPSV lamp & 2 nos. LED type aviation lamp- 1 no.
1.3.22 GI pipes, structural steel, MS frames, supports, canopies, brackets, anchor fastners,
etc and all materials for foundations for 11kV poles etc.
1.3.23 Hot dip galvanized prefabricated cable trays, cable tray structures and accessories
including all materials, fittings and fixtures and GI cable tray covers.
1.3.24 Cable markers/identification tags, GI saddles, saddle bars and associated accessories.
1.3.25 End termination and straight through jointing kits for 11/6.6/1.1 KV grade power/,
control/lighting cables.
1.3.26 Single/Double compression Nickel plated brass cable glands, tinned copper lugs.
1.3.27 Complete materials for earthing such as GI earth electrodes, GI earthing strip (75x10
GI), lightning rods, earth plates and grounding conductor of various sizes, connectors
etc.
1.3.28 DC junction boxes.
1.3.29 Junction boxes/ Main distribution Frame (MDF) for telephone cables with varying
number of control terminals and telephone sockets.
1.3.30 Exhaust fans and air circulators in substation buildings and corrosion resistant exhaust
fan/tiles in battery room.
1.3.31 Site work involving cabling, lighting, earthing and lightning protection including supply
of materials as per cl. No. 2.20 of Job specification.
1.3.32 Fire emulsifying system for 11/11.5KV, 7.5MVA ISOL TRAFO#3 located in GTS s/s.
1.3.33 Safety equipment in sub-stations and wherever specified as per IE rules.
1.3.34 Portable emergency lighting units.
1.3.35 Civil structural works and foundations for installation of Contractor’s supplied electrical
equipments along with supply of all required material
1.3.36 Safety equipment, fire extinguishers in new raw water intake substation.
1.3.37 Fabrication, supply, erection and painting of steel structural supports required for
various electrical equipment such as switchgears, push button stations, transmission
line poles etc.
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DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 7 of 10
1.3.38 Special tools and tackles for installation of electrical equipment are included in
contractor’s scope.
1.3.39 Mandatory spares for Electrical equipments as per the list enclosed elsewhere in the
bid package.
1.3.40 One year operation & maintenance spares for different electrical equipments supplied
by Contractor as per Annexure-1. Contractor shall give itemsied unit price for the listed
spares as a minimum. Apart from the listed items, Contractor shall also quote itemized
unit price for other suggested spares. Ordering of the spares shall be decided by client
separately.
1.3.41 Miscellaneous material for civil works like sand, bricks, cement, reinforcement steel
rods etc. and structural steel for cable trays, supports, canopies, pole foundation etc.
1.3.42 Any other material required for completion of the work as per specifications, drawings
and instruction of Engineer-in-charge
Note: Pole foundations/size of structural items for transmission line shall be calculated by
contractor based on soil investigation report carried out by contractor, forces, wind
velocity, sag-tension for 50mtr. span & other structural parameters.
1.4 Supply by Owner (free issue)
The following items shall be in owner's scope of supply (free issue)

1.4.1 Suitable rated 11KV plant feeder from existing 11KV switchboard (HT-227) located in
GTS s/s shall be provided. Contractor’s scope of work shall start from outgoing
terminal of this feeder panel including modifications in feeder. Extent of modification
shall be as follows:
 Supply & installation of new dual core protection cum metering CT (Ratio:-
400/1/1A, 5P10 & CL 1.0)
 Supply & installation of PS class CT (ratio:- 400/1A)
 Supply & installation of numerical relay suitable for power transformer protection
(suitable for IEC-61850)
 Existing breaker shall be retained
 Protection realys shall be rovided., Differential relay (87T) shall be installed at
upstream (ABB) breaker & transformer trouble/ trip relay (63TX) shall be supplied
by Siemens & installed at downstream breaker. Inter Trip commands from both the
relays shall be routed accordingly. Accordingly, modification in control wiring shall
be carried out considering new relays i.e. main protection relay, differential relay &
transformer trouble relay & inter tripping of breakers.
 Supply & installation of new terminal block
1.5 Installation, testing and commissioning

1.5.1 Testing and commissioning of all owner’s supplied equipment and material as well as
equipment and material supplied by contractor is included in the scope of the
Contractor including parameterization of relay located in owner’s panel.
1.5.2 Carrying out soil resistivity test at at least two locations.
1.5.3 The job includes repairing of all civil works damaged during installation of electrical
facilities. Civil works connected with grouting of equipment to be installed, providing
foundation for control stations, lighting poles and 11kV pole structures.
1.5.4 Checking & making of all connections, i.e., power, control cables and earthing
connections of various electrical equipment such as motors, switchgears,
transformers, lighting fittings and other equipment etc., including pre-commissioning
checks, testing and commissioning.
Page 1286 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 8 of 10
1.5.5 Cable laying and termination of 11kV & 6.6 unearthed grade cables.
1.5.6 Cable laying and termination of 1.1kV grade cables.
1.5.7 Complete installation, testing & commission of 11KV overhead transmission line
system which shall include poles, conductor, earthing & lightning protection system
(from refinery to new intake s/s & from tapping point to existing intake s/s).
1.5.8 Scope of work under this contract shall be inclusive of breaking of walls/floors and
chipping of concrete foundations necessary for the installation of equipment, materials
and making good of the same after completion of work.
1.5.9 Minor modifications wherever required to be done in the owner free supplied
equipment/ devices to enable cable entry/ termination, etc.
1.5.10 Sealing of openings made in the walls/ floors for the cables to be suitably closed using
fire retardant materials, acceptable practice and standards.
1.5.11 Supply and installation of all other accessories not specifically mentioned herein but
nevertheless necessary for completion of job.
1.5.12 Obtaining clearance for energising the complete electrical facilities covered under this
tender and approval of installation/drawings from Central Electricity Authority / any
other statutory authority (This includes equipment installed/ commissioned by others
within the battery limit. This is for the purpose of obtaining comprehensive approval in
one go).
1.5.13 Up-dation and submission of all owner's drawings to incorporate as-built status. Both
hard and editable soft print in AutoCAD format shall be submitted.
1.5.14 Test certificates, catalogues, vendor drawings, installation, operation and maintenance
manuals for all equipment/materials in contractor's scope of supply.
1.5.15 Engineering and preparation of specification and drawings for electrical equipment and
installation wherever applicable or required by the owner and submit to owner for
approval.
Note: All commissioning formats shall be handed over to the successful contractor at the time
of award of contract.
1.6 Co-ordination with other Contractors/ Agencies

It is the responsibility of the contractor to coordinate and provide all necessary
assistance to other contractors/ agencies/ vendors involved in the Complex for proper
and timely execution of the works.
Page 1287 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 9 of 10
ANNEXURE-1
1 Power Transformer (7.5MVA)

 HV bushing
 Neutral bushing
 Rubber bag
 Winding temperature indicator
 Buchholz relay
 Oil level indicator for main tank
 Dehydrating breather
 Silica gel fill
 Contactor of each type used in the main control box
 PRV
2 11KV/6.6KV Switchboard
 Spring Charging Motor
 Indication lamps
 Switch
 Push button
3 Distribution Transformer (2.5/0.63MVA)

 HV bushing with metal part
 LV bushing with metal part
 Neutral bushing with metal part
 HV bushing porcelain
 LV bushing porcelain
 Neutral bushing porcelain
 PRV
 Double float Buchloz’s relay
4 415V LT Panels
 Spring charging motor
 CT One No. each Type
 PT One No. each Type
 Power contactors One No. each Type
 Switches One No. each Type
 2/3 position selector switch One No. each Type
 2/3 position selector switch lockable One No. each Type
 Ammeter selector switch
 Voltmeter selector switch
 TNC switch
 DC Selector switch
 Indicating lamps
5 110V DC VRLA Battery.

 Spares cell
 Inter Cell connector
 Nut, Bolt & Washer suitable for 5 cells
Page 1288 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 10 of 10
6 110V DC Battery Charger

 Pulse Board
 Power Supply Board
 Negetive Power supply card
 Mother Board
 Digital Board
 Discrete components like SCR's, Diodes, Capacitors, resisters
 SCR for rectifier Bridge
 Switches, MCCB’s, MCB etc
 Switches
 AC Input Switch
 DC output switch
 Power / auxiliary contractor/DC Contactors, contactor coils and kits
 AC input contactor
 AC input contractor coil
 AC input contactor aux kit
 Filter capacitor HRC Fuse links
 Indicating lamp assembly/bulbs/LED's
 Indicator assembly-240V AC-Red
 Indicator assembly-240V AC-Yellow
 Indicator assembly-240V AC-Blue
 Toggle switches/Push buttons
 Toggle switches
 Push buttons
 Annunciator, relays
 Annunciator (Spare mother board)
7 HV Motor
 Cooling fan (bi-directional)
 Terminal box
Page 1289 of 2065

DOCUMENT No.
JOB SPECIFICATION B001-302-16-50-SP-9001,
(ELECTRICAL) Rev. B
Page 1 of 21
JOB SPECIFICATION
FOR
ELECTRICAL WORKS
PROJECT: 2ND RAW WATER INTAKE PUMP

HOUSE & PIPELINE AT DAMANJODI,
NALCO.
CLIENT: NALCO.
B 20.04.2017 ISSUED WITH BID PACKAGE CS MKS MKS
A 20.12.2016 ISSUED WITH BID PACKAGE JM MKS MKS

Date Purpose
No by by by
Page 1290 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 2 of 21
1.0 GENERAL
1.1 Introduction
The intent of this specification is to define the requirement for the supply of
equipment and materials (wherever specified), installation, testing and
commissioning of complete electrical power distribution system, consisting of
equipment, lighting, earthing, lightning protection and cabling system for New Raw
Water Intake System.
The work shall be carried out in the best workmanship, in conformity with these
specifications, approved drawings and the instructions of the Owner or Engineer-in-
Charge from time to time.
The contract shall include clearing of temporary construction, waste materials and loose
earth, which might get collected in and nearby the work site consequent to the execution
of work under this contract.
1.2 The work shall be performed in conformity with these specifications and Codes of
Practice of the Bureau of Indian Standards. In case of any conflict, the stipulations under
these specifications shall govern.
In addition, the work shall also conform to the requirements of the following:
a) The Indian Electricity Act and the Rules framed there under
b) The Fire Insurance Regulations.
c) The regulations laid down by the Chief Electrical Inspector of the state government.
d) The regulations laid down by the Factory Inspector.
e) The regulations laid down by the Central Electricity Authority.
Any other regulations laid down by the Central, State or Local Authorities from time to
time during the execution of this contract.
1.3 Guarantee
1.3.1 The contractor shall guarantee the installation against any defect of workmanship
and materials (supplied by the contractor) for a period of 12 months from the date of
issue of the completion certificate. Any damage or defect that may be undiscovered at
the time of issue of the completion certificate, but may arise or come to light
thereafter, shall be rectified or replaced by the contractor at his own expense as
deemed necessary and as per the instructions of the Owner or Engineer-in-Charge
within the time limit specified by the Owner or Engineer-in-Charge.
1.3.2 The above guarantee shall be applicable for the quality of the work executed as well as
for the equipments/cables/fittings/other materials supplied by the contractor.
1.4 Site conditions
The equipment offered and the installation shall be suitable for continuous operation
under the following site conditions:
Ambient Temperature (Max./Min.) : 47º C / 3º C
Design Ambient : 47º C
Max relative humidity : 89%(max.)
Altitude above MSL : <1000m
Page 1291 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 3 of 21
Rainfall : Avg. annual: 1624mm;

Maximum daily: 354mm
Atmosphere : Tropical & Dusty
1.5 System Particulars
The equipment and materials to be supplied by the contractor shall be designed for the
following power supply conditions.
HV : 11 KV± 10%
6.6 KV± 10%
MV : 415 V± 10%
Frequency : 50 Hz ± 3%
1.6 Utilisation voltage & operating philosophy
A. HV distribution voltage : 11kV

B. HV distribution voltage for motors : 6.6 kV
C. 11KV system neutral earthing : Effectively earthed as
transmission line provide
large impedence to earth
D. 6.6KV system neutral earthing : Resistance
fault currentearthed
(refer key SLD)
E. HV motor voltage : 6.6 kV, above 220 kW
Less then equal to 220kW,
F. Auto transfer at 11KV & 6.6KV : 415V
No
G. Auto transfer at MV : No
H. MV motor voltage (415 V AC) : 0.22 kW to 220 kW

I Battery Chargers Incomer : 415 V AC
K AC Lighting/Power Panels and : 415V AC
MV Boards
L Welding Receptacles : 415V AC
N Normal Lighting : 240V AC
O Motors rated below 0.22 kW : 240V AC
P Convenience outlets : 240V AC
Q DC utilization voltage : 110V DC
1.7 Utilisation voltage for critical supplies

A. Switchgear protection power supply : 110 V DC
B. Critical lighting power supply : 110 V DC
1.8 Power Distribution Philosophy & Project Overview
Due to expansion of NALCO refinery, an additional water of 580m3/hr is required to

meet the water supply demands for various purposes. The required quantity is
proposed to be tapped from Kerandi river by constructing an Intake System (Intake
Well). This proposal shall include single stage pumping. In this scheme, 580m3/hr
water shall be drawn from Kerandi river and pumped to a collection chamber of NALCO
Page 1292 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 4 of 21
water treatment plant located with in alumina refinery.
To execute this facility, approximately 17 kM long pipeline network has been envisaged
from the bank where proposed intake well shall be constructed to the water treatment
plant located with in alumina refinery. Two (2) nos. pumps (one working & another
one is stand by) of each capacity for 580m3/hr shall be installed with electrical motor
of BKW. For calculation of actual motor name plate rating, please follow the mechanical
part of Tender.
To run the electrical motor at new water intake well, a new electric substation has
been planned at near to location of new intake well. All civil/structural construction
works pertaining to this has been included in contractor’s scope of work. Location
of this substation has been shown in schematic arrangement drawing (B001-000-
11-42-3001) attached along with this Tender. Tentative size of this substation
(refer drawing no: B001-302-16-50-SS-9001) has been worked out based on
preliminary key single line diagram & same has been attached with this Tender for
contractor’s reference.
To meet the power requirement of this package, owner shall provide one (1) no.
suitable rated 11KV plant feeder from existing 11KV double busbar switchboard
(HT-227 located at GTS s/s) for contractor’s use. Contractor’s scope of work shall
intiate from outgoing terminal of 11KV breaker located in above mentioned trafo. feeder
panel. Extent of modification in existing feeder shall be as follows:-
 Supply & installation of new dual core protection cum metering CT

(Ratio:-400/1/1A, 5P10 & CL 1.0)
 Supply & installation of PS class CT (ratio:- 400/1A)
 Supply & installation of numerical relay suitable for power transformer protection
(suitable for IEC-61850)
 Existing breaker shall be retained
 Differential relay (87T) shall be installed at upstream (ABB) breaker & transformer
trouble/ trip relay (63TX) shall be supplied by Siemens & installed at downstream
breaker. Inter Trip commands from both the relays shall be routed accordingly.
Accordingly, modification in control wiring shall be carried out considering new relays i.e.
main protection relay, differential relay & transformer trouble relay & inter tripping of
breakers.
 Supply & installation of new terminal block
This 11KV power supply from HT-227 shall be extended further to another Siemens
make 11KV single busbar switchboard (new to be supplied & installed by contractor)
which shall be extension of existing Siemens make 11KV switchboard (HT-227A). In
between this two board, one (1) no. 7.5MVA, 11/.11.5KV isolator transformer has
been envisaged for isolation purpose. This 11KV power supply shall be further
connected to 11KV overhead transmission line which shall start from plant’s
boundary. F o u r pole lattice structure shall be used for cable to conductor
connection & same shall be located just outside of plant’s boundary wall. Within
plant, 11KV power shall be transmitted through 11KV cable only & existing route
shall be followed/utilized through which power supply for existing raw water intake well
has been provided. No new infrastructure is required for this cable laying.
Existing 4-pole structure used for construction power & ‘Suraksha Vihar’ shall be
dismantled. In that place, new one no. 7.5MVA, 11/11.5KV transformer (ISOL#3) shall
be installed. Suitable sized transformer bay along with soak pit, water sprinkler system,
fire wall of 2 hour rating & fencing arrangement shall be constructed at this place. Due
to construction of new transformer bay, existing approach road to GTS coming from
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(ELECTRICAL) Rev. B
Page 5 of 21
west side shall be blocked. Hence, new maintenance/ approach road to be prepared
from north side direction for connectivity with GTS substation. Same shall be included
in bidder’s scope.
For new water Intake substation, power shall be transmitted through 11KV cable from
HT 227A switchboard at GTS to Four Pole Structure (to be constructed new) near
Kantabausuni temple. From the 4 pole structure, power shall be transmitted through
lattice poles to 4 Pole Structure (to be constructed near existing water intake
substation). From the 4 pole structure, power shall be transmitted through 11KV cable
for bridge/road crossing upto another 4 pole structure (to be constructed near new
water Intake substation). Power shall be transmitted through 11KV cable from the four
pole structure to new 11KV Switchboard at new water Intake sub station.
Overhead transmission line of 17.6kM length shall be used to transmit 7.5MVA

power at 11KV level to new electric substation located at nearby location of new
raw water intake well. Typical key single line diagram (B001-302-16-50-SLD-9001)
of entire power distribution system is attached with Tender.
In addition to above, it is envisaged to maintain redundancy in power supply

arrangement between two intake well systems (new & existing). To execute the
same, the following works are envisaged in scope of contractor:
 Supply & Installation of 02 nos of 4 pole structures near Existing Water Intake
Substation (01 of these shall feed power to the New Water Intake Sub Station & the
other shall replace the existing 02 pole structure presently transmitting power to the
existing Water Intake substation).
 Inter Connection of the above 02 nos of newly constructed 4 pole structures through
11KV cable.
 Laying of 01 nos of cable from new 4 pole structure to existing water intake substation
(Incomer 1)
 Re Routing of existing cable (including supply of all associated materials like End
termination Kit, straight Through Jointing kit etc) from existing 02 pole structure to the
new 4 pole structure
 Laying of Cable from new 4 Pole Structure to Existing 11KV Switchboard at Existing
Water Intake Substation (Incomer 2)
 Dismantling of existing 2 pole structure.
2.0 Job Specification
2.1 General
Equipments and materials to be supplied by contractor shall conform to the

following min. detailed specifications, site & system conditions. All equipments,
materials, fittings to be supplied by the contractor shall be of the best quality. The
equipment shall be manufactured in accordance with relevant Indian standards. No
proto type equipment/newly launched product shall be offered by contractor. All
similar materials and removal parts shall be interchangeable to each other.All the
breakers of 11KV, 6.6KV switchboard shall be of VCB type.
2.2 11kV Extension Panel (Siemens make) at GTS s/s
11kV, 1600A, 40kA (1 sec.) single busbar extension panels both at incoming and
outgoing (RHS, LHS to existing Siemens make board, HT-227A).
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(ELECTRICAL) Rev. B
Page 6 of 21
Existing right most panel of existing HT-227A has been used as incomer feeder to 4-
pole structure for construction power # 1, construction power # 2 & ‘Surakshya Vihar’.
This bifurcation has been made on 4-pole structure installed in between GTS s/s &
ISOL # 1 on north side. This 4-pole structure shall be dismantled. Hence, before this
dismantling work, existing feeder used for construction power # 1 & construction power
# 2 shall be disconnected from 4-pole structure & same shall be re-connected with
newly procured Siemens make extension panel installed HT-227A. Existing 11KV
incomer shall be re-connected with the 3rd outgoing feeder used for ‘Surakshya Vihar’
by using straight through joint. Dismantling of 4-pole structure along with
disconnection/reconnection of cable along with supply of straight through joint, End
termination Kit etc shall be considered in bidder’s scope. Feeder description of
extensions panels are as follows:-
 Bus coupler
 Incomer From Isolation Transformer #3 with Line PT
 Bus PT
 Outgoing Plant feeder for New Water Intake
 Outgoing Plant feeder for CSS 7
 Plant feeder for construction power
 Outgoing Plant Feeder for CSS 8
 Spare plant feeder
Further the the switchboard extensions shall be as per enclosed data sheet (B001-
302-16-50- DS-9004/9007/9013) and EIL standard specification. 6-51-0001
and shall meet the minimum following requirements:-
2.2.1 Selection, sizing and suitability of all components shall be the contractor’s
responsibility. The equipment as required for safe and satisfactory operation shall
be considered included in contractor’s scope even not specifically mentioned in
Tender.
2.2.2 The contractor shall solely responsible to co-ordinate the relay characteristics with
relay manufacturer for the proper selection of CT with special care to select PS class
CT.
2.2.3 Relay settings (calculations & incorporating the same in numerical relay) shall be
undertaken done by the contractor.
2.2.4 Hardware datasheet (B001-302-16-50-DS-9007) & feeder list (B001-302-16-50-DS-

9013) includes only the major items such as numerical relays, CT, meter & control
switches. Any aux. relays, switches, timers etc. required to develop required control
schematic shall be supplied & installed by contractor without any cost implication to
owner.
2.2.5 CT ratios shall be calculated by contractor considering full load current rating & 20%
design margin. The value shown in key single line diagram are tentative & same shall
change at later date without any cost & time implication to owner. The VA burden,
knee point voltage, CT resistance, magnetizing current shall be calculated by
contractor for owner’s/EIL review before proceeding for manufacturing/procurement.
2.2.6 No dummy panel is required as new extension panel is of same make as existing (M/s
Siemens).
2.2.7 VCB rating specified in several documents (SLD & data sheets) are tentative & may
change at later date with out any cost implication owner. Only in-panel rating shall be
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(ELECTRICAL) Rev. B
Page 7 of 21
furnished.
2.2.8 All 11kV (extension) panels shall have numerical type relay for specific application
having IEC-61850 protocol. Same shall be exactly in line with EIL standard spec. 6-
51-0055. Numerical relay shall have integral metering function & lock out element
shall be part of relay only. Each relay shall have 16 nos. DI/DO & all of them shall
be programmable at site. All numerical relays shall be procured considering IEC-
61850 protocol. All relays of 11KV extension panels (in GTS s/s) shall be internally
hooked up with each other. A laptop plug point to be made available inside the switch
board to access all relays for parameterization. Entire communication activity including
laying & termination is in bidder’s scope.
Each panel shall be provided with a communicable multifunction meter which is to be

networked. The MW / Mvar / Current / MWH / MvARH data from the meter shall be
linked to existing Electrical Control System (ECS). The analog inputs shall be extended
to existing Serial link Controller (SLC) card of ECS. Digital I/O (08 nos per panel) of the
extension panel shall be hard wired to ECS through a JB to the marshalling box located
inside the switchgear room.
2.2.9 Following automation software shall be provided along with extension panels:
 DIGSI software (version 4.87) along with driver

 RS485 to USB converter
 One no. laptop of latest configuration having 9 nos. pin serial port suitable for
RS232. Same shall be loaded with relay parameterization software (full version)
through which relay data can be altered at site.
 In addition to the above, all necessary s/w & h/w for numerical relays
corresponding to 11KV , 6.6KV,415V switchboards at new Water Intake s/s to be
supplied.
2.2.10 Following mentioned test certificates for identical rated panel shall be submitted for
review & approval:-
 Heat run test
 Short circuit withstand capacity
 Power frequency & lightning impulse withstand capacity
 Internal arc
 Breaker duty cycle
2.3 11kV New Switchboard, HT-240 (at new raw water intake s/s)
11kV, 630A, 40kA (1 sec.) single busbar extension panels shall be as per
enclosed data sheet (B001-302-16-50-DS-9007/9012/9013) and EIL standard
specification. 6-51-0001 and shall meet the following requirements:-
responsibility. The equipment as required for safe and satisfactory operation
shall be considered included in contractor’s scope even not specifically mentioned
in Tender.
relay manufacturer for the proper selection of CT.
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SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 8 of 21
2.3.4 Hardware data sheet (B001-302-16-50-DS-9007) & feeder list (B001-302-16-50-

DS-9013) includes only the major items such as numerical relays, CT, meter & control
switches. Any aux. relays, switches, timers etc. required to develop required control
schematic shall be supplied & installed by contractor without any cost implication to
owner.
2.3.5 All necessary s/w & h/w for numerical relays corresponding to 11KV switchboards at
new Water Intake s/s to be supplied. One no. laptop of latest configuration having
suitable communication port for communication with Numerical Relay to be supplied.
Same shall be loaded with relay parameterization software (full version) through which
relay data can be altered at site.
2.3.6 Each panel shall be provided with communicable multi function meter.
2.3.7 Substation automation system must be capable of wireless Data transmission to

remote about Motor loading / breaker status etc.
2.3.8 SMS system of any tripping (86 operated) to be incorporated
2.3.9 CT ratios shall be calculated by contractor considering full load current rating &
20% design margin. The value shown in key single line diagram are tentative &
same shall change at later date with out any cost & time implication to owner.
2.3.10 VCB rating specified in several documents (SLD & data sheets) are tentative &
may change at later date without any cost implication owner. Only in-panel rating
shall be furnished.
2.3.11 All 11kV (new) panels shall have numerical type relay for specific application having
IEC-61850 protocol. Same shall be exactly in line with EIL standard spec. 6-51-
0055. Numerical relay shall have integral metering function & lock out element shall
be part of relay only. Each relay shall have 16 nos. DI/DO & all of them shall be
programmable at site.
review & approval:-
 Heat run test
 Internal arc
2.4 6.6kV New Switchboard, HT-265 (at new Water intake Substation)
6.6kV, 630A, 20kA (1 sec.) single busbar extension panels shall be as per
enclosed data sheet (B001-302-16-50-DS-9005/9007/9013) and EIL standard
specification. 6-51-0001 and shall meet the following requirements:-
responsibility. The equipment as required for safe and satisfactory operation shall be
considered included in contractor’s scope even not specifically mentioned in Tender.
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DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 9 of 21
relay manufacturer for the proper selection of CT.
2.4.4 Hardware data sheet (B001-302-16-50-DS-9007) & feeder list (B001-302-16-

50-DS-9013) includes only the major items such as numerical relays, CT, meter &
control switches. Any aux. relays, switches, timers etc. required to develop required
control schematic shall be supplied & installed by contractor without any cost
implication to owner.
2.4.5 CT ratios shall be calculated by contractor considering full load current rating &
20% design margin. The value shown in key single line diagram are tentative &
same shall change at later date with out any cost & time implication to owner.
2.4.7 VCB rating specified in several documents (SLD & data sheets) are tentative &
may change at later date without any cost implication owner. Only in-panel rating
shall be furnished.
2.4.8 All 6.6kV (new) panels shall have numerical type relay for specific application having
IEC-61850 protocol. Same shall be exactly in line with EIL standard spec. 6-51-
0055. Numerical relay shall have integral metering function & lock out element
shall be part of relay only. Each relay shall have 16 nos. DI/DO & all of them shall
be programmable at site. In addition to that, motor protection relay shall have min.
4 nos. programmable AI for analog signal interface. All necessary s/w & h/w for
numerical relays corresponding to 11KV switchboards at new Water Intake s/s to be
supplied.
2.4.9 Each Panel shall be provided with a communicable multifunction meter.
review & approval:-
 Heat run test
 Internal arc
2.4.11 Laptop with following configuration shall be provided wherever mentioned bid package:
 Make: HP / Dell / Lenovo / Sony.
 Processor: Intel Core i5 2.26 GHz, 3MB L3 Cache, or higher
 RAM Memory : 4GB DDR3 1060 MHz or higher
 Chipset: Mobile Intel GS45 or higher
 Hard Disk: 500 GB SATA Hard Disk or higher with impact protection.
 Display: 13 to 15.4 inches LED with inbuilt web camera.
 Graphics: 1 GB graphics video card memory.
 Optical Drive: Internal DVD Writer.
 Network Interface: Gigabit Ethernet (10/100/1000 Mbps) port.
 Wireless: Wireless and Bluetooth.
 Ports: 3 USB 4.0 Ports, External display (VGA) port.
 External Mouse: External small optical Scroll mouse with mouse pad.
 Audio: Two Built-in speakers with integrated microphone
 Battery: Lithium-Ion 6 Cell battery.
 Carry Bag: Deluxe Cushioned OEM Carry Bag
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DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 10 of 21
 Operating System: Windows 10 Prof, 64 bit with Recovery CD.

 Drivers: Driver softwares for Network, Audio, Video etc on DVD / CD media.
 Warranty: One year comprehensive On-Site warranty .
2.5 Lightning Arrester
2.5.1 Lightning arrester shall be single pole, gapless type (having ZnO) suitable for
use in 11kV effectively earthed system. Same shall be strictly complying to IS:
3070. All ferrous part shall be hot dip galvanized to prevent corrosion. LA shall be
provided with event counter & mA leakage current meter.
2.5.2 The rated voltage rating of lightning arrester shall be 9kV (rms).
2.5.3 The nominal discharge current rating of the lightning arresters shall be 5kA.
2.6 Insulators
2.6.1 Pin/strain/post insulators shall be made from high grade porcelain and shall
be uniformly Pin/Strain insulators shall be made from high grade porcelain and
shall be uniformly brown glazed. The porcelain shall be homogeneous, free from
laminations, cavities and other flaws or imperfections that might affect the
mechanical or dielectric quality and shall be thoroughly vitrified, tough and
impervious to moisture. When operating at normal rated voltage, there shall be no
electric discharge which would cause erosion or injury to conductors, insulators or
supports by the formation of substance produced by chemical action. The
hardware shall be hot dip galvanized. The insulation design shall conform to
relevant IS. Strain insulators shall consist of standard 10 inch discs and shall be ball
and socket type.
2.7 Gang Operated Air-Break Switch

2.7.1 Air break switches shall be of triple pole, manually gang operated, suitable for
system and shall also be suitable for mounting on a two or four pole structure.
The air break switches shall be vertical tilting type. The switch shall be capable of
operating through a system levers and rods by a single person standing on ground.
It shall be capable of being padlocked in open and close- positions. Expansion
type terminal connectors shall be provided at each end for connecting switch
terminals to standard ACSR leads as required. Switch shall be provided with arcing
horns of ample section and approved shape. All the iron and steel parts shall be hot
dip galvanised. For load break switch with earth switch, electrical interlock
provision with earth switch and corresponding breaker shall be provided.
2.8 Overhead transmission line structures

2.8.1 Overhead line structures (1/2/4 Pole) shall be of lattice structured pole type
complete with foundation as per site data and Civil/structural specifications
enclosed with the Tender. Structure with gang operated, 3 pole isolators shall also
include upper and lower bus-bars, lighting arrestors, pin type insulators, flexible
jumpers etc. All steel structures shall be rigid in construction and complete with
G.I. stay wire, anti-climbing devices and caution/warning plate. etc, to the
satisfaction of the Engineer-in-charge.
Stay shall normally consist of 2500 mm long, 20 mm G.I. stay rod, 300 x 300 x 10
mm anchor plate, 7/10 SWG galvanized stay wire with H.T Insulator, thimble, twin-
buckles etc. Stays shall be provided at dead ends. Each pole shall have 300 x 300
x 10 mm MS base plate which shall be at least 1500 mm below grade. Red
Page 1299 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 11 of 21
enameled danger/caution plates of approved type shall be provided on each

structure.
All poles shall be installed 1500 mm below ground level. Pole structures shall be
earthed with electrodes as per drawing No. 7-51-117. Separate earth electrodes in
test pit shall be provided for lightning arrestors. All earth electrodes shall be driven
to a sufficient depth to reach permanent moist soil. All electrodes shall be tested
for earth resistance by means of standard earth meager. A continuous earth wire
shall be run along the entire route of overhead line and connected to earth at three
points in every km as per rules.
2.9 Overhead line supports
For overhead line, 8m high lattice structured poles shall be used. Typical GA
drawing (B001-302-16-50-DS-9017A/B/C/D/E) of each type of poles envisaged in
this package is attached. However, contractor shall design the pole structures along
with its foundations based on soil resistivity data, wind velocity, allowable sag of
800mm. from down most phase, forces, dead weight & other structural
parameters.
The stay wires with insulators shall be provided wherever necessary. The size of
stay wire shall be 7/10 SWG. It shall be complete with turn buckles, anchor clamps
etc.
Guard wire shall be provided where O/H line is crossing the roads.
All the structures shall be earthed with electrodes as per drawing No. 7-51-117.
Separate earth electrodes in test pit shall be provided for lightning arrestors. All
earth electrodes shall be driven to a sufficient depth to reach permanent moist
soil. All electrodes shall be tested for earth resistance by means of standard
earth meager. A continuous earth wire shall be run along the entire route of
overhead line and connected to earth at three points in every km as per rules.
2.10 Clamps, connectors & Hardware

The clamps and connectors shall conform to the requirements of Indian Standards.
Aluminum alloy clamps shall be used for ACSR DOG conductors. Clamps &
connectors shall be designed to carry rated current as that of conductor, without
exceeding the permissible temperature rise of conductor and to withstand the
mechanical stresses.
All current carrying parts shall be designed and manufactured to have minimum
contact resistance and to carry rated current at ambient temperature.
The items of hardware and fittings shall make complete assemblies and shall
include all bolts, nuts and washers, check nuts, pins etc., which are necessary for
their satisfactory performance. Such parts shall be deemed to be within the
scope of this specification whether specifically mentioned in schedule of rate or
not.
2.11 Transformer
7.5MVA, 11/11.5KV isolation transformer (ISOL #3), TR-2500/2501

(2.5MVA11/6.9) and TR-2502/2503 (0.63 MVA min, 11/0.433KV) shall be as per
enclosed data sheet (B001-302-16-50-DS-9001/9002) and EIL standard specification.
6-51-0041, 6-51-0044 and shall meet the following requirements:-
2.11.1 7.5MVA, 11/11.5KV isolation transformer shall be oil filled type where as 2.5MVA,
Page 1300 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 12 of 21
11/6.9KV and 0.63 MVA 11/0.433 transformers shall be dry type cast resin insulated.
2.11.2 7.5MVA transformer shall be located in place of dismantled existing 4 pole structure
used for constructon power and suraksha vihar by contractor.
2.11.2 11/6.9KV & 11/0.433KV dry type transformers shall be located inside the new water
intake substation.
2.11.3 All external hardware (like those of tank cover, terminal box, marshalling box, pipe
flanges etc.) and name plate/rating plate etc. shall be of stainless steel.
2.11.4 7.5MVA, 11/11.5KV isolation transformer, 2.5 MVA 11/6.9KV transformers,

0.63MVA 11/0.433KV transformers shall have off-load tap changer
2.11.5 Following mentioned test certificate shall be submitted for identical rated transformer:-
- Heat run test
- Short circuit withstand capacity (primary/secondary/tertiary)
- Power frequency & Lightning impulse withstand voltage
- Ingress protection
- Partial discharge
If suitable test certificates are not available, then new test shall be carried out on
identical rated transformer without any cost and time implication.
2.11.6 The following tests shall be carried out in addition to routine tests as per cl. no. 13.3 of
EIL spec.6-51-0041 & 5-51-0044.
i) Oil leakage test- All tanks and oil filled compartments. ii. Vacuum test- One
transformer tank of each size.
ii) Pressure test- One transfer tank of each size.
Test certificates of above tests shall be furnished during detailed engineering for review
purpose.
2.11.7 The transformer shall comply to the following requirements:-

a. The transformers shall be suitable for using emulsifiers as a part of fire
protection system.
b. Cable boxes shall be supplied with cable lugs and glands.
c. HV & LV Cable box shall be weatherproof to IP-55.
d. For fixed portion of cable box, Inspection cover with lifting handle shall be
provided.
e. The primary cable box (11KV) shall be able to withstand 40KA fault level
for 1 sec.
f. The marshalling box shall be weatherproof to IP-55.
g. Test certificates for primary/secondary cable box and marshalling box shall
be furnished during detail engineering by the vendor.
h. The neutral CT shall be mounted before bifurcation of the neutral.
i. The transformer shall be supplied with first fill of oil and 10% extra oil in non-
returnable drums.
j. The transformer shall be provided with pressure relief valve with alarm contact.
2.12 DC system
Separate 110V DC system comprising VRLA battery, battery charger and
DCDB (as per datasheet no. B001-302-16-50-DS-9011)shall be provided to cater
switchgear control supply & DC critical lighting of the substation.
The battery charger shall be fed from MV SWBD and the same shall be
parallel redundant complying with the requirement of EIL Specification 6-51-0019.
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DOCUMENT No.
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(ELECTRICAL) Rev. B
Page 13 of 21
The battery for the DC system shall be sized considering backup time of 2 hours.
2.13 HV Motors
2.13.1 All offered HV motors shall be exactly in line with EIL standard spec. 6-51-0031 &
motor data sheet (B001-302-16-50-DS-9015). In addition to that, following shall also
fulfilled:
2.13.2 All the motors shall be designed for direct on line starting.
2.13.3 Motor shall be supplied with VPI poor insulation.
2.13.4 The motor starting current shall strictly limit to 6 times of the motor full load current
subject to tolerance.
2.13.5 All motors shall be totally enclosed type having degree of protection IP-55 suitable for
outdoor installation. The vendor shall furnish a copy of test certificates for IP-55 degree
of protection.
2.13.6 All Motors shall be with class ‘F’ insulation with temperature rise limited to Class ’B’.
2.13.7 RTD & BTD shall be provided in motor and same shall be wired to motor protection
relay for protection against temperature rise.
2.13.8 Motor body & its terminal boxes shall be made of cast iron only.
2.13.9 Motor body shall be painted by epoxy based shade 632 as per IS-5 suitable for
outdoor location.
2.13.10 Name plate material shall be of stainless steel with external bolts of stainless steel.
Following shall also be provided on the name plate in addition to requirements of EIL
standard specification:
-
i) Description & code no. of motor.
ii) Degree of protection of enclosure
iii) Driving end and non-driving end bearing type and no.
iv) Weight of the motor
v) Type of lubrication and recommended interval of lubrication.
2.14 Neutral Grounding resistor (NGR)

Neutral gounding resistor shall be in line EIL standard spec. 6-51-0043 & data
sheet (B001-302-16-50-DS-9003). Exact value of NGR shall be calculated by
contractor to ensure that earth fault current should not increase beyond 200A value
on 6.6KV voltage level. Detailed calculation of NGR shall be submitted for EIL
approval.
2.15 Local control station/ Power socket cabinet
2.15.1 The Local control stations shall be supplied as per EIL standard specification 6-51-
0014.
2.15.2 All push button cabinets & power socket cabinets shall be fabricated out of minimum
14SWG thick sheet steel.
2.15.3 Following control/metering shall be provided on the Local control stations.

a) ON/OFF push button
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(ELECTRICAL) Rev. B
Page 14 of 21
b) Ammeter
2.16 MV Switchboard
2.16.1 MV switchboards shall be as per enclosed datasheets (B001-302-16-50-DS-

9006/9007/9013) and attached EIL standard specifications 6-5-0018 for drawout type
switchboards.
2.16.2 MV switchboards shall be single front, drawout and compartmentalized in design.
2.16.3 It shall have two nos. of incomer with interlock facility with in them. Bus shall be suitable
for fault level of 50kA for 1 sec.
2.16.4 It shall be provided with min. IP-41 degree of protection.
2.16.5 Type test certificates (i.e. IP protection, temperature rise & short circuit withstand
capacity) shall be submitted during detailed engineering stage. If test certificates are
more then five year old, fresh tests shall be carried out without any cost & time
implication.
2.16.6 At least 20% spare outgoing feeders, subject to a minimum of 1 of each type shall be
provided
2.16.7 All indicating lamps shall be LED type only and provided with low voltage glow
protection (LVGP) feature.
2.16.8 Separate control module/terminal box shall be provided on either side of the MCC for
interfacing control signals.
2.17 HV/MV cable (power/control)

All HV/MV power & control cables shall be supplied complying with the requirement
of EIL Specification 6-51-0051 & cable data sheet (B001-302-16-50-DS-9010).
2.18 Flood light mast
Flood light mast (30mtr. high) shall be supplied complying with the
requirement of EIL Specification 6-51-0039 & cable data sheet (B001-302-16-50-
DS-9017). Same shall have twelve (12) nos. of light fixture each
having LED lams equivalent to 2X400W HPSV shall be used.Same shall
have motorized winch facility. Foundation required for this high mast shall be
carried out by contractor based on site data. Location of this mast shall be decided
during lighting arrangement drawing of new raw water intake s/s area.
2.19 New Intake well Substation Building
The substation shall be adequately sized with proper equipment layout and this shall
be subject to Owner/ EIL’s approval. Contractor shall increase the size of the
building, if required, to accommodate electrical equipment of the package and
owner’s equipment, including minimum spare space of 20% without cost and time
implication to owner/ EIL.
Contractor shall also include provision for cut outs, floor insert plates, equipment
foundations etc. for all equipment to be supplied by them and to be installed in
substation building.
Cable trench shall be provided for spreading cables for substation building.
Adequately ventilated battery room(s) with washbasin, water tap etc., as required,
shall be considered.
Page 1303 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 15 of 21
Switchboard shall not be located on building expansion joints. However, if

unavoidable, dummy panels shall be provided on the expansion joints.
Fire fighting system like portable type CO2 extinguishers, sand buckets, Insulating
rubber mats etc. shall be provided for substation, transformer room etc. as per
statutory regulations and as defined elsewhere.
Any other civil work required for completion of work is included in contractor’s
scope of work.
2.20 Cabling, Lighting, Earthing and Lightning Protection
Cabling system
Scope of cabling system (supply, laying & termination) shall start from outgoing
terminals of 11KV breaker panel free issued by NALCO (HT-227 of GTS s/s).
All downstream power & control cabling till intake well motor terminals at new
intake well s/s & incoming terminals of 11KV breaker of existing 11KV switchboard
(at existing intake well s/s) is in scope of contractor. Above mentioned cabling system
shall conform to enclosed EIL specification 6-51-0082.
All control cables shall be 2.5 sq. mm. and shall have solid conductor instead of
stranded conductor.
The size of cable trays (if required) shall be limited to 300 / 450 / 600 /750mm
(as required). Size of angle shall be min. 65x65x8 mm with flat runner 50x3 mm at a
distance of 300 mm.
Lighting system
Indoor lighting of new intake well s/s building as well as outdoor lighting around new
s/s shall be carried out by contractor. All hardware such as fixture, lamp, cable,
lighting panel, lighting poles etc. along with site work shall be carried out by
contractor.
For lighting circuit 3 core 2.5 sq. mm. copper conductor cable shall be used, third
core shall be used for earthing purposes.
To avoid complete darkness in case of power failure, 100W/200W GLS

incandescent lamp and fixtures fed by DC supply shall be provided at new intake well
s/s. Adequate number of self-contained portable hand lamps and battery operated
emergency units shall be provided for immediate use at substation and strategic
locations as required for personnel safety. Each lighting or power panel shall be
provided with maximum 40A MCB (without release) and upto maximum 12 nos.
outgoing SPN MCB circuits.
LED lamps shall be used for high bay lighting and outdoor area lighting. All roads to be
constructed with in new intake well s/s area (if any) shall be provided with street
lighting.
Lighting system shall conform to enclosed EIL specifications 6-51-0083
Earthing system
Earthing system shall be designed, supplied and installed as per enclosed
EIL standard specifications 6-51-0084.
Earthing system envisages the earthing network with designed number of earth
electrodes attached to meet the required values of earth resistance
Page 1304 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 16 of 21
Contractor shall carry out soil resistivity test at site and size the earthing grid
accordingly. Earthing (includes supply of all materials & site work) of all
equipments/system from 11/11.5KV, 7.5MVA isolation transformer onwards to new
intake well motor & double pole structure envisaged at existing intake well s/s is
included in contractor’s scope.
Lightning protection system

Lightning protection of new intake well s/s building conform to IS: 2309 and NFPA-78
is included in contractor’s scope. An independent earthing network shall be
provided for lightning protection and this shall be bonded with the main earthing
network with a minimum 40x5 mm GI strip. Supply of all materials including site work
is included in contractor’s scope of work.
3.0 STATUTORY APPROVAL OF WORKS
3.1 The contractr has to duly comply to all the observations raised by the statutory bodies
like CEA etc.Contractor shall make an application on behalf of the owner for
submission to CEA/ Electrical Inspectorate along with copies of required certificates
complete in all respects and submit to the engineer-in-charge for onward
transmission well ahead of time so that the actual commissioning of system/
equipment is not delayed for want of inspection by the Inspector. Contractor
shall arrange the actual inspection of work by the Electrical Inspector. Necessary
coordination and liaison work in this respect shall be the responsibility of the
contractor.
3.2 Statutory approvals from CEA shall be taken by contractor. All documents,
drawings, certificates and test reports as required shall be furnished by the
contractor as and when required and contractor's representative shall be available
upto the end for carrying out all formalities with the statutory authorities. The owner
shall extend all help for taking statutory approvals as regards supplying information
about the existing plant and facilities.
3.3 The Inspection and acceptance of the work as above shall not absolve the
Contractor from any of his responsibilities under this contract.
3.4 Any other statutory approval of works required for the electrical installation is also
included in the contractor's scope.
4.0 MAKES OF EQUIPMENTS / COMPONENTS

Make of electrical equipments, materials and components shall be as per the enclosed
EIL/Nalco Vendor List (B001-302-16-50-VL-9001). Equipment for which makes are not
indicated shall be subjected to EIL / Nalco’s approval before placement of order.
Contractor shall furnish the detailed PTR of these vendors in this regard. No prototype
equipment/newly launched equipment shall be acceptable.
Type of lighting fixture shall be as per Lighting Fixture Datasheet Doc. No. B001-
302-16-50-DS-9019, enclosed herewith.
5.0 INSPECTION, TESTING & COMMISSIONING
5.1 Site inspection, testing and commissioning of electrical installation shall be carried
out as per enclosed Specification no. 6-51-0087 and Inspection and Test Plans
included or referred in this Tender.
5.2 All the equipment installed by the contractor shall be tested and commissioned as
required and no separate payments shall be made. Contractor shall carefully
inspect all equipment before receiving them from owner for installation
purposes. Any damage or defect noticed shall be brought to the notice of the
Page 1305 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 17 of 21
Engineer-in-charge at that time.

5.3 Any work not conforming to the execution drawings, specifications or codes shall
be rejected forthwith and the contractor shall carry out the rectification at his own
cost.
5.4 The contractor shall carry out all the tests as enumerated in the technical
specification and technical documents which may be furnished to him during
execution of the work.
5.5 Before the electrical system is made live, the electrical contractor shall carry out
suitable tests to establish to the satisfaction of Engineer-in-Charge/Owner that the
installation of equipment, wiring and connections have been correctly done and
are in good working condition and that it will operate as intended.
5.6 All tests shall be conducted in the presence of Owner/Engineer-in-Charge or
his authorized representative unless he waives this requirement in writing. All
testing equipment necessary to carry out the test shall be arranged by the
contractor. The tests shall be recorded on approved Performa and certified records
of the tests shall be submitted to Owner/Engineer-in-Charge.
5.7 After the completion of all tests and rectification of all defects pointed out during final
inspection, plant start-up trials would be commenced. During the start-up trials
contractor shall provide skilled/unskilled personnel and supervision round the clock
at his cost. The number and category of workmen and duration up to which required
will be decided by the Engineer-in-Charge/Owner. Any defects noticed during the
start-up trial relating to the equipment supplied and work carried out by the
Contractor, will be rectified by the contractor at his own cost.
5.8 Owner/Engineer-in-Charge shall have the right to get these defects rectified at the
risk and cost of the contractor if he fails to attend to these defects immediately as
desired.
6.0 SYSTEM TESTS AND START-UP

6.1 Complete testing of power distribution system envisaged in this package would be
carried out under the supervision of the Owner and the contractor shall furnish as
part of the works and within his quoted rates, on round the clock basis, skilled
personnel and supervisors to carry out the plant testing. The number and category
of skilled personnel to be deployed by the contractor shall be decided by the
Engineer-in-Charge and the Contractor shall abide by his decision.
6.2 During start-up, the contractor's responsibilities would be limited to attending to
the defects attributable to him in the plant as and when they are brought to his
notice by the Owner. The Owner shall have the right to have these defects
rectified at the risk and cost of the contractor if he fails to attend to these defects
immediately.
6.3 After the operating conditions are fully achieved in all the plants and the
requirement stated in relevant clause of General conditions of contract are fulfilled,
the contractor would be eligible for completion certificate.
6.4 Where the works are carried out at the cost of the contractor, the Engineer-in-
Charge would recover the actual cost incurred towards, labor, supervision and
materials, consumables or otherwise, plus 10% towards overheads, from any
pending bill of the contract or the security deposit.
7.0 DRAWINGS
7.1 The drawings accompanying the tender document are indicative of the nature of
Page 1306 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 18 of 21
work and issued for tendering purposes only. Purpose of these drawings is to
enable the tenderer to make an offer in line with the requirements of the Owner.
However, no extra claim, whatsoever, shall be entertained for any variation
in the "Approved for Construction" and "Tender Drawings" regarding any
changes in units. Construction shall be as per drawings/specifications issued/
approved by the Engineer-in-Charge during the course of execution of
work. Detailed construction drawings on the basis of which actual execution
of work is to proceed will be furnished to the contractor progressively based on
the detailed construction programme evolved after the award of work and also
based on construction progress achieved by the contractor.
7.2 Prospective contractor shall be deemed to have studied the drawings enclosed
with tender or displayed for scrutiny and fully understood the nature and
magnitude of the work before submitting the bids.
7.3 Where the contractor has to prepare drawings e.g. for fabrication of lighting and
power panels etc. contractor should submit the drawings to Engineer-in-Charge
and the approval in writing of the Engineer-in-Charge shall be obtained before
commencing fabrication.
7.4 After the job completion, contractor shall prepare 'AS-BUILT' drawings, Final
certified "As Built" drawings in editable soft copy shall be submitted by the
contractor to owner in bound volume with one set of reproducible original sepia plus
ten sets of prints.
7.5 Contractor shall submit equipment manufacturer’s drawings for supply items for
review in five sets of prints, and the approval in writing of the Engineer-in-
Charge shall be obtained before commencing manufacture. However, it is to be
understood that the review of drawings shall not absolve the Contractor from his
basic responsibility to check total compliance to specifications included in tender
document. Final drawings in bound volumes with one set of reproducible
original sepia plus ten sets of prints shall be submitted by contractor along
with supply of materials at site.
Page 1307 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 19 of 21
8.0 LIST OF ATTACHMENTS

8.1 List of EIL specifications
S.NO DESCRIPTION DOCUMENT NO REV
1. Specification of Industrial type weatherproof 6-51-0014 5
push button station
2. Specification of numerical relay 6-51-0055 2
3. Specification for MV Switchboard 6-51-0018 4
4. Specification for HV switchboard 6-51-0001 6
5. Specification for HV and MV cables 6-51-0051 7
6. Specification for electrical equipment installation 6-51-0081 4
7. Specification for cable installation 6-51-0082 4
8. Specification for lighting installation 6-51-0083 5
9. Specification for earthing installation 6-51-0084 4
10. Specification for field inspection, testing and 6-51-0087 3
commissioning of electrical installation
11. Specification for oil filled transformer 6-51-0041 5
12. Specification for dry type distribution transformer 6-51-0044 5
13. Specification for battery & battery charger 6-51-0019 4
14. Specification for HV motor 6-51-0031 5
15. Specification for MV motor 6-51-0032 5
16. Specification for flood light mast 6-51-0039 3
8.2 List of EIL installation standards

1. Typical earth electrode for earthing system 7-51-0101 5
2. Typical earth electrode in test pit 7-51-0102 6
3. Typical earth plat fixing details 7-51-0103 6
4. Typical arrangement for earthing of motor 7-51-0104 5
5. Typical arrangement for earthing of transformer 7-51-0105 6
6. Typical earth connection for push button station. 7-51-0106 5
7. Typical earth connection for street lighting pole 7-51-0107 5
8. Earthing of tanks, vessels and spheres 7-51-0108 6
9. Typical arrangement for earthing of overhead 7-51-0109 5
cable tray and electric motor.
10. Typical earthing arrangement for process 7-51-0111 5
equipment.
11. Earthing/ bonding of pipes and pipe racks 7-51-0112 5
12. Fence and gate earthing (Transformer yard) 7-51-0115 5
13. Typical details of directly buried earth electrode 7-51-0117 5
14. Typical installation of lighting fixture at ground 7-51-0201 4
level
15. Typical installation of lighting fixture on platform 7-51-0202 4
16. Typical open area flood light mounted on wall or 7-51-0203 4
column
17. Typical installation of flood light fixtures (two) 7-51-0205 4
mounted on pole
18. Typical installation of street lighting fixture 7-51-0207 4
19. Typical marshalling box details for lighting poles 7-51-0208 5
Page 1308 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 20 of 21

20. General arrangement for flood light mast 7-51-0209 4
21. Typical installation of fluorescent fixture 7-51-0212 4
mounting in exposed conduit wiring system
22. Typical installation of recessed mounted 7-51-0213 4
fluorescent fixture
23. Typical installation of recessed mounted or 7-51-0214 5
below false ceiling mounted fluorescent fixture
24. Typical installation of recessed mounted 7-51-0215 5
fluorescent fixture (block of four)
25. Typical installation of high bay lighting fixture 7-51-0216 4
26. Typical installation of well glass lighting fixture 7-51-0217 4
27. Typical installation of bulk head lighting fixture. 7-51-0218 4
28. Typical installation of dispersive reflector fixture. 7-51-0219 4
29. Typical installation of aviation obstruction light 7-51-0220 4
30. Typical installation of weatherproof lighting 7-51-0224 4
fixture
31. Typical installation of lighting/ power 7-51-0226 4
panel wall (surface) mounted.
32. Typical installation of lighting fixture 7-51-0229 4
mounting in concealed conduit system
33. Typical installation of lighting/ power 7-51-0230 4
panel flush mounted
34. Typical installation for metsec channel 7-51-0232 3
35. Marking of trenches for electric cables 7-51-0301 4
36. Typical section of cable trench in unpaved areas 7-51-0302 4
37. Installation details for conduit or cable support 7-51-0305 4
on wall/slab/ beam
38. Installation details for control station on 7-51-0306 4
structural channel in paved area
39. Installation details for control station on 7-51-0307 4
concrete/ steel column in paved areas
40. Installation details for control stations on 7-51-0308 4
structural channel in unpaved areas
41. Connection details for vertical motor and 7-51-0311 4
control station (cable below ground)
42. Connection details for horizontal motor 7-51-0312 4
and control station (cable below ground)
43. Connection details for horizontal motor 7-51-0313 4
(cable below ground)
44. Connection details for motor and control station 7-51-0314 4
(cable in tray)
45. Installation details for socket/ Receptacle 7-51-0316 4
mounted on column (cable tray)
46. Installation details for socket/ Receptacle/ 7-51-0317 4
control station mounted on hand rail.
47. Details of RCC duct above finished grade level. 7-51-0321 3
48. Details of ERC below grade level 7-51-0322 3
49. Cable termination for motors (cable 7-51-0323 4
dropping from overhead cable trays)
Page 1309 of 2065

DOCUMENT No.
SCOPE OF WORK B001-302-16-50-SW-9001,
(ELECTRICAL) Rev. B
Page 21 of 21

50. Cable termination for motors (cable 7-51-0324 4
dropping along column)
51. Safety measures for electrical 7-51-0332 3
installations during constructions
52. Details for hot dip galvanized ladder type cable 7-51-0333 2
trays
53. Typical installation details of electrical panels 7-51-0335 3
on false flooring
54. Typical installation details of electrical panels 7-51-0336 3
on cable trench
8.3 List of Documents/Data Sheets

1. Isolation transformer (ISOL#3) data B001-302-16-50-DS-9001 A
sheet
2. 3-winding transformer data sheet B001-302-16-50-DS-9002 A
(TR-2500 & TR-2501)
3. Data sheet of NGR B001-302-16-50-DS-9003 A
4. Data sheet for 11kV extension panel B001-302-16-50-DS-9004 A
5. Data sheet for 6.6kV switchboard B001-302-16-50-DS-9005 A
6. Data sheet for 415V switchboard B001-302-16-50-DS-9006 A
7. Hardware data sheet B001-302-16-50-DS-9007 A
8. Lightning Arrester data sheet B001-302-16-50-DS-9008 A
9. Data sheet for numerical relay B001-302-16-50-DS-9009 A
10. HV/MV cable data sheet B001-302-16-50-DS-9010 A
11. Data sheet for battery & battery B001-302-16-50-DS-9011 A
charger
12. Data sheet for 11kV new switchboard B001-302-16-50-DS-9012 A
13. Feeder list (HV/MV) B001-302-16-50-DS-9013 A
14. Typical pole GA drawing of 11KV B001-302-16-50-DS-9014 A
transmission line
15. HV motor data sheet B001-302-16-50-DS-9015 A
16. Data sheet of lighting fixture B001-302-16-50-DS-9016 A
17. Data sheet for flood light mast B001-302-16-50-DS-9017 A
8.4 List of Drawings & Miscellaneous documents

1. Overall key single line diagram B001-302-16-50-SLD-9001 A

2. Typical substation layout B001-302-16-50-SS-9001 A
3. Typical overall plan view of 11kV B001-302-16-50-PL-9001 A
transmission line A
4. Vendor list B001-302-16-50-VL-9001
5. Technical compliance B001-302-16-50-TC-9001 A
6. Mandatory Spares List B001-302-16-50-MS-9001 A
7. Vendor data requirement B001-302-16-50-VR-9001 A
Page 1310 of 2065

SPECIFICATION STANDARD SPECIFICATION No.
t31 ENGINEERS FOR
etrone Govt of Ind. 1J„0ert*ng) HIGH VOLTAGE SWITCHBOARDS Page 1 of 16
*AT Rig -1461sY

fo-R
Trrw feitu
SPECIFICATION
FOR
HIGH VOLTAGE SWITCHBOARDS
\IM4r1
00.4 3-
REVISED & ISSUED AS STANDARD
6. 15.10.2013 VB HK UAP/JMS SC
SPECIFICATION
5. 28.04.2010 HK SA NS/JMS ND
SPECIFICATION
4. 03.03.2005 RM AKT AAN SKG
SPECIFICATION
3. 31.12.2001 RM AAN VPS MMR
SPECIFICATION
2. 15.07.1996 AP VPS SG AS
SPECIFICATION
1. 22.05.1987 ISSUED AS STANDARD SPECIFICATION PVR KVS SG GNT/AK
Standards Standards
Rev. Prepared Checked Committee Bureau
No by by
Approved by
Page 1311 of 2065

ENGINEERS
Itgar Ofaidg
elecrwe LINJP9.11
INDIA LIMITED
IA Go. of indo Undettalmg)
FOR
6-51-0001 Rev. 6
Page 2 of 16
Abbreviations:
A Ampere
AC Alternating Current
BIS Bureau of Indian Standards
BS British Standard
CNT Close-Neutral-Trip
CPRI Central Power Research Institute
CRCA Cold Rolled Cold Annealed
CT Current Transformer
DC Direct Current
EPDM Ethylene Propylene Diene Monomer
FRP Fiber Reinforced Polyester
HV High Voltage
Hz Hertz
IAC Internal Arc Classification
IEC International Electro-Technical Commission
IEEE Institute of Electrical & Electronics Engineer
IP Ingress Protection
kV Kilo Volt
kW Kilo Watt
kWH Kilo Watt Hour
LED Light Emitting Diode
LOTO Lock-Out Tag-Out
LSC Loss of Service Continuity
MCB Miniature Circuit Breaker
MCC Motor Control Center
MCCB Moulded Case Circuit Breaker
NEMA National Electrical Manufacturers Association
NO Normally Open Contact
NC Normally Close Contact
PO Purchase Order
PT Potential Transformer
PU Polyurethane
PVC Poly Vinyl Chloride
RAL Reichs-Ausschuss fur Lieferbedingungen
SF6 Sulphur Hexafluoride
SWG Standard Wire Gauge
VCB Vacuum Circuit Breaker
VDE Verband Deutscher Elektrotechniker
VFD Variable Frequency Drive
VT Voltage Transformer
XLPE Cross linked Poly Ethylene
Electrical Standards Committee
Convenor: Mr. U A Patro

Members: Mr. B.R. Bhogal
Ms. Sumita Anand
Mr. Parag Gupta
Mr. A K Chaudhary (Inspection)
Ms. N P Guha (Projects)
Page 1312 of 2065

■31 ENGINEERS
ligar faWg INDIA LIMITED FOR 6-51-0001 Rev. 6
G" Unde"") HIGH VOLTAGE SWITCHBOARDS
4111W! ewWe 401 .001111
Page 3 of 16
CONTENTS
1.0 SCOPE. 4
2.0 CODES AND STANDARDS 4
3.0 GENERAL REQUIREMENTS 5
4.0 SITE CONDITIONS 5
5.0 DESIGN AND FABRICATION REQUIREMENTS .5
6.0 SWITCHBOARD COMPONENTS 11
7.0 INSPECTION, TESTING AND ACCEPTANCE 15
8.0 PACKING AND DESPATCH 16
Page 1313 of 2065

7111~ ENGINEERS
FOR
r fdfaj
$1g-aoiren eg INDIA LIMITED 6-51-0001 Rev. 6
rwcrxt LIM ..iNsn+.1,
HIGH VOLTAGE SWITCHBOARDS Page 4 of 16
1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of indoor,
drawout type High Voltage Switchboards up to and including 33 kV, incorporating Vacuum or
SF6 circuit breakers.
2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of the following standards
issued by BIS, unless otherwise specified:
IS: 5 Colours for ready mixed paints and enamels
IS: 1248 Direct acting indicating analogue electrical measuring instruments and their
accessories
IS: 2071 High Voltage Test Technique
IS: 2544 Porcelain post-insulators for systems with nominal voltage greater than1000V
IS: 2705 Current transformers
IS: 3156 Voltage transformers
IS: 3231 Electrical relays for power system protection
IS: 3427 AC Metal enclosed switchgear and control gear for rated voltages above lkV
up to and including 52 kV
IS: 3618 Phosphate treatment of iron and steel for protection against corrosion
IS: 5082 Wrought aluminium and aluminium alloy bars, rods, tubes and sections for
electrical purposes
IS: 5578 Guide for marking of insulated conductors
IS: 6005 Code of practice for phosphating of iron and steel
IS: 9920 High voltage switches for rated voltage above 1 kV
IS: 9921 AC disconnectors (isolators) and earthing switches for voltage above 1000V
IS: 10601 Dimensions of terminals of high voltage switchgear and controlgear
IS: 11353 Guide for uniform system of marking and identification of conductors &
apparatus terminals
IS: 12729 Common High voltage Switchgear and Controlgear standards
IS: 13118 High Voltage Alternating Current Circuit Breakers
IS: 13703 Low voltage fuses for voltages not exceeding 1000V AC or 1500V DC.
IEC 60282-1 High voltage fuses — Current Limiting fuses
IS/IEC 60470 High Voltage Switchgear Alternating Current Contactors and Contactor based
motor starters
IS/IEC 62271 High Voltage Switchgear and Controlgear
(Part 1, 102,
105, 200)
IEC 62271 High Voltage Switchgear and Controlgear
2.2 In case of imported equipment, standards of the country of origin shall be applicable, if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other
statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by
IEC/BSNDE/IEEE/NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standards/specifications/data sheet and
statutory regulations the following order of priority shall govern:
- Statutory regulations
- Data sheets
- Job specification
- This specification
Codes and standards
Page 1314 of 2065

ENGINEERS
$11gZIT Wes w INDIA LIMITED FOR 6-51-0001 Rev. 6
lotion
G" M in" Undert*"9) HIGH VOLTAGE SWITCHBOARDS Page 5 of 16
3.0 GENERAL REQUIREMENTS

3.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment for at least 15 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to enable the end user for placement of order for spares and
services.
4.0 SITE CONDITIONS

4.1 The switchboards shall be suitable for installation and satisfactory operation in a pressurised
sub-station or in a substation with restricted natural air ventilation in a tropical, humid and
corrosive atmosphere.
4.2 The switchboards shall be designed to operate under site conditions as specified in the data
sheets. If not specifically mentioned therein, a design ambient temperature of 40°C and an
altitude not exceeding 1000 metres above mean sea level shall be considered.
4.3 All equipments described in this specification are intended for continuous duty operation, as
per nameplate rating under the specified ambient conditions, unless indicated otherwise.
5.0 DESIGN AND FABRICATION REQUIEMENTS

5.1 Enclosure and Protection
5.1.1 The High Voltage Switchboard shall be metal-enclosed and shall comprise of standard pre-
fabricated, cold-rolled, sheet steel units, assembled to form a rigid, freestanding, dead-front
structure. As a minimum, 2mm (14 SWG) CRCA sheet steel shall be used for all front and rear
doors and covers, and 1.6mm (16 SWG) CRCA sheet steel for inter-panel partitions. Wherever
required, stiffeners shall be provided to increase stiffness of large size doors and covers.
As an alternative to CRCA, Aluzinc/pre-galvanised sheet steel can also be provided for
internal inter-panel partitions only. However, all external surface shall be of CRCA with
specified paint shade.
5.1.2 Vertical panels shall be assembled to form a continuous line-up of uniform height both for HV
chamber as well as control chamber. Rear extension panels shall also be of full height.
5.1.3 The switchboards shall be totally enclosed and vermin-proof. If necessary, openings for
natural ventilation shall be provided. These shall be louvered and provided with wire mesh
having opening less than 1 mm. Design of louvers/ opening shall be such that the arc does not
come out in case of internal arc. The same shall be type tested for internal arc, as specified.
The enclosure shall have complete protection against approach to live parts or contact with
internal moving parts (IP-4X) as per IS: 3427.
5.1.4 All openings, covers and doors shall be provided with suitable Neoprene/ XLPE/ EPDM
gaskets around the perimeter to make the switchboard dust and vermin proof.
5.1.5 Each unit of the switchgear shall have necessary internal sheet metal barriers to form separate
compartments for circuit breaker, busbars, instruments and relays, cable connections etc.
Compartments for cable connections shall allow cable termination and connection work with
the switchgear energised. Suitable interlock shall be provided such that cable compartment can
be opened only when earth switch is ON or Earthing truck is inserted.
5.1.6 The panel shall be internal arc tested as per IS/IEC 62271-200 requirements for full short
circuit current and for a duration of 0.1 second (minimum) unless specified otherwise in job
specification/ datasheet and shall be qualified to comply with all the 5 criteria as per IS/IEC
Page 1315 of 2065

-

ENGINEERS
0?-zir faaeg INDIA LIMITED FOR 6-51-0001 Rev. 6
rwcrx1,
151,3■IVISA,
Go" in" Unde""ng) HIGH VOLTAGE SWITCHBOARDS Page 6 of 16
62271-200. Independent pressure relief devices shall be provided for all I-1V compartments,
i.e. bus bar, cable and breaker compartments and each compartment shall have type test
certificate for internal arc classification (IAC) as per IS/IEC 62271-200 for the short circuit
current and duration as specified. IAC test shall be conducted on the offered panel variants
such as smallest width panel, panel with louvers, panel with thermography window and any
other variants (as applicable) as per job requirements. The panel shall also be AFLR tested as
per IS/IEC 62271-200 requirements.
5.1.7 All identical equipment and corresponding parts shall be fully interchangeable.
5.1.8 Safety barriers / shutters shall be provided to permit personnel to work safely within an empty
compartment with the bus bars energised. Loss of Service Continuity (LSC) category of the
switchgear shall be LSC2B as per IS/IEC-62271-200.
5.1.9 It shall be possible to extend the switchgear in either direction at a later date. Ends of bus bars
shall be suitably drilled for this purpose. Panels at extreme ends shall have openings, which
shall be covered with plates screwed to the panel. Details of drilled holes in bus bar and
openings in the panels, provided for future extension shall be clearly shown in the vendor
drawings.
5.1.10 The drawout carriage on the switchboard shall have three positions: "Service", "Test" and
"Drawout" viz:
"Full in" or "Service" position - In this position both power and control circuits shall
be connected. This shall be the normal operating position of the circuit breaker.
"Test" position - The power contacts shall be disconnected in this position but the
control connections shall not be disturbed, it shall be possible to close and trip the
breakers in this position.
- "Draw out" Position - both power and control circuits shall be disconnected in this
position. Alternatively, "Test Position" with the secondary control circuit disconnected
may be provided in lieu of "Draw out Position"
Circuit breaker operation shall be possible only in "Service" and "Test" positions. The circuit
breaker shall be lockable in "Test" / "Draw-out" positions. Automatic safety shutters shall be
provided to ensure the inaccessibility of all live parts after the carriage is drawn out.
There shall be a distinct overall door for the breaker compartment, which can be closed with
the carriage in drawout position and it shall be lockable type.
5.1.11 All circuit breaker modules of the same rating shall be inter-changeable. Suitable interlocks
shall be provided to prevent the following operations:
"Plugging in" or "drawing out" of a closed breaker.
"Plugging in" a breaker with the earthing isolator closed.
"Closing" of the earthing isolator with the breaker "plugged in".
Pulling out the auxiliary circuit plug with the breaker in the service position. Pushing
in the breaker to the service position, with the auxiliary circuit plug not in position.
Additionally, the following shall also be provided:
All operations such as breaker rack-in, breaker rack-out, breaker On/Off, spring
charging, earth switch On/Off etc. shall be possible only with panel door closed.
Pad locking arrangement shall be provided for rack in operation of breaker as well as
for the panel door meeting LOTO requirements.
LOTO arrangement shall include provision for the following:
a) Provision for hooking lockout devices by multiple lock arrangement to prevent
opening of panel door and racking-in of circuit breaker.
Page 1316 of 2065

ENGINEERS
$'1g-ZTE fell5ieg INDIA LIMITED FOR 6-51-0001 Rev. 6
111121I 2770,12- m13705.11 IA Goof of indo Undetaiong)
b) Provision for attaching tag-out device for warning against energisation and to
provide information regarding date of isolation, agency working on the
equipment, etc.
c) Provision for Hasp such that the same shall be put-in and closed in the locking
arrangement of the breaker/switch and panel door.
5.1.12 All hardware shall be corrosion-resistant. All joints and connections of the panel members
shall be made by zinc-passivated high-quality Grade 8.8 or superior steel bolts, nuts and
washers, secured against loosening.
5.1.13 Suitable eyebolts/ lifting clamps shall be provided for the lifting of the panel/shipping section.
The bolts, when removed shall not leave any opening in the panels.
5.1.14 If specified in datasheet, light/ arc/ pressure based sensors with controller shall be provided to
quickly detect internal arc and immediately initiate tripping action.
5.1.15 Thermo-graphy window for infrared electrical inspection shall be provided if specified in the
datasheet. The switchgear with thermo-graphy window shall be type tested and certified for
internal arc faults as per IS/IEC 62271-200 requirements.
5.2 Accessibility
5.2.1 All relays, metering, and control components shall be mounted on the panel front only.
However, auxiliary contact multiplier relays with auto reset can be mounted inside the panel.
5.2.2 The switchgear shall be considered to be accessible to authorized personnel having access all
around and shall be tested for following type of accessibility as per IS/IEC 62271-200:
Type of accessibility AFLR
where
Accessibility type A Restricted to authorised personnel only
F for front side
L for lateral side
R for rear side
5.2.3 Checking and removal of components shall be possible without disturbing adjacent equipment.
All equipment shall be easily accessible. It shall be possible to set all measuring relays and
instruments in-situ without de-energising the switchboard. All mounted equipment shall have
identification tags of self-sticking PVC tapes at the rear also. In addition, permanent
identification details shall be provided on the panel. Mounting of relays for a particular
breaker feeder panel shall be limited to that particular feeder only.
5.2.4 All terminals shall be shrouded with plastic covers to prevent accidental contact.
5.3 Bus Bar
5.3.1 The switchboard shall comprise of 3-phase bus bars which shall extend through all units of the
switchgear line-up. The main bus bars shall have uniform cross-section throughout their length
and shall be sized to carry continuously the rated current specified in the data sheet.
5.3.2 Bus bars shall be of high conductivity electrolytic aluminium or copper supported on
insulators made of non-hygroscopic, non-inflammable material with tracking index equal to or
more than that defined in Indian standards. Self supporting busbars can also be accepted
provided the same is type tested design.
5.3.3 Bus bars shall be housed in a separate chamber and shall be accessible for inspection. Wire
guards /cover shall be provided inside the enclosure to avoid accidental contact when the cover
is removed.
5.3.4 Both bus bars and the supports shall be adequately sized and braced to withstand the specified
short-circuit current for 1 second. Dynamic stresses shall be calculated on the basis of the
specified peak short-circuit current. All bus supports shall be of non-carbonising material,
resistant to acids and alkalies.
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell — All rights reserved
Page 1317 of 2065

ENGINEERS
fgz-jr faWes w INDIA LIMITED FOR 6-51-0001 Rev. 6
1.01VR elecnr, miavasni
'A Gov' of
Undertaking)
5.3.5 Bus bars shall be insulated by using heat-shrinkable sleeves suitable for withstanding heat
under worst operating condition. The sleeves shall be rated to withstand the system line-to-line
voltage for 1 minute. This shall be verified by a type test in which the line voltage will be
applied between the sleeved main bus bar and an aluminium foil wrapped closely around the
insulation over a length of at least 500mm.
5.3.6 All bus bar joints and all tap-off connections from the main horizontal bus bars shall be
provided with removable FRP/PU/PVC shrouds. The material of the shrouds shall be flame
retardant (FR).
5.3.7 Bus bars shall be prominently marked with Red, Yellow and Blue colour rings/ stickers for
easy phase identification at regular interval and at every power tap off point.
5.3.8 The thermal design of the bus bars shall be based on installation of the switchgear in poorly
ventilated conditions. The cooling air volume shall take into account only the bus bar
enclosure.
5.3.9 The hot spot temperature of busbars, including joints, at design ambient temperature shall not
exceed 90°C under normal operating conditions while for silver plated joints, the allowable
maximum temperature shall be 115°C in line with IS/IEC-62271-1.
5.3.10 Only zinc passivated high tensile strength high-quality Grade 8.8 or superior steel bolts, nuts
and washers shall be used for all busbar joints and supports.
5.3.11 The current rating as defined for switchboard and components in data sheet/job specification
are for design ambient temperature at site conditions and for being inside the cubicle at fully
loaded condition. The vendor shall suitably derate the nominal rating to suit the above
condition.
5.4 HV Power Connections
5.4.1 The incoming power connection shall be through XLPE cables / busduct and outgoing power
connection shall be through XLPE cables, as indicated in the data sheet. Ample space for
connection of these cables shall be provided at the rear of the switchboards. In order to avoid
accidental contact in the cable compartment while carrying out inspection by opening the rear
cover, a removable expanded metal barrier/ wire mesh shall be provided in the cable
compartment. In order to facilitate infra-red electrical inspection through thermography
window, metal barrier/ wire mesh may not be provided. Unless otherwise specified, the power
cable shall enter the switchboard from the bottom. Non-magnetic cable gland plates shall be
provided for feeders wherever single core cables are used.
5.4.2 The switchboard shall be supplied complete with supports for clamping outgoing and
incoming cables. The head-room available between cable gland plate and terminal lugs shall
not be less than 600 mm for switchgear up to 11 kV, and 900 mm for 22 and 33 kV cables.
5.4.3 In case the standard panel depth cannot accommodate the specified number of cables, a rear
extension panel of full height shall be provided. An earth strip shall also be brought to this
extension panel.
5.4.4 Unless otherwise specified, all power cables shall enter the switchgear from the bottom.
5.5 Auxiliary Wiring and Terminals
5.5.1 Inside the cubicles, the wiring for control, signalling, protection and instrument circuits shall
be done with BIS approved, PVC insulated, flame retardant low smoke (FRLS) type, copper
conductor wire. The insulation grade shall be 660 V. The wiring shall preferably be enclosed
in plastic channels or neatly bunched together. Wiring between I-W breakers or cable
compartments to relay and metering compartments shall be routed through flexible conduits.
5.5.2 A minimum of 10% spare terminals shall be provided on each terminal block. Conductors
shall be terminated with adequately sized compression-type lugs for connection to equipment
terminals and strips. Stranded conductors shall be soldered at the ends/ crimped with suitable
Page 1318 of 2065

.3
rifaq_iel ENGINEERS
Ewes
1,1ren efroye an.3trom)
INDIA LIMITED
(A Govt of Inch,' Undertalong)
FOR
6-51-0001 Rev. 6
Page 9 of 16
lugs before connections are made to the terminals. Sufficient terminals shall be provided on
each terminal block to ensure that not more than one outgoing wire is connected per terminal.
Terminal strips shall preferably be separated from power circuits by metal barriers or
enclosures. All spare contacts of auxiliary relays, timers, etc shall be wired up to the terminals.
5.5.3 Each wire shall be identified at both ends by correctly sized PVC ferrules. Shorting links shall
be provided for all CT terminals.
5.5.4 PVC insulated copper conductor of cross section 1.5 mm2 may normally be used provided the
control fuse rating is 10A or less. For 16A control fuse circuit 2.5 mm2 copper conductors shall
be used. Each wire shall be terminated at a separate terminal. CT Circuit wiring shall be done
with 2.5 mm2 copper conductors. Shorting links / suitable shorting arrangement for shorting
CT secondary shall be provided.
5.5.5 Unless otherwise specified, all control cables shall enter the switchgear from the bottom.
5.5.6 Supporting facilities shall be provided for clamping the control cables.
5.5.7 All inter-panel control wiring within each shipping section shall be by switchgear vendor. The
inter-panel wiring shall be taken through PVC sleeves or suitable grommets. For inter-panel
wiring between the shipping sections, wires in rolls of the required length, connected at one
point, shall be supplied with the panel for connection at site.
5.6 Control and Indication
5.6.1 Breaker tripping, closing and spring charging devices shall be fed with DC control power
supply. The rated DC voltage shall be as specified in the data sheet. The power supply for
breaker opening, closing and indication devices shall be arranged as follows:
a. One DC feeder shall be provided for each bus section. The bus coupler panel may be
fed from any of the two supplies.
b. One separate, single-phase power supply shall be provided for each bus section for
feeding space heaters, etc. Supply voltage shall be 240 V AC, unless otherwise
specified.
Provision to receive DC and AC control supply shall preferably be provided in bus-coupler
panel / bus PT panel.
5.6.2 Breaker positions (CLOSE, OPEN, spring-charged, test position, service position) shall be
indicated mechanically. Electrical indications, with colours as given below, shall also be
provided:
Breaker 'CLOSED' Red lamp
Breaker 'OPEN' Green lamp
Breaker 'Auto-trip' Amber lamp
Trip circuit healthy White lamp
Spring charging Blue lamp
5.6.3 A common DC control supply fail indication shall be provided for each bus section with a blue
coloured lamp.
5.7 Earthing Connections
All cubicles shall be connected to an earth bus bar running throughout the length of the
switchboard. The minimum earth bus bar size shall be 30 x 6 mm2 copper, up to short-circuit
withstand capacity of 31.5 kA, and 50 x 6 mm2 copper, for a short-circuit withstand capacity
above 31.5 kA. All doors and movable parts shall be connected to the earth bus with flexible
copper connections. Provision shall be made to connect the earthing bus bar to the plant
earthing grid at two ends. All non current-carrying metallic parts of the equipment and
components shall be earthed. The earth bus shall be brought back to the cable compartment,
Format No. 8-00-0001-F1 Rev. 0 Copyright EL — All rights reserved
Page 1319 of 2065

■
-11 ENGINEERS
Ifgar feVeg INDIA LIMITED FOR 6-51-0001 Rev. 6
■
Hr,-er r1000105-13U-95.
A G'of n" Unde"'"g) HIGH VOLTAGE SWITCHBOARDS Page 10 of 16
and earthing bolts shall be provided to ground cable armour. The mating surfaces of all bolted
parts shall be zinc passivated to ensure continuity between them.
5.8 Space Heaters
The panels shall be provided with space heaters to prevent moisture condensation, and
maintain cubicle temperature 5°C above the ambient. The space heaters shall be located at the
bottom of the panel, and shall be controlled through a double pole MCB and a thermostat with
an adjustable setting range of 30 to 70°C. The thermostat shall preferably be located in the
metering or relay chamber. Space heaters shall be supplied from 240V AC auxiliary bus for
space heater.
5.9 Panel Supporting Frame
The panels shall be suitable for installation on panel supporting frame, to be supplied by
others. The panels shall be suitable for tack welding, directly to this frame.
5.10 Nameplates
5.10.1 The switchgear shall be provided with durable and clearly legible nameplate in accordance
with Table-1 of IS/IEC 62271-200 requirements.
5.10.2 A nameplate with the switchboard designation shall be fixed at the top of the central panel.
A separate nameplate giving details for each feeder compartment of all panels shall be
provided. Danger plate (Red) shall be provided at the front and rear for each panel.
5.10.3 The nameplates for feeder compartments shall be in two parts. One part shall have necessary
details pertaining to the compartment's number of vertical panel of the switchboards. The
other parts shall be removable and shall contain all details regarding the feeder number for
drives/equipment controlled by the particular module as per approved single line diagram.
5.10.4 Blank nameplates shall be provided for all spare and vacant modules.
5.10.5 Nameplate or polyester adhesive stickers shall be provided for each equipment mounted inside
the switchboard. Special warning plates shall be provided on removable covers or doors giving
access to cable terminals and bus bars.
5.10.6 Special warning labels shall be provided inside the switchboards also, wherever considered
necessary. Identification tags shall be provided inside the panels matching with those shown
on the circuit diagram.
5.10.7 Engraved nameplates shall preferably be of 3- ply (Black-White-Black) lamicoid sheets or
anodised aluminium. However back engraved perspex sheet nameplates may also be
acceptable. Nameplates shall be fastened by screws and not by adhesives.
5.11 Painting
5.11.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease
and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The
under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. Alternately, supplier's standard paint procedure as per their ISO standard is
also acceptable. The under surface shall be made free from all imperfections before
undertaking the finishing coat.
5.11.2 After preparation of the under surface, the switchboard shall be spray painted with two coats
of epoxy based final paint or shall be powder coated.
5.11.3 Colour shade of final paint shall be as RAL 7032 unless specified otherwise.
5.11.4 The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall
be free from imperfections like pinholes, orange peels, runoff paint etc. Vendor shall supply
final paint (1 litre per switchboard) in non-returnable container for final touch up at site.
Page 1320 of 2065

2.14 ENGINEERS
OgZif fa54eg INDIA LIMITED FOR 6-51-0001 Rev. 6
INITer 247[Fre CRI Jsgr>41, IA Govt of India Unclertak.9) HIGH VOLTAGE SWITCHBOARDS Page 11 of 16
5.11.5 All unpainted steel parts shall be Zinc passivated or suitably treated to prevent rust formation.
If these parts are moving elements then they shall be greased. Aluzinc/ pre-galvanised sheet,
wherever provided, need not be painted.
6.0 SWITCHBOARD COMPONENTS

6.1 Circuit Breakers
6.1.1 Vacuum or SF6 circuit breakers shall be used in the switchboard. The exact type and rating of
breakers shall be as indicated in the data sheet. Breaker transport trolleys required for cassette-
mounted breakers shall be provided for each switchboard. Number of trolleys to be provided
shall be as per data sheet.
6.1.2 Vacuum circuit breakers shall be designed to have low switching-over voltage levels and with
a long switching life. The interrupter shall be leak-free.
6.1.3 In case of SF6 circuit breaker, each pole shall be provided with a pressure switch to monitor
the gas pressure with local indication / lockout, and remote annunciation in the event of SF6
gas leakage.
6.1.4 The breakers shall have at least 6 normally open (NO) and 6 normally closed (NC) spare
auxiliary contacts for purchaser's use. If these are not available, auxiliary relays shall be used
to multiply the auxiliary contacts of the breakers.
6.1.5 The breakers shall have a motor-operated, spring-charging mechanism. It shall also be possible
to charge the springs manually. The closing spring shall get re-charged (for subsequent
closing) soon after a closing shot and prior to breaker tripping. In case the limit switch fails to
cut out the spring-charging motor with the springs fully charged, the motor shall be
automatically de-coupled or else positive isolation (at both ends) of power supply to spring
charging motor shall be ensured. The control circuit shall be suitable for local as well as
remote control. Breakers shall be trip-free and shall have an anti-pumping device. The breaker
operating duty shall be O-3min.-CO-3min.-CO, unless otherwise agreed.
6.1.6 Operating Mechanism
a) Electric power operating mechanism shall be motor wound spring charged stored
energy type. However, manual-operating mechanism may be of the spring charging
stored energy type or spring assisted type. For circuit breakers with electrical power
operating mechanism, provision shall also be made for manual spring charging.
Closing time of circuit breakers with manual operating mechanism shall be
independent of the speed of the operating handle.
b) All stored energy operating mechanisms shall be equipped with the following features:
i) Failure of springs, vibrations or shocks shall not cause unintended operation
of breaker or prevent intended tripping operation.
ii) Closing of circuit breakers shall be prevented unless the spring is fully
charged.
c) All electrical power operating mechanisms shall be suitable for remote operation and
shall be equipped with following features:
i) Provided with motors operable on AC or DC control supplies as specified.
ii) Provided with emergency manual charging facility. The motor shall be
automatically, decoupled (mechanically) once the manual-charging handle is
inserted.
iii) Closing operation of circuit breaker shall automatically initiate charging of the
spring for the next closing operation without waiting for tripping of circuit
breaker.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved
Page 1321 of 2065

ENGINEERS
taig& INDIA LIMITED FOR 6-51-0001 Rev. 6
eircme Jgor
°""' HIGH VOLTAGE SWITCHBOARDS Page 12 of 16
iv) Closing operation shall be completed once the closing impulse is given and
the first device in the control scheme has responded even though the control
switch / Push Button is released, provided no counter trip impulse is present.
6.1.7 Circuit breaker trip and closing coils, in case of electrically operated breakers, and trip coil in
case of mechanically operated breakers and circuit breaker indication shall be suitable for
satisfactory operation on a control supply system indicated in data sheets/job specification.
Additional second shunt trip coil (operating on different control voltage supply) shall also be
provided if specified in the datasheet.
6.1.8 All circuit breakers shall be provided with mechanically operated emergency trip device. This
device shall be available on the front of the panel. Mechanically operated 'closing' device
shall be provided for all breakers. However mechanical closing shall be inhibited for all circuit
breakers in service position.
6.1.9 The breakers shall be provided with anti pumping & trip free feature. Each breaker shall be
also provided with an operation counter.
6.1.10 For all HV VFD feeders, breaker shall be provided with one no. shunt trip coil and with
undervoltage release. However, in case it is not possible to provide undervoltage release in the
standard design, as an alternative, two shunt trip coils shall be provided. One shunt trip coil
shall be suitable for switchgear DC control supply while second shunt trip coil shall be
suitable for external AC control supply. The control supply voltage level shall be as specified
in data sheet.
6.1.11 Metal Oxide surge suppressors shall be provided on all outgoing vacuum circuit breakers to
limit the over voltage to a maximum of 2.2 p.u. rated peak line to earth voltage. Sizing
calculations for surge suppressor shall be provided post order.
6.1.12 Line PT shall be mounted in a separate drawout carriage. In case of truck mounted breaker, line
PT shall be provided in a separate panel.
6.1.13 The complete breaker assembly should have inter-changeability with breakers of identical
ratings.
6.1.14 For switchgears specified with double tier circuit breaker arrangement, the outgoing feeder
breakers shall have double tier arrangement and incomer breakers with Line/bus PT shall be
housed in one vertical panel. In double tier arrangement, sheet steel partitions shall be
provided for each compartment. Compartmentalization shall be such that maintenance of one
breaker is possible without disturbing the adjacent breaker compartment. Suitable trolley(s)
shall be supplied for drawing out the breakers in upper tier. The maximum height of the
operating handle/switches/reset knobs/pushbuttons shall not exceed 1900 mm and minimum
height shall not be below 300 mm.
6.1.15 An integral earthing system, or a separate earthing carriage/truck, shall be provided. In case of
a separate earthing carriage, the necessary trolleys for bus-side and cable-side earthing shall be
supplied. After withdrawing the circuit breaker, this can be inserted to facilitate earthing of
cables and bus bars. Earthing truck shall be complete with the PT and voltmeter, giving audio-
visual indication and solenoid interlock to prevent closing of bus side earthing truck on live
busbars. Suitable interlock shall also be provided for Earthing switch. Earthing truck/ earthing
switch operation shall be only with door closed.
Integral earthing truck/earthing switch shall be suitable for short time withstand current and
peak withstand current rating equal to the corresponding breaker withstand rating.
6.1.16 Number and type of earthing trucks shall be as specified elsewhere.
Page 1322 of 2065

ENGINEERS
0g-a
,.112",f
tiaj
eg
eiecnreA513,
1;f.1)
INDIA LIMITED
IA Govt of Ind* Undertaking)
FOR
6-51-0001 Rev. 6
Page 13 of 16
6.2 Fuse Contactor Units

For outgoing feeders requiring fuse contactor (as specified in job specification/ datasheet),
following shall be complied with:
Fuse contactors shall be fully drawable type.
Contactors shall comply with IS/IEC-60470 and shall be suitable for intermittent duty class
0.1 as well as for uninterrupted duties.
The minimum short circuit breaking capacity of the contactor shall be at least 6 kA at rated
voltage.
Anti-pumping device (APD) shall be included to prevent "pumping actions" of mechanisms.
Overvoltage surge diverters shall be installed if required to keep high over-voltages during
operating conditions within acceptable values.
Contactors for motor starters and capacitor Bank feeders shall be of the latched type. The
tripping supply shall be obtained from the DC tripping and closing supply. Motor contactor
panels shall be provided with restarting facilities as specified in job specification/ datasheet.
Fuse links shall be in accordance with IEC 60282-1 and shall have high rupturing capacity.
They shall be short circuit current limiting type. Fuses shall be provided with striker pin
arrangement tripping the contactor.
Fuses for motor starters shall have a time-current characteristic suitable for the method of
starting.
Correct discrimination shall be established between fuse characteristics and contactor breaking
capacities. This shall ensure that overload and fault currents are safely interrupted by the
appropriate devices avoiding any risk of welding or other damage to the contactor.
6.3 Instrument Transformers

Current and voltage transformers shall be cast-resin insulated. The primary and secondary
terminals shall be marked indelibly and easily approachable for termination and testing etc.
6.3.1 Current transformer
i) Current transformers shall conform to IS: 2705. The short-time rating shall be equal to
that of the switchboard. They shall be mounted on the stationary part of the
switchboard. The CT ratings shall be as shown in the data sheet. Protective CTs shall
have an accuracy class of 5P and an accuracy limit factor greater than 10. CTs for
instruments shall have an accuracy class of 1.0 and an accuracy limit factor less than
5.0. For numerical relays having protection and metering functions, dual rated CT
shall be provided suitable for protection class and metering class. One leg of the CTs
shall be earthed. Separate CTs shall be provided for Differential and Restricted Earth
fault protection.
ii) All CTs shall be star connected. Interposing CT (ICT) shall be provided (if required)
for differential protection of transformers having star-delta connection.
iii) Proper access to each set of CTs shall be provided for repair / maintenance.
6.3.2 Potential transformer
i) The potential transformers shall conform to IS: 3156. The potential transformers shall
be of drawout-type, and shall be provided with 4 pole miniature circuit breakers with
auxiliary contacts on the secondary side.
Page 1323 of 2065

ENGINEERS
ig-zif Oa& INDIA LIMITED FOR 6-51-0001 Rev. 6
14117,1c-femrt an,3705,)
G" Und'i*"9) HIGH VOLTAGE SWITCHBOARDS Page 14 of 16
ii) The drawout mechanism shall disconnect the PT from the busbars. The primary
connection shall be disconnected before the PT becomes accessible. Neutral point of
the star connected PTs both on the primary and secondary sides shall be earthed.
iii) The PTs shall have an over-voltage factor of 1.9 for 30 seconds, and an accuracy class
of 1.0 from 10% to 120% of normal voltage. PT selected shall be compatible with
system grounding.
iv) The primary rated voltage shall be equal to the rated voltage V of the system, or V/43,
if the PT is connected between phase and neutral.
v) If not otherwise specified, the secondary voltage shall be 110 V, or 110/43 V. The
burden and class of accuracy shall be as specified in data sheets. For directional relays,
either a 3-phase 5-limb PT, or 3 single-phase PTs with secondary windings connected
in open delta shall be provided.
6.4 Measuring Instruments

All analogue instruments shall be of square pattern, 96 x 96 mm, flush-mounted type.
Measuring instruments shall be provided, as specified in the data sheet. All required auxiliary
equipment such as shunts, transducers, CTs, PTs, etc, shall be included in the scope of the
switchboard supplier. The accuracy class for all instruments shall be 1.0 as per IS: 1248.
Digital instruments shall also be acceptable, provided specific approval of EIL/Owner for
make and model is obtained before placement of switchboard order.
6.4.1 Ammeters and voltmeters
Analogue meters shall be of moving-iron type. The range shall be as indicated on the
drawings. Ammeters for motor feeders shall have a non-linear compressed scale above rated
current to indicate motor starting current.
6.4.2 kW / kWh meters
The kW / kWh meters shall be suitable to measure unbalanced loads on a 3-phase, 3-wire
system. The kW meters shall operate on a PT secondary voltage of 110 V.
6.4.3 Frequency meters
These shall be of direct-reading or digital type and shall operate on a PT secondary voltage of
110V. The standard range shall be 45-50-55 Hz.
6.4.4 Power factor meters
Power factor meters shall operate on a PT secondary voltage of 110 V. The CT secondary
current shall be as shown on the relevant drawings. The standard range shall be 0.5 lead-1.0-
0.5 lag.
6.4.5 Digital meters shall be provided, if specified in job specification/data sheets. All digital meters
shall be highly reliable, accurate, compact and self powered. Digital meter data shall be saved
in case of power failure. Field programming from front of the meter shall be possible and shall
have RS232/485 port in case specified in the job specification/data sheet.
6.5 Relays
6.5.1 Type of relay i.e. electromechanical, static or numerical shall be as defined in data sheet / job
specification.
6.5.2 All electromechanical protective relays shall be back-connected, of drawout type, suitable for
flush mounting, and fitted with dust-tight covers. Alternatively, "plug-in" type relays will also
be acceptable. Auxiliary relays are acceptable in fixed execution.
Page 1324 of 2065

ENGINEERS
ligZIE RAG
1.1e7, riecnte AA Jr,131.1,
INDIA LIMITED
IA Govt Of lode UndeItakIn9)
FOR
6-51-0001 Rev. 6
Page 15 of 16
6.5.3 The protective relay cases shall have a provision for insertion of a test plug at the front for
testing and calibration using an external power supply without disconnecting the permanent
wiring. The insertions of the test plug shall automatically short circuit the CTs and permit
extension of external power supply to the relay.
6.5.4 All protective relays shall have hand reset facility and clear operating indication, e.g. flags for
electro-mechanical type relays or light emitting diodes for static/numerical type relays. It shall
be possible to reset the flag without opening the relay case.
6.5.5 All tripping relays (electrical fault trip) shall be of lockout type with hand-reset contacts, and
shall be suitable to operate on the specified voltage. These relays shall have self coil cut off
contacts, and shall be provided with hand-reset operation indicators. However, for process trip,
the lock out relay shall be self reset type Tripping relays will be acceptable in non-drawout
cases.
6.5.6 The tripping relay shall be suitable for satisfactory operation from 50% to 110% of the
specified control supply voltage.
6.6 Auxiliary Equipment

6.6.1 Auxiliary relays and contactors:
Auxiliary relays and contactors shall generally be used for inter-locking and multiplying
contacts. Auxiliary contacts shall be capable of carrying the maximum anticipated current.
6.6.2 Control Switches:
i) All control switches shall be rotary type, having a cam-operated contact mechanism
otherwise stated. Circuit breaker control switches shall be 3-position CNT, spring return
to neutral from both Close and Trip positions. They shall have pistol-grip handles and
shall be lockable.
ii) Ammeter selector switches shall have a make-before-break feature on its contacts. The
selector switch shall generally have four positions, three positions for reading 3-phase
currents and the fourth position for OFF. The voltmeter selector switch shall also have
four positions, three positions shall be used to measure phase-to-phase voltages and the
fourth position shall be for OFF.
6.6.3 Timers:
For re-acceleration duty, timers unless otherwise stated, shall be pneumatic type and shall have
adjustable time setting of 0-60 seconds. Alternatively static timer may be considered. The time
settings, where specified, shall be accurately set before despatch of the switchboard. Timer
provided for control of capacitor feeder shall have minimum setting of 0-5 minutes.
6.6.4 Indicating Lamps:
Clustered LED type indicating light with minimum 8mm diameter size shall be provided for
indications. The LED shall have a low glow voltage protection and shall not glow on voltage
leakage.
7.0 INSPECTION, TESTING AND ACCEPTANCE

7.1 During fabrication, the switchboard shall be subject to inspection by EIL / Owner, or by an
agency authorised by the Owner, to assess the progress of work, as well as to ascertain that
only quality raw material is used. The manufacturer shall furnish all necessary information
concerning the supply to EIL / Owner's inspectors.
7.2 For testing requirements refer Inspection & Test Plan No. 6-81-1001.
Page 1325 of 2065

k31 ENGINEERS
Ige_jr 02-
eg
' INDIA LIMITED FOR 6-51-0001 Rev. 6
INIT,elrowe C013,70,.1)
8.0 PACKING AND DESPATCH

The switchboard shall be divided into several shipping sections for protection and ease of
handling during transportation. All outgoing feeders shall be packed as separate shipping
sections. The equipment shall be properly packed for selected mode of transportation i.e.
ship/rail or trailer. The panels shall be wrapped in polyethylene sheets before being placed in
wooden crates/cases to prevent damage to the finish. Crates/cases shall have skid bottoms for
handling. Special notations such as 'Fragile', 'This side up', 'Weight', 'Owner's particulars',
`PO number.' etc., shall be clearly marked on the package together with other details as per
purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
should also be suitable for outdoor storage in areas with heavy rains and high ambient
temperature unless otherwise agreed.
Page 1326 of 2065

(-aei 4
ENGINEERS FOR
5fgar kiPegW" INDIA LIMITED
RAM IA Govt 01 Inge Undertalung)
INDUSTRIAL TYPE
6-51-0014 Rev. 5
CONTROL STATIONS Page 1 of 6
3fre-Trw f-*-7:14 faiffur

RY.R fq-1-4-Tr
SPECIFICATION
FOR
INDUSTRIAL TYPE CONTROL
STATIONS
REVISED AND ISSUED AS STANDARD

5 11.03.16
SPECIFICATION
REVISDANU STDAR
4 11.04.11 JM ANPS UAP DM
SPECIFICATION
3 24.08.07 ANPS UAP JMS VC
SPECIFICATION
2 30.01.02 UAP AAN VPS GRR
SPECIFICATION
1 26.12.96 AP VPS SG AS
SPECIFICATION
Standards Standards
Rev. Committee Bureau
Prepared Checked
No by by
Approved by
Page 1327 of 2065

ENGINEERS FOR
r Rift INDIA LIMITED 6-51-0014 Rev. 5
a-traw oRual, IA Gov, 04 Ind. Undertaking) INDUSTRIAL TYPE
Abbreviations:
BIS Bureau of Indian standards
BS British Standards
CEA Central Electricity Authority
DC Direct Current
FRP Fibre Reinforced Plastic
GI Galvanised Iron
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
IS Indian Standard s
LV Low Voltage
NC Normally Closed
NO Normally Open
SS Stainless Steel
VDE Verband Der Electrotechnik, Elecktronik and Information Stechnik
Convenor: Mr. BR Bhogal
Members: Ms. S. Anand

Mr. Parag Gupta
Mr. M.K. Sahu
Ms. N.S. Bhattacharya
Mr. Saeed Akhtar (Inspection)
Ms. N.P. Guha (Projects)
Page 1328 of 2065

6-11 ENGINEERS FOR
twat,' (A Govt of India Undertaking) INDUSTRIAL TYPE
CONTENTS
1.0 SCOPE 4
5.0 TECHNICAL REQUIREMENTS 4
Page 1329 of 2065

ENGINEERS FOR
laelf Wieleg INDIA LIMITED 6-51-0014 Rev. 5
Ia+12R avrane 051,RM, IA Govt of Ind. Undertakmg) INDUSTRIAL TYPE
1.0 SCOPE
This specification covers the requirements of design, manufacture, testing, packing and supply
of industrial type control stations and accessories suitable for installation in non-hazardous/
safe outdoor areas.

2.1 The equipment shall comply with the requirements of latest revision of following standards
issued by BIS:
IS: 5 Colours for ready mixed paints and enamels.

IS: 1248 (Parts 1 & 2) : Direct acting indicating analogue measuring instruments and their
accessories.
IS / IEC: 60529 Degrees of protection provided by enclosures (IP code).
IS / IEC 60947 LV switchgear and control gear.
2.2 In case of imported equipment, standards followed in the country of origin shall be applicable
if these standards are equivalent or more stringent than the applicable Indian Standards.
2.3 The equipment shall also conform to the provisions of CEA Regulations and other statutory
regulations with latest amendments currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent requirement shall govern. However, Owner's/EIL's decision in this
regard will be final and binding.

The offered equipment shall be brand new with state of art technology and having proven field
track record. No prototype equipment shall be offered.
4.0 SITE CONDITIONS

The equipment shall be suitable for installation and satisfactory operation in tropical, humid
and corrosive atmosphere as prevalent in refineries, petrochemical and fertilizer plants. Unless
otherwise specified, a design ambient temperature of 40° C and an altitude not exceeding 1000
m above mean sea level shall be considered.
5.0 TECHNICAL REQUIREMENTS

5.1 Construction
5.1.1 The enclosures of the control stations shall be made of sheet steel.
5.1.2 The control stations shall be suitable for use in outdoor open locations and shall have
minimum IP-55 degree of protection. Suitable canopy shall be provided for protection against
rain from top and two sides. The separate canopy shall be made of at least 14 SWG (2mm)
galvanised sheet steel.
5.1.3 All control stations shall be suitable for 240V AC as well as for 110V/220V DC control
supply.
5.1.4 The control stations shall be provided with neoprene gaskets.
Page 1330 of 2065

ENGINEERS
$1gell acs O INDIA LIMITED
IA Govt of India Undeltaiong)
FOR
INDUSTRIAL TYPE
6-51-0014 Rev. 5
5.1.5 All metal surfaces shall undergo manufacturer's standard cleaning/ painting cycle. After
preparation of under surface, the equipment shall be painted with two coats of epoxy based
final paint with colour shade as dark admiralty grey, shade 632 of IS-5/ RAL 7031. All
unpainted steel parts shall be suitably treated to prevent rust formation. If these parts are
moving elements, then they shall be greased.
5.1.6 All accessories like nuts, bolts, washers etc and operating shaft of pushbuttons and switches
etc. shall be made of stainless steel SS-304.
5.1.7 The control stations shall be provided with two earthing studs with lugs on the external
surface of the enclosures suitable for termination of 8 SWG GI wire.
5.1.8 The control stations shall be provided with undrilled gland plate. However, double
compression nickel-plated brass cable gland shall be supplied loose to suit the specified cable
sizes.
5.1.9 The control stations shall have external fixing lugs for mounting on wall or column. The holes
provided on these lugs shall be of oblong type.
5.1.10 Engraved nameplate indicating Tag Number shall be permanently fixed on each control
station.
5.2 Component Specification
5.2.1 Push buttons for START and STOP shall be of GREEN and RED colour respectively. Each
push button shall have two NO and two NC contacts. The STOP push button shall be
mushroom type with stay put feature and lockable in pressed position.
5.2.2 All control switches shall be provided with a pistol grip handle. Circuit breaker control switch,
wherever specified, shall have three positions (START - NEUTRAL - STOP) with spring
return to neutral from START position and stay put in STOP position. All selector switches
shall have minimum two poles for each position. Each position of switch shall be indelibly
marked on the control station. Exact configuration of selector switch (LOCAL-OFF-
REMOTE or AUTO-OFF-MANUAL) shall be as per datasheet / MR requirement.
5.2.3 All ammeters shall be of moving iron type having an accuracy class of 3 and suitable for
lAmpere 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 100-800% 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.
5.2.4 Indicating lamp(s), wherever provided, shall be clustered LED type with minimum 3 numbers
LEDs, preferably connected in parallel, mounted inside an enclosure of minimum diameter of
15mm.
5.3 Terminals & Wiring

5.3.1 The control stations shall be provided with sufficient number of terminals. More than 2 wires
per terminal shall not be permitted. If required, additional terminal with shorting link may be
used. Each terminal for external cable connection shall be suitable for termination of 2.5 mm 2
solidcpernut.Tdcoperlgshabvidforcletmnawhvr
applicable.
5.3.2 All internal wiring shall employ 1.5 mm 2 , 660V grade, FR type PVC insulated copper
conductor wires.
Format No. 8-00-0001-F1 Rev. 0 Copyright DL — All rights reserved
Page 1331 of 2065

SPECIFICATION
a
STANDARD SPECIFICATION No.
ENGINEERS FOR
Et jeg
INIRN tier3,1, elS1.301171
INDIA LIMITED
IA Goof of India IlnOeffabong) INDUSTRIAL TYPE
6-51-0014 Rev. 5

6.1 During fabrication, the equipment shall be subjected to inspection by EIL/ Owner or by an
agency authorised by the Owner, if specified/ agreed in Inspection Test Plan. Manufacturer
shall furnish all necessary information concerning the supply to EIL/ Owner's inspector. All
routine/ acceptance tests shall be carried out at manufacturer's works under his care and
expense.
6.2 For testing requirements refer inspection and test plan no. 6-81-1014.

All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for the selected mode of
transportation, i.e. by ship/ rail or trailer, and shall be wrapped in polythene sheets before
being placed in crates/ cases to prevent damage to finish. The crates/ cases shall have skid
bottom for handling. Special notations such as 'Fragile', 'This side up', 'Center of gravity',
`Weight', 'Owner's particulars', 'PO no.' etc., shall be clearly marked on the packages
together with other details as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage, in areas with heavy rains/ high ambient
temperature. A set of instruction manuals for installation, testing and commissioning, a set of
operation & maintenance manuals and a set of final drawing shall be enclosed in a waterproof
cover along with the shipment.
Page 1332 of 2065

ENGINEERS FOR 6 - 51 - 0018 Rev. 4
INDIA LIMITED MEDIUM VOLTAGE SWITCHBOARD
MTl eaeog,tm IA GoA of fn[fia Undeff..ogl
Page 1 of 16
TruriT
fafT
SPECIFICATION
FOR
MEDIUM VOLTAGE SWITCHBOARD

QAY2.
4 23.03.2011 DA SG UAP DM
SPECIFICATION
3 01.03.2005 SSM RR AAN SKG
SPECIFICATION
2 19.11.2001 SSM AAN VPS GRR
SPECIFICATION
REVISED AMD ISSUED AS STANDARD
1 26.12.1996 AAN VPS SG
SPECIFICATION
0 31.08.1984 ISSUED AS STANDARD SPECIFICATION ALG KVS SG
Standards Standards
Prepared Checked
No by by
Approved by
Page 1333 of 2065

'7=-4 ENGINEERS
f' INDIA LIMITED FOR 6-51-0018 Rev. 4
mon eloometecloom IA Govt of India Undertaking) MEDIUM VOLTAGE SWITCHBOARD Page 2 of 16
Abbreviations:
A Ampere kW kilo Watt

AC Alternating Current LV : Low Voltage
ACB : Air Circuit Breaker LED : Light Emitting Diode
BIS Bureau of Indian Standard mA : milli Ampere
BS British Standard MCC : Motor Control Center
CT Current Transformer MCCB : Moulded Case Circuit Breaker
CPRI : Central Power Research NO Normally Open
Institute NC Normally Closed
CRCA : Cold Rolled Cold Annealed National Electrical Manufacturer
NEMA :
DC Direct Current Association
EIL Engineers India Limited PCC Power Control Center
HRC : High Rupture Capacity PMCC : Power cum Motor Control Center
IEC International Electrotechnical PT Potential Transformer
Commission Poly Vinyl Chloride
PVC
IEEE : The Institute of Electrical and Standard Wire Gauge
SWG :
Electronics Engineers
V Volt
VA • Volt Ampere
IS Indian Standard
VDE • Verband Deutscher
kA kilo Amperes Elektrotechniker
kVA kilo Volt Ampere
Convenor: Mr. U.A. Patro
Members: Mr. A.K. Tickoo

Mr. M.P. Jain
Mr. B.R.Bhogal
Mr. Arun Kumar
Mr. K.K. Gera
Mr. Saeed Akhtar
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—All rights reserved
Page 1334 of 2065

ENGINEERS
5itgar fal5reg INDIA LIMITED FOR 6-51-0018 Rev. 4

low,,MOIRMIJ‘10.3) to Govt. of in Undertakm1
MEDIUM VOLTAGE SWITCHBOARD Page 3 of 16
CONTENTS
1.0 SCOPE 4
5.0 DESIGN AND FABRICATION REQUIREMENTS 5
6.0 SPECIFIC REQUIREMENTS OF AIR CIRCUIT BREAKER PANELS 8
7.0 SPECIFIC REQUIREMENTS OF FEEDERS OTHER THAN ACB FEEDERS 10
8.0 SWITCHGEAR MODULES 11
9.0 SWITCHBOARD COMPONENTS 11
Page 1335 of 2065

ENGINEERS
51gar fEtikg INDIA LIMITED FOR 6-51-0018 Rev. 4
(HIM FrelAZ 01,13.77.0 (A GoN of lode Undettalong) MEDIUM VOLTAGE SWITCHBOARD Page 4 of 16
1.0 SCOPE
1.1 This specification covers the requirements of design, manufacture, testing, packing and supply
of fixed and draw out type medium voltage switchboards.
2.1 The equipment shall comply with the requirements of the latest revision of the following
standards issued by BIS unless otherwise specified.
IS : 5 Colours for ready mixed paints and enamels
IS : 1248 Direct Acting Indicating Analogue Electrical Measuring Instruments
and their Accessories
IS : 2705 Current transformers
IS : 2824 Method for determining the proof and the comparative tracking
indices of solid insulating materials.
IS : 3156 Voltage transformers
IS : 3231 Electrical relays for power systems protection.
IS : 3618 Phosphate treatment of iron and steel for protection against corrosion.
IS : 5082 Wrought aluminum and aluminum alloy bars, rods, tubes and sections
for electrical purposes.
IS : 5578 Guide for marking of insulated conductor.
IS: 8623(Part-2): Low voltage switchgear and control gear assemblies. Particular
requirement for bus bar trunking system.
IS : 11353 Guide for uniform system marking and identification of conductors
and apparatus terminals.
IS : 13703 Low voltage fuses for voltages not exceeding 1000V AC or 1500V
DC.
IS/ IEC: 60529 : Degree of protection provided by enclosures (IP Code).
IS/ IEC: 60947 : LV Switchgear and control gear.
2.2 In case of imported equipments, standards of the country of origin shall be applicable if these
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/BS /
2.5 In case of any contradiction between various referred standards / specifications / data sheet
and statutory regulations the following order of priority shall govern:
Statutory regulations
Data sheets
Job specifications
This specification
Codes and standards
offered equipment at least for 15 years from the date of supply.
Page 1336 of 2065

4011 ENGINEERS
ligar Wag INDIA LIMITED FOR 6-51-0018 Rev. 4
WWI F/EMBIV am JW11.1) (A Gov/ of India Undertaking( MEDIUM VOLTAGE SWITCHBOARD Page 5 of 16
services.
4.0 SITE CONDITIONS
4.1 The switchboards shall be suitable for installation and satisfactory operation in a pressurised
substation or in a substation with restricted natural air ventilation in a tropical, humid and
corrosive atmosphere.
4.2 The switchboards shall be designed to operate under specified site conditions. If not
specifically mentioned, a design ambient temperature of 40° C and altitude not exceeding
1000 metres above mean sea level shall be considered.
4.3 All the equipment described in this specification is intended for continuous duty at the
specified ratings under the specified ambient conditions, unless specified otherwise.
5.0 DESIGN AND FABRICATION REQUIREMENTS
5.1 Medium voltage switchboard shall be metal enclosed fully draw out or fixed, as specified in
datasheet/ job specification, free standing, floor mounting, compartmentalised, modular type
suitable for indoor installation.
5.2 The switchboard enclosure shall be dust and vermin proof and shall provide a degree of
protection not less than IP-41.
5.3 The switchboard shall be assembled out of vertical panels of uniform height, not exceeding
2450mm in a single line up.
5.4 It shall be possible to extend the switchboard, in either direction at a later date. End of bus
bars shall be suitably drilled for this purpose. Panels at extreme end shall have openings,
which shall be covered with plates screwed to the panel.
5.5 The switchboard shall be designed to ensure maximum safety during operation, inspection,
connection of cables, relocation of outgoing circuits and maintenance, with the bus bar system
energised and without taking any special precautions.
5.6 Adequate means shall be provided to prevent shorting of power and / or control terminals due
to accidental dropping of maintenance tools etc. inside the switchboard. Checking and
removal of components shall be possible without disturbing adjacent equipment.
5.7 All identical equipment and corresponding parts shall be fully interchangeable.
5.8 The frame, of individual vertical panels shall be fabricated using pressed and cold rolled sheet
steel. The sheet steel used for panel shall be of minimum 2mm (14SWG) CRCA except the
doors and covers that may be made of 1.6mm (16SWG) CRCA. Wherever required, stiffeners
shall be provided to increase stiffness of large size doors and covers.
5.9 The switchboard shall be provided with integral base frame for each vertical panel. The
switchboard integral base frame shall be suitable for tack welding.
5.10 All openings, covers and doors shall be provided with gaskets around the perimeter to make
the switchboard dust and vermin proof.
5.11 All hardware shall be corrosion resistant. All joints and connections of the panel members
shall be made of galvanized or zinc passivated or cadmium plated high quality steel bolts, nuts
and washers, secured against loosening.
5.12 Suitable removable type eyebolts/ lifting hooks shall be provided for lifting of the
panel/shipping section. These eyebolts/ lifting hooks, when removed shall not leave any
opening in the panels.
5.13 Non-magnetic cable gland plates shall be provided for termination of single core cables.
5.14 The switchboard shall be formed using distinct vertical panels each comprising of the
following compartments.
Page 1337 of 2065

ENGINEERS
Ogar feffireg INDIA LIMITED FOR 6-51-0018 Rev. 4
OM/ 212,1AZ 0113,raril) IA GoN of India Undertaking) MEDIUM VOLTAGE SWITCHBOARD Page 6 of 16
5.14.1 A metal enclosed horizontal bus bar compartment running at the top, unless otherwise
specified.
5.14.2 Individual feeder modules in multitier mode.
5.14.3 Vertical bus bars serving all feeder modules in the vertical panel.
5.14.4 Cable termination compartment.
5.14.5 Perforated sheet steel / insulating material enclosed, horizontal auxiliary bus bars for control,
interlock, indication and metering running horizontally.
5.15 Metal sheets shall be provided between two adjacent vertical panels running upto the full
useful height of the switchboard.
5.16 MCC shall be of single/double front execution as specified in data sheet/job specification.
However circuit breaker panels and fixed type switchboard shall be in single front execution
only.
5.17 Motor starter and switch fuse modules shall not be accommodated at front and rear of ACB
Incomer and bus coupler panel.
5.18 All metering and protection equipment associated with a particular circuit, as specified in data
sheet, shall be housed in separate and independent compartment earmarked for that particular
circuit and in the fixed portion of the vertical panel in case of breaker panels.
5.19 All auxiliary devices for control, reset, indication, measurement and protection such as push
buttons, control and selector switches, indicating lamps, measuring instruments and protective
relays shall be mounted on the front side of the respective compartment. The design shall be
such that all power ON/OFF or START / STOP and relay reset operations shall be performed
without opening the panel door.
5.20 Space Heaters
The switchboard panels shall be provided with space heaters to prevent moisture
condensation. The space heater shall be located in the bottom part of each panel and shall be
supplied from 240 V AC auxiliary buses for space heater. The space heater shall be provided
with a switch, fuse or double pole MCB and thermostat having adjustable setting range of 30-
70° C. Further, one number 240V AC, 5/ 15A, 5 Pin socket for owner's use shall be provided
inside panels.
5.21 Auxiliary Bus bars
5.21.1 Auxiliary bus bars, each of minimum size 18-mm2 copper, shall be provided for the following
applications.
Panel space heater supply and motor space heater supply.
AC Control supply.
DC Control supply.
AC PT supply for energy meters, voltage operated relays etc.
5.21.2 Tee-off connectors shall be used for distributing auxiliary supply to each vertical panel.
Rubber grommets shall be used for all wire entries to make the entries dust and vermin proof.
5.21.3 Provision for hook up of external AC space heater/ DC control supply to be provided either in
bus PT panel or bus coupler panel.
5.22 Bus Bar
5.22.1 Bus bars shall be of high conductivity electrolytic aluminium or copper supported on
insulators made of non-hygroscopic, non-inflammable material with tracking index equal to or
more than that defined in Indian standards.
5.22.2 The main bus bars shall have uniform current ratings throughout their length as specified in
data sheet/job specification. The current rating of the neutral shall be half that of the phase bus
Page 1338 of 2065

ei ENGINEERS
/gar 25lftU
Off Moffe Off aaorff
INDIA LIMITED
IA Govt of India Undo!taking)
FOR
MEDIUM VOLTAGE SWITCHBOARD
6-51-0018 Rev. 4
Page 7 of 16
bars. Removable neutral links shall be provided on feeders to permit isolation of the neutral
bus bar.
5.22.3 Both horizontal and vertical bus bars, bus joints and supports shall be capable of withstanding
dynamic and thermal stresses of the specified short circuit currents.
5.22.4 Only zinc passivated or cadmium plated high tensile strength steel bolts, nuts and washers
shall be used for all bus bar joints and supports.
5.22.5 The hot spot temperature of bus bars, including joints, at design ambient temperature shall not
exceed 95° C under normal operating conditions. However, for silver plated joints, the
allowable maximum temperature shall be 115°C.
5.22.6 The current rating as defined for switchboard and components in data sheet/job specification
are for design ambient temperature at site conditions and for being inside the cubicle at fully
loaded condition. The vendor shall suitably derate the nominal rating to suit the above
condition.
5.22.7 All bus bars shall be insulated with heat shrunk PVC sleeves of 1100 V grade. Red, yellow
and blue colour shall be used for phase bus bars and black colour shall be used for neutral bus
bars. Alternatively, colour bands at suitable intervals along PVC sleeved bus bars may be
provided. Removable type shrouds shall be provided for joints.
5.22.8 Minimum clearance between live parts, between live parts/neutral to earth shall be 19 mm.
However clearances between terminals at components shall be as per applicable individual
standards for components.
5.22.9 Vertical bus bars for circuit breaker panels shall be sized depending upon the rating and
number of breakers per vertical panel. However vertical bus bars of all other panels shall be of
uniform cross section.
5.23 Wiring and Terminals
5.23.1 Inside the cubicles, the wiring for control, signaling, protection and instrument circuits shall
be done with BIS approved, PVC insulated, flame retardant type, copper conductor wire. The
insulation grade shall be 1100 V. The wiring shall preferably be enclosed in flame retardant
plastic channels or neatly bunched together.
5.23.2 PVC insulated copper conductor of cross section 1.5 mm 2 may normally be used provided the
control fuse rating is 10 A or less. For 16 A control fuse circuit 2.5 mm 2 copper conductor
shall be used. Each wire shall be terminated at a separate terminal. CT circuit wiring shall be
done with 2.5mm2 copper conductor.
5.23.3 Shorting links/suitable-shorting arrangement for shorting CT secondary shall be provided.
5.23.4 Each wire shall be identified at both ends by PVC ferrules.
5.23.5 Inter panel wiring within each shipping section shall be switchboard vendor's responsibility.
For wiring between shipping sections, vendor shall provide terminal blocks on adjoining
shipping sections and supply suitable jumpering wires. Inter-panel wiring shall be taken
thorough PVC sleeves or rubber grommets.
5.23.6 A minimum of 10% spare terminals shall be provided on each terminal block.
5.23.7 Conductors shall be terminated with adequately sized compression-type lugs for connection
to equipment terminals and strips. Sufficient terminals shall be provided on each terminal
block to ensure that not more than one outgoing wire is connected per terminal.
5.23.8 Terminal strips shall preferably be separated from power circuits by metal barriers or
enclosures. All spare contacts of auxiliary relays, timers, etc shall be wired up to the
terminals.
5.24 Earthing
5.24.1 All panels shall be connected to a tinned copper earth bus bar running throughout the length of
the switchboard.
Page 1339 of 2065

In ei ENGINEERS
g--e-ff 1E12ft INDIA LIMITED FOR 6-51-0018 Rev. 4
OMR 2420W OA 300.1) Govt of lode Undefta0o9) MEDIUM VOLTAGE SWITCHBOARD Page 8 of 16
5.24.2 The minimum earth bus size shall be 30x6 mm2 copper for fault level up to 31.5kA and 50x6
mm2 copper for fault level above 31.5kA.
5.24.3 All doors and movable parts shall be earthed, using flexible copper connections, to the fixed
frame of the switchboard. Provision shall be made to connect the earthing bus bar to the plant-
earthing grid at two ends.
5.24.4 All non-current carrying metallic parts of the mounted equipment shall be earthed. Minimum
4 nos, 10 mm diameter bolts with nuts shall be provided on the earth bus for termination of
fourth core of cable per vertical panel.
5.25 Name plate
5.25.1 A nameplate with the switchboard designation shall be fixed at the top of the central panel. A
separate nameplate giving details for each feeder compartment of all panels shall be provided.
Danger nameplate shall be provided at the front and rear of each panel.
5.25.2 The nameplates for feeder compartments shall be in two parts. One part shall have necessary
details pertaining to the compartments number of vertical panel of the switchboards. The other
parts shall be removable and shall contain all details regarding the feeder number for
drives/equipment controlled by the particular module as per approved single line diagram.
5.25.3 Blank nameplates shall be provided for all spare and vacant modules.
5.25.4 Nameplate or polyester adhesive stickers shall be provided for each equipment mounted inside
the switchboard. Special warning plates shall be provided on removable covers or doors
giving access to cable terminals and bus bars.
5.25.5 Special warning labels shall be provided inside the switchboards also, wherever considered
necessary. Identification tags shall be provided inside the panels matching with those shown
on the circuit diagram.
5.25.6 Engraved nameplates shall preferably be of 3- ply (Black-White- Black) lamicoid sheets or
anodised aluminium. However back engraved perspex sheet nameplates may also be
acceptable. Nameplates shall be fastened by screws and not by adhesives.
5.26 Painting
5.26.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease
and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid.
The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow
zinc chromate primer. The under surface shall be made free from all imperfections before
5.26.2 After preparation of the under surface, the switchboard shall be spray painted with two coats
of epoxy based final paint or shall be powder coated.
5.26.3 Colour shade of final paint shall be 631 as per IS: 5 or RAL 7032, unless otherwise specified.
5.26.4 The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall
be free from imperfections like pinholes, orange peels, runoff paint etc.
5.26.5 All unpainted steel parts shall be zinc passivated or cadmium plated or suitably treated to
prevent rust formation. If these parts are moving elements then they shall be greased
6.0 SPECIFIC REQUIREMENTS OF AIR CIRCUIT BREAKER PANELS
6.1 The breaker panels shall have distinct bus bar, breaker and cable compartments.
6.2 The design of each compartment shall be such as to prevent movement of vermin from a
particular compartment to any other compartment of the panel when the breaker is withdrawn
and compartment door is closed.
6.3 In order to minimise accidental access and avoid accidents due to falling tools, all the
outgoing links shall be shrouded.
Page 1340 of 2065

ENGINEERS
$ifgar Rif& INDIA LIMITED FOR 6-51-0018 Rev. 4
JOWL)
1.11Cott eretlxv CA (A Goo. of India undertaking) MEDIUM VOLTAGE SWITCHBOARD Page 9 of 16
6.4 Outgoing air circuit breaker can be mounted in a maximum of two-tier execution while the
incoming/bus coupler air circuit breaker shall be in single tier execution only.
6.5 Cable Compartment
6.5.1 Separate compartment, totally enclosed from all sides, shall be provided for cable termination,
on the rear side. Access to cables shall be from the rear side after opening the cabling
compartment cover.
6.5.2 The incoming / outgoing cable termination shall be staggered for each circuit and barriers of
sheet steel or insulating material shall be provided between terminations of two circuits such
that maintenance on one circuit could be carried out while the other circuit is live. Suitable
clamping arrangements shall be provided for cables and cable termination. Terminal blocks
shall not be used for supporting the cables.
6.5.3 The incoming supply for PCC/ PMCC panels shall be through top entry bus ducts or through
bottom entry cables unless specified otherwise. The outgoing cables shall have bottom entry
unless specified otherwise.
6.5.4 The cable terminations shall be suitably sized for receiving specified number of cables per
termination and provision shall be made for terminating each outgoing cable with a separate
bolted connection. In case the total number of cables entering a particular panel cannot be
accommodated in the cabling compartment of the panel, an extension panel of full height shall
be added to the cabling compartment for accommodating extra cables. Alternatively, in view
of extra cables, provision for back to back connections of cables may be offered.
6.6 Circuit Breaker Compartment
6.7.1 The circuit breaker compartment shall be fully draw out. Suitable guides shall be provided to
facilitate easy withdrawal of the circuit breaker.
6.7.2 The current transformers for the ammeter/protection circuits shall be mounted on the
fixed portion of the compartment. However, current transformers associated with built-in
releases may be mounted on the breaker trolley.
6.7.3 All terminals except wiping/sliding type control terminals shall be shrouded with plastic
covers to prevent accidental contact. For direct termination, clip-on shrouded type terminals
shall be provided.
6.7.4 There shall be three positions for the draw out trolley viz:
"Service" position - In this position both power and control circuits shall be
connected. This shall be the normal operating position of the circuit breaker.
"Test" position - The power contacts shall be disconnected in this position but the
control connections shall not be disturbed, testing provision for the entire control
circuitry shall be available in test mode including close and trip of breakers.
"Drawout" Position - both power and control circuits shall be disconnected in this
position and breaker removed from the cubicle.
6.7.5 The circuit breaker shall be lockable in "service" and "test" positions. Safety shutters shall be
provided when the breaker is in withdrawn/drawout position.
6.7.6 The earth connection must remain connected in "Test" position; Earthing of the unit shall be
done with a "pin" or with scrapping earth connections.
6.7.7 The earth connection shall make before the main power / control contacts make and break
after the power /control contacts are disconnected. Earthing connection through a plug and
socket connection shall not be acceptable
6.7 Interlocks
Following interlocks shall be provided:
6.7.1 Compartment doors shall be interlocked against opening when breaker is in closed condition.
However, it shall be possible to defeat this interlock for inspection purposes.
Page 1341 of 2065

In ENGINEERS
FOR
ligar tlf54-au INDIA LIMITED 6-51-0018 Rev. 4
I MIVI MOW CT ORM A Govt of India Undeftakm MEDIUM VOLTAGE SWITCHBOARD Page 10 of 16
6.7.2 It shall not be possible to push "in " a drawn out circuit breaker in closed condition or
withdraw a circuit breaker in closed condition.
6.7.3 It shall be possible to operate a circuit breaker only in the defined "Full in" or "service" and
"test' position inside the panel. It shall not be possible to operate the breaker in intermediate
positions while inserting or withdrawing circuit breaker.
6.8 Any unused circuit breaker compartment shall be fully equipped and provided with
compartment door, vertical busbars and control terminals/ wiring etc. such that the same could
be used for housing outgoing breakers in future without any modifications to the panel.
7.0 SPECIFIC REQUIREMENTS OF FEEDERS OTHER THAN ACB FEEDERS
7.1 The design of drawout feeder modules shall not change for single front or double front
execution. Separate vertical bus bars shall be provided for each front side modules.
7.2 All identical feeder modules shall be interchangeable.
7.3 Each vertical panel shall have a separate cable alley. The width of this cable alley shall be
sufficient to accommodate all the cables and shall have free access for cable terminations and
in any case shall not be less than 200mm minimum. Cable alleys shall be provided with
suitable doors.
7.4 Sheet steel barrier shall be provided between individual compartments and cable alley. This
barrier shall be provided with opening for power and control connections and it shall be
possible to safely carryout maintenance work on cable connections to any one circuit in the
cable alley with the busbars and the adjacent circuits live.
7.5 Maintenance and connection of cables to any modules shall be possible without having to take
out the modules from its position from the panel.
7.6 The outgoing feeder trolleys for drawout type switchboard shall be fully drawout and shall
have the following features.
7.6.1 It shall be possible to withdraw the trolley without having to unbolt or unscrew any power and
control connections to the equipment mounted on the withdrawable trolley.
7.6.2 Both power and control connections shall be drawout type. All line and bus PTs shall be in
drawout execution only. However, outgoing modules having size more than half of the useful
vertical height of the panel may be in mixed combination of drawout /fixed type.
7.6.3 Control supply transformer modules with burden higher than 2.5kVA may be in fixed
execution.
7.6.4 The trolley withdrawal shall be by means of crank and screw arrangement. Alternatively
movement on guided rollers may also be acceptable. Plug in operation shall be independent of
manual force. An insulating handle for racking in/ out modules shall be provided, as required.
7.6.5 For drawout type feeders of size equal to or greater than half the useful vertical height of
panel, positive clamping arrangement shall be provided on the top portion of the trolley in
addition to clamping arrangement at the bottom, to ensure all round positive pressure on the
power drawout contacts once the trolley is plugged in.
7.6.6 Power drawout contacts shall preferably be located towards the bottom portion of each trolley.
The trolley shall be lockable in fully plugged in position and devices shall be provided to
ensure positive plugging in. In test position, power contacts shall be totally isolated and a
device shall be provided for indication of test position. In test position, testing provision for
the entire control circuitry shall be available.
7.7 The incomer and bus tie feeders with load break switches rated 800A and above may be in
fixed execution
7.8 Various compartment sizes in a vertical panel shall be multiples of a basic dimension.
However the minimum module size for switch fuse feeder and motor startor/contactor feeder
shall not be less than that defined in data sheet/job specification. Vertical bus bars shall be pre-
drilled at regular intervals for complete flexibility for changes in size of modules.
Page 1342 of 2065

ENGINEERS
101
Ogeji 215ft INDIA LIMITED FOR 6-51-0018 Rev. 4
(A Goo. of India Undertaking) MEDIUM VOLTAGE SWITCHBOARD Page 11 of 16
7.9 All switch drives other than rotary control switches, shall be lockable in 'OFF' position.
7.10 The switches/Moulded case circuit breakers /MCB shall be interlocked with the compartment
door to prevent opening of the door when the switch/ moulded case circuit breaker is in 'ON'
position and to prevent switching on when the door is open. A defeat mechanism for this
interlock shall also be provided.
7.11 The maximum height of the operating handle and switches shall not exceed 1900 mm and the
minimum height shall not be below 300 mm.
7.12 Unused modules in the panel shall be fully equipped with hinged door and shall be suitable for
mounting power and control terminals for starter modules and cradle for future use.
8.0 SWITCHGEAR MODULES
8.1 Switchboard shall be completely lined up in one straight row with the type and quantities of
feeders as defined in switchboard data sheet. Generally the feeders of three main categories are
identified as circuit breaker, motor starters and switch fuse.
8.2 Starter modules required for motor control shall be of the following types and internal control
wiring of all starter modules of each type shall be identical for all ratings.
8.2.1 FVNR Full Voltage Non -Reversing starter with minimum 18 control terminals.
8.2.2 FVR Full Voltage Reversing starter with minimum 24 control terminals.
8.2.3 FVNR - HD Full Voltage Non -Reversing Heavy Duty starter with long starting time such
as for compressors and fans etc. with minimum 18 control terminals.
8.3 Switch fuse /contactor feeder modules shall be of following types and internal control wiring
of all modules of each type shall be identical for all ratings.
8.3.1 SFU Switch Fuse Unit modules with no control terminals.
8.3.2 SFC Switch Fuse Contactor modules with 18 control terminals.
8.4 Control transformer shall be provided for each bus section of the PMCC/MCC switchboard
having contactor control feeders and each transformer shall be sized for the entire switchboard.
Switchboard having two bus sections and coupled by bus tie shall have manual changeover
switch for the control transformers. The control transformer shall have at least 10% spare
capacity.
8.5 To facilitate site modification due to changes in motor KW ratings and to minimise spares
inventory, overload relays and power fuse links shall meet the following requirements.
8.5.1 All bimetal overload relays shall be separately mounted type with connecting links rated for
the maximum rating of the contactor in a starter module.
8.5.2 Bimetal overload relays of various current ranges required for motors likely to be connected to
a contactor must be identical in dimension for inter-changeability. In case offered relays are
with different dimension for any particular starter module, special mounting plate suitable for
mounting different relays shall be provided in all the modules of that size.
8.6 Heavy duty starters shall be provided with saturable type, current transformer operated;
overload relays only, which shall be suitable for motor starting time of 15-60 seconds.
8.7 All contactor controlled starter feeders shall meet the requirements of type-2 co-ordination as
per IS/IEC: 60947
9.0 SWITCHBOARD COMPONENTS
9.1 Circuit Breakers
9.1.1 Circuit breakers shall be air break, 3 pole and drawout type. However circuit breaker for
generator incomer shall be with four poles unless specified otherwise.
9.1.2 The circuit breakers shall be provided with mechanically operated emergency tripping device.
This device shall be available on the front of the panel. Mechanically operated 'closing' device
Page 1343 of 2065

t-11 ENGINEERS FOR
ligar tafireg INDIA LIMITED 6-51-0018 Rev. 4
(011ETI 2120A1,513U)
AGov o inde Undenak.9( MEDIUM VOLTAGE SWITCHBOARD Page 12 of 16
shall be provided for all breakers. However mechanical closing shall be inhibited for all
breakers in service position
9.1.3 The circuit breakers shall be provided with minimum 4 NO + 4 NC contacts, wired and
available for owner's use.
9.1.4 Circuit breaker's Open and closed positions; Service and test locations and spring charged
condition shall also be indicated mechanically in addition to electrical indications.
9.1.5 Unless otherwise specified, all circuit breakers in the switchboard shall be provided with
electrical power operating mechanism. Wherever circuit breakers are provided in place of
Isolators, Breaker can be manually operated type.
9.1.6 Operating Mechanism
Electric power operating mechanism shall be motor wound spring charged stored
energy type. However, manual-operating mechanism may be of the spring charging
stored energy type or spring assisted type. For circuit breakers with electrical power
operating mechanism, provision shall also be made for manual spring charging.
Closing time of circuit breakers with manual operating mechanism shall be
independent of the speed of the operating handle.
All stored energy operating mechanisms shall be equipped with the following features:
Failure of springs, vibrations or shocks shall not cause unintended operation of
breaker or prevent intended tripping operation.
Closing of circuit breakers shall be prevented unless the spring is fully charged.
c) All electrical power operating mechanisms shall be suitable for remote operation and
shall be equipped with the following features:
Provided with universal motor operable on AC or DC control supplies.
Provided with emergency manual charging facility. The motor shall be
automatically, decoupled (mechanically) once the manual-charging handle is
inserted.
Closing operation of circuit breaker shall automatically initiate charging of the
spring for the next closing operation without waiting for tripping of circuit
breaker.
Closing operation shall be completed once the closing impulse is given and the
first device in the control scheme has responded even though the control switch /
Push Button is released, provided no counter trip impulse is present.
9.1.7 Circuit breaker trip and closing coils, in case of electrically operated breakers and trip coil in
case of mechanically operated breakers and circuit breaker indication shall be suitable for
satisfactory operation on a control supply system indicated in data sheets/job specification.
9.1.8 Circuit breakers shall be provided with anti-pumping and trip free feature.
9.1.9 Circuit breakers shall be provided with operation counters.
9.1.10 Releases are not required to be provided with breakers where relays are used. However
breaker-having AC control supply voltage shall be provided with under voltage release unless
specified otherwise.
9.2 Switches
9.2.1 All switches or fuse switches shall be air break type provided with quick make/break manual
operating mechanism. The operating handle shall be mounted on the door of the compartment
having the switch.
9.2.2 Rating of switches for starter module shall meet the requirements of AC-23 duty as per IS/ IEC
60947 and minimum rating shall be as specified in job specification/data sheets.
Page 1344 of 2065

ENGINEERS
ei
Igeir tlf5Itu INDIA LIMITED FOR 6-51-0018 Rev. 4
1.1PM 21VORE,7113,17.1) A Gout of India Undertaking) MEDIUM VOLTAGE SWITCHBOARD Page 13 of 16
9.3 Fuses
9.3.1 Fuses shall be non-deteriorating HRC cartridge link type.
9.3.2 Power fuses shall be pressure fitted type and shall preferably have ribs on the contact blades to
ensure good line contact.
9.3.3 It shall be possible to handle fuses during off load conditions with full voltage available on the
terminals. Wherever required fuse pullers shall be provided. The fuse base shall be so located
in the modules to permit insertion of fuse pullers and removal of fuse links without any
problem.
9.4 Contactors
9.4.1 The contactors shall be air break type, equipped with three main contacts and minimum
1NO+1NC auxiliary contacts. The main contacts of a particular contactor for motor starter
module shall have AC-3 or AC4 ratings, as specified in data sheet
9.4.2 Unless specified otherwise, the coil of the contactor shall be suitable for operation on 240 V, 1
Phase, AC supply.
9.5 Thermal Overload Relay
9.5.1 Bimetal relays shall be provided for protecting the motor from thermal overload.
9.5.2 Bimetal relays shall be manually reset type with the reset push button brought out on the front
of the panel. The reset push button shall be capable of being operated without opening the
compartment door.
9.5.3 Bimetal relays shall be positive acting ambient temperature compensated type with adjustable
setting range.
9.5.4 Bimetal relays shall have built-in single phasing prevention feature, which operates even with
50% rated current at the time of single phasing.
9.6 Moulded Case Circuit Breakers
9.6.1 MCCBs shall be provided with spring assisted quick make/ break manually operated trip free
mechanism. Wherever specified, MCCB shall be suitable for remote tripping operation and
the tripping device shall be suitable for the specified control supply voltage.
9.6.2 MCCBs shall be provided a tripping device with inverse time characteristic for over load
protection and instantaneous characteristics for short circuit protection and MCCB rated above
125A shall preferably have adjustable settings.
9.6.3 'ON' and 'OFF' position of the operating handle of MCCB shall be displayed and the
operating handle shall be mounted on the door of the compartment housing MCCB.
9.6.4 Each MCCB shall be provided with minimum 1 NO + 1 NC auxiliary contact and 1NO
contact for tripping indication/alarm for owner's use.
9.6.5 MCCBs shall be provided with solenoid/ motorised closing mechanism to make them suitable
for remote closing operation if specified. The closing solenoid/motor shall be suitable for
specified control supply voltage.
9.6.6 MCCB's as part of motor starter module shall be current limiting type and type tested for type-
2 co-ordination as per IS/ IEC 60947.
9.7 Relays
9.7.1 Type of relay shall be numerical, static or electro-mechanical type as specified in the data
sheet /job specification.
9.7.2 All electro-mechanical protective relays shall be back connected, of drawout type, suitable for
flush mounting, and fitted with dust-tight covers. Alternatively, "plug-in" type relays will also
be acceptable. Auxiliary relays and lock out relays are acceptable in fixed execution.
Page 1345 of 2065

ENGINEERS
5i ar Ea&
g J INDIA LIMITED FOR 6-51-0018 Rev. 4
1.11,2n MUNE,. 3,ITIM) IA Govt. of India Undertaking) MEDIUM VOLTAGE SWITCHBOARD Page 14 of 16
9.7.3 The protective relay cases shall have a provision for insertion of a test plug at the front for
testing and calibration purpose using an external power supply. It shall be possible to test the
relays without disconnecting the wiring and without withdrawing the relays. The insertion of
the test plug shall automatically short circuit the CTs and permits extension of external power
supply to the relay.
9.7.4 Each protective relay shall be provided with minimum 2 numbers potential free contacts of
required configuration.
9.7.5 Each tripping relay shall be of lockout type with hand reset coil cut-off contact.
9.7.6 Protective relays shall be preferably mounted on the front side and upper part of the panel and
mounting of relays on the lower portion shall be avoided.
9.8 Instrument Transformers (CTs/PTs)
9.8.1 Current transformers shall generally conform to IS: 2705 and any special requirement with
respect to numerical relay shall be taken care by the vendor.
9.8.2 For general guidance the vendor shall note that the protective current transformers shall have
an accuracy class "5 P" and an accuracy limit factor greater than "10 ". However CTs for
restricted earth fault shall be of class "PS". Vendor shall co-ordinate the knee point voltage,
magnetising current for PS class CTs to avoid saturation and mismatching of CTs provided at
other end by other vendor.
9.8.3 Current transformers for instruments shall have an accuracy class 1.0 and accuracy limit factor
less than 5.0. However accuracy class of 3.0 is acceptable for CT meant for remote ammeters.
9.8.4 The current transformers in breaker feeders shall be capable of withstanding the applicable
peak momentary short circuit and the symmetrical short circuit current.
9.8.5 The voltage transformers shall be cast resin type transformers and PT shall generally conform
to IS: 3156. PT shall be provided with HRC fuses on primary side and Miniature circuit
breakers with auxiliary contact on the secondary side.
9.9 Measuring Instruments
9.9.1 All measuring instruments shall be of 96 x 96 mm and 72 x 72 mm square pattern, flush
mounting type for incomer and outgoing feeders respectively in the switchboard.
9.9.2 All auxiliary equipment such as shunts, transducers, CT, PT, etc. as required shall be included
in the supply of the switchboard.
9.9.3 All AC ammeters and voltmeters shall be of moving iron type with accuracy class of 1.5 or
better as per IS: 1248. Ammeters for motor feeders shall have a non-linear compressed scale at
the end to indicate motor starting current and red mark for the full load current.
9.9.3 The KW/KWH meters shall be suitable to measure unbalanced loads on 3 phases 4-wire
system. Test terminal block shall be provided for KWH meters. The accuracy class of KWH
meters shall be 2.5 or better.
9.9.4 Digital meters shall be provided, if specified in job specification/data sheets. All digital meters
shall be highly reliable, accurate, compact and self powered. Digital meter data shall be saved
in case of power failure. Field programming from front of the meter shall be possible and shall
have RS232/485 port in case specified in the job specification/data sheet.
9.10 Control Switches
9.10.1 All control switches shall be rotary type, having a cam operated contact mechanism. Switch
shall have pistol grip handle for circuit breaker control and knob type handle for other
applications.
9.10.2 Ammeter selector switches shall have make before break feature on its contacts. The selector
switch shall generally have 4 positions, three for reading 3 phase currents and the fourth
position for off. The voltmeter selector switch shall also have 4 positions. Three positions shall
be used to measure phase-to-phase voltage and fourth shall be OFF position.
Page 1346 of 2065

it e..it ENGINEERS
$' gar fiReg U INDIA LIMITED FOR 6-51-0018 Rev. 4
OM. MOW,. JOO rn) IA GO. of Ind. Undenak.d) MEDIUM VOLTAGE SWITCHBOARD Page 15 of 16
9.11 Push Buttons

Push button colours shall be as follows:
Stop /open/emergency stop Red
Start/close Green
Reset/test Yellow / Black /white
The stop push button shall be stay put type.
9.12 Indication
9.12.1 Clustered LED type indicating light with minimum 8mm diameter size shall be provided for
indications.
9.12.2 Breaker positions (Close, Open, spring-charged, test position, service position) electrical
indications, with colors as given below, shall also be provided:
Breaker ' Closed'/ ON Red lamp
Breaker Open'/ OFF Green lamp
Breaker auto-trip Amber lamp
Trip circuit healthy White lamp
Spring charging Blue lamp
9.12.3 Outgoing feeder (Close, Open, trip) electrical indications, with colors as given below, shall
also be provided:
' Closed' Red lamp
' Open' Green lamp
`Trip' Amber lamp
9.13 Auxiliary Relays/Contactors
Auxiliary relays/contactors shall generally be used for interlocking and multiplying contacts.
However, in the case of numerical relays, the interlocking logic shall be built in the relay
itself.
9.14 Timers
For re-acceleration duty, timers shall be electronic type or static type. The time settings, where
specified, shall be accurately set before despatch of the switchboard. Timer provided for
control of capacitor feeder shall have minimum setting of 0-5 minutes.
9.15 Miniature Circuit Breaker
MCB shall provide high mechanical and electrical life, reliable protection of circuits against
overload and short circuit and shall have minimum breaking capacity of 9kA unless otherwise
specified. Positive ON/OFF indication shall be provided.
10.1 During fabrication, the switchgear shall be subject to inspection by EIL/ Owner, or by an
agency authorised by the owner. The manufacturer shall furnish all necessary information
concerning the supply to E1L/ Owner's inspectors.
10.2 All routine and acceptance tests shall be carried out at manufacturer's work under his care and
expense.
10.3 Type tests, if specified shall be performed. Short circuit test shall be performed at CPRI or
equivalent approved testing agency and heat run test may be performed at manufacturer's
works. Heat run test shall be performed at least on one incomer and two outgoing vertical
panels of the ordered switchboard.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved
Page 1347 of 2065

ENGINEERS
$'g-ar INDIA LIMITED FOR 6-51-0018 Rev. 4
MeINE,MIXRem) (A Govt of no Unclertalong) MEDIUM VOLTAGE SWITCHBOARD Page 16 of 16
10.4 Type and shop tests shall be witnessed by an inspector of EIL / Owner or of an agency
authorised by the owner. Prior notice of minimum 4 weeks shall be given to the inspector for
witnessing the tests.
10.5 Acceptance Tests
Acceptance tests shall be as follows:
10.5.1 A general visual check and dimensional check shall be carried out. This shall cover
measurement of overall dimension, location, number and type of devices, location and
connection of terminals, etc,
10.5.2 Manual and electrical operation of Circuit Breakers. / Relays shall be checked under the worst
conditions of auxiliary supply voltage.
10.5.3 Verification of bus bar supports with respect to type tested panel drawings, provision for
external cable termination and bus duct flange dimensions.
10.5.4 Make of components.
10.5.5 Dry insulation test with power frequency voltage shall be conducted for the power, control and
auxiliary circuits.
10.5.6 Insulation resistance of the main and auxiliary circuits shall be checked before and after power
frequency voltage withstand test.
10.5.7 Operation check shall be carried out for every control function /interlocks as per the schematic
diagrams by manually simulating fault conditions and operation of control switches/relays etc.
10.5.8 Relay operation check through secondary injection.
10.5.9 Communication check between relays and data concentrator/ MMI.
10.5.10 MMI operation and functional check.
10.5.11 For equipment bought from other sub-suppliers, certified test reports of tests carried out at the
manufacturer's works shall be submitted. Normally all routine tests as specified in the relevant
standards shall be conducted by the sub-supplier at his works.
10.5.12 Interchange ability of similar modules shall be checked on a random basis for draw out
switchboards.
All the equipment shall be divided into several shipping sections for protection and ease of
handling during transportation .The equipment shall be properly packed for selected mode of
transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polyethylene sheets
before being placed in wooden crates /cases to prevent damage to the finish. Crates /cases
shall have skid bottoms for handling. Special precaution notations such as 'Fragile', 'This side
up', 'Centre of gravity', 'weight', Owner's particulars, Purchase order number etc. shall be
clearly marked on the package together with other details as per purchase order.
should be suitable for outdoor storage in areas with heavy rains and high ambient temperature
unless otherwise agreed.
Page 1348 of 2065

15ffitlet e%r ENGINEERS FOR 6-51-0019 Rev. 4
elgez fifileg ler INDIA LIMITED BATTERY CHARGER
INKRIelexiW =ammo (A Gout. of India Undertalmg) Page 1 of 15
*at bide
fuR feitu
SPECIFICATION
FOR
BATTERY CHARGER
REVISED AND REISSUED AS STANDARD 14'4

r1-- UAP ‘713,-/2,‘,4
4 11/04/11 SPECIFICATION RS DM
3 10/09/08 REVISED AND REISSUED AS STANDARD RS NS JMS VC
SPECIFICATION
2 25/03/02 REVISED AND REISSUED AS STANDARD VCB VPS GRR
SPECIFICATION JMS
1 30/08/96 REVISED AND REISSUED AS STANDARD RKM VPS SG
SPECIFICATION AS
0 04/12/87 ISSUED AS STANDARD SPECIFICATION RKM SG GNT
RECOMPOSED IN NOV'95
Standards Standards
No Date Purpose by by Convenor Chairman
Approved by

Copyright EIL — All rights
Page 1349 of 2065
101 ei ENGINEERS
51g-ar klf5leg INDIA LIMITED FOR 6-51-0019 Rev. 4
Men mien an Jow) IA Govt of India Undertaking) BATTERY CHARGER Page 2 of 15
Abbreviations:
Ah Ampere-hour
BS British Standard
CFL Compact Fluorescent Camp
CRCA Cold Rolled Cold Annealed
DC Direct Current
DCDB Direct Current Distribution Board
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
IS Indian Standard
MR Material Requisition
MSL Mean Sea Level
Ni-Cd Nickel Cadmium
PO Purchase Order
RFI Radio Frequency Interference
RMS Root Mean Square
UPS Uninterrupted Power Supply
V Volt
VDE Verband Der Elecktrotechniker, Elektronik and Information stechnik
VRLA Valve Regulated Lead Acid

Convenor: Mr. UA Patro
Members: Mr. AK Tickoo

Mr. MP Jain
Mr. BR Bhogal
Mr. Arun Kumar
Mr. KK Gera
Mr. Saeed Akhtar
Page 1350 of 2065

R SPECIFICATION STANDARD SPECIFICATION No.
401 (74 FOR
5itg-91 0151-eu INDIA LIMITED 6-51-0019 Rev. 4
IA Govt of India Undertaking) BATTERY CHARGER Page 3 of 15
CONTENTS
1.0 SCOPE 4
7.0 PACKING & DESPATCH 13
Page 1351 of 2065

ENGINEERS
irEr:„•
FOR 6-51-0019 Rev. 4
5Ifg7 laRrg, INDIA LIMITED
IA GoN of India Undertaking) BATTERY CHARGER Page 4 of 15
1.0 SCOPE
This specification covers the design, manufacture, testing at manufacturer's works, packing
and supply to site of Battery Chargers and Distribution Boards.
2.1 The equipment shall comply with the requirements of latest revision of the following
standards issued by BIS (Bureau of Indian Standards) :
IS 5 Colours for ready mixed paints and enamels.
IS 1248 Direct acting indicating analogue electrical measuring instruments and
accessories.
IS 3700 Essential rating and characteristics of semi-conductor devices.
IS 3715 Letter symbols for semi-conductor devices.
IS 4411 Code of designation of semi-conductor devices.
IS 5001 Guide for preparation of drawings for semi-conductor devices and
integrated circuits.
IS 5469 Code of practice for the use of semi-conductor junction devices.
IS 6619 Safety code for semiconductor rectifier equipment.
IS 7204 Stabilised power supplies DC output.
IS 12021 Control transformers for switchgear and controlgear for voltages not
exceeding 1000VAC.
IS 13703 Low voltage fuses for voltages not exceeding 1000VAC or 1500VDC.
IS/ IEC 60947 Low voltage switchgear and control gear.
IEC 60146 Semiconductor converters.
2.2 In case of imported equipment, the standards of the country of origin shall be applicable, if
these standards are equivalent or more stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.
2.5 In case of any conflict between requirements specified in various applicable documents for
the project, the most stringent one shall prevail. However, Owner's decision in this regard
will be final and binding.
3.1 The offered equipment shall be brand new with state of the art technology and a proven field
phasing out the product/spares to enable the end user to place order for spares and services.
4.0 SITE CONDITIONS

The Battery Chargers shall be suitable for installation and satisfactory operation in a
pressurised or non-pressurised substation with restricted natural air ventilation in a tropical,
humid and corrosive atmosphere. The Battery Chargers shall be designed to operate under
Page 1352 of 2065

401 1_.1 ENGINEERS SPECIFICATION STANDARD SPECIFICATION No.
Itgar fageg INDIA LIMITED FOR 6-51-0019 Rev. 4

1011wr eletwoRagorsil IA Govt of India Undertaking) BATTERY CHARGER Page 5 of 15
site conditions as specified in the data sheet. If not specifically mentioned therein, design
ambient temperature of 40°C and altitude not exceeding 1000 m above MSL shall be
considered for all equipment.
5.1 Input Power Supply
5.1.1 The Battery Chargers shall be suitable for input power supply as defined in the data sheet. If
not specified therein, they shall be suitable for the following input power supply:
Voltage : 415V + 10%
Frequency : 50 Hz + 3%
In addition to the above variations, the input voltage may be subject to transient variations
comprising of voltage dips up to 20% of normal voltage during motor start-up, voltage
interruptions during short circuits as well as frequency variations due to large motor start-up.
The Battery Chargers shall operate satisfactorily with a total harmonic distortion of up to 5%
in the input power supply.
The Battery Chargers shall also be designed to operate satisfactorily while drawing input
power from an emergency diesel generator set.
5.1.2 The incoming power supply to the Battery Charger system shall be provided by 2
independent feeders. One feeder shall supply power to each rectifier.
5.2 Battery Charger
5.2.1 Design Basis
5.2.1.1 The Battery Charger system shall have two chargers (Charger-1 & Charger-2). Both chargers
shall be of identical design and rating. The battery to be connected to the chargers shall be of
Nickel Cadmium/ flooded electrolyte Lead Acid/ VRLA type as indicated in the data sheet.
Battery Chargers for flooded Lead Acid and Nickel Cadmium batteries shall be sized to
provide quick charging of the battery within a duration of 10 hours. Battery Chargers for
VRLA battery shall be sized to provide quick charging of the battery up to 90% of rated
Amperehours within a duration of 24 hours and to 100% within 4 days. Each charger shall be
sized for the most stringent of the following duty conditions, whichever is higher:
Offline quick charging of the battery assembly. The charger shall be sized as under:
Charger rating in Amps. = 0.14 Ah(C 10) of battery (for Lead Acid battery)
= 0.2 Ah(C io) of battery (for VRLA battery)
0.2 Ah(C5) of battery (for Nickel Cadmium battery).
Online float charging of the battery assembly while feeding the complete DC load.
The charger shall be sized as under:
Charger rating in Amps. = 1.15 x Average DC load + float charging current

(Average DC load = Area under the battery duty cycle/ battery duty cycle duration).
5.2.1.2 Each charger shall have a 3 phase full wave, controlled rectifier bridge with protective
devices.
5.2.1.3 Independent current limits shall be provided for charger load current and battery charging
current. Subsequent to a discharge cycle and completion of quick charging, when battery is
connected to charger under float mode, the battery current shall be monitored, controlled and
limited to set value automatically irrespective of the value of load current. Fast acting semi-
conductor fuses shall be provided for protection against internal short circuits. In case of
external short circuits, the chargers shall be protected by rapid shutdown of the semi-
conducting power devices. The high speed semi-conductor fuses used for rectifier protection
shall be complete with trip indication.
Page 1353 of 2065

ENGINEERS
k3I FOR
Of5Idg INDIA LIMITED 6-51-0019 Rev. 4
(mien eszOWOM3O9sai) la Goo. of India Undertakno BATTERY CHARGER Page 6 of 15
5.2.1.4 Filter circuits consisting of smoothing choke and condenser, complete with protection to
limit the ripple content at the output, shall be provided.
5.2.1.5 Silicon blocking diodes shall be provided in the charger output circuit to prevent back-feed
from battery into the charger and filters.
5.2.1.6 Protection against reverse battery connection and DC earth fault relay for earth leakage
detection shall be provided.
5.2.1.7 Silicon blocking diodes (min. 4 nos.) connected to 80% tap of the battery bank shall be
provided to maintain continuity in the DC supply to the load.
5.2.1.8 Internal cooling of the charger unit shall preferably be by natural ventilation. If forced air
cooling is necessary, a redundant air cooling fan shall be provided. The charger components
shall be capable of delivering their rated output with one forced air cooling fan out of
service. Under this condition, maximum continuous temperature of components shall not
exceed the permissible limits. In case of chargers with forced cooling, loss of ventilation
alarm/ trip with override facilities shall be provided.
5.2.1.9 Selection, sizing and suitability of all components used for various applications shall be
vendor's responsibility and the rating of components shall be increased, if required, to suit
associated components during execution of the order without any claim for extra price or
time.
5.2.1.10 The DC system shall be unearthed. However, a high impedance earth fault relay shall be
provided for the protection of the battery.
5.2.1.11 Each charger shall be galvanically isolated from the input power supply by providing a
double wound transformer at its input. The transformer shall be natural air cooled, dry type
suitable for location inside a panel.
5.2.1.12 An RFI filter shall be provided to suppress the radio frequency interference to permissible
limits. The production of radio frequency interference voltages shall not exceed the value of
suppression grade N' as defined in VDE-0875.
5.2.1.13 Transient/ surge protection devices shall be provided in the input circuit of chargers to
protect them against surges & voltage spikes.
5.2.1.14 The Chargers shall be designed to draw power from mains supply at a minimum power factor
of 0.85 lag while sharing the rated load in normal operating configuration.
5.2.1.15 The chargers shall be designed to ensure that the harmonic component in the input currents
are limited so as not to cause undue harmful effects on other sensitive equipment operating
on the same supply bus. Suitable filters/ harmonic traps shall be provided, as required, for
this purpose.
5.2.1.16 All breakers shall be adequately rated for the required continuous rating and breaking
capacity as applicable. Paralleling of breaker/ switch/ contactor poles to achieve the required
current rating is not acceptable. All output isolating devices shall be double pole type. The
DC contactors shall be operated with a DC control supply using ON/ OFF selector switches
and not push buttons.
5.2.1.17 All the thyristors, diodes and other power electronic devices shall be protected with high
speed semiconductor fuses. Pt co-ordination between fuse and semi-conducting power
devices shall be ensured.
5.2.1.18 The Battery Chargers shall be specifically designed to limit float and quick charging voltages
to the battery to limits recommended by the battery manufacturer. Output voltage shall be
limited to maximum +10% of nominal system voltage when the battery is float charged
while feeding the load. Vendor shall specifically ensure that the charger output voltage does
not exceed the recommended limits of operation under any conditions of internal/ external
fault or operation, including:
- Filter capacitor fuse failure of either charger
Page 1354 of 2065

ei ENGINEERS
Igar E12-es INDIA LIMITED FOR 6-51-0019 Rev. 4
ORR MOM aRawrau IA Go. of haw undenoong) BATTERY CHARGER Page 7 of 15
- DC output switch OFF of either charger

- DC output fuse blown of either charger.
Other specific current/ voltage limits during normal charging/ operation of the chargers shall
also be incorporated in the design of the chargers.
5.2.2 Operation and Performance
5.2.2.1 Operation (Option — I)
The DC system shall comprise of 2 Nos. Float cum quick Chargers (each rated for 100%
capacity) with 1 set of battery (Refer typical scheme block diagram option — I).
Normal operation requires that the battery assembly shall be float charged
simultaneously by both Chargers-1 & 2 while feeding the DC load, the chargers thus
operating in parallel and equally sharing the total load.
However in case of failure of either of the chargers, the other charger shall float
charge the battery while feeding the complete DC load. Faulty charger shall
automatically get disconnected from the healthy system.
In case of AC mains failure, the battery shall continue to supply the load.
The process of changeover from float to quick charging and reverting from quick to
float charging shall be selectable in Automatic or Manual mode by means of an Auto/
Manual selector switch. In Automatic mode, the changeover from float to quick
charging shall be initiated through a current sensor, set at a preset value. Similarly, the
changeover from quick to float charging shall also be automatic based on current
sensing. In Manual mode, both change over from float to quick charging and from
quick to float charging shall be performed manually using push buttons. When quick
charging mode is selected, the battery charger shall initially charge the battery under
constant current mode followed by constant voltage (finishing charging) mode or as
per the battery manufacturer's recommendation. Changeover from constant current to
constant voltage (finishing charging) mode shall be fully automatic. A backup
synchronous or digital timer shall also be provided for initiating the changeover to
float mode by default after a preset time period. The timer range shall be 0 to 24 hours
or the nearest available as per manufacturer's standard range.
In the event of failure of the charger feeding the load, when battery is being quick
charged by the other charger, continuity in DC supply shall be maintained from the
battery to the load through 80% tap of the battery bank followed by full battery
supplying the load through contactor C-2 (refer block diagram Option — I).
Interlock shall be provided to ensure that when either of the chargers is selected in
quick charging mode, it will be disconnected from both the DC load and the other
charger operating under float charging mode.
The chargers shall have facility for manual mode of operation in the event of failure of
controller under closed loop control. The selection shall be done through Auto/
Manual selector switch.
Energisation of contactor for DC critical lighting shall be initiated by means of an AC
mains failure relay complete with Auto/ Manual selector switch, On/ Off push
buttons etc.
5.2.2.2 Operation (Option — II)

The DC system shall comprise of 2 nos. Float cum quick Chargers (each rated for
100% capacity) and 2 sets of Batteries (each of the battery sets rated for 50% All
capacity). (For typical scheme, refer block diagram Option - II).
Normal operation requires that Battery-1 shall be float charged by Charger-1 while
Battery-2 shall be float charged by Charger-2. In this case both the chargers 1 and 2
shall feed the DC load by operating in parallel and equally sharing the total load.
Page 1355 of 2065

T) ENGINEERS
irrr, FOR
Igar Eledg
I NW, eteetre Jeare)
INDIA LIMITED
IA Gov. of India Undertaking) BATTERY CHARGER
6-51-0019 Rev. 4
Page 8 of 15
Selection of Float / quick mode shall be Automatic or Manual based on the position of
selector switch for Auto / Manual selection.
In case of failure of either of chargers, the other charger shall float charge both the
batteries while feeding the complete DC load. Faulty charger shall automatically get
disconnected from the healthy system.
e) In case of AC mains failure, both the batteries shall continue to supply the load.
0 After restoration of power supply, one of the Charger (say Charger-1) shall float
charge Battery-1 and also feed the complete DC load while the other Charger-2 shall
quick charge Battery-2. Upon completion of quick charge of Battery-2, Charger-2
shall switchover to float mode and shall float charge Battery-2 and also feed the
complete DC load while the other Charger-1 shall switchover to quick mode and shall
quick charge Battery-1.
The process of changeover from float to quick charging and reverting from quick to
float charging mode shall be selectable in Automatic or Manual mode by means of
Auto / Manual selector switch.
In automatic mode, the changeover from float to quick charging shall be initiated
through a current sensor set at a preset value. Similarly, the changeover from quick to
float charging shall also be automatic based upon current sensing and through timer.
i) In manual mode, both the changeovers i.e. from float to quick charging and from
quick to float charging shall be performed manually using push buttons. When quick
charging mode is selected, one of the battery charger (say Charger-1) shall initially
charge the battery under constant current mode followed by constant voltage
(finishing charging) mode or as per the battery manufacturer's recommendation.
Changeover from constant current to constant voltage (finishing charging) mode shall
be fully automatic. A back-up synchronous or digital timer shall also be provided for
initiating the changeover to float mode by default after a preset time period. The timer
range shall be 0 to 24 hours or the nearest available as per manufacturer's standard
range.
In the event of failure of charger feeding the load (say Charger-1), when Battery-2 is
being quick charged by the other Charger-2, Charger-2 shall changeover to float mode
and continuity of 100% DC supply to the load shall be maintained from the Charger-2
while float charging both Battery-1 as well as Battery-2 after providing suitable time
delay.
k) In an event of AC mains failure, when one of the Charger (say Charger-1) is float
charging the Battery-1 and supplying the 100% DC load while the other Charger-2
was quick charging Battery-2, continuity of 100% DC supply to the load shall be
maintained from Battery-1 (through 100% tap). Further, Battery-2 (which was being
quick charged) shall also be made available, after providing suitable time delay, to
feed the DC load by operating in parallel with Battery-1 and sharing the total load.
1) Interlock shall be provided to ensure that when either of the chargers (say Charger-1)
is selected in quick charging mode, it will be disconnected from both the DC load as
well as the other Charger-2 operating under float charging mode.
The chargers shall have facility for manual mode of operation in the event of failure of
controller under closed loop control. The selection shall be done through Auto/Manual
selector switch.
Energisation of contactor for DC critical lighting shall be initiated by means of an AC
mains failure relay complete with Auto/Manual selector switch, On/Off push buttons
etc.
Page 1356 of 2065

lot ti ENGINEES
R
$Igar Raft INDIA UMITED FOR 6-51-0019 Rev. 4

ORR 21121,TP Mt 3RVA) IA Govt of Inclia Undertaken) BATTERY CHARGER Page 9 of 15
5.2.2.3 Performance
Both chargers shall be of solid state design, constant voltage and current limit type.
The output voltage shall be stabilised to within +1% of set value in float charging
mode for mains steady state voltage and frequency variation of +10% and +3%
respectively, and load variation of 10 to 100% at any temperature up to the design
ambient temperature specified in the data sheet. However, the variation in output
voltage can be up to +2% for chargers with rated output voltage up to 24V.
Under constant current quick charging condition, the DC output current shall be
maintained within +2% of set value.
The output voltage dynamic response of the charger unit with battery disconnected
shall not vary more than +10% of nominal output voltage in the event of step load of
up to 50% of the rated output. The output voltage shall be restored to a value within
the steady state limits within 250 msec.
The maximum allowable RMS ripple voltage, with battery disconnected, shall be
equal to or less than 2% of the nominal output voltage.
The maximum noise level from the chargers measured at 1 metre distance in any
position, at any load between 0- 100% with all normal cooling fans running shall not
exceed 75 dB(A).
5.2.2.4 Controls
The minimum controls shall include but not be limited to those shown in the block diagrams
(OPTION-I or OPTION-II as applicable):
5.2.2.5 Panel Metering and Indication
These shall include but are not limited to those shown in the block diagrams (OPTION-I or
OPTION-II as applicable):
LEDs provided for indication shall be cluster type with adequate brightness and minimum 2
Nos. LEDs chips per light. LEDs shall be connected in parallel and each LED chip having
diameter not less than 3mm.
5.2.2.6 Annunciation
Static type audio-visual annunciator with annunciation windows, acknowledge, test and reset
push buttons and hooter shall be provided on each charger for the following annunciations.
Any additional relays/ components, including DC undervoltage relay and current sensors,
required for this purpose shall be provided in the chargers. Facility for bypassing the audio
alarm on each charger shall also be provided.
DC under voltage
DC overvoltage
DC earth leakage
AC incoming power supply failure
AC input fuse blown-off
Thyristor/ diode failure
DC output fuse blown-off
DC battery fuse blown-off
Filter Capacitor fuse blown-off
Load on Battery (using current direction sensing with time delay)
Battery undervoltage/ Disconnected during discharge (using zero current sensing)
Cubicle fan failure/ cubicle temperature high (for chargers with forced cooling).
One summary alarm potential-free contact each for Battery, Charger-1 and Charger-2 shall
be wired to terminal block for remote annunciation.
Page 1357 of 2065

ENGINEERS
$1g-ar faileg INDIA LIMITED FOR 6-51-0019 Rev. 4
(•• M 21E0AE013,11511) IA Gout. of India undertakng) BATTERY CHARGER Page 10 of 15
5.2.2.7 Printed Circuit Boards (PCBs)

PCBs used in the chargers shall be made of glass epoxy material. The PCBs shall be firmly
clamped in position so that vibration or continued usage do not result in loose contacts. All
PCBs shall be fitted in a manner to avoid replacement of a PCB by a wrong spare card. The
PCBs shall be provided with visual light emitting diode (LED) status indications, monitoring
points/ test connections and setting potentiometers in a readily accessible location which is
visible without removing the PCBs.
5.2.2.8 Vendor shall provide adequate protection to the system.
5.3 Construction of Chargers/ Distribution Board
5.3.1 Each Battery Charger and DC distribution board shall be housed in a separate free standing
cubicle with minimum IP-31 degree of protebtion. All panels shall be of the same height so
as to form a panel line up which shall have good aesthetic appearance. Chargers-1 & 2 shall
be installed side by side whereas DCDB may be located separately and interconnected to the
charger through cables. The DCDB shall accommodate outgoing feeders as desired. Each
panel shall be provided with an 11W CFL light with a door operated switch and a
thermostatically controlled MCB protected space heater.
The DCDB shall be compartmentalised with each outgoing feeder housed in a separate
compartment. Cable alley of minimum 200mm width with suitable supports shall be
provided for the termination of cables for each vertical arrangement of outgoing feeders in
DCDB.
5.3.2 The Chargers, DCDB and Cell Booster enclosures shall be fabricated from structural/ CRCA
sheet steel. The frames shall be fabricated by using minimum 2 mm thick CRCA sheet steel
while the doors and covers shall be made from minimum 1.6 mm thick CRCA sheet steel.
Wherever required, suitable stiffeners shall be provided. The panels shall be provided with
suitable louvers for ventilation backed by wire mesh. They must be suitable for use in a
tropical climate. Hinged doors shall be provided at the front and back as required. Inter panel
sheet steel barriers shall be provided.
5.3.3 Bus bars shall be colour coded and live parts shall be shrouded to ensure complete safety to
personnel intending routine inspection by opening the panel doors. All the equipment inside
the panel and on the doors shall have suitable nameplates and device tag numbers as per the
schematic diagram. All wires shall be ferruled and terminals shall be numbered.
5.3.4 The DCDB incomer and main bus bars shall be rated based on the maximum load current
considering an additional 10% design margin for contingencies. The rating shall be selected
from standard available ratings and shall be adequate for the expected short circuit current.
The bus bar voltage shall be higher than the recommended quick charging voltage for the
system. The insulation for all equipment where provided shall be heat resistant, moisture
proof and tropicalised.
5.3.5 All power and control switches shall be rotary/ cam operated type. All power switches shall
be air insulated load break type. Vendor shall ensure that all equipment/ components such as
incomer switches, outgoing DC switches, MCCBs, push buttons, indicating lamps, charger
mode selector switches, voltage control switches, annunciator windows etc. are suitably
located on the charger and distribution board door such that they can be operated without
opening the front door. Power switches shall be provided with a door interlock. In case of
difficulty in installation on the charger front panel door, the AC incoming power switches,
DC outgoing switches and MCCBs may be installed within the panel provided that they are
operable after opening the front panel door. However, all other selector/ control switches,
push buttons, indicating lamps, annunciators, meters etc. shall necessarily be installed on the
front panel door as specified above.
5.3.6 All instruments shall be switchboard type, back connected and 72 x 72 mm square size.
Accuracy class of all meters shall be 1%. Digital meters capable of displaying different
parameters can be considered subject to Owner's/ EIL's approval. Analogue instrument
scales shall have a red mark indicating maximum permissible operating rating.
Page 1358 of 2065

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1.5tRzieg trr) ENGINEERS FOR
ligar INDIA LIMITED 6-51-0019 Rev. 4
Govt or India Undertaking)
MOT eiWIRU JW1.1) IA BATTERY CHARGER Page 11 of 15
5.3.7 All fuses shall be link type and shall be located inside the panel. Diazed fuses shall not be
accepted.
5.3.8 All power and control wiring connections within the panels shall be carried out with 660V
grade, PVC insulated, BIS marked wires having stranded copper conductors. However,
copper strip connections shall preferably be used for currents exceeding 100A. Control
wiring for electronic circuits/ components shall be through flat ribbon cable or copper wire
of minimum 0.5mm diameter. Ferruling of wires shall be as per relevant IS.
5.3.9 For all cabling external to panels, power cables shall be with aluminium/ copper conductors
and control cables shall be with copper conductors. All cable connections shall be from the
bottom of the panel. Removable bolted undrilled gland plates shall be provided along with
single compression type nickel plated brass cable glands for all external cable connections.
Separate test terminals shall be provided for measuring and testing the equipment to check
performance. All panels shall be supplied complete with tinned copper cable termination
lugs.
5.3.10 A suitably sized earth bus shall be provided at the bottom of the panels running through the
panel line up with provision for earth connections at both ends to owner's main earth grid.
All potential free metallic parts of equipment shall be suitably earthed to ensure safety.
5.3.11 The maximum height of the operating handles/ switches shall not exceed 1800 mm and the
minimum height shall not be below 300 mm.
5.3.12 All components/ devices/ feeders shall be provided with screwed nameplates and lettering
shall be of minimum 6 mm height.
5.3.13 Panels shall undergo manufacturer's standard cleaning and painting cycle. After preparation
of the under surface, the panel shall be painted with two coats of epoxy based final paint.
Colour shade of final paint shall be 631 of IS 5/ RAL 7032. All unpainted steel parts shall be
suitably treated to prevent rust formation. If these parts are moving elements, then they shall
be greased.
5.4 Cell Booster
Cell booster shall be suitable for charging one to six cells within the time duration specified
at C1.5.2.1.1. It shall be suitable for charging not only new cells before being introduced to
the battery bank but also for any treatment to be given to individual weak cells. Cell booster
shall be suitable for 240 V + 10%, 50 Hz + 3% SPN input power supply. Cell booster output
voltage shall be in the range of 0-18V and 0-12V for Lead Acid and Nickel Cadmium
batteries respectively. Cell booster shall be sized as under:
For Lead Acid battery 0.14 x Ah(C io) of cell

For VRLA battery 0.2 x Ah(C io) of cell
For NiCd battery 0.2 x Ah(C5) of cell.
Cell booster shall have a heavy duty switch fuse or MCCB on both AC incomer and DC
output sides, along with AC voltmeter, DC ammeter, DC voltmeter and indicating lamps for
AC/ DC power ON. The output voltage and current of cell booster shall be manually
controlled using a suitably rated variac or a full wave controlled rectifier bridge. Suitable
interlock shall be provided so as to ensure that the variac/ controlled rectifier is at its
minimum position while switching on the cell booster. Cell booster shall be portable type
with wheels. Each cell booster shall be supplied with 5 m long flexible copper conductor,
PVC insulated braided cables for both AC incoming power supply and DC output connection
to the battery. An industrial type 3 pin 15A plug shall be provided on AC incoming cable
end and lugs shall be provided on DC outgoing cable end.
5.5 Reliability
All necessary care shall be taken in selection, design, manufacture, testing and
commissioning of the equipment for ensuring high system reliability. The following design
considerations shall be taken into account to ensure maximum availability of the system:
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ENGINEERS
5.tgar 215ieg w INDIA LIMITED FOR 6-51-0019 Rev. 4
laiRrr ereeee aa..719.0 IA Govt of India Undertaking) BATTERY CHARGER Page 12 of 15
5.5.1 There shall be no common device between the two units, the failure of which could cause
shutdown of more than one charger.
5.5.2 It shall be possible to attend to any individual power circuit for maintenance without
affecting the total DC supply.
5.5.3 Series-parallel combination of smaller devices to achieve specified rating shall not be
acceptable.
6.1 During fabrication, the equipment shall be subjected to inspection by EIL / Owner or by an
agency authorised by the Owner. Manufacturer shall furnish all necessary information
concerning the supply to EIL's/ Owner's inspector. Tests shall be carried out at
manufacturer's works under his care and expense.
6.2 Each Battery Charger/ DCDB/ Cell Booster shall be tested in accordance with applicable
standards. The following acceptance tests shall be performed on each Battery Charger and
DCDB as a minimum. Detailed test schedule and procedures shall be formulated by the
vendor and submitted for EIL's/ Owner's approval. Vendor shall indicate the maximum
allowable tolerance against each test parameter in line with applicable standards. All tests
shall be witnessed by owner or his authorised representative and 4 weeks prior notice shall
be given before the date of commencement of tests. In case the equipment fails to meet any
requirements of the specifications, necessary modifications/ corrections shall be made by the
vendor to ensure compliance to the specifications, and the equipment shall be retested before
acceptance. Test certificates indicating the test results shall be submitted to owner.
6.2.1 Insulation Tests
Insulation tests shall be performed as per IEC 60146-1-1.
The insulation tests shall be carried out using an AC power frequency voltage or a DC
voltage at the choice of the manufacturer. In the case of AC power frequency voltage test,
the test voltage at the frequency available in the test facility or at the rated frequency, but not
exceeding 100 Hz, shall be increased to the full value shown in the following table in not
less than 10 seconds continuously or in maximum steps of 0.05 p.u. of the full value starting
at a maximum of 0.5 p.u. The unit on test shall withstand the specified voltage for 1 minute.
In case DC voltage is used for the test, the value of DC voltage shall be equal to the crest
value of the test voltage specified in the table.
V p / /2 (Vp is the highest crest voltage to be Test Voltage (AC RMS value)
expected between any pair of terminals)
# 60 V 500 V
# 125 V 1000 V
# 250 V 1500 V
# 500 V 2000 V
6.2.2 Printed Circuit Boards
PCBs and other electronic circuits shall undergo a burn-in test for 96 hours at 50°C at a
voltage varied between the maximum and minimum supply voltage. In case of failure of any
component during testing, the tests shall be repeated after replacement of the faulty
component. Supplier's test certificates are also acceptable for the test.
6.2.3 Heat Run Test
Prior to execution of functional tests, each of the two chargers of each Battery Charger set
shall be subjected to a Heat Run test performed at rated load and voltage for a period not less
than 8 hours. The other charger of the set shall be energized under zero load current
condition throughout the test period. The temperature of electronic power devices shall be
measured and the device junction temperature shall be calculated. The calculated value shall
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Plaaeg a ENGINEERS
iatategligie INDIA MITED
LI FOR 6-51-0019 Rev. 4
(A Gov( ol Indb undetlakingi
BATTERY CHARGER Page 13 of 15
be at least 10-20°C lesser than the maximum rated junction temperature of the device with
proper ambient temperature correction applied.
6.2.4 Functional Tests
Functional tests shall be performed on each charger. If during execution of functional tests,
an electronic component of the charger is required to be replaced, e.g. due to charger
malfunction or failure of the unit to fulfil the performance requirements of the specification,
then the heat run test shall be repeated at rated current following which functional tests shall
be carried out.
6.2.4.1 Charger Testing at Constant Output Voltage
Measurements shall be carried out in the float charging mode and in the quick charging
mode. In each mode, measurements shall be carried out at nominal AC input voltage and at
zero, 50% and 100% of rated output current. Measurements at 100% rated load current shall
be repeated at 90% and 110% of nominal AC supply voltage. Measurements shall include
input AC phase voltage, frequency, current and power and DC output voltage, current and
output voltage ripple.
6.2.4.2 Charger Testing at Constant Output Current Limit
Measurements shall be carried out both in the float charging and quick charging mode. In
each mode, measurements shall be carried out when the charger is operating under DC
current limiting conditions with DC output voltage between zero and set value
corresponding to constant voltage operation. Measurements shall include DC output voltage
and current.
6.2.4.3 Auxiliary Equipment and Control Circuit Tests
The correct functioning of all measuring instruments, alarms, indications, protections and
controls mentioned in the specification shall be verified.
6.2.4.4 Parallel Operation
Parallel operation of both chargers, sharing of the load and automatic isolation of faulty
charger shall be checked.
6.2.4.5 Charger Efficiency
This shall be determined by measurement of the active power input and output at 50%, 75%
and 100% load.
6.2.4.6 Audible Noise Test
Audible noise shall be measured around each charger at 1 meter distance in at least 4 to 5
positions.
6.3 Site Acceptance Test
The Battery Chargers, DCDB and Cell Boosters shall be tested at site along with the battery.
Vendor shall perform all tests at site as per the approved SAT procedure.
7.0 PACKING & DESPATCH
during transportation. The equipment shall be properly packed for transportation by ship/ rail
or trailer. It shall be wrapped in polythene sheets before being placed in crates/ cases to
prevent damage to finish. The rates/ cases shall have skid bottoms for handling. Special
notations such as 'Fragile', 'This side up', 'Center of gravity', 'Weight', 'Owner's
particulars', 'PO Nos.' Etc., shall be clearly and indelibly marked on the packages together
with other details as per purchase order.
shall be completely suitable for outdoor storage in areas with heavy rains and high ambient
temperature
Page 1361 of 2065

loilfaeJel ENGINEERS
51?-ar Elf5i-eu INDIA LIMITED FOR 6-51-0019 Rev. 4

MIETVWRMJ.19,M (A Govt. of India Undertaking) BATTERY CHARGER Page 14 of 15
OPTION-1
FROM 415V,TPN BUS FROM 415V,TPN BUS
CHARGER -1 P CHARGER-
0
AC POWER 'ON'
AC POWER 'ON'
o■ 0
■ ON/OFF
SEL. SWITCH 0 ON/OFF
SEL. SWITCH
•
CONT. Cl • CONT. C •
(:2)
(1-1) CHARGER
FAULT O 11:11 CHARGER
MDDE P.B.
FLOAT QUICK FLOAT QUICK
FLOAT CH. QUICK CH. CH. 'ON' CH. 'ON' FLOAT CH. QUICK CH.
CH. 'ON' CH. 'ON'
CHARGER-1 MODE P.B.
FLOAT CHARGER _ 2 MODE P.B. MODE P.B.
FLOAT
CH. ADJ CH. ADJ
QUICK QUICK
CH. ADJ 0-24HR. A/M SEL. CH. ADJ 0 -24HR. A/M SELI
SWITCH SWITCH1
PB TEST PB ACK PB TEST PB ACK
PB RESET PB RESET
TRIP
11
TRIP, L
• T
• CONT,2A \IL/ \Iv CDNT.2B
• 0 •
• • •k
• l< TRIP TRIP
0
CONT.1A CDNT.IB
) SEE NOTE:-2
-
EU Y
ci1D-1171-
II vs-0
L J
50% 80%
41:14:1 elle
CONT.
C2
r CRITICAL TEST P.B.

LTG. 'ON' CRIT. LTG.
6 DCDB1
O 000
"'
CONT. C3 LOAD D C. BUS
( .';AA/M SEL
SWITCH
•
1
ON OFF
PB PB
CRITICAL DC FEEDER
_ LTG. (TYP) (TYP)
NOTES: —
1. a) THE DC CONTACTORS SHALL HAVE A TESTED/ PUBLISHED DC RATING EQUAL TO OR EXCEEDING THE MOST
STRINGENT CURRENT CARRYING AND BREAKING REQUIREMENTS CONSIDERING ADEQUATE DESIGN MARGINS.
PUSH BUTTONS ARE NOT ACCEPTABLE IN PLACE OF SELECTOR SWITCHES FOR THE ON/OFF SWITCHING
OPERATIONS OF THE CONTACTORS.
THE DC CONTACTORS SHALL BE OPERATED WITH A DC CONTROL SUPPLY.
2. SUITABLY RATED DC MCCB CAN BE ACCEPTED IN PLACE OF SWITCH FUSE UNIT AT BATTERY OUTPUT.
Page 1362 of 2065

ENGINEERS
I ar tlf5ltu
g INDIA LIMITED FOR 6-51-0019 Rev. 4
(411ZPI MIR2,1,13cRRA) IA Govt of India Undertaking) BATTERY CHARGER Page 15 of 15
OPTION-II
FROM 415V,TPN BUS FROM 415V,TPN BUS
AC POWER 'ON'
0 n
CHARGER-T1
0
AC POWER 'ON'
CHARGER-
0 ON/OFF
SEL. SWITCH 0 ON/OFF
SEL. SWITCH
: .0
CONT. CI CONT. CI• I
(12)
CHARGER CHARGER
(2) ; FAULT (I) FAULT
FLOAT QUICK FLOAT QUICK FLOAT CH. QUICK CH.
CH. 'ON' FLOAT CH. QUICK CH. CH. 'ON'
HARGER,MODE P.B. MODE P.D.
o••
MODE P.B. FLOAT HARGER_,MODE
FLOAT
CH. ADJ CH, ADJ
QUICK IM • • • 49
11.
QUICK A/M SEL.,
CH. ADJ 0-24HR. A/M SEL. CH. ADJ 0-24HR.
SWITCH SWITCH
PB TESTIPBI ACK
PB RESET
PB TEST PB ACK
PB RESET
Oro
co CD
a4 TRIP
7
CD
E-3 (111 TRIPI . 11
r
CONT.2A W 1;/ CONT.213
0 0 0 -0
0 00
TRIP k TRIP
CONT.1A CDNT.IB
27 NOTE-2 SEE NOTE-2
BrIEB1-1.16-14=11 B LER Y..72.16-1411}
—4-11111 VS H6-14111— VS0

L_ J
50X 80% 50% 80%
(1) 41) 0ICONT. mm 0 ICONT.
o C2 o C2
CRITICAL TEST P.B.

LTG. 'ON' CRIT. LTG.
DCDIT
000 I
CONT. C3 --- LOAD D.C. BUS

(?)A/M SEL
100 0 0
SWITCH
I
ON OFF
PB PB
1
CRITICAL DC FEEDER
LTG. (PIP) (PIP)
_J
THE DC CONTACTORS SHALL HAVE A TESTED/ PUBLISHED DC RATING EQUAL TO OR EXCEEDING THE MOST
STRINGENT CURRENT CARRYING AND BREAKING REQUIREMENTS CONSIDERING ADEQUATE DESIGN MARGINS.
PUSH BUTTONS ARE NOT ACCEPTABLE IN PLACE OF SELECTOR SWITCHES FOR THE ON/OFF SWITCHING
OPERATIONS OF THE CONTACTORS.
c) THE DC CONTACTORS SHALL BE OPERATED WITH A DC CONTROL SUPPLY.
2. SUITABLY RATED, DC MCCB CAN BE ACCEPTED IN PLACE OF SWITCH FUSE UNIT AT BATTERY OUTPUT.
Page 1363 of 2065

ENGINEERS FOR HIGH VOLTAGE 6-51-0031 Rev. 5
$ig-ar ffieg INDIA LIMITED INDUCTION MOTORS
(A Govt of India Undeftalongl Page 1 of 18
d-wci 5c1-k111 r("R
f~r
SPECIFICATION
FOR
HIGH VOLTAGE
INDUCTION MOTORS
\k.
t .■, -
'4•1 CV/'' 7,Q
REVISED AND ISSUED AS STANDARD SA BRB UAP/JMS SC
5 20.11.13
SPECIFICATION
REVISED AND ISSUED AS STANDARD SD BRB JMS VC
4 26.09.07
SPECIFICATION
3 09.04.02 UG AAN VPS SKG
REVISED AND RE-ISSUED
REVISED AND ISSUED AS STANDARD AAN VPS SG AS
2 01.02.97
SPECIFICATION
1 30.01.89 ISSUED AS STANDARD SPECIFICATION VPS VPS SKG RCPC
Standards Standards
Comm ittee Bureau
No by by
Approved by
Page 1364 of 2065

ENGINEERS
$1&:1T12-&g INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
1.1127f c.-W■srxeMIJVCISA) (A Govt of incha Undeltaking)
MOTORS Page 2 of 18
Abbreviations:
BIS Bureau of Indian Standard

CIMFR Central Institute of Mines and Fuel Research
EIL Engineers India Limited
FM Factory Mutual
FRP Fiberglass Reinforced Plastic
IEC International Electro-technical Commission
IEEE Institute of Electrical & Electronics Engineers
IS Indian Standard
JEC Japanese Electro-technical Committee
LCIE Laboratoire Central des Industries Electriques
LRWT Locked Rotor Withstand Time
PO Purchase Order
p.u. per unit
r.m.s Root Mean Square
RPM Revolutions per Minute
TETV Totally enclosed Tube Ventilated
UL Underwriter's Laboratories
DOL Direct On line
VFD Variable Frequency drive
OEM Original Equipment manufacturers
TPIA Third party Inspection Agency
PESO Petroleum & Explosives safety organisation
Members: Mr. BR Bhogal

Ms. S. Anand
Mr. Parag Gupta
Mr. A.K. Chaudhary
Ms. N.P. Guha
Page 1365 of 2065

ENGINEERS
INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
Go" of India Undedok,nd)
MOTORS Page 3 of 18
CONTENTS
1.0 SCOPE .4
3.0 GENERAL REQUIREMENTS .5
4.0 OPERATING CONDITIONS ..5
5.0 PERFORMANCE 7
6.0 CONSTRUCTION DETAILS 7
7.0 CONTROL, ALARM AND TRIP DEVICES 13
8.0 MISCELLANEOUS ACCESSORIES 14
9.0 NOISE LEVEL 16
10.0 MOTOR VIBRATIONS 16
11.0 CRITICAL SPEEDS 16
12.0 PAINTING 16
13.0 INSPECTION AND TESTING 16
14.0 CERTIFICATION . 17
Page 1366 of 2065

7111~1 ENGINEERS
$1g-aiffUn
r IMf 6 INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
cv,er+W ,151~) IA Govl of India Undetalong)
MOTORS Page 4 of 18
1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of high
voltage squirrel cage induction motors.
2.1 The squirrel cage induction motors and their components shall comply with the latest
editions of following standards issued by BIS (Bureau of Indian Standards) unless
otherwise specified:
IS - 5 Colours for ready mixed paints and enamels

IS - 325Three phase induction motors
IS - 1271 Thermal evaluation and classification of electrical insulation
IS - 2071 Methods of high voltage testing
IS - 2253 Designation for type & construction and mounting arrangement of
rotating electrical machines
IS - 2968 Dimensions of slide rails for electrical motors
IS - 4029 Guide for testing of three phase induction motors
IS - 4889 Method of determination of efficiency of rotating electrical machines
IS - 6362 Designation of methods of cooling of rotating electrical machines
IS - 7816 Guide for testing insulation resistance of rotating machines
IS - 8223 Dimensions and output series for rotating electrical machines
IS — 8789 Values of performance characteristics for three phase induction motors
IS - 12065 Permissible limits of noise level for rotating Electrical Machines
IS - 12075 Mechanical vibration of Rotating Electrical Machines with shaft heights
56 mm and higher measurement, evaluation and limits of vibration
severity
IS - 13529 Guide on effects of unbalanced voltages on the performance of three
phase induction motors
IS - 13555 Guide for selection and application of three phase induction motors for
different types of driven equipments
IS - 14222 Impulse voltage withstands levels of rotating electrical machines with
form-wound stator coils
IS - 14568 Dimension and output series for rotating electrical machines, frame
numbers 355 to 1000 and flange numbers 1180 to 2360
IS / IEC60079-0 Electrical apparatus for explosive gas atmospheres (General Requirements)
IS/IEC60079-1 Equipment protection by Flame proof enclosures "d'.
IS/IEC60079-2 Explosive protection by pressurized enclosure "p"
IS/IEC60079-7 Explosive atmospheres-Equipment protection by increased safety —"e"
IS/IEC60079-15 Electrical apparatus for explosive gas atmospheres Construction, test &
marking of type of protection "n"
IS/ IEC: 60529 Degree of protection provided by enclosures (IP Code)
IS/IEC-60034-1 Rotating Electrical machines Rating & Performance.
IS/IEC-60034-5 Degrees of protection provided by enclosure for rotating electrical
machinery.
IS/IEC 60034-8: Terminal marking and direction of rotation for rotating electrical machinery.
2.2 In case of imported motors, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian Standards.
2.3 The motors shall also conform to the provisions of CEA regulations and other statutory
Page 1367 of 2065

t31 ENGINEERS
$1g-ar fafe5 INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
Govt of India Undedaking)
MOTORS Page 5 of 18
2.4 In case Indian Standards are not available, standards issued by

IEC/BS/VDE/IEEE/JEC/NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents,
the most stringent one shall prevail. However, owner's decision in this regard shall be
final and binding.
3.1 The offered equipment shall be brand new with state of the art technology and proven
field track record. No prototype equipment shall be offered.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL
before phasing out the product/spares to enable the end user for placement of order for
spares and services.
4.0 OPERATING CONDITIONS
4.1 Ambient Conditions
Motors shall be suitable for operating satisfactorily in humid and corrosive atmospheres
found in refineries, fertilizer, petrochemical and metallurgical plants. Service conditions
shall be as specified in the motor data sheet. If not specifically mentioned therein, a
design ambient temperature of 40°C and an altitude not exceeding 1000 meters above
mean sea level shall be taken into consideration.
4.2 Frequency and Voltage variations.
Unless otherwise agreed, motors shall be designed for continuous operation at rated
output under the following conditions:
a) The terminal voltage differing from its rated value by not more than ± 6 % or
b) The frequency differing from its rated value by not more than ± 3 %
c) Any combination of (a) and (b)
4.3 Starting
a) Motors shall be designed for direct on line starting or other method of starting as
specified in datasheet.
b) Motors shall be designed for re-acceleration with full load after a momentary loss
of voltage with the possibility of application of 100% of the rated voltage when the
residual voltage has dropped down to 50% and is in phase opposition to the applied
voltage.
c) Motors shall be designed to allow the minimum number of starts on full load
indicated in Table below:-
500 to 1000 Above 1000

Up to 500 KW
KW KW
Min. Number of starts
No. of consecutive start-ups with
initial temperature of the motor at 3 3 2
ambient level (cold.)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — AII rights reserved
Page 1368 of 2065

ENGINEERS FOR HIGH VOLTAGE INDUCTION
$'gar 92es
.417,2~ ,P727.4
INDIA LIMITED
IA Govt of India Undenaking) MOTORS
6-51-0031 Rev. 5
Page 6 of 18
No. of consecutive start-ups with

initial temperature of the motor at 2 2 1
full load operating level (hot)
d) Unless otherwise specified, the locked rotor withstand time under hot condition at
100% voltage (time tE for increased safety i.e. Ex e motor) shall be minimum 5
seconds more than the starting time at 100 % voltage, under specified load
conditions.
4.4 Unless otherwise stated in the motor data sheet, motors shall be suitable for starting at
80% of the rated voltage against the torque speed characteristics of the driven equipment.
a) Starting torque and minimum torque of the motor shall be compatible with the
speed torque characteristics of the driven equipment under specified starting and
operating conditions.
b) For heavy duty drives such as blowers, crushers, compressors etc., high starting
torque motors shall be provided.
This shall be checked against the speed torque characteristics of the load and the
thermal withstand characteristics of the motors.
4.5 The pull out torque at rated voltage shall be not less than 175 percent of the rated load
torque with no negative tolerance. In case of motors driving equipments with pulsating
loads (e.g. reciprocating compressors), the minimum value of the pull out torque at 80%
of rated voltage shall be more than the peak value of the pulsating torque and the current
pulsation shall be limited to 40%.
Unless otherwise agreed, the pull out torque shall not exceed 300% of the rated load
torque.
4.6 Direction of rotation
Motors shall preferably be suitable for either direction of rotation. In case unidirectional
fan is provided for motors, direction of rotation for which the motor is designed shall be
permanently indicated by means of an arrow. Any alteration required for obtaining a
change in the direction of rotation such as reversal of the fan, must be clearly specified.
Motors which are suitable for only one direction of rotation shall have this direction of
rotation clearly indicated on the motor together with the phase sequence of the terminals
associated with this rotation in indelible marking. Motors suitable for bi-directional
rotation shall be provided with a double headed arrow. Directional arrow should be
manufactured from corrosion resistant material.
Normally, clockwise rotation is desired as observed from the driving (coupling) end,
when the terminals ABC are connected to a supply giving a terminal phase sequence in
the order ABC. Counter clockwise rotation of the motor shall be obtained by connecting
the supply to terminals so that the phase sequence corresponds to the reversed
alphabetical sequence of the terminal letters. Ample space shall be provided at the
terminal box for interchanging external leads C and A for this purpose.

Page 1369 of 2065

ENGINEEFZS
$1fg-ar 2fai
dg INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
1.11277 232,7,retTR,~3) Ift Govt of Intha Undertakingt
MOTORS Page 7 of 18
5.0 PERFORMANCE
5.1 Motors shall be rated for continuous duty (S1 ), unless otherwise specified.
5.2 Motors shall have adequate torque to accelerate the load from zero to full speed under the
specified starting and operating conditions.
5.3 Starting current shall be 500% subject to IS/IEC tolerance for motors up to 1000 kW. For
motors above 1000 kW, it shall be agreed with purchaser for each case.
5.4 In particular cases, when the starting current is to be limited, care shall be taken such that
the design values of torque meets the load requirement while at the same time complying
with clause 4.3 above of this specification.
5.5 In particular cases, when the starting with reduced voltage is specified, care shall be taken
such that the design values of torque meets the load requirement while at the same time
complying with clause 4.4 and 4.5 above of this specification.
5.6 Motors fed by variable frequency drive shall additionally meet the following requirements:
5.6.1 The motors shall be suitable for the current wave forms produced by the power supply
including harmonics generated by the drive.
5.6.2 The motors shall be designed to operate continuously at any speed over the range (1—
100%) of rated speed or as specified in data sheet. The characteristics shall be based on the
application — in terms of constant torque / variable torque as per the driven equipment.
Additional cooling fan shall be provided if required to limit the temperature rise to
specified limits.
5.6.3 The motors shall withstand torque pulsation resulting from harmonics generated by the
solid state power supply.
5.6.4 The motors required to be transferred to DOL bypass mode shall be rated for specified
variations in line voltage and frequency.
6.0 CONSTRUCTION DETAILS
6.1 Windings
6.1.1 Motors shall be provided with class-F insulation. The permissible temperature rise above
the specified ambient temperature shall be limited to those specified in the applicable
Indian Standards for class-B insulation.
6.1.2 The windings, along with the stator, shall be tropicalised and shall be vacuum
impregnated(resin poor type).
Winding shall be adequately braced to prevent any relative movement during operation. In
this respect, special care shall be taken for the stator windings of direct-on-line starting
squirrel cage motors. Insulation shall be provided between coils of different phases which
lie together.
6.1.3 Core laminations must be capable of withstanding burnout for rewind at 400°C without
damage or loosening.
Page 1370 of 2065

11 ENGINEERS SPECIFICATION STANDARD SPECIFICATION No.
5g-a 1&2e-g
CI,CP1t,R1~1)
IA Govt of Inche Undertahrng)
MOTORS Page 8 of 18
In case of motors driving equipment with pulsating loads, special attention shall be paid
to the joints of rotor bars and end rings to avoid premature failures due to induced fatigue
stresses.
For Ex n and Ex e motors, the conductor insulation must be carried right up to the
terminal clamp.
6.1.4 Motors shall be designed to withstand impulse voltages specified in applicable Indian
Standards/relevant IEC. The wave shape shall be as per IS/relevant IEC.
6.1.5 Windings of motors shall be star connected. For VFD fed motors, the main winding
connected in `Delta' can also be considered acceptable subject to motor manufacturer
having adequate proven track record.
6.2 Terminals, terminal boxes and cable entries
6.2.1 The ends of the winding shall be brought out into a terminal box. The terminations shall
be by means of clamp type bushing or bushings with adequately sized bolted terminals.
Line terminals shall be properly insulated from the frame with material resistant to
tracking.
6.2.2 The terminal box shall be located on the right hand side viewed from the driving
(coupling) end. Unless otherwise specified, the terminal box shall be suitable for side
cable entry. The size of the cable end boxes shall be large enough to provide a minimum
distance of 600 mm between cable gland plate and terminal lug.
6.2.3 The neutral point of the star windings shall also be brought out to a separate terminal box.
This shall house the current transformers for differential protection of motors wherever
required and shall be located on the opposite side of main terminal box.
6.2.4 The main and neutral terminal box shall be of fabricated sheet steel. The main terminal
box shall be phase segregated type, unless otherwise agreed.
Motors can have elastimold phase insulated terminals in a common box. Ex d type (flame
proof) motors can have phase insulated terminal box of Exd rating whereas Ex p type
(pressurized) motors can have phase insulated terminal box of Ex d/Ex p rating. Ex d
(Flameproof) motors with non phase segregated & non phase insulated flameproof
terminal box duly tested at independent test laboratory can be considered acceptable
subject to motor manufacturer having adequate proven track record.
6.2.5 The terminal box must be of robust construction, with necessary clearance, creepage
distances between live parts and between live parts to earth considering air insulation and
without any compound filling.
6.2.6 The terminal box shall be provided with pressure relief flaps/devices for increase safety
i.e. Ex e motors, non-sparking i.e. Ex n motors and safe area motors, as per
manufacturer's standard.
6.2.7 The terminal box shall be capable of withstanding the fault current for a period of 0.25
seconds specified in the motor data sheet.
6.2.8 Appropriate phase markings as per IS shall be provided inside the terminal box. The
markings shall be non-removable and indelible.
Page 1371 of 2065

ENGINEERS
Og-u02eg INDIA LIMITED FOR HIGH VOLTAGE 1NDUCTION 6-51-0031 Rev. 5
1~1rrrmrr en 3,70.1)
MOTORS
(A Govt of ■rttha Undertalon91
Page 9 of 18
6.2.9 The terminal box shall be provided with entries for suitable cable glands corresponding to
the size of the specified cables.
Equipment and accessories provided shall conform to the hazardous area classification
and the environmental conditions as specified in the motor data sheet.
6.2.10 An adequately sized earth terminal shall be provided for cable armour termination. It is
essential that all metal parts (mounting rail and cable glands) are bonded and connected to
the earth system. Bonding straps are also required across joints on non-active parts.
6.2.11 Separate terminal boxes shall be provided for space heaters, resistance temperature
detectors and vibration probes.
6.2.12 Main and neutral terminal box covers must be provided with handles to facilitate easy
removal.
6.3 Motor casing and type of enclosure
6.3.1 All Motors shall be suitable for installation directly outdoor and must have degree of
protection corresponding to IP-55 as per IS.
6.3.2 All internal and external metallic parts, which can come into contact with cooling air
(Piping, air supply and discharge conduits, protective grills air deflectors, filters and
supports etc.) shall be of corrosion resistant material or appropriately treated to resist
corrosive agents which may be present in the atmosphere. Screws and bolts shall be of
rust proof material or protected against corrosion.
6.3.3 Effective equipotential bonding straps to guard against the occurrence of sparks due to
presence of circulating currents shall be provided in type Ex n, Ex e and Ex p motors.
6.4 Bearing and lubrication
6.4.1 Motors shall have grease lubricated ball or roller type bearings or of the manufacturer's
standard type. However, 2 pole motors above 750 kW rating shall be provided with
sleeve bearings as a minimum. Sleeve bearings when provided shall be of proven design.
6.4.2 The bearings shall be chosen to give a minimum L- 10 rating life of 5 yrs. (40,000 hrs) at
rated operating conditions.
(The L -10 rating life is the number of hours at constant speed that 90 % of a group of
identical bearings will complete or exceed before the first evidence of the failure ).
6.4.3 Where bearing supports are attached to the motor casing adequate bracing shall be
provided on these supports to reduce vibrations and ensure long life of the bearings.
Bearings shall be adequate to absorb axial thrust in either direction produced by the motor
itself or due to shaft expansion.
6.4.4 Motor bearings exposed to high temperatures (e.g. motors for hot oil/boiler feed pumps)
shall have adequate provisions for cooling of bearings.
6.4.5 Vertical motors shall be provided with thrust bearings suitable for the load imposed by
the driven equipment.
6.4.6 Motors shall be designed to permit removing/replacement of bearings.
Page 1372 of 2065

ENGINEERS
$1g-ar INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
vnrnav on.intatIO (A Govt of India Undettaking)
MOTORS Page 10 of 18
6.4.7 Grease lubricated bearings
Bearings shall be capable of grease injection from outside without removal of covers.
The bearing boxes shall be provided with labyrinth seals, to prevent loss of grease or
entry of dust or moisture. When grease nipples are provided, these shall be associated,
where necessary, with appropriately located relief devices, which ensure passage of
grease through the bearings.
The motors shall have facility for on-line greasing.
6.4.8 Sleeve bearings
Sleeve type bearings shall be fitted with oil rings for continuous lubrication. The oil
reservoirs shall have a form suitable for allowing settling of any solids or residual
particles contained in the oil.
The covers shall be provided with suitable openings for adding and draining oil, together
with an overflow plug and level indication. The shaft shall have perfect seals so as to
prevent entry of dust or moisture.
6.4.9 Forced lubrication bearings
The oil lubrication system shall be independent of the driven machine. Common
lubrication system for the driven equipment and the motor can be accepted provided it is
separate from the seal oil system. The common lubrication system shall be provided with
suitable degassing equipments to extract gas reducing the probability of gas entering the
motor.
In the independent lubrication system, oil supply shall be guaranteed by one of the
following methods:
With a mechanical pump co-axial with the motor and supplemented by a separate
electric motor driven pump for initial lubrication during start up and stopping
operations.
With a separate electric motor driven pump. In this case the lubricating system
shall consist of two identical motor driven pumps, one running and one acting as
standby.
In addition to the pumps, the lubrication system shall be supplied complete with the
following as a minimum:
a) An oil cooler of shell and tube type with tubes of inhibited admiralty brass.
Internal coolers shall not be accepted. To prevent the oil from being
contaminated, if the cooler fails, the oil side operating pressure shall be higher
than the water side operating pressure.
b) An austenitic stainless steel oil reservoir with the following characteristic :
The capacity to avoid frequent filling, to provide adequate allowance for system
rundown and to provide a retention time of at least 3 minutes to settle
Provision to eliminate air and minimize flotation of foreign matter to the pump
suction
Page 1373 of 2065

■
31 ENGINEERS
$.1gzff 02&g INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
‘1,1,3~ IA Govt ot Ind,a UnclertaNingt
Fill connections, reflex type level indicators and breathers suitable for outdoor
use
Sloped bottoms and connections for complete drainage
Clean out openings as large as is practicable
A bypass line that returns below the oil level to eliminate aeration and static
electricity
A thermostat with two electrical contacts for alarm & tripping in case of high oil
temperature
c) A supply and return system
d) A duplex full flow filter with replaceable elements and filtration of 25 tm

nominal or finer as recommended by the bearing manufacturer. Filter cartridge
material shall be corrosion resistant. Metal mesh or sintered metal filter elements
shall not be acceptable. The filter shall not be equipped with a relief valve or an
automatic bypass
e) The motor driven auxiliary pumps shall be provided with suction stainer and an
automatic/manual control system arranged to start automatically on low oil
pressure and with manual shutdown only
0 Sight flow indicators in each bearing drain line
g) Temperature gauges (with thermowells) in the reservoir, after the oil cooler and
each bearing drain line
h) Low oil pressure alarm and shutdown switches
i) A pressure gauge (valved for removal) for each pressure level and a pressure
differential indicator to measure filter pressure drop
j) Thermostatically controlled electric immersion heater with a sheath of austenitic

stainless steel for heating the charge capacity of oil before start-up in cold
weather. The heating device shall have sufficient capacity to heat the oil in the
reservoir from the specified minimum site ambient temperature to the start-up
temperature, as required by the manufacturer, within 12 hours. The watt density
of heater shall not exceed 2.33 watts per sq. mm.
k) The oil pumps shall have steel casings unless they are enclosed in a reservoir. All
other oil containing pressure components shall be steel.
A control panel shall be provided for operation & control of the lubrication system. The
control panel shall include fuses, electrical contactors and thermal relays for the
protection and operation of the motor driven pumps, push-buttons, auxiliary relays and
timer relays for the automatic and manual starting up and shutting down of the oil pump.
Equipment and accessories provided shall conform to the hazardous area and the
environmental conditions specified in the motor data Sheet.
Armoured cables suitable for high temperature duty shall be used for extemal electrical
connections between the control panel and the lubrication system.
Page 1374 of 2065

■
31 ENGINEERS
51g-ar 051eg INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
t-Ircort'as■ JOONO GoN of Indu UnOeflaking)
6.4.10 Bearing Insulation-Shaft Voltage
Induced voltage at the shaft end of the motor at no load shall not exceed 250 mV r.m.s.
for roller and ball bearings and 400 mV r.m.s. for sleeve bearings. The non driving end
bearing shall be insulated from the motor frame to avoid circulating current.
The insulated bearing end shield or pedestal shall bear a prominent warning and
manufacturer shall provide detailed drawings showing insulation arrangement.
6.5 Cooling System
All motors shall preferably be self-ventilated. Motors with higher outputs having
manufacturer's standard designs using forced ventilation cooling or closed circuit cooling
employing external coolants may also be considered.
6.5.1 Self Ventilated Motors
A11 motors shall be fan cooled. The fans shall be of corrosion resistant material and
appropriately protected. For fertilizer plants, brass or bronze are not permitted materials.
The material of fan for motors to be used in hazardous areas shall be anti-static and non-
sparking type.
Motors for installation in dusty atmospheres or in the presence of sand, fuels or other
suspended solid particles in the air shall be fitted with filters for the cooling air. The
filters shall be easily accessible for inspection and removable for cleaning and re-use. The
material of the filters and supports trays shall be rust proof or protected against oxidation
or corrosion.
6.5.2 Motors with forced ventilation
Motors with forced ventilation shall be equipped with two motor driven fans each capable
of supplying the full quantity of cooling air required by the motor at full load.
Where air cooler design permits provision of one fan only; the second fan shall be
supplied loose. Cooler design shall allow easy replacement of fan in such case.
The ventilating system shall include the flanges for the air intake and the mating flanges
for the discharge ducts. An airflow indicator as described in paragraph 7.3 (a) shall also
be provided.
Motors and fans used for forced ventilation shall conform to the hazardous area
classification and environmental conditions specified in the motor data sheet.
6.5.3 Motors with closed circuit cooling with water to air heat exchangers
The material of the heat exchangers shall be corrosion resistant (e.g. cupro-nickel alloy,
muntz metal, admiralty brass) and suitable for the type of water used. The heat
exchangers shall be designed for minimum water pressure of 5 kg / cm 2 and with head
losses not greater than 0.5 kg / cm 2 , unless otherwise agreed.
The heat exchangers shall be arranged by the side(s) of the motor, if possible. Screens
shall be provided to protect the motor windings from water leaks or leakage in the tubes.
Suitable drains shall be fitted for draining water in case of leakage. The cooling system
Page 1375 of 2065

ENGINEERS
Og'w £42es
(.1127,,,,man.3~1
INDIA LIMITED
IA Govt of Undertak,o9)
FOR HIGH VOLTAGE INDUCTION
MOTORS
6-51-0031 Rev. 5
Page 13 of 18
shall include the trip and alarm devices mentioned in paragraph 7.3 (b). Heat exchangers
for identical motors shall be interchangeable.
6.5.4 Motors with closed circuit cooling with air to air heat exchangers
The heat exchanger tubes shall be of steel or extruded aluminium. All exposed surfaces of
the heat exchanger and of the motors shall be safeguarded against corrosion by
immersion in varnish followed by baking.
Joints between the heat exchanger and the main body of the motor shall be sealed by
weather-proof gaskets.
6.6 Rotor
The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration
level and a long service Life to the bearings. The accepted values of vibrations for a motor
at rated voltage and speed shall not exceed those given in the IS. The shaft ends shall be
provided with suitably threaded hole or holes to facilitate the assembly or removal of
couplings and bearing races.
6.7 Shaft extension
Motors shall be provided with a single, bare shaft extension with key way and key.
Motor shaft shall be sized to withstand 10 times the rated design torque.
6.8 Lifting hooks
All motors shall be provided with lifting facility (i.e. hooks etc.) of adequate capacity.
For motors provided with heat exchangers, lifting facility shall also be provided for the
heat exchanger.
6.9 Earth terminals
Two earth terminals shall be provided on the frame of each motor at diametrically
opposite points. Minimum size of the stud shall be 12 mm. Necessary nuts and spring
washers shall be provided for earth connection. These earth terminals shall be in addition
to the earth terminals provided in the terminal box for earthing of the armour.
7.0 CONTROL, ALARM AND TRIP DEVICES
All electrical contacts for the devices described below (e.g. at sections 7.3 & 7.4) shall
have a current carrying capacity not lower than 5 A and a minimum interrupting capacity
of 1 A at 220 V DC or 5 A at 240 V AC.
The contacts shall be located in explosion proof or totally sealed housing according to the
type of motor enclosure. The cable ends shall be brought together to the terminal box.
Any external connections between the housing containing the relay contacts and the
terminal box shall be carried out by insulated copper wires in steel conduits or by PVC
insulated, armoured, copper conductor cables with cable entries through double
compression type cable glands.
Page 1376 of 2065

-

ENGINEERS
5-fg-ar Ofdl
eg INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
tmZrt ofsfewfut~) Govt of Indw Undertaking)
IA
7.1 Measurement of winding temperature
Motors with outputs greater than 750 KW or those provided with filters for cooling air
irrespective of output shall be provided with platinum resistance temperature measuring
devices of 100 ohms resistance at 0°C and a temperature co-efficient of 3.85 x 10 -3
located in suitable positions to measure the winding temperature. A minimum of three
(one per phase) detectors shall be provided between the coil sides to measure the winding
temperature and three (one per phase ), preferably at the base of the slots, to measure core
temperature, each placed 120° apart. TETV motors may not be provided with core
temperature detectors.
A separate terminal box shall be provided for the temperature detectors for hook up with
a remote located control / monitoring unit.
7.2 Measurement of bearing temperature
Motors with sleeve type self-lubricated bearing shall be provided with :
a) Two mercury bulb type, indicating dial thermometers for checking of bearing
temperatures.
b) For motors with output greater than 750 KW, a resistance type of temperature
measuring device shall be provided for bearings with connections terminating in
the common terminal box for winding temperature detectors.
7.3 Measurement of cooling medium for heat exchangers
Motors with forced ventilation and those with air water heat exchangers shall be provided
with:
a) An airflow circulation indicator with electrical trip contacts that operate if the
flow of cooling air is interrupted or is inadequate.
b) A cooling water flow circulation indicator with electrical trip contacts, which
close if the flow of cooling water is interrupted or is inadequate. The indicator
shall be located on the discharge piping of the heat exchanger.
7.4 Pressurization Control Panel
All pressurized motors (Type Ex p) shall be provided with a control panel for controlling
the initial purging and pressurization of the motor. The pressurization control panel shall
be mounted on the motor itself and shall be suitable for the hazardous area classification
specified in the motor data sheet.
The panel shall be complete with but not limited to the following items :
Timers
Push buttons for purging/pressurization
Solenoid valves/dampers
Indicating lamps for purging ON, purging OVER etc.
Pressure switches and flow switches with alarm and trip contacts.
8.0 MISCELLANEOUS ACCESSORIES
8.1 Current transformers
Unless otherwise specified, motors rated 1500 KW and above shall have differential
protection and shall be equipped with current transformers suitably designed for
installation in the neutral terminal box.
Page 1377 of 2065

ENGINEERS
$'gzrr IMfdleg INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
e../cnfc',
771~1) IA Govt of looia Undedakongi
Unless otherwise specified, the CTs shall be supplied along with the motor and mounted
in the terminal box, which shall be suitable for housing the CTs and providing the
necessary connections. CT terminals shall be brought out to a separate auxiliary terminal
box.
These transformers shall have a secondary current of 1 A, and the characteristics of the
CTs (Vk, RcT and Im) shall be finalized at detailed engineering stage in consultation with
the purchaser. CT ratio shall be as indicated in the motor data sheet.
8.2 Anti condensation heaters
All motors shall be provided with 240 V anti-condensation heaters, sized and located so
as to prevent condensation of moisture during shut down periods. The heaters shall
remain 'ON' when the motor is not in service and shall not cause damage to the windings.
Motors with heaters installed in hazardous atmospheres (Zone-1 or Zone-2), shall

conform to the provisions of applicable Indian standards and temperature classification
specified in the motor data sheet.
The heater leads shall be brought out to a separate terminal box of the same specification
and grade of protection as the main power terminal box.
A warning label with indelible red inscription shall be provided on the motor to indicate
that the heater supply shall be isolated before carrying out any work on the motor.
8.3 Special tools and spanners
Motors with special features (e.g. motors with single bearing, explosion proof and
increased safety motors) shall be provided with a set of spanners and special tools,
required for dismantling and maintenance of the motor.
8.4 Motors shall be supplied complete with double compression Nickel plated brass (or
Aluminum, if specifically required) cable glands, crimp type tinned Cu cable lugs for all
power, space heater and auxiliary cables (for the specified cable sizes) and first filling of
lube oil for forced lubricated bearings.
8.5 Auxiliary motors, if any, shall be as per relevant Indian / International standards and shall
be suitable for the hazardous classification as specified in the motor data sheet.
8.6 Name plates
A stainless steel name plate manufactured from series 300 stainless steel and having
information as per IS shall be provided on each motor. In addition to the motor rating
plate, a separate number plate for motor tag number shall be fixed in a readily visible
position. This number shall be as per the motor data sheets.
Additional information as stipulated in applicable Standards shall be included in the name

plate for motors meant for use in hazardous atmospheres.
Page 1378 of 2065

ENGINEERS
off INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
til2R c0vente11
,1,11r0,-.0 Govt 01 In0. Undeltaking)
9.0 NOISE LEVEL
The permissible noise level shall not exceed the stipulations laid down in IS.
10.0 MOTOR VIBRATION
Motor vibrations at bearing housing shall be within the limits of IS, unless otherwise
specified for the driven equipment. Limits of shaft vibration for motors with sleeve
bearings shall be as per IEC-60034-14.
Two and four pole motors having sleeve bearings with forced oil lubrication shall be
provided with proximity probes to measure the shaft vibration adjacent and relative to the
bearings.
11.0 CRITICAL SPEEDS
The first actual critical speed of stiff rotors shall not be lower than 125% of the
synchronous speed. For flexible rotors, this shall be between 60% and 80% of the
synchronous speed. The second actual synchronous speed shall be above 125% of the
synchronous speed.
12.0 PAINTING
All metal surfaces shall undergo manufacturer's standard cleaning /painting cycle. After
preparation of the under surface, the equipment shall be painted with two coats of epoxy
based final paint. Color shade of final paint shall be 632 of IS: 5/ RAL-7035. All
unpainted steel parts shall be suitably treated to prevent rust formation. If these parts are
moving elements, then these shall be greased.
13.0 INSPECTION AND TESTING
13.1 All tests shall be carried out at manufacturer's shop under his care and expense.
13.2 The manufacturer shall submit all internal test records of the tests carried out by him on
the bought-out items, motor sub-assembly and complete motor assembly.
13.3 All the type, routine and other acceptance tests shall be witnessed by EIL Inspector/TPIA
(appointed by OEM supplier.)
13.4 Tests certificates duly signed by the EIL Inspector/TPIA (appointed by OEM supplier.)
shall be a part of final documentation.
The following type tests (on one motor of each rating and frame size) shall be carried out
as per applicable Indian Standards and shall form part of acceptance testing :
a) Full load test and measurement of voltage, current, power & slip
b) Measurement of starting torque, starting current, full load torque and pull out
torque
c) Measurement of efficiency and p.f. at 100%, 75% and 50% load
d) Temperature rise test
e) Momentary overload test
f) Tan delta test
g) Measurement of noise level
i) Over speed test
i) Measurement of radial & axial clearance between fan & stationary parts &
measurement of radial air gap (if provision for measurement is not available in
fully assembled motor stage records/calculations to be reviewed by Inspection)
Page 1379 of 2065

ENGINEERS
$ifg-ar ca INDIA LIMITED FOR HIGH VOLTAGE INDUCTION 6-51-0031 Rev. 5
C1,4>T2 J‘rcr.4 A Govt of Incha Undertakm91 MOTORS Page 17 of 18
13.5 Routine tests shall be carried out on all motors.

The manufacturer shall carry out routine tests as per applicable Indian Standards. Routine
tests not limited to the following shall form part of acceptance testing:
a) General visual checks/dimensional check, name plate details including punching
of statutory references.
b) Verification of type of terminals ( for Ex e , Exd & Ex n motors )
c) Free rotation of shaft, direction of rotation
d) Measurement of winding resistance
e) Reduced voltage starting and running at no load.
f) No load test and measurement of voltage, speed current, wattage
g) Locked rotor test at reduced voltage and measurement of voltage, speed, current,
wattage
h) Insulation resistance test ( before & after high voltage test )
i) Polarisation index
j) High voltage test
k) Vibration measurement (under no load)
I) Measurement of shaft vibrations in case of sleeve bearing motors
m) Verification of mark of End play on shaft and measurement of end play, incase of
sleeve bearing motors.
n) Bearing noise
o) Shaft voltage
p) Resistance measurement of space heaters, RTDs & BTDs
q) Operation of control panel ( for Ex-p motors )
r) Tests on the Ex d enclosures as per IS
13.6 The manufacturer shall submit the following certificates for verification by the
EIL/Owner's Inspector:
a) Test certificate from recognised testing laboratory for area classification.
b) BIS certificate for indigenous FLP motors and accessories as applicable.
c) CCOE/PESO approved certificates for motors and accessories as applicable
d) Fault level of terminal box
e) Degree of protection of enclosure
f) Impulse test certificate for coils
g) Hydraulic test certificate for coolers
13.7 For VFD fed motors, all tests as specified in the VFD specification shall be followed in
addition to the above.
13.8 In case any of the Type & Routine tests mentioned above can not be carried out due to
manufacturer's test bed limitations etc., altematively calculations to establish the required
parameters as per International codes eg IEC, JEC etc. may be accepted which shall be
furnished to attending inspector. However, acceptance of calculations in place of actual
test shall be with prior approval (agreement between motor manufacturer & purchaser).
13.9 Though the motors shall be accepted on the basis of the satisfactory result of the testing at
the shop, it shall not absolve the Vendor from liability regarding the proper functioning of
the motors coupled to the driven equipment at site.
14.0 CERTIFICATION
The motors and associated equipment shall have test certificates issued by recognised
independent test house (CIMFR/ CPRI/ ERTL/ Baseefal LCIE/ UL/ FM or equivalent).
All indigenous motors shall conform to Indian standards and shall be certified by Indian
testing agencies. All motors (indigenous & imported) shall also have valid statutory
Page 1380 of 2065

31 ENGINEERS
Ogu 2f51-dg
'
,~ s-frcnr2 M,3,1-0.1)
(A Govt ol InOia Undedaking)
approvals (e.g. PESO, DGMS etc. as applicable for the specified location. All indigenous
flameproof motors shall have valid BIS license and marking as required by statutory
authorities.
All the equipment shall be divided into several sections for protection and ease of
handling during transportation. The equipment shall be properly packed for
transportation by ship/rail or trailer. The equipment shall be wrapped in polythene sheets
before being placed in crates/cases to prevent damage to finish. Crates/cases shall have
skid bottom for handling. Special notations such as Tragile', `This side up', `Centre of
gravity', `Weight', Òwner's particulars', `PO Nos.' etc. shall be clearly marked on the
package together with other details as per purchaser order.
shall be completely suitable for outdoor storage in areas with heavy rains/high ambient
temperature, unless otherwise agreed.
Page 1381 of 2065

ENGINEERS FOR
6-51-0032 Rev. 5
Weg
Ivoitot vvrcore 051,10S.
INDIA LIMITED
IA Govt ol India Undertalongt
MEDIUM VOLTAGE INDUCTION
MOTORS Page 1 of 15
f-~
SPECIFICATION
FOR
MEDIUM VOLTAGE
INDUCTION MOTORS

5 02.05.14 SA VKJ BRB SC
SPECIFICATION
REVISED AND ISSUED AS STANDARD BRB
4 26.09.07 SD JMS VC
SPECIFICATION
3 09.04.02 REVISED AND RE-ISSUED UG AAN VPS SKG

2 01.02.97 AAN VPS SG AS
SPECIFICATION
1 26.07.84 ISSUED AS STANDARD SPECIFICATION CSM VPS GNT

Standards Standards
Prepared Checked
No by by
Approved by
Page 1382 of 2065

k31 ENGINEERS FOR
c-tvotrt om.loo,) IA Govt of India Unclettatongt MEDIUM VOLTAGE INDUCTION
MOTORS Page 2 of 15
Abbreviations:
BASSEFA British Approvals Service for Electrical Equipment in Flammable Atmospheres

CIMFR Central Institute of Mines and Fuel Research
FM Factory Mutual
FRP Fiberglass Reinforced Plastic
IEC International Electro-technical Commission
IEEE Institute of Electrical & Electronics Engineers
IS Indian Standard
JEC Japanese Electro-technical Committee
LCIE Laboratoire Central des Industries Electriques
LRWT Locked Rotor Withstand Time
PO Purchase Order
p.u. per unit
r.m.s Root Mean Square
RPM Revolutions per Minute
TETV Totally enclosed Tube Ventilated
UL Underwriter's Laboratories
DOL Direct On line
VFD Variable Frequency Drive
OEM Original Equipment Manufacturers
TPIA Third party Inspection Agency
PESO Petroleum & Explosives Safety Organisation

Mr. Parag Gupta
Mr. M.K. Sahu
Mr. A.K. Chaudhary
Ms. N.P. Guha
Page 1383 of 2065

ENGINEERS FOR
fafj1 -g
NRR cv,nrc,0,1 .~1)
INDIA LIMITED
(A Govt of indla Underta(ong(
6-51-0032 Rev. 5
MOTORS Page 3 of 15
CONTENTS
1.0 SCOPE 4
4.0 OPERATING CONDITIONS 5
5.0 PERFORMANCE 6
6.0 CONSTRUCTION DETAILS 10
7.0 MISCELLANEOUS ACCESSORIES 14
8.0 CRITICAL SPEEDS 14
9.0 PAINTING 14
11.0 CERTIFICATION 15
Page 1384 of 2065

ENGINEERS FOR
Og-
ar
>11277 J021,
71, IA Govt of lnela Undeflakingf MEDIUM VOLTAGE INDUCTION
MOTORS Page 4 of 15
1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of three phase
medium voltage squirrel cage induction motors for line voltages upto 1000V AC.
2.1 The squirrel cage induction motors and their components shall comply with the latest editions
of following standards issued by BIS.
IS - 5 : Colors for ready mixed paints and enamels.

IS - 325 : Three phase induction motors.
IS - 1076 : Preferred numbers.
IS - 1231 : Dimensions of three phase foot mounted induction motors.
IS - 1271 : Thermal evaluation and classification of electrical insulation.
IS - 2223 : Dimensions of flange mounted AC Induction motors.
IS - 2253 : Designation for type of construction and mounting arrangement of
rotating electrical machines.
IS - 2254 : Dimensions of vertical shaft motors for pumps.
IS - 2968 : Dimensions of slide rails for electric motors.
IS - 4029 : Guide for testing three phase induction motors.
IS - 4889 : Method of determination of efficiency of rotating electrical machines.
IS - 6362 : Designation of methods of cooling of rotating electrical machines.
IS - 7816 : Guide for testing insulation resistance of rotating machines.
IS - 8223 : Dimensions and output series for rotating electrical machines.
IS - 8789 : Values of performance characteristics for three phase induction
motors.
IS - 9283 : Motors for submersible pump sets.
IS - 12065 : Permissible limits of noise level for rotating electrical machines.
IS - 12075 : Mechanical vibration of rotating Electrical Machines with shaft
heights 56 mm and higher - measurement, evaluation and limits of
vibration severity.
IS - 13529 : Guide on effects of unbalanced voltages on the performance of three
phase cage induction motors.
IS - 13555 : Guide for selection and application of three phase induction motors for
different types of driven equipment.
IS - 14568 : Dimensions and output series for rotating electrical machines, frame
numbers 355 to 1000 and flange numbers 1180 to 2360.
IS-15880 : Three phase cage induction motors when fed from IGBT Converters-
Application guide
IS-15881 : Three phase cage induction motors specifically designed for IGBT
converter supply
IS /IEC 60079-0 : Electrical apparatus for explosive gas atmospheres (General
Requirements)
IS/IEC 60079-1 : Equipment protection by Flame proof enclosures "d'.
IS/IEC 60079-7 : Explosive atmospheres-Equipment protection by increased safety —"e"
IS/IEC 60079-15 : Electrical apparatus for explosive gas atmospheres Construction, test
& marking of type of protection "n"
IS/IEC 60529 : Degree of protection provided by enclosures (IP Code)
IS/IEC 60034-5 : Degrees of protection provided by enclosure for rotating electrical
machinery.
IS/IEC 60034-8 : Terminal marking and direction of rotation for rotating electrical
machinery.
Page 1385 of 2065

II ENGINEERS FOR
$g2:1[
>IRPI
02e
— g
051,40,.1) A Govt ol Indu UndeAaking)
MOTORS Page 5 of 15
2.2 In case of imported motors, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian Standards.
2.3 The motors shall also conform to the provisions of CEA regulations and other statutory
2.4 In case Indian Standards are not available, standards issued by IEC/ BS/ VDE/ IEEE/
JEC/NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents, the
most stringent one shall prevail. However, owner's decision in this regard shall be final and
binding.
3.1 The offered equipment shall be brand new with state of the art technology and proven field
phasing out the product/spares to ensure the end user for placement of order for spares and
services.
4.0 OPERATING CONDITIONS
4.1 Ambient Conditions
Motors shall be suitable for operating satisfactorily in humid and corrosive atmosphere found
in refineries, petrochemical, fertilizer and metallurgical plants. Service conditions shall be as
specified in the motor data sheet. If not specifically mentioned therein, a design ambient
temperature of 40°C and an altitude not exceeding 1000 meters above mean sea Level shall be
taken into consideration.
4.2 Frequency and Voltage Variations
Unless otherwise agreed, motors shall be designed for continuous operation at rated output
under the following conditions:
a) The terminal voltage differing from its rated value by not more than V 6 % or
b) The frequency differing from its rated value by not more the V 3 % or
c) Any combination of (a) and (b)
4.3 Starting
a) Motors shall be designed for direct-on-line starting or other method of starting as

specified in datasheet.
b) Motors shall be designed for re-acceleration under full load after a momentary loss of
voltage with the residual voltage being 100% and in phase opposition to the applied
voltage.
c) Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds
under cold conditions and 8 seconds under hot conditions. In addition, Locked Rotor
withstand time under hot conditions at 75% & 100% voltages, shall be minimum 1.4
times the starting time at the corresponding voltage.
Page 1386 of 2065

ENGINEER.S FOR
$1g-ar Odj
eg INDIA LIMITED MEDIUM VOLTAGE INDUCTION
6-51-0032 Rev. 5
I Nf"1,1 ,V1 .3~1 IA GoN ol Ind. Undertakingi
MOTORS Page 6 of 15
d) Al1 motors shall be suitable for starting under specified load conditions with 75 % of
the rated voltage at the motor terminals.
e) Motors shall be designed to allow the minimum number of consecutive starts

indicated in Table below:
Starts Min. no. of consecutive starts

No. of consecutive start-ups with initial temp. of
3
the motor at ambient level (cold)
No. of consecutive start-ups with initial temp. of
2
the motor at full load operating level (hot).
4.4 Direction of Rotation
Motors shall be suitable for either direction of rotation. In case unidirectional fan is provided
for motors, direction of rotation for which the motor is designed shall be permanently
indicated by means of an arrow. When a motor is provided with bi-directional fan, a double-
headed arrow should be provided.
Normally, clockwise rotation is desired as observed from the driving (coupling) end, when the
terminals ABC are connected to a power supply giving a terminal phase sequence in the order
ABC. Counter-clockwise rotation of the motor shall be obtained by connecting the power
supply to terminals so that the phase sequence corresponds to the reversed alphabetical
sequence of the terminal letters. Ample space shall be provided at the terminal box for
interchanging any two external leads for obtaining the reverse phase sequence.
5.0 PERFORMANCE
5.1 Unless otherwise specified, Motors shall be rated for continuous duty (S1).
5.2 Unless otherwise specified, the starting current (as % rated current) shall not exceed 600%
(subject to IS tolerance). However, motors upto 22KW motors having starting current upto
700% of rated current (subject to IS tolerance) shall also be acceptable.
5.3 In particular cases, when the starting current is to be limited, care shall be taken such that the
design values of torque meets the load requirement while at the same time complying to
clause 4.3 above of this specification.
5.4 In particular cases, when the starting with reduced voltage is specified, care shall be taken
such that the design values of torque meets the load requirement while at the same time
complying to clause 4.3 above of this specification.
5.5 Starting torque and minimum torque of the motor shall be compatible with the speed torque
curve of the driven equipment under specified starting and operating conditions.
In case where characteristics of driven equipment are not available while selecting the motor,
minimum starting torque shall be 110% of rated value for motors up to 75 kW and shall be
90% of rated value for motors above 75 kW.
5.6 The breakdown torque at the rated voltage shall not be less than 175 percent of the rated load
torque with no negative tolerance. the breakdown torque shall not exceed 300 percent of the
rated load torque.
In case of motors driving equipment with pulsating loads (e.g. reciprocating compressors), the
minimum value of breakdown torque at 75 percent of the rated voltage shall be more than the
peak value of pulsating torque and the current pulsation shall be limited to 40%.
Page 1387 of 2065

ENGINEERS FOR
(A Govt ol indw Undertaking) MEDIUM VOLTAGE INDUCTION
MOTORS Page 7 of 15
5.7 Motors fed by variable frequency drive shall additionally meet the following requirements:-
5.7.1 The motors shall be suitable for the current wave forms produced by the power supply
including harmonics generated by the drive. The necessary coordination by motor
manufacturers with drive manufacturers regarding harmonics generated by VFD shall be taken
care and incorporated in motor design suitably.
5.7.2 The motors shall be designed to operate continuously at any speed over the range as per
process requirement with minimum range as 10-100% of rated speed or as specified in data
sheet. The characteristics shall be based on the application - in terms of constant torque /
variable torque as per the driven equipment. Additional cooling fan shall be provided if
required to limit the temperature rise to specified limits.
5.7.3 The motors shall withstand torque pulsation resulting from harmonics generated by the solid
state power supply.
5.7.4 The motors required to be transferred to DOL bypass mode shall be rated for specified
variations in line voltage and frequency.
5.8 The minimum values for performance characteristics of motors shall be as per Table 1-4 below
TABLE 1
Values of Performance Characteristic of 2 Pole Induction Motors
Rated Frame Full Full Breakaway Breakaway Nominal
output Designation Load Load Torque in Current in Terms Efficiency
speed Current terms of Full of full Current,
load Torque Equal or Below
(Refer cl. 5.2)
Min Max
kW Rev/min Amp Min (Percent) (Percent) (Percent)
(1) (2) (3) (4) (5) (6) (8)

0.37 71 2790 1.2 170.0 600 66.0
0.55 71 2760 1.6 170.0 600 70.0
0.75 80 2780 2.0 170.0 600 73.0
1.1 80 2790 2.8 170.0 600 76.2
1.5 90S 2800 3.7 170.0 600 78.5
2.2 90L 2810 5.0 170.0 600 81.0
3.7 100L 2820 8.0 160.0 600 84.0
5.5 132S 2830 11.0 160.0 600 85.7
7.5 132S 2840 15.0 160.0 600 87.0
9.3 160M 2840 18.5 160.0 600 87.7
11.0 160M 2860 21.5 160.0 600 88.4
15.0 160M 2870 29.0 160.0 600 89.4
18.5 160L 2880 35.0 160.0 600 90.0
22.0 180M 2890 41.5 160.0 600 90.5
30.0 200L 2900 54.0 160.0 600 91.4
37.0 200L 2900 67.0 160.0 600 92.0
45.0 225M 2955 80.0 160.0 600 92.5
55.0 250M 2960 95.0 160.0 600 93.0
75.0 280S 2970 130.0 160.0 600 93.6
90.0 280M 2970 150.0 160.0 600 93.9
110.0 315S 2980 185.0 160.0 600 94.0
125.0 315M 2980 209.0 160.0 600 94.5
132.011 315M 2980 220.0 160.0 600 94.5
160.011 315L 2980 265.0 160.0 600 94.8
NOTE: - Output to frame size relation is maintained in accordance with IS 1231 for all
motors, except those marked as 11 , where in frame size indicated is `preferred frame size'.
Page 1388 of 2065

‘31 ENGINEERS FOR
(A Govt of india Undertaking) MEDIUM VOLTAGE INDUCTION
MOTORS Page 8 of 15
TABLE 2
Values of Performance Characteristic of 4 Pole Induction Motors.

(Refer cl. 5.2)
Min Max
(1) (2) (3) (4) (5) (6) (8)
0.37 71 1330 1.4 170.0 600 66.0
0.55 80 1340 1.7 170.0 600 70.0
0.75 80 1360 2.2 170.0 600 73.0
1.1 90S 1370 2.9 170.0 600 76.2
1.5 90L 1380 3.8 170.0 600 78.5
2.2 100L 1390 5.1 170.0 600 81.0
3.7 112M 1410 8.1 160.0 600 84.0
5.5 132S 1420 11.4 160.0 600 85.7
7.5 132M 1430 15.4 160.0 600 87.0
9.3 160M 1430 18.5 160.0 600 87.7
11.0 160M 1440 22.0 160.0 600 88.4
15.0 160L 1440 30.0 160.0 600 89.4
18.5 180M 1440 36.0 160.0 600 90.0
22.0 180L 1440 43.0 160.0 600 90.5
30.0 200L 1450 56.0 160.0 600 91.4
37.0 225S 1450 69.0 160.0 600 92.0
45.0 225M 1460 84.0 160.0 600 92.5
55.0 250M 1460 99.0 160.0 600 93.0
75.0 280S 1470 134.0 160.0 600 93.6
90.0 280M 1470 164.0 160.0 600 93.9
110.0 315S 1480 204.0 160.0 600 94.4
125.0 315M 1480 234.0 160.0 600 94.7
132.011 315M 1480 247.0 160.0 600 94.7
160.011 315L 1480 288.0 160.0 600 95.0
Page 1389 of 2065

ENGINEERS FOR
Igaffa25 INDIA LIMITED 6-51-0032 Rev. 5
I NT, IA Govt ot Incha Undettak,ngt MEDIUM VOLTAGE INDUCTION
MOTORS Page 9 of 15
TABLE 3

(Refer cl. 5.2)
Min Max
(1) (2) (3) (4) (5) (6) (8)
0.37 80 870 1.4 160.0 600 65.0
0.55 80 870 1.9 160.0 600 68.0
0.75 90S 890 2.3 160.0 600 71.0
1.1 90L 900 3.2 160.0 600 74.0
1.5 100L 900 4.0 160.0 600 76.0
2.2 112M 910 5.5 150.0 600 79.0
3.7 132S 920 8.8 150.0 600 82.5
5.5 132M 920 12.7 150.0 600 84.5
7.5 160M 930 16.7 150.0 600 86.0
9.3 160L 930 20.5 140.0 600 87.0
11.0 160L 935 23.0 140.0 600 87.5
15.0 180L 940 30.5 140.0 600 88.5
18.5 200L 940 37.5 140.0 600 89.5
22.0 200L 945 44.0 140.0 600 90.0
30.0 225M 945 59.0 140.0 600 91.0
37.0 250M 950 72.0 140.0 600 91.5
45.0 280S 960 87.0 140.0 600 92.0
55.0 280M 960 107.0 140.0 600 92.5
75.0 315S 970 145.0 140.0 600 93.0
90.0 315M 970 175.0 140.0 600 93.3
110.011 315M 970 214.0 140.0 600 93.5
132.011 315L 980 257.0 140.0 600 93.8
Page 1390 of 2065

5 tll ENGINEERS FOR
Z:Er 02eg
IA Govt of ind,a Undettalongi
TABLE 4

(Refer cl. 5.2)
Min Max
(1) (2) (3) (4) (5) (6) (8)
0.37 90S 640 1.5 150.0 600 62.0
0.55 90L 640 2.1 150.0 600 67.0
0.75 100L 650 2.7 150.0 600 70.0
1.1 100L 660 3.5 150.0 600 72.0
1.5 112M 670 4.5 150.0 600 74.0
2.2 132S 680 6.1 140.0 600 77.0
3.7 160M 690 9.8 140.0 600 80.0
5.5 160M 690 14.2 140.0 600 82.5
7.5 160L 695 19.0 140.0 600 84.0
9.3 180L 700 23.0 140.0 600 85.0
11.0 180L 700 26.0 140.0 600 86.0
15.0 200L 705 35.0 130.0 600 87.0
18.5 225S 705 45.0 130.0 600 88.0
22.0 225M 710 52.0 130.0 600 88.5
30.0 250M 710 70.0 130.0 600 90.0
37.0 280S 710 86.0 130.0 600 90.5
45.0 280M 720 99.0 130.0 600 91.0
55.0 315S 720 118.0 130.0 600 91.5
75.0 315M 730 153.0 130.0 600 92.3
90.0 315L 730 182.0 130.0 600 92.8
110.011 315L 730 218.0 130.0 600 93.3
6.0 CONSTRUCTION DETAILS
6.1 Windings
6.1.1 Unless otherwise specified, Motors shall be provided with class 'B' insulation as a minimum.
In case of motors with class 'F' insulation, the permissible temperature rise above the
specified ambient temperature shall be limited to those specified in the applicable Indian
standards for class 'B' insulation.
6.1.2 The winding shall be tropicalised. The windings shall preferably be vacuum impregnated.
Alternately the windings shall be suitably varnished, baked and treated with epoxy gel for
operating satisfactorily in humid and corrosive atmospheres.
6.1.3 Windings shall be adequately braced to prevent any relative movement during operation. In
this respect, particular care shall be taken for the stator windings for direct-on-line starting
squirrel cage motors. Insulation shall be provided between coils of different phases that lie
together. Core laminations must be capable of withstanding burnout for rewind at 400EC
without damage or loosening.
Page 1391 of 2065

k31 ENGINEERS FOR
$1g- xfa2e INDIA LIMITED 6-51-0032 Rev. 5
IA Go,t of Unde■ taMm)
6.1.4 In case of motors driving equipment with pulsating loads, special care shall be taken for the
joints of rotor bars and end rings to avoid premature failures due to induced fatigue stresses
6.1.5 The windings shall be connected in delta. However, for motors rated 2.2 kW and below, star
connection may be accepted. In case of motors with star-delta starting, the motor windings
shall be fully insulated for delta connection.
6.1.7 The ends of the windings shall be brought out into a terminal box. These shall be terminated
by means of terminals mounted on an insulating base made of non-hygroscopic and non-
flammable material.
6.1.6 All motors shall be with six terminals and suitable links to connect them in star or in delta
except for motors rated up to and including 2.2 kW which may be accepted with three
terminals.
6.2 Terminal Box and Cable Entries
6.2.1 The terminal box shall be located on the right hand side as viewed from the driving (coupling)
end. The terminal box shall have side cable entry from non-driving end. However, as a special
case, terminal box located on top may also be accepted, particularly for hazardous area
motors, in case manufacturer has only TOP mounted terminal box design which is duly
tested/certified by CIMFR and approved by PESO/CCOE for installation in hazardous area.
The terminal box design shall allow rotation in steps of 90° to facilitate cable entry from any
direction.
6.2.2 Terminal box cover shall be provided with handles to facilitate easy removal. However, for
terminal box covers weighing less than 5 kg., terminal box covers without handles can be
accepted.
6.2.3 The terminal box shall be provided with entries for suitable cable glands corresponding to the
size of the specified cable. Crimp type tinned Cu lugs and nickel-plated brass (or aluminum if
specifically required), double compression type cable glands shall be supplied along with the
motors for the specified cable sizes for power and space heater cables.
6.2.4 For flameproof motors, terminal box can be provided in increased safety Èxe' execution.
Page 1392 of 2065

ENGINEERS FOR
fg`-ar£;125 INDIA LIMITED
IA Govt ot India Unclettakotg) MEDIUM VOLTAGE INDUCTION
6-51-0032 Rev. 5
6.2.5 The terminals, cable lugs, terminal box, cable entries and cable glands shall be suitable for the
maximum cables sizes as specified below for 2 pole, 4 pole or 6 pole motors:
Motor rating up to and including Size of phase conductor (mm2)

2.2 kW and below 4 A1./ 2.5 cu
3.7 kW 10 Al./ 6 cu
5.5 kW 16 Al./ 10 cu
7.5 kW 25 A1./ 16 cu
9.3 kW 25 Al./ 16 cu
11.0 kW 25 Al./ 16 cu
15.0 kW 50 Al.
18.5 kW 70 Al
22.0 kW 70 AI
30.0 kW 95 Al
37.0 kW 120 Al
45.0 kW 150 Al
55.0 kW 185 Al
75.0 kW 2x95 Al
90.0 kW 2x120 Al
110.0 kW 2x185 Al
125.0 kW/132 kW 2x240 Al
150.0 kW 2x240 Al
160.0 kW 2x240 Al
6.2.6 Cable sizes for motors having synchronous speeds 750 RPM and below shall be as agreed
between the purchaser and the manufacturer.
6.2.7 Cables used are of 650/1100 V grade aluminum conductor, PVC /XLPE insulated, PVC
extruded inner sheath, armoured with overall PVC sheath. However for cables up to &
including 16 mm2 cross-section, cables used may be with copper or aluminum conductor as
indicated in the motor data sheet.
6.3 Motor Casing and Type of Enclosure
6.3.1 The minimum degree of motor enclosures including terminal boxes and bearing housing shall
be IP-55 as per IS.
6.3.2 Motors for outdoor use shall be suitable for installation and satisfactory operation without any
protective shelter or canopy. Motor casing shall be provided with a suitable drain for removal
of condensed moisture except in case of flameproof motors (Type Ex d/Exde).
6.3.3 A11 internal and external metallic parts, which may come into contact with cooling air, shall be
of corrosion resistant material or appropriately treated to resist the corrosive agents, which
may be present in the atmosphere. Screws and bolts shall be of rust proof material or protected
against corrosion.
6.3.4 Unless otherwise agreed, motors shall have standard frame sizes for various output ratings as
stipulated in IS.
6.4 Bearing and Lubrication
6.4.1 Motors shall have grease lubricated ball or roller bearings. In all cases, the bearings shall be
chosen to provide a minimum L-10 rating Life of 5 years, (40, 000 hours) at rated operating
conditions.
Page 1393 of 2065

ENGINEER.S FOR
i(WR c.-werAcV1 JA0.0 (A GoN of Ind. Undeflak,ngi MEDIUM VOLTAGE INDUCTION
(The L-10 rating life is the number of hours at constant speed that 90% of a group of identical
bearings will complete or exceed before the first evidence of failure).
6.4.2 The bearings shall be adequate to absorb axial thrust produced by the motor itself or due to
shaft expansion. Motors designed to handle external thrust from the driven equipment shall be
supplied with a thrust bearing at the non-driving end.
6.4.3 In cases such as pumps for hot liquids where the driven equipment operates at high
temperatures, bearings shall be cooled by a shaft-mounted fan. This shall ensure efficient
ventilation of the bearing and disperse the heat transmitted from the driven equipment by
conduction or convection.
6.4.4 Bearings shall be capable of grease injection from outside without removal of covers with
motors in the running conditions. The bearing boxes shall be provided with necessary features
to prevent loss of grease or entry of dust / moisture e.g. labyrinth seal. Where grease nipples
are provided, there shall be associated, where necessary, with appropriately located relief
devices, which ensure passage of grease through the bearings.
6.4.5 Pre-lubricated sealed bearings may be considered provided a full guarantee is given for 4 to 5
years of trouble-free service without the necessity of re-lubrication.
6.5 Cooling System
A11 motors shall be self-ventilated, fan cooled. Fans shall be corrosion resistant or
appropriately protected. They shall be suitable for motor rotation in either direction without
affecting the performance of the motor. If this is not possible for large outputs, it shall be
possible to reverse the fan without affecting the balancing of the motor.
For motors operating in hazardous area, the fans shall be of an anti-static non-sparking
material.
6.6 Rotor
The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration level
and long service life for the bearings. Die cast aluminum rotors for motors in hazardous areas
may be accepted provided the same are type tested and approved by competent authorities.
6.7 Shaft Extension
Motors shall be provided with a single shaft extension with key-way and full key. Motor shaft
shall be sized to withstand 10 times the rated design torque.
6.8 Lifting Hooks

A11 motors weighing more than 30 kg. shall be provided with lifting hooks of adequate
capacity.
6.9 Earth Terminals
Two earth terminals located preferably on diametrically opposite sides shall be provided for
each motor. Necessary nuts and spring washers shall be provided for earth connection.
Page 1394 of 2065

ENGINEERS FOR
$'1gLar fafes INDIA LIMITED 6-51-0032 Rev. 5
(A Govl of India Undeffolong)
7.0 MISCELLANEOUS ACCESSORIES
7.1 Anti-Condensation Heaters
A11 motors rated 30 kW and above shall be provided with 240 V anti-condensation heaters,
sized and located so as to prevent condensation of moisture during shutdown periods.
Motors with heaters installed in hazardous atmospheres (Zone-1 or Zone-2), shall conform to
the provisions of applicable Indian standards and temperature classification specified in the
motor data sheet
The heater leads shall be brought out, preferably, to a separate terminal box which shall be of
the same specification and grade of protection as the main terminal box.
A warning label with indelible red inscription shall be provided on the motor to indicate that
the heater supply shall be isolated before carrying out any work on the motor.
7.2 Name Plates
In addition to the motor rating plate, a separate number plate for motor tag number shall be
fixed in a readily visible position. This tag number shall be as per the motor data sheets.
8.0 CRITICAL SPEEDS
The first actual critical speed of stiff rotors shall not be lower than 120 % of the synchronous
speed. For flexible rotors this shall be between 60 % and 80 % of the synchronous speed; the
second actual critical speed shall be above 120 % of the synchronous speed.
9.0 PAINTING
All metal surfaces shall undergo manufacturer's standard cleaning /painting cycle. After
preparation of the under surface, the equipment shall be painted with two coats of epoxy based
final paint. Color shade of final paint shall be 632 of IS: 5/ RAL-7035. All unpainted steel
parts shall be suitably treated to prevent rust formation. If these parts are moving elements,
then these shall be greased.
10.1 A11 tests shall be carried out at manufacturer's shop under his care and expense.
10.2 The manufacturer shall submit all internal test records of the tests carried out by him on the
bought-out items, motor sub-assembly and complete motor assembly.
10.3 The manufacturer shall carry out the following routine and acceptance tests as per applicable
Standards/ITP on all the motors.
a) General visual checks, nameplate details

b) Mounting, shaft centre height measurement
c) Terminal box location, clearances, size, entries, space adequacy and cable gland sizes
d) Terminals type of Exn, Exe, Exd motors
e) Free rotation of shaft, shaft centre height, lubrication, fan mounting
f) Direction of rotation
g) Coupling, bearing details
h) Cable glands, cable lug size and no. of entries in terminal box
i) Winding resistance
Page 1395 of 2065

ENGINEERS FOR
92e5
1~1 C41.TC JY13+.1) IA Govt of Indta Undertakingl MEDIUM VOLTAGE INDUCTION
j) No load test & measurement of voltage, speed, current, power input

k) Locked rotor test at reduced voltage and measurement of voltage , current & wattage
l) Reduced voltage starting & running
m) Insulation resistance before and after high voltage test
n) High voltage
o) Vibration
10.4 The manufacturer shall submit the following type test certificates (one sample from each
type/rating):
a) Full load test & measurement of voltage, current, power slip, power factor, bearing,
noise
b) Efficiency & pf at 100%, 75% and 50% load
c) Temperature rise test
d) Momentary overload test
e) Vibration
f) Noise Level
g) Over speed
h) Measurement of starting torque, starting current, full load torque.
10.5 For VFD fed motors, all tests as specified in the VFD specification shall be followed in
addition to the above.
11.0 CERTIFICATION
The motors and associated equipment shall have test certificates issued by recognised
independent test house (CIMFR/ CPRI/ ERTL/ Baseefa/ LCIE/ UL/ FM or equivalent).
A11 indigenous motors shall conform to Indian standards and shall be certified by
recognised testing agencies. All motors (indigenous & imported) shall also have valid
statutory approvals (e.g. PESO, DGMS etc). as applicable for the specified location. All
indigenous flameproof motors shall have valid BIS license and marking as required by
statutory authorities.
A11 the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for selected mode of
transportation i.e. ship/rail or trailer. The equipment shall be wrapped in polythene sheets
before being placed in crates/cases to prevent damage to the finish. Crates/cases shall have
skid bottom for handling. Special notations such as `Fragile', `This nide up', `Center of
gravity', `Weight', Òwner's particulars', `PO Nos.' etc. shall be clearly marked on the
package together with other details as per purchaser for scrutiny.
The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage, in areas with heavy rains/ high ambient
temperature.
Page 1396 of 2065

ENGINEERS FOR
IA Govt of India Undertakig) HIGH MAST LIGHTING SYSTEM Page 1 of 11
-grrkz Few mulicii

MER 1-419-4r
SPECIFICATION
FOR
HIGH MAST LIGHTING SYSTEM
3 28.04.2015 REVISED AND REISSUED AS STANDARD

SPECIFICATION VT 'k29g11-..
SPECIFICATION RS PG NS JMS ND
SPECIFICATION SSM RR AAN SKG
0 31.12.2001 ISSUED AS STANDARD SPECIFICATION SSM RR VPS

Standards Standards
No Date Purpose Convenor Chairman
by by
Approved by
Page 1397 of 2065

k31 ENGINEERS
Ilgez tilfiteg INDIA LIMITED FOR 6-51-0039 Rev. 3
14117e,
C's4 Und'"") HIGH MAST LIGHTING SYSTEM Page 2 of 11
Abbreviations:
A : Ampere
BIS : Bureau of Indian Standards
BS : British Standard
CEA : Central Electricity Authority
CRCA : Cold Rolled Cold Annealed
EIL : Engineers India Limited
ELCB : Earth Leakage Circuit Breaker
EPR : Ethylene Propylene Rubber
FGL : Finished Grade Level
GI : Galvanized Iron
HPP : Highest Pavement Point
HRC : High Rupture Capacity
ICAO : International Civil Aviation Organisation
IEC : International Electrotechnical Commission
IEEE : Institute of Electrical and Electronics Engineers
IP : Ingress Protection
IS : Indian Standard
LED : Light Emitting Diode
LM-6 : Light Metal Alloy
MCB : Miniature Circuit Breaker
NEMA : National Electrical Manufactures Association
PO : Purchase Order
PVC : Poly Vinyl Chloride
QAP : Quality Assurance Plan
TMT : Thermo Mechanically Treated
TPN : Three Phase and Neutral
V : Volt
VDE Verband Deutscher Elecktrotechniker
Convener: Mr. B.R.Bhogal
Members: Ms. Sumita Anand

Mr. Parag Gupta
Mr. M.K. Sahu
Mr. A.K. Chaudhary (Inspection)
Page 1398 of 2065

ENGINEERS
INDIA LIMITED FOR 6-51-0039 Rev. 3
GO Und"W"ng) HIGH MAST LIGHTING SYSTEM Page 3 of 11
CONTENTS
1.0 SCOPE 4
5.0 EQUIPMENT SPECIFICATIONS 5
6.0 CIVIL STRUCTURAL WORKS 8
7.0 INSPECTION, TESTING AND ACCEPTANCE AT WORKS 10
9.0 FIELD TESTING AND COMMISSIONING 11

Page 1399 of 2065

t.71 (
rr ENGINEERS SPECIFICATION STANDARD SPECIFICATION No.
Oge_ll e5legli1V INDIA LIMITED FOR 6-51-0039 Rev. 3

Unde""ng) HIGH MAST LIGHTING SYSTEM Page 4 of 11
1.0 SCOPE
This specification defines the requirements for design, fabrication, testing at manufacturer's
works, supply, installation at site, testing and commissioning of high mast lighting system,
including supply and installation of associated cables and materials, design and supply of civil
and structural foundation and supply of all related materials.
2.1 The equipment shall comply with the requirements of latest revision of the following standards
issued by BIS, unless otherwise specified.
IS-325 Three-phase induction motors

IS-383 Specification for coarse and fine aggregates from natural sources for
concrete
IS-455 Specification for Portland slag cement
IS-456 Plain & reinforced concrete — code of practice
IS-875 Code of practice for design loads (other than earth quake) for
buildings and structures: Part-3- Wind loads
IS-1363 Hexagon Head bolts, screws and nuts of product Grade 'C' Part-1:
Hexagon Head Bolts (size range M5 to M64)
IS-1489 PT-1 Specification for Portland Pozzolana cement (Fly Ash based)
IS-1554 PVC insulated (Heavy-duty) electrical cables
IS-1786 High strength deformed steel bars and wires for concrete
reinforcement — Specification
IS-2062 Hot Rolled Medium and High Tensile Structural Steel
IS-2309 Code of practice for protection of buildings and allied structures
against lightning
IS-2629 Recommended practice for hot dip galvanising of iron and steel
IS-3043 Code of practice of earthing
IS-3618 Specification for Phosphate treatment of iron and steel for protection
against corrosion
IS-4759 Hot dip zinc coating on structural steel and other allied products
IS-6623 Specification for High Strength Structural Nuts
IS-6649 Hardened and tempered Washers for High Strength Structural Bolts
and Nuts
IS-8112 43 Grade ordinary Portland cement-specification
IS-9103 Concrete Admixtures — Specification
IS-9968 Elastomer insulated cables (Part-1) for working voltage upto and
including 1100V
IS-12269 Specification for 53 grade Ordinary Portland cement
IS-12330 Specification for Sulphate Resisting Portland cement
IS/IEC-60529 : Degree of protection provided by enclosure of rotating electrical
machinery
IS/IEC-60947 : Specification for Low voltage switchgear and control gear
2.3 The equipment shall also conform to the provisions of CEA Regulations and other statutory

Page 1400 of 2065

ENGINEERS
slgem kateg INDIA LIMITED FOR 6-51-0039 Rev. 3
I MIEref eiRRIR7 Mlownso
G" Und'""ng) HIGH MAST LIGHTING SYSTEM Page 5 of 11
2.4 hi case Indian standards are not available for any equipment, standards issued by
IEC/BSNDE/ IEEE /NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between various referred standard/specification/datasheet and statutory
regulations, the most stringent requirement shall govern and decision of owner in this regard
shall be final & binding.
3.3 Vendor shall give a notice for at least one year to the end user of equipment and E1L before
services.
3.4 The high mast lighting system shall have a minimum design life of 25 years unless otherwise
specified.
4.0 SITE CONDITIONS
The equipment and materials to be supplied & installed by the vendor shall be suitable for
continuous and trouble free operation at 40° C unless specified otherwise in the data sheet.
5.0 EQUIPMENT SPECIFICATIONS
The high mast and other equipment and materials shall be of the best quality and shall conform
to the specifications given hereunder.
5.1 Mast
5.1.1 The high mast shall be of continuously tapered, polygonal cross section construction.
Minimum height of mast shall be 30 meters unless otherwise specified. The mast shall be
fabricated from steel plates in suitable number of sections, telescopically jointed, giving a
continuous tapered profile and presenting good visual appearance. The base flange shall be
provided with gaskets and high/medium tensile anchor bolts. The bottom section shall have
adequate sized opening with a hinged door to accommodate electric drive for winch, cable,
plug socket, etc. The opening shall be such as to permit clear access to the above components
inside the mast. The opening shall be complete with a close fitting, dust and vermin proof
door, weather protected with gaskets of durable material and provided with a heavy-duty
double locking arrangement.
5.1.2 The means for natural ventilation of the mast shall be provided.
5.1.3 Both the inner and the outer surfaces of the entire fabricated mast along with the attached
accessories shall be hot dip galvanized. The amount of galvanizing shall be 610gm per sq.
metre (85 micron uniform thickness) in accordance to IS: 2629 unless otherwise specified.
5.1.4 The whole head frame assembly shall be covered and protected by an aluminum/ galvanised
sheet steel canopy secured to the frame by stainless steel bolts and nuts. The canopy shall have
suitable prevention arrangement against entry of birds etc.

Page 1401 of 2065

15ilfazieg ENGINEERS SPECIFICATION STANDARD SPECIFICATION No.
11?-zir evaw
E1151ft INDIA LIMITED FOR 6-51-0039 Rev. 3
/mayors')
1.41L7f IA Gov[. of
in" U"dena" ) HIGH MAST LIGHTING SYSTEM Page 6 of 11
5.1.5 The mast shall have integral power tool for winch drive unless otherwise specified in the
datasheet.
5.1.6 The mast shall have stainless steel/galvanized earthing terminals at convenient location in the
base compartment and these shall be suitable for connection with 40x5mm GI strip to the
plant-earthing network unless otherwise specified.
5.1.7 Lightning rod at the top of the mast for the lightning protection of the lighting mast system as
per standard: IS-2309 shall be provided.
5.1.8 Horizontal deflection shall be limited to 1/40 of mast height at 2/3 of design wind speed as per
technical report no. 7 of Institution of Lighting Engineers.
5.1.9 The complete design of the mast and associated foundation shall be such that mast is
structurally and mechanically safe.
5.2 Lantern Carriage
5.2.1 The Lantern carriage shall be of steel tubular ring type construction designed to accommodate
the specified number of lighting fixtures and balance counter weights shall be provided
wherever required. The carriage shall be fabricated in two halves jointed by bolted flanges to
enable easy removal from the erected mast for replacement and maintenance purpose.
5.2.2 The complete lantern carriage assembly shall be hot dip galvanized after fabrication. It shall
have perfect self-balance arrangement so as to avoid swing and to prevent damage to mast
surface or other installed parts, during lowering/raising operation of carriage.
5.2.3 All hardware used shall have necessary corrosion protection. The carriage shall have weather
protected IP-55 cast aluminum junction box with required number of terminals (phase, neutral
and earth) for connection to the designed number of flood light fittings and associated control
gear boxes fixed on the carriage.
5.2.4 Unless otherwise specified, Lantern carriage shall be suitable for accommodating a minimum
of 12 numbers of flood light fixtures. The number, wattage and type of lighting fixture of the
high mast shall be supplied as specified in job specification/data sheet.
5.2.5 The flood light fixtures shall have die cast aluminum body with facility for lamp centering and
focusing and shall be provided with angle indicator for aiming, and also with anodized and
polished aluminum reflector with control gearbox.
5.2.6 Each high mast shall have minimum two numbers aviation obstruction lighting fixtures. The
lighting fixtures shall have cluster LED lamps of medium intensity (as per ICAO regulations)
and of red color.
5.2.7 Provision shall also be available to test the luminaries while lantern carriage is in lower
position by connecting the plug to the receptacle provided on the lantern carriage.
5.3 Winch Assembly
5.3.1 For lowering and raising of lantern carriage assembly, a winch arrangement shall be fixed in
the bottom of the mast. This shall have provision to operate both manually and electrically.
5.3.2 The winch shall be suitable to handle the weight of the lantern carriage assembly with lighting
fixtures and all other accessories, with factor of safety not less than two unless otherwise
specified.

Page 1402 of 2065

51Q-ZIEg ENGINEERS
4Ig WWI 11•05144%9Jc10.1)
C's4 Ind'a Unden`lung) HIGH MAST LIGHTING SYSTEM Page 7 of 11
5.3.3 Minimum two number of winch drums shall be provided for the winch assembly. The winch
shall be of self-sustaining type with positive locking arrangement without the need for brake
shoe, springs or clutches.
5.3.4 The winch shall be self-lubricating type by means of an oil bath.
5.3.5 The mast shall be fitted with flexible stranded high tensile strength stainless steel wire ropes,
which shall have a factor of safety not less than five times the safe working load of winch.
5.3.6 Particular care shall be exercised in all aspects of design, manufacture, testing and installation
arrangements of the system to ensure safety under all operation conditions.
5.3.7 The material of construction for top pulley block shall be non-corrosive and preferably made
up of die cast LM-6 aluminum alloy, with self-lubricating bearing. The design shall ensure
that the operation of pulleys is maintenance-free.
5.4 Power Tool for Winch Drive
The rating and capacity of the electric motor used in power tool shall be compatible to lift the
design load of lantern carriage with design margin of minimum 20%. The winch drive shall
incorporate torque limiter. Manual handle shall also be provided for hand operation of
winches. Power tool shall have self-alignment arrangement.
5.5 Feeder Pillar Distribution Box
5.5.1 Each high mast shall be supplied with one power supply feeder pillar distribution box, which
shall be located near it.
5.5.2 The feeder pillar distribution box shall be metal enclosed, freestanding type made out of 2mm
thick mild sheet steel/CRCA, epoxy painted and IP-55 weather protected. Additional canopy
for rain protection shall be provided as an integral part of feeder pillar distribution box.
5.5.3 The feeder pillar distribution box shall be complete with incomer Switch, HRC fuse/MCB,
ELCB, motor starters for winch drive, MCB for lighting control and a 3 pin 5/15A socket
alongwith 15A MCB. MCB and ELCB shall be separate unit.
5.5.4 Motor starter shall be complete with switch, HRC fuse, contactor, and bimetal relay with
single phasing prevention feature.
5.5.5 LEDs for indication of incoming power supply healthy for feeder pillar distribution box
incomer shall be provided. Feeder pillar shall also have provision to receive emergency power
supply for aviation fixtures in case specified in the data sheet.
5.5.6 Adequately rated space heater with MCB, thermostat shall be provided for the feeder pillar
distribution box.
5.5.7 Feeder pillar distribution box shall have adequate space to receive incoming and outgoing
cable terminations for 415V, TPN supply loop in and loop out arrangement.The feeder pillar
distribution box shall be complete with double compression nickel-plated brass cable glands
and tinned copper lugs.
5.5.8 The feeder pillar distribution box shall have two numbers external earthing terminals.
5.5.9 The feeder pillar distribution box shall have required wiring interface for taking signals from
hand held external control push button station for raising and lowering of lantern carriage.

Page 1403 of 2065

ig-zrr 056
1.717e1 eirco,,151.3.70.1,
ENGINEERS
INDIA LIMITED
,AG-4.."^d-unded..-3)
FOR
6-51-0039 Rev. 3
Page 8 of 11
5.5.10 The feeder pillar distribution box shall be installed on a raised concrete foundation block and
foundation shall be up to the level of minimum 300mm above ground level.
5.6 Local Control Station
5.6.1 Local control station shall be hand held type. This control station shall have necessary
raise/lower pushbuttons, emergency stop push button etc.
5.6.2 The hand held control Pushbutton station shall be supplied with minimum of 5 meters length
of 5Cx2.5 sq mm flexible cable and cable shall be with copper conductor, PVC insulation,
metal braiding and overall PVC sheath.
5.6.3 The hand held control station and associated cable shall be kept inside feeder pillar
distribution box when not in use and suitable arrangement shall be provided for the same.
5.7 Cable and Cable Connections
5.7.1 All power and control cables including flexible trailing cables shall be supplied laid and
terminated by the high mast vendor.
5.7.2 The electrical connections from base compartment to the junction box on the lantern carriage
shall be made through special multicore trailing cable of minimum size 4 sq.mm copper
conductor, EPR insulated, metal braided and sheathed in heavy duty Polychloroprene.
5.7.3 Minimum 5 cores shall be provided unless otherwise specified. Separate cores shall be used
for lighting fixtures, aviation fixtures and one dedicated core shall be kept for earthing.
Suitable chemicals shall be added to outer sheath of cable to protect the cable against birds,
rodent and termite attack.
5.7.4 All power and control cables shall be 1100V grade and shall conform to IS-1554 and all
flexible-trailing cables shall also comply with requirement of IS-9968.
5.7.5 The trailing cable shall be terminated by means of metal cased plug and socket, which shall be
provided at the base compartment to enable easy disconnection.
5.7.6 The cable for connection to flood lighting fixtures /aviation lighting fixtures from junction box
provided on lantern carriage shall be through 3C x 2.5 sq.mm copper conductor, PVC
insulated, armoured and overall PVC sheathed cable. The trailing cable at the lantern carriage
shall be taken in flexible metal conduit.
5.7.7 Connection to the power tool motor inside mast at the bottom shall be through metal cased
plug and socket arrangement to enable easy disconnection.
5.7.8 All cabling from feeder pillar distribution box to high mast shall be laid in directly buried
trenches.
6.0 CIVIL STRUCTURAL WORKS
6.1 Scope of Work
The scope of work under this also includes design, detailing, supply and construction of
foundations for high mast lighting system works. The work shall in general be executed as per
IS-456 and all referred codes therein.

Page 1404 of 2065


k31"--lfa..itq ENGINEERS
ligar 251-eg
1.en arrant
643.7 0,79,
G" Unded'") HIGH MAST LIGHTING SYSTEM Page 9 of 11
6.2 Materials
6.2.1 Cement
The cement used shall be any one of the following types unless otherwise specified in project
data sheet:
43 Grade ordinary Portland cement conforming to IS-8112.

Portland Pozzolana Cement (Fly Ash based) conforming to IS: 1489 Pt-1.
53 grade Ordinary Portland cement conforming to IS: 12269.
Portland slags cement conforming to IS-455.
e. Sulphate resisting Portland cement conforming to IS-12330.
6.2.2 Aggregates
Only natural existing aggregates conforming to IS-383 shall be used.

Coarse aggregate shall be 20mm down graded as per IS-383.
c. Fine aggregate shall be graded evenly from fine to coarse as per Zones II and III of IS-
383. Zone IV aggregate shall not be used.
6.2.3 Water
Water used for manufacture and curing of concrete shall be clean and free from injurious
amounts of oils, acids, alkalies, salts, sugar, organic materials or other substances that may be
deleterious to concrete or steel as specified in IS-456. Potable water shall be considered
satisfactory.
6.2.4 Chemical Admixtures
Chemical admixtures, if used, shall conform to IS-9103.

Criteria of use of chemical admixtures shall be as per IS-456.
6.2.5 Reinforcing Steel
Only high strength deformed steel bars of grade Fe 500 (TMT)/ Fe 500 D conforming to
IS: 1786 shall be used.
Minimum diameter of main reinforcing bars in foundation and pedestal shall be 12mm.
Links shall be of minimum 8mm diameter.
6.2.6 Anchor / Foundation Bolts
High/Medium tensile steel bars for turning anchor bolts shall conform to IS-2062 Grade
A/BR/BO. Nuts shall conform to IS-1363 & IS 6623. Washers shall conform to IS: 6649.
6.3 Concrete
The concrete shall be design mix of minimum grade of M25 as per Geotechnical Document
(whichever is higher) and other requirements as mentioned in project data sheet. 75mm thick
lean concrete shall be provided under the structural foundation of proportion 1:5:10 using
40mm down aggregates. The mud mat of lean concrete shall project 50mm beyond all sides of
the structural foundation slab. Minimum cover to reinforcement shall be 50 mm.
Height of pedestal shall be minimum 300mm above FGL/HPP. Sleeves for cable entry and
exit shall be placed in the pedestal. Minimum thickness for foundation slab shall be 500mm.

Page 1405 of 2065

k31 ENGINEERS
Orr Me iI
g
rirawc,513105A)
INDIA LIMITED
A GoN
dind' Unde"'N)
FOR
6-51-0039 Rev. 3
Page 10 of 11
6.4 Design of Foundation
The foundation shall be placed minimum 1.5 meters below Finished Grade Level (FGL)
or as per Geotechnical Document No. XXXX-16-60-GD-0001.
Factor of safety against overturning and sliding shall be considered as 2.0 and 1.5,
respectively. Only 50% of the overburden weight of backfilled soil over base slab of the
foundation shall be accounted for checking of over-turning and sliding. All design
parameters for foundation shall be as per IS-456 and referred BIS codes. Limit state
method shall be used.
c. Information of Soil bearing capacity/ filled up soil/ ground improvement etc. shall be as
per Geotechnical Document No. XXXX-16-60-GD-0001.
6.5 Loadings
Loading in general shall be as per IS-875. The basic wind speed shall be as per the Project/site
location and as called for in IS-875 (Part-3). The value of K 1 , K2 and K3 shall be as follows:
K1 = As per IS 875 for 25 Years

K2 = 1.0
K3 shall be appropriate to topography but not less than 1.0.
6.6 Review of Foundation Design/Drawing
Design and drawing shall be prepared on standard size sheets and submitted for
review/approval prior to execution of works. Construction shall not be taken up prior to
documents/drawings reviewed in code 1 or 2.
6.7 Construction Requirements
Construction shall be done following all safe practices required in IS-456 and other referred
codes.
7.0 INSPECTION, TESTING AND ACCEPTANCE AT WORKS
7.1 During fabrication, the High mast lighting system equipment and materials shall be subject to
inspection by EIL / Owner, or by an agency authorized by the Owner, to assess the progress of
work, as well as to ascertain that only proven raw material is used. The manufacturer shall
furnish all necessary information /data concerning the supply to Elf, / Owner's inspectors. The
vendor shall give at least 15 days notice to the purchaser regarding the date of testing to enable
him or his representative to witness the tests.
7.2 Tests shall be carried out at the manufacturer's works under his care and expense. All routine
tests as specified by the applicable standard codes shall be conducted. Type test certificates for
the high mast lighting system equipments used shall be furnished from a recognized testing
organization.
7.3 Inspection and testing requirements for high mast system shall be as per Inspection and test
plan, specification no. 6-81-1039 and owner-approved vendor's QAP to check mechanical and
electrical operation.
7.4. All tests shall be conducted as per relevant applicable standards.
The equipment shall be divided into several shipping sections for protection and ease of
handling during transportation. The equipment shall be properly packed for transportation by
Page 1406 of 2065


t31 ENGINEERS
ligar 015 1e- g :
1 .1W, rira^neam ovum)
G" °"""nde1 *'ng) HIGH MAST LIGHTING SYSTEM Page 11 of 11
ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets before being placed
in wooden crates/cases to prevent damage to the finish. Crates/cases shall have skid bottoms
for handling. Special notations such as 'Fragile', 'This side up', 'Weight', 'Owner's
particulars', 'PO nos.' etc., shall be clearly marked on the package together with other details
as per purchase order.
should also be suitable for outdoor storage areas with heavy rains/ high ambient temperature
unless otherwise agreed.
9.0 FIELD TESTING AND COMMISSIONING
9.1 Supervision during installation, testing and commissioning shall be carried out by vendor's
experienced and trained engineer/supervisor. Any defect pointed out by EIL/Owner shall be
rectified by vendor at no extra cost to the owner.
9.2 Before any part of the High mast lighting system is energised, the pre-commissioning tests
shall be carried out. This shall include but not be limited to the following:
Insulation resistance tests

Continuity test
Earth continuity check and measurement
Load current in all phases shall be measured in each mast
All safety interlocks
Feeder pillar distribution box wiring schematics and functional requirements
All pre-commissioning checks and tests both for power distribution and lighting system shall
be carried out by vendor in the presence of Engineer-in-charge of EIL/Owner.
9.3 After completion of job, vendor shall carry out the measurement of achieved illumination
level in different areas and shall furnish test reports. The focusing angle of fixture shall be
changed/ adjusted where required.
9.4 After inspection and pre-commissioning tests are carried out, vendor shall obtain necessary
statutory approval of the system from Central Electricity Authority or any other statutory body
as specified in the specification. All test results shall be recorded and submitted to ELL/owner.

Page 1407 of 2065

dallaglai
eJei ENGINEERS FOR 6-51-0041 Rev. 5
.
51ges We:WNW INDIA LIMITED
1.410 1e1VaWasIJOOM (A Govt of Inda Um:WU/long) OIL FILLED TRANSFORMERS Page 1 of 11
1 -TiTff VRENTIfT fuR

form-itu
SPECIFICATION
FOR
OIL FILLED TRANSFORMERS
t'4,01vj'I ,tia) WAri 1A^')

5 08.04.2011 REVISED & REISSUED AS STANDARD MK SA UAP DM
SPECIFICATION
4 27.02.2009 REVISED & REISSUED AS STANDARD SA NS JMS VC
SPECIFICATION
3 10.02.2004 REVISED & REISSUED AS STANDARD NPG RR VPS
SPECIFICATION MG
2 21.05.98 REVISED & REISSUED AS STANDARD
SPECIFICATION NPG VPS SG AS
1 10.05.96 REVISED & REISSUED AS STANDARD
SPECIFICATION NPG VPS SG AS
0 2.6.1981 ISSUED AS STANDARD SPECIFICATION
GNT RSG
Standards Standards
No Date Purpose by by Convenor Chairman
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright El L - All rights reserved
Page 1408 of 2065

FOR 6-51-0041 Rev. 5
IA Govt of India Undertalono)
OIL FILLED TRANSFORMERS Page 2 of 11
Abbreviations:
CBIP : Central Board of Irrigation & Power
GI Galvanised Iron
HV High Voltage
IEC International Electro Technical Commission
IS Indian Standards
LV Low Voltage
MV Medium Voltage
KV Kilo Volt
KVA : Kilo Volt Ampere
NGR Neutral Grounding Resistor
OLTC : On Load Tap Changer
ONAF : Oil Natural Air Forced
ONAN : Oil Natural Air Natural
OTI Oil Temperature Indicator
PO Purchase Order
PRV Pressure Release Valve
RTCC : Remote Tap Changer Control
TPN Three Phases and Neutral
VDE Verband Der Electrotechnik, Elecktronik and Information Stechnik
WTI Winding Temperature Indicator
XLPE : Cross Linked Polyethylene
Convener: Mr. UA Patro
Members: Mr. AK Tickoo

Mr. MP Jain
Mr. BR Bhogal
Mr. Arun Kumar
Mr. KK Gera
Mr. Saeed Akhtar
Page 1409 of 2065

611faelef ENGINEERS
51gea iaiReg INDIA LIMITED FOR 6-51-0041 Rev. 5

Wen 01021W MIJ92151.1) IA Govl of India Undertaking)
CONTENTS
1.0 SCOPE 4
5.0 CONSTRUCTION 5
6.0 TERMINALS AND MARSHALLING BOX 5
7.0 COOLING 6
8.0 TAPPINGS AND CONTROLS 6
9.0 ACCESSORIES 8
10.0 NOISE LEVEL 9
Page 1410 of 2065

ENGINEERS
0?e41 Oa& INDIA LIMITED FOR 6-51-0041 Rev. 5
1441E7felivtofForiagns1) (A Govt of lode undertaking)
1.0 SCOPE
The intent of this specification is to define the requirements for design, manufacture, testing,
packing and supply of oil filled power/distribution transformers.
2.1 The equipment shall comply with the requirements of the latest revision of the following standards
issued by BIS.
IS: 335 :New Insulating oils

IS: 1271 :Thermal evaluation and Classification of electrical insulation.
IS: 2026 :Power transformers
IS: 2099 : Bushing for Alternative voltages above 1000 V.
IS: 2705 : Current transformers.
IS: 3347 : Dimensions for porcelain Transformer Bushings
IS: 3637 : Gas operated relays.
IS: 3639 : Fitting & accessories for power transformers
IS: 4201 : Application guide for CTs.
IS: 6600 : Guide for loading of oil immersed transformers
IS: 8478 : Application guide for ON-load tap changers
IS: 8468 :On-load tap changers
IS/ IEC: 60529 :Degree of protection provided by enclosures (IP Code)
IS/IEC: 60947 : LV switchgear and control gear.
2.2 In case of imported equipment, standards of the country of origin shall be applicable if these
2.3 The equipment shall also conform to the provisions of CEA Regulations and any other statutory
2.4 In case Indian standards are not available for any equipment, standards issued by
IEC/BSNDE/IEEE/NEMA or equivalent agency shall be applicable.
project, the most stringent one shall prevail. However owner's decision in this regard will be final
and binding.
3.1 The offered equipment shall be brand new with state of art technology and proven field track record.
No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered
equipment for at least 10 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before phasing
out the product/spares to enable the end user for placement of order for spares and services.
Page 1411 of 2065

oozed& ENGI NEERS SPECIFICATION
Ogelf faRtg er INDIA UMTED
T
FOR 6-51-0041 Rev. 5
Wen Govt d toftt. Undertaking) OIL FILLED TRANSFORMERS Page 5 of 11
4.0 SITE CONDITIONS
Transformer shall be suitable for installation and satisfactory operation in tropical, humid and
corrosive atmospheres. The transformer shall be designed to operate under site conditions as
specified in data sheet. If not specifically mentioned therein, design ambient temperature of 40°C
and altitude not exceeding 1000m above MSL shall be considered.
5.0 CONSTRUCTION
5.1 Transformer tank shall be of welded sheet steel construction and provided with gasketed steel cover
plates. Base shall be suitably reinforced to prevent any distortion during lifting. Base channels shall
be provided with skids and pulling eyes to facilitate handling.
5.2 Transformer shall be double wound, core type with high grade cold rolled non-aging grain
oriented low loss, high permeability silicon steel laminations (M-4 or better grade) perfectly
insulated and clamped to minimise vibration and noise. Care shall be taken to insulate core-fastening
bolts to reduce losses and avoid hot spots. All parts of magnetic circuit shall be bonded to earth
system.
5.3 Transformers shall have conventional type of windings. Foil type windings are not acceptable.
Windings shall be of copper and shall be designed to withstand the applicable thermal and dynamic
short circuit stresses.
5.4 All covers and seals shall be oil and airtight and shall not be affected by mineral or synthetic oil
action. Detachable radiators (tank mounted) equipped with air vent, drain plug and lifting lugs shall
be provided with shut-off valves for transformer rated more than or equal to 500kVA to permit
removal of any radiator unit without emptying the tank. Radiators shall be securely braced to prevent
undue vibration.
5.5 All fasteners and bolts etc. shall be galvanised. All surfaces to be painted shall be thoroughly
cleaned, de-scaled, made free from rust and transformer shall be epoxy painted.
5.6 Different non-current carrying parts of transformers shall be connected by copper flexibles for earth
continuity purpose.
5.7 Transformer shall be supplied with first filling of oil and 10% extra oil in non-returnable drums Oil
shall conform to IS-335.
6.0 TERMINALS AND MARSHALLING BOX
6.1 Windings shall be brought out and terminated on outdoor bushings, cable boxes or bus-duct
chamber, which will be located as specified on the data sheet.
6.2 When outdoor bushings are specified they shall be supplied complete with terminal connectors
suitable for the specified conductor size.
6.3 Cable boxes shall be supplied with cable lugs and glands.
6.3.1 For HV XLPE Cables and MV PVC Power/control cables double compression cable glands and
crimped type tinned copper cable lugs shall be supplied. Gland plate shall be removable type. For
single core cables, gland plate shall be of non-magnetic material. HV cable box shall be suitable for
termination of specified size of XLPE insulated cable .The head-room available between cable gland
plate and terminals shall not be less than 600mm for cable upto 11 kV, and 900 mm for 22 kV and
33 kV cables. Cable box and disconnecting chamber shall be air insulated.
Page 1412 of 2065

dal eJ F ENGINEERS
gh
iagieUW INDIA LIMITED FOR 6-51-0041 Rev. 5
laik7f eleaskr ial310.1) IA Govt of inda Undertaking)
6.3.2 Cable box shall be weatherproof to IP-55. For fixed portion of cable box, inspection cover with
lifting handle shall be provided.
6.3.3 Primary cable box (where applicable) shall be able to withstand specified primary system fault level
for 0.20 secs.
6.4 Terminal chamber for bus-duct termination shall have a gasketed cover plate bolted to it and shall be
weatherproof to IP-55. A separate inspection cover with lifting handle shall be provided to facilitate
connection and inspection. Phase sequence of the bus bars shall be as specified in the data sheets.
6.5 Marshalling box shall be mounted on transformer and shall be weatherproof to IP-55. All protective
devices and neutral CTs shall be wired by means of PVC insulated copper conductor armoured
cables upto the marshalling box. Terminals shall be clamp type. Removable gland plate with double
compression type glands shall be provided. Lamp with switch & socket shall be provided in the
marshalling box. Preferably, marshalling box shall be located on the front side of transformer.
6.6 For transformers having provisions for terminating TPN bus duct on the 433V side, neutral of the
star connected secondary winding shall be brought out to a secondary terminal chamber. A CT shall
be mounted (if specified) on the neutral terminal with CT secondary wired up to the marshalling
box.
6.7 A separate neutral bushing shall be provided for neutral earthing of transformers. The neutral CT
shall be mounted as below:-.
CT for 51 G shall be located in the earth path after bifurcation of neutral.
CT for 64 R can be located before bifurcation of neutral.
Supporting arrangement for GI strip/cable as applicable shall be provided for connection of neutral
bushing to earth/NGR.
7.0 COOLING
7.1 Type of cooling shall be in accordance with data sheet.
7.2 Forced air-cooling system shall have a weather proof IP-55 control panel to be installed on the body
of the transformer, complete with cooler controls and cable glands necessary for Purchaser's
external cable connections. Contacts shall be provided for remote indication/alarm for following
operating conditions:
Auto/manual selection
Winding over temp.
(iii) Fans ON (for each fan separately) & Fans tripped (for each fan separately).
Cooling fans shall be complete with mounting/supporting structure. These shall be suitably sized to
limit the temperature rise of the transformer to specified values with continuous maximum loading
of ONAF rating and at maximum specified ambient temperatures. One standby fan per 50% cooler
bank shall be provided.
In Auto mode all fans including redundant fans shall be running. In manual mode, provision shall
be made for starting each fan independently.
8.0 TAPPINGS & CONTROL
8.1 These shall be provided on high voltage side and connected to off circuit or on-load tap changing
gear as specified on data sheet. Under conditions of external short circuit, the tap changing
equipment shall be capable of carrying the same current as the windings.
Page 1413 of 2065

01 Mk - ENGINEERS SPECIFICATION STANDARD SPECIFICATION No.
'iges Raft Itliv INDIA LIMITED FOR 6-51-0041 Rev. 5

rmwoarnI
(MEW IA Govt. of Inds Undertaking)
8.2 Off circuit tap changing gear:
Off circuit tap changing gear shall have an external operating handle mounted on the transformer
side and shall meet the following requirements:
Positive snap-action contact changing
The mechanism shall be such that it is impossible for the contacts to be set in a position
whereby the windings remain open-circuited or partly short-circuited.
Mechanical stops at the ends shall be provided to prevent overrun.
The driving rod through cover or tank wall shall be properly sealed against oil leakage under
all service conditions.
The handle shall be metallic and the adequately sized in order to allow operation without the need of
tools and be located in a directly accessible position.
The handle shall be provided with padlock facilities to lock the tap changer in the desired position.
Tap positions shall be clearly marked in line with the data given on the rating plate.
8.3 On Load Tap Changer
8.3.1 High speed on load tap changing gear with number of steps as specified on the data sheet shall be
provided and mounted on the transformer. The OLTC gear shall have diverter resistance and the
current diverting contacts shall be housed in a separate oil chamber segregated from the main tank of
the transformer. The contacts shall be accessible for inspection and their tips shall be replaceable.
OLTC oil chamber shall have oil filling, drain and sampling facility. It shall be provided with oil
level indicator, connection orifices, valves and silica gel breather shall be provided.
8.3.2 OLTC shall be provided with local and remote controls.
8.3.2.1 Local Control
Manual-Mechanical Control
The cranking device for operation of the OLTC gear shall be removable and located at a height not
exceeding 1500mm above ground level for easy operation. The mechanism shall be complete with
normal accessories including at least the following:-
A mechanical tap position indicator (Rated tap voltages shall be marked on the diagram
plate).
A mechanical operation counter.
Mechanical stops to prevent over cranking of the mechanism beyond extreme tap positions.
Electrical Control
Control circuit shall incorporate the following:

Local/remote manual electrical operation.
Device to ensure a positive and full completion of tap change once it is initiated even if here
is loss of power.
An interlock to cut-off electrical control automatically upon recourse being taken to manual
mechanical control in emergency.
Electrical interlock to cut-off a counter impulse for a reverse tap change, being initiated
during a progressive tap change and until the mechanism comes to rest and resets circuits for
a fresh operation.
Page 1414 of 2065

lsarao_lef ENGINEERS
tzar failtu INDIA LIMITED FOR 6-51-0041 Rev. 5
WPM elETneWasiagins0 IA Govt of India undettaiong)
v) All auxiliaries and devices for electrical control of OLTC gear should be housed in a
weather-proof cabinet mounted on the transformer and shall include:
Local tap position indicator

5 digit operation counter
Cubicle lighting
Thermostatically controlled space heater.
Miniature circuit breaker with magnetic and thermal overload devices for ontrolling
the incoming supply to the OLTC motor.
Padlocking arrangement for the hinged cabinet door.
Removable plate with cable glands.
Inside tag with control scheme indelibly marked.
8.3.2.2 Remote Tap Changer Control Panel
Remote Tap Changer control panel shall comprise of the following:
Individual/parallel control on Master follower sequence selector switch.

Raise/lower control switch.
Potentiometer type tap position indicator.
Out of step relay.
Time delay relay.
Indicating lamp for out of step.
Out of step buzzer.
Indicating lamp for tap changer supply available.
Indicating lamp for tap change in progress.
Voltage Sensing Relay (If specified)
RTCC panel shall be dust & vermin proof, floor mounting, and freestanding type. The
enclosure shall be cold rolled sheet of 2.0 mm thick. All doors and opening shall be provided
with neoprene gaskets.
8.3.4 OLTC wherever called for shall be suitable for bi-directional power flow.
9.0 ACCESSORIES
9.1 The following accessories shall be provided as a minimum:
Rating Plate
Terminal marking Plate
Two earthing terminals
De-hydrating breather(For transformer rated 25 kVA and above for rated voltage 11 kV and
below, and all ratings above 11 kV)
Conservator (For transformer rated 50 kVA and above for rated voltage 11 kV and below,
and all ratings above 11 kV)
Air release Device (for transformers with conservator)
Oil filling hole with cover
Oil Level indicator with alarm contact
Thermometer pocket
Oil temperature indicator with alarm & trip contacts
Winding temperature indicator with alarm & trip contacts (for transformers of rating 500
KVA and above)
4-20mA transducers for OTI & WTI (For Transformers rated above 1000kVA)
Pressure relief valve shall be provided (with alarm contact).
Sampling valve
Page 1415 of 2065

n ett ENGINEERS
INDIA LIMITED
SPECIFICATION
FOR
6-51-0041 Rev. 5
Ogeir f&Pleu
1.1,MORMENEIJMINF) (A Gout. of India undertaiong)
Conservator drain valve

Top oil filter valve
Drain cum bottom filter valve
Double float Buchholz relay
Separate neutral bushing outside terminal box with connector assembly
Inspection cover
Terminal box
Marshalling box
Lifting lugs
Jacking lugs
xxv) Cross channels with towing lugs
9.2 Conservator shall be complete with oil filling plug and cap, oil drain valve, oil level gauge in
addition to magnetic oil level gauge. A flexible oil resistance air bag shall be provided for
conservator for transformer rated above 2500kVA. Air bag shall be designed to withstand repeated
expansion and contraction due to changes in oil level.
9.5 Separate buchholz relay shall be provided for main tank and OLTC chamber. This shall be double
float type for the main tank with separate normally open trip and alarm contacts. For the OLTC
chamber the relay shall be of single float type or oil surge relay with one trip contact. Isolating valve
shall be provided on either side of the relay and distance piece shall be supplied.
9.9 Size of valves for drain, filter and sampling shall be as per table below.
Transformer rating Size of drain Size of filter valve Size of sampling valve
(kVA) valve (mm) mm Mm
Upto 1600 25 25 15
>1600 to 10000 50 25 15
>10000 to 25000 80 50 15
>25000 to 50000 100 50 15

>50000 100 50 15
9.10 ECS Interface signals as listed below shall be provided if specified in the data sheet / projects
specifications.
Selector switch status (OLTC/RTCC/Remote Control mode)

Master / Follower status
Auto/Manual mode status
Tap changer out of step status
Tap changer stuck status
Tap changer status signal (Digital) for each step
Control Supply failure for RTCC Panel / OLTC
Raise/Lower Control from ECS
10.0 NOISE LEVEL
Audible Noise level shall not exceed the limits indicated in CBIP manual.
Page 1416 of 2065

ISIRZE'T ENGNEERS SPECIFICATION STANDARD SPECIFICATION No.
Eliateg INDIA LIMITED FOR 6-51-0041 Rev. 5

eRZINV CeRagLISIO (A Govt of India Undertaking)
11.1 Owner's representative shall be given free access in the works from time to time for stage wise
inspection and progress reporting. Four weeks advance notice shall be given to witness the final
routine test as per IS: 2026 and other tests as agreed upon. These tests shall be performed on the
complete assembly at manufacturer's works. Test certificates duly signed by owner's representative
shall be issued as part of final document.
11.2 Routine tests and special tests as listed below shall be carried out on all transformers:
11.2.1 GA along with verification of all accessories
11.2.2 Dimensional & electrical clearance
11.2.3 Rating plate details
11.2.4 Terminal/ tapping markings
11.2.5 Earthing arrangement
11.2.6 Measurement of winding resistance
11.2.7 Measurement of voltage ratio and check of voltage vector relationship
11.2.8 Measurement of impedance voltage and load loss
11.2.9 Measurement of no- load loss and current
11.2.10 Induced over voltage withstand test
11.2.11 Separate-source voltage withstand test (HV Test)
11.2.12 Measurement of insulation resistance before and after HV test
11.2.13 Noise level check
11.2.14 Magnetic Balance test
11.2.15 Dielectric test
11.2.16 BDV on transformer oil
11.2.17 Tests on OLTC/ control panel (if applicable)
11.2.18 Measurement of power taken by fans & oil pumps (on sample basis on one transformer)
11.3 Additional Tests:
11.3.1 Oil leakage Test - All tanks and oil filled compartments shall be tested for oil tightness by being
completely filled with air/oil of a viscosity not greater than that of insulating oil to IS: 335 at an
ambient temperature and subjected to a pressure equal to the normal pressure plus 35 kN/m2
measured at the base of the tank. This pressure shall be maintained for a period of not less than 12
hours for oil and 1 hour for air, during which time no leakage shall occur.
11.3.2 Vacuum Test - One transformer tank of each size shall be subjected to the specified vacuum as in
table-1. The tanks designed for vacuum of 760mm of mercury shall be tested at a maximum internal
pressure of 3.33 kN/m2 (25mm of Hg) for one hour. The permanent deflection of flat plates after the
vacuum has been released shall not exceed the value specified in Table-2 without affecting the
performance of the transformer.
Table —1
Highest System Vacuum Gauge
MVA Rating mm of Hg
Voltage pressure kN/m2
Upto 1.6 34.7 250
Upto 72kv above 1.6 & upto 20 68.0 500
Above 20
100.64 760
Above 72kv For all MVA ratings
Page 1417 of 2065

‘311-a.Jelieth ENGINEERS
Ogeil twever INDIA LIMITED FOR 6-51-0041 Rev. 5
(NM Maslen:43MM (A Govt of India Undertaking)
Table — 2
Horizontal length of flat plate (in mm) Permanent deflection (in mm)
Upto and including 750 5
751 to 1250 6.5
1251 to 1750 8
1751 to 2000 9.5
2001 to 2250 11
2251 to 2500 12.5

2501 to 3000 16
Above 3000 19
11.3.3 Pressure Test - One transformer tank of each size shall be subjected to a pressure corresponding to
twice the normal head of oil or to the normal pressure plus 35 kN/m2 whichever is lower measured
at the base of the tank and will be maintained for one hour. The permanent deflection of flat plates
after the excess pressure has been released shall not exceed the figure specified in Table-2.
11.3.4 One transformer of each rating shall be subjected to heat run test, if specified in data sheet.
11.3.5 Impulse test, if specified in the data sheet, shall be carried out on all three limbs of the transformer.
11.3.6 Transformer shall be subjected to short circuit test, if specified in the data sheet.
All the equipment shall be divided into several sections for protection and ease of handling during
transportation. The equipment shall be properly packed for the selected mode of transportation i.e.
by ship/ rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in
the crates/ cases to prevent damage to the finish. Crates / cases shall have skid bottom for handling.
Special notations such as 'Fragile', 'This side up', 'Centre of gravity', 'Weight', 'Owner's
particulars', 'P.O. numbers' etc., shall be clearly marked on the package together with other tag
numbers, P.O. number etc.
The equipment may be stored outdoors for long periods before erection. The packing shall be
suitable for outdoor storage in areas with heavy rains/ high ambient temperature.
Page 1418 of 2065

arae,
*geir laiReg.
ENGINEERS FOR
6-51-0044 Rev. 5
INDIA LIMITED DRY TYPE DISTRIBUTION
(A Govt of Ind. Undertakong)
TRANSFORMERS Page 1 of 7
7FF ich*4-1
f~F T
SPECIFICATION
FOR
DRY TYPE DISTRIBUTION
TRANSFORMERS
REVISED AND REISSUED AS STANDARD

5 23.11.16 NT SA BRB RN
SPECIFICATION
4 11.04.11 MK SA UAP DM
SPECIFICATION
3 21.03.11 NT SA UAP DM
SPECIFICATION

ND AKT AAN VJN
1 08.11.01 REVISED AND REISSUED NS AAN VPS MRR

Standards Standards
Rev Committee Bureau
Prepared Checked
by by
No
Approved by
Page 1419 of 2065

1511aTrt4 ENGINEERS FOR
$ige...110Wreg INDIA LIMITED 6-51-0044 Rev. 5
1.1PA OleasremAJOinvIO IA Goof of India Undettaking) DRY TYPE DISTRIBUTION
Abbreviations:

BS : British Standards
CEA : Central Electricity Authority
CT : Current Transformer
GI Galvanised Iron
HV : High Voltage
IEC : International Electrotechnical Commission
IP : Ingress Protection
KVA : Kilo Volt Amperes
MV : Medium Voltage
NEMA : National Electrical Manufacturers Association
SWG : Standard Wire Gauge
VDE : Verband Der Electro technik and information Stechnik
51 G : Back up Earth Fault Protection Relay
64R : Restricted Earth Fault Protection Relay
Convener: Mr. B.R. Bhogal
Members: Ms. Sumita Anand

Mr. Parag Gupta
Mr. M.K. Sahu
Page 1420 of 2065

elei ENGINEERS FOR
*Ige../1 tititeg INDIA LIMITED
Govt of InOla UndeltaVong) DRY TYPE DISTRIBUTION
6-51-0044 Rev. 5
CONTENTS
1.0 SCOPE 4
5.0 CONSTRUCTION 4
6.0 TERMINALS AND MARSHALLING BOX 5
7.0 COOLING 6
8.0 TAPPINGS AND CONTROLS 6
9.0 ACCESSORIES 6
10.0 NOISE LEVEL 7
Page 1421 of 2065

t ZIEq ENGINEERS
stirtifite-g K9 INDIA LIMITED FOR
6-51-0044 Rev. 5
IME71212,13ROAJW15711 IA Gov! of India Undertak ■ ng) DRY TYPE DISTRIBUTION
1.0 SCOPE
The intent of this specification is to define the requirements for design, manufacture, testing,
packing and supply of cast resin / resin impregnated dry type distribution transformers.
2.1 The equipment shall comply with the requirements of the latest revision of the following
standards issued by BIS (Bureau of Indian Standards) unless otherwise specified.
IS: 5 Colours for ready mixed paints and enamels

IS: 1271 Thermal evaluation and classification of electrical insulation
IS: 2705 Current transformers
IS: 10028 Code of practice for selection, installation and maintenance of
transformers
IS: 11171 Dry type power transformers
IS/IEC: 60529 : Degrees of Protection Provided by Enclosures (1P Code)
standards are equivalent to or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of the CEA Regulations with latest
amendments and other statutory regulations currently in force in the country.
project, the most stringent one shall prevail. However Owner's / EIL's decision in this regard
will be final and binding.
services.
4.0 SITE CONDITIONS
Transformer shall be suitable for installation and satisfactory operation in tropical, humid and
corrosive atmospheres found in refineries, Petrochemical and Fertiliser Plants or as specified
in the Material Requisition / Tender . The transformer shall be designed to operate under site
conditions as specified in data sheet. If not specifically mentioned therein, design ambient
temperature of 40°C and altitude not exceeding 1000m above MSL shall be considered.
5.0 CONSTRUCTION
5.1 The transformers shall have core type construction. The core shall be assembled out of
low-loss, nonageing, high permeability cold rolled grain oriented steel laminations.
Page 1422 of 2065

15illaZA ENGINEERS FOR
VII5teg
1.2,1 212 ' A113,10.41
INDIA LIMITED
IA Govt of India Undertaking) DRY TYPE DISTRIBUTION
6-51-0044 Rev. 5
5.2 The windings shall be of high-grade electrolytic copper. The insulation system for cast resin
transformers shall comprise of windings cast under vacuum, free of voids in a homogenous
uniform laminate of epoxy resin/ polyester resin. The totally assembled core and coil
assembly, for resin impregnated transformers, shall be vacuum pressure impregnated to
effectively make it impermeable to moisture, dirt, salt, air and other industrial contaminants.
5.3 The entire core assembly shall be covered with a resin-based lacquer for corrosion protection.
5.4 Lifting lugs shall be provided for core and winding assemblies.
5.5 The HV and MV windings shall have class 'F' or better insulation. The temperature rise of
windings under continuous full load shall not exceed the maximum allowable temperature for
the appropriate class of insulation as per IS 11171, above the design temperature specified in
the data sheet.
5.6 The insulation material used shall be non-hygroscopic, non- inflammable and self-
extinguishing if ignited by direct flame or arc. No toxic or harmful gases shall form during
heating and for burning. The insulation materials shall be sufficiently resistant to ageing.
5.7 The transformers shall be capable of withstanding the thermal and mechanical effects of a
dead short circuit on any or all winding terminals with full voltage maintained on other
windings as per IS. The transformers shall sustain a symmetrical short circuit on secondary
terminals for 2 seconds without damage or impairment.
5.8 Each limb shall have two solid state winding temperature monitoring elements to initiate an
alarm and trip for winding over temperature.
5.9 The transformers for Indoor & outdoor location shall have minimum degree of protection as
IP 23 & IP 43 respectively. However the marshalling box, cable termination box, bus-duct
termination chamber etc. shall have a degree of protection not less than IP-55.
5.10 All fasteners and bolts shall be galvanised.
5.11 The transformers shall be spray-painted or powder coated with epoxy paint. Colour shade of
final paint shall be as specified in the data sheet.
6.0 TERMINAL AND MARSHALLING BOX
6.1 Windings shall be brought out on suitable nickel-plated copper terminals for cable
termination. HV side termination shall be from the bottom. Suitable disconnection chambers
shall be provided to permit the transformer to be removed without disconnecting the cable
termination. The MV side termination shall be by bus-duct or cable as defined in datasheet /
job specification.
6.2 The high voltage and medium voltage cable termination arrangement shall be complete with
cable box and bolted type undrilled cable gland plates. Non-magnetic gland plate shall be
provided for single core cables.
6.3 Primary cable box shall be able to withstand specified primary system fault level for 0.2 secs.
6.4 Terminal chamber for busduct termination shall have a gasketed cover plate, bolted to it.
Separate inspection covers shall be provided to facilitate connection and inspection.
Page 1423 of 2065

ENGINEERS FOR
$1g-aiMreg II
NVW INDIA LIMITED 6-51-0044 Rev. 5
FIER/517 i131,17.731 IA Govt of 10041 UndettakIngt DRY TYPE DISTRIBUTION
6.5 All protection, alarm and indication devices and neutral CTs shall be wired by means of PVC
insulated cables upto the marshalling box. There shall be two gland plates, one for internal
wiring to the marshalling box from various devices which shall be glanded and pre-wired,
while the second gland plate shall be removable and undrilled for glanding outgoing cables.
6.6 One neutral terminal inside the cable box/ MV bus-duct connection chamber and a separate
neutral terminal outside shall be provided for earthing of transformer winding neutral on the
secondary side. The neutral terminal shall be complete with connector block assembly for
easy termination of GI earth strip/cable.
6.7 The neutral CT shall be mounted as below:-
a) CT for 51 G shall be located in the earth path after bifurcation of neutral.

b) CT for 64 R can be located before bifurcation of neutral.
6.8 Two earthing terminals shall be provided on the transformer frame for transformer body
earthing. Suitable lifting arrangement shall be provided in the transformer frame. The
transformer shall be supported on flat rollers.
7.0 COOLING
Type of Cooling shall be in accordance with the datasheet.
8.0 TAPPINGS AND CONTROLS
Primary off-circuit rotary type tap changer shall be provided and shall have a range as
specified in the data sheet. Tap changing arrangement through links is not acceptable. Under
conditions of external short circuit, the tap changing device shall be capable of carrying the
same current as the windings.
9.0 ACCESSORIES
9.1 Accessories as specified on data sheet shall be included in the scope of supply. All protective,
alarm and indicating devices shall have minimum I no. potential free contact each for alarm
and trip. All transformers must be provided with at least the following:
Bi-directional flat rollers

Rating and terminal marking plate
Marshalling box
Lifting hooks and jacking pads, towing holes
Earthing terminals
Neutral CT (as per data sheet)
Off-circuit tap changer
Temperature monitoring system (For rating 500KVA & above)
9.2 Temperature monitoring system shall be supplied with temperature sensors fitted in each limb.
Temperature monitoring system shall initiate alarm and trip for winding over temperature.
Alarm and trip temperatures shall be site settable. The monitoring system shall also have an
indicating device.
Page 1424 of 2065

rJ111 31a'.1 t9 ENGINEERS FOR
*Pae-Ir INDIA LIMITED 6-51-0044 Rev. 5
(xiFn c-lecnre ,7513441.9 (A Govt of India Undettaking) DRY TYPE DISTRIBUTION
10.0 NOISE LEVEL
The average audible sound level for the transformers at a distance of 30 cm shall be as below:
KVA AVERAGE SOUND LEVEL (DECIBEL)

0-50 50
51-150 55
151-300 58
301-500 60
501-700 62
701-1000 64
1001-1500 65
1501-2000 66
2001-3000 68
3001-4000 70
4001-5000 71
EIL / owner's representatives shall be given free access to enter the plant and inspect the
equipment at any time during fabrication. However, 4 weeks advance notice shall be given by
vendor to witness the final tests.
For testing requirements, refer Inspection & Test Plan doc. no. 6-81-1044. All testing shalt be
carried out at manufacturer's works under his care and expense.
during transportation. The equipment shall be properly packed for the selected mode of
transportation i.e. by ship/ rail or trailer. The equipment shall be wrapped in polythene sheets
before being placed in the crates/ cases to prevent damage to the finish. Crates / cases shall
have skid bottom for handling. Special notations such as 'Fragile', 'This side up', 'Centre of
gravity', 'Weight', 'Owner's particulars', 'P.O. numbers' etc., shall be clearly marked on the
package together with other tag numbers etc.
The equipment may be stored outdoors for long periods before erection. The packing shalt be
suitable for outdoor storage in areas with heavy rains/ high ambient temperature.
Page 1425 of 2065

largt-Qie? ENGINEERS FOR 6-51-0051 Rev. 7
laelaileg} INDIA LIMITED MEDIUM AND HIGH VOLTAGE
IA Geri al Inds Undeddlunpl
CABLES AND ACCESSORIES Page 1 of 10
TRAIT id s q A
c;iski 3ikkurk-A.
1-ff‘ 1-4ffkr
SPECIFICATION
FOR
MEDIUM AND HIGH VOLTAGE
CABLES & ACCESSORIES

7 01/04/16
SPECIFICATION
6 11/04/11 PS ANPS UAP DM
SPECIFICATION
5 20/04/09 PB UAP JMS ND
SPECIFICATION
4 15/03/04 RKM AAN VPS SKG
SPECIFICATION
3 30/07/98 SKG RKM VPS AS
SPECIFICATION
Standards
StandardsCommitteeC
Bureau
Rev. Prepared Checked onvenor
Date Purpose Chairman
No by by
Approved by
Page 1426 of 2065

SPECIFICATION STANDARD SPECIFICATION No .
ISKUtzleft ENGINEERS FOR

aZ:11 fagegW INDIA LIMITED 6-51-0051 Rev. 7
IA GcM a/ Inds Undertaking) MEDIUM AND HIGH VOLTAGE
Abbreviations:
ASTM American Society for Testing and Materials

BS British Standard
DGMS Director General of Mines and Safety
EPR Ethylene Propylene Rubber
FR Flame Retardant
FRLS Flame Retardant Low Smoke
FS Fire Survival
HR PVC Heat Resistant Polyvinyl Chloride
ICEA Insulated Cable Engineers Association
IEC International Electro technical Commission
IS Indian Standards
PVC Polyvinyl Chloride
UV Ultra Violet
XLPE Cross linked Polyethylene

Mr. Parag Gupta
Mr. M. K. Sahu
Ms. N S Bhattacharya
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL -All rights reserved
Page 1427 of 2065

SPECIFICATION STANDARD SPECIFICATION No .
Olazie?e, ENGINEERS FOR
51:gzrr tagreg W INDIA LIMITED 6-51-0051 Rev. 7
cos d India UndeplaMirgi MEDIUM AND HIGH VOLTAGE
CONTENTS
1.0 SCOPE 4
3.0 GENERAL CONSTRUCTION 5
4.0 CABLE ACCESSORIES 7
Page 1428 of 2065

SVIZIei#SENGINEERS FOR
les W INDIA LIMITED 6-51-0051 Rev. 7
MEDIUM AND HIGH VOLTAGE
1.0 SCOPE
This specification along with data sheets covers requirements for design, manufacture, testing
at works and supply of Fire survival Medium voltage cables and Flame Retardant Low Smoke
Medium & High Voltage cables and cable jointing / terminating accessories for medium and
high voltage systems.
2.1 The cables and cables jointing & terminating accessories shall comply with the latest edition
of the following standards as applicable:
IS: 209 Specification for zinc.

IS: 1554 • PVC insulated (heavy duty) electric cables.
IS: 3961(Pt-2) : Recommended current ratings for cables: Part - 2 PVC Insulated and
PVC sheathed heavy-duty cables.
IS: 3975 Mild steel wires, strips and tapes for armouring of cables.
IS: 5831 PVC insulation and sheath of electric cables.
IS: 6380 Specification for elastomeric insulation and sheath of electric cables.
IS: 7098 Cross-linked polyethylene insulated PVC sheathed cables.
IS: 8130 Conductors for insulated electric cables and flexible cords.
IS: 10418 Drums for electric cables.
IS: 10462 (Pt-1): Fictitious calculation method for determination of dimensions of
protective coverings of cables: Part - I Electrometric and thermo-
plastic insulated cables.
IS: 10810 Methods of test for cables:
Part 41: Mass of zinc coating on steel armour
Part 58: Oxygen index test
Part-61: Flame retardant test
Part-62:Fire resistance test for bunched cables.
Part-63: Measurement of Smoke density of Electric cables
under fire conditions
IS: 13573 Joints and terminations for polymeric cables for working voltages
from 6.6kV up to and including 33kV.
IEC: 60331-21: Tests for electric cables under fire conditions circuit integrity —
Procedures and requirements — Cables of rated voltage up and
including 0.6/1.0kV.
IEC: 60332-1 : Test of the fire behaviour on single core or single cable (flame
retardancy)
IEC: 60332-3 : Tests of the fire behaviour on bunched cables (reduced flame
propagation)
IEC: 61034 : Measurement of smoke density of cables burning under defined
condition
NEMA-WC70 : Standard for non shielded power cables rated 2000V or less for the
distribution of electrical energy.
NEMA-WC53 : Standard test methods for extruded dielectric power, control,
instrumentation and portable cables for test.
ASTM-G-154 : Standard practice for operating fluorescent light apparatus for UV
exposure of non-metallic materials.
ASTM-D-2863 : Measurement of minimum oxygen concentration to support candle
like combustion of plastics
BS: 7846 Electric cables- 600/1000V armoured fire resistant cables having
thermosetting insulation and low emission of smoke and corrosive
gases when affected by fire.
Page 1429 of 2065

Sanaa&te, ENGINEERS FOR
• fsr.7f EVIeG W INDIA UMITED MEDIUM AND HIGH VOLTAGE
6-51-0051 Rev. 7
2.2 The cables and accessories shall also conform to the provisions of CEA Regulations and other
statutory regulations, as applicable.
project, the most stringent one shall prevail. However, Owner's decision in this regard will be
final and binding.
3.0 GENERAL CONSTRUCTION
3.1 The cables shall be suitable for laying in trays, trenches, ducts, and conduits and for
underground-buried installation with uncontrolled backfill and possibility of flooding by water
and chemicals.
3.2 Outer sheath of all cables shall be black in colour and the minimum value of oxygen index
shall be 29% at 27 ± 2 ° C. In addition suitable chemicals shall be added into the PVC
compound of the outer sheath to protect the cable against rodent and termite attack. However,
for earthing cables; colour of outer sheath shall be green.
3.3 All cables covered in this specification shall be Flame Retardant Low Smoke (FRLS) or Fire
Survival (FS). The outer sheath of FRLS cables shall possess flame propagation properties
meeting requirements as per IS-10810 (Part-62) category AF. FRLS cable shall be identified
by indenting, embossing or printing the appropriate legend i.e. 'FRLS, Category — C2'
throughout the cable length. FRLS properties shall be as per IS:10810 Part 61 & 62, IEC-
60332 Part 1 & Part 3, IEEE-383, IEC-61034, IEC-60754 Part 1, ASTM-D-2863.
3.4 Sequential marking of the length of the cable in metres shall be provided on the outer sheath at
every one metre. The embossing/engraving shall be legible and indelible.
3.5 The overall diameter of the cables shall be strictly as per the values declared by the
manufacturer in the technical information subject to a maximum tolerance of ±2 mm up to
overall diameter of 60mm and ±3mm for beyond 60mm.
3.6 PVC/ Rubber end caps shall be supplied free of cost for each drum with a minimum of eight
per thousand metre length. In addition, ends of the cables shall be properly sealed with caps to
avoid ingress of water during transportation and storage.
3.7 The joints in armour wire/strips shall be made by brazing or welding and any surface
irregularities shall be removed. A joint in any wire/strip shall be at least 300mm. from the
nearest joint in any wire/strip in the complete cable.
3.8 The cables meant to be used in mining area under the jurisdiction of DGMS shall satisfy the
following
(a) "DGMS CERTIFIED" to be embossed at outer sheath at regular interval.

(b) Cables to be used in Mines shall have copper conductor only.
(c) The resistance of armour shall not exceed that of the conductor as specified in IS-8130
by more than 33%. To satisfy this, substitution of galvanised steel wire/strip in
armouring by the required number of tinned copper wires/strips is permissible.
(d) For mining cables, the size and type of armour shall be such that the combined
conductance of armour shall be equivalent to 75 percent of the conductance of the
largest conductor of the cable.
Page 1430 of 2065

lataae ENGINEERS FOR
laileGWP INDIA LIMITED 6-51-0051 Rev. 7
ereew? niTIR (A Govt al !oda Undettakprw MEDIUM AND HIGH VOLTAGE
3.9 Medium Voltage Cables
3.9.1 All power/control cables for use on medium voltage systems shall be heavy-duty type,
650/1100V grade with aluminium/ copper conductor, PVC/XLPE (as mentioned in datasheet /
Material requisition) insulated, inner-sheathed, armoured/ unarmoured and overall PVC
sheathed. XLPE insulated cables shall meet the requirement specified in IS-7098 (Part-1).
3.9.2 The conductors shall be solid for conductor of nominal area up to and including 6mm2 and
stranded beyond 6mm2 . Conductors of nominal area less than 16 mm 2 shall be circular only.
Conductors of nominal area 16 mm 2 and above may be circular or shaped as per IS 8130.
Cables with reduced neutral conductor shall have sizes as per Table 1 of IS 1554 (Part-1).
3.9.3 The core insulation shall be with PVC/XLPE compound applied over the conductor by
extrusion. PVC compound shall conform to the requirements of type 'C' compound as per IS:
5831. The thickness of insulation and the tolerance on thickness of insulation shall be as per
Table 2 of IS: 1554 (Part-1). Control cables having 6 cores and above shall be identified with
prominent and indelible Arabic numerals on the outer surface of the insulation. Colour of the
numbers shall contrast with the colour of insulation with a spacing of maximum 50 mm
between two consecutive numbers. Colour coding for cables up to 5 cores shall be as per
Indian standard.
3.9.4 The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC
conforming to the requirements of Type ST-2 PVC compound as per IS: 5831. The minimum
thickness of inner sheath shall be as per Table-4 of IS: 1554 (Part-1). Single core cables shall
have no inner sheath.
3.9.5 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-magnetic
material. For multicore cables, the armour shall be by single round galvanised steel wires
where the calculated diameter below armouring does not exceed 13 mm and by galvanised
steel strips where this dimension is greater than 13 mm. Requirement and methods of tests for
armour material and uniformity of galvanisation shall be considered as per IS 3975 and IS -
-
10810 (Part 41). The dimensions of armour shall be considered as per method (b) of IS - 1554
(Part -1).
3.9.6 The outer sheath for the cables shall be applied by extrusion and shall be formulated for lower
smoke and shall be of PVC compound conforming to the requirements of type ST-2
compound as per IS: 5831. The minimum and average thickness of outer sheath for
unarmoured cables and minimum thickness of outer sheath for armoured cables shall be as per
Table-7 of IS: 1554 (Part -I).
3.9.7 If heat resisting PVC cables are specified in the data sheet„ it shall be possible to continuously
operate the cable at a maximum conductor temperature of 85°C under full load condition and
160°C under short-circuit condition.
3.9.8 For XLPE insulated cables, it shall be possible to continuously operate the cable at a
maximum conductor temperature of 90°C under full load condition and 250°C under short-
circuit condition.
3.9.9 The fire survival cables shall meet the following additional requirements :
i) The insulation shall be of EPR or equivalent material with glass mica tape below or
above insulation.
ii) The cables shall meet requirement of circuit integrity test for a minimum period of 3
hours at maximum temperature of 950° C.
iii) Vendor shall have the test certificate for circuit integrity test as per IEC: 60331-21.
Page 1431 of 2065

lardzie ENGINEERS FOR
s'g7 fataiegw INDIA LIMITED
(A can a Inds Uneertakpng) MEDIUM AND HIGH VOLTAGE
6-51-0051 Rev. 7
3.10 High Voltage Cables
3.10.1 Power cables from 3.3kV and up to and including 33kV systems shall be Aluminium/ Copper
conductor, XLPE insulated, sheathed, armoured/ unarmoured and overall PVC sheathed.
3.10.2 The conductors shall be stranded and compacted circular for all cables.
3.10.3 All cables rated 3.8/ 6.6kV and above shall be provided with both conductor screening and
insulation screening. The conductors shall be provided with non-metallic extruded semi
conducting screen.
3.10.4 The core insulation shall be with cross linked polyethylene insulating compound dry cured,
applied by extrusion. It shall be free from voids and shall withstand all mechanical and
thermal stresses under steady state and transient operating conditions. It shall conform to the
properties given in Table-I of IS: 7098 (Part -2).
3.10.5 The insulation screen shall consist of non-metallic extruded semi-conducting compound in
combination with a non-magnetic metallic copper screen. The copper screen for all the three
cores together shall be capable of carrying the single line to ground fault current value and the
duration specified in the data sheet. For single core cable, non-magentic armour shall
constitute the copper screen which shall be capable of carrying the single line to ground fault
current value and the duration specified in the data sheet.
3.10.6 The conductor screen, XLPE insulation and insulation screen shall all be extruded in one
operation by 'Triple Extrusion' process to ensure perfect bonding between the layers. The core
identification shall be by coloured strips or by printed numerals.
3.10.7 The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the
requirements of type ST 2 compound of IS: 5831. The extruded inner sheath shall be of
uniform thickness. In case of single core cables, there shall be extruded inner sheath between
insulation metallic screen and armouring.
3.10.8 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-magnetic
material. For multicore cables, the armour shall be by galvanised steel strips. Requirement and
methods of tests for armour material and uniformity of galvanisation shall be as per IS - 3975
and IS -10810 (Part 41). The dimensions of armour shall be as per method (b) of IS - 7098
(Part -2).
3.10.9 The outer sheath of the cables shall be applied by extrusion over the armouring and shall be of
PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831. The
minimum and average thickness of outer sheath for unarmoured cables and minimum
thickness of outer sheath for armoured cables shall be as per IS: 7098 (Part-2).
3.10.10 The thickness of the insulation, inner sheath shall be governed by values given in Table-4 and
Table-5 of IS: 7098 (Part -2).
4.0 CABLE ACCESSORIES
4.1 The termination and straight through jointing kits for use on the systems shall be suitable for
the type of cables offered as per this specification and shall meet requirements of IS 13573.
4.2 The accessories shall be supplied in kit form. Each component of the kit shall carry the
manufacturer's mark of origin.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — AU rights reserved
Page 1432 of 2065

aazieLl
ida ENGINEERS FOR
a tifiIegW WA LIMITED 6-51-0051 Rev. 7
lawn eia5,40r.povail
(A Gal 0/ Inas Undellakingl MEDIUM AND HIGH VOLTAGE
4.3 The kit shall include all stress grading, insulating and sealing materials apart from conductor
fittings and consumable items. An installation instruction sheet shall also be included in each
kit.
4.4 The contents of the accessories kit including all consumable shall be suitable for storage
without deterioration at a temperature of 45° C, with shelf life extending to more than 5 years.
4.5 Terminating Kits
The terminating kits shall be suitable for termination of the cables to an indoor switchgear or
to a weatherproof cable box of an outdoor mounted transformer/ motor. For outdoor
terminations, weather shields/ sealing ends and any other accessories required shall also form
part of the kit. The terminating kits shall be from one of the makes/ types mentioned in the
data sheet.
4.6 Jointing Kits
The straight through jointing kits shall be suitable for installation on overhead trays, concrete
lined trenches, and ducts and for underground burial with uncontrolled backfill and possibility
of flooding by water and chemicals. These shall have protection against any mechanical
damage and suitably designed to be protected against rodent and termite attack. The inner
sheath similar to that provided for cables shall be provided as part of straight through joint.
The jointing kits shall be from one of the makes/ types mentioned in the data sheet.
The cables shall be tested and inspected at the manufacturer's works. Manufacturer shall
furnish all necessary information concerning the raw material supply to EIL/ Owner's
inspectors. The inspector shall have free access to the manufacturer's works for the purpose of
inspecting the process of manufacture in all its stages and will have the power to reject any
material, which appears to be of unsuitable description or of unsatisfactory quality. For HV
cables, the vendor shall give at least 2 weeks advance notice to the purchaser, regarding the
date of testing to enable purchaser's representative to witness the tests.
5.1 Cables
5.1.1 After completion of manufacture of cables and prior to despatch, the cables shall be subjected
to type, routine, acceptance and special tests as detailed below. The test reports for all cables
shall be got approved from the Engineer before despatch of the cables.
5.1.2 All routine tests, acceptance tests, type tests and additional type tests for improved fire
performance shall be carried out as listed in IS: 1554 (Part-1) and IS: 7098 (Part-2) on PVC
and XLPE insulated cables respectively.
5.1.3 The test requirements for PVC insulation and sheath of cables shall be as per latest revision of
IS: 5831.
5.1.4 Test for Resistance to Ultra Violet Radiation: This test shall be carried out as per ASTM-G-53
or ASTM-G-I54 on outer sheath. The retention value of tensile strength and ultimate
elongation after the test shall be minimum 60 % of tensile strength and ultimate elongation
before the test. Test certificates with respect to this test (not older than one year) from
recognised testing laboratory to be furnished for review by EIL before despatch clearance of
cables. In case test certificates are not available, test is to be conducted by vendor at his own
cost in any recognised test laboratory or in house testing laboratory, before despatch clearance
Page 1433 of 2065

SPECIFICATION STANDARD SPECIFICATION No
18ilfrkie? ENGINEERS FOR
.
la{a 051.agi WA LIMITED 6-51-0051 Rev. 7

A Gaol al Inds Undeplaltingi, MEDIUM AND HIGH VOLTAGE
of cables. Sampling for this test is to be done randomly once for each order, provided outer
sheath remains same.
5.1.5 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 sampling plan for all cables. However these tests are
required to be witnessed by EIL/ Owner for HV cables.
a. Accelerated water absorption test for insulation as per NEMA-WC-70. (For PVC
insulated cables) and as per NEMA-WC-53 (for XLPE/ EPR insulated cables). Test
certificates with respect to this test (not older than one year) from recognised testing
laboratory to be furnished for review by EIL before despatch 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 despatch clearance of
cables. Sampling for this test is to be done randomly once for each order, provided type of
insulation remains same.
b. Dielectric Retention Test: The dielectric strength of the cable insulation tested in
accordance with NEMA-WC-70 at 75 ± 1° C shall not be less than 50 % of the original
dielectric strength. (For PVC insulated cables). Test certificates with respect to this test
(not older than one year) from recognised testing laboratory to be furnished for review by
EIL before despatch 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 despatch clearance of cables. Sampling for this test is to be done
randomly and once for each order.
c. Oxygen Index Test: The test shall be carried out as per IS-10810 (Part 58). Sampling to
be done for every offered lot/size as per sampling plan.
d. Flammability Test: The test shall be carried out on finished cable as per IS-10810 (Part 61
& 62). Sampling for these tests is to be done randomly once for each order, provided
outer sheath remains same. The acceptance criteria for tests conducted shall be as under:
Part-61-The cable meets the requirement if there is no visible damage on the test
specimen within 300 mm from its upper end
Part-62-The maximum extent of the charred portion measured on the test sample should
not have reached a height exceeding 2.5 m above the bottom edge of the burner at the
front of the ladder.
e. Test for rodent and termite repulsion property shall be done by analysing the property by
chemical method.
5.1.6 Following tests shall be carried out to prove FRLS property of the cable.
a. Critical oxygen index as per ASTM-D-2863 i.e. Determination of % of oxygen required

for combustion at room temperature of FRLS sheath which shall remain as 29%(min.)
b. Temperature index as per ASTM-D-2863 i.e. To determine at what temperature normal

oxygen content of 29% in air will support combustion of FRLS sheath which shall remain
as 250°C.
c. Halogen acid gas emission as per IEC-60754 Part 1 i.e. To determine the % of release of
hydrochloric acid gas from the FRLS sheath under fire which shall be 20% (max.)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —AU rights reserved
Page 1434 of 2065

15ilfazle? ENGINEERS FOR
sal laiRegCW t■DIA LIMfTED
IA Gal Olinda UneerVATVI MEDIUM AND HIGH VOLTAGE
6-51-0051 Rev. 7
d. Smoke Density Test shall be as per ASTM D - 2843 and Smoke Density Rating of FRLS
Sheath shall be 60% (max.).
5.1.7 The test for circuit integrity for fire survival cables shall be carried out as per IEC-60331
(Part-21).
5.2 Cable Accessories
Type tests should have been carried out to prove the general qualities and design of a given
type of termination/ jointing system as per IS-13573. The type test certificates from
independent testing laboratory shall be submitted before despatch.
6.1 Cables shall be despatched in non-returnable steel drums of suitable barrel diameter, securely
packed, with the take-off end fully protected against mechanical damage. Ferrous parts used
shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit
or storage.
6.2 On the flange of the drum, necessary information such as project title, manufacturer's name,
type, size, voltage grade of cable, length of cable in metres, drum no., cable code, BIS
certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum
with suitable instructions to show the direction of rotation of the drum.
6.3 Cables shall be supplied in drum lengths as follows:
6.3.1 MV Cables
Multicore Power cables upto 6 mm2 1000 m
Multicore Power cables from 10 mm 2 up to 500 mm2 500 m
Single Core Power cables upto 630 mm 2 1000 m
Control cables upto 61 cores 1000 m
6.3.2 HV Power Cables Upto 11kV Grade
Three Core cables upto 400 mm 2 500 m

Single Core cables upto 400 mm 2 1000 m
Single Core cables above 400 mm 2 and upto 1000 mm2 750 m
6.3.3 HV Power Cables Above 11kV Grade and upto 33kV Grade
Three Core cables upto 300 mm 2 grade 350 m

Single Core cables upto 400 mm 2 1000 m
Single Core cables above 400 mm 2 and upto 1000 mm 2 500 m
However exact drum lengths shall be finalised during order execution. A tolerance of ± 3 %
shall be permissible for each drum. However overall tolerance on each size of cable shall be
limited to ±2%.
Page 1435 of 2065

SPECIFICATION SPECIFICATION NO.
k31 ENGINEERS FOR 6-51-0055 Rev. 2
INDIA LIMITED NUMERICAL RELAYS &
rtrmtct trnJoo.0 IA Govt ol India undertaking)
SUBSTATION AUTOMATION SYSTEM Page 1 of 15
Wt)‹ii
kaie11 VTITT
RiR fq-r-4krr
SPECIFICATION
FOR
NUMERICAL RELAYS &
SUBSTATION AUTOMATION SYSTEM
/
REVISED AND ISSUED AS STANDARD SC
2 12-06-14 SV
SPECIFICATION
1 24-03-09
SPECIFICATION SKM AK JMS ND
0 12-08-02 ISSUED AS STANDARD SPECIFICATION RCS AAN VPS GRR
Standards Standards
Committee Bureau
No by by
Approved by
Page 1436 of 2065

t31 ENGINEERS FOR
1.1277 ewcnrc'013WFA) IA Govt of India Undenakong) NUMERICAL RELAYS &
Abbreviations:
AC : Alternating Current LCD : Liquid Crystal Display

BS : British Standard LED : Light Emitting Diode
BTD : Bearing Temperature Detector HMI : Human Machine Interface
CBCT Core Balance Current Transformer TCP-IP Transmission Control Protocol-
Internet Protocol
CPU : Central Processing Unit MOG : Magnetic Oil Gauge
CT : Current Transformer NEMA : National Electrical Manufacturers
Association
DC : Direct Current NO : Normally Open
DCS Distributed Control System OTI : Oil Temperature Indicator
ECS : Electrical Control Station PC : Personal Computer
EMI : Electromagnetic Interference PCB : Printed Circuit Boards
FIFO : First in first out PLC : Programmable Logic Controller
FO : Fibre Optic PT : Potential Transformer
GPS : Global Positioning System PVC Poly Vinyl Chloride
HV : High Voltage REF : Restricted Earth Fault
I/O Input/output RSTP : Rapid Spanning Tree Protocol
ICT : Intermediate Current Transformer RTD : Resistance Temperature Detector
IDMTL Inverse Definite Minimum Time Lag RTU : Remote Terminal Unit
IEC : International Electrotechnical SNTP : Simple Network Time Protocol
Commission
IEEE : Institute of Electrical and Electronics SOE : Sequence of event
Engineers
IP : Ingress Protection VDE : Verband Deutscher Elecktrotechniker
IRIG- B : Inter-Range Instrumentation Group WTI : Winding Temperature Indicator
Subcarrier Channel-B
KEMA : Keuring Electrotechnisch Materieel
Arnhem
LAN : Local Area Network
Convenor : Mr. BR Bhogal
Members : Ms. S. Anand

Mr. Parag Gupta
Mr. M.K. Sahu
Page 1437 of 2065

ENGINEERS FOR
w INDIA LIMITED 6-51-0055 Rev. 2
« ern~› (A Govt ol Inda UndettakIng) NUMERICAL RELAYS &
CONTENTS
1.0 SCOPE 4
6.0 SUBSTATION AUTOMATION SYSTEM 9
Page 1438 of 2065

■
31 ENGINEERS FOR
~g.INDIA LIMITED 6-51-0055 Rev. 2
1.11Z71 r,rmict ,1,1~11 IA Govt ol In0. Undertalong) NUMERICAL RELAYS &
1.0 SCOPE
The intent of this specification is to define the minimum requirement of design, manufacture,
testing, packing and dispatch of numerical relays. The specification also defines the requirement
of communication and integration for Substation Automation System.
2.1 The equipment shall comply with the requirements of latest revision of following IEC standards /
equivalent Indian Standards, unless otherwise specified:
IEC 60068 : Environmental Testing
IEC 60073 : Basic safety principles for man machine interface, marking & identification —
Coding principles for indicators and actuators
IS/IEC 60529 : Degree of protection provided by enclosure (IP Code)
IEC 60255 : Electrical relays
IEC 61000 : Electromagnetic compatibility (EMC)
IEC 61850 : Communication networks & systems in substations
2.2 In case of imported equipment, standards of the country of origin shall be applicable, if there
standards are equivalent or more stringent than the applicable IEC / Indian standards.
2.3 The equipment shall also conform to the provisions of CEA regulations and other statutory
2.4 In case Indian standards are not available for any equipment, standards issued by IEC / BS /
VDE / IEEE / NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standard/ specification/ data sheet and
statutory regulation, most stringent requirements shall prevail. However, Owner's decision in
this regard will be final and binding.
3.0 SITE CONDITIONS
3.1 The relay shall be tropicalised, for satisfactory operation when installed in a panel located in a
pressurised substation with restricted natural air ventilation, in tropical humid and corrosive
atmosphere. Relay shall be designed to perform all its functions and operate under site conditions
specified in numerical relay data sheet. If not specifically mentioned there in, a design ambient
temperature of 40°C and an altitude not exceeding 1000M above the mean sea Level shall be
cons idered.
4.1 The equipment offered shall be brand new with state of the art technology with proven field
track record of similar type and model or model in same series with additional features. No
prototype equipment shall be offered.
equipment at least for 15 years from the date of supply.
services.
4.4 In case of relays manufactured outside India, the relay manufacturer through his Indian
establishment or associate in India shall provide application, testing, commissioning, after sales
service and other necessary support for minimum of 15 years to customer. Their Indian
establishment or associate company in India shall also maintain adequate inventory of each type
of relay or spares to meet the requirement arising during project execution and plant operation.
Relay manufacturer shall possess a signed Memorandum of Understanding with their Indian
associate for providing customer support
Page 1439 of 2065

ENGINEERS FOR
IA Govt of Incha Undertafong) NUMERICAL RELAYS &

5.1 Auxiliary Power Supply
Unless otherwise specified, numerical relays, data concentrator, Ethernet switches, gateway &
HMI shall be suitable to accept both AC/DC supplies with range 110V to 240V with tolerance of
± 15%. The auxiliary power supply shall preferably be site-selectable requiring no additional
hardware.
5.2 Basic Requirement and Construction Details
5.2.1 Relay shall be suitable for flush mounting. The relay enclosure front shall be dust tight having
degree of protection minimum as IP5X.
5.2.2 Relay terminals shall be suitable for termination of 1.5/2.5/4 sq mm wires, for all hardwired
connections.
5.2.3 Relay shall be modular with plug in type PCB for easy replacement. The relay terminals shall be
easily accessible for testing and commissioning.
5.2.4 Current operated relay shall have provision for minimum 3 number phase CT inputs and 1
number CBCT input. Voltage operated relay shall have provision of minimum 3 numbers PT
inputs. The exact number of CT and PT inputs shall be based on the schematic requirements,
relays shall be selected accordingly.
5.2.5 CT shorting link shall be provided at terminal block as required.
5.2.6 All numerical relays shall have key pad/ keys to allow relay setting from relay front. All hand-
reset relays shall also have reset button on relay front. Self reset or hand reset feature of the relay
shall be software selectable and password protected.
5.2.7 Relay shall be suitable for 1 A or 5A CT secondary. CT secondary 1A or 5A shall either be
software selectable or by providing suitable link. Selection between IA or 5A should be possible
at site.
5.2.8 Relays shall have self-diagnostic feature with indication of relay failure on relay front. Relay
faults (Self- diagnostic) shall be communicated and annunciated to substation automation
system.
5.2.9 Relays shall, as a minimum, have protection functions as per feeder equipment data sheets. Other
functions such as metering and control shall be provided, if specified in data sheets/job
specifications.
5.3 Software Security
The relays shall be provided with suitable security (pass word protection) against unauthorized
WRITE ACCESS for change in relay setting. However it should be possible to view metering,
protection settings, status and event data as READ ONLY without password protection.
5.4 Display and Indication
5.4.1 All relays shall have LCD display along with LED indications for display of settings, status,
faults and events. Relays for generator protection, switchyard and GIS shall be provided with
medium size LCD display having facility for graphical display of mimic with upto 15 objects on
each page.
5.4.2 LCD display shall be backlit and temperature compensated up to 55°C for contrast and legibility.
5.4.3 Relays shall have 3 fixed LEDs for Relay ON/Control supply ON, fault trip & relay unhealthy
apart from freely configured LEDs.
5.5 Protection Functions
5.5.1 Over Current/Earth Fault Protection
i) This section describes over current & earth fault protection function, which mainly include
different setting stages such as low set, high set and high set instantaneous (51, 50, 51N,
Page 1440 of 2065

ENGINEEFZS FOR
Oga- fdf51-
c-ircnr, L1113~)
INDIA LIMITED
(A Govt ol Indo undenaxng) NUMERICAL RELAYS &
6-51-0055 Rev. 2
50N). Over current protection function provided should have IDMTL characteristic for low
set and high set stages and definite time delay for high set instantaneous stage.
ii) Over current relay shall be three phase type with 4 elements; 3 elements for inverse and
definite time delay over current and one element for inverse and definite time delay earth
fault current. Selection of inverse or definite time feature shall be user selectable.
iii) The IDMTL characteristic (for 51 and 51N) shall be as per IEC. The inverse characteristics
shall include normal inverse, very inverse, extremely inverse, long inverse and shall be soft
ware selectable. Inverse element shall have two or more stages (low and high set) for
selection of required inverse characteristic to achieve close protection as required.
Definite time characteristic shall have minimum 2 stages with adjustable current and time
setting.
iv) Relay shall also have separate current input from CBCT for measured earth fault current
element. It shall be possible to connect earth fault element either through CBCT or to be
connected residually. Minimum setting current for sensitive earth fault element shall be 1%.
v) Directional overcurrent & earth fault element shall be provided, wherever required.
vi) Voltage biased overcurrent / earth fault element shall be provided wherever required.
5.5.2 Motor Protection
i) Motor protection relay shall have all protection function such as over current, thermal (over
load), locked rotor current, zero sequence, negative sequence, maximum number of start,
motor overload pre-alarm, motor re-acceleration, lock out, inhibit of over current protection
during motor starting through contactor feeders, hour run count, inhibit start after elapse of
maximum number of starts etc.
ii) The relay shall be provided with 6 Nos. RTD and 2 Nos. BTD analog inputs, if specified in
the data sheet / job specification. Alternatively, external RTD/BTD module having interface
with numerical relay can be provided. The numerical relay with RTD / BTD inputs shall be
suitable for shielded triad cable of conductor size 1.5sqmm copper, unless otherwise
specified.
iii) Separate motor differential protection shall be provided, wherever specified.
5.5.3 Transformer Protection
i) In addition to overcurrent & earth fault function, wherever required, the main numerical
relay shall also include standby earth fault protection function (51G) for the transformer.
The standby earth fault shall operate from a separate neutral CT input and shall have
definite time / IDMTL characteristics as per IEC.
ii) Wherever the transformer requires restricted earth fault protection (64R), separate
numerical relay shall be provided. 64R function can be included as a part of main
differential protection relay (87T), unless otherwise specified. For details of transformer
differential protection relay refer Cl. 5.5.6.
iii) Transformer auxiliary protection (OTI/WTI/Buchholz/MOG etc) shall be included as a part
of numerical relay.
iv) Transformer differential protection shall be provided, wherever specified.
5.5.4 Generator Protection
i) Medium Voltage Generators (415V) shall have all protection functions such as voltage
restrained overcurrent (51V), standby earth fault (51G), negative sequence (46), Reverse
power (32), under voltage (27), overvoltage (59), thermal overload (49), PT fuse failure
monitoring function (60), generator differential (87G) as a minimum.
ii) In addition to the above, HV generators (turbine / diesel engine driven) shall have additional
protection functions such as rotor back up earth fault (64R)-1st and 2nd stage, low forward
Page 1441 of 2065

ENGINEERS FOR
fffliteg INDIA LIMITED 6-51-0055 Rev. 2
IHRFi vtrotrv on~) IA Govt of InOia Undeflaiong) NUMERICAL RELAYS &
power flow (37), loss of excitation (40), under frequency (81U), rate of change of frequency
(df/dt) unless otherwise specified.
iii) If specified in the datasheet, additional protection functions such as field overcurrent, over
frequency (810), back up impedance (21), over fluxing (99), out of step shall be provided
as a part of generator protection numerical relay.
iv) The generator protection functions can be included as a part of one numerical relay or a
separate numerical relays can be provided.
5.5.5 Voltage Operated Protection Functions
i) These functions include under voltage (27), over voltage (59), ON delay and OFF delay
timers, phase sequence voltage, neutral displacement and Synchro-check functions etc.
ii) The under voltage and overvoltage protective function shall have different stages with
IDMTL and definite time characteristics.
iii) If specified in datasheet, the relay shall have under and over frequency function along with
frequency supervised Rate of change or average rate of change of frequency function.
5.5.6 Differential Protection
Suitable differential protection shall be provided as required as per data sheet / job specification
for the specific application such as for generator, transformer, overall generator & transformer,
motor, feeder, bus section etc. The following requirements, as applicable, shall be complied:
i) Differential protection shall be either high impedance or low impedance type. In case of
high impedance type, suitable non linear resistor shall be provided to limit the peak
overvoltage.
ii) Transformer differential protection shall have suitable harmonic restraint feature to avoid
maltripping during switching.
iii) For transformer differential protection, necessary correction for ratio error and for
transformer primary and secondary vector grouping shall be taken care in the relay itself
without additional ICTs. The required relay setting for this shall be programmable.
iv) Bus differential relay shall have feature for CT supervision and check differential.
v) In case separate hard-wired relay is used for check differential, the status/ event of same
shall be communicated through the numerical relay provided for main differential
application.
vi) Unless otherwise specified, the differential relays such as generator differential, transformer
differential, overall generator transformer differential, motor differential, feeder differential
etc. shall be suitable for cable connection between CTs and relay using 2.5 sq.mm., Cu
conductor, PVC insulated, armoured cable. However for differential protections provided
for feeders having long lengths, armoured FO cable may be considered. In cases where FO
cable is not suitable, shielded twisted pair cable of conductor size 1.5sqmm copper shall be
specifically mentioned by the bidder in the offer for EIL/Owner's acceptance on case to
case basis.
5.6 Metering Functions
The metering function shall be provided as required and same shall be built inside the numerical
relays.
5.7 Control Functions
5.7.1 The control function shall be built inside the numerical relays. For this purpose relays shall have
all graphical PLC/Boolean logic functions such that complete control logic of the feeder along
with all necessary interlocks as required can be developed inside the relay.
Page 1442 of 2065

tt (‘f£
ENGINEERS FOR
ge-a 1~1 232,,,I2 A51~9)
INDIA LIMITED
IA Govt of InOia Unclertatong) NUMERICAL RELAYS &
6-51-0055 Rev. 2
5.7.2 Relays for motor feeder shall be equipped with all control functions and interlocks related to
motor feeder. If reacceleration is a part of motor feeder, the control function shall also cover
reacceleration logic.
5.7.3 Relays shall have sufficient integral I/Os to take care of complete feeder logic. External I/O
module for implementation of logics is not acceptable.
5.8 Lock Out (86), Trip Circuit Supervision (95), Auxiliary Relays and Timer Functions
5.8.1 Unless otherwise specified the numerical relays shall have built in lock out function. For motor
feeders additional built-in lockout element shall be provided to receive process trip signals. Lock
out elements shall be self reset or hand reset and shall be software selectable.
5.8.2 The numerical relays shall have built in trip circuit supervision function, unless otherwise
specified.
5.8.3 Auxiliary relays/ Timers function etc as required for control schematics shall be programmable
as a part of numerical relay. The number of such elements as required for schematic shall be
considered.
5.8.4 Timer function shall be programmable for both ON/OFF delays.
5.9 Disturbance/ Event Recording and Data Storage
5.9.1 Breaker trip/ close status, relay faults, trip values, event data and disturbance record data shall be
stored in the relay in non-erasable memory or memory backed up by lithium battery. Under no
circumstances such as withdrawal of power to the relays shall the status, data and events in the
memory get erased. Unless otherwise specified, it should be possible to store total 10 seconds of
disturbance recording and 200 sequence of event records. Subsequent events shall be overwritten
following principle of FIFO.
5.9.2 All disturbances/ events shall be time stamped within the relay.
5.10 Input/ Output Interface, Filters and Galvanic Isolation
5.10.1 Voltage (through PT) input to relay, shall be 110V +/- 10%, unless otherwise specified.
5.10.2 Out put relays shall have 4 numbers spare NO contacts; each shall separately be programmable
for either hand reset or self- reset.
5.10.3 Contacts of pushbuttons from field, interlocks from DCS/ other switchboards shall be wired to
the relay as binary input using 1.5/2.5sqmm, multi core, copper conductor cables. The distance
between push buttons/ interlock to switchboard may be considered as 1000m, unless otherwise
specified. The pick-up voltage for BIs/BOs shall be site selectable. The additional components as
required to overcome the cable capacitance effect shall be considered as a part of supply of relay.
The binary input to relay from field contacts and interlocks shall be momentary type. Logic to
latch the momentary contact, as required shall be built as a part of protection relay.
5.10.4 All I/Os shall have galvanic isolation. Analog inputs shall be protected against switching surges,
harmonics etc.
5.11 Relay Communication
5.11.1 All numerical relay shall have RS232/RJ45/USB port on the front for hooking laptop.
5.11.2 At the rear numerical relays shall have suitable communication port for communication with data
concentrator/ HMI/ Station bus. The type of port shall be selected based on method of
communication (Serial or Ethernet) and type of physical transmission medium (twisted pair
copper or fiber optic). For serial communication, the relay port shall be RS485 or FO (fiber
optic) and for Ethernet (IEC 61850 based) communication same shall be RJ45or FO.
5.11.3 The communication protocol shall be selected to transfer all information including time stamp
data from relay to data concentrator/ substation HMI. The relays shall communicate on industry
open protocol such as IEC 60870-5-103/IEC 61850/ Modbus-RTU / Modbus TCP-IP or any
other open protocol.
Page 1443 of 2065

ENGINEERS FOR
Ogzu1a2eselr.rt 3.~)
INDIA LIMITED
IA Govt of Incha Undettalong) NUMERICAL RELAYS &
6-51-0055 Rev. 2
5.11.4 For IEC 61850 based communication, each relay shall be suitable for communicating with
minimum three numbers client devices.
6.0 SUBSTATION AUTOMATION SYSTEM
Substation automation system broadly comprises of numerical relays, data concentrator panels
(as required), HMI, laptop, printers and their associated software for monitoring of the electrical
system.
6.1 Communication
Communication is the backbone of any substation automation system. It is through this medium,
the monitoring of various parameters takes place effectively.
6.1.1 Serial Communication
i) Data concentrator shall have two serial ports (1 no. in each CPU module) for simultaneous
remote communication on relay LAN. The relays shall be multi-dropped on RS485 through
single drop from LAN to each relay. In the event of either failure of any relay or break in
LAN cable or failure of port at data concentrator, the redundant hardware shall ensure
healthy communication between relay and data concentrator (refer Figure-1).
ii) Alternatively, relays shall communicate in star topology using star coupler. Communication
from relays to star coupler shall be through single communication port. Communication
from star coupler to data concentrator shall be through redundant communication link (each
link part of separate star coupler unit). RS485 to FO converters wherever required shall be
part of offered relay/ other hardware. Star coupler shall be provided with dual power supply
module
iii) The maximum number of relays in one loop shall be decided so as to achieve maximum
scan time as 500 ms for status input and maximum 6 sec for analog and historical data
considering total number of serial loop and star coupler as a total integration. The above
scan time does not include screen refresh rate at HMI.
iv) For sequence of event recording, time discrimination between two events shall be
maintained to 1 m sec or better.
6.1.2 IEC-61850 based Communication
i) Ethernet switches shall provide error free communication in harsh substation environment
and shall be immune to EMI. The Ethernet switches shall comply to IEC 61850-3 and shall
be KEMA approved or equivalent.
ii) For real time deterministic performance, managed Ethernet switch shall be considered in the
Ethernet network. The switch shall support following features:
- Full duplex operation
- Priority Queuing
- Virtual LAN (VLAN)
- Rapid Spanning tree
- Multicast filtering
iii) Dedicated Ethernet switches shall be provided for each switchboard. 20% spare ports shall
be provided in each Ethernet switch.
iv) Ethernet switch shall have dual DC power supply facility.
v) Communication between relay and HMI shall be provided as follows:
Redundant Ethernet communication architecture shall have RSTP topology. Numerical
relays shall be hooked up to Ethernet switch in star topology and the switches (within the
switchboard) shall be further connected in ring (refer Figure 2).
Page 1444 of 2065

ENQNEERS FOR
$'fgzir 2ffleg INDIA LIMITED
Govt ol lnOa Undertak.ng) NUMERICAL RELAYS &
6-51-0055 Rev. 2
Alternatively, from each switch (within the switchboard) redundant communication link
shall be extended to two number backbone switches to be located within the switchboard
(refer Figure 3).
For hooking up to HMI/gateway for upper level connectivity, redundant communication
link either from any two switches within the ring or from back bone switches shall be
further extended and hooked up to two numbers master Ethernet switches dedicated for
hooking HMI/gateway/printers/GPS etc. From HMI redundant communication link shall be
extended to the master Ethernet switches.
6.2 Data Concentrator
6.2.1 Data concentrator shall be supplied to facilitate communication with relays on open protocol.
6.2.2 As a minimum data concentrator shall have separate power supply module, CPU module and I/0
module. To achieve redundant architecture, either separate data concentrator shall be considered
or data concentrator shall have redundant power supply module and redundant CPU module. The
CPU module shall have sufficient communication ports depending on relay LAN requirement.
6.2.3 Data concentrator shall provide gateway to upper level control system on Ethernet/ 1EC61850
protocol/Modbus-RTU protocol or protocol as specified in the data sheet. The communication to
upper level control system shall be redundant as per data sheet/ system architecture.
6.2.4 Data concentrator shall have binary and analog (4 to 20mA) I/0 cards suitable for interface
requirement specified in data sheet. Unless otherwise specified, 20% 1/0s shall be considered as
spare. Alternatively, a separate Data Acquisition Unit may be supplied for binary and analog
interface.
6.2.5 Data concentrator shall have required number of ports for relay LAN/ star couplers. Number of
relay LAN/ star couplers shall be as per project requirement. 20% or minimum 2 Nos. spare
ports whichever is maximum shall be provided for future extensions.
6.2.6 Data concentrator shall have required number of RS232/ RS422/RJ45 ports for connection to
Laptop PC and substation HMI having operator's work station and engineering station PC.
6.2.7 Data concentrator shall have redundant RS485/ FO/ Ethernet port for communication to
substation HMI and upper level ECS-RTU. Hook up to upper level system shall be carried out
by extending serial connectivity from each communication ports in two CPU modules.
6.3 Gateway
6.3.1 Gateway for upper level connectivity if separately provided shall have redundancy in power
supply module, CPU module. Alternatively, redundant gateways can be provided.
6.3.2 In case of IEC-61850 based communication, if gateway is envisaged, gateway shall have binary
and analog (4 to 20mA) I/0 cards suitable for interface requirement specified in datasheet.
Unless otherwise specified, 20% 1/0s shall be considered as spare. Alternatively, a separate Data
Acquisition Unit may be supplied for binary and analog interface with communicates to ethernet
switch on IEC-61850 protocol.
6.4 Human Machine Interface (HMI)
6.4.1 Following functions as a minimum shall be a part of HMI:
Display of Single Line Diagram
- Feeder status monitoring
- Data logging
Relay parameterization
- Event recording
- Historical data & trending
- Annunciation
Page 1445 of 2065

ENGINEERS FOR
$1g-ar ffl2eg INDIA LIMITED
Govt of Indta Undertalong) NUMERICAL RELAYS &
6-51-0055 Rev. 2
6.4.2 Human machine interface shall include engineering and operator function. Engineering and
operator workstations shall be separate.
6.4.3 HMI shall be of industrial grade suitable for continuous operation at design ambient temperature
with restricted natural ventilation.
6.4.4 HMI shall be of latest version of industrial grade PC and the same shall be provided with 21"
color monitor (TFT flat screen) with non glare glass filters to minimize glare from external
lighting.
6.4.5 Operator workstation shall have user friendly software for interactive display of substation data
in multiwindow feature. Software shall have capability to display substation single line
diagrams, display of electrical system parameters, reports, alarm annunciation, daily and monthly
data logging, continuous polling, relay monitoring, relay supervision, fault disturbance record of
each relay, graphic representation and trending of data etc. The offered system shall comply with
requirements of IEC for basic and safety requirements for Human-machine interface.
6.4.6 Engineering workstation shall have software for engineering, detailed self diagnostic for
maintenance, trouble shooting and changing parameters. Further, it shall also have facility to
program and configure numerical relays, data concentrator and other intelligent devices. In
addition engineering work station shall have all the facilities as provided for operator
workstation.
6.4.7 The HMI system shall be provided with color laser jet A3 printer for generating hardcopy of
alarm, event and logging report. The printing shall be on demand, unless otherwise agreed.
6.4.8 If specified, separate laptop shall be provided. The laptop shall include all functionalities as
specified for HMI system and the same shall be provided with required licensed software,
hardware, accessories and material. System configuration shall be latest proven model and
upgradable.
6.4.9 HMI system shall be provided with all associated furniture for PC, printer etc.
6.5 Time Synchronization
6.5.1 All internal clocks of numerical relay, data concentrator, SOE modules, HMI etc. shall always
work in synchronism such that there is one and only one system-wide time. GPS shall be
considered to synchronize with an external satellite clock. The time synchronization accuracy
shall be ± 1.0 msec or better.
6.5.2 The GPS system shall consist of GPS antenna, lightning arrestor, GPS receiver/server and
associated cables.
6.5.3 The time synchronization shall be carried out either through communication over substation
relay LAN or by considering dedicated time synchronization channel. In case of synchronization
through relay LAN, the communication protocol shall support to carry time synchronization
message to the relays/data concentrator/HMI and maintain the desired accuracy. In case of time
synchronization through dedicated time synchronization channel, relays, data concentrator and
HMI shall be provided with IRIG- B port and the same shall be directly hooked up to GPS
receiver.
6.5.4 In Ethernet based communication network, GPS receiver shall be directly hooked up to Ethernet
LAN and all internal clocks of HMI and numerical relays shall be updated using SNTP protocol.
7.1 During assembly, EIL / Owner or his authorized representative shall be permitted to assess the
progress of work as well as to ascertain that quality raw material is used for the same. All
assistance as required during inspection shall be given to inspector.
7.2 For testing requirements refer Inspection & Test Plan No. 6-81-1055.
Page 1446 of 2065

11
k- ENGINEERS FOR
g-111d2-
eg INDIA LIMITED 6-51-0055 Rev. 2
(A Govt of India Underlaking) NUMERICAL RELAYS &

The equipment shall be properly packed for transportation by ship/rail or trailer. All equipments
shall be wrapped in polyethylene sheets before being placed in wooden crates/ cases with fillers
to prevent damage to the finish. Crates/cases shall have skid bottoms for handling. Special
notations such as `Fragile', `This side up', `centre of gravity', `weight', Òwner's particulars',
nos.' etc. shall be clearly marked on the package together with other details as per purchase
order.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL -All rights reserved
Page 1447 of 2065

ENGINEERS FOR
v<NT,?vmsrvAm~/ 1,4 Govt Indla Undeltak.,.2) NUMERICAL RELAYS &
0WS EW S
LAPTOP PRINTER
LAPTOP
/\
L E _J
L T
L2J LiJ L4J L_11 22-1 LIJ L.4]
ETHERNET SWITCH-1 ETHERNET SWITCH-2
12 I 11 . I. I. I In
I L
r—
_T I
I
REDUNDANT DATA CONCENTRATOR
GPS Clock DATA CONCENTRATOR-1 DATA CONCENTRATOR-2

With Annetna
I I I II I I 1
li I I I
j_ ii I I I
to ECS 'I
I I j
_l I I L
(on specified protocol) rr I I I L
I I I L
to DCS I I
(MODBUS-TCP/IP)
I NR-1 NR-1 I NR-1

I NR-2 1NR-2 1NR-2
I NR-3 1NR-3 I NR-3
I I
EJ NR-n
L_
L
FIGURE 1: TYPICAL ARCHITECTURE FOR SERIAL COMMUNICATION
Page 1448 of 2065

ENGINEERS FOR
1711WI cyrmrt an,~) IA Govt of lntlia UndenakIng) NUMERICAL RELAYS &
EWS
PRINTER
LAPTOP
LAPTOP
,/MN JJ
r
I
GPS Clock 1
With Annetna 1
Lit
LLI L2J LIJ LAJ L1J 2
IJ L3J
MASTER MASTER
191?1 - I - 1-1-121 121 3 I I. 1-1-1n1
ECS RTU
to ECS or ti—
r- GATEWAY (IEC-61 850)
II
to DCS =JJ
L
J L
r—
HV SWITCHBOARD MV SWITCHBOARD
— —i
12J 12J 11J L2J
ETHERNET SWITCH-1 ETHERNET SWITCH-n ETHERNET SWITCH-1 ETHERNET SWITCH-n

'I -I 121
I 1
I 1 1
I I I
I I
NR-1H NR-111 I NR-1H I NR-1}-,
NR-21- I NR-21- I NR-2}--;
NR-31- — NR — [ NR-3f- — IN R —
iNR-n ——— {NR-n 1NR-n _J INR-n
Note: connectivity to DCS is envisaged from ECS RTU. Where ECS RTU is not envisaged, gateway shall be
considered as part of Substation Automation System
FIGURE 2: TYPICAL ARCHITECTURE FOR IEC-61850 COMMUNICATION
Page 1449 of 2065

ENGINEERS
FOR
$'gzirlaa4-eg
«Iirrt c`le nnI1 M 3Vi6AI
INDIA LIMITED
I A Govt ol InOia Undenaking) NUMERICAL RELAYS &
6-51-0055 Rev. 2
EWS
PRINTER
LAPTOP
LAPTOP
/,\
r JJ
J_
GPS Clock
With Annetna L1J L2] L3J LsJ LSJ LiJ L2J L3J L9.J
MASTER MASTER
I 1 1,1 I- I- In I I t 1> I I. In I
ECS RTU _
to ECS 27.= or -) ti
1=
1 GATEWAY (IEC-61850)
II
to DCS
r -r
HV SWITC1f1BOARD MV SWITCHBOARD
lZ UJ UJ uJ tZ 1.1.1
BACKBONE BACKBONE BACKBONE BACKBONE
ETHERNET SWITCH-1 ETHERNET SWITCH-2 ETHERNET SWITCH-1 ETHERNET SWITCH-2
1 I
I I __J
UJ LU üJ
ETHERNET SWITCH-n ETHERNET SWITCH-n

. v I
NR-11-1 1NR-1P 1 1 I NR-11-1

NR-21- I I NR-2}-- I I NR-21---J I
— I NR-31----1 I —
1NR-n — — — IN R -n — — —
Note: connectivity to DCS is envisaged from ECS RTU. Where ECS RTU is not envisaged, gateway shall be
considered as part of Substation Automation System
FIGURE 3: TYPICAL ARCHITECTURE FOR IEC-61850 COMMUNICATION
Page 1450 of 2065

SPECIFICATION FOR STANDARD SPECIFICATION No.
r"_11
1 Reig ENGINEERS ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
$'g?;ir INDIA LIMITED
IA Govt of Ilioia Undertakingt INSTALLATION Page 1 of 15
fqxja `CID Tzrp-ir9r NfffhT
SPECIFICATION FOR
ELECTRICAL EQUIPMENT
INSTALLATION
4 21.05.14 REAFFIRMED & ISSUED AS SPECIFICATION FA SA BRB SC
3 25.04.08 REVISED & ISSUED AS SPECIFICATION RKS SSM JMS VC
2 28.02.03 REVISED & ISSUED AS SPECIFICATION HKM RSG VPS SKG
REVISED & ISSUED AS STANDARD RR VPS SG AS

1 26.08.97
SPECIFICATION
0 28.08.81 ISSUED AS STANDARD SPECIFICATION RR RR SGG
Standards Standards
Committee Bureau
No by by
Approved by
Page 1451 of 2065

ENGINEERS
$11gui&W- eg INDIA LIMITED 6-51-0081 Rev. 4
rycnrc ~I) IA Govt of India Undeffoloogf INSTALLATION Page 2 of 15
Abbreviations:
ACDB AC Distribution Board
AL Aluminium
CCoE Chief Controller of Explosives
CD Compact Disc
CIMFR Central Institute of Mining and Fuel Research
CTC Carbon Tetrachloride
CU Copper
DC Direct Current
DCDB DC Distribution Board
DGMS Directorate General of Mines and Safety
Ex(d) Flameproof
HV High Voltage
IR Insulation Resistance
IS India Standard
LV Low Voltage
HMI Human Machine Interface
MV Medium Voltage
OISD Oil Industry Safety Directorate
OSR Oil Surge Relay
OTI Oil Temperature Indicator
PF Power Factor
PI Polarisation index
PRV Pressure relief Valve
PT Potential Transformer
SLD Single Line Diagram
VRLA Valve Regulated Lead Acid
WTI Winding Temperature Indicator

Mr. Parag Gupta
Mr. M. K. Sahu
Mr. A.K. Choudhury (Inspection)

Page 1452 of 2065

‘3-1R_Jt4
1 ENGINEERS ELECTRICAL EQUIPMENT
orrrn c,craddaJnadfan IA Govt of India Undeftalong) INSTALLATION Page 3 of 15
CONTENTS
1.0 SCOPE 4
3.0 INSTALLATION OF EQUIPMENT 4
4.0 EQUIPMENT COMMISSIONING 14
5.0 LIST OF CONSTRUCTION EQUIPMENT 14

Page 1453 of 2065

ENGINEERS
$11g-a 22-g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
aiT7ii CRI dYtn. (A Govt of lochA UnderfAk(.9) INSTALLATION Page 4 of 15
1.0 SCOPE
This specification defines the requirements for the installation, field inspection, testing and
commissioning of electrical equipment, forming part of electrical power distribution and
utilisation system, including Communication and Fire alarm system.
2.1 The work shall be carried out in the best workmanlike manner in conformity with this
specification, EIL Installation Standards, layout drawings and to the following specifications/
codes of practice of Bureau of Indian Standards and OISD standards.
SP-30 (BIS) National Electrical Code.

IS:7816 Guide for testing Insulation resistance of rotating machines.
IS:10028 (Part-2) Code of practice for selection, Installation and maintenance of
transformers; Part 2 : Installation.
OISD 137 Inspection of Electrical Equipment.
OISD 147 Inspection and safe practices during electrical installations
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:
a. CEA Regulations.
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by CCoE/DGMS (as applicable).
d. The petroleum rules (Ministry of Industry Government of India).
e. Any other regulations laid down by central/state/local authorities and Insurance
agencies.
3.0 INSTALLATION OF EQUIPMENT
Prior to start of installation of the electrical equipment, Contractor shall verify that equipment
and complete materials have been received. Handling, shifting to required site location,
installation, testing and commissioning of all electrical equipment shall be done by contractor
with utmost care. Manufacturer's instructions and the requirements given in their technical
manuals shall be strictly adhered. The substation/switchgear room wherein the equipment
shall be installed shall be kept clean, dry and free from all debris. Panel floor cutouts not in
immediate use shall be suitably covered to avoid any mishap. When handling the switchboard
panels, care shall be taken to observe the correct lifting arrangements and to make sure that
slings are attached to the manufacturer's designated lifting points,where applicable. No parts
shall be subjected to undue strains or sudden stresses which could cause damage to the
equipment.
The lifting position mark indicated on packing casing shall be adhered to strictly, for keeping
it in required vertical position.
Contractor shall check and report to the Engineer-in-charge about any damaged item and / or
missing component for getting the same replaced as per specifications. During installation, all
accessories and loose items shall also be inspected by the contractor before their
assembly/mounting.

Page 1454 of 2065

ENGINEERS
Otait INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
1~,.r2",1,77 ,1713,21,) (A Govt ol InOla Undedalong) INSTALLATION Page 5 of 15
3.1 Switchboards and Bus Ducts
3.1.1 The term switchboard here includes all HV / MV/ LV switchboard panels, motor control
centers, power and lighting distribution boards, UPS panels, ACDB, Battery charger panels,
DCDB etc.
The switchboard panels shall be handled with care, avoiding any impact to the equipment.
Dragging of the panels directly on floor shall be avoided. Roller bars may be used for shifting
of panels. Use of a crane and trailer shall be made for handling of equipment. The
switchboard panels shall be properly supported on the truck or trailer by means of ropes to
avoid any chance of tilting. The switchboards shall be lifted after ensuring that panel supports,
nuts and bolts are all intact and tightened. While lifting the panels in packed conditions,
utmost care shall be taken to avoid any damage to insulators, bushings, metering and
protective equipment and if specified in the tender document tyre mounted hydraulic trolley
shall be used.
The panels shall be preferably kept inside the packing cases till foundations are ready. Proper
rain/sun/dust protection shall be ensured till switchboards are installed.
3.1.2 The switchboard panels shall be installed on prepared foundations or floor cutouts. Steel base
channels shall be welded to inserts provided in floor slab. Cross members shall be provided at
the junctions of each shipping section and other places as required.. It shall be ensured that the
base plate level of HV switchboard shall match with the finished floor level.
The foundation pockets and the grouted bolts shall be cured for a minimum period of 48
hours. Proper level of base frames shall be maintained throughout and shall be checked with
water level/spirit level. Steel Shims shall be provided below base frame wherever required.
3.1.3 The switchboard panels shall be taken out from the packed cases and shifted one by one to
their proper place. Al1 the panels shall be assembled, aligned and leveled. Alignment of
panels shall be checked in both longitudinal and lateral directions. It shall be ensured that
panel to panel coupling bolts, bus bar links etc. fit properly without any strain on any part. No
new holes for jointing of the panels other than those recommended by the vendor shall be
drilled. No gaps shall be left between the panels. Gap if any found between panels shall be
suitably sealed using sealing compound or T-profile. The lifting, racking in and out operation
of the breaker and all other motions shall be free from any obstruction.
The panels shall be checked for correct vertical position using Plumb line and spirit levels.
The switchboard panels shall be tack welded at suitable intervals to base channel.
After erection of switchboard panels, all uncovered portions of floor cutouts shall be covered
with 6 mm thick removable chequered plates finished with floor level. The design of the
chequered plates shall be such that the maximum allowable deflection is L/200 (where L is the
span of the chequered plates in meters) for a live load of 500 kg./sq. meters.
Additional stiffer shall be provided at the bottom if required. Suitable lifting arrangements
shall be provided for chequered plates. The chequered plates shall be painted with a coat of
red oxide zinc chromate primer after proper surface preparation as per specifications. Where
specified, panels' cutouts provided for future use shall be filled with lean concrete.
3.1.4 After completion of Installation of switchboards, all the cubicles, switchboard components
such as switches, starters, CT and PT chambers, bus bar chamber shall be cleaned and
checked for tightness of all the components.
Vacuum circuit breakers shall be checked for integrity of bottle seals. A11 loosely supplied
items shall be fitted up. Bus bar sections or links shall be inserted and where specified, of high
Copyright EIL All rights reserved

Page 1455 of 2065

ENGINEERS
Ordie'g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
eivavv'dv~) IA Govt of Intha Undertaking) INSTALLATION Page 6 of 15
voltage equipment shall be insulated. Interconnection wiring between shipping sections shall
be done by contractor.
All the wiring connections shall also be checked. Contact resistance of all bus bar joints and
contactors shall be checked. Insulator shall be checked for any damage. All the starters,
switches, contacts shall be cleaned with CTC where required.
A11 the moving parts shall be checked for easy and free movement. Hinges of panel doors
shall be lubricated to give free and noise less movement. A11 openings shall be kept
completely closed to avoid ingress of any foreign particles inside the panel.
Functional scheme verification of individual feeder shall be carried out and minor wiring
modifications in the panel wiring, if required shall be done as per the directions of Engineer-
in-charge. Special attention shall be paid to CT circuits' polarity, wiring continuity and
correctness in the protection as well as measurement circuits. Auto transfer scheme shall be
simulated and verified. During the course of scheme verification tests, defective components
if any shall be taken out, after bringing to the notice of Engineer-in-charge. The same shall be
replaced by component supplied by owner.
3.1.5 Where switchboard is damp or having a low IR value due to damaged insulators/
bushings/any other insulated parts, or any other reason, the entire switchboard shall be dried-
up according to the instruction of the Engineer-in-charge for the IR value to improve to a safe
level for commissioning. Care shall be taken to protect the surrounding insulation from direct
local heating during the drying up process.
3.1.6 All the metering instruments, protective relays and other relays and contactors shall be tested
as per manufacturer's recommendations and according to the instructions of the Engineer-in-
charge. Protection relays shall be inserted and connected and settings adjusted as required by
the Engineer- in- charge
3.1.7 All moving parts, of closing/tripping mechanism, racking in and racking out mechanism,
spouts and shutter closing mechanism shall be checked for proper operation. A11 the auxiliary
contacts of breaker shall be checked-up, cleaned and contact pressure measured.
3.1.8 All the control wiring, PTs, bushings, bus bars, other live parts of switchgear, incoming and
outgoing cables shall be meggered.
3.1.9 Electrical simulation tests shall be carried out for all the protective, alarm and annunciation
relays and external interfaces to ascertain proper functioning.
3.1.10 Safety insulation mats of approved make and of required voltage grade shall be provided in
the sub-station.
3.1.11 Pre-Commissioning Check List

Before commissioning any switchboard, following points shall be checked and ensured for
safe energising of the switchboard:
i. That the installation of equipment to be commissioned is complete in all respects with

its auxiliaries and all other mounting including earthing. Openings in floor within and
outside panels have been sealed off. All cover and door gaskets are intact to make the
enclosure vermin proof.
ü. That all the metering instruments have been checked and found in working order.
Indicating lamps are healthy and are in correct position. All power and control fuses
are of proper rating.

Page 1456 of 2065

ENGINEERS
g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
(A GoV1 ol Ind. Unde(l.k,n91 INSTALLATION Page 7 of 15
iii. That the polarity test and ratio test of all the PTs and CTs is complete and phase
sequence of CTs conforms to the correct vector group connections. Wiring continuity
and correctness are ensured in the protection and measurement circuits. Polarity of
D.C. supply for all the circuits is correct.
iv. That the high voltage tests of incoming and outgoing cables have been conducted and
results are satisfactory.
v. That all the protective relays including both conventional and microprocessor based
numerical relays and thermal overload relays/electronic motor protection relays have
been tested for secondary injection tests. (Primary injection tests shall be carried out
for differential protection, Restricted Earth fault protection at full / reduced current to
ensure correctness of complete wiring). Relay settings, status indications, fault
annunciations, data logging, display of switchboard SLDs shall be verified from HMI
in case the same is provided.
vi. That IR Value has been recorded for bus bars, circuit breaker, incoming and outgoing
cables, control wiring and potential transformers. Where required joint resistance of
bus bars have been recorded and found to be satisfactory. All the surroundings and
panels have been cleaned and temporary earth leads have been removed.
vii. Following tests shall be ensured for all CTs
- Insulation resistance test
Ratio test through primary injection
Polarity test
Knee point voltage for class PS CTs
viii. Following tests shall be ensured for all PTs
Insulation resistance test
Ratio test through primary injection
- Polarity test
ix. Following tests shall be ensured for all breakers
- Insulation resistance test
- Breaker closing, opening sequence using 3 pole timers
- High voltage test both in open and close condition for HV breaker
Contact resistance of all three poles using 100A DC Kit
x. Following tests shall be ensured for all meters
- Calibration of meters
Functional verification and settings
xi. Following tests shall be ensured for all relays
Secondary injection test
- Relay settings
Timing check with timers
- Any other test recommend by the supplier
xii. Following tests shall be ensured for all bus bars
- Tightness of all nuts/bolts using Torque wrench
IR value
- Contact resistance using 100A DC Kit
- Cleaning of bus bar chamber using vacuum cleaner
- Conducting jelly shall be applied on AL/CU joints as per manufacturer's
recommendations
- HV test in case of HV switchboard

Page 1457 of 2065

k31naf t IENGINEERS
$1gzir INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
1~7tYleaHt an .3~1 Ift Govt of Incha Undertaking) INSTALLATION Page 8 of 15
xiii Following tests/Checks shall also be performed on the switchboards

Functional verification of individual feeders including all spare feeders
Simulation test for under voltage tripping of related feeders such as motor
feeder, capacitor feeders etc
Verification of control supply schemes
Stability test for all differential protections
Simulation test for bus auto/manual change over scheme
Checks for all panel illuminations, indicating lamps, sockets
All upstream and down stream interlocks
3.1.12 Bus Ducts
The bus ducts as per issued drawings will be supplied in parts and all the parts shall be
assembled and the bus bar connections shall be made at site. The insulators in bus ducts shall
be inspected for any possible damage during transit and the defective ones shall be replaced.
The insulators shall be cleaned. Contact surface of bus bars, bus bar bolts and nuts shall be
thoroughly cleaned. Petroleum jelly shall then be applied and bolted connection made. The
bus duct enclosure shall be checked for earth continuity and then earthed at two places. The
bus duct shall be properly supported between switchgear and transformer. The opening in the
wall where the bus duct enters the switchgear room shall be completely sealed to avoid rain
water entry. Expansion joints, flexible connections etc. supplied by the manufacturer of the
bus duct shall be properly connected. The bus duct levelling shall be checked with spirit level
and pendulum weight.
Pre-commissioning check list
Before commissioning any bus duct, following points shall be checked and ensured for safe
energising of the bus ducts
All joints are tightened using torque trench

Cleaning of bus duct chamber with vacuums cleaner
Silica gel breather shall be connected if supplied. If required, silica gel shall be
reactivated as per the instruction of engineer in charge.
Space heater circuit shall be checked and tripping through thermostat shall be ensured
Contact resistance shall be measured for all phases/neutral using 100A DC kit
High voltage test in case of HV bus ducts
3.2 Transformers
Transformers on receipt at site shall be unloaded by means of crane or lifting devices of

adequate capacity. All lifting lugs shall be used to avoid unbalanced lifting and undue
stresses on lugs. Lifting lugs if any provided for partial lifting (e.g. for active part,
conservator) etc. shall not be used for lifting complete transformer. Parts other than those
identified for lifting of the transformer shall not be used for lifting. While slinging, care shall
be taken to avoid slings touching other parts.
3.2.1 Before lifting transformer, it shall be ensured that all cover bolts are tightened fully. In case
when it is necessary to use jacks for lifting, projections provided for the purposes of jacking
shall be used . Lifting jacks shall not be used under the valves or radiator tubes. For
transporting transformers from stores to site, the transformers shall be loaded on a suitable
capacity truck or trailer. The transformers shall be properly supported by steel ropes and
stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and vibrations.
At no instance, the transformer shall be kept on bare ground. Where it is not possible to
Page 1458 of 2065

k5-1
1 ENGINEERS
Og-LITI&2eg INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
aiWn 4,
1 .3~1/ (A Govt ol Indla Undertaking) INSTALLATION Page 9 of 15
unload the transformer directly on a foundation, it shall be unloaded on a properly built

wooden sleeper platform. A transformer shall never be left without putting stoppers to the
wheels.
3.2.2 Transformers shall be examined, for any sign of damage in transit. Particular attention shall
be given to the following in this regard.
i. Dents on tank wall or cooling tubes, radiators

ü. Damage to protruding parts like valves, sight glass etc.
Loosening of bolts due to vibration in transit.
iv. Cracked or broken bushings.
v. Oil leakage particularly along welds.
If any thing adverse is noted, the same shall be brought to the notice of Engineer- in- charge.
3.2.3 Contractor shall examine the transformer base, oil pit, fire walls and foundations made by the
civil contractor. It shall be ensured that oil spills can not propagate along cable trenches. Any
discrepancy noted will be brought to the notice of Engineer- in- charge. Transformers shall be
placed on channels or rails over concrete foundations. The transformers shall be levelled,
aligned and checked for free movement on the channels or rails. Stoppers shall be provided to
the transformers immediately to prevent any movement. Normally transformers upto 1000
kVA rating shall be received duly fitted with radiator tubes, conservator tanks, valves, wheels
and other accessories. While the transformers of above 1000 kVA rating may be supplied with
loose accessories. All the accessories like radiators, cooling fans, valves, conservator tanks,
explosion vent pipe, bushings and other devices which are supplied in different packages
shall be checked for any transit damage and cleaned thoroughly before fixing on the
transformer. All loosely supplied parts shall be assembled as per manufacturer's instruction
manuals/ drawings and documents. All the connections for CTs bushings and other wiring
shall be checked for tightness and correctness before replacing the lid or tightening all the
bolts. Gravels shall be filled in the transformer bay, soak pit as per requirement.
3.2.4 Topping of transformer with oil
Before topping up with oil, transformer shall be fitted with all accessories such as valves,
gauges, thermometers etc. Oil samples shall be taken from each drum and tested for
determination of dielectric strength. Any sign of leakage of the barrel or of its having been
opened shall be recorded and reported. It is necessary to filter the oil before the transformers
are filled. It shall be ensured in oil filling operation that no air pockets are left in the tank and
that no dust or moisture enters the oil. All air vents shall be opened. Oil shall be filled
through a streamline oil filter using metal hose. To prevent aeration of the oil, the transformer
tank shall be filled through the bottom drain valve. In a transformer with conservator tank, the
rate of oil flow shall be reduced when the level is almost upto the bottom of the main cover to
prevent internal pressure from rupturing the pressure relief-pipe diaphragm. Sufficient time
shall be allowed for the oil to permeate the transformers and also for the locked -up air
bubbles to escape. Any air accumulation in the buchholz relay shall be released.
3.2.5 Transformer Oil
i. Sample of oil from the transformer shall be taken from the bottom of the tank.
ii. Testing of Oil

For dielectric test, the oil shall be tested as described in IS: 335. The oil shall also be
tested for acidity in accordance with the methods prescribed.
3.2.6 Drying out of the transformers, if required, shall be carried out and record maintained in
accordance with IS: 10028. Normally a streamline filter shall be used for drying-up. IR value

Page 1459 of 2065

01 ENGINEERS
ogur 015:1&g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
14~ ,le'crn( 0,1 3,121,1) (A Govt of India Undettakingi
INSTALLATION Page 10 of 15
versus time of both windings along with OTI/WTI and filtrations machine temperature curve
for IR value Vs time shall also be plotted and recorded during the drying-up process.
Precautions when drying
i. The maximum sustained temperature to which transformer oil may be subjected shall
be limited to 80° C.
ü. The transformer shall be carefully monitored throughout the drying out process and
all observations shall be carefully recorded.
Drying out shall be continued so that the insulation resistance as prescribed in the
standard code of practice is attained and the value remains constant for more than 12
hours. However, a minimum number of cycles shall be done for each transformer as
found necessary by the Engineer-in-charge. Generally a Megger reading of 2
megohms / kV at 60° C temperature. with a 5 kV Megger may be a rough indication
for stopping the dehydration.
3.2.7 The following work on transformers shall be performed by the contractor if specifically called
for:
i. Before finally commissioning the transformer it may sometimes be desired to run it

for a few hours on short-circuit, applying a low voltage, approximately equal to the
impedance voltage of the transformer. During this process, regular readings of the
insulation resistance of the winding to earth and winding to winding and temperature
against time shall be recorded.
ü. Testing of radiator tubes for any leakage and rectifying these by welding / brazing.
3.2.8 Pre-commissioning Check List
Before commissioning of any transformer, the following points shall be checked for safe
energisation of the transformer:
i. All the accessories have been fixed properly and transformer body and neutral are
properly earthed. The transformer dehydration is over and results are satisfactory and
approved by the Engineer-in-charge. In case transformers are idle for more than one
month after dehydration, transformer oil has been given at least two circulations.
ü. Oil level, in the transformer conservator tank and all the bushings is upto the marked
point and the oil has been tested for dielectric strength and acidity.
Silicagel is in reactivated condition. The breather pipe is clear from any blocking and
contains oil upto the proper level.
iv. The explosion vent diaphragm does not have any dents. Accumulation of any oil and
air had been released.
v. Operation of off-load and on-load tap changers on all the tap positions is satisfactory.
The mechanical parts of the on-load tap changer are lubricated. Motor IR value has
been taken and found satisfactory. Tap position mechanical indicator on the
transformer and tap position indication meter on the control panel are reading the
same tap positions. Tap changer limit switches are operating satisfactorily on the
maximum and minimum tap positions. On-load tap changer contact pressure and
resistance is as per manufacturers recommendations. Oil level of tap changer tank is
upto the required level and oil has been tested for dielectric strength. The tap setting
on which the off load tap switch is locked shall be recorded. Generally the off-load
tap switch shall be kept on nominal tap.
Page 1460 of 2065

ENGINEERS
51gzuc-wert -"dg
2a1ams..) INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
(A Govt of India Unde(tak,ngj INSTALLATION Page 11 of 15
vi. Buchholz relay has been tested and checked up for any friction in the movement, and
floats are free. All the other protective relays, alarm and annunciation relays have
been tested.
vii. Metering equipment has been tested and polarity test of PT's and transformer winding
is satisfactory. Phase sequence and connections have been checked for proper vector
group.
viii. Ratio test and winding resistance on all the tap positions is satisfactory.
ix. Gaps of arcing horns for the bushings where provided are in order and earth
connections for the surge diverters have been checked.
x. Winding and oil temperature thermometer pockets contain oil and the winding and oil
temperature settings on dial gauges are in order.
xi. Transformers fitted with fans for forced air cooling have been checked up for starting
and stopping of the fans both in manual and auto mode and air-displacement has been
verified.
xii. Simulation tests for all external interface connection alarm, annunciation and trip
circuits have been checked and are in order.
xiii. Insulation resistance of all the control circuits and IR value of the transformer
windings and all the incoming and outgoing cables have been checked.
xiv. Valves in the cooling system and valve between the buchholz relay and the
conservator tank are in open position.
xv. Setting of all the protective relays is at the desired value and DC Trip supply is
healthy.
xvi. Magnetic, current and magnetic balance test have been conducted
xvii Simulation test for WTI,OTI,PRV,OSR
xviii Settings of WTI/OTI as per the instruction of the manufacturer
xix Earth resistance value for the neutral earthing
3.2.9 Observations after Commissioning
After switching on the transformer the following points shall be observed and recorded.
i. The inrush magnetizing current and no-load current.

ü. Alarm, if any, or if any relay flag has operated.
Voltage and current on all the three phases.
iv. Transformer hum or abnormal noise.
v. Circulation of oil and leakages.
vi. Record current, voltage, cooling air temperature, winding temperature and oil
temperature readings, hourly for 24 hours.
vii. Cable end boxes for any over-heating.
3.3. HV and MV MOTORS
3.3.1 All the motors generally would be erected by the mechanical contractor.
3.3.2 Electrical contractor shall keep the motor space heater energised as per the directions of
Engineer-in-charge. Electrical contractor shall measure the insulation resistance of motor
windings and PI in case of HV motors. Insulation resistance of the motors shall be measured
between the winding of the machine and its frame by means of a 500 / 1000 V Meggar in case
of 415 V motors. A minimum value of 1 megohm for 415 V motors shall be considered a safe
value. In case of lower I.R. Value, the insulation value shall be improved by any of the
following methods as directed by the Engineer-in-charge.

Page 1461 of 2065

ENGINEERS
Og'zIr faf-Zs
ei2LIW ,
R13,,g1,
11)
INDIA LIMITED
IA Govt ot Intha Undertakmg
INSTALLATION
6-51-0081 Rev. 4
Page 12 of 15
i. Blowing hot air from external source.

ii. Putting the motor in oven.
iii. Placing heaters or lamps around and inside after making suitable guarding and
covering arrangements so as to conserve the heat.
In case the insulation is low, the following method of drying has to be adopted, after
consultation with Engineer-in-charge. During drying the temperature rise of winding shall not
exceed the permissible value for the class of insulation used.
i. By locking the motor so that it can not rotate and then applying such a low voltage to
the stator terminals so as to pass full load current in the stator keeping the stator
winding temperature below 90° C . In this case a close watch shall be kept for any
possible overheating and I.R. Values vs. temperature shall be plotted and heating
continued till I.R. value becomes steady.
ü. By blasting hot air from external source, Maximum temperature of winding while
drying shall be 70° C to 80° C (thermometer) or 90° C to 95° C by resistance
method. Heating shall be done slowly first till steady temperature of winding is
reached after 4 to 5 hours, and for large machines after 10 hours. A record has to be
kept for drying process, with half an hour readings and, till steady temperature is
reached. In case it is essential, the drying process can be supplemented by blower.
3.3.3 It shall be ensured that the motor leads are correctly connected in the terminal box, as
indicated in the `Name Plate'. The covers of all terminal boxes shall be properly fixed, the
gaskets intact. The control circuit shall be tested for proper functioning as per circuit diagram.
3.3.4 In case of synchronous machines, slip rings and brush gear shall be polished and brushes shall
be fixed in their holders with clearance and pressure as recommended by the manufacturers.
3.3.5 Before commissioning, the ventilation and cooling system of the motor must be inspected. In
case of motor with forced ventilation the air inlet shall be examined to ensure that it is free
from moisture and any foreign material. It shall also be ensured that recommended flow and
pressure of air is available to produce the required cooling effect.
3.3.6 The motor control gear shall also be carefully examined, the over-load settings may be
reduced or time lags bypassed from protective gear to ensure rapid tripping of switchgear in
event of faults. The direction of rotation of a new motor specially of large capacity , and phase
sequence of supply shall be kept in view while joining and connecting to the motor terminals
3.3.7 Finally the motor shall be started on no-load after decoupling, and shall be allowed to run for
a minimum period of 4 hours, or for a time as instructed by Engineer-in-charge. Attention
shall be given to the proper running of the bearings, vibration or unusual noises if any.
Voltage, starting current, no load current, stator winding and bearing temperature shall be
recorded after every 1 hour during this test. Direction of rotation shall be checked and
recorded. Normally the motors run in clockwise direction as viewed from the driving end
with reference to the phase sequence R, Y, B.
3.3.8 After switching off the motor, the insulation resistance of the motor shall be recorded under
hot and cold conditions.
3.3.9 If the no load test run is found satisfactory, the motor shall be allowed to run for 8 hours and
all readings shall be recorded.
3.3.10 The following work on motors, may be performed by the contractor if specifically called for.

Page 1462 of 2065

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31 ENGINEERS
ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
$'fgu Offleg INDIA LIMITED
1.2T (A Govt of India Untleltakmgl INSTALLATION Page 13 of 15
i. The proper level of bearing oil has to be checked. The condition of grease in bearings
shall be checked and in case it is necessary, complete replacement of bearing with
specified grade of grease after proper cleaning of the bearing shall have to be done.
Wherever external greasing facility exists, the condition of grease may be checked by
pumping some new grease of specified grade at start. If the grease coming out is
deteriorated grease shall be replaced.
ü. All the motors, motor exciter set and induction generators directly coupled or coupled
through reduction gears shall be checked for abnormal vibration, if any Large rated
HV motors with journal type bearings are liable to get damaged from shock, rough
handling during transit. Any minor defect in a race or roller may give rise to
considerable amount of vibration and noise. Contractor shall check and bring to the
attention of Engineer-in-charge any defect noticed in this regard.
Due care shall be taken to avoid any damage to bearing insulation wherever provided.
3.4. Batteries/Battery charger
Battery (Lead acid, Nickel Cadmium or VRLA type as specified) shall be erected on stands
and insulators supplied by the manufacturer of the batteries. The installation shall be done as
per the layout drawings and manufacturer's instructions. Electrolyte if required / as applicable
shall be filled as per manufacturer's instructions. Interrow connections shall be made with the
leads supplied by the manufacturer. Functional check shall be done on the battery charger
including battery charging and discharging, recharging as per the recommendation of the
manufacturer.
3.5. Neutral Earthing Resistor
The neutral earthing resistor shall be inspected for any damage to the resistor grid and other
components. The resistor shall be levelled and installed. All covers etc. shall be checked for
tightness to ensure that the enclosure of the resistor is dust, vermin and weatherproof.
Earthing conductors shall be taken from the out end terminal of the resistor, for connection to
earth electrodes and to the main grid. Check such as IR, operation of space heater, earth
resistance shall be done before the commissioning.
3.6 Welding Receptacles
The welding receptacles shall be erected on steel/concrete structures as per the drawings. In
isolated places a separate support shall be fabricated and installed.
3.7 Push Button/Control Stations
The push buttons / control stations shall be installed near to the motors to be controlled.
Individual channel supports shall be installed as per EIL standard. If control stations for
hazardous areas are to be supplied by contractor, these shall be of Ex (d) type, tested by
CIMFR and approved by CCoE or other applicable certifying authorities. All outdoor push
buttons / control stations shall preferably have integral canopies for additional weather
protection. The canopy shall be made of 2 mm thick galvanized sheet steel or FRP where
these are not integral with the equipment.
3.8 Gang operated Isolators/outdoor Disconnectors
The isolators shall be transported to site in the dismantled condition. All the insulators may be
also supplied loose. The contractor shall inspect, clean, assemble and install the isolator on the
base structure previously fabricated, erected and levelled by him. The operating mechanism

Page 1463 of 2065

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31 ENGINEERS
5ga. 22-- g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
Govt of Incha Undertalongt INSTALLATION Page 14 of 15
shall be installed on the structure and connected to the isolator poles. The operating
mechanism shall be tested by slowly bringing the isolator to the closed position and carrying
out the necessary adjustment as per the manufacturer's instructions. The earthing switches,
frames and operating handle etc. shall be earthed.
3.9 Contractor shall provide the following items in substation, as per CEA Regulations.
3.9.1 Fire buckets filled with clean dry sand and ready for immediate use for extinguishing fires and
fere extinguisher (carbon dioxide, dry chemical extinguisher etc.) suitable for dealing with
electric fires shall be conspicuously marked and kept.
3.9.2 First aid boxes containing ointments and medicines for immediate treatment of injuries (As
prescribed by Indian Red Cross Society or equivalent).
3.9.3 Instructions of restoration of persons suffering from electric shock in English, Hindi and Local
language of the district shall be affixed in a conspicuous place.
3.9.4 Danger boards (HV., MV.) shall be provided on transformer bay gate, switchboards, entrance
to switchgear room and at other places as required by Engineer-in-charge.
3.10 The Communication system and Fire alarm system panels and equipment shall be installed
complying to manufacturer's instructions. The location of field station (call back station unit,
break glass unit, telephone set etc.) shown on the drawing are indicative. The exact location
shall be decided at site by contractor in consultation with Engineer-in-charge. Correct type of
equipment with regard to hazardous protection as specified on drawing shall be adhered to by
contractor, for installation.
4.0 EQUIPMENT COMMISSIONING
4.1 Field inspection, testing and commissioning of the complete electrical installation shall be
carried out as per EIL specification no. 6-51-0087.
After the equipment is installed properly in accordance with drawings and specifications,
contractor shall carry out all pre-commissioning checks and tests as per EIL format in the
presence of Engineer-in-charge and test readings shall be recorded and furnished to EIL in
triplicate.
4.2 All equipment layout drawings shall be marked by the Contractor for "AS BUILT STATUS"
and two sets of hard copies shall be submitted to EIL.
5.0 LIST OF CONSTRUCTION EQUIPMENT
The contractor shall have all necessary construction equipment, tools and tackles and testing
instruments to carry out the erection works and to commission the system as specified. These
shall include but not be limited to the following, and these shall be brought to site by
contractor before the start of work.
5.1 Equipment
i. Portable grinder.
ü. Portable welding machine.
üi Portable gas cutting / welding set.
iv. Pipe threading machine.
v. Pipe bending machine (hydraulic).
Page 1464 of 2065

ENGINEERS
$11g-a [R6 UINDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
(.T-rn an,ram IA Govt or Indo Undertaking) INSTALLATION Page 15 of 15
vi. Portable drill machine suitable to take up drilling for different sizes as per
requirement.
vii Dewatering pump sets (diesel driven).
viii. Power Hacksaw.
ix. Conduit dye set.
x. Hydraulic crimping machine with round/hexagonal dye set.
xi. Hand crimping tool.
xii. Portable electric blowers, vacuum cleaners.
xiii. Miscellaneous items such as slings, pulleys, tarpaulins, wooden sleepers, ladders. etc.
as required.
xiv. Safety belts, safety goggles, and gloves.
xv. Separate tool kit for each Electrician.
xvi. Hydraulic/Hand held grease gun
5.2 Test Instruments
i. Insulation tester 1000 V hand driven.

ü. Insulation tester 2500 V motor/hand driven.
Insulation tester 5000 V motor/hand driven
iv. Phase sequence indicator.
v. Earth Resistance tester.
vi. Single phase variac
vii. 3 phase variac of adequate capacity.
viii. Secondary and primary injection testing kit.
ix. Multimeter, both analogue and digital
x. Portable Ammeters, Wattmeters, P.F. meters.
xi. Portable Voltmeters.
xii. Clip on meters of different ranges.
xiii. Tacho-meter.
xiv. Kelvins double bridge for measurement of very low resistance.
xv. D.C. high -pot test kit.
xvi. A.C. high -pot test kit.
xvii. Oil filtration machine of adequate capacity.
xviii. Lux Meter to measure illumination levels.
xix. Breaker timing 3 pole kit
xx. Timers
xxi. 100A DC milli volt drop(Contact resistance) kit
xxii. Vibration measuring Instrument
xxiii. Thermo meters

Page 1465 of 2065

ENGINEERS FOR
sig-ar W- INDIA LIMITED 6-51-0082 Rev. 4
(A Govt o11nUia Undertakm) CABLE INSTALLATION Page 1 of 11
et;eim sicA fru fqr-4147
SPECIFICATION
FOR
CABLE INSTALLATION
4 21.11.13 REVISED AND ISSUED AS SPECIFICATION FA SA UAP/JMS SC
3 25.04.08 REVISED AND ISSUED AS SPECIFICATION RKS SSM JMS VC
2 28.02.03 REVISED and ISSUED AS SPECIFICATION HKM RSG VPS SKG

REVISED and ISSUED AS STANDARD
1 04.08.97 RR VPS SG AS
SPECIFICATION
0 17.08.84 ISSUED AS STANDARD SPECIFICATION RR YKJ SG
Standards Standards
Rev. Com m ittee Bureau
Prepared Checked
No by by
Approved by
Page 1466 of 2065

ENGINEERS
5fgur I812eg INDIA LIMITED FOR 6-51-0082 Rev. 4
>11??T rremrrangt (A Govt of Inrlia Undert~9) CABLE INSTALLATION Page 2 of 11
Abbreviations:

CCOE Chief Controller of Explosives
CD Compact Disc
DC Direct Current
DGFASLI Directorate General Factory Advice Service & Labour Institutes
DGMS Directorate General of Mines and Safety
ET Electrical Thread
FGL Finished Ground Level
FLP Flame Proof
GI Galvanized Iron
HV High Voltage
IS Indian Standards
ISMC Indian Standard Medium Channel
MS Mild Steel
RCC Reinforced Concrete Cement
Members: Mr. BR Bhogal

Ms. S. Anand
Mr. Parag Gupta
Mr. A.K. Chaudhary
Ms. N.P. Guha
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reserved
Page 1467 of 2065

■
31 ENGINEERS
vorcor2ottJvcnti, IA Govt of India Unclettalongj
CABLE INSTALLATION Page 3 of 11
CONTENTS
1.0 SCOPE 4
3.0 MATERIAL SPECIFICATIONS 4
4.0 CABLE LAYING 6
5.0 TERMINATIONS 9
6.0 TESTING AND COMMISSIONING 11
Page 1468 of 2065

ori ENG1NEERS
Og-arfaffleg INDIA LIMITED FOR 6-51-0082 Rev. 4
I .1r2R ,1,4W asf xTas-,,i) (A Govt of India Undenakingj
1.0 SCOPE
This specification defines the requirements for supply of materials, wherever applicable,
installation, testing and commissioning of cable installation.
2.1 The work shall be carried out in the best workman like manner in conformity with this
specification, EIL installation standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD standards listed
below :
SP:30 (BIS) Special Publication - National Electrical Code.

IS:1255 Code of practice for installation and maintenance of power cables
upto and including 33 KV rating.
IS:10810(Part 43) Method of Test for cables ; Part 43 Insulation resistance.
IS:10810(Part45) Method of Test for cables ; Part 45 High voltage test.
OISD RP- 147 Inspection and safe practice during electrical installation
OISD 173 Fire prevention and protection system for electrical installation
a. CEA Regulations
c. Regulations laid down by CCOE/DGMS/DGFASLI (as applicable).
d. The petroleum rules (Ministry of Industry, Government of India)(As applicable)
e. Any other regulations laid down by central/state/local authorities and insurance
agencies
3.0 MATERIAL SPECIFICATIONS
All materials and hard wares to be supplied by the contractor shall be new, unused and of best
quality and shall conform to the latest specifications of Bureau of Indian Standards.
3.1 Cable Trays
These shall be ladder type trays either prefabricated hot dip galvanised sheet steel trays or site
fabricated angle iron painted trays or FRP trays as specified in job specification.
3.1.1 Pre-fabricated hot dipped galvanised trays
The cable trays shall comply with the requirements specified in EIL installation standard
enclosed with the specification/Tender.
3.1.2 Site fabricated angle iron trays
Angle iron cable trays shall be fabricated from standard rolled angle iron sections of size
75x75x8 for runners for supporting spans limited to 3000 mm. Cross support shall be 25 x 6
Page 1469 of 2065

■
71 ENGINEERS r.
Ogzu1812-
'
dg INDIA LIMITED FOR 6-51-0082 Rev. 4
f F2MT20n3gasfl) IA Govt of Incha Undeltaltingt
mm MS flat for tray width upto 500 mm and 32 x 6 mm flat for tray of more than 500 mm
wide and spacing between two cross supports shall not exceed 250 mm.
3.1.3 Vertical supports for both the prefabricated and site fabricated type trays shall be fabricated
out of ISMC 100 and horizontal supports shall be with 65 x 65 x 6 mm angle iron sections.
Outer most tier of all vertical cable trays shall be covered with GI sheet for protection against
physical damage to cables.Bottom most cable tray shall also be provided with GI sheet from
the bottom side for the protection of the cables from the hydrocarbon pipes located below. GI
Covers also shall be provided for the top most cable trays located outdoors.
Cable racks and trays shall be covered by removable top covers on upper most tiers allowing
adequate ventilation in following cases where:
Mechanical damage of cables is likely to occur during maintenance in the plant.

Oil or spillage of chemicals can be expected.
Protection from exposure to sun is required.
GI cover sheet shall allow adequate ventilation to the cables and shall be in standard length of
3000 mm, flanged on both sides for fixing on cable tray.
3.1.4 FRP type cable trays
The cable trays shall comply with the requirements specified in EIL standard specification
and installation standard enclosed with the specification/Tender
3.2 Cable Glands
Cable glands shall be of nickel plated brass unless otherwise specified. The single
compression type cable glands shall be used for indoor panels/equipment (e.g. substation,
control room etc). The cable glands for outdoor terminations shall be weather protected,
double compression type. Cable glands forming a part of relevant FLP enclosure shall be FLP
type, tested by CIMFR or any other recognized independent testing laboratory and approved
by CCoE/DGMS or any other statutory authority as applicable. Indigenous FLP glands shall
have valid BIS license as per the requirements of statutory authorities. All cable glands shall
comply with the requirements given in IS/IEC-60079 Part 0.
Entry thread of cable gland shall be compatible to the entry thread provided in the equipment
(BS, ET, NPT, PG as applicable). If required, suitable reducers/adopters shall be used.
3.3 Connectors
Terminations of cables with stranded conductor shall be made with crimped type tinned
copper solder less lugs which shall be suitable for the cable size mentioned in cable schedule.
3.4 Ferrules
Ferrules shall be of approved type and of size to suit core size mentioned and shall be
employed to designate the various cores of control/signal cable by the terminal numbers to
which the cores are connected, for ease of identification.Furrule shall be printed type.
Page 1470 of 2065

ENGINEERS
Og-arl8dleg INDIA LIMITED FOR 6-51-0082 Rev. 4
ittIV-or o1vovv't1,3O-Osvit IA Govt of Indu Undertaking)
4.0 CABLE LAYING
4.1 General
Cable installation shall include power, control, lighting, fire alarm, telephone and
communication cables. These shall be laid in trenches/ cable trays /Duct as detailed in the
cable layout drawings. Cable routing given on the cable layout drawings shall be checked in
the field so as to avoid interference with structures, heat sources, drains, piping, air-
conditioning duct etc. Any change in routing shall be done to suit the field conditions
wherever deemed necessary, after obtaining approval of Engineer-in-charge.
4.1.1 High voltage, medium voltage power and control cables shall be separated from each other by
adequate spacing or by running through independent pipes, trenches or cables trays, as shown
on layout drawings/installation standards. Details of cable routes and cable spacing not shown
in detail on these drawing shall be determined by the contractor and approved by the
engineer- In-charge.
The individual cable fixing clamps and spacers for laying of single core cables shall be of
non-magnetic material. As a general practice, the metallic sheath, screen and armour of
single core cables shall be earthed at one point to keep the same at earth potential unless
otherwise stated. The continuity of armour and semiconductor screen shall be broken at each
joint. Single core cables, when laid in trefoil formation shall be braced by suitable clamps at a
distance, not exceeding 3 meters along the cable routing.For laying of long length of single
core cables recommendations from vendor shall be followed.
If straight through joints are required to be provided on single core cables, armour shall be
broken at joints as per manufacturer's recommendations. For single core cables, armour shall
be earthed at one end for the cable run length as per manufacturer's recommendation.
The Telephone, Communication and Fire alarm cables shall run on instrument trays/ducts/
trenches in the units. Wherever these are not available, cables shall be taken in a separate
trench/tray with a minimum spacing of 300 mm from power and control cables
Telephone, fire alarm and plant communication cables shall be directly buried in road berm
area, (unless otherwise specified in cable layout drawings). These cables shall cross power
cables preferably at right angles. Street lighting cables shall be laid on the other nide of road
berm area
4.1.2 The lengths indicated in the cables schedule are only approximate. The contractor shall
ascertain the exact length of cable for a particular feeder by measuring at site. All cable routes
shall be carefully measured .Before the start of cable laying, the contractor shall prepare cable
drum schedule and get that approved by Engineer-in-charge to minimize/avoid straight
through joints and then the cables cut to the required lengths, leaving sufficient lengths for the
terminations of the cable at both ends. The various cable lengths cut from the cable reels shall
be carefully selected to prevent undue wastage of cables. Extra loop length shall be given for
feeder cables where required as per the directions of Engineer-in-charge to meet
contingencies
Cables shall be laid in directly buried trench or in RCC trench (underground trench) or in
cable tray along pipe sleepers or in over head trays as shown on cable layout drawings.RCC
covers of trenches shall be effectively sealed to avoid ingress of chemicals and oils.
Overhead trays shall be installed 2700 mm (minimum) above grade level and 300mm above
FGL in case cable trays are installed along with pipe sleepers. At road crossings overhead
Page 1471 of 2065

ENGINEERS
$1g-ar 2151- g INDIA LIMITED FOR 6-51-0082 Rev. 4
lk Govt ar India Underlaking)
trays shall be installed at 7000 mm (minimum) above grade level or cables shall be routed
cable tray culvert/ Electrical road crossings as per layout drawings.
Sufficient care shall be taken while laying cables to avoid formation of twist, sharp bend etc.
in order to avoid mechanical injuries to cables. Rollers shall be used for pulling of cables.
Cable installation shall provide minimum cable bending radii as recommended by cable
manufacturer.
4.1.3 Cables shall be neatly arranged in the trenches / trays in such a manner that criss-crossing is
avoided and final take off to the motor / switchgear is facilitated. Arrangement of cables
within the trenches / trays shall be in line with cable layout drawings. Cable routing between
cable trench and equipment/motors shall be taken through GI pipe sleeves of adequate size.
Pipe sleeves shall be laid at an angle of maximum 45 to the trench wall. Bending radii of
pipes shall not be less than 12D. It is to be ensured that both the ends of GI pipe sleeves shall
be sealed with approved weather proof sealing plastic compound after cabling. In places
where it is not possible, cables shall be laid in smaller branch trenches. Different rows of
cable trays in cable cellar below the cutout shall be fixed so that the trays don't obstruct cable
entry to the panels.
4.1.4 All cables shall be identified close to their termination point by cable tag numbers as per cable
schedule. Cable tag numbers shall be punched on aluminium /Lead straps (2mm thick, 20 mm
wide and of enough length) securely fastened to the cable and wrapped around it.
Each underground cable shall be provided with cable tags of lead /Aluminium securely
fastened every 30 m of its underground length with at least one tag at each end before the
cable enters/leaves the ground. In unpaved areas, cable trenches shall be identified by means
of cable markers as per installation drawing. These cable markers shall be placed at location
of changes in the direction of cables and at intervals of not more than 30 m and also at cable
straight through joint locations. Cable route markers shall extend 600mm above ground.
4.1.5 All temporary ends of cables must be protected against dirt and moisture to prevent damage to
the insulation. For this purpose, ends of cables shall be covered with an approved PVC end
cap or rubber insulating tape.
4.1.6 Each row of cables shall be laid in place and before covering with sand. All wall
openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage
of water inside building/lined trench. Every cable shall be given an insulation test in presence
of Engineer-in-charge/Owner before filling the cable trench with sand Any cable which is
found defective shall be replaced.
4.1.7 Where cables pass through foundation walls, the necessary openings shall be provided in
advance for the same by another agency. However, should it become necessary to cut holes
in existing structures for example floor slab etc., the electrical contractor shall determine
their location and obtain approval of the Engineer-in-charge before carrying out the same.
4.1.8 Cables for road crossings shall be taken through ERC (Electrical Road Crossing) as shown in
the cable layout drawings and sleeves/ducts shall be effectively sealed thereafter.
At road crossing and other places where cables enter pipe sleeves adequate bed of sand shall
be given so that the cables do not slack and get damaged by pipe ends.
4.1.9 Wherever cable trench crosses storm water, waste water channel/drain, cables shall be taken
through PVC/RCC pipes. Where cables are required to cross drains of depth more than 1200
Page 1472 of 2065

‘31 ENGINEERS
s'eu effileg INDIA LIMITED FOR 6-51-0082 Rev. 4
1~, 42"41,-W 951
Jqinl) IA Govt of India Undeftakngj
mm, cables shall be taken over the drain on cable trays supported suitably using ISMC
150/200 sections.
4.1.10 Ends of cables leaving trench shall be coiled and capped and provided with protective cover
till such time the final termination to the equipment is completed.
4.2 Cables Laid Direct in Ground
Cables shall be laid underground in excavated cable trenches where specified in cable layout
drawings. Trenches shall be of sufficient depth and width for accommodation of all cables.
Cables shall be properly spaced as per installation standards. Maximum number of cable
layers in trench shall be preferably limited to 6 layers.
Minimum depth of directly cable trench shall be 750 mm, for medium voltage and 900 mm
for HV. Cables. The depth and the width of the trench shall vary depending upon the number
of layers of cables as per EIL installation Standards.
Cables shall be laid in buried trenches at depth as shown in the cable layout drawings. It is to
be ensured by the contractor that the bottom of buried trenches shall be cleared of all rocks,
stones and sharp objects before cables are placed. The trench bottom shall be filled with a
layer of sand or stone dust. This sand /stone dust shall be leveled and cables laid over it.
These cables shall be covered with 150 mm of sand on top of the largest diameter cable and
sand shall be lightly compacted. A flat protective covering of 75 mm thick second class red
bricks or concrete tiles as per specification shall then be laid and the remainder of the trench
shall then be back -filled with natural soil, rammed and leveled.
4.3 Cables Laid in Concrete Trench
Cables shall be laid in 5 or 6 tiers in concrete trench as shown on layout drawings. Concrete
cables trenches shall be filled with sand /stone dust in hazardous area to avoid accumulation
of hazardous gases and oil. RCC covers of trenches shall be effectively sealed to avoid
ingress of chemical and oil in process area. Removal of concrete covers where required for
the purpose of cable laying and reinstating them in their proper position after cables are laid
shall be done by electrical contractor.
Minimum depth of RCC cable trench shall be 500mm for all voltage grades with 300mm
clearance between the bottoms of the trench cover and top of the cable. The depth and the
width of the trench shall vary depending upon the number of layers of cables and bending
radius required for cables as per EIL installation Standards
A11 wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid
seepage of water
4.4 Above Ground Cables
4.4.1 Cables installed above grade shall be run in cable trays, clamped on walls, ceiling or
structures and shall be run parallel or at right angles to beams, walls or columns. Cable
routing shall be planned to be away from heat sources such as hot piping, gas, water, oil
drainage piping, air-conditioning duct etc. Each cable tray shall contain only one layer of
cables as far as possible for power cables. However control cables may be laid in multiple
layers in the cable trays.
4.4.2 Individual cable or small group of cables (upto 3 cables) which run along structures / walls
etc. shall be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle bars.
Alternatively small group of cables can be taken through 60/100/150 mm slotted channel tray
Page 1473 of 2065

n61 ENGINEERS
$1gz:ir f&flj-g INDIA LIMITED FOR 6-51-0082 Rev. 4
(~f ciecngc`M"Mil IA Govt of India Undertaking)
or channel ISMC-75/100. Cables shall be supported so as to prevent sagging. In general,

distance between supports shall be approximately 300 mm for cables upto 25 mm diameter
and maximum 450 mm for cables larger than 25 mm dia. to prevent the sagging of cables.
4.4.3 Cable laid on supporting angle in cable trenches, structures, columns and vertical run of cable
trays shall be suitably clamped by means of GI saddles / clamps, whereas cables in horizontal
run of cable trays shall be tied by means of nylon cords. Distance between supporting angles
shall not exceed 600 mm.
4.4.4 All cable trays (other than galvanized/FRP trays) and supporting steel structures shall be
painted before laying of cables. The under surfaces shall be properly degreased, derusted,
descaled and cleaned. The painting shall be done with one coat of redoxide zinc chromate
primer. Final painting shall be done with two coats of approved bituminous aluminium paint
unless otherwise specified.
4.4.5 Where cables rise from trench to motor, lighting panel, control station, junction box etc., they
shall be taken in GI pipe for mechanical protection upto a minimum of 300 mm above grade
for outdoor area. Cable ends shall be carefully pulled through conduit to prevent damage to
cable.
4.4.6 All GI Pipes shall be laid as per layout drawings and site conditions. Before fabrication of
various profiles of pipes by hydraulically operated bending machine (which is to be arranged
by the contractor) all the burrs from the pipes shall be removed. GI Pipes having bends shall
be buried in soil / concrete in such a way that the bend shall be totally concealed. For G.I.
pipes buried in soil, bitumen coating shall be applied on the buried lengths, Installation of G.I.
pipes shall be undertaken well before paving is completed and necessary co ordination with
paving agency shall be the responsibility of Electrical Contractor.
Following guide shall be used for sizing of GI. pipe.
a) 1 cable in a pipe -53% of pipe cross-sectional area occupied by cables.
b) 2 cables in a pipe -31% of pipe cross-sectional area occupied by cables.
c) 3 cables in a pipe - 43% of pipe cross-sectional area occupied by cables.
d) 4 and above cables in a pipe - 40% of pipe cross-sectional area occupied by cables.
4.4.7 After the cables are installed and all testing is complete, conduit ends above grade shall be
plugged with a suitable weatherproof plastic compound/bitumen/suitable sealing compound.
Alternatively rubber bushes shall be employed for the purpose of sealing.
4.4.8 Fire proofing of end of power cables at least 1 meter at each end as per OISD norms for the
refinery and Petroleum industry, shall be carried out as per the recommendation of the paint
supplier .Rates for the fire proofing of cables shall be included in the cable installation and no
separate payment shall be made for the painting.
5.0 TERMINATIONS
5.1 All cables up to 1100V grade and higher levels shall be terminated at the equipment by means
of compression type cable glands suitable for the cable size. They shall have a screwed nipple
with electrical threads and check nut. The cables shall be identified close to their termination
points at both the ends of cable(cable numbers shall be punched on aluminium/Lead straps
2mm thick and securely fastened to the cable, wrapped around it) and also along the route at
regular intervals, by cable tag numbers.
Page 1474 of 2065

-

ENGINEERS
5f--&-JE Et26 INDIA LIMITED FOR 6-51-0082 Rev. 4
e,,nrc,m,ffilsn«) in Govi of mma Underlak.9) CABLE INSTALLATION Page 10 of 11
All cable entries for outdoor termination shall be through bottom/side. Outdoor cable
termination through top of equipment shall not be permitted.
5.2 Power cables cores wherever colour coding is not available shall be identified with red,
yellow and blue PVC tapes. Where copper to aluminium connections are made, necessary
bimetallic washers shall be used.
5.3 In case of control cables, all cores shall be identified at both ends by their terminal numbers
by means of PVC ferrules suitable for core size. Wire numbers shall be as per schematic/
wiring/inter-connection diagram. All unused spare cores of control cables shall be neatly
bunched and ferruled with cable tag at both ends, for future use.
5.4 Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of non-
magnetic material/ aluminium sheet in case of single core cables. All unused cable entries on
equipment/panels shall be plugged/sealed.
5.5 The cable shall be terminated at electrical equipment/switchboards through glands of proper
size. The individual cores shall then be dressed and taken along the cables ways or shall be
fixed to the panels with polyethylene straps. The cable glanding shall be done as per
manufacturer's instructions. Cable armour shall not be exposed after termination is complete.
In case of termination of cables at the bottom of a panel over a cable trench having no access
from the bottom close fit holes shall be drilled in the gland plate for all the cables in one line,
then gland plate shall be split in two parts along the centre line of holes. After fixing bottom
plate, uncovered cable holes/gaps shall be sealed with cold setting compound.
5.6 Crimping of lugs to cable leads shall be done by hand crimping / hydraulically operated tool
as per requirement. Insulation of the leads shall be removed before crimping. Conductor
surface shall be cleaned and shall not be left open. Suitable conducting jelly shall be applied
on the conductor lead. Lugs shall enclose all strands of cable core. Cutting of strands shall
not be allowed.
5.7 The contractor shall bring to the notice of Engineer-in-charge any mismatch in cable glands,
lugs provided with the equipment vis-à-vis to the cable size indicated in cable schedule for
taking corrective action.
5.8 The cable joints shall be avoided as far as possible . In case a joint is unavoidable, the
following shall be insured:
- The number of joints shall be restricted to minimum as far as possible.
The location of joints shall be identified with permanent markers.
No joints shall be allowed in hazardous areas without the approval of Engineer-in-

charge.
The jointing and termination of medium voltage power cables shall be carried out by trained
personnel only. Jointing and termination of high voltage and EHV cables shall be done by
skilled and experienced jointer duly approved by Engineer-in-charge. Only type tested
jointing and termination kits of approved make shall be used.
5.9 No unauthorized repairs, modifications shall be carried out on the hazardous area equipment
terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall be
brought to the notice of Engineer-in-charge by contractor. After termination is complete, all
Page 1475 of 2065

ENGINEERS
$1g-ar 0154--eg INDIA LIMITED FOR 6-51-0082 Rev. 4
,rzr.o (A Go,t af Intlia Und.l.k.91 CABLE INSTALLATION Page 11 of 11
the bolts, nuts, hard wares of terminal box shall be properly placed in its position and
tightened.
5.10 Where required, cable sealing boxes intended to be used with the apparatus shall be filled with
solid setting type bituminous compound unless otherwise specified.
5.11 All cables glands installed outdoor shall be provided with suitable sized shrouds and rates for
the same shall be included in the scope of the termination of the cable glands. No separate
payment is envisaged for the same.
6.0 TESTING AND COMMISSIONING
6.1 Field testing and commissioning of electrical installation shall be carried out as per EIL
specification.
6.2 Before energising, the insulation resistance of every circuit shall be measured from phase to
phase, phase to neutral and from phase/neutral to earth.
6.3 Where splices or terminations are required in circuits rated above 650 volts, insulation
resistance of each length of cable shall be measured before splicing and or / terminating. After
completion of splices and /or terminations measurements shall be repeated.
6.4 The insulation resistance of directly buried cables shall be measured before cable trenches are
backfilled. Measurements shall be repeated after back filling.
For cables upto 1.1 KV grade 1000 V Megger and for H.V. Cables 2.5 KV / 5 KV Megger
shall be used.
6.5 D.C. High Voltage test shall be conducted on cables given below after installation.
a) A11 1100 volts grade power cables in which straight through joints have been made.
b) A11 cables above 1100 V grade.
The DC High Voltage test shall be performed as detailed below in the presence of the
Engineer-in-charge or his authorized representative only.
Cables shall be installed in final position with the entire straight through joints complete.
During the high voltage test, all other electrical equipment related to the cable installation,
such as switches, instrument transformers, bus bars, etc., must be earthed and adequate
clearance shall be maintained from the other equipment and framework to prevent flash over.
In each test, the metallic sheath/screen/armour shall be connected to earth.
6.6 All checks and tests shall be made as per EIL standard test Performa available with site
engineer.
All test readings shall be recorded and submitted to EIL in triplicate sets.
6.7 Cable schedule, cable layout drawings, Interconnection drawings shall be revised and marked
by contractor for ÀS BUILT STATUS' and two sets of copies along with CD shall be
submitted to EIL.
Page 1476 of 2065

tt~iei ENGINEERS FOR
$igar taf4eg INDIA LIMITED 6-51-0083 Rev. 5
0177 er,er,.,try, IA Gosn of India UndeFlakinqi LIGHTING INSTALLATION Page 1 of 13
WIRT FzraTlIT 3-
entrR-
fe4-4-tr
SPECIFICATION
FOR
LIGHTING INSTALLATION
j/ sjr)
. twV
5 10.03.15 REVISED AND ISSUED AS SPECIFICATION AKG SA BR /' SC
4 15.01.14 REVISED AND ISSUED AS SPECIFICATION FA SA UAP SC
3 25.04.08 REVISED AND ISSUED AS SPECIFICATION

RKS SSM JMS VC
2 28.02.03 REVISED and ISSUED AS SPECIFICATION HKM RSG VPS SKG
REVISED and ISSUED AS STANDARD

1 01.09.97 RR VPS SG AS
SPECIFICATION
0 31.03.82 ISSUED AS STANDARD SPECIFICATION RR VPS

Standards Standards
Committee Bureau
No by by
Approved by
Page 1477 of 2065

ENGINEERS
tJ1 e.1
ligar faWeg INDIA LIMITED
1.727 er,o,,fojoin-,0
FOR 6-51-0083 Rev. 5
(A GoN of India Undertalongf
LIGHTING INSTALLATION Page 2 of 13
Abbreviations:
CCoE Chief Controller of Explosives
CD Compact Disc
CFL Compact Fluorescent Lamps
DC Direct Current
DG Diesel Generator
DGMS Director General Mines and Safety
ELCB Earth Leakage Circuit Breaker
FFL Finished Floor Level
GI Galvanised Iron
HPMV High Pressure Mercury Vapour
HPSV High Pressure Sodium Vapour
HRC High Rupturing Capacity
IS Indian Standards
JB Junction Box
MDB Main Distribution Board
MS Mild Steel
PE Polyethelene
TPN Three Phase and Neutral

Mr. Parag Gupta
Mr. M.K. Sahu
Page 1478 of 2065

■
ìtfaelel
J ENGINEERS
51g-ar tif54- g
1.771,Teeure omFirrm,
IA Go, of India Undertaking)
CONTENTS
1.0 SCOPE 4
3.0 EQUIPMENT SPECIFICATIONS 4
4.0 LIGHTING INSTALLATION 7
5.0 TESTING AND COMMISSIONING 12
Page 1479 of 2065

t_71 el ENGINEERS
$fgar faft-eg INDIA LIMITED FOR 6-51-0083 Rev. 5
oNr77-1,3-7.77 ■74,1-cry. IA GAN Of indo UndertakIng,
1.0 SCOPE
This specification defines the requirements for the supply of equipment, materials,
installation, testing and commissioning of the lighting system (lighting fixtures, lighting
power distribution, telephone wiring etc.).
specification, EIL installation standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD standards listed
below :
SP:30 (BIS) Special Publication - National Electrical Code.
IS:5 Colours for ready mixed paints and enamels.
IS:3854 Switch for domestic & similar purpose
IS/IEC 60947 L.V. Switch gear and control gear
IS: 1293 Plugs & socket outlets of rated voltage upto and including 250V &
rated current upto 16A.
IS:9537 Conduits for electrical installations
IS 694 Polyvinyl Chloride insulated unsheathed & sheathed cables/cords
upto & including 450/750V
OISD RP- 147 Inspection and safe practice during electrical installation
OISD 173 Fire prevention and protection system for electrical installation
a. CEA Regulations
c. Regulations laid down by CCoE/DGMS (as applicable).
agencies.
3.0 EQUIPMENT SPECIFICATIONS
All materials, fittings and appliances to be supplied by the contractor shall be new, unused and
of the best quality and shall conform to the specifications given hereunder. These shall be
manufactured in accordance with the latest revision of the specifications of Bureau of Indian
Standards/International standards. In the absence of any specifications for a particular item,
contractor shall bring material samples along with proven track record to site and get the same
approved by Engineer-in-Charge/Owner before installation.
3.1 Lighting and Power Panels
3.1.1 Lighting and Power panels (general purpose panels for safe area) shall be made of 1.6mm
thick sheet steel or polycarbonate material as specified and shall be dust and vermin proof.
All metal surfaces shall be cleaned free of rust, given a coat of red-oxide primer and finished
with two coats of epoxy based paint of shade 632 of IS 5. Panels shall be indoor/outdoor type
as specified. Indoor type panels shall have IP42 degree of protection and shall be suitable for
surface or flush mounting on wall surface as specified. Lighting and power panels located
outdoor shall be IP55 weather protected and shall also preferably have integral canopy for
Page 1480 of 2065

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_11 ENGINEERS
el
12--a faWs d INDIA LIMITED FOR 6 -51-0083 Rev. 5
isirerr A26,7 711,17/TA) IA Govt of incto Undettakingt
additional weather protection. The canopy shall be made of 2mm thick galvanized sheet steel
or FRP where these are separate from the equipment.
3.1.2 Lighting and Power panels shall have TPN incoming feeder and single phase outgoing
feeders. Lighting circuit feeders shall be rated for 10 amps and power circuit feeders shall
have current rating of 16Amps.In power panels for window Air conditioning units, power
circuit feeder shall be rated for 20 amps. Panels shall be equipped with phase and neutral bus
bars of required current carrying capacity. The outgoing feeders shall be provided with single
pole miniature circuit breakers (MCBs) for safe areas and double pole MCBs for hazardous
areas. The incomer shall be with MCB and ELCB unit unless otherwise specified. In case of
panel for Green Buildings incomer shall also be provided with Energy Meter as per GRIHA
requirements. Accordingly, CTs shall be provided in all the three phases for current
measurement and voltage shall be tapped directly from phases through control fuses.
Miniature circuit breakers shall be mounted in such a way that the operating levers project
outside the front Bakelite cover plates for ease of operation. A hinged door to cover the
operating knobs shall be provided. In addition, a circuit diagram indicating incomer details
and outgoing details viz. Circuit number, circuit rating, and load connected and details of the
load shall be pasted inside the panel. Also a laminated copy of the diagram shall be provided
inside the panel in a suitably designed pocket. Two external earthing studs for connection to
the plant earthing grid shall be provided on the panel. Further, the panel shall be provided
with an earth bus bar with terminal studs for connection to the third core of each outgoing
circuit. Each circuit phase and neutral shall be given ferrule numbers. Complete wiring inside
the panel, shall be neatly bunched with PVC tape and button. Sufficient terminals shall be
provided in the terminal block so as to ensure that not more than one wire (core) is connected
to a terminal. The panel shall have knock out holes or removable gland plate for the entry of
incoming and outgoing conduits or cables. The panels shall be complete with requisite
number of cable glands as specified.
3.1.3 The Main distribution board (MDB) where used, shall be made of 2mm thick sheet steel
panel, dust and vermin proof similar in construction to Lighting and Power panels but with
TPN MCCB or switch fuse incoming and TPN outgoings ( MCB with ELCB units and MCB
without ELCB unit as applicable) of required numbers as specified.
3.1.4 All MCBs shall be of M9 category as per IS 8828 and sensitivity of ELCBs shall be 100 mA-
300 mA unless otherwise specified.
3.1.5 Wherever the size of incoming cable to lighting, power panels/MDB is more than 35 sq.mm a
suitable cable adapter box shall be provided and attached to the panel. The incoming cable
leads shall be connected to terminal block (bolted type terminals) of required size. This
terminal block shall be connected to TPN incomer unit through separate PVC insulated copper
conductor wires/bus bars. Sufficient space shall be provided (minimum 300mm) between
gland plate and the bottom of terminal block for easy termination.
3.2 Lighting Fixtures
The types, makes and catalogue numbers of various types of lighting fixtures shall be as given
in Fixture schedule job data sheet. HPMV/HPSV/fluoroscent lighting fixtures shall be
complete with ballast, starters and capacitor, as required. Control gears for these fixtures shall
be integral or non-integral as specified in lighting layout drawings. Unless otherwise
specified, all fixtures shall be supplied complete with lamps. Ballast for fixture shall be
copper wound or electronic type. The fixtures shall be of high power factor type i.e. at least
0.9 or more.
3.3 Switches
Switches, manufactured in accordance with IS:3854 shall be used for non hazardous areas.
Switches in areas where concealed wiring has been adopted, shall be flush mounting piano
Page 1481 of 2065

k.it et ENGINEERS
51g-a 054- eg
' INDIA LIMITED FOR 6-51-0083 Rev. 5
,,,foral,
I.77 elec.', IA Govl of India UncleItai,Ing,
type unless otherwise specified. For surface conduit wiring, piano type switches in surface
mounted box shall be provided. Industrial Type switches (Weather protected) shall be used
for outdoor areas. Modular switches along with required boxes shall be provided for indoor
application in case shown in the layout.
3.4 Receptacles
Three pin type 5A/15A receptacles manufactured in accordance with IS: 1293 shall be used
for non hazardous areas. The receptacles and the controlling ON/OFF switch shall be mounted
in the same enclosure box but these shall be in separate units to facilitate replacement by
parts. Flush mounting type receptacles shall be used in areas where concealed wiring has been
adopted and surface type shall be used in other areas. For exhaust fans and wall mounted air
circulators, socket and switch enclosures shall be separate. In buildings such as sub-station,
DG. Shed, Workshop, maintenance shop etc. industrial type metal clad socket outlets and
plugs shall be provided. These sockets shall be supplied complete with plugs. Modular type
receptacles along with required boxes shall be provided for indoor application in case shown
in the layout
3.5 Outlet Boxes
The outlet boxes used as point outlets shall be prefabricated type 65mm deep junction boxes.
Outlet boxes custom fabricated for sockets, switches, fixtures and fan regulators etc. shall be
made of MS sheet having minimum thickness of 1.6mm.Outlet boxes shall be galvanized/
nickel plated after fabrication. These shall be complete with terminal block suitable for
connection of wires up to 4 sq. mm Front cover plate shall be of 3mm thick Bakelite / PE
sheet. The colour shall suit the shade of the walls or shall be white if the shade of the walls is
not finalised. The sheet shall extend at least 2 cm on all sides of outlet box. Cover plate shall
be fixed by cadmium plated brass screws and cup washers. Outlet boxes shall be provided
with adequate number of knock outs on all the sides for ease of wiring either with conduits or
without conduits.
3.6 Conduit and Accessories
Conduits for Electrical installations shall conform to IS: 9537. The type of conduit (steel / GI/
PVC) shall be as specified on drawing. Black enameled steel or GI conduit shall be of 1.6mm
thick and the minimum wall thickness of PVC conduit shall be 1.6mm. Generally PVC
conduits shall be used in concealed wiring and for surface wiring GI conduit (in plant
buildings) and black enameled steel conduit (in non plant buildings) shall be used.
3.7 Lighting Poles
Lighting poles shall be fabricated as per EIL installation standards enclosed with the
specification from ERW steel tubular pipes of specified section, with joints, swaged together
when hot and beveled on outside edges or hexagonal shape. Poles shall be coated with
bituminous preservative solution on the ground portion of the outside surface. Remainder of
the outside surface shall be given one coat of redoxide primer and finished with two coats of
aluminium paint. The pole shall have a marshalling box near the bottom to contain HRC
fuses, a neutral link, an earth stud and terminal block. FRP type lighting poles shall be
provided in case shown in the layout.
3.8 Lighting Mast
3.8.1 Lighting masts (Lattice tower) where used, shall be fabricated as per EIL Standard Drawing
enclosed with the tender/specification. They shall be complete with 2 nos. MS flats provided
at the base plate for connection to the plant earthing grid. A ladder, platform, handrail, a
weather protected TPN switch (at 1500mm from ground level) and a weather protected
distribution board fabricated out of sheet steel shall be provided at the top of mast. The TPN
Page 1482 of 2065

k31 el ENGINEERS
lfgar 204- g
170271 21-,a2 ,2,1,111,711
t A Go4 ut maw Undellalkini
Switch and the distribution board shall also have a canopy for additional weather protection.
The TPN switch shall be suitable for looping one more lighting mast from the same incoming
power supply. The distribution board shall have TPN bus bars of 30 Amps. rating and 12 Nos.
outgoing circuits each with a 6A single pole MCB. The distribution board shall have cable
entries from bottom. Necessary space provision and suitable mounting arrangement shall be
made on top of the tower for mounting of ballast (choke) and condensers for all the circuits
and the lighting fixtures. The masts shall be given one coat of red oxide primer and two coats
of aluminium paint. Distribution board shall be fabricated out of 2mm thick sheet steel and
shall be painted with two coats of enamel over a base coat of red oxide.
3.8.2 Unless otherwise specified the flood lighting high masts shall be telescopic type conforming
to EIL specification and data sheet.
3.9 Wires
Wires shall be PVC insulated and shall be of 660 Volts grade as per IS694. Conductor shall be
of stranded copper and size shall be minimum 1.5 Sq. mm for lighting, 2.5 Sq. mm for 15A
power socket circuits and 4 sq. mm for split A/C power socket circuits. Red/Yellow/blue
wires for phases, black wire for neutral and green wire for earth shall be used (size of earth
wire shall be same as for phase and neutral size). Wire size for air conditioning circuit feeders
shall be as indicated in the panel schedule.
3.10 Ceiling fan/Exhaust fan
Ceiling fans shall be of 1200mm sweep with BEE (Bureau of energy efficiency) rating of
minimum 3 star, unless otherwise specified with double ball bearing and regulator. The
suspension down rod shall be sturdy mild steel rod of adequate diameter and of minimum
length of 300mm with shackles suspension arrangement as per IS. For exhaust fans, the sweep
dia. and air CFM shall be as specified in job specification. Exhaust fans for battery room shall
be with anticorrosive blades suitable for use in acidic fumes. Exhaust fans shall be with BEE
rating of minimum 3 star.
3.11 Decorative switches and sockets
Decorative lighting switches and sockets where specified, shall be modular in design. All
these items shall fit into the same frame with overall standard dimensions. Frames shall be
suitable for surface and flush mounting in brick / concrete wall. The frames shall be suitable
for conduit entry from all the sides. Switches and sockets shall match colors of the frame and
cover plates to obtain a combination which shall match decor of the interiors of Control
Room, Administrative buildings, offices rooms etc.
4.0 LIGHTING INSTALLATION
4.1 General
4.1.1 The lighting fixtures in the plant shall be fed from lighting panel. All outdoor lighting shall be
group controlled manually or through synchronous timer or photocell. Lighting wiring
between panel and lighting fixtures shall be done with PVC insulated 3-core (phase, neutral
and earth) copper conductor armoured cable for hazardous areas. Wiring in the building shall
be done by means of 3-core copper, conductor PVC insulated, un-armoured cables, or PVC
insulated copper conductor wires in conduit/Metsec channel as specified. All joints of
conductors in Switch boards/JBs Fittings shall be made only by means of approved
mechanical connectors (nylon/PVC connectors). Bare twisted joints shall not be permitted any
where in the wiring system.
4.1.2 The lighting layouts furnished by owner will indicate approximate locations of lighting
fixtures. The electrical contractor shall determine, with approval of Engineer-in-Charge, the
Page 1483 of 2065

til ENGINEERS
FOR
a- r ttijit‘g
51g INDIA LIMITED 6 -51-0083 Rev. 5
.7,77 051 ..717.0 IA Gov't of Indo Undeltakingt
exact locations of each fixture in order to avoid interference with piping or other mechanical
equipment and also with a view to obtain as much uniform illumination as practicable, and to
avoid objectionable shadows. Conduits shall be laid out by the contractor to suit field
conditions and as per directions of the Engineer-in-Charge.
4.1.3 On walkways, platforms and other outdoor area, lighting fixtures shall be located nearer to
landing of stairs or ladders, gauges, flow meters, panel boards and other equipment to provide
proper illumination.
4.1.4 The minimum height of any lighting fixture shall be preferably not less than 2.5 meters above
the floor level.
4.1.5 All outdoor cable terminations to outdoor junction boxes, panels, socket outlets etc. shall be
through bottom or from side. Top entries for cables shall be avoided to avoid water entry. All
cable glands for outdoor terminations shall be double compression type and the gland shall be
covered with PVC or rubber boot shroud. All unused cable entries shall be plugged with
suitable blanking plugs.
4.1.6 Mounting height of equipment shall be as under:-
Top of Switch Box 1200 mm from FFL (Finished floor level)

Top of Lighting/Power Panel 1800mm from FFL
5/15 Amp. receptacle 300mm from FFL unless otherwise specified (1200
mm for process areas and industrial sheds)
Lighting fixture As indicated in layout drawing
Exhaust fan In the cutout provided / as indicated in Layout
drawings.
4.1.7 Fixtures shall be firmly supported from the structures. Support clamps etc. may be bolted or
welded to the existing steel work or metal inserts. In case of concrete structures, where metal
inserts are not available, fixtures shall be suspended from concrete surfaces with the help of
anchor fasteners. In such cases special care shall be taken to see that anchoring is firm. In
places where ceiling fans are provided, lighting fixtures shall be suspended below the level of
fan to avoid shadow effect.
4.1.8 The lighting fixtures on various circuits shall be suitably interlaced so that failure of any one
circuit does not result in complete darkness.
4.1.9 Circuit cables in a group shall be cleated to structure by using galvanised strip clamps or cable
run in cable trays wherever trays are available. Spacers and cleats shall be of required size to
accommodate the cables. All hardware shall be galvanised or zinc passivated. Underground
lighting cables (in paved areas) shall be taken in suitable GI sleeves buried at a minimum
depth of 300mm from FFL. GI pipe sleeves shall be extended to 300mm above FFL. Exact
termination/layout of GI pipes (for protection of cables) shall be decided at site as per site
convenience in consultation with Engineer-in-charge.
4.1.10 Wiring for all outlet sockets shall be done with 3 cores of equal sizes for phase, neutral and
earth. The terminals of switch sockets shall be suitable to receive the size of wire specified.
4.1.11 All lighting fixtures shall be provided with terminal block with required terminals suitable for
connection of wire up to 2.5 sq. mm copper conductor.
4.1.12 The cable shall be straightened after unwinding it from the drum. All cables are clamped/laid
in straight run without any sag and kink.
Page 1484 of 2065

t_71 el ENGINEERS
$1gar tV1- g INDIA LIMITED FOR 6-51-0083 Rev. 5
I 44-
171 ett47,77 011 J7,37.9, IA GM of India Unaellaiong)
4.1.13 For location where fan points are shown, fan hooks with junction box shall be provided during
concreting.
Where fan hooks and JBs. are provided separately JB shall be located within a distance of
300mm from hook for mounting of ceiling rose.
4.1.14 Industrial type plug sockets with 20A MCB or rating as per job specification shall be provided
at a height of 500mm from FFL for window AC units.
Socket outlets and plugs for installation in Sub-station building, DG shed, workshop, and
maintenance shop etc. shall be of industrial metal clad type.
4.1.15 Wiring for exhaust fans shall be terminated in receptacles as specified in layout drawing and
the connection from receptacle to the exhaust fan shall be by means of a flexible cord
equivalent in size to the main run of wires. Switch for exhaust fan shall be located in a
separate switch board along with other switches.
4.2 Conduit System
4.2.1 Surface or concealed conduit system of wiring shall be adopted, as specified in the drawings.
Required number of pull boxes shall be used at intervals to facilitate easy drawing of wires.
Separate conduit shall be run for lighting and power circuits. Further, conduits for Normal
lighting/Emergency lighting/DC critical lighting shall be separate. Conduit layout shall be
decided at site as per site conditions. Drop conduits for switch boards shall be decided by
contractor as per wall locations shown in Architectural drawings. All exposed run of conduits
on surface, shall be vertical or horizontal.
4.2.2 Only threaded type conduit fittings shall be used for metallic conduit system. Pin grip type or
clamp type fittings are not acceptable. Conduit ends shall be free from sharp edges or burrs.
The ends of all conduits shall be reamed and neatly bushed.
Conduit shall be of minimum 25mm dia. Maximum number of wires permissible in a conduit
shall be seven/nine for wire size of 2.5 sqmm/1.5 sq.mm. respectively.
4.2.3 The exposed outer surface of the conduit pipes, including all accessories forming part of the
conduit system, shall be adequately protected against rusting. In all cases, bare threaded
portion of conduit pipe shall not be exposed unless such bare threaded portion is treated with
anti corrosive preservative or covered with approved plastic compound.
4.2.4 Conduit connection to outlet boxes shall be by means of screwed hubs or check nuts on either
side. Where concealed wiring is done, junction boxes (65mm deep) shall be used so as to rest
on shuttering properly. Conduits shall be laid above reinforcement. All conduit connections
shall be properly screwed and Junction box covers shall be properly fitted so as to avoid entry
of concrete slurry.
4.2.5 Conduit pipes shall be fixed by 1.6mm thick GI saddles on 3mm thick Gl. saddle bars of
required width in an approved manner at intervals of not more than 50cms for straight run. At
places near junction boxes, bends, or similar fittings, saddle and bars shall be provided on
either side.
4.2.6 Where concealed wiring is to be adopted, conduits shall be laid in time before concreting of
the slab. Pull wire (GI or steel) shall be provided inside conduit for the ease of wire pulling.
The contractor shall coordinate his work with other agencies involved in the civil works in
such a way, that the work of the other agencies is not hampered or delayed. Vertical conduit
runs shall be made in wall before plastering is done so as to avoid chasing. Where chases are
made for conduit run contractor shall fill these chases or any other openings made by them
after completing the work and patch the surface. During installation, care shall be taken to see
Page 1485 of 2065

tll ENGINEERS
5g-ar We's- INDIA LIMITED FOR 6-51-0083 Rev. 5
2T7377 TI IA CAM or Inclo Unde)taking,
that proper covers are provided to prevent rusting of conduits. Locations of all point outlets,
junction boxes shall be marked with brick powder or sand so that these are easily identified
after shuttering removal. As built conduit layout drawing shall be submitted by contractor
after completion of the work.
4.2.7 All junction boxes, bends and other accessories shall be of the same material as that of conduit
and shall have the same protective coatings.
4.2.8 After erection, the entire conduit system shall be tested, for mechanical and electrical
continuity and shall be permanently connected to earth by means of approved type of earthing
clamps.
4.3 Hazardous Area Installation
4.3.1 Wiring in hazardous area shall be done by using minimum 2.5mm2 copper conductor
armoured cable.3' core of the cable shall be used as earth conductor for earthing of lighting
fixture. Circuit wiring feeding hazardous areas shall be controlled by two pole
switches/MCBs (for phase as well as neutral isolation).Switches for lighting panels installed
in hazardous area shall have a pole to break the neutral in addition to poles for phases.
4.3.2 Correct type of lighting equipment (fixtures and JBs) with regard to hazardous protection as
specified in the drawing shall be installed for the areas classified as Zone 1, Zone 2 etc.
4.3.3 The terminations in the junction boxes and the lighting fittings shall be done avoiding
possibility of loose connections due to vibrations. After the terminations are made the cover of
the junction boxes and the lighting fittings shall be closed properly with all bolts and hard
wares in correct position, retaining its explosion and weather protections. In fixtures having
double cable entries, both the entries shall be used for looping in and looping out connection,
thus minimising the use of a separate junction box. Wherever separate control gear boxes (CG
box) are provided looping in and looping out connections shall be through CG box, thus
avoiding the use of an additional junction box. All unused cable entries shall be sealed with
suitable plugs.
4.3.4 Circuit cables shall be firmly cleated in a group along columns/ beam/ladders/side
channels/platform using 1.6mm thick GI saddles on 25x3 mm GI saddle bar at intervals of
400mm to 500mm for straight run and on either side close to bending and at both termination
ends as per the directions of Engineer-in-charge. Where required 3 or more of cables shall be
taken in perforated150mm wide slotted channel cable tray after getting the approval of
Engineer-in-charge. Minimum straight run shall be 3000mm.Cables shall not be routed along
hand rails.
Where fire proofing column/structures are encountered, all cabling shall be taken in GI pipes
of required size and both ends shall be sealed, well before fire proofing is done. Similarly
equipment such as lighting fixture, control gear box, lighting/ power panels, field call stations,
junction boxes etc. shall be installed on suitable steel mounting frame/distance bracket,
thereby avoiding direct contact with the concrete used for fire proofing.
4.3.5 Cable glands for terminating cable on flameproof equipment shall be of double compression
FLP type. Any material/equipment specified to be supplied by contractor for installation in
hazardous areas, shall be tested by CIMFR and duly approved by CCoE or DGMS or any
other applicable statutory authority. All indigenous FLP equipment shall also have valid BIS
license as required by statutory authorities.
4.4 Building Lighting
4.4.1 The type of wiring system shall comprise surface/concealed conduit system or cable wiring as
specified on layout drawings.
Page 1486 of 2065

til~fzt ENGINEERS
FOR
Oar s& 1.1-2a. eren,,rajtgraa,
INDIA LIMITED
IA Gov't of India Uncle'flung)
LIGHTING INSTALLATION
6-51-0083 Rev. 5
Page 11 of 13
4.4.2 Mounting details of fixtures shall be indicated on the drawings. If specified on the drawings, a
group of fluorescent lighting fixtures which are to be mounted end to end shall be fixed to
mild steel cold rolled sections of 50mm x 50mm and of I .2mm thick (Metsec channel). The
entire assembly shall be fixed to the ceiling with necessary number of supports which may be
by means of steel conduit or chromium plated chain link as required. The 'Metsec' Channel
shall run continuous in suitable sections from one end to other end of wall. The complete
channel shall be spray painted, with approved colour as per the directions of Engineer-in-
Charge. All wires inside channel shall be neatly bunched by nylon tape and buttons.
4.4.3 Wiring in areas above false ceiling shall be done in Surface Conduit (25mm dia GI conduit)
suitably clamped to the true ceiling. Vertical drops from true ceiling for panels, switches,
receptacles etc. shall be taken in 25mm dia PVC conduit concealed in walls upto
switchboards/panels. Lighting fixtures shall be supported from true ceiling. Exact location of
fixtures shall be finalised in co-ordination with air-conditioning duct diffuser layout, panel's
layout and false ceiling grid layout. To facilitate easy maintenance 'Looping back system' of
wiring shall be followed throughout. Accordingly supply tapping's and other interconnections
including for earthing are made only at fixture connector blocks or at switch boards. Required
number of junction boxes shall be used at intervals for wire pulling and inspection.
4.4.4 All wires in conduit shall be colour coded as specified. Each circuit shall have independent
phase neutral and earth wire. However when group of circuits are run in a single conduit the
earth wire can be common.
4.4.5 Building conduit lighting system of wiring where measurement is done on point wiring basis
generally consists of two parts. The first part is the circuit wiring which includes the work
necessary from lighting panel up to switch box and from switch box to another switch box.
The second part is the point wiring which shall include the work necessary from tapping point
in the switch box upto various fixtures or fan outlets/ceiling roses.
4.4.6 Switches for light fixtures/exhaust fans in battery room shall be provided outside the Battery
room.
4.4.7 Lighting layouts for non-plant buildings (such as ware house, cement godown, gate house,
workshop, service building, rest room, etc.) shall be prepared by installation contractor as
defined in the scope of work.
The following basic data/document for preparation of layouts will be provided to the
contractor.
i) Architectural drawings
ii) Illumination level required
iii) Type of lighting fixture
iv) Type of wiring (concealed/surface conduit/cable wiring etc.)
Based on the above input, contractor shall prepare and submit lighting layout drawings, panel
schedules, conduit layout drawings for concealed wiring, design calculations wherever
required, for review by purchaser before erection work is started. The lighting layout drawing
shall show the location, type and mounting details of lighting fixtures, receptacles, junction
boxes, layout of circuit indicating number of wires etc. The number of points in a circuit shall
not exceed ten and the load in each circuit shall be less than 1000 Watts.
The panel schedule shall include rating of incoming and outgoing feeders, number of outlets,
load for each outgoing circuit, etc.
Page 1487 of 2065

ENGINEERS
sIgar faaL dINDIA LIMITED FOR 6-51-0083 Rev. 5
iqerme )9511 IA Gov! of India UncleIlaking)
All drawings shall be prepared preferably in AO and Al size. Panel schedules shall be in A4
size drawings. Final submission of drawings shall be in soft copies (CD form) and in bound
volumes.
4.5 Street Lighting
4.5.1 Street lighting poles to be located on road side shall be installed at a minimum distance of
300mm from the edge of the walkway of the road (road berm). Size of wires from marshalling
box upto fixture shall be 1.5mm2/2.5mm2, copper conductor PVC insulated.
4.5.2 Each pole shall be earthed at two points by connecting to the plant earth grid as shown on
Installation standards.
4.5.3 Street lighting fixture shall be mounted on steel tubular poles as per standard drawings. The
foundation for the street lighting poles will be made by electrical contractor. Street lighting
poles shall be supplied with a base plate.
4.5.4 The poles shall be numbered as per the drawings/ directions of Engineer Incharge.
4.6 Mast Lighting
4.6.1 The lattice structure masts shall be installed on concrete foundations with the base plate bolted
on to the anchor bolts. The lattice structure shall be painted with a coat of primer and two
coats of aluminium paint, the second coat to be given just before handing over to the owner.
The masts shall be numbered as per drawings. The masts shall be connected to the plant earth
grid at two points
4.6.2 The main feeder upto the distribution board of lighting mast shall be through PVC insulated
armoured cable of size as specified in the respective drawing. Wiring from Distribution Board
to each flood-light fixture shall be by means of a 3-core 2.5sqmm, copper conductor PVC
insulated armoured cable. All the cables shall be neatly clamped to the structure at intervals
not exceeding 25 cms.
4.6.3 Exact orientation of flood lighting fixtures shall be decided at site to achieve optimum utility
of these fixtures.
4.7 Telephone Wiring
Conduits for telephone wiring in buildings shall be of 1.6mm thickness. 25mm dia black
enameled steel conduit/PVC as per IS 9537, installed on wall surface or concealed or as
specified in job specification.
Conduit installation system shall comply with the requirements given in clause 4.2 'conduit
system'. Required number of pull boxes shall be provided at interval for easy drawing of
wires. The telephone wiring shall be done with 0.63mm dia annealed copper conductor PVC
insulated 660V grade, twin flat wire, unless otherwise specified in job specification. One
telephone socket outlet shall be provided for connection to telephone instrument.
5.1 Lighting installation shall be tested and commissioned by installation contractor as per EIL
specifications. Precommissioning checks and tests shall include but not be limited to the
following:
(i) The insulation resistance of each circuit without the lamps (load) being in place shall
be measured and it should not be less than 500,000 ohms. (Between phases, phases to
neutral, phase/neutral to Earth).
Page 1488 of 2065

■
JI el ENGINEERS
2fWeg
larr, i"-RU,
J.70, iA Govt of now undeFtakingi
(ii) Current and voltage of all the phases shall be measured at the lighting panel bus bars
with all the circuits switched on with lamps. If required load shall be balanced on the
three phases.
(iii) The earth continuity for all socket outlets shall be checked. A fixed relative position
of the phase and neutral connections inside the socket shall be established for all
sockets.
(iv) After inserting all the lamps and switching on all the circuits, minimum and
maximum illumination level shall be measured in the area and recorded.
(v) It shall be ensured that switch provided for ON/OFF control of point (light/fan/socket)
is only on LIVE side.
(vi) Operation of ELCB's shall be checked.
Contractor shall duly fill in all the above test results and submit the test reports to Engineer-
in-Charge in triplicate.
5.2 All lighting layout drawings shall be marked by contractor for 'AS BUILT STATUS' and two
sets of hard copies plus 1 set of soft copy in CD, shall be submitted to EIL.
Page 1489 of 2065

ENGINEEFZS FOR
laaleg INDIA LIMITED 6-51-0084 Rev. 4
C1,7,W MI,~) (A Govt of lndw Undertaking) EARTHING INSTALLATION Page 1 of 7
3Trztrr f«R-r
SPECIFICATION
FOR
EARTHING INSTALLATION

FA SA BRB SC
RKS SSM JMS VC
2 28.02.03 REVISED & ISSUED AS SPECIFICATION HKM RSG VPS SKG
REVISED & ISSUED AS STANDARD AS
1 16.07.97 RR VPS SG
SPECIFICATION
0 25.07.94 ISSUED AS STANDARD SPECIFICATION RR SGC SCG SCG
Standards Standards
Committee Bureau
No by by
Approved by
Page 1490 of 2065

ENGINEERS SPECIFICATION
ffig"ar fl2eg
1.11271 21~ 9>f JOCFA)
INDIA LIMITED
(A Govt ot Inda Undertakng)
FOR 6-51-0084 Rev. 4
EARTHING INSTALLATION Page 2 of 7
Abbreviations:

PESO Petroleum and Explosive safety organization.
CD Compact Disc
DGMS Director General Mines and Safety
GI Galvanized Iron
IS Indian Standard
MS Mild Steel

Mr. Parag Gupta
Mr. M.K. Sahu
Page 1491 of 2065

" ENGINEERS SPECIFICATION
122e5IVWINDIA LIMITED FOR 6-51-0084 Rev. 4
013, I
1;15711 A Govt of Inda undertaking)
CONTENTS
1.0 SCOPE 4
3.0 MATERIAL SPECIFICATIONS .4
4.0 EARTHING NETWORK .4
5.0 INSTALLATION OF EARTH ELECTRODE .5
6.0 CONNECTION 6
7.0 TESTING AND COMMISSIONING .7
Page 1492 of 2065

sf " INDIA LIMITED
1.1,271232x1Wqs~.1) IA Govt ot Intha Undeltalong)
FOR 6-51-0084 Rev. 4
1.0 SCOPE
This specification defines the requirements for the supply of earthing and lightning protection
materials and installation of the earthing and lightning protection systems.
specification, EIL Installation Standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD Standards listed
below :
SP:30 (BIS) Special Publication-National Electrical Code

IS:2309 Protection of buildings and allied structures against lightning.
IS:3043 Code of practice for earthing
IS:7689 Guide for control of undesirable static electricity.
OISD 110 Recommended practices on static electricity
OISD 147 Inspection and safe practice during electrical installation.
OISD GDN 180 Lightning protection.
a. CEA Regulations
c. Regulations laid down by PESO/DGMS (as applicable).
agencies.
3.0 MATERIAL SPECIFICATIONS
3.1 All materials and hardware to be supplied by the contractor shall be new, unused and of best
quality and shall conform to the specifications given here under and to latest specifications of
Bureau of Indian Standards. Contractor shall bring material samples to site and get it approved
by Engineer-in-charge before installation.
3.2 The main earth grid conductor shall be hot dip galvanised M.S. flat unless otherwise specified.
Sizes for main conductors shall be as indicated on the earthing layout drawing .Amount of
galvanizing shall be 610gm per sq.metre. Earth electrodes and Earth plate shall be as per EIL
Installation Standards.
4.0 EARTHING NETWORK
4.1 This consists of main earth conductor (grid conductor) forming a closed ring network with
required number of earth electrodes connected to it to provide a common earth for electrical
devices and metallic structures. From each earth electrode two distinct connections shall be
made to the main earth conductor. The earth plates shall be used for taking multiple earth
connections to two or more equipment.
4.2 The earth conductor shall be laid along cable trays/cable trench/pipe racks/ buried in
Page 1493 of 2065

A"ENGINEERS SPECIFICATION
2151egglii/
VINDIA LIMITED
1~1 ,h,f, CrA 3,10,
A
FOR 6-51-0084 Rev. 4
IA Govt of Indo Undertaking)
pavement/ below finished grade level as indicated on the earthing layout drawing. Where
lined cable trenches are available, the earth conductor shall be preferably laid in the trenches
and shall be firmly cleated to the sidewall of concrete trenches using GI clamps at interval of
400 mm to 500 mm and near to the termination end. The earthing conductor shall run along
one of the cable trays along the overhead cable route. The earthing conductor shall be suitably
cleated and electrically bonded to all the other cable trays on the same cable route at a regular
interval of 25 to 30 meter. The earthing for equipment shall be tapped from the main earth
conductor and not from cable tray support structure. Earth conductor when laid underground
shall be at a depth of 500mm below finished grade level.
4.3 Joints and tapping's in the main earth loop shall be made in such a way that reliable and good
electrical connections are permanently ensured. All joints below grade shall be welded and
shall be suitably protected by giving two coats of bitumen and covering with Hessian tape.
Earth strip laid above ground shall be welded across straight through joints and joints shall be
suitably protected by giving two coats of bitumen to avoid oxidation and insulation film
formation of the strip surface. When two earth strips are to be jointed by means of welding,
lap welding with an overlapping of strip equivalent to double the width of the strip and all
four sides shall be continuously welded. All joints at tappings above ground shall be by
means of connector/lugs. A minimum of two bolts of adequate size shall be used for this
purpose. Earthing strip joints at earth plate and equipment shall be through GI bolts, nut etc.
5.0 INSTALLATION OF EARTH ELECTRODE
5.1 Earth Electrode shall be installed as shown on installation standard and layout drawings.
The location shown on the layout drawings are indicative.
The exact location of earth electrodes in the field shall be determined by contractor in
consultation with the Engineer-in-charge, depending on the soil strata and resistivity. Earth
electrodes shall be located avoiding interferences with road, building foundation, column,
pipelines etc. The civil area drawings shall be referred for this. The distance between two
electrodes shall not be less than twice the depth of electrode.
5.2 Electrodes shall preferably be located in a moist soil which has a fine texture, grain size and
distribution. Wherever practicable the soil shall be dug up, all lumps broken and stones
removed from the immediate vicinity of the electrodes and soil packed by watering and
ramming as tight as possible.
5.3 The electrodes shall have a clean surface, not covered by paint, enamel, grease or other
materials of poor conductivity.
5.4 All earth electrodes shall be tested for earth resistance by means of standard earth test meter.
The tests shall take place in dry months, preferably after a protracted dry spell.
5.5 The disconnect facility shall be provided for the individual earth electrode to check its earth
resistance periodically.
5.6 Location of earth electrodes shall be marked by permanent markers for easy identification. All
earth Electrodes shall be serial numbered and also marked on Às Built' drawing for future
reference.
5.7 Individual earth electrodes shall be provided for each lightning arrestor and flood light mast.
5.8 Earthing system provided for concrete paved area by other agency where applicable; shall be
connected to the plant earthing system below ground by minimum two earth connections.
Page 1494 of 2065

ENGINERS
E SPECIFICATION
INWR ei2LIW C151JPC1,74, IA Govt ot Intha undertaifing)
6.0 CONNECTION
The earth system connections shall generally cover the following:

Equipment earthing for personnel safety
- System neutral earthing
Static and lightning protection
6.1 The following shall be earthed.

System neutral
- Current and potential transformer secondary neutral
- Metallic non-current carrying parts of all electrical apparatus such as transformers,
switchboards, bus ducts, motors, neutral earthing resistors, capacitors, UPS, battery
charger panels, welding receptacles, power sockets, lighting/power panels, control
stations, lighting fixtures etc.
- Steel structures/columns, rail loading platforms etc.
- Cable trays and racks, lighting mast and poles
- Storage tanks, spheres, vessels, columns and all other process equipment.
Fence and Gate for electrical equipment (e.g. transformer yard etc.)
- Cable shields and armour
Flexible earth provision for Wagon, Truck
- Shield wire
Conductor size for branch connection to various equipment shall be as per EIL Installation
Standards unless otherwise stated on earthing layout drawings.
6.2 A11 process pipelines shall be bonded and earthed at the entry and exist points of battery limit
of hazardous area.
6.3 Steel pipe racks in the process units and offsite area shall be earthed at every 24 meters.
6.4 Equipment/street light pole etc. located remote from main earth network may be earthed by
means of individual earth electrode and earth conductor unless otherwise stated in job
specifications/earthing layout drawing.
6.5 Lightning protection shall be provided for the equipment, structures and buildings as shown
on layout drawing. Self conducting structures shall not require separate aerial rod and down
conductors. These shall however be connected to the earthing system at two or more points as
shown on layout drawing. Each down conductor shall be provided with an earth electrode and
all earth electrodes shall be interconnected through underground strip. Lightning protection
earthing system may be bonded to electrical safety earthing system, inside ground. Lightning
down conductor shall be brought to earth electrode in shortest straight path as feasible to
minimise surge impedance.
6.6 The main earthing network shall be used for earthing of equipment to protect against static
electricity.
6.7 All medium and high voltage equipment (above 250V) shall be earthed by two separate and
distinct connections with earth.
Page 1495 of 2065

0&.ff OfJlegw'INDIA LIMITED
tem", IA Govt of lneha Undettaking)
FOR 6-51-0084 Rev. 4
6.8 Plant instrument system clean earthing, UPS system clean/safety earth, Data concentrator
panel, HMI etc shall be separate from the electrical earthing system, if mentioned in job
specification/ layout drawings.
6.9 All paint, scale and enamel shall be removed from the contact surface before the earthing
connections are made.
6.10 All earthing connections for equipment earthing shall be preferably from the earth plate
mounted above ground wherever provided
Equipment foundation bolts shall not be used for earthing connection.
6.11 Earth connections shall be made through compression type cable lugs/by welded lugs.
6.12 All hardware used for earthing installation shall be hot dip galvanised or zinc passivated.
Spring washers shall be used for all earthing connections and all connections adequately
locked against loosening.
6.13 Lighting fixtures and receptacles shall be earthed through the extra core provided in the
lighting circuit/cable for this purpose.
6.14 The reinforcements of sub-station building and the sub-station floor shall be connected to
main earth grid.
7.1 Field inspection, testing and commissioning of electrical installation shall be done as per EIL
standard specification.Earthing systems/connections shall be tested as follows:
7.2 Resistance of individual earth electrodes shall be measured after disconnecting it from the grid
by using standard earth test meggar.
7.3 Earthing resistance of the grid shall be measured after connecting all the earth electrodes to
the grid. The resistance value of an earth grid to the general mass of earth shall be as follows:
- For the electrical system and equipment a value that ensures the operation of the
protection device in the electrical circuit but not in excess of 4 ohm. However for
generating stations and large sub-systems, the value shall not be more than 1 ohm.
- For lightning protection, the value of 5ohms as earth resistance shall be desirable, but
in no case it shall be more than 10 ohms
7.4 The resistance to earth shall be measured typically at the following points:
a) At each electrical system earth or system neutral earth.
b) At each earth provided for structure lightning protections.
c) At one point on earthing system used to earth electrical equipment enclosures.
d) At one point on earthing system used to earth wiring system, enclosures, such as
metal conduits and cable sheaths or armour.
e) At one point on fence enclosing electrical equipment.
7.5 All earthing layout drawings shall be marked by contractor for ÀS BUILT STATUS' and
two sets of hard copies plus 1 set of soft copy, shall be submitted to EIL. For projects, where
layout drawings have been prepared based on 3D modeling, contractor shall carryout
necessary changes for ÀS BUILT STATUS' in the 3D model.
Page 1496 of 2065

SPECIFICATION FOR FIELD SPECIFICATION No.
ENGINEERS INSPECTION, TESTING AND
gfga faWs INDIA LIMITED 6-51-0087 Rev. 3
lair,i237,15,2,131,05.) IA Govt of Indla Undertalong)
COMMISSIONING OF
ELECTRICAL INSTALLATIONS Page 1 of 8
-ftw #f-~
PiRkurr, -crftwr
SPECIFICATION
FOR
FIELD INSPECTION, TESTING
AND
COMMISSIONING OF ELECTRICAL
INSTALLATIONS
REAFFIRMED & ISSUED AS STANDARD

3 10.6.14
SPECIFICATION AKG SA BRB *". SC
2 03.03.09
SPECIFICATION RKS NS JMS ND
1 14.07.03 HKM RSG VPS SKG
SPECIFICATION
0 02.08.01 ISSUED AS STANDARD SPECIFICATION UAP RR VPS MI
Standards Standards
Committee Bureau
No by by
Approved by
Page 1497 of 2065

k31 ENGINEERS INSPECTION, TESTING AND
laW5 INDIA LIMITED 6-51-0087 Rev. 3
iairerf r-freA, asl,~7,) A GoN of Indla Undeltaking) COMMISSIONING OF
Abbreviations:
AFC Approved for Construction
CCOE Chief Controller of Explosives
DC Direct Current
DCS Distributed Control System
DGMS Director General for Mines and Safety
ECS Electrical Control Station
GI Galvanized Iron
HV High Voltage
IS Indian Standard
MV Medium Voltage

Mr. Parag Gupta
Mr. M.K. Sahu
Page 1498 of 2065

ENG1NEERS
fawres, INDIA LIMITED
IA Govt ol Ind. Undertaiong)
INSPECTION, TESTING AND
COMMISSIONING OF
6-51-0087 Rev. 3
CONTENTS
1.0 SCOPE 4
3.0 FIELD INSPECTION, TESTING AND COMMISSIONING 4
4.0 RECORDS 8
Page 1499 of 2065

k`51
12..itq ENGINEERS INSPECTION, TESTING AND
$'1gz:IT ft- s INDIA LIMITED 6-51-0087 Rev. 3
I.R77 c`F,1,4, CA3PC1171) IA Govt of India Undertalong) COMMISSIONING OF
1.0 SCOPE
This specification covers the requirements for the field inspection, testing and commissioning
of Electrical Equipment and Installation, forming part of electrical power distribution and
utilisation system.
2.1 The field inspection, testing and commissioning of electrical equipment shall be carried out in
line with this specification and the latest edition of following Indian Standards and OISD
standards.
SP-30(BIS) National Electrical Code.

IS 1255 Code of practice for installation and maintenance of power cables up
to & including 33 kV rating.
IS-7816 Guide for testing Insulation resistance of rotating machines.
IS 10810(Part 43) Method of Test for cables; Part 43 Insulation resistance.
IS 10810(Part 45) Method of Test for cables; Part 45 High voltage test.
IS 12729 HV Switchgears
OISD 137 Inspection of Electrical Equipment.
OISD 147 Inspection and safe practice during electrical installation.
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of
the following as applicable:
a. CEA Regulations
b. Regulations laid down by CEA / Electrical Inspectorate.
c. Regulations laid down by Tariff Advisory Committee/Loss prevention council.
d. Regulations laid down by CCoE/DGMS (as applicable).
e. The petroleum rules (Ministry of Industry, Government of India).
f. Any other regulations laid down by central / state / local authorities / insurance
agencies
3.0 FIELD INSPECTION, TESTING AND COMMISSIONING
3.1 Contractor shall carry out complete field inspection, testing and commissioning of electrical
equipment as per Inspection & Test plans.
3.2 Before the completed installation or an addition to the existing installation is put into service,
inspection / pre-commissioning checks and tests shall be carried out by contractor. In the
event of defects being found out, the same shall be rectified and the installation retested as
applicable.
3.3 The pre-commissioning inspection among other requirements shall include visual inspection,
checking the workmanship of the installation, the rating of equipment, safety clearances, sizes
of cables installed, conformance to the AFC document, soundness of switchgear bus
connections, wiring properly dressed and labeled, sealing of unused cable entries, checking of
all safety interlocks, control/interface functions as per requirement etc.
3.4 Visual inspection for soundness of bus bar connections of busducts, terminal connections of
equipment/motor shall be carried out. It shall be ensured that no foreign materials are present
inside busduct and equipment terminal boxes. After the visual inspection, all the covers of
terminal boxes, inspection chambers shall be refitted with gaskets, bolts & nuts as per
equipment manufacturer's instructions.
Page 1500 of 2065

k31 ENGINEERS INSPECTION, TESTING AND
Og-ar 2f5:1- g
~srz as,:ror.)
(~1
INDIA LIMITED
(A GoN cd InEia Und<rlAk(A9) COMMISSIONING OF
6-51-0087 Rev. 3
3.5 Pre-commissioning tests shall include but not be limited to the following:
Continuity test for each winding and power and control circuits.
Insulation test for each winding and power and control circuit
High voltage test for cables
- Dielectric strength test on transformer oil.
- Checking the correctness of wiring schemes, control circuit interlocks for intended
functioning.
- Verification of phase sequence.

Testing of all types of relays/releases for required operation.
- Testing of measuring instruments for proper functioning.
- Earth continuity test for all circuits.
Checking of safety features for correctness of operation, etc.
Checking of all wired interface contacts (analogue, digital input/output contacts) for DCS
and ECS interface, at panel and equipment terminal chambers as applicable.
(Electrical contractor shall co-ordinate with other agencies involved for the above and
provide support services for checking interfaces of electrical equipment and the intended
functioning)
Earth resistance measurement for each earth electrode, and the earthing system as a whole.
Lighting installation shall be tested for correct illumination levels, with fittings installed.
Fittings shall be operated only with specified type of a lamp or tube.
3.6 After the above tests and inspection are completed, control circuits shall be tested for correct
operation under all operating combinations and proved correct before applying power to
main circuit.
3.7 Plant Communication, Fire alarm detection and telephone system shall be checked for correct
operation and intended function.
3.8 A close visual inspection of electrical equipment in hazardous areas shall be made to ensure
that equipment is suitable for the classified zone and gas group and correctly installed, with all
covers, bolts, nuts and hardwares intact and there is no physical damage mark seen on the
enclo sure
3.9 Site Acceptance Test procedure for specific equipment shall be furnished by the respective
equipment vendor. The contractor shall provide necessary assistance to the equipment vendor
to perform Site acceptance testing to enable the equipment vendor to perform the same.
3.10 All pre-commissioning checks and tests shall be carried out as per the directions of Engineer-
in-charge. In addition to the equipment manufacturer's instructions, pre-commissioning check
requirements shall also be complied. All tests shall be carried out by contractor in the presence
of EIL/Owner' s representatives
3.11 The contractor shall bring to site all required tools, tackles, and testing instruments for
carrying out field testing. Contractor shall use only calibrated measuring and test instruments
and shall maintain valid calibration records.
Page 1501 of 2065

$tigzrr
IN■fn
fa2es INDIA LIMITED
IF GoN of lndN Underfakrogf COMMISSIONING OF
6-51-0087 Rev. 3
3.12 The Insulation Resistance test values for various electrical equipment shall be as below:
3.12.1 Cables
The insulation resistance test values for cables shall be as per following table:
Rated voltage of the Cable DC Test Voltage in Volts Minimum Insulation

resistance in Mega ohms
Lighting and power circuit
250 1
wiring
650/1100V grade cables 1,000 10
1,900/3,300V grade cables 1,000 200
3,800/6,600V grade cables 1,000 200
6,350/11,000V grade cables 5,000 200
8,700/15,000V grade cables 5,000 200
12,700/22,000V grade cables 5,000 200
19,000/33000V grade cables 5,000 200
3.12.2 IIV, MV and Miscellaneous Switchboards
The insulation resistance test values for the switchboards shall be as per following table:
Rated voltage of the DC Test Voltage in Volts Minimum Insulation

Switchboard resistance in Mega ohms
33,000V 5,000 200
11,000V 5,000 200
6,600V 1,000 200
3,300V 1,000 200
415V 1,000 100
240V 500 10
110V 500 10
3.12.3 Generators and Motors
3.12.4 The insulation resistance test values for the Generators and Motors shall be as per following
table:

Generators and Motors resistance in Mega ohms at
40 °C
11,000V 5,000 120
6,600V 1,000 80
3,300V 1,000 50
415V 1,000 15
240V 500 12
Page 1502 of 2065

I f ~5)
irr0n twor,on
INDIA LIMITED
in Govt ol IndU Undertalong) COMMISSIONING OF
6-51-0087 Rev. 3
3.12.5 Transformers
3.12.6 The insulation resistance test values for the Transformers shall be as per following table:

Transformers resistance in Mega ohms at
40 °C
Up to 600V 1,000 100
601 to 5000V 2,500 1,000
5001 to 15,000V 5,000 5,000
15001 to 35,000V 5,000 10,000
3.12.7 It shall be ensured that during insulation tests, electronic devices and components that are
liable to get damaged on applied test voltage shall be disconnected from circuit. The
instructions of equipment/panel manufacturer shall be followed strictly in this regard.
3.13 High-voltage Testing
3.13.1 DC high voltage test shall be conducted as per following table on all HV feeder cables and
also on 1100 V grade cables where straight through joints have been made.
Rated Voltage of TEST VOLTAGE (kV) BETWEEN Duration

Cable (kV) (Minutes)
U. / U* Any Conductor and Metallic Conductor to Conductor
Sheath/ Screen/Armour (For Unscreened Cables)
0.65/1.1 3 3 5
1.9/3.3 5 9 5
3.3/3.3 9 9 5
3.8/6.6 10.5 18 5
6.6/6.6 18 18 5
6.35/11 18 30 5
11/11 30 30 5
12.7/22 37.5 - 5
19/33 60 - 5
*U. : Phase Voltage
U : Line Voltage
The cable cores must be discharged on completion of DC high voltage test and cable shall be
kept earthed until it is put into service.
DC test voltage for old cables shall be 1.5 times rated voltage or less depending on the age of
cables, repair work or nature of jointing work carried out, etc. In any case, the test voltage
shall not be less than the rated voltage.
Page 1503 of 2065

mar faZ5 INDIA LIMITED
l aiWn 23~ ag,o.) IA Gosn of Intha Undertakog) COMMISSIONING OF
6-51-0087 Rev. 3
3.13.2 AC high voltage test shall be conducted as per following table on all HV Switchboards.
Rated Voltage Rated 1 Min. Power Frequency Withstand Voltage Duration in

(rms Value in (rms Value in kV) Minutes
kV)
U To Earth, Between Across the Isolating
Poles and Across Open Distance
Switching Device
3.6 10 12 1
7.2 20 23 1
12 28 32 1
24 50 60 1
36 70 80 1
72.5 140 160 1
The withstand voltage values across the isolating distances are valid only for switching
devices, where the clearance between open contacts is designed to meet the safety
requirements specified for disconnectors.
3.14 All protective relays including thermal overload relays shall be tested by secondary injection
current. Primary injection tests shall be carried out for differential protection, restricted earth
fault protection at full/reduced current to ensure correctness of complete wiring.
3.15 Before energizing any equipment, `COMMISSIONING CLEARANCE FORM' as per

standard format shall be duly filled in by contractor and submitted to EIL/owner.
3.16 It shall be ensured that the electrical inspectorate approval is available before energizing the
equipment
4.0 RECORDS
Contractor shall keep up-to-date records of all activities carried out and test results. Field
inspection / test reports shall be submitted to EIL / Owner by the contractor in bound volumes
(triplicate copies).
Page 1504 of 2065

diaMOENGNEERS NDIAMAIM
TYPICAL EARTH ELECTRODE STANDARD No.
FOR 7-51-0101 Rev. 5

(A GovL 661u Umisrb,Wroi)
EARTHING SYSTEM Page 1 of 1
40 11-51
1 130 n ,40
REMOVABLE CAP SEE DETAIL-1
10 DIA TAPED HOLE
300X75x10 M.S. PLATE

WELDED TO PIPE
65 DIA N.B. PIPE (MEDIUM)
12 DIA HOLES
M.S. PLATE BENT TO SHAPE
REMOVABLE CAP MADE OF

M.S. PLATE WELDED TO
DETAIL-1
NOTE:-
1. THE PIPE ASSEMBLY SHALL BE HOT DIP GALVANISED AFTER FABRICATION.
5 08.11.16 UPDATED & ISSUED AS STANDARD BP FA/HK RN

4 27.06.11 REAFFIRMED & ISSUED BP RKS/RSC UAP DM
No. by by
Approved by
Page 1505 of 2065

TYPICAL EARTH ELECTRODE STANDARD No.
ENGINEERS
eliBMO NDR LIMITED
(A Govt. of Indio Undertaking)
IN 7-51-0102 Rev. 6
TEST PIT Page 1 of 1
6 THICK CHEQUERED
PLATE COVER REMOVABLE CAP SEE
REFER DETAIL-1 NOTE-3 AND DETAIL-3
(SEE NOTE-4)
1060 SQ
BRICK WORK
0
(SEE NOTE- 5 ) (SEE NOTE-2)
FINISHED GRADE LEVEL
0 1000 PVC PIPE ON FOUR SIDES

0 FOR ENTRY OF EARTH STRIPS
SEE DETAIL-2
—X-5
PAINTED SYMBOL
G.I. EARTH STRIP IN RED ON
(SEE NOTE-6) WHITE BASE
CHARCOAL LAYER
'RESISTANCE VALUE
ALTERNATE LAYER OF DATE-XX.XX.XXXX
0
CHARCOAL OR COKE HANDLE f 0
N
AND COMMON SALT
NUMBER PLATE
FIXED TO EARTH ELECTRODE
3000 LONG, 65 DIA. N.B. TOP COVER
PIPE (MEDIUM), WITH CAP PIT NO.-XX
(FOR DETAILS REFER
STD. 7-51-0101) 700
0
0
CV
DETAIL-1
1000 PVC PIPE
BRICK
WORK
II
li
NOTES:- DETAIL-2
FUNNEL WITH
1. ALL DIMENSIONS ARE IN MM. STEELWIRE
2. BRICK WORK SHALL BE DONE AFTER COMPACTING THE SOIL. MESH
3. AFTER REMOVAL OF CAP, OWNER SHALL BE ABLE TO POUR (REMOVABLE)
WATER THROUGH HIS OWN FUNNEL WITH STEEL WIRE MESH.
4. COLOUR CODING & PAINTING OF COVERS SHALL BE AS PER 65 DIA N.B.
OISD NORMS. PIPE
(MEDIUM)
5. IN CASE OF PAVED AREAS, TOP OF PIT SHALL BE FLUSHED
WITH FFL, WHEREAS IN UNPAVED AREAS, TOP OF PIT SHALL
BE PROJECTED 100MM ABOVE FGL.
6. CONNECTIONS OF G.I. EARTH STRIP TO THE PLATE SHALL BE
IN LINE WITH STD. 7-51-0103. D E TA I L- 3
.- .1\ 1 1101.1e11b91
,1 11
6 08.11.16 UPDATED & ISSUED AS STANDARD BP FA/HK BR RN
No. by by
Approved by
Format No. 8-00-0001JF4 Rev.O Copyright EIL - All rights reserved
Page 1506 of 2065

eggrg ENG/VEERS eINDIALIMRED
TYPICAL EARTH PLATE STANDARD No.
AND 7-51-0103 Rev. 6
(A Govt. of hada Undertaking)
FIXING DETAILS
Page 1 of 1
400 FOR CONNECTION WITH

G.I. STRIP OF SIZE 75x10.
25 50 I 50 I 50 i 50 I 50 t 50 i 50 25 (TYPICAL)
II
U)
II
10 DIA HOLES FOR

8MM DIA BOLTS FOR CONNECTION WITH
G.I. STRIP OF SIZE 50x6
AND BELOW (TYP.)
G.I. EARTH PLATE
WELDED CARBON STEEL
RCC STRUCTURE BOLT-8 MM DIA
(SEE NOTE-2)
STEEL
STRUCTURE
MIL
12 DIA G.I. SPACER SEE
PIPE (TYP.) NOTE-2
ini
% 11 %/
/ 11 %/
/ 4! 11 %
// 11 %/
/ /,11 %/
/ %4111! 7411v Alv 4117 Air A1117 41Iv zIlv All'4
nW 1111 IUI
G.I. ANCHOR G.I. NUT, SPRING 10 MM THICK G.I.

BOLT 8 MM DIA AND PLAIN EARTH PLATE (TYP.)
WASHERS (TYP.)
LOCK NUT & BOLT

(SEE NOTE —2) G.I. EARTH
SOS •011 STRIP
1111 1111
SEE SEE \I1\ NM
NOTE-2 NOTE-2 %AU% AIIVA
50 1 10 50 p_ci T 1111 1 111
.
G.I. EARTH
PLATE
TYPICAL FIXING DETAIL

OF G.I. EARTH STRIP
TO EARTH PLATE
NOTES:-
2. WHERE FIRE PROOFING OF STEEL

STRUCTURES ARE ENCOUNTERED
LENGTH OF CARBON STEEL BOLTS
SHALL BE SUITABLY INCREASED FOR
FIXING OF EARTH PLATE.
3. ALL CONNECTIONS WITH EARTH PLATE
SHALL BE MADE WITH 8MM DIA. G.I.
TYPICAL INSTALLATION TYPICAL INSTALLATION BOLT, NUT, SPRING AND PLAIN WASHERS.
OF EARTH PLATE ON OF EARTH PLATE ON 4. CRIMP TYPE CABLE LUGS SHALL BE
R.C.C. STRUCTURES STEEL STRUCTURES USED FOR CONNECTION WITH G.I.
WIRE ROPE.
6 08.11.16 UPDATED & ISSUED AS STANDARD

No. by by
Approved by
Page 1507 of 2065

TYPICAL ARRANGEMENT STANDARD No.
ENGINFERS
01415/04INCIA ummED (A Govt. of India Undertaking)
FOR 7-51-0104 Rev. 5
EARTHING OF MOTOR Page 1 of 1
SEE NOTE-1
is
. .
.
• .
t:1 •
EARTH PLATE AS PER WELD

STD. 7-51-0103 G.I. MAIN EARTH STRIP
DETAIL-1
CONNECTION WITH BURIED EARTH GRID
— SEE NOTE-1
G.I. EARTH STRIP
IC 1 EARTH PLATE AS PER

STD. 7-51-0103
..
CABLE TRENCH •
•
•
G.I. EARTH STRIP
DETAIL-2
CONNECTION WITH EARTH GRID IN RCC TRENCH
NOTE:-
1. MOTOR FOUNDATION BOLT SHALL NOT BE USED FOR EARTHING.
2. EARTHING OF P.B. STN. INSTALLED NEAR MOTOR FOUNDATION SHALL BE DONE BY
TAPPING 8 SWG G.I. WIRE FROM EARTH PLATE.
5 08.11.16 REAFFIRMED & ISSUED BP FA/HK B - : RN

No. by by
Approved by
Page 1508 of 2065

..arge. LIMITED
(A Govt. of Inefia Undortalakvo)
TYPICAL ARRANGEMENT
FOR
EARTH!NG OF TRANSFORMER
STANDARD No.
7-51-0105 Rev. 6
Page 1 of 1
NEUTRAL BUSHING
G.I. STRIP / HV CABLE
TRANSFORMER
10 DIA STUD WITH

NUT & LOCK NUT ■■• ■■•
x °) G.I. EARTH STRIP
4? 4.
F.F.L./F.G.L.
I 1.1
I I L - -x-
X
--Z TO EARTH ELECTRODE IN TEST PIT
5-- ->4F- _ _ _x_
EARTH PLATE AS PER LMAIN EARTH GRID
STD. 7-51-0103
EARTH ELECTRODE IN TEST PIT EARTH ELECTRODE IN TEST PIT

AS PER STD. 7-51-0102 AS PER STD. 7-51-0102
NEUTRAL BUSHING NEUTRAL BUSHING

L 7 I-
1
1(
_- -44- --$- -4( I 1
I )11r L34__ __ _1 Y
2--*
14
--44 --*- -- -- -4,4- -4-- -X-- 4 ---t ...x__
1, __ __x_44._ __,Ar__ __ ...x..1 _,
L__ __J L_ _J
- -
LINE DIAGRAM LINE DIAGRAM

NEUTRAL EARTHING THROUGH NGR SOLID NEUTRAL EARTHING
NOTES:-
1. EARTH ELECTRODE IN TEST PITS SHALL BE SO LOCATED THAT DISTANCE BETWEEN TWO PITS
SHALL BE MINIMUM 6 METER.
6 08.11.16 REAFFIRMED & ISSUED BP FA/HK BRB RN

No. by by
Approved by
Format No 8-00-0001-F4 Rev.0 Copyright EIL All rights reserveo
Page 1509 of 2065

TYPICAL EARTH CONNECTION STANDARD No.
ENGIMERS
l8MONDIA LIMED
digu (A Govt. of Indio Undertaking)
FOR 7-51-0106 Rev. 5
PUSH BUTTON STATION Page 1 of 1
PUSH BUTTON
STATION
• •
0 0
TINNED COPPER LUG
0
CONCRETE COLUMN
STEEL SUPPORT
8 SWG G.I. WIRE
EARTHING STUD WITH

G.I. LUG CONNECTIONS NUT & WASHERS
(SEE NOTE-1)
0
0
C•1
4- F. F. L./F.G.L.
:
4, • • • •• .
1.
•
• • • .4 a. • .
/ i
WELD —/ WELD—/
MAIN EARTH GRID MAIN EARTH GRID
NOTES:-
1. ALTERNATIVELY, CONNECTION SHALL BE TAKEN FROM THE NEAREST AVAILABLE EARTH PLATE.
_ IL\
5 08.11.16 REAFFIRMED & ISSUED BP FA/HK BR B RN

No by by
Approved by
Page 1510 of 2065

TYPICAL EARTH CONNECTION STANDARD No.
ENGNEERS FOR
diggilgeNDIA LIAM (A Govt. of illtn0 Undertaking)
7-51-0107 Rev. 5
LIGHTING POLE
Page 1 of 1
STREET LIGHT OR FLOOD LIGHT POLE
50 MM WIDE x 60 MM x 6 MM THICK
M.S. FLAT WELDED TO POLE FOR EARTH
TERMINATION (SEE DETAIL-1)
8 MM DIA GLAVINISED M.S. BOLT,

NUT AND SPRING WASHER.
O • TERMINAL CONNECTOR
rn
F.F.L./F.G.L.
10 MM DIA G. I. WIRE ROPE FROM

NEAREST MAIN EARTH GRID OR
FROM DIRECT BURIED EARTH ELECTRODE
AS PER STD. NO. 7-51-0117
10 MM DIA HOLE
WELDED TO POLE
DETAIL-1
NOTES:-
1. USE TWO WIRES ROPES IF VOLTAGE IN THE POLE JUNCTION BOX IS 415 VOLTS.

Rev Prepared Checked Stds. Committee Stds. Bureau
No. by by
Approved by
Page 1511 of 2065

STANDARD No.
13■4GINEERS TYPICAL EARTHING OF
dieMO NDIA LIMITED 7-51-0108 Rev. 6
(A Govt. of Indio Undartaldng) TANKS, VESSEL AND SPHERES
Page 1 of 2
12 DIA 25 LONG BOLT, NUT

AND TWO SPRING WASHERS.
EARTHING FOR NUMBER OF EARTHING
LUG CONNECTIONS SEE TABLE–A
G.I. STRIP
0
40x5 MM
0
M
FINISHED FLOOR/GRADE LEVEL
a- --x- - -x- - - -x- T -x- - -x- -1-

il \..._ —1K— --i
I—MAIN G.I. EARTH GRID

WELD
DETAIL-1 (TANK)
TABLE-A 14 DIA HOLE
TANK/SPHERE DIAMETER(D) EARTHING

(IN MTRS) CONNECTION
<15 2 AT 180 °
15 < D <25 3 AT 120 °
25 < D <35 4 AT 90 °
EARTH LUG ON IANK
35 < D <45 5 AT 72 °
45 < D <55 6 AT 60 ° BY TANK FABRICATOR
55 < D <65 7 AT 51.43 °
65 < D <75 8 AT 45 °
75 < D <85 9 AT 40 °
85 < D <95 10 AT 36 °
NIL
6 08.11.16 REVISED & ISSUED AS STANDARD —'B P FA/HK BR 2 RN
No. by by
Approved by
Page 1512 of 2065

STANDARD No.
OMO FiNGNEERS
INDIA UNITED
(A Govt. of Mick Undertaking)
TYPICAL EARTHING OF
TANKS, VESSEL AND SPHERES
7-51-0108 Rev. 6
Page 2 of 2
12 DIA 25 LONG BOLT, NUT

EARTHING AND TWO SPRING WASHERS
LUG
G.I. STRIP
40x5 MM
17 J---7I c FINISHED FLOOR/GRADE LEVEL

iiiii~ii\\". Z N \\\c--1 //\\f \%
-
o
I I in
2-X— — — -x- T -x- - Lx- - -K- ---)C-
I--- MAIN G.I. EARTH GRID
WELD
DETAIL-2 (SPHERE)
16 DIA G.I. WIRE
ROPE TO EARTH LUG
ON VESSEL SADDLE
10 MM DIA 25 LONG BOLT, NUT G.I. BOLT
AND TWO SPRING WASHERS VESSEL
PAD AND NUT
(SEE NOTE-3) •
L (M) . •
F.F.L./F.G.L.
4111P11=INII EARTH LUG

ON VESSEL
G.I. EARTH STRIP
TO MAIN EARTH GRID
DETAIL-4
VESSEL SADDLE F.F.L./F.G.L.
SADDLE
SEE I—G.I. STRIP 4Ox5MM

INI:TM -4 V (SEE NOTE 3)
—X— — -4 —X— — —X— —t
MAIN EARTH GRID
DETAIL-3 (HORIZONTAL VESSEL)
NOTES:-
1. FOR VESSELS TWO NOS. OF DIAMETRICALLY OPPSITE EARTHING LUGS WILL BE AVAILABLE ON LEG
SUPPORTS OF EQUIPMENT FOR PROVIDING EARTH CONNECTION.
2. ALL VESSELS SHALL HAVE TWO EARTH CONNECTIONS IN GENERAL.
3. HORIZONTAL VESSEL OF LENGTH MORE THAN 20 METERS :-

TWO EARTH LUGS ARE PROVIDED ON EACH SADDLE OF HORIZONTAL VESSELS, ACCORDINGLY
THERE SHALL BE TWO EARTH CONNECTIONS TO THE EARTH GRID FROM EACH SADDLE.
6 08.11.16 REVISED & ISSUED AS STANDARD BP BR: RN

No
Date Purpose
by by
Convenor Chairman
Approved by
Page 1513 of 2065

TYP. ARRANGEMENT FOR EARTHING STANDARD No.
ENCNEERS INDIALIMITED
efitMO pormogrotasio to Govt. of India Undertaking)
OF OVERHEAD CABLE TRAY 7-51-0109 Rev. 5
AND ELECTRIC MOTOR Page 1 of 1
CEILING
• •
SEE DETAIL-1 TO MOTOR BODY

TO BE SUPPORTED
CABLE TRAY ALONG WITH CABLES
G.I. EARTH STRIP
WALL / COLUMN
EQUIPMENT
• CLAMP (NP)
TO EARTH GRID
F.F.L./F.G.L.
CABLE TRAY
G.I. EARTH STRIP

X
G.I. WIRE ROPE

X
DOWN CONDUCTOR TO G.I. CLAMP

MAIN GRID AT INTERVALS
AS PER PLAN DRAWING G.I. EARTH
STRIP
PLAN VIEW G.I. BOLT, NUT
AND WASHERS
DETAIL-1
5 08.11.16 REAFFIRMED & ISSUED FA/HK BRB RN

4 27.06.11 REAFFIRMED & ISSUED RKS/RSC UAP DM
No. by by
Approved by
Page 1514 of 2065

ENGNERs TYPICAL EARTHING ARRANGEMENT STANDARD No.
FOR 7-51-0111 Rev. 5
NOW111.11111111111111106 (A Govt. or India Undertaking)
PROCESS EQUIPMENT
Page 1 of 1
PORTABLE MIXING TANK —
G.I. BOLT AND NUT

CONNECTION AS PER
STANDARD OR CONNECT
TO NOZZLE USING EARTH
CLAMP
SHARP JAW, TONG STRIP

HEAVY DUTY SPRING
CLAMP-100A
G.I. EARTH STRIP

STATIONARY
MIXING TANK
EARTH STRIP FIXED ON
STRUCTURE FOR LUG
CONNECTIONS.
25 SQ. MM COPPER CONDUCTOR

FLEXIBLE CABLE
ATTACH TERMINAL LUG TO EXISTING

SUPPORT I..IIO ON ì/Fc'FL
CARRY LEAD TO EARTH PLATE
AS PER STANDARD.
NOTE:-
1. ALL PROCESSING EQUIPMENT SUCH AS MIXTURES, CHURNS, AUTOCLAVES, COLUMNS,
CENTRIFUGES, FILTERS, PRESS PUMPS ETC. SHALL BE EARTHED, IF THESE ARE NOT
IN DIRECT CONTACT WITH PROPERLY EARTHED STEEL MEMBERS.
2. ALL TEMPORARY EARTH CONNECTIONS SHALL BE MADE BEFORE OPENING THE VESSEL.
ileMZE9r.RSPMw
■
RN
lit
5 08.11.16 REAFFIRMED & ISSUED BP FA/HK BB
No. by by
Approved by
Page 1515 of 2065

EARTHING / BONDING OF STANDARD No.
ENGNEERS
011MO INDIA LIMITED
PIPES AND PIPE RACKS 7-51-0112 Rev. 5
FIrLEXIB
(IN HAZARDOUS AREA) Page 1 of 2
SEE DETAIL-2
465
1P
CONNECTION
o r SEE DETAIL-1
FOR LUG
40X5 G.I.
EARTH STRIP
r F.F.L./F.G.L.1
a- - - — 4t — -- —X -- -- X— -- q— —K — --t -- X—
FRONT VIEW LMAIN EARTH GRID SIDE VIEW
PIPE TO BONDED
30
CRIMPED -J
CABLE LUG SEE DETAIL-3
6
25 SQ. MM
FLEXIBLE
8 DIA G.I. - COPPER CABLE (L=INSULATION THICKNESS+50)
BULI, NUT
DETAIL-1 & WASHERS DETAIL-3
DETAIL-2 (SEE NOTE-3)
NOTES:-
1. UNLESS MENTIONED OTHERWISE ON PLANS OR JOB SPECIFICATIONS, THE PIPE LINES SHALL BE
BONDED AND EARTHED ONLY AT THE ENTRY AND EXIT POINTS OF BATTERY LIMIT OF PROCESS UNIT
HANDLING FLAMMABLE SUBSTANCES.
2. STEEL PIPE RACKS IN THE PROCESS UNIT AND OFFSITE AREA SHALL BE EARTHED AT MAXIMUM
SPACING OF 25 METRES.
3. BEFORE HYDROTESTING OF PIPELINES, PIPING CONTRACTOR SHALL WELD A PLATE (AS SHOWN IN
DETAIL-3) OF SUITABLE MATERIAL TO SUIT PIPELINE MATERIAL.
4. SUPPLY OF FLEXIBLE COOPER CABLE, LUGS, BOLTS, NUTS AND WASHERS ETC. AND MAKING
CONNECTIONS SHALL BE DONE BY ELECTRICAL CONTRACTOR.
5 08.11.16 REVISED & ISSUED AS STANDARD BP FA/HK BRB RN

4 27.06.11 REVISED & ISSUED BP RKS/RSC UAP DM
No. by by
Approved by
Page 1516 of 2065

Orig. ENGNEERS
EARTHING / BONDING OF STANDARD No.
MIA UNIFIED PIPES AND PIPE RACKS 7-51-0112 Rev. 5

(A Govt. of knee Undertaking)
(IN HAZARDOUS AREA) Page 2 of 2
SEE DETAIL-3 WELD

(SHT. 1 OF 2)
SEE NOTE-4
(SHT. 1 OF 2)
25 SQ. MM FLEXIBLE
COPPER CABLE ARRANGEMENT-1
PIPE FLANGE
PIPE
CABLE LUG (CRIMPED) HOT DIP GALVANISED

M.S. FLAT
25 SQ. MM FLEXIBLE COPPER CABLE
ARRANGEMENT-2
(APPLICABLE WHERE WELDED FLAT ARE
NOT AVAILABLE AS PER ARRANGEMENT-1)
PIPE
PIPE
EARTH CONNECTION
PIPE SUPPORT
M.S. FLAT
SEE DETAIL-1 (SHT. 1 OF 2)
40x5 G.I. EARTH STRIP

F.F. L./F.G. L.
MAIN EARTH GRID —1
_L -->f-
ARRANGEMENT-3
(APPLICABLE WHEREVER PIPE SUPPORTS ARE WELDED
ON BOTH SIDES OF FLANGES / VALVES ETC.)
5 08.11.16 REVISED & ISSUED AS STANDARD -* BP FA/HK RN

4 27.06.11 REVISED & ISSUED BP RKS/RSC UAP DM
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - AI! rights reserved
Page 1517 of 2065

STANDARD No.
ORM -0 ENCINEERS
INDIA
A UNITED
FENCE AND GATE EARTHING
(TRANSFORMER YARD)
7-51-0115 Rev. 5
Page 1 of 1
EARTHING CLAMP
SEE DETAIL-1
FENCE POST
FENCE GATE
FENCE
8 SWG G.I. WIRE 25 SQ. MM FLEXIBLE

COPPER CABLE
EARTHING CONNECTIONS
TO G.I. BOLT AND NUT
G.I. EARTHING LUG
F.F.L./F.G.L.
2-X— — —X— — —X— - xJ G.I. NUT

AND BOLT
MAIN EARTH GRID DETAIL-1
FENCE GATE
FENCE POST
TO FENCE POST
FENCE POST
G.I. NUT
AND BOLT
TO MAIN
EARTH GRID
DETAIL-2
WELD
G.I. EARTHING LUG
(SEE DETAIL-2)
FENCE
•
1#■••■••■■••■•■■•■•■ ■•■•■■•■
MAIN EARTH GRID

FENCE POST

No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright E1L - All rights reserved
Page 1518 of 2065

.groa.),A
miwnsimmomm
EICINEERS
LIMITED
undertakkno
(A Govt. of India
TYPICAL DETAILS OF DIRECTLY
BURIED EARTH ELECTRODE

STANDARD No.
7-51-0117 Rev. 5
Page 1 of 1
F.F.L./F.G.L.
0 z
USE 8 DIA GALVANISED M.S. BOLT,

NUT AND WASHERS FOR CONNECTING
EARTH CONDUCTORS
M.S. FLAT
50x6x85 LONG
(SEE DETAIL-1)
I
w WELD
0
z
Lu 40 DIA, 2500 MM LONG
PIPE (MEDUIM)
(SEE NOTE-1)
20 45 20
0
0
of
40 DIA. 2500 MM
LONG PIPE (MEDUIM)
(SEE NOTE-1)
10 DIA HOLE
6 THICK M.S.
FLAT
WELD
DETAIL-1
NOTES:-
1. PIPE ASSEMBLY SHALL BE HOT DIP GALVANISED AFTER FABRICATION.
2. THE ELECTRODE SHALL BE DRIVEN TO A DEPTH TO REACH PERMANENT MOIST SOIL.
AitA)
a Imo' -----
'
5 08.11.16 REAFFIRMED & ISSUED BP :f2B RN

No. by by
Approved by
Page 1519 of 2065

STANDARD No.
TYPICAL INSTALLATION
ENGINEERS 7-51-0201 Rev. 4
INDIA LIMITED OF LIGHTING FIXTURE AT
14ta7lVigilreN3
NT27 3ga.) (A Govt. of India Undertaking)
GROUND LEVEL Page 1 of 1
LIGHTING FIXTURE WITH

50 DIA G.I. PIPE
HPMV/HPSV LAMP
ARMOURED CABLE
ADAPTOR OR REDUCER 500
TO SUIT FIXTURE
450
0
0
Li)
LIGHTING
FIXTURE
G.I REDUCER 100/50
50 DIA G.I. PIPE
G.I. REDUCER 100/50
100 DIA G.I. PIPE
DETAIL-2
100 DIA. G.I. PIPE
MARSHALLING BOX
AS PER STD. 7-51-0208
OR FLP/DIV 2 JUNCTON BOX/
o CONTROL GEAR BOX
0 (SEE NOTE-2)
0 500
SEALING COMPOUND/BUSHING
FLUORESCENT
CABLE GLAND FIXTURE
4e (FOR SAFE AREA)
EARTHING LUG —s.
50x60x6 MM M.S. 0
0
FLAT WELDED TO
POLE
0
0 50 DIA G.I. PIPE
G.I. PIPES FOR 0
INCOMING AND
OUTGOING CABLES
G.I. REDUCER 100/50
(DIA. AND LENGTH
AS REQUIRED) 100 DIA G.I. PIPE
0 F.F.L. /F.G.L
A.K\
DETAIL-3
O
In
400 MM DIA. PLAIN CONCRETE (M15)
0
0 200x200x8 MM M.S. PLATE
WELDED TO POLE
DETAIL-1
NOTES:-
2. MARSHALLING BOX, JUNCTION BOX AND G.I. PIPES FOR CABLES SHALL BE LOCATED
FACING CABLE TRENCH SIDE.
3. ALL G.I. PIPES SHALL BE MEDIUM GRADE.
REAFFIRMED & ISSUED AS STANDARD BP FA/SA DM

4 1 7.07.1 3
BP RKS/NS JMS VC
3 15.12.08 REAFFIRMED & ISSUED AS STANDARD
Prepared Checked
Rev. Convertor Chairman
Date Purpose by by
No. Approved by
Format No. 8-00-0001-F4 Rev.O
Page 1520 of 2065
STANDARD No.
TYPICAL INSTALLATION OF
(31 ENGINEERS 7-51-0202 Rev. 4
INDIA LIMITED LIGHTING FIXTURE ON
517Z1119Rtg (A Govt. of India Undertaking)
(44re woven.) PLATFORM Page 1 of 1
50 DIA. G.I. PIPE
ADAPTOR OR REDUCER
TO SUIT FIXTURE
0
0
LIGHTING FIXTURE
VIP
ARMOURED CABLE
500
BUSHING
ADAPTOR
50 DIA. G.I. PIPE FLUORESCENT

FIXTURE
(FOR SAFE AREA)
0 0
0 0
0
C•1
M.S. ANGLE
75x75x6-125 LONG
50 DIA. G.I. PIPE
WELDED TO HANDRAIL
ADAPTOR
GLAVANISED U BOLT
50 DIA. G.I. PIPE
FIXED TO ANGLE IRON
PIECE WELDED TO
HAND RAIL FOR
PLATFORM HANDRAIL
DETAIL-2
POLE SUPPORT
JUNCTION BOX/CONTOL GEAR BOX

(IF REQUIRED)
0
M.S. ANGLE
100X75X6-100 MM LONG
WELDED TO PLATFORM 0
MEMBER FOR VERTICAL
0
Li)
SUPPORT OF THE POLE
PLATFORM
REDUCER 50/25 RESTING
IN DRILLED HOLE OF
ANGLE IRON PIECE
DETAIL-1
NOTES:-
2. TYPE OF FIXTURE USED SHALL BE INDICATED ON THE LAYOUT DRAWING BY DESIGNATION
AND IDENTIFIED FROM DATA SHEET FOR LIGHTING FIXTURE SCHEDULE.
BP FA/SA UAP/JM DM
RKS/NS JMS VC
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP
3 Stds. Committee Stds. Bureau
Prepared Checked
Rev. Convenor Chairman
Date Purpose by by Approved by
No.
Page 1521 of 2065
STANDARD No.
TYPICAL INSTALLATION OF
k31 ENGINEERS 7-51-0203 Rev. 4
INDIA LIMITED OPEN AREA FLOOD LIGHT FIXTURE
$Nuffe1fRerg (A Govt. of India Undertaking)
MOUNTED ON WALL OR COLUMN Page 1 of 1
JUNCTION BOX (IF REQUIRED)
CABLE
OPEN AREA
FLOOD LIGHT FIXTURE
0
0
40 MM DIA. G.I. PIPE (MEDIUM)

WELDED TO M.S. PLATE
WALL OR COLUMN
ELBOW
EXPANSION BOLTS 4 NOS. 12 MM DIA.
100x100x6 MM M.S. PLATE
NOTES:—
la
Ye.,,f,1
FA/SA UAP/JMS DM
4
RKS/NS JMS VC
Prepared Checked
No.
Page 1522 of 2065
250 250
♦
FLOOD LIGHT
`tee gig FIXTURE
/14.3x3 6 0011
THICK
VP %VP
MARSHALLING
BOX/CONTROL GEAR
BOXES(2 NOS.)
CABLE GLAND
0
0
N
SEE
DETAIL-2 50 DIA. G.I.
PIPE(MEDIUM)
11'
ARMOURED CABLE
0
0 SEALING COMPOUND/ %ENTINE.
0 BUSHING
ELBOW
450 TEE REDUCER
ROUND o F.F. L./F.G. L.
S /la /he 114.3 O.D.
0 50 DIA. G.I. PIPES
0
(SEE NOTE-2)
0
139.7x ,
0 5 0 0 DETAIL-1
co THICK 0 0
0
N
350x350x10 MM M.S. LIGHTING

PLATE WELDED TO POLE FIXTURE
HOLES
1100 MM SQ. PLAIN (NOS. AND
DIA. TO SUIT
CONCRETE (M15)
BASE PLATE FIXTURE BASE)
OF FIXTURE
BOLTS,NUTS
1654)(5 0 AND WASHERS 6 MMBASE
THICK PLATE WELDED
WITH POLE
HOLE FOR TAKING
TUBULAR THE WIRES IN
POLE 410SP-54 FLEXIBLE CONDUIT
AS PER IS:2713
50x60x6 MM M.S.
FLAT WITH 10 DIA.
U) 0 `SLOT FOR CABLE
HOLE WELDED TO PO U)
o.) ENTRY INTO POLE
N N
POLE FOR EARTH (SEE NOTE-3)
CONNECTION

WELDED TO POLE
MOUNTING ARRANGEMENT
NOTES:- FOR SAFE AREA FIXTURES
2. MINIMUM TWO AND MAXIMUM THREE NUMBERS OF SLEEVES SHALL BE PROVIDED AS PER PLAN DRAWING.
3. 2 NOS. 25 DIA. HOLES SHALL BE POVIDED ON OPPOSITE ENDS FOR FIXING OF MARSHALLING BOX
ON ONE END AND CONTROL GEAR BOX ON OTHER END.
417.07.13 REVISED & ISSUED AS STANDARD BP FA/SA UAP/JMS

3 15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS VC

Rev.
No. by by
Approved by
Page 1523 of 2065
TYPICAL INSTALLATION OF STANDARD No.
` 11 GkJ
~ ENGINEERS
$fgar 0151-
eg INDIA LIMITED
FLOOD LIGHT FIXTURES (TWO) 7-51-0205 Rev. 4
MOUNTED ON POLE Page 2 of 2
HAZARDOUS AREA FLOODLIGHT FIXTURE

WELDED TO POLE
STIFFENING PLATES WELDED TO

TOP PLATE AND POLE (4 NOS.)
100X40 MM WIDE SLOT FOR

CABLE ENTRY
1 14.3x3.65
THICK
STEEL TUBULAR POLE

410 SP-54 AS PER IS:2713
139.7x4.5
THICK
165.1x5.4
THICK
FLAMEPROOF CONTROLGEAR BOX
100X10 MM PLATES WELDED ARMOURED CABLE

TO POLE (LENGTH Sc SPACING
SLOT FOR CABLE
TO SUIT CONTROL GEAR BOX
ENTRY INTO POLE
DIMENSIONS)
450 ROUND SEALING COMPOUND/BUSHING

0
0 EARTH CONNECTION
0
0
0 F.F.L./F.G.L.
>.\\
0
0
(ID
0 50 DIA. G.I. PIPES (MEDIUM)

0 (SEE NOTE-2)
co
1100 MM SQ. PLAIN CONCRETE (M15)
350x350x10 MM M.S.
0
Lo PLATE WELDED TO POLE
MOUNTING ARRANGEMENT FOR

HAZARDOUS AREA FIXTURES
NOTES:-
2. MINIMUM TWO AND MAXIMUM THREE NUMBERS OF SLEEVES SHALL BE PROVIDED AS PER PLAN DRAWING.
4 17.07.13 REVISED & ISSUED AS STANDARD BP FA/SA UAP/J MS DM

3 15.12.08 REAFFIRMED Sc ISSUED AS STANDARD BP RKS/NS JMS VC
Rev.
No. by by
Approved by
Page 1524 of 2065

STANDARD No.
ENGINEERS TYPICAL INSTALLATION
7-51-0207 Rev.4
INDIA LIMITED OF STREET LIGHTING FIXTURE
(AGovt. of India Undertaking)
Page 1 of 2
LIGHTING FIXTURE
1000
MARSHALLING BOX
0 R 800
O CABLE GLAND
U)
50x60X6 MM M.S.
FLAT WELDED TO
50 DIA G.I. PIPE
POLE FOR EARTHING AS
PER STD. 7-51-0107
ARMOURED CABLE
88.9 x 3.25 THICK
SEALING COMPOUND/
0 BUSHING
0
U) 0 O o 450 ROUND
0 to
to o
F.F. F.
LT
40 DIA. G.I. PIPES
114.3 x 3.65 THICK
0 600 MM SQ. PLAIN
0 CONCRETE (M15)
to STEEL TUBULAR POLE
410 SP-8 AS PER IS:2713
350x350x10 MM M.S.
PLATE WELDED TO POLE
139.7 x 4.85 THICK
0
O VIEW-AA
U)
MARSHALLING BOX
AS PER STD 7-51-0208
EARTHING LUG 1000 I 1000
VIEW-AA
O 100
O O
O
O O
OT—.s I LI)
o F.F.L./F.G.L. R-800
r),
0 A/
0
0 O
O to
U)
ARRANGEMENT FOR
O TWO FIXTURES
U)
(7.5M HIGH ABOVE ROAD LEVEL)
NOTES:-
1. ALL G.I. PIPE SHALL BE MEDIUM GRADE.
BP FA/SA UAP/J MS DM
RKS/NS JMS VC
Prepared Checked Chairman
Rev. Convenor
No
Format No. 8-00-0001-F4 Rev.0
Page 1525 of 2065
STANDARD No.
TYPICAL INSTALLATION
2.1 ENGINEERS 7-51-0207 Rev. 4
g"ra INDIA LIMITED OF STREET LIGHTING FIXTURE
Page 2 of 2
LIGHTING FIXTURE
700
MARSHALLING BOX
CABLE GLAND
50x60X6 MM M.S.
FLAT WELDED TO
POLE FOR EARTHING AS
0 PER STD. 7-51-0107
0
ARMOURED CABLE
SEALING COMPOUND/
50 DIA. G.I. PIPE
0 0
BUSHING
450 ROUND
o
F.F. .
~A%
W/4 /71 o
114.3 x 3.65 THICK ccip)
0
40 DIA. G.I. PIPES
N
N
700 MM SQ. PLAIN
CONCRETE (M15)
350x350x10 MM M.S.
PLATE WELDED TO POLE
VIEW—AA
139.7 x 4.50 THICK
0
N
N
STEEL TUBULAR POLE
410 SP-38 AS PER IS:2713
EL\
165.1 x 4.85 THICK
700 700
16
MARSHALLING BOX
VIEW—AA AS PER STD. 7-51-0208
R-800
EARTHING LUG
0
n
°
o 8
0 Lci),
n
F.F.L./F.G.L.
^VA\
0
0
D
_L
0 0
0 Lc)
c0
ARRANGEMENT FOR
TWO FIXTURES
u)
(9.2M HIGH ABOVE ROAD LEVEL) NOTES:-
FA/SA UAP/JMS DM
BP RKS/NS JMS VC
Prepared Checked
Date Purpose by by
No. Approved by
Page 1526 of 2065
STANDARD No.
ENGINEERS TYPICAL MARSHALLING BOX DETAILS
7-51-0208 Rev. 5
INDIA LIMITED FOR LIGHTING POLES
Page 1 of 1
M.S. SHEET (14SWG/

2 MM THICK) FUSE
25 MM DIA.,
25 MM LONG NEOPRENE GASKET 3 MM THICK
ALL AROUND FOR WEATHER
HALF COUPLING 75
PROTECTION
HINGE (TYP.)
-SEE DETAIL-1 FRONT
A COVER
COVER SHEET(12 SWG/
GASKET
2.64 MM THICK)
WELD 50x20x5 MM M.S.
PLATES WELDED
DETAIL-1
TO BOX
BAKELITE SHEET/ INSULATOR BASE
POLE
FOR MOUNTING OF TERMINAL
BLOCK WITH BRASS BOLT,
NUT AND WASHERS TO EARTHING
STUD ON
2.5 SQ. MM, COPPER MARSHALLING
BOX
CONDUCTOR, PVC
INSULATED WIRES
(PHASE, NEUTRAL
SCREW KNOB
AND EARTH) TO
WITH ANTI—
LIGHTING FIXTURES
FALLING
ARRANGEMENT
(CIRCLIP) j HINGES
'D'
BOX COVER
TO
EARTHING
STUD
G.I. NUT AND BAKELITE HINGE WELDED TO CABLE
'C' SHEET MARSHALLING BOX
BOLT HARDWARE GLAND
ENCLOSURE AND COVER
PVC BUSH ARMOURED
(TYP.) CABLE
BOX COVER (FRONT)

WIRING DIAGRAM OF
HOLES TO SUIT
CABLE GLANDS. MARSHALLING BOX
REMOVABLE GLAND
PLATE (14 SWG /
2 MM THICK)
6 MM DIA. BRASS SCREW WITH KNOB

25x3 MM M.S.
FLAT CLAMP BENT L
TO SUIT DIAMETER 2 NOS. DOUBLE THREADED 8 MM DIA.,
OF POLE 30 MM LONG STUD FOR EARTH CONNECTIONS
SECTION-AA MARSHALLING BOX DIMENSIONS

DIMENSIONS IN MM
CABLE SIZE (IN SQ. MM) CABLE 'C"D'
ENTRIES 'A' 'B'
UPTO 4 X 16 2 250 100 45 210
ABOVE 4 X 16 AND 3 300 150 75 210

NOTES:- UPTO 3.5 X 50
2. MARSHALLING BOX SHALL BE HAVE WEATHER PROOF (IP55) ENCLOSURE PROTECTION, WITH
CABLE GLANDS & LUGS.
3. THE BOX WITH ALL WELDED ATTACHMENTS, SHALL BE THOROUGHLY CLEANED AFTER
FABRICATION AND SHALL BE PAINTED WITH EPDXY PAINT.
BP FA/SA UAP/J MS DM
BP RKS/NS JMS VC
4 15.12.08 REVISED & ISSUED AS STANDARD
Prepared Checked
Date Purpose by by
No. Approved by
Page 1527 of 2065
STANDARD No.
404 ENGINEERS GENERAL ARRANGEMENT FOR 7-51-0209 Rev. 4

4ig-zrrOf51e
- g INDIA LIMITED
FLOODLIGHT MAST
Page 1 of 1
3x2.5 SQ. MM- —CONTROL GEAR

WEATHER PROTECTED (IP55)
HAND RAIL DIST. BOARD MADE OF M.S. SHEET YWY CABLE
STEEL SIZE TO SUIT NUMBER OF (SEE NOTE-2)
FLOODLIGHTS
RYBN
FLOODLIGHT FIXTURE
PLATFORN
FLOODLIGHT
CABLE GLAND
INCOMING AND
CABLE CLEATED OUTGOING CABLES
TO LADDER SIDE
RUNNER
P N ISOLATOR
6A HRC FUSE
EARTH BAR WITH
0 CONNECTING LINK
0
0
co EARTHING STUD (S)
LADDER
2(40x5 MM) G.I.
STRIPS TO THE
BOTTOM OF MASTS
TERMINALS
MAST AS PER
STRUCTURAL DETAILS WIRING DIAGRAM OF
TPN ISOLATOR DISTRIBUTION BOARD
IN WEATHER
PROTECTED (IP55) AND ISOLATOR
ENCLOSURE
MAST NUMBER PLATE
SIZE 150x225 MM
50x60x6 MM M.S. FLATS WELDED
TO STRUCTURE FOR EARTHING
0
0
F.G.L.
0
0
2(40x5 MM) G.I. EARTH STRIPS

50 DIA. TO EARTH GRID OR EARTH PIT
G.I. PIPE FOUNDATION AS PER
(MEDIUM) STRUCTURAL DETAILS
NOTES:-
ALL CABLES FROM DISTRIBUTION BOARD TO CONTROL GEAR BOX / LIGHTING FIXTURE
2.
SHALL BE NEATLY CLAMPED TO THE HANDRAIL STRUCTURE.
I FA/SA UAP/JMS DM
RKS/NS JMS VC
Prepared Checked Chairman
Rev. Convenor
No.
Page 1528 of 2065
ENGINEERS
11?„-Eraiwilten3 INDIA LIMITED FLUORESCENT FIXTURE MOUNTING 7-51-0212 Rev.4
IN EXPOSED WIRING SYSTEM Page 1 of 1
FIXED TO CEILING
CEILING
SPACER
CLAMP
CABLE OR CONDUIT SEE NOTE-2
SUPPORT BOX WITH SPRING
LOADED BALL & SOCKET
ARRANGEMENT
(CHROMIUM PLATED)
19 DIA. G.I. PIPE (MEDIUM)
CHECK NUT
(PAINTED WHITE OR
AS SPECIFIED) NON—METALLIC BUSHING
MOUNTING HEIGHT
•
FLUORESCENT FIXTURE
DETAIL-1
SUSPENSION MOUNTING
FIXED TO CEILING
CABLE OR CONDUIT—
CEILING
CLAMP SEE NOTE-2
SPACER
CHECK NUT AND
NON METALLIC CABLE GLAND IN CASE
BUSHING OF CABLE WIRING
FLUORESCENT FIXTURE
DETAIL-2
CEILING MOUNTING
NOTES:-
2. SUSPENSION/FIXING CENTRES SHALL BE AS PER FIXTURE MANUFACTURER'S DETAILS.
3. IN CASE OF CABLE WIRING ONE NO. JUNCTION BOX COMPLETE WITH CABLE GLANDS
SHALL BE PROVIDED NEAR EACH FIXTURE.
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/ SA UAP/JMS DM

BP RKS/NS JMS VC
Rev.
Date Purpose
No. Convenor Chairman
by by
Format No. 8-00-0001-F4 Rev.0 Approved by
Page 1529 of 2065
TYPICAL INSTALLATION STANDARD No.
ENGINEERS
dgar54e-gr
laTeR eTea617 ,673,70,47)
INDIA LIMITED
OF RECESSED MOUNTED 7-51-0213 Rev.4
FLUORESCENT FIXTURE
Page 1 of 1
INSPECTION BOX
(NO WIRE JOINT INSIDE
THE INSPECTION BOX)
FIXED TO CEILING
- CEILING
FIXED TO CEILING
SPACER
32x6-110 MM LONG
CONDUIT M.S. FLAT BEND TO
SHAPE (PAINTED)
CLAMP
EYE BOLT & NUT SUPPORTING CHAIN

CHROMIUM PLATED
(LENGTH AS REQUIRED)
FALSE CEILING
WIRES IN 19 DIA.
FLEXIBLE PVC CONDUIT
FLUORESCENT FIXTURE
RUBBER GROMMET
LOOPING BACK SYSTEM

OF WIRING AT LIGHT POINT
MOUNTING ARRANGEMENT WITH CHAIN SUPPORT
NOTES:-
4 14^-4A
17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS
3 DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD
BP RKS/NS JMS VC
Rev.
Date Prepared Checked Stds. Committee Stds. Bureau
No. Purpose
by by Convenor Chairman
Format No. 8-00-0001-F4 Rev.O Approved by
Page 1530 of 2065
TYPICAL INSTALLATION OF RECESSED STANDAR D No.
ENG14316 MOUNTED OR BELOW FALSE CEILING
digaTMONDIA LRCM 7-51-0214 Rev. 5
Nomiwnewsixo (A Go.t. a p.m Undertaking) MOUNTED LIGHTING FIXTURE
Page 1 of 1
INSPECTION BOX
FIXED TO CEILING
(NO WIRE JOINT INSIDE — CEILING
THE INSPECTION BOX)
CONDUIT
SPACER WIRES IN 19 DIA.
FLEXIBLE METALLIC CONDUIT
CLAMP
RUBBER GROMMET
M.S. FLAT AT BOTH
ENDS OF FIXTURE
BOLT WITH FLY NUT
LOOPING BACK SYSTEM OF
WIRING AT LIGHT POINT
FALSE CEILING
LIGHTING FIXTURE
DETAIL-1
RECESS MOUNTED FIXTURE
SUPPORTED ON WOODEN FRAME
• • • •
CONDUIT
JUNCTION BOX
SPACER FIXED TO CEILING
CLAMP
SEE NOTE-2
OPENING IN
19 DIA. G.I. PIPE (MEDIUM) FALSE CEILING
(TYP.)
r/MMAI I IAI PM PrA I V/4II/At IIIIIM// I IMMA I 'AVIIA
FALSE CEILING
CHECK NUT
LIGHTING FIXTURE
NON METALLIC BUSHING
DETAIL-2
FIXTURE MOUNTING BELOW FALSE CEILING
NOTES: -
2. SUSPENSION/FIXING CENTRES SHALL BE AS PER FIXTURE MANUFACTURER'S DE "
Nrip,
e•
Y
5 21.10.16 REVISED & ISSUED AS STANDARD BP FA/HK BRB RN
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS DM
No. by by
Approved by
Format No. 8 - 00 - 0001 - F4 Rev.O Copyright EIL - All rights reservec
Page 1531 of 2065

TYPICAL INSTALLATION OF RECESSED STANDARD No .
BVGINIEERS
1MOICIA LIMITED
045 MOUNTED LIGHTING FIXTURE 7-51-0215 Rev. 5
01111,11111111101a1M) (A Govt. of India Undertaking)
BLOCK OF FOUR
Page 1 of 1
INSPECTION BOX SPACER

FIXED TO CEILING
CEILING — — CONDUIT
(NO WIRE JOINT INSIDE
THE INSPECTION BOX) FIXED TO CEILING
32x6 THICK 110 LONG

M.S. FLAT BEND TO
SHAPE (PAINTED)
SUPPORTING CHAIN
CHROMIUM PLATED
EYE BOLT & NUT
— FALSE CEILING
LIGHTING FIXTURES
WIRES IN 19 MM DIA.
FLEXIBLE METALLIC CONDUIT
4- 141
4.h
LIGHTING FIXTURES
(BLOCK OF FOUR)
4- ther
4 4
44 \4
WIRING CONNECTIONS
BETWEEN THE
FITTINGS
4-
It
NOTES:—
1 ALL DIMENSIONS ARE IN MM.
2. SUSPENSION/FIXING CENTRES SHALL BE AS PER FIXTURE MANUFACTURER'S DETAILS.
)4.–
5 21.10.16 REVISED & ISSUED AS STANDARD P FA/HK BRB RN
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS DM
No . by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reservec
Page 1532 of 2065
STANDARD No.
011 ENGINEERS TYPICAL INSTALLATION OF
I xren
rae INDIA LIMITED 7-51-0216 Rev. 4
05,3,
4N N) (A Govt. of India Undertaking) HIGH BAY LIGHTING FIXTURE
Page 1 of 1
CABLE GLAND IN CASE

OF CABLE WIRING
CEILING
SPACER
41111111101111.11
__,10
. 0 VI=I
.w
/Q1
SEE DETAIL 1
.1-.1 CABLE OR CONDUIT
CLAMP
ADAPTOR
JUNCTION BOX
INTEGRAL BALLAST
I WIRES IN 19 MM
FLEXIBLE PVC CONDUIT
HIGH BAY
LIGHTING FIXTURE
10 DIA. ANCHOR FASTENER

350 (USE RIGID CLAMPS IN CASE
300 OF STEEL TRUSSES)
25x3 MM M.S. ST
BENT TO SHAPE BOLT,NUT AND WASHER 8 DIA. OR
TO SUIT FIXTURE
LIGHTING FIXTURE
DETAIL-1
NOTES:-
4 7
17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS
3 DM
Rev. , __BP _ RKS/NS JMS VC
No. Date Purpose Checked Stds. Bureau
Approved by
Page 1533 of 2065 Copyright EIL - All rights reserved
401 elt4 ENGINEERS
ad
laiTFR ,Veffre 0/13,;71.7
INDIA LIMITED
WELL GLASS 7-51-0217 Rev.4
LIGHTING FIXTURE (SAFE AREA) Page 1 of 1
19 MM DIA. CONDUIT GOOSE NECK
R-225 WELL GLASS FIXTURE

JUNCTION BOX
AMOUNTING HEIGHT
VAS PER PLAN
THROUGH CONDUIT
OR CABLE 30
600
WALL
WALL-MOUNTED
CABLE GLAND IN CASE OF CABLE

WIRING JUNCTION BOX
SPACER CEILING
CLAMP
AMOUNTING HEIGHT
\LAS PER PLAN
REDUCER 25/19 AND
19 MM DIA. NIPPLE
CEILING-MOUNTED
NOTES:-
2. APPLICABLE FOR SAFE AREAS.
0:1k.'
- / / I 2P1 A - •.1
). -
BP FA/SA
3 UAP/JMS DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS VC
Rev.
Date Purpose Prepared Checked Stds. Committee Stds. Bureau
No.
STANDARD No.
ENGINEERS TYPICAL INSTALLATION OF
• eieme 41)
INDIA LIMITED BULKHEAD LIGHTING FIXTURE 7-51-0218 Rev.4
Page 1 of 1
FIXED TO CEILING CEILING
SPACER
CABLE OR CONDUIT
CLAMP
CHECK NUT AND NON METALLIC

BULK HEAD FIXTURE BUSHING FOR CONDUITS
(USE CABLE GLAND IN CASE
OF CABLE WIRING)
DETAIL-1
CEILING MOUNTED
BULK HEAD LIGHTING

FIXTURE FIXED TO WALL
WALL
CHECK NUT AND NON METALLIC

WIRES/CABLE BUSHING FOR CONDUITS
THROUGH CONDUIT (USE CABLE GLAND IN CASE
OF CABLE WIRING)
(SEE NOTE-2)
JUNCTION BOX
DETAIL-2
NOTES:- WALL MOUNTED
2.
FOR INSTALLATION IN OUT DOOR FIXTURES, JUNCTION BOX SHALL BE IP-55
(WEATHER PROTECTED).
3.
PROPER SEALING SHALL BE ENSURED WHEREVER REQUIRED TO PREVENT INGRESS OF WATER.
4 432111W
FA/SA UAP JMS DM
3 15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS
Rev. VC
Date Checked Stds. Committee Stds. Bureau
No. Purpose
ENGINEERS
Iggbael g
01
07 ete=2 M-5,
0,
..)
INDIA LIMITED
DISPERSIVE REFLECTOR 7-51-0219 Rev. 4
FIXTURE
Page 1 of 1
SPACER JUNCTION BOX WITH

WALL & SOCKET COVER
CABLE/CONDUIT
CEILING
CLAMP
REDUCER CABLE GLAND IN CASE
OF CABLE WIRING
(IF REQUIRED)
WIRES IN 19 DIA.
G.I. CONDUIT
CHECK NUT
LIGHTING FIXTURE
AAQl4N7Iw
.-1 HT
NOTES:-
4 17.07.13REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS DM

BP RKS/NS JMS VC
Rev.
Date Prepared Checked Stds. Committee Stds. Bureau
No Purpose
Page 1536 of 2065
STANDARD No.
• a-4 dal alalt,.1 (A Govt. of India Undertaking) AVIATION OBSTRUCTION LIGHT
Page 1 of 1
AVIATION DOUBLE OBSTRUCTION

LIGHTING FIXTURE
REDUCER
M.S. ANGLE
75x75x6-125 MM LONG
SUPPORT FOR POLE
GLAVANISED U BOLT
FIXED TO ANGLE IRON
PIECE WELDED TO PLATFORM HANDRAIL
HAND RAIL 0
0
N
N
CABLE JUNCTION BOX
(IF REQUIRED)
M.S. ANGLE
100X75X6-100 MM LONG
0
WELDED TO PLATFORM MEMBER 0
FOR VERTICAL SUPPORT OF LO
THE POLE
PLATFORM
REDUCER 50/25 RESTING IN
DRILLED HOLE OF ANGLE IRON
PIECE
MOUNTED ON TOP OF STRUCTURE PLATFORM

DETAIL-1
AVIATION DOUBLE OBSTRUCTION

LIGHTING FIXTURE
REDUCER
50 DIA G.I. PIPE-

(MEDIUM)
0
0
N
N
/REDUCER 50/25 AND
25 NIPPLE
PARAPET WALL — ---- JUNCTION BOX
0
0 ROOF TOP
r)
MOUNTED ON TOP OF BUILDING PARAPET WALL

NOTES:- DETAIL-2
4 I.\-r.--01
3 _ BP FA/. A UAP/JMS DM
BP RKS/NS JMS
Rev. VC
Date Purpose Checked Stds. Bureau
No.
by Convenor Chairman
by
Copyright EIL - AU rights reserved
Page 1537 of 2065
STANDARD No.
k74 ENGINEERS TYPICAL INSTALLATION OF
11 1r Braes
1.11FR Fet,re 2613,
PA1Ji)
INDIA LIMITED WEATHER PROOF LIGHT FIXTURE 7-51-0224 Rev.4
Page 1 of 1
LIGHTING FIXTURE
MOUNTING HEIGHT
REDUCER
50 DIA. G.I. PIPE
(MEDIUM)
0
0 (30° IF MOUNTING HEIGHT
IS MORE THAN 5 METRES)
0
M.S. CLAMPS o
to
WALL OR COLUMN
REDUCER 50/25 AND 25 DIA. NIPPLE
WEATHER PROOF
JUNCTION BOX
(SEE DETAIL-1)
MOUNTED ON WALLS OR COLUMNS
/--- REDUCER 50/25 AND 25 DIA. NIPPLE
USE CABLE GLANDS FOR CABLE WIRING
i
(SEE NOTE-2)
WIRES IN G.I. PIPE
CONDUIT OR CABLE
COVER FIXED WITH BRASS

MACHINE SCREWS
JUNCTION BOX
(WEATHER PROTECTED)
DETAIL-1
NOTES:-
2.
PROPER SEALING SHALL BE ENSURED TO PREVENT INGRESS OF WATER.
3.
WHERE FIRE PROOFING COLUMNS / STRUCTURES ARE ENCOUNTERED RECEPTACLE,
JUNCTION BOX AND CABLE SHALL BE INSTALLED ON A SUITABLE DEEP LEGGED
ANGLE IRON FRAME / DISTANCE BRACKET.

FA/SA UAP/JMS DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS
Rev. VC
No. Date Purpose Prepared Checked Stds. Committee Stds. Bureau
Approved by
Page 1538 of 2065 Copyright EIL - All riahts rpnprvori
,1001 ENGINEERS
fg-affaW -
63
i-leoreevavd,i-d
INDIA LIMITED
LIGHTING / POWER PANEL 7-51-0226 Rev.4
WALL (SURFACE)'MOUNTED
Page 1 of 1
JUNCTION BOX
(WHEREVER REQUIRED) CEILING SLAB
OR STEEL MEMBER
MS SPACER
CABLE GLAND / CHECK NUT

CLAMP
WALL OR COLUMN OUTGOING CABLE OR CONDUIT
CABLE GLAND / CHECK NUT
FIXING BOLTS LIGHTING / POWER PANEL
0
0 EARTH TERMINAL ON PANEL
oo
CLAMP
EARTH CONDUCTORS INCOMING CABLE
F.F.L.
G.I. PIPE (MEDIUM)

(DIA. AS REQUIRED)
NOTES:-
4
2154^ 'K
3 FA/SA UAP/JMS DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS
Rev. VC
Date Purpose Prepared Checked Stds. Bureau
No.
Page 1539 of 2065 Copyright EIL - All rights 11,4SPrVPri
TYPICAL INSTALLATION DETAILS STANDARD No.
ENGINEERS OF
(A Govt. of India Undertaking) LIGHTING FIXTURE MOUNTING
IN CONCEALED CONDUIT SYSTEM Page 1 of 1
PULL/INSPECTION BOX
R.C.C. SLAB
``.-1 120(MIN)
CONCEALED CONDUIT
(PAINTED WHITE OR SPRING LOADED BALL AND SOCKET
AS SPECIFIED) SEE NOTE-2 ARRANGEMENT (CHROMIUM PLATED)
LOCK NUT (TYP.)
MOUNTING HEIGHT
FLUORESCENT FIXTURE
DETAIL-1
SUSPENSION MOUNTING
PULL/JUNCTION BOX
FIXING SCREW
R.C.C. SLAB
I. 1
1 20(MIN.)
SEE NOTE-2 CONCEALED CONDUIT
FLUORESCENT FIXTURE
DETAIL-2
CEILING MOUNTING
NOTES:-
2. SUSPENSION/FIXING CENTERS SHALL BE AS PER FIXTURE MANUFACTURER'S DETAILS.
4
17.07.13 REAFFIRMED & ISSUED AS STANDARD ti
BP FA/SA
3 UAP/JMS DM
BP RKS/NS
Rev JMS VC
No. Date Prepared
Purpose Checked Stds. CommitteeStds. Bureau
Format No. 8-00-0001-F4 Rev.O by by Convenor Chairman
Ap roved b
Page 1540 of 2065
ENGINEERS
dab.
rt4.a fa5tegr trz INDIA LIMITED

■
KreR P.TF 3QL•1.1
LIGHTING / POWER PANEL
7-51-0230 Rev. 4
FLUSH MOUNTED
Page 1 of 1
JUNCTION BOX/PULL BOX CONCEALED CONDUIT
R.C.C. SLAB
!— •
20(MIN.)
TOP OF PANEL
CHECK NUT
LIGHTING/POWER PANEL
CABLE GLAND
CABLE
G.I. BOX
(SEE NOTE-2)
CHECK NUT AND
WALL OR COLUMN
F.F.L.
G.I. PIPE (MEDIUM)

(SIZE AS REQUIRED)
NOTES:-
2.
G.I. ADAPTOR BOX OF SUITABLE SIZE WITH REMOVABLE COVER SHALL BE PROVIDED
BELOW THE PANEL TO FACILITATE CABLE TERMINATION.
4 T9,1111 —
BP FA/SA
3 UAP/JMS DM
BP RKS/NS
Rev. JMS VC
No. Date Purpose Prepared Checked Stds. Committee Stds. Bureau
Approved by
STANDARD No.
INDIA LIMITED METSEC CHANNEL 7-51-0232 Rev. 3
Page 1 of 1
50x50 MM, 18 SWG

METSEC CHANNEL
0 PRESS FIT
REMOVABLE COVER
50
DETAIL-1
METSEC CHANNEL
RCC SLAB/BEAM
41
CHECK/LOCK NUTS 19 MM DIA. G.I. SUSPENSION CONDUIT

@ 2 M TO SUPPORT METSEC CHANNEL
WITH BALL AND SOCKET ARRANGEMENT AND
3/16" DIA. ANCHOR FASTENER (TYPICAL)
METSEC CHANNEL (SEE NOTE-2)
SPACE FOR WIRES
(SEE NOTE-5)
LIGHTING FIXTURE
NUT AND BOLT ARRANGEMENT
FOR SUPPORTING OF
LIGHTING FIXTURE
MOUNTING HEIGHT —1
DETAIL-2
INSTALLATION OF LIGHTING FIXTURE BELOW METSEC CHANNEL
NOTES:-
2. LENGTH OF SUSPENSION CONDUITS SHALL BE ADJUSTED AS PER MOUNTING HEIGHT OF
LIGHTING FIXTURES.
3. IN CASE, METSEC CHANNEL IS NOT TO BE SUSPENDED, IT SHALL BE DIRECTLY FIXED
TO THE CEILING BY 3/16" DIA. ANCHOR FASTENERS @ 2 M INTERVALS.
4. METSEC CHANNEL AND SUSPENSION CONDUITS SHALL BE SPRAY PAINTED AFTER INSTALLATION.
5. WIRES FOR EACH TYPE OF CIRCUIT (t k;HTING/POWER/DC LIGHTING) SHALL BE NEATLY
BUNCHED IN METSEC CHANNEL.
irk
3 17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS
2 15.12.08 REAFFIRMED & ISSUED AS SIANUARD . BP RKS/NS JMS VC
No. by by
Approved by
Copyright Ell. - AN rights reserved
Page 1542 of 2065
MARKING OF TRENCHES STANDARD No.
‘31 ENGINEERS
lffETT EIRWiffl"2.1)
INDIA umrrED
(A Govt. of Indla UnOortakIng)
FOR 7-51-0301 Rev. 4
ELECTRIC CABLES
Page 1 of 1
SIGN - 'B' SIGN -'C'

0 0
MARKER POST
65x65x6 MM ANGLE
PAINTED WHITE
< >
0
to 0 0
60 60
4. j
47 ,c
r)
SIGN -'A'
—200 MM SQ.
Lr) PLAIN CONCRETE
(M15)
BURIED ELECTRIC
CABLES
200
TYPICAL ARRANGEMENT OF MARKER

(SEE NOTE-2)
II II
__ _
fr-- BURIED CABLE TRENCH r-
. . . .
ANGLE 65x65x6 ANGLE 65x65x6 ANGLE 65x65x6 ANGLE 65x65x6
1100 MM LONG 1100 MM LONG 1100 MM LONG 1100 MM LONG
ASSEMBLY SIGN.—A-1 N0. SIGN.—A-1N0. SIGN.—A-1N0. SIGN.—A-1N0.

CONSISTING SIGN.—C-2 NOS. SIGN.—B-1N0. SIGN.—B-1N0. SIGN.—B-2NOS.
OF
SIGN.—C-1NO.
NOTES: -
2. TRENCHES SHALL BE MARKED AT ALL DIRECTION CHANGES, INTERSECTIONS AND STRAIGHT RUNS.
3. SIGN BOARDS SHALL BE MADE OF 14 GAUGE ENAMELED STEEL PLATE WHITE LETTERING SHALL
BE ON JADE GREEN BACKGROUND.
•?.
4 21.11.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS SC
No. by by
Approved by
Page 1543 of 2065
TYPICAL SECTION OF CABLE TRENCH STANDARD No.
ENGNEERS
f212e.5
(.41Miffl,WM.3.1~)
IND1A LIMI I ED
Govt. of lncfio Undertoking}
IN 7-51-0302 Rev. 4
UNPAVED AREAS Page 1 of 1
F.G.L.
NATURAL SOIL (BACK FILLING)
EARTH STRIP
SPECIFIED)
BRICKS
M.V. CABLES
SAND/STONE DUST
u")
0
0 CONTROL CABLES
tf, 0
tr)
O
O
/ 001 200 I 300 11001100{101

H.V. CABLES
/ 900
200 MIN. OR TWICE

THE 0.D. OF CABLE
TYPICAL SECTION WITH H.V. AND M.V. CABLES
NATURAL SOIL (BACK FILLING)
EARTH STRIP SPECIFIED)

BRICK
SAND/STONE DUST
M.V. POWER CABLES

CONTROL CABLES
TYPICAL SECTION WITH M.V. CABLES
NOTES:-
2. LEAVE SPACE FOR LATER ADDITION OF AT LEAST 2 CABLES OR 15% AVERAGE SPARE SPACE
FOR FUTURE EXPANSION.
3. IF FIRE ALARM AND COMMUNICATION CABLES ARE LAID IN THE SAME TRENCH A CLEARANCE
OF 300 MM (MIN.) FROM ELECTRIC POWER CABLES SHALL BE PROVIDED.
?5\4rt
4 21.11.13 REVISED & REISSUED AS STANDARD BP FA/SA UAP/JMS SC
No. by by
Approved by
Page 1544 of 2065

INSTALLATION DETAILS FOR STANDARD No.
ENGINEERS
INDIA LJM1TED CONDUIT OR CABLE SUPPORT 7-51-0305 Rev. 4
(A Govt. of Indlo UndortokIng)
ON WALL / SLAB / BEAM
Page 1 of 1
M.S. CLEAT
(SEE DETAIL 3 & 4)
40x40x6 MM M.S. SLOTTED ANGLE

CABLE OR CONDUIT
(TYP.)
WALL
ONE HOLE 'C' CLAMP
OR GROUP CLAMP
ON G.I. SPACER
WELD
DETAIL-1
SUPPORT ON WALL
SLAB / BEAM —
M.S. CLEAT
(SEE
ELD DETAIL 3 & 4)
W
40x40x6 MM M.S. SLOTTED ANGLE
CABLE OR CONDUIT
ONE HOLE 'C' CLAMP
DETAIL-2
SUPPORT ON SLAB / BEAM
1, 40
o
WALL / SLAB / BEAM
SUPPORTING ASSEMBLY WELD co

FIXED T0 WALL / SLAB /
BEAM WITH 1 0 MM DIA.
ANCHOR BOLT
SLOTTED M.S. ANGLE 1 1 DIA. HOLE

NOTES:-
DETAIL-4
1. ALL DIMENSIONS ARE IN MM. DETAIL-3 M.S. CLEAT
4 21.1 1.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS SC

No. by by
Approved by
Page 1545 of 2065
ENGNEERS CONTROL STATION
INDIA LIMI I IL) ON STRUCTURAL CHANNEL
7-51-0306 Rev.4
(A Govt. of Indio Undertoking)
IN PAVED AREA Page 1 of 1
75X1OMM M.S. FLAT WELDED

TO CHANNEL
AS REQD.
DRILL THE FLAT TO SUIT
FIXING HOLES ON CONTROL STATION
CONTROL STATION
z
O
cn
0
CABLE GLAND
0
0
o_ G.I. CLAMP 300
0
o CABLE
0
ISMC— 1 00 CHANNEL
SEALING COMPOUND BUSHING

G.I. CLAMP
200X150X6MM M.S. PLATE F.F.L. (PAVED AREA)
R=12D OF PIPE
G.I. PIPE
SEE NOTE-2
150 MM (MIN.) FOR INDOOR LOCATION

A=
{300 MM (MIN.) FOR OUTDOOR LOCATION
G.I. PIPE
4 NOS. 1 0 MM DIA. WELD

ANCHOR FASTNERS 200 I 19
SECTION-AA
NOTES:-
2. SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DRAWINGS.
4 21 .1 1.1 3 REAFFIRMED & ISSUED AS STANDARD BP FA/S UAP/J MS

3 1 5.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS VC
No. by by
Approved by
Page 1546 of 2065

ENGINEERS CONTROL STATION
INDIA LIMITED 7-51-0307 Rev.4
(A Govt. of India Undertaking) ON CONCRETE / STEEL COLUMN
IN PAVED AREA Page 1 of
N CONTROL STATION
400 (TOP OF CONTROL STATION)
CABLE GLAND
G.I. CLAMP 300
CABLE
COLUMN
SEALING COMPOUND / BUSHING

G.I. CLAMP
F.F.L. (PAVED AREA)
• 4
STEEL COLUMN
2NOS. 75X1OMM
R=12D OF PIPE
M.S. FLAT
G.I. PIPE WELDED TO
SEE NOTE-2 STEEL COLUMN
CONTROL
VIEW A-A BOLTED TOSTATION
CONCRETE (FOR STEEL COLUMN M.S. FLAT
COLUMN WITHOUT FIRE PROOFING)
FIRE PROOFING
75X10 MM M.S. STEEL COLUMN
FLAT BENT TO
CONTROL STATION SHAPE & FIXED 2NOS. 75X1OMM
BOLTED TO
TO COLUMN WITH M.S. FLAT
M.S. FLAT
10MM DIA. WELDED TO
VIEW A-A ANCHOR FASTNER STEEL COLUMN
(FOR CONCRETE COLUMN)
L
25x25x6 MM ANGLE
WELDED TO ISMC 100
150 MM (MIN) FOR INDOOR LOCATION
A= CHANNEL
{300 MM (MIN) FOR OUTDOOR LOCATION
NOTES:- VIEW A-A

(FOR STEEL COLUMN
1. ALL DIMENSIONS ARE IN MM. WITH FIRE PROOFING)
2. SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DRAWINGS. CONTROL STATION
BOLTED TO ANGLE
v cA,V
No. by by
Approved by
Page 1547 of 2065

ENGNEERS CONTROL STATION
g..11t812eg' INDIA LIMffED ON STRUCTURAL CHANNEL 7-51-0308 Rev4
1~9 ~TE! 43131PW1) (A Govt. of India Undertoking)
IN UNPAVED AREAS Page 1 of 1
75X1OMM M.S. FLAT WELDED

TO CHANNEL
AS REQD.
DRILL THE FLAT TO SUIT
"Tf Tr FIXING HOLES ON CONTROL STATION
1:
1M
O
CONTROL STATION
Z-
-
0 < -er-t1-
F- -11 +L
FQ
- L-k,1/451 .
O
CABLE GLAND
c.)
O
G.I. CLAMP C9 300
J
CABLE
ISMC-100 CHANNEL
SEALING COMPOUND / BUSHING

G.I. CLAMP
1
Z4
0 I
11 I. I
I • I •
F.G.L.
4 1.
•••r
R-12D OF PIPE
tr)
• di• I. 4
O • •II •
•
G.I. PIPE
44 • . A• SEE NOTE-2
400 MM SQ. PLAIN CONCRETE (M15)
NOTES:-
2. SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DRAWINGS.
■ •■V
,g'221j-j" /
No. by by
Approved by
Page 1548 of 2065

CONNECTION DETAILS FOR STANDARD No.
‘31 irE'n INGINEERS
g11 fa5leg INDIA LIMITED VERTICAL MOTOR AND CONTROL 7-51-0311 Rev. 4
(7.17rt ~IffC Z013111$7:0 (A Govt. of Indlo Undortalting)
STATION (CABLE BELOW GROUND) Page 1 of 1
ISMC— 1 00
SUPPORT FOR
CONTROL STATION
CONTROL STATION
CABLE GLAND
O
O
0
CABLE
G.I. CLAMP
A
F.F.L.
. • • ,
• . ,• :
R=12D OF PIPE
G.I. PIPES
y =
SEE NOTE-2
G.I. PIPES, NOS. AND

SIZES TO SUIT CABLES
SUPPORT FOR FOR CONTROL CABLE
1,}
CONTROL STATION
FOR MOTOR CABLES
1Cl
i>
A 150 MM (MIN.) FOR INDOOR LOCATIONS
300 MM (MIN.) FOR OUTDOOR LOCATIONS
SECTION-AA = 1
NJ OTE.S : --
2. QUANTITY AND SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DRAWINGS.
4 21.1 1.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS SC

No. by by
Approved by
Page 1549 of 2065

CONNECTON DETAILS FOR STANDARD No.
ENGINEERS
laf;;15
I NRii 7£mfi26139i64,1)
INDIA LIMITED HORIZONTAL MOTOR AND CONTROL
(A Covt. of Indlo Undertaking)
7-51-0312 Rev. 4
STATION (CABLE BELOW GROUND) Page 1 of 1
.....,_ CONTROL
IU
STATION
CABLE GLAND
CABLE GLAND
CABLE
0
0
SEALING
COMPOUND/
BUSHING
I I F.F.L.
I.• . ' •
CABLE TO MOTOR TERMINAL BOX

(SIDE ENTRY)
ISMC-100 CHANNEL
G CLAMP 0 300
CA°1;°1
g
A - 150 MM(MIN.) FOR INDOOR LOCATIONS
300 MM (MIN.) FOR OUTDOOR LOCATIONS
G.I. PIPES
SEE NOTE-2
11111 1141 elli
NOTES:- CABLE TO MOTOR TERMINAL BOX

1. ALL DIMENSIONS ARE IN MM. (BOTTOM ENTRY)
2. QUANTITY AND SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DR WING

No. Date Purpose Convenor Chairman
by by
Approved by
Page 1550 of 2065

CONNECTION DETAILS STANDARD No.
k31 ENGINEERS
$41gzu la2e5 INDIA LIMITED FOR HORIZONTAL MOTOR 7-51-0313 Rev. 4
Iff277 P.RZAZ «39111,74) Govt. of lndia Undertoking)
(CABLE BELOW GROUND) Page 1 of 1
CABLE GLAND
MOTOR
SEALING COMPOUND/
i BUSHING
F.F.L.
. e.
G.I. PIPES
SEE NOTE-2
DETAIL-1 R= 12D OF PIPE
(SIDE ENTRY)
MOTOR CABLE GLAND
• •
SEALING COMPOUND/
BUSHING
a
•
G.I. PIPES
SEE NOTE-2
R= 12D OF PIPE
A 150 MM (MIN.) FOR INDOOR LOCATIONS
= 300
[ MM (MIN.) FOR OUTDOOR LOCATIONS
DETAIL-2
(BOTTOM ENTRY)
NOTES:-
2. QUANTITY AND SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DRAWINGS.
3. UNDER NORMAL CONDITION DETAIL-1 SHALL BE FOLLOWED. ONLY IN EXCEPTIONAL
CASES DETAIL-2 SHALL BE FOLLOWED.

No. by by
Approved by
Page 1551 of 2065

CONNECTION DETAILS STANDARD No.
ENGINEERS FOR MOTOR AND
INDIA LIWIITED CONTROL STATION 7-51-0314 Rev. 4
laiRrt ~13re ral.~.1) (A Govf. of locno Undoftokb9)
(CABLE IN TRAY) Page 1 of 1
CEILING INSERT PLATE
A
n.
WELD
M.S. ANGLE
(SIZE TO SUIT) CABLE TRAY
CABLE SUPPORT
1I
11
CABLE GLAND
CL I
O OBLONG HOLE WITH
PVC / RUBBER BUSHING
O
ISMC-100 CHANNEL
HEIGHT 3500MM (MAX.)
c
c
EQUIPMENT
F.F.L.
NOTES:-
2. WHERE FEASIBLE MAIN CABLE TRAY CAN BE ROUTED IN SUCH A WAY THAT
ISMC CHANNEL CAN BE DIRECTLY WELDED TO TRAY / SUPPORT.
>d)'"'
4 21.11.13 REAFFIRMED & ISSUED AS STANDARD G BP FA/SA UAP/JMS SC
No. by by
Approved by
Page 1552 of 2065
ENGINEERS SOCKET/RECEPTACLE
INDIA LIMITED MOUNTED ON COLUMN 7-51-0316 Rev. 4
(A Govt. of Indla Undertaking)
(CABLE IN TRAY) Page 1 of 1
COLUMN
SOCKET / RECEPTACLE
PLUG
FIXED TO COLUMN
WITH ANCHOR, BOLTS
AND NUTS
(SEE NOTE-2)
CABLE GLAND 7— CABLE
0
G.I. CLAMP 0
C■1
SEALING
COMPOUND/
BUSHING INSERT PLATE
G.I. PIPE SLEEVE OR

CUT OUT OF FFL
SUITABLE SIZE
,
a , . .•
.•
=12D OF CABLE
CABLE ENTRY
TO BE SEALED
1040
M.S. ANGLE (SIZE TO SUIT) CABLE TRAY
G.I. CLAMP
NOTES:--
2. WHERE STEEL STRUCTURES ARE ENCOUNTERED, SOCKET RECEPTACLE SHALL BE
MOUNTED ON SUITABLE ANGLE IRON FRAME WELDED TO STEEL STRUCTURE.
3. WHERE FIRE PROOFING COLUMNS / STRUCTURES ARE ENCOUNTERED
SOCKET / RECEPTACLE AND CABLE SHALL BE INSTALLED ON A
SUITABLE DEEP LEGGED ANGLE IRON FRAME / DISTANCE BRACKET.

No. by by
Approved by
Page 1553 of 2065

ENGNEERS SOCKET / RECEPTACLE /
.
ISIAM WiMIPOSL3OPffll
INDIA LIMITED
(A Govt. of india UndertokIng) CONTROL STATION 7-51-0317 Rev.4
MOUNTED ON HAND RAIL Page 1 of 1
HAND RAIL HAND RAIL

SOCKET/ RECEPTACLE CONTROL STATION
PLUG
CABLE CABLE
11 4—
Wr
i
G.I. CLAMP
11 1
CABLE
PLATFORM
G.I. CLAMP
1111
CABLE
PLATFORM
HOLE TO BE DRILLED ON
50x6 M.S. FLATS TO MATCH
HAND RAIL
WITH THOSE ON SOCKET /
SUPPORT
RECEPTACLE / CONTROL STATION
NOTES:-
2. CABLE SHALL NOT BE ROUTED ALONG HAND RAIL.

No. by by
Approved by
Page 1554 of 2065

STANDARD No.
DETAILS OF
1k31 ENGINEERS
$1fl a[tR
- -47' INC IA LIMITED RCC DUCT ABOVE 7-51-0321 Rev.3
“11.01~1¢.13,711.1 (A Govt. of mak UndortakIng)
FINISHED GRADE LEVEL Page 1 of 1
STORM WATER DRAIN ROAD WIDTH

(IF THERE)
11!
==
RCC DUCT WITH
RACK/TRAYS
== =
X
t-- heee.~K
IN M M ffill
= = = =
CABLE RACKS/TRAYS = = = =
= = = = DIRECTLY BURIED/
= = = =
RCC CABLE TRENCH
(SIZE AS PER LAYOUT)
PLAN
TOP OF ROAD
CABLE RACKS/TRAYS —
FGL
DIRECTLY BURIED/
SECTION X—X RCC CABLE TRENCH
r
HEAVY DUTY HEAVY DUTY

REMOVABLE/FIXED REMOVABLE/FIXED
RCC COVER . TOP OF ROAD RCC COVER ATOP OF ROAD
MAS PER GEN. CIVIL) MAS PER GEN. CIVIL)
•11
.. •
N
• 0
z
I
a_ w
1.- 4
0
INSERT PLATE z
(TYP.) •
4L o
o
.. •
• 4 ANGLE WELDED
I ie I 600 soo TO INSERT PLATE
AS REQUIRED 0500 MM (TYP.)
MIN. MIN
CABLE RACK
SECTION A—A SECTION
. A—A WELDED TO ANGLE
0500 MM (TYP.)
(ONE SIDE RACK/ (BOTH SIDES RACK/
TRAY ARRANGEMENT) TRAY ARRANGEMENT)
NOTES:—
2. CABLE SUPPORT ARRANGEMENT SHALL MATCH WITH THE ARRANGEMENT
OF OUTSIDE TRAY / TRENCH ON THE SIDES.
3 21 .11 .13 REVISED & REISSUED AS STANDARD BP FA/SA UAP/JMS SC

No. by by
Approved by
Page 1555 of 2065

STANDARD No.
ENGINEERS DETAILS OF
laf(RG INDIA LIMfTED 7-51-0322 Rev. 3
(A Govt. of lndla Undertoking)
(441?71 PWWIE CIS:391/.1)
ERC BELOW GRADE LEVEL
Page 1 of 1
ROAD WIDTH
STORM WATER DRAIN
(IF THERE)
PLAN
— DIRECTLY BURIED
TOP OF ROAD CABLE TRENCH
\IFGL
ERC (NO. OF LAYERS/

PIPES AS PER LAYOUT)
SECTION X-X
150 DIA. PVC PIPE
flk
0 0 41»
BOTTOM OF DUCT
\I(AS PER LAYOUT)
SECTION A-A (ERC)

(AS PER GEN. CIVIL STD.)
NOTES:-

Rev. Checked Stds. Committee Stds. Bureau
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - Alirights reserved
Page 1556 of 2065

lwrio . CABLE TERMINATION FOR MOTORS
( CABLE DROPPING FROM
STANDARD No.
7-51-0323 Rev. 4
wirimminaw. (A Govt. of Indio Undortaldng)
OVERHEAD TRAYS )
Page 1 of 1
ELECT. CABLE TRAYS
TRAY ARRANGEMENT
AS PER JOB
REQUIREMENT
CABLE TRAY
WALKWAYS
AS PER JOB
REQUIREMENT
CABLES LAID IN
CABLE TRAY/CLAMPED
ON STRUCTURE
LOWEST STRUCT. BEAM

CABLE TRAY
LOWEST STRUCT.
BEAM
ISMC— 100/150
HORIZONTAL SUPPORT ISMC-100/150
(BY ELECT.) VERTICAL SUPPORT PIPE RACK
(BY ELECT.)
FFL
VIEW A-A
HORIZONTAL CABLE TRAY

SUITABLY SUPPORT THROUGH
STRUCT. BEAM
OF COLUMN
CABLE TRAY DROPPING INSERT ANGLE (BY STRUCT.)

FROM OVERHEARD
ALONG COLUMN PUSH BUTTON STATION
P. B. STATION SUPPORT
VERTICAL SUPPORT
WELDED TO INSERT CABLE SUITABLY CLEATED
ALONG WITH FOUNDATION
OF COLUMN
PLAN
4 04.04.16 REVISED & ISSUED AS STANDARD FA/SA BRB RN

3 21.11.13 REVIED & REISSUED AS STANDARD BP FA/SA UAP/JMS SC
No. by by
Approved by
Page 1557 of 2065

CABLE TERMINATION FOR MOTORS STANDARD No.
ENGNEERS
dik=4
porsuommasino
). WiTECI CABLES DROPPING ALONG COLUMN
(A Govt. of Indio Unclortaldnc)
7-51-0324 Rev. 4
(FOR HV/MV MOTORS) Page 1 of 1
INSERT ANGLE (BY STRUCT.)
PUSH BUTTON STATION

P. B. STATION SUPPORT
••
UNPAVED AREA
(SEE NOTES-1 & 2)
•♦
bb UNDERGROUND G.I. PIPES
(SIZE, LOCATION AND NOS.
•• AS PER ELECT. DRAWING)
(SEE NOTE-3)
A
r •
A
PLAN
0
0 COLUMN
FFL
R-12D (15D FOR HT)

(D=DIA OF PIPE)
SECTION A A —
NOTES:-
1. AREA SHOWN AS HATCHED NEAR PUMP MOTOR EACH FOUNDATION SHALL BE LEFT UNPAVED
BY PAVEMENT CONTRACTOR.
2. CABLE LAYING & SAND / LEAN CONCRETE FILLING IN THIS UNPAVED AREA SHALL BE
DONE BY ELECTRICAL CONTRACTOR.
3. CIVIL CONTRACTOR SHALL PROVIDE G.I PIPES AND SEAL AT BOTH ENDS OF THE PIPES
WITH PVC BUSHINGS.
4 04.04.16 REVISED & ISSUED AS STANDARD ":13 FA/SA RBA RN

No. by by
Approved by
Page 1558 of 2065

diarg INGNEERS elN1ALIMITED
SAFETY MEASURES FOR STANDARD No.
ELECTRICAL INSTALLATIONS 7-51-0332 Rev. 3
DURING CONSTRUCTION Page 1 of 2
ELECTRICAL POWER IS THE MAINSTAY OF ANY CONSTRUCTION ACTIVITY. AT THE SAME TIME IT REQUIRES
UTMOST CARE IN IT'S UTILISATION TO AVOID ACCIDENTS DUE TO ELECTRICAL SHOCK, FIRE INCIDENTS OR
ELECTRIC SHORT CIRCUITS. EXPOSURE OF ELECTRICAL INSTALLATION TO ADVERSE ENVIRONMENTAL
CONDITIONS INCREASE THE RISK OF SUCH ACCIDENTS. HENCE IT IS NECESSARY TO TAKE EXTRA
PRECAUTIONS FOR SUCH INSTALLATIONS TO ENSURE SAFETY OF PERSONNEL AND EQUIPMENT. THIS
STANDARD ADDRESSES THE SAFETY MEASURES REQUIRED TO BE ADOPTED FOR THE ELECTRICAL
INSTALLATIONS BY ALL CONTRACTORS DURING CONSTRUCTION PHASE.
1. ALL ELECTRICAL CONNECTIONS/WORK FOR ELECTRICAL INSTALLATIONS SHALL BE CARRIED OUT AS PER
PROVISIONS OF THE LATEST REVISION OF THE FOLLOWING CODES AND STANDARDS IN ADDITION TO THE
REQUIREMENTS OF STATUTORY AUTHORITIES AND CEA REGULATIONS-2010.
OISD—STD-173 : FIRE PREVENTION AND PROTECTION SYSTEM FOR ELECTRICAL INSTALLATIONS.
OISD—STD-192 : SAFETY PRACTICE DURING CONSTRUCTION.
SP-30 (BIS) : NATIONAL ELECTRIC CODE.
THE INSTALLATION SHALL HAVE APPROVAL FROM CONCERNED STATUTORY AUTHORITIES.
2. ALL ELECTRICAL CONNECTIONS SHALL BE DONE BY AN ELECTRICIAN WITH VALID LICENCE AND TO THE
SATISFACTION OF ENGINEER—IN—CHARGE.
3. ONE COMPETENT UCENCED ELECTRICIAN SHALL BE MADE AVAILABLE BY CONTRACTOR AT SITE ROUND
THE CLOCK TO ATTEND TO THE NORMAL/EMERGENCY JOBS.
4. ALL SWITCH BOARDS/WELDING MACHINES SHALL BE KEPT IN WELL VENTILATED & COVERED SHED.
THE SHED SHALL BE ELEVATED TO AVOID WATER LOGGING. NO FLAMMABLE MATERIALS SHALL BE
USED FOR CONSTRUCTING THE SHED. ALSO FLAMMABLE MATERIALS SHALL NOT BE STORED IN AND
AROUND ELECTRICAL EQUIPMENT/SWITCHBOARD. ADEQUATE CLEARANCES AND OPERATIONAL SPACE
SHALL BE PROVIDED AROUND THE EQUIPMENT.
5. FIRE EXTINGUISHERS AND INSULATING MATS SHALL BE PROVIDED IN ALL POWER DISTRIBUTION CENTERS.
6. TEMPORARY ELECTRICAL EQUIPMENT SHALL NOT BE EMPLOYED IN HAZARDOUS AREAS WITHOUT OBTAINING
SAFETY PERMIT.
7. PROPER HOUSE KEEPING SHALL BE DONE AROUND THE ELECTRICAL INSTALLATIONS.
8. ALL TEMPORARY INSTALLATIONS SHALL BE TESTED BEFORE ENERGISING, TO ENSURE PROPER

EARTHING, BONDING, SUITABILITY OF PROTECTION SYSTEM, ADEQUACY OF FEEDERS/CABLES ETC.
9. ALL WELDERS SHALL USE HAND GLOVES IRRESPECTIVE OF HOLDER VOLTAGE.
10. MULTIUNGUAL (ENGLISH, HINDI AND LOCAL LANGUAGE) CAUTION BOARDS, SHOCK TREATMENT CHARTS
AND INSTRUCTION PLATE CONTAINING LUCATION OF ISOLATION POINT FOR INCOMING SUPPLY, NAME
& TELEPHONE NO. OF CONTACT PERSON IN EMERGENCY SHALL BE PROVIDED IN SUBSTATIONS AND
NEAR ALL DISTRIBUTION BOARDS/LOCAL PANELS.
11. OPERATION OF EARTH LEAKAGE DEVICE SHALL BE CHECKED REGULARLY BY TEMPORARILY CONNECTING
SERIES TEST LAMP (2 BULBS OF EQUAL RATING CONNECTED IN SERIES) BETWEEN PHASE AND EARTH.
12. THE FOLLOWING DESIGN FEATURES SHALL BE ENSURED FOR ALL ELECTRICAL INSTALLATIONS DURING
CONSTRUCTION PHASE.
12.1 EACH INSTALLATION SHALL HAVE A MAIN SWITCH WITH A PROTECTIVE DEVICE, INSTALLED IN AN
ENCLOSURE ADJACENT TO THE METERING POINT. THE OPERATING HEIGHT OF THE MAIN SWITCH
SHALL NOT EXCEED 1.5 M. THE MAIN SWITCH SHALL BE CONNECTED TO THE POINT OF SUPPLY
BY MEANS OF ARMOURED CABLE.
12.2 THE OUTGOING FEEDERS SHALL BE DOUBLE OR TRIPLE POLE SWITCHES WITH FUSES/MCBs. LOADS
IN A THREE PHASE CIRCUIT SHALL BE BALANCED AS FAR AS POSSIBLE AND LOAD ON NEUTRAL
SHOULD NOT EXCEED 20% OF LOAD IN THE PHASE.

2 02.03.12 REAFFIRMED & ISSUED BP RKS/RSC UAP/JMS DM
No. by by
Approved by
Page 1559 of 2065

SAFETY MEASURES FOR STANDARD No.
ENCIMERS
eitrigeNDIA MEM
POINI111111111111111111111) (A Govt. of India Undertaking)
ELECTRICAL INSTALLATIONS 7-51-0332 Rev. 3
DURING CONSTRUCTION Page 2 of 2
12.3 THE INSTALLATION SHALL BE ADEQUATELY PROTECTED AGAINST OVERLOAD, SHORT CIRCUIT AND EARTH
LEAKAGE BY THE USE OF SUITABLE PROTECTIVE DEVICES. FUSES WHEREVER USED SHALL BE HRC TYPE.
USE OF REWIRABLE FUSES SHALL BE STRICTLY PROHIBITED. THE EARTH LEAKAGE DEVICE SHALL HAVE
AN OPERATING CURRENT NOT EXCEEDING 30 mA.
12.4 ALL CONNECTIONS TO THE HANDTOOLS/WELDING RECEPTACLES SHALL BE TAKEN THROUGH PROPER
SWITCHES, SOCKETS AND PLUGS.
12.5 ALL SINGLE PHASE SOCKETS SHALL BE MINIMUM 3 PIN TYPE ONLY. ALL UNUSED SOCKETS SHALL BE
PROVIDED WITH SOCKET CAPS.
12.6 ONLY 3 CORE (P+N+E) OVERALL SHEATHED FLEXIBLE CABLES WITH MINIMUM CONDUCTOR SIZE OF
2
1.5 MM COPPER SHALL BE USED FOR ALL HAND TOOLS.
12.7 ONLY METALLIC DISTRIBUTION BOXES WITH DOUBLE EARTHING SHALL BE USED AT SITE. NO WOODEN
BOXES SHALL BE USED.
12.8 ALL POWER CABLES SHALL BE TERMINATED WITH COMPRESSION TYPE CABLE GLANDS. LUGS SHALL BE
USED FOR MULTISTRAND WIRES/CABLES HAVING MUTISTRAND/SOUD CONDUCTOR.
12.9 CABLES SHALL BE FREE FROM ANY INSULATION DAMAGE.
12.10 CABLES SHALL BE LAID IN UNDERGROUND AT A MINIMUM DEPTH OF 750 MM, FOR LV & CONTROLS
AND 900MM FOR HV CABLES COVERED WITH SAND, BRICK AND SOIL FOR ENSURING MECHANICAL
PROTECTION. CABLES SHALL NOT BE LAID IN WATER LOGGED AREA AS FAR AS PRACTICABLE.
CABLE ROUTE MARKERS SHALL BE PROVIDED AT EVERY 25 M OF BURIED TRENCH ROUTE. WHEN
LAID ABOVE GROUND, CABLES SHALL BE PROPERLY CLEATED OR SUPPORTED ON RIGID POLES OF
ATLEAST 2.1 M HIGH. MINIMUM HEAD CLEARANCE OF 6 METERS SHALL BE PROVIDED AT ROAD CROSSING.
12.11 UNDER GROUND CABLES SHALL NOT BE ALLOWED TO CROSS THE ROADS WITHOUT PIPE SLEEVE.
12.12 ALL CABLE JOINTS SHALL BE DONE WITH PROPER JOINTING KIT. NO TAPED/TEMPORARY JOINTS SHALL
BE USED.
12.13 AN INDEPENDENT EARTHING FACILITY SHOULD PREFERABLY BE ESTABLISHED WITHIN THE TEMPORARY
INSTALLATION PREMISES. ALL APPLIANCES AND EQUIPMENT SHALL BE ADEQUATELY EARTHED. IN CASE
ARMOURED CABLES ARE USED, THE ARMOUR SHALL BE BONDED TO THE EARTHING SYSTEM.
12.14 ALL CABLES AND WIRE ROPE USED FOR EARTH CONNECTIONS SHALL BE TERMINATED THROUGH TINNED
COPPER LUGS.
12.15 IN CASE OF LOCAL EARTHING, EARTH ELECTRODES SHALL BE BURIED NEAR THE SUPPLY POINT AND
EARTH CONTINUITY WIRE SHALL BE CONNECTED TO LOCAL EARTH PLATE FOR FURTHER DISTRIBUTION
TO VARIOUS APPLIANCES. ALL INSULATED WIRES FOR EARTH CONNECTION SHALL HAVE INSULATION OF
GREEN COLOUR.
12.16 SEPARATE CORE SHALL BE PROVIDED FOR NEUTRAL. EARTH/STRUCTURES SHALL NOT BE USED AS A
NEUTRAL IN ANY CASE.
12.17 ON/OFF POSITION OF ALL SWITCHES SHALL BE CLEARLY DESIGNATED/PAINTED FOR EASY ISOLATION
IN EMERGENCY.
13. ALL INSULATIONS AND ELECTRICAL INSTALLATIONS SHALL BE INSPECTED BY ENGINEER-IN-CHARGE

ATLEAST ONCE IN A MONTH.

No by by
Approved by
Page 1560 of 2065

DETAILS FOR STANDARD No.
ENGINEERS
Irg;Uft9g:Ang HOT DIP GALVANISED 7-51-0333 Rev.2
RITerr FleaRUC.3,141.0
(IANGPAII"' 2\("I'ITE2g) LADDER TYPE CABLE TRAYS SH. 1 OF 3
3000 /11
250 125 125 250 250 250 I 1500 250 250 125
40x15 HORIZONTAL
A -4-1 RUNG (TYP.)
W
[45 45
40
SLOTTED RUNG
MEIMIMUrAMPIELIMINIMPLIMIR
1451
451
100x45 SIDE RUNNER (TYP.)
14 0 HOLE FOR SECTION-AA
12 0 BOLT (TYP.)
LADDER TYPE CABLE TRAY

(w=300/450/600/750)
250
of
10x30 LONG SLOT SLOTTED RUNG

(TYP.) (TYP.)
SLOTTED RUNG SIDE RUNNER
D-07 lc
0 0
0 a) 0 II
1=1MM
11111111111111111
IMAM_
mm411111111
ROUND HEAD BOLT
12 MM DIA
PL.215x90x2 THK.
1301401 75 i 40 P SPLICE PLATES
VIEW B-B SECTION D-D
VIEW C-C
0
N
L--50
BARRIER PLATE
100 HOLE FOR
80 BOLT
(100 MM LONG)
NOTES:-
1 12 DIA ROUND HEAD BOLT WITH WASHERS & NUTS CONFORMING TO

IS 1363 & IS 1367 SHALL BE USED FOR FIXING OF SPLICE PLATE.
7A10> ;14'"A
C)4
2 23.04.13 REVISED AND REISSUED BP FA/RSC UAP/J MS DM
1 11.01.08 REVISED AND REISSUED BP RKS/SSM JMS VC
No. by by
Approved by
Page 1561 of 2065

STANDARD No.
DETAILS FOR
/8ifWEIq ENGINEERS
fatalft INDIA LIMITED HOT DIP GALVANISED 7-51-0333 Rev. 2
21E¢15WC613,131171)
"t
(A Go Ind° UndethAing) LADDER TYPE CABLE TRAYS SH. 2 OF 3
125
140 HOLES FOR FIXING
SPLICE PLATE (TYR)
H (Pi')
40x15 MM
RUNG @ 250 C/C
VERTICAL OUTSIDE BEND
HORIZONTAL BEND
125 _1
(TYP)
VERTICAL INSIDE BEND

125
I (np)
W1
s aFM I a I a FA CaINIMIWIEMilaW/ Mi
0
U-)
N
[ W2 J
LEFT HAND REDUCER
W W1
`T' JOINT
W — WIDTH OF CABLE TRAY (300/450/600/750)

W1 — WIDTH OF CABLE TRAY ON ONE SIDE
W2 — WIDTH OF CABLE TRAY ON OTHER SIDE L W2 I
BR— BENDING RADIUS (750/1000/1250)
RIGHT HAND REDUCER
/f"4 ;,e4211
2 23.04.13 REVISED AND REISSUED BP FA/RSC UAP/JMS DM

Rev.
No. by by
Approved by
Page 1562 of 2065

STANDARD No.
DETAILS FOR
ENGINEERS
iaPiez INDIA LIMITED HOT DIP GALVANISED 7-51-0333 Rev.2
C61.3917.1) (A Govt of India Undertoking)
LADDER TYPE CABLE TRAYS SH. 3 OF 3
GENERAL NOTES:-
1 THE CABLE TRAYS AND ACCESSORIES SHALL COMPLY WITH LATEST EDITION OF INDIAN STANDARDS
IS: 1363, IS: 1367(PART-13), IS:2629, IS:5986.
2. THE CABLE TRAYS SHALL BE LADDER TYPE PREFABRICATED, HOT DIP GALVANIZED. THE LADDER
TYPE TRAYS SHALL CONSIST OF SIDE RUNNERS & HORIZONTAL RUNGS AS PER DETAILS SHOWN
IN SH. 1 & 2.
3. THE LADDER TYPE TRAYS AND ACCESSORIES SHALL HAVE RIGID WELDED CONSTRUCTION AND
SHALL BE FABRICATED OUT OF 2 mm THICK HOT ROLLED SHEET STEEL. THE RUNGS SHALL
BE WELDED TO THE SIDE RUNNERS.
4. SIDE RUNNERS SHALL BE 100 x 45 mm CHANNEL WITH THE FLANGES FACING INSIDE. RUNGS
SHALL BE 40 x 15 mm SLOTTED CHANNEL TYPE.
5. CABLE TRAYS SHALL BE SUITABLE FOR A CABLE WEIGHT OF 75 kg PER METRE OF RUNNING
LENGTH OF TRAY AND SHALL BE SUPPORTED AT 3 m INTERVALS. IN ADDITION, TRAYS SHALL
BE SUITABLE FOR A POINT LOAD OF 70 kg (EQUIVALENT WEIGHT OF A MAN WORKING ON THE
CABLE TRAY).
6. SIDE RUNNER CHANNELS SHALL BE CONNECTED AT ENDS USING 2 SPLICE PLATES ONE EACH SIDE
AS SHOWN IN SHEET-1.
7. THE SIDE RUNNER WILL ALSO HAVE SUITABLE HOLES AT EVERY METRE FOR CLEATING EARTHING
STRIP. SUITABLE THREADED HOLES SHALL BE PROVIDED ON THE RUNNER TOP AND BOTTOM
FOR SUPPORTING AND FIXING TRAY COVERS WITH SCREWS AT EVERY METRE.
8. HOT DIP GALVANIZING SHALL BE DONE AFTER FABRICATION AS PER THE RELEVANT INDIAN
STANDARD SPECIFICATIONS. THE AMOUNT OF GALVANIZING SHALL BE MINIMUM 610 g/m 2
9. THE TYPE OF CONSTRUCTION SHALL BE SUCH AS TO FACILITATE EASY HANDLING, ASSEMBLY
AND INSTALLATION AT SITE. FOR THE CONSTRUCTION OF CABLE TRAYS THE STANDARD STRAIGHT
LENGTH OF CABLE TRAY SHALL BE 3 METERS UNLESS OTHERWISE SPECIFIED.
10. SPLICE PLATE OF CABLE TRAYS SHALL BE PLACED NOT MORE THAN 750 MM FROM
SUPPORT ANGLE.
11. THE WORKMANSHIP SHALL BE SUCH AS TO ENSURE EASY LAYING OF CABLES WITHOUT CAUSING
DAMAGE TO CABLES. ALL SURFACES SHALL BE FREE FROM DEFECTS SUCH AS BURRS, SHARP
EDGES ETC.
12. THE HARDWARE SHALL CONFORM TO THE RELEVANT INDIAN STANDARD SPECIFICATIONS AND SHALL
BE ABLE TO WITHSTAND THE MAXIMUM LOADING CONDITIONS AS REQUIRED. ALL HARDWARE AND
FITTINGS SHALL BE HARD CHROME OR CADMIUM PLATED. HARDWARE SHALL INCLUDE BOLTS,
NUTS, WASHERS ETC.
13. THE BENDS, TEES, REDUCERS AND DROPPERS SHALL HAVE A BENDING RADIUS AS DESCRIBED
IN THE SCHEDULE OF RATES.
14. THE FOLLOWING TESTS FOR THE AMOUNT OF ZINC COATING SHALL BE CARRIED OUT:
• THICKNESS OF GALVANIZED COATING BY ELCOMETER.
• MASS OF GALVANIZED COATING BY STRIPPING TEST.
• DETERMINATION OF UNIFORMITY OF GALVANIZED COATING.
AN. ^
2 23.04.13 REVISED AND REISSUED BP FA/RSC UAP/JMS DM

No. by by
Approved by
Page 1563 of 2065

TYP. INSTALLATION DETAILS STANDARD No.
ENGNES
elitMON:1A WIRD (A Cwt. of India Undertaking)
OF ELECTRICAL PANELS 7-51-0335 Rev. 3
ON FALSE FLOORING Page 1 of 1
DEPTH
(SENOT-1)
INTEGRAL BASE FRAME/

KICK PLATE
FRONT —0P-
ELECTRICAL PANEL TOP OF FALSE FLOORING
MC-100 (SEE NOTE-3)
BASE FRAME
0
MC-100
(TYP.)
0
0
to
z
RCC FLOOR
200x200x10 MM THICK M.S. -I

BASE PLATE FIXED TO FLOOR
WITH 4 NOS. 1/2" DIA. ANCHOR
FASTENERS (TYP.)
ELEVATION
(VIEW-A)
MC-100 BOX (TYP.)
MC-100 BASE FRAME

0 EACH PANEL JOINT
0
(TYPICAL)
z
rn
MC-100 BASE FRAME

(TYPICAL)
PLAN
NOTES:-
1. FOR PANELS DEPTH UPTO 800 MM SUPPORTING ARRANGEMENT AS SHOWN SHALL BE FOLLWED.
FOR PANELS DEPTH MORE THAN 800 MM ADDITIONAL SUPPORTS AS PER VENDOR'S FDN. PLAN
SHALL BE PROVIDED.
2. ALL PANELS SHALL BE TACK WELDED WITH BASE FRAME OF SWITCHBOARD.
3. SUPPORTING ARRANGEMENT FOR FALSE FLOORING SHALL BE AS PER ARCHITECTURAL DRAWINGS.
3 08.11.16 REAFFIRMED & ISSUED FA/HK BRB

No. by by
Approved by
Page 1564 of 2065

MC-100 TO BE LOCATED
AS PER VENDOR'S FDN.
PANEL FRONT PLAN (TYPICAL)
H.V. SW.BD . 120x120x8THK. PLATE
MC-100 0 EACH (TYPICAL)
PANEL JOINT 6 MM THK. REMOVABLE
75
CHEQUERED PLATE
MC-100 WELDED
TO INSERT ANGLE
BETWEEN CROSS
DETAIL—A 50mm THK.
FINISH FLOOR
MEMBERS (TYP.)
1
FL (SEE NOTE-1)
1
0
0
U)
750 L110x110x8
0 THROUGHOUT THE
0 (MIN.)
LENGTH OF CABLE
0 MC-100 0 EACH TRENCH (TYP.)
0
M
PANEL JOINT
0
0 CABLE SUPPORTS RCC CABLE TRENCH
(TYP.)
L45X45X6
MC-100 6 MM THK. REMOVABLE —
WELDED WITH
CHEQUERED PLATE
CHQD. PLATE FFL
L110x110x8
120x120x8THK. PLATE L45X45X6 THROUGHOUT THE LENGTH
WELDED TO MC-100 WELDED WITH OF CABLE TRENCH (TYP.)
TO SUPPORT MC-100 MC-100 MC-100
CLEAT L75x75x6
DETAIL-A 70 MM LONG

No. by by
Approved by
Page 1565 of 2065

...eme. 1.1111111M1111110
MEM
OF ELECTRICAL PANELS
ON CABLE TRENCH
STANDARD No.
7-51-0336 Rev. 3
Page 2 of 2
ti
PANEL FRONT INTEGRAL BASE FRAME/
MV SWITCH BOARDS/ KICK PLATE
MC-100 0 EACH
PANEL JOINT MISC. PANELS
6 MM THK. REMOVABLE
CHEQUERED PLATE
50/75
MC-100 WELDED
TO INSERT ANGLE
BETWEEN CROSS
DETAIL-A 50mm THK.
FINISH FLOOR
MEMBERS (TYP.)
FFL (SEE NOTE-1)
o
0 Z
750
I
(MIN.5 L110x110x8
0 THROUGHOUT THE
0 MC-100
M, LENGTH OF CABLE
Io_ 0 EACH
TRENCH (TYP.)
0 PANEL JOINT
0
0
0
RCC CABLE TRENCH
IL CABLE SUPPORTS
(TYP.)
0
0
WIDTH
TYPICAL INSTALLATION DETAIL OF M.V. PANELS ON CABLE TRENCH
L45X45X6
MC-100 6 MM THK. REMOVABLE — WELDED WITH
CHEQUERED PLATE CHQD. PLATE FFL
\=[
0
L110x110x8
MC-100 - L45X45X6 THROUGHOUT THE LENGTH
WELDED WITH OF CABLE TRENCH (TYP.)
120x120x8THK. PLATE MC-100
WELDED TO MC-100 75
TO SUPPORT MC-100
CLEAT L75x75x6
DETAIL-A 70 MM LONG
NOTES:-
1. 50 THICK FINISH FLOORING SHALL BE DONE ONLY AFTER INSTALLATION OF BASE FRAME
2. ALL PANELS SHALL BE TACK WELDED WITH BASE FRAME OF SWITCHBOARD.
3. UNUSED PORTION OF CUTOUTS SHALL BE COVERED WITH 6 MM THICK CHEQUERED PLATES.
4. WIDTH OF TRENCH TO SUIT THE DIMENSIONS OF SWITCHBOARD SHALL BE AS PER AFC
DRAWING OF THE PROJECT.
3 08.11.16 REVISED & ISSUED AS STANDARD BP FA/HK BR RN

No. by by
Approved by
Page 1566 of 2065

Datasheet No.
DATA SHEET
B001-302-16-50-DS-9001
POWER TRANSFORMER
Rev.No. A
(ISOLATION TRANSFORMER #3)
Page 1 of 2
PURCHASER'S DATA
A Site conditions
1 Maximum ambient temperature: 47 °C 4 Relative humidity: 85 %
2 Minimum ambient temperature: 10 °C 5 Altitude above MSL: < 1000 m
3 Design ambient temperature: 47 °C 6 Environment: Humid & corrosive
B Technical particulars
1 Tag no.: ISOL # 3 22 Tap changer
2 Duty: Continuous Location HV winding
3 No. of windings: Two Type OLTC
4 Type of cooling: ONAN Range ± 7.5%
5 Rated MVA (ONAN) 7.5MVA No. of steps 7
6 Oil type Mineral (as per IS 335) RTCC Panel Required
7 Rated voltage AVR Required
HV winding 11 kV Master-follower sys. Required
LV-1 winding 11.5 kV Bi Dir. Power flow Not Applicable
LV-2 winding Not applicable Local Remote operation Not Applicable
8 HV Phase sequence UVW 23 Normal load: 40%
9 LV Phase sequence To suit switchgear 24 Temp. rise at extreme tap
10 System earthing: having max. losses:
HV side Resistance earthed oil 55°C
LV side-1 Solidly earthed winding 50°C
LV side-2 Not applicable 25 Min. guaranteed efficiency at Minimum 99.5
11 Rated frequency: 50 Hz ± 3% 0.8 p.f at 40% of ONAN rating:
12 No. of phases: Three 26 Power flow: Unidirectional
13 Fault level on primary side: 40 kA(1sec.) 27 Explosion protection PRV
Fault level on secondary side: 40kA(1 sec.)
14 Connection Terminal location:
HV side Delta HV side Larger side
LV side-1 Star LV w.r.t HV 90°
LV side-2 Not applicable 28 Terminal connection
15 Vector group: Dyn11 HV side Cable box
16 Impedance at max. MVA: LV side Cable box
HV-LV1 0.0835 29 Cable size
HV-LV2 Not applicable HV side 2Rx3Cx300 sq.mm. XLPE (Al))
17 Insulation class: A LV-1 side 2Rx3Cx300 sq.mm. XLPE (Al))
18 Insulation level: LV-2 side Not Applicable
P. f withstand Neutral 1Rx3Cx300 sq.mm. XLPE (Al))
HV winding 28 kV
LV-1 winding 28 kV 30 Neutral CT specification:
LV-2 winding 51G
Impulse withstand HV side Not Applicable
HV winding 75 kVp LV-1 side 400/1A, 5P10, 15VA
LV-1 winding 75 kVp LV-2 side Not Applicable
LV-2 winding 64R Required
19 Winding insulation type: HV side
HV winding Uniform Vk
LV winding-1 Uniform Im at Vk/2
LV winding-2 Not applicable RCT
LV-1 side By contractor
20 Creepage distance:
HV winding Vk By contractor
total As per IS Im at Vk/2 By contractor
protected As per IS RCT By contractor
LV -1 winding LV-1 side Not applicable
total As per IS Vk Not applicable
protected As per IS Im at Vk/2 Not applicable
LV-2 winding Not Applicable RCT Not applicable
total
21 Clearance 31 Installation Outdoor
Ph-Ph As per IS 32 Painting & colour Epoxy & shade 632
Ph-N As per IS
A 20.12.16 Issued with Bid Package JM MKS MKS

Rev. Date Purpose Prepared Checked Approved
Format No: EIL-1650-689 P1 Rev.1 Copyrights EIL - All rights reserved
Page 1567 of 2065

Datasheet No.
DATA SHEET
B001-302-16-50-DS-9001
POWER TRANSFORMER
Rev.No. A
(ISOLATION TRANSFORMER #3)
Page 2 of 2
34 AC Auxiliary voltage 415 V ± 10% TPN Dial type thermometer Yes (See Note 5)
35 DC Auxiliary voltage 110 V ± 10% DC & contacts for OTI & WTI
36 Bidirectional roller type Flat Drain valve Yes
37 ¢ distance of flat rollers 840 mm Marshalling box Yes
38 Applicable specifications EIL std. 6-51-41 Double float Buchholz Yes
39 Loss Capitalization Not applicable Channels & towing lugs Yes
Rate for copper loss Rs./kW: Not applicable Rollers Yes
Rate for iron loss Rs./kW: Not applicable Neutral bushing Yes
Rate for aux. loss Rs./kW: outside terminal box with
40 ECS interface Required connector assembly
Digital o/p from RTCC: Required Inspection cover Yes
Tap changer out of step Required Disconnecting chamber Yes
Tap changer stuck Required WTI & OTI Yes
Tap changer status signal Required Busduct flange on LV Yes
Supply failure Required Lugs and cable glands Yes
Individual/Parallel mode Required 42 OLTC accessories
Raiser/Lower control Required Single float Buchholz/ Yes
Digital o/p from cooling Required oil surge relay
control panel 43 Additional loose supply
Fan 'ON' (for each fan) Required Tap position indicator Yes
Fan 'Tripped (for each fan) Required Raise/lower push buttons Yes
Auto manual mode Required Transducers & necessary Yes
interface
41 Accessories requirement 44 Tests requirements
Sampling valve Yes Impulse test: Required
Conservator drain valve Yes Heat run test: Required
Top oil filter valve Yes Vacuum test on tank: Required
Explosion vent/PRV Yes Pressure test on tank: Required
Air bag for conservator Yes Short circuit test: Required
MANUFACTURER'S DATA
A Make: C Construction features
Rating MVA 1 Location of terminals
Primary
Secondary
B Performance: 2 No of cooler banks
1 No load loss at 3 Qty. of cooling fans:
100% Voltage; kW Working: Nos.
110% Voltage: kW Standby: Nos.
3 Full load copper loss at 75°C: kW 4 Location of Neutral CT
4 Auxiliary losses: kW 5 Explosion protection Explosion vent/PRV
5 No load current at 6 OLTC specification:
100% Voltage: A Rated voltage kV
110% Voltage: A Rated current A
6 Efficiency at full load at 75°C Location Separate tank/chamber
at 0.8 p.f: % Accessories Single float Bucholz/OSR
at 1.0 p.f: % D Mechanical data
7 Eff. at 50% load at 75°C 1 Core & winding weight: Kgs.
at 0.8 p.f; % 2 Tank & fitting weight: Kgs.
at 1.0 p.f: % 3 Radiator without oil weight: Kgs.
8 Maximum efficiency: % 4 Total weight: Kgs.
9 Load at which max eff. Occurs: MVA 5 Total quantity of oil: ltrs.
10 Regulation at 75°C 6 Quantity of oil in radiators: ltrs.
at 0.8 p.f: % 7 Qty of oil in OLTC chamber: ltrs.
at 1.0 p.f: % 8 Overall dimensions:
11 X1/R1 Ratio Length mm
X0/R0 Ratio Breadth mm
12 Zero sequence impedence, Z0 Height mm
Note
1 Performance data shall be furnished for ONAN rating & principal tap.
2 Losses shall be inclusive of positive tolerance and shall be at nominal tap.
3 Minimum guranteed effciency at 0.8 p.f. at 40% of ONAN rating shall be 99.5% (inclusive of all tolerance).
4 Makes of components shall be as per vendor list enclosed.
5 Transducers for providing 4-20mA signal for OTI & WTI for owner's interface shall be provided.
Format No: EIL-1650-689 P1 Rev.1 Copyrights EIL - All rights reserved
Page 1568 of 2065

Datasheet No.
DATA SHEET FOR
B001-302-16-50-DS-9002
DRY TYPE
Rev : B
DISTRIBUTION TRANSFORMER
Page 1 of 2
PURCHASER'S DATA
A Site conditions
1 Tag no.: TR-2500/2501, TR-2502/2502
27 Explosion protection PRV
2 Duty: Continuous 28 Terminal location:
3 No. of windings: 2 HV side Larger side
4 Type of cooling: ONAN LV w.r.t HV 90°
5 Rated MVA 29 Terminal connection
6 Rated voltage HV side Cable box
HV winding 11 kV LV side Cable box
LV-1/LV-2 winding 6.9kV, 0.433 kV 30 Cable size
7 System earthing: HV side
HV side Unearthed LV-1 side
LV-1/LV-2 side LV-2 side
Resistance earthed/solidely earthed 31 Neutral CT specification:
8 Rated frequency: 50 Hz ± 3%
9 No. of phases: Three 51G 200/1A, 5P10, 15VA
10 Fault level on HV side: 40 kA 64R Not Applicable
fault level on LV-1/LV-2 20kA/20kA Vk
11 Connection Im at Vk/2
HV side Delta RCT
LV-1/LV-2 side Star 32 Installation Outdoor
12 Vector group: DyN11 33 Painting & colour Epoxy & shade 632
13 Impedance at max. MVA: 0.0625 34 AC Auxiliary voltage 415 V ± 10% TPN
14 Insulation class: A 35 DC Auxiliary voltage 110 V ± 10% DC
15 Insulation level: 36 Bidirectional roller type Flat
P. f withstand 37 ¢ distance of flat rollers 1000 mm
HV winding 28 kV 38 Applicable specifications EIL std. 6-51-41
LV-1/LV-2 winding 28kV/3kV 39 Loss Capitalization Applicable
16 Impulse withstand a Rate for copper loss Rs./kW:
HV winding 75 kVp b Rate for iron loss Rs./kW:
LV-1/LV-2 winding 60kV/N.A
17 Oil type Mineral (as per IS 335) 40 Accessories requirement
18 Winding insulation type: Uniform Sampling valve Yes
19 Clearance: Conservator drain valve Yes
Ph to Ph As per IS Top oil filter valve Yes
Ph to N As per IS Explosion vent/PRV Yes
20 Tap changer Air bag for conservator Yes
Location HV winding Dial type thermometer Yes
Type Offcircuit & contacts for OTI, WTI
Range ± 7.5% Drain valve Yes
No. of steps 7 Marshalling box Yes
21 Normal load: 60% Double float Buchholz Yes
22 Temp. rise at extreme tap Channels, towing lugs : Yes
having max. losses: Rollers Yes
oil 55°C Neutral bushing Yes
winding 50°C outside terminal box
23 Minimum Guaranteed efficiency 99.3 with connector assembly
at 0.8 p.f at 80% of ONAN rating: Inspection cover Yes
24 Load at which max eff. occurs: 1.2 MVA Disconnecting chamber Yes
25 Power flow: Unidirectional WTI & OTI Yes
26 HV/LV phase sequence UVW/To suit switchgear Busduct flange on LV Yes
Lugs and cable glands Yes
B 18.04.17 Issued with Bid Package CS MKS MKS

Rev. No. Date Purpose Prepared by Checked by Approved by
Format No: EIL 1650-689 P2 Rev.2 Copyrights EIL - All rights reserved
Page 1569 of 2065

Datasheet No.
DATA SHEET FOR
B001-302-16-50-DS-9002
THREE-WINDING
Rev : A
DISTRIBUTION TRANSFORMER
Page 2 of 2
41 Tests requirements
Impulse test: Type test certificate reqd.
Heat run test: Type test certificate reqd.
Vacuum test on tank: Type test certificate reqd.
Pressure test on tank: Type test certificate reqd.
Short circuit test: Type test certificate reqd.
MANUFACTURER'S DATA
A Make:
B Performance: C Constructional Features
1 No load loss at 1 Location of terminals
100% Voltage; kW Primary
110% Voltage: kW Secondary
2 Full load copper loss at 75°C: kW 2 Location of Neutral CT
3 No load current at 3 Explosion protection Explosion vent/PRV
100% Voltage: A
110% Voltage: A D Mechanical data
4 Efficiency at full load at 75°C 1 Core & winding weight: Kgs.
at 0.8 p.f: % 2 Tank & fitting weight: Kgs.
at 1.0 p.f: % 3 Radiator without oil weight: Kgs.
5 Eff. at 50% load at 75°C 4 Total weight: Kgs.
at 0.8 p.f; % 5 Total quantity of oil: ltrs.
at 1.0 p.f: % 6 Quantity of oil in radiators: ltrs.
6 Maximum efficiency: % 7 Overall dimensions: ltrs.
7 Load at which max eff. Occurs: MVA Length mm
8 Regulation at 75°C Breadth mm
at 0.8 p.f: % Height mm
at 1.0 p.f: %
9 X1/R1 Ratio
X0/R0 Ratio
10 Zero sequence impedence, Z0
Note
1 Losses shall be inclusive of positive tolerance and shall be at nominal tap.
2 Minimum Guaranteed efficiency for transformers at 0.8 p.f & at 40% of ONAN rating shall be as below:
Transformer rating Maximum efficiency

<1000kVA >=99 %
>1000 kVA upto 1250 kVA >=99.1 %
>1250 kVA upto 5000 kVA >=99.3 %
3 Makes of components shall be as per vendor list enclosed.

4 Transducers for providing 4-20mA signal for OTI & WTI for owner;s interface shall be provided.
Format No: EIL 1650-689 P2 Rev.2 Copyrights EIL - All rights reserved
Page 1570 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9003
NEUTRAL GROUNDING RESISTOR Rev.No. A
Page 1 of 1
PURCHASER'S DATA
Project 2nd Raw water intake project Location Damanjodi
Client NALCO Unit New intake Well s/s
A Site conditions
1 Maximum ambient temperature: 47°C 4 Relative humidity: 85 %
2 Minimum ambient temperature: 10°C 5 Altitude < 1000 m
3 Design temperature: 47°C 6 Environment: Humid & corrosive
1 Rated voltage 3.81 Volts 6 Installation Indoor
2 Rated current By contractor 7 Cable connections
3 Short time rating By contractor 7.1 Cable entry Side
4 Continuous rating Required 7.2 Separate bolted removable Required
(10% of short time rating) gland plate for cable entry
4 Resistance of NGR By contractor 7.3 Cable glands & lugs Required
5 Terminal Connections 8 Current transformer Required
5.1 Transformer nuetral to NGR Al Conductor Voltage grade By contractor
Cable size mm2
1Rx3Cx300 sq.mm. Ratio By contractor
Voltage grade 12 kV (UE) Burden By contractor
5.2 NGR to Earth GI earth strip Accuracy class By contractor
Size mm2
1Rx3Cx300 sq.mm. 9 Painting/Painting shade Epoxy & shade 632
Voltage grade 12 kV (UE) 10 Degree of protection Min. IP31
MANUFACTURER'S DATA
1 Make 4 Min. creepage distance
2 Resistor element Total mm
Material code Protected mm
Specific resistance ohm cm 5 P.f. withstand voltage kV (rms)
Temp. co-efficient 6 Overall dimensions
Resistance of banks ohms Width mm
No. of resistor banks Depth mm
Series nos. Height mm
Parallel (Min. two) nos. 7 Overall weight of panel kg
3 Separate canopy provided Required 8 Copies of type test certificates
furnished
Note:-
1. Actual value of earth fault current to be limited at 6.6kV level shall be calculated by contractor. Accordingly CT ratio shall be
selected.
2. NGR sizing calculation shall be submitted for review & approval.
3. Time to be considerd as 10 sec.
4.maximum system volatge to be considerd as 6.6kV
5. Resistor material to be considerd as metallic.
6. Temperature co-efficient to be considerd as 3.5% per 100 degree C temp. rise.
7. Nos. of terminal to be considered as three (3) nos.
8. Neutral terminal bushing rated voltage to be considerd as 6.6kV.
9. Earth bushing rated voltage to be considerd as 1.2kV.
10. Enclosure shall be made of 304 stainless mild steel.

Format No: EIL-1650-2018 Rev.3 Copyrights EIL - All rights reserved
Page 1571 of 2065

Altitude NGR to earth
< 1000 m GI Strip
> 1000 m Cable
Environment Cable glands & lugs

Humid & corrosive Required
Not required
Rated voltage
33/√3 kV Rated current
11/√3 kV 300 A
6.6/√3 kV 400 A
3.3/√3 kV 600 A
800 A
Degree of protection
Min. IP31 Painting & colour
Epoxy & shade 632
Epoxy & shade 631
Page 1572 of 2065

Datasheet No.
DATA SHEET
B001-302-16-50-DS-9004
HV SWITCHBOARD
Rev : A
(11KV EXTENSION PANEL)
Page 1 of 3
PURCHASER'S DATA
Project 2nd Raw water intake project Location Damanjodi, Odisha

Client NALCO Unit GTS s/s
A Site conditions
1 Maximum ambient temperature: 47 °C 3 System Breaking capacity 40 kA(1 sec.)
2 Minimum ambient temperature: 10 °C 3.1 % D.C. Component As per IEC
3 Design ambient temperature: 47 °C 4 System making capacity 100 kA (peak)
4 Relative humidity: 85 % 5 Type of Circuit Breaker VCB
Shunt Trip Coil-1 : 110V DC
5 Altitude above MSL: <1000mtr. m 6 Duty Cycle of C.B. 0-3min-CO-3 min-CO

6 Environment: Dusty & corrossive 7 Suitability for Cap. Switching Not reqd.
B Operating conditions 8 Surge supressor for Motor Feeder. Not required
1 Voltage 11 kV ± 10% 9 IDMTL Relay type 1 sec.
2 Frequency 50 Hz ± 3% 10 Provision of earthing
3 Number of Phases Three Earthing truck Required
4 System Fault Level 40 kA Earthing switch Required
5 System Earthing Non effectively earthed D Miscellaneous
6 Auxiliary Supply 1 Interface with ECS Reqd.
a. AC 240V 2 Incoming Power Entry Cable
b. DC 110V 3 Cable Entry Top
C Electrical Data 4 Separate bolted removable Reqd.(Gland plate
1 Busbar current rating (inside 1600A (single bus) gland palte for cable entry drilled at side)
panel at design temp.) 5 Cable glands and lugs for
2 1 sec. Short Circuit withstand cable termination Required
capacity 40 kA at 11 kV 6 Painting/Paint shade As per existing
Note:
1) Marked particulars may be referred in respective switchboard feeder detail data sheet.
MANUFACTURER'S DATA
A Switchboards
1 Make 9 Recommended clearances
2 Type designation Front mm
3 Degree of protection Rear mm
4 Max. overall weight of C.B. panel Kg Above mm
5 Overall dimensions of C.B. panel 10 Shock loading on foundation
a Width mm 11 Max. size/no. of cables that can be
b Depth mm terminated inside the panel
c Height mm a. without rear extension panel
6 Overall dimensions of dummy / b. with rear extension panel
adaptor panel of each type c. size of rear extension panel
a Width mm 12 Clearance in air
b Depth mm a. Phase to Phase (min.) mm
c Height mm b. Phase to Earth (min.) mm
7 Overall weight and dimensions of 13 Busbar current rating at design
largest shipping section ambient temperature A
a Weight Kg 14 Busbar (separately for each swbd)
b Width mm a. Horizontal main busbar size
c Depth mm (No. of flats x size of each flat)
d Height mm b. Horizontal main busbar size as
8 Overall dimensions of each swbd. tested at CPRI for full short ckt.
including all dummy/adaptor/rear withstand as per specification
extension panels requirement (No. of flats x size
Width of each flat)
Depth c. Vertical dropper size
Height (No. of flats x size of each flat)
Note: Contractor shall note that siemens manke panels has been envisaged. Hence dummy panel is not
required as existing HT-227A is of siemens make.

Rev. No Date Purpose Prepared by Checked by Approved by
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
Page 1573 of 2065

Datasheet No.
DATA SHEET
B001-302-16-50-DS-9004
HV SWITCHBOARD
Rev : A
Page 2 of 3
15 Horizontal main busbar/Vertical b Removable FRP shrouds for all Yes

busbar material Al/Cu busbar joints and tap-off
16 Insulating material (Busbar supports) connections provided
17 Earth busbar size 50x6 mm2 c Arc propagation barrier in busbar Yes
18 Earth busbar material Copper compartment provided
19 1 min. power frequency withstand d Breaker service, test and drawn-
voltage (rms) 28 kV out position provided Yes
19.1 Over voltage factor for PTs 1.9 for 30 sec. e Distinct overall lockable door for
20 Impuse withsatnd voltage (peak) 60 kV breaker compartment provided Yes
20.1 Wave shape of impulse voiltage f Automatic safety shutter provided Yes
21 1 sec. short ckt. Withstand capacity kA g Independent pressure release
22 Peak dynamic withsatnd capacity kA flaps provided for all HV
23 Windows at the rear side of panels Not Required compartments Yes
for thermography h Wire mesh for all louvered
24 Safety Features openings provided Yes
a Heat shrinkable sleeves, rated to i Suitable intrlocks to prevent
withstand the system line to line faulty operation as per Cl. 5.1.11
voltage for one min., provided Yes of spec. 6-51-0001 provided Yes
on busbar
B Circuit Breaker
1 Type VCB 16 Power required for closing W/VA
2 Make 17 Power required for spring

3 Type Designation charging motor W/VA
4 Circuit Breaker mounting in panel Truck 18 Breaker is trip free Yes
5 No. of poles/phase 19 Closing mechanism
o
6 Current rating (in free air) A at C 20 Provision of manual spring
7 Current rating inside the panel at charging provided Yes
specified design tempeature A 21 Mechanical Trip PB provided Yes
8 Short time rating ( 1sec.) kA 22 Mech. On/Off indicator provided Yes
9 Symmetrical breaking capapcity kA 23 Operation counter provided Yes
9.1 % D.C. Component 24 Time taken for spring charging sec.
10 Peak making current kA 25 No. of aux. contacts and their NO +
11 1 min. dry withsatnd voltage current ratings NC , A
(power frequency) kV 26 Interrupter
12 Duty Cycle a Make
13 Total openeing time m sec. b Pressure switch for monitoring
14 Total closing time m sec. of SF6 gas pressure provided not applicable
15 Power required for opening W/VA c Re-filling arrangement of SF6 not applicable
Page 1574 of 2065

Datasheet No.
DATA SHEET
B001-302-16-50-DS-9004
HV SWITCHBOARD
Rev : A
Page 3 of 3
27 Supressor
a Type designation
b Make
28 Derating reqd. for Cap. Switching %
29 Earthing System Integral earthing/
Separate earthing
carriage
30 Copies of following test cerificates
enclosed : Yes (*)
30.1 For each type of offered circuit
breaker panel with breaker
a. Short Circuit tests (Peak and 1 sec.
withstand)
b Heat run test
c Internal arc test
d Impulse and power freq. withstand
breaker (in panel)
a. Short Circuit test duties
* Switchboard offered shall be of proven design and shll havbe been successfully type tested. Type test
certificates for an exactly identical design of offered switchboard shall be furnished by bidders. These
test reports shall not be more than 5 years old, as on the final bid opening date. In case these type tests
have not been conducted during the last 5 years, bidder shall conduct these type tests on the offered
design of switchboard before despatch without any cost and delievery impact.
Page 1575 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9005
HV (6.6KV) SWITCHBOARD Rev : A
Page 1 of 3
PURCHASER'S DATA

Client NALCO Unit New Raw Water Intake s/s
A Site conditions
1 Maximum ambient temperature: 47 °C 3 System Breaking capacity 20 kA
5 Altitude above MSL: <1000 m 6 Duty Cycle of C.B. 0-3min-CO-3 min-CO

6 Environment: Dusty & Corrossive 7 Suitability for Cap. Switching Not Reqd.
B Operating conditions 8 Surge supressor for Motor Feeder. Required
1 Voltage 6.6 kV ± 10% 9 IDMTL Relay type 1 sec.
6 Auxiliary Supply 1 Interface with ECS Not Reqd.
b. DC 110V 3 Cable Entry Bottom
1 Busbar current rating (inside 630A gland palte for cable entry drilled at side)
capacity 20 kA at 6.6 kV 6 Painting/Paint shade IS:5
Note:
MANUFACTURER'S DATA
A Switchboards
Width of each flat)
Note: Vendor shall furnish the dimensins of various types/ratings of swbds., CB panels

Page 1576 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9005
Page 2 of 3

busbar material Al/Cu busbar joints and tap-off
voltage (rms) 21 kV out position provided Yes
20 Impuse withsatnd voltage (peak) kV breaker compartment provided Yes
23 Windows at the rear side of panels Required/Not Required compartments Yes
on busbar
B Circuit Breaker
2nd shunt trip coil for VFD feeders Yes

o
14 Total closing time m sec. of SF6 gas pressure provided Not applicable
15 Power required for opening W/VA c Re-filling arrangement of SF6 Not applicable
Page 1577 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9005
Page 3 of 3
27 Supressor
a Type designation
b Make
Separate earthing
carriage
enclosed : Yes *
withstand)
b Heat run test
c Internal arc test
breaker (in panel)
Page 1578 of 2065

Datasheet No.
DATA SHEET FOR B001-302-16-50-DS-9006
MV SWITCHBOARD Rev : A
Page 1 of 2
PURCHASER'S DATA
Client NALCO Unit New Intake Well s/s
A Site conditions
B Operating Conditions
1 Voltage 415 V ± 10% TPN 6 Auxiliary supply
2 Frequency 50Hz ± 3% AC 240 V ± 10% SPN
3 No of phases Three & Neutral DC 110 V ± 10% DC
4 System fault level 50kA (1sec) 7 Power supply for spring 240VAC/110V DC
5 System earthing Solidly earthed charging motor
C Electrical Data
1 Short circuit withstand capacity 50 kA 7 Incoming power entry Thro' cable (3Rx3.5Cx300)
for 1 sec. 8 Cable entry (I/C & O/G) Required
2 Busbar current rating inside panel 800A 9 Bus duct entry Not required
panel at specified ambient 10 Cable gland/lugs Included
3 Busbars Heat shrunk PVC sleeved 11 Colour shade Exterior Epoxy & shade 631
4 System breaking capacity 50 kA 12 Feeder arrangementSingle front & compartmentalised
5 System making capacity 105 kA (peak) 13 Minimum motor starter module 240mm/Vendor standard
6 Circuit breaker size
Type ACB 14 Minimum switchfuse module 200mm/Vendor standard
Duty cycle 0-3 min-co-3 min-co size
Rating 800A 15 Floor fixing Integral base frame & tack
welding to the floor channel
Note
* marked particulars may be referred in respective switchboard feeder detail data sheet
MANUFACTURER'S DATA
A Switchboards 12 Largest shipping section:
1 Tag no. Max. overall weight kg
2 Make Length*Depth*Height mm
3 Type designation 13 Recommended clearances for SWBD
4 Degree of protection Front*Rear*Above mm
5 CB panel 15 Max. size/no. of cables that
Overall weight can be terminated
Incomer kg with rear extension
Outgoing kg without rear extension
Overall dimensions 16 Size of rear extension panel
Length*Depth*Height mm 17 Clearance in air
6 Overall dimensions of MCC/ Phase to Phase mm
contactor controlled feeder panel: Phase to Earth mm
Length*Depth*Height mm 18 Main horizontal bus bar
7 Overall dimensions of each PCC Bus bar current rating at A
Length*Depth*Height mm design ambient temp.
8 Overall dimensions of each PMCC Main bus bar size
Length*Depth*Height mm Main bus bar material Al / Cu
9 Overall dimensions of each MCC Main bus bar location Top/ Bottom
Length*Depth*Height mm 19 Vertical bus bars
10 Overall dimensions of each ASB Bus bar current rating at
Length*Depth*Height mm design ambient temp. A
11 Overall dimensions of each LDB Bus bar size
Length*Depth*Height mm Bus bar material
14 Shock loading on foundation Bus bar location

Format No: EIL 1650-3054 Rev.2 Copyrights EIL - All rights reserved
Page 1579 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9006
MV SWITCHBOARD Rev : A
Page 2 of 2
20 Insulating material 23 Short circuit
21 Earth bus bar size 50x6 mm² 1 second kA
Material Cu Peak dynamic
22 1min power freq voltage kV 24 Whether adaptor panel required Yes/No
between PCC/MCC panel
If Yes, furnish dimensions
B Circuit breaker
1 Type designation 15 Power requirement
2 Make Opening W/VA
3 Mounting Closing W/VA
4 No. of poles/phases Spring charge motor W/VA
5 Current rating (in air) A at °C 16 Time for spring charging
6 Current rating (inside panel A 17 Breaker is trip free Yes
at design temperature) 18 Closing mechanism
7 Short time rating (1 sec) 19 Provision of manual spring Yes
8 Sym breaking capacity kA charging
% DC component 20 Tripping mechanism
9 Peak making capacity kA (peak) 21 Mechanical trip PB provided Yes
10 Power frequency withstand 22 Mechanical ON/OFF indicator Yes
11 Impulse withstand voltage provided
12 Duty cycle 23 Operation counter provided Yes/ No
13 Total opening time m sec 24 Time taken for spring charging sec
14 Total closing time m sec 25 No. of auxiliary contacts NO+ NC
26 Derating required for capacitor %
switching
C CONTACTOR
1 Type designation 9 Life
2 Make Electrical
3 Rated Voltage Mechanical
4 Rated current 10 Coil consumption - Pick up
AC-3 Duty 11 Coil consumption - Pick up
AC-4 Duty 12 Coil consumption - Hold on
5 Thermal rating 13 Closing time
6 Making capacity 14 Opening time
7 Breaking capacity 15 No of aux. contacts NO+ NC
8 Switching frequency 16 Maximum permitted back up fuse rating
D SWITCH
1 Rated voltage 6 Rated short circuit withstand
2 Rated current current with max. permissible
3 AC 23 rating rated fuses
4 Rated making capacity 7 Mechanical life
5 Rated breaking capacity 8 Maximum permitted back
up fuse rating
E THERMAL OVERLOAD RELAY
1 Make 5 Type of operation Direct / CT operated
2 Type 6 Maximum permitted back
3 Setting range up fuse rating
4 Single phasing preventor Intergral / Separate
F FUSES
1 Make 3 Current rating
2 Type
Note
1 Switchboard offered shall be of proven design and shall have been successfully type tested. Type test
certificates for an exactly identical design of offered switchboard shall be furnished by bidders. These test
reports shall be not more than 5 yeas old, as on the final bid opening date. In case these type tests have not
been conducted during the last 5 years, bidder shall conduct these type tests on the offered design of
switchboard before despatch without any extra cost and delivery impact.
Page 1580 of 2065

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Page 1593 of 2065
Datasheet No.
DATA SHEET B001-302-16-50-DS-9008
TRANSMISSION LINE Rev.No. A
Page 1 of 1
PURCHASER'S DATA
Project 2nd Raw water intake project Location DAMANJODI
Client NALCO Unit TRANSMISSION LINE

A Site conditions
1 Nominal system voltage 11KV 9 Nominal discharge current 5 kA, series A
2 Maximum system voltage 12KV 10 Line discharge class Heavy duty
3 System earthing: Solidly earthed 11 Pressure relief class A
4 Sytem fault level 40 kA 12 High current w.s capacity 10 kA
5 Rated arrestor voltage 9KV 13 Min Cantilever strength-housing
6 Rated frequency 50Hz 14 Total creepage distance 3400 mm
7 Max. continuous operating voltage 9KV 15 Applicable standard EIL std. 6-51-96
8 Terminal connector 16 Installation Outdoor
Busbar ACSR
Take off Vertical
MANUFACTURER'S DATA
1 Make: 11 Components of continuous
2 Rated arrestor voltage kV leakage current at MCOV at
3 Max. continuous operating voltage kV specified amb. Temperature
4 Max. residual voltage at nominal kV Ic
discharge current Ir
5 Max. residual voltage at 1 kAp kV 12 Housing insulation level kV
switching current Impulse withstand
6 Nominal discharge current kA Power frequency
7 Line discharge class Wet kV
8 Pressure relief class Dry kV
9 High current withstand capacity kA 15 Weight kg.
10 Temporary overvoltage capacity 16 Height mm
for 0.1 sec kV 17 G.A. Drawing Enclosed/Not Enclosed
for 1 sec kV 18 Clearence Diagram Enclosed/Not Enclosed
for 10 sec kV 19 Whether Offered LA type is Type Testes
for 100 sec kV Yes/NO

Page 1594 of 2065

Page 1 of 10
Datasheet No.
NUMERICAL RELAY B001-302-16-50-DS-9009
Rev. A

PURCHASER'S DATA
A PROJECT DATA TICK FOR SELECTION
1 Project details 2 SITE CONDITIONS
a Project : 2nd Raw water intake project a Ambient tempeature
b Client : NALCO b Min 10 °C Max 47 °C Design 47 °C
c Location : Damanjodi c Relative Humidity : 85%
d Unit : New intake Well s/s d Altitude : Less than 1000M
e Atmospheric condtion : Highly corrosive
f Installation : Indoor inside pnl
B RELAY SELECTION TICK FOR SELECTION
1 RELAY FUNCTIONS 4 INPUT POWER SUPPLY
a Only Protection a Site selectable feature
b Protection and metering b Input supply : 110V DC/ 240V AC
c Protection and metering and control :
d Ethernet based commuication :
e Password protection
a. For write
b. For both read and write
2 CONSTRUCTION FEATURE 5 CT/ PT INPUT TO RELAY
a Enclosure type : IP5X a Current operated relays
b Terminal size- sqmm : 2.5 for control a1 Main CT input :
for external wires : 4 for CT/ PT a2 CT for sensitive EF :
c Mounting : Flush or back up EF
d Drawout feature : As per 6-51-0055 b Voltage operated relays
e Display type : AlphaNumeric LCD b1 PT input : 3phase, 4wire
+ LED Indication
3 SPECIAL REQUIREMENT IF ANY c Comprehensive relay
a Applicable standards: IEC c1 Main CT input : 3 CTs, 4wire
b Distance for cable capacitance up to 1200 m c2 PT input : 3phase, 4wire
for application where field contacts are c3 CT for sensitive EF : 1 CT, 2 wire input
directly wired to relay e.g. Motor start/ stop or back up EF (Yes for IC& TR FDR)
c4 CBCT input for motor
d CT Secondary current : Refer swbd data sht
C RELAY PROTECTION/ METERING FUNCTIONS TICK FOR SELECTION SPECIFICATION: 6-51-0055

(where no check box is shown, the requirement is minimum but not limited. Refer SWBD data sht for fdr wise protection)
1 Current operated functions 2 Voltage operated functions
a. 3 phase O/C element (50, 51) a. 3 phase O/V element with time delay (59+2)
* I> * I >> * I>>> * OV> * OV>>
Characteristics as per IEC b. 3 phase U/V element with time delay (27+2)
* Inverse (normal, very, extremely, long) @ UV> @ UV>>
and definite time for I > and I >> Characteristics as per IEC
* Definite time for I >>> * Inverse (normal, very, extremely, long)
@ U/V Relay shall be part of the motor protection relay
b. E/F relay (50N, 51N, 51G)
* IO > * IO >> * IO >>> c. Under/ Over Frequency element with time delay
Characteristics as per IEC (81U/ 81O)
* Inverse (normal, very, extremely, long) * Settable under voltage restraint
and definite time for I O >, I O >> * df/dt element
* Definite time for I O >>> * Number of stages with u/f
* Number of stages with df/dt
c. Metering/ event recording d. Synchrocheck function
* 3 phase/ line currents d. Metering/ event recording
* Disturbance record * 3 phase/ line Voltages
* Breaker trip/ close status * Disturbance record
* Relay faults * Breaker trip/ close status
* Trip Values * Relay faults
* Trip Values
TICK FOR SELECTION
Format No: 1650-2055 Rev.0 Copyrights EIL - All rights reserved
Page 1595 of 2065

Page 2 of 10
Datasheet No.
Rev. A
C RELAY PROTECTION/ METERING FUNCTIONS TICK FOR SELECTION

(where no check box is shown, the requirement is minimum but not limited. Refer SWBD data sht for fdr wise protection)
3 Motor Protection relay 5 Special protection relays
a. Protection elements * Part of main relay
* Thermal overload (49) * Separate relay
* OC protection with doubling feature (50) a. Differential relays
* EF protection (50N) * BUS
* Locked Rotor protection * Feeder
* Maximum start time * Trafo With harmonic restraint
* Maximum number of starts * Machine
* Negative phase sequence b. Distance relays (67, 67N)
* Under voltage delayed trip c. Restricted EF (64R) Required for ISOL#3
* EF Through CBCT d. Generator protection
* Single phasing e. Distance protection
b. Metering/ events f. Reverse power relay
* 3 phase/ line current
* Hour run 6 Other relay Features
* KW, KWH, pf a. Analog inputs 4-20mA
* Disturbance record * RTD/ BTD-MPR 4 NOS
* Plot start characteristic (in
relay or MMI) * WTI/ OTI-Trafo relay 4 NOS
* Trip values
* Start time WTI= Winding temperature indicator
* Start current OTI= Oil temperature indicator
c. Control
* Breaker close in test mode b. Out put relays
* Reacceleartion logic * Number of relays 16NOS
* Breaker trip * Contact rating 5A, 240V AC
* Reset Self reset
FUNCTIONS part of numerical relay
4 Comprehensive numerical relay c. Lock out function (86)
a. Current op elements d. Trip circuit supervision(95)
(51, 50, 51N, 50N, 51G) e. Watch dog
b. Voltage op elements (59, 27, 2, 81U, 81O) f. Time stamp
c. Control function g. Modular construction
* Breaker close/ trip from relay for easy and quick replacement
* Breaker close/ trip on serial of faulty PCB/circuit
* PLC logic function for control scheme
* Digital I/P : Vendor to estimate
* Motor Feeder control function
D COMMUNICATION AND RELAY INTEGRATION TICK FOR SELECTION
1 Relay integration 3 Redundancy requirement for DC/MMI
a Communication ports at Relay a Ports at STAR coupler
* Relay front : RS 232 * For each relay Not Applicable
* Relay back : FO * For DC Not Applicable
b Protocol : IEC-61850 b Data concentrator
of relay LAN * Power supply card Not Applicable
c Requirment of data concentrator (DC) * Communication port for Not Applicable
* Integraton through DC each relay LAN
* Directly to MMI * Communication Processor Not Applicable
d Topology Ring
e Data concentrators Not Applicable
4 communication from DC to MMI/ ECS RTU
a DC to MMI
2 Redundancy * Topology Not Applicable
a Relay LAN * Protocol Not Applicable
* Redundant(Serial)
* Non redundant(Star) b DC to ECS-RTU Not Applicable
b From DC to MMI c Scan time 500ms for event/status
* Redundant 2sec Data acquisition
* Non redundant 5 Other requirement
c From DC to SCADA-RTU a Time synchronization Detail during engg
* Redundant b Remotor relay parameterization
* Non redundant c Annunciation at MMI
Page 1596 of 2065

Page 3 of 10
Datasheet No.
Rev. A
MANUFACTURER'S DATA
1 NUMERICAL RELAYS TYPES
Feeder type INCOMER BUS PT BUS TIE MOTOR TRANSFORMER
Main relay
*Indicate equivalent
NEMA no. of element
offered inMainRelay
* lockout feature 86
* trip ckt sup 95
Relay selection
* relay model & extra

element for syn mot
Differential relay
CT circuit supervision
REF relay
Direction relay
Reverse Power
Impedance relay
* 86 with all special
protection relays
RS232
Nos of Serial
RS485
RS422
Port
FO
RTD -PT100
BTD- PT100
Analog input
WTI input
OTI input
* DI used by MFR
Nos of DI
* DI avaialble for
customer interlock
* DI for auto C/O logic
* Main relay
* Special relays
Protocol
* Protocol for relay

setting from remote
Any other data
REMARKS
Page 1597 of 2065

Page 4 of 10
Datasheet No.
Rev. A
2 DATA CONCENTRATOR AND RELAY INTEGRATION

a Model no. g Serial Interface -ECS-RTU
Make * Topology
* Protocol
b Input power supply * Type of Port
* Voltage * Cable type
* Power reqt
h Number of Digital Input/ Aanalog Input (4-20mA)
c Redundancy * DI for substation eqpt
* Power supply * Spare DI
* Communication processor * AI as per project data sht
* Communication port * Spare AI
* Relay LAN
* ECS-RTU interface I Maximum Scan Time
* MMI interface * Status
* events
d Serial interface- Relay LAN * Data acqusition (analog)
* Topology
* Protocol j Other features
* Nos of relay in each LAN * Spare capacity for
* Topology additional devices for
* Protocol relay LAN
* Type of port * Time synchronization
* Cable type options
f Serial interface- MMI

* Topology
* Protocol
* Type of Port
* Cable type
3 Standard features of relay/ system architecture

Vendor to provide data as applicable for the product offered
1. Relay envisaged in HT-227A shall be suitable for interface with ECS.
Page 1598 of 2065

OPTIONS
SITE CONDITIONS
AMB TEMP MIN MAX DESIGN ATMOSPHERIC CONDTION
5 °C 45 °C 40 °C
10 °C 50 °C 45 °C
15 °C 47.6 °C 50 °C
47.6 °C
HUMIDITY MIN MAX DESIGN INSTALLATION

40
60
>90
100
ALTITUDE MIN MAX DESIGN

100 m
200 m
< 1000 m
> 1000 m
DISPLAY TYPE SELECT INPUT POWER SUPPLY

AlphaNumeric LCD
Graphic LCD
+ LED Indication
CT-PT INPUT CONSTRUCTION FEATURES

MAIN CT CBCT PT CTSECONDARY
3 CTs 3wire (Yes for IC& TR 3phase,
FDR) 4wire1A ENCL TML SIZE MTNG
3 CTs, 4wire 1 CT, 2 wire input
3phase, 3 wire5A IP5X 2.5 Flush
1phase 5A-Main, 1A Other IP41 4.0 Surface
1A/5A site selectable IP23 2.5 for control
Refer swbd data sht IP55 4 for CT/ PT
PROTECTION FUNCTIONS
FREQUENCY RELAY SELECTION DIGITAL INPUTS FOR INTERLOCKS/ SCHEMATICS
UNDER FREQUENCY 2
df/dt 4
5
6
DIFFERENTIAL PROTECTION SELECTION ANALOG INPUT/ OP RELAYS

Low Imp with checK diff 4-20mA
High Imp with check diff
High Impedance
Low Impedance
Pilot wire
Biased low Impedance
With harmonic restraint
High/Low Imp, vendor to select
Biased differential
Page 1599 of 2065

OPTIONS
DISTANCE SELECT TOPOLOGY PROTOCOL

BETWEEN RELAY AND MOTOR up to 300 m STAR Proprietary
up to 500 m RING Modbus
up to 750 m RING-Multidrop Profibus
up to 1000 m LILO Field bus
up to 1500 m Daisey Chain LON
Vendor to decide SPABUS
Ethernet Ring Courier Bus
K-bus
DNP-3
IEC870-5-103
Vendor to decide
TCP-IP
REDUNDANCY SELECT
Dual Redundant
SCAN TIME Non Redundant
500ms for event/status One Port
2sec Data acquisition Two Ports
MIS REQUIREMENT TIME SYN
GPS
Plant Clock
MMI Clock
Detail during engg
Page 1600 of 2065

OPTIONS
SELECT
Highly corrosive
SELECT
indoor inside pnl
Indoor- in airconditioned room
Indoor- in pressurised room
Indoor
SELECT
110V DC
220V DC
110V AC
240V AC
110V DC/ 240V AC
DOUT
Drawout
Fixed
as per 6-51-0055
TS FOR INTERLOCKS/ SCHEMATICS

SELECT
10 (min)
15
10min or as reqd
As required
Vendor to estimate
SELECT SELECT
2 NOS 2 NOS
4 NOS 4NOS
6 NOS 6 NOS
8 NOS 8 NOS
10 NOS 10 NOS
Not REQD Hand reset
Self reset
2A, 220V DC
5A, 240V AC
Page 1601 of 2065

OPTIONS
PORTS
RS 232
RS422
RS485
FO
Dual RS485
Dual FO
FO Rx/ Tx
IEC870-5-103
Vendor to decide
DATA CONCENTRATOR REQT

Separate for HV system
Separate for MV system
Common for both HV/MV system
Detail during engg
Page 1602 of 2065

OPTIONS
Page 1603 of 2065

PROJECT CLIENT LOCATION UNIT
Page 1604 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9010
HV/MV CABLE Rev : A
Page 1 of 1
PURCHASER'S DATA
A Site conditions
2 Minimum ambient temperature: 10 °C 5 Altitude < 1000 m
3 Ground temperature: 47 °C 6 Environment: Humid & corrosive
1 System voltage 3 Conductor material
Nominal Highest Voltage grade HV Power cable Aluminium
415 V 500 V 650/1100V MV Power cable Aluminium
3.3kV(E) 3.6 kV 1.9/3.3kV MV control cable Copper
3.3kV(UE) 3.6 kV 3.3/3.3kV
6.6kV(E) 7.2 kV 3.8/6.6kV 4 Installation under DGMS jurisdiction No
6.6kV(UE) 7.2 kV 6.6/6.6kV (See note-3)
11kV(E) 12 kV 6.35/11kV 5 Applicable spec. 6-51-0051 Rev 7
11kV(UE) 12 kV 11/11kV
22kV(E) 24 kV 12.7/22kV
33kV(E) 36 kV 19/33kV
2 Frequency 50 Hz ± 3%
MANUFACTURER'S DATA
1 Name of manufacturer 9 Inner sheath
2 MR/PR item no. Type of compound
3 Cable type/ code Thickness mm
4 Conductor material 10 Nominal dia under armour mm
5 Conductor semiconducting screen (HV cables) 11 Calculated dia under armour mm
Material 12 Armour
Thickness mm Material
6 Insulation Type
Type of compound Size
Thickness mm 13 Nominal dia under outersheath mm
7 Insulation semiconducting screen (HV cables) 14 Calculated dia under outersheath mm
Material 15 Outersheath
Thickness mm Type of compound
8 Copper tape Thickness mm
Thickness mm 16 Nominal outer dia of cable mm
17 Tolerance on outer dia %
18 Weight of cable per km kg
19 Maximum drum length mtr.
Notes
1 Single line to ground fault current (applicable for HV cables) for sizing of insulation screening shall be as under :
Size System Voltage Current value (kA) Duration(sec)

3Cx300 sq.mm. (UE) 11kV 5.4kA 1
3Cx120 sq.mm. (UE) 6.6kV 0.3 0.6
3Cx50 sq.mm.(UE) 6.6kV 0.3 0.6
2 E- Earthed system
UE-Un Earthed system
3 Where the installation falls under the jurisdiction of Directorate General of Mines Safety, cables shall comply

Page 1605 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9011
BATTERY AND CHARGER Rev: A
Page 1 of 3
PURCHASER'S DATA
Client NALCO Unit New Intake Well s/s
A Site conditions
2 Min. amb temp for battery sizing 10 °C 5 Altitude above MSL: < 1000 m
1 Battery
a Type VRLA d Boost charging time 10 hours
b Plate construction Plante positive
c Discharge duty requirements e Electrolyte liquid in containers Required
Nominal Duty cycle No. of cells End cell voltage
Item no. DC First 1 Next 28 Next 90 Last 1 Lead Lead
VRLA Ni-cd VRLA Ni-Cd
voltage min. min. min. min. acid acid
1.85 V 1.85 V 1.16 V
By contractor
f Battery stand formation Single storied rack h Cable details between

g Accessories (Per battery set) battery & charger By contractor
i Hydrometer (syringe type) * 3 nos. Item no.
ii Thermometer * 3 nos.
iii Cell testing voltmeter (3V-0-3V) 1 no.
iv Rubber gloves 4 pairs
v Spanner 1 no.
vi Acid resistant jugs & funnels * 2 nos. each
vii Wall mounting teakwood holder * 1 no.
2 Battery charger
a System voltage 415 V±10% AC, TPN m Incoming cable details for
b System frequency 50 Hz ± 3% battery charger
c System neutral earthing Solidly earthed Item no. By contractor
d System fault level 50 kA
e Charger voltage range
Float charging voltage range/cell VRLA-2.05-2.25 V
Boost charging voltage range/cell VRLA-2.25-2.4 V
f Cable entry Bottom
g Mounting Free Standing,
Floor Mounted
h Access Front
i Earth Bus 25X6 mm2 Cu (Min)
Separate bolted removable Required(Gland Plate

j
undrilled gland plate for cable entry shall be drilled at site)
k Cable glands and lugs Required

l Painting Shade 631 of IS-5
3 DC distribution board
a Type Compartmentalized
b Feeder requirements As per requirement
Rating of DC contactor for
Item no. Feeder type Feeder rating No. of feeders Max. cable size
lighting
To be decided by contractor as per requirement & spare philosophy

Page 1606 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9011
Page 2 of 3
4 ECS Interface
a Indication-Charger failure Not required c Indication-Battery discharged Not required
b Indication-Inverter failure Not required d Indication-Battery isolated Not required
Notes
1 NO (Normally Open) potential free contacts shall be wired upto terminal strip for connection to ECS interface by
owner, for the following conditions.
2 End cell voltage shall confirm to the values specified.
3 * Asterisk marked items are not applicable for Ni-Cd and VRLA batteries.
4 Cable details shall be furnished during post order document review.
MANUFACTURER'S DATA
A Battery B Battery charger
1 Item no. 1 Item no.
2 Tag. No. 2 Tag. No.
3 Manufacturer's name 3 Manufacturer's name
4 Type & Catalogue no. of cell 4 Rating
5 Ampere hour capacity Charger rating
6 No. of cells Output voltage
7 Nominal cell voltage Output current
8 Cell voltage at the end of full 5 Nominal voltage
discharge at 10 hrs/ 5 hrs rate Float charging
9 Specific gravity of electrolyte at the Quck charging
end of full charging at °C 6 Float chrging voltage range
10 Specific gravity of electrolyte at the 7 Quick charging voltage range
end of full discharge at 10 hrs/ 8 Min. efficiency of charger
5 hrs rate at °C at light load (40%)
11 Quantity of electrolyte per cell at rated load
12 Weight of cell with electrolyte 9 Power factor at rated voltage
13 Quick charging current & load
Max. safe quick charging rate 10 Max. RMS ripple voltage at
Permissible ripple content rated load
14 Suggested quick charging rate with battery connected
15 Quick charging voltage without battery
Max. quick charging voltage/cell 11 Method of volatege control
Quick charging voltage/cell for Float charging mode
constant voltage finish charging QuIck charging mode
16 Float charging voltage/cell 12 Method of current control
17 Float charging current Float charging mode
Float charging current range QuIck charging mode
Permissible ripple content 13 Safety factor for component
18 AH efficiency at 10 hrs/5 hrs rate selection
19 Short ckt current of battery bank 14 Charger dimensions
20 Short circuit withstand time Width
21 Max. allowable termp.of electrolyte Depth
the cells can withstand without Height
injurious effects 15 Max. heat loss in watts
Continuously 16 Degree of protection
Short period
Page 1607 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9011
Page 3 of 3
22 Type of positive plate C DCDB
23 Type of negative plate 1 Item no. As per MR/PR
24 No. of positive plates/cell 2 Tag. No.
25 No. of negative plates/cell 3 Manufacturer's name
26 Material & thickness of separators 4 DCDB dimensions
27 Ampere hour capacity at min. amb. Width
10 hrs rate to end cell voltage Depth
specified at s.no. 8 above Height
5 hrs rate to end cell voltage 5 Degree of protection
specified at s.no. 8 above D Cell booster
2 hrs rate to end cell voltage 1 Item no. As per MR/PR
specified at s.no. 8 above 2 Tag. No.
1 hr rate to end cell voltage 3 Manufacturer's name
specified at s.no. 8 above 4 Current rating
30 min. rate to end cell voltage 5 Voltage range
specified at s.no. 8 above 6 Dimensions
28 Dimensions of each battery rack Width
Width Depth
Depth Height
Height
29 No. of battery racks
Page 1608 of 2065

System voltage Altitude Painting
415 V±10% AC, TPN < 1000 m Shade 631 of IS-5
> 1000 m
System frequency DCDB
50 Hz ± 5% Environment Compartmentalized
Humid & corrosive Non-compartmentalized
Fault level
50 kA Float charge voltage Cable entry
Lead acid-2.05-2.3 V Bottom
System earthing Ni-Cd- 1.3-1.45 V Top
Solidly earthed VRLA-2.05-2.25 V
Electrolyte liquid
Battery type Boost charge voltage Required
Lead acid Lead acid-2.25-2.7 V Not required
VRLA Ni-Cd- 1.42-1.7 V
Ni-Cd VRLA-2.25-2.4 V
Plate construction Boost charging time

Tubular positive
Plante positive 8 Hours
Pocket plate 10 hours
Sintered plate 90%AH in 24 hrs
Page 1609 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9012
HV (1KV) SWITCHBOARD Rev : A
Page 1 of 3
PURCHASER'S DATA

Client NALCO Unit New Water Intake s/s
A Site conditions
1 Maximum ambient temperature: 47 °C 3 System Breaking capacity 40 kA
5 Altitude above MSL: <1000 m 6 Duty Cycle of C.B. 0-3min-CO-3 min-CO
6 Environment: Dusty & corrossive 7 Suitability for Cap. Switching Not required
B Operating conditions 8 Surge supressor for Motor Feeder. Not required
1 Voltage 11 kV ± 10% 9 IDMTL Relay type 1 sec.
6 Auxiliary Supply 1 Interface with ECS Reqd.
b. DC 110V 3 Cable Entry Bottom
1 Busbar current rating (inside 630 gland palte for cable entry drilled at side)
capacity 40 kA at 11 kV 6 Painting/Paint shade 631as per IS:5
Note:
MANUFACTURER'S DATA
A Switchboards
Width of each flat)

Page 1610 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9012
Page 2 of 3

busbar material Al busbar joints and tap-off
voltage (rms) kV out position provided Yes
20 Impuse withsatnd voltage (peak) kV breaker compartment provided Yes
23 Windows at the rear side of panels Not Required compartments Yes
on busbar
B Circuit Breaker

o
14 Total closing time m sec. of SF6 gas pressure provided Not Required
15 Power required for opening W/VA c Re-filling arrangement of SF6
Page 1611 of 2065

Datasheet No.
DATA SHEET B001-302-16-50-DS-9012
Page 3 of 3
27 Supressor
a Type designation
b Make
Separate earthing
carriage
enclosed : Yes *
withstand)
b Heat run test
c Internal arc test
breaker (in panel)
Page 1612 of 2065

AC Auxiliary voltage Altitude Painting & colour
415 V ± 10% TPN < 1000 m Epoxy & shade 631
240 V ± 10% SPN > 1000 m
Circuit breaker type
DC Auxiliary voltage Environment SF6
110 V ± 10% DC Humid & corrosive Vacuum
220 V ± 10% DC MOCB
Accessories requirement
Applicable standards Required Duty cycle
EIL std. 6-51-41 Not required 0-3 min-co-3 min-co
Type of relays
Electromechanical
Static
Numerical
Page 1613 of 2065

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or used, except in the
limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1650-682, Rev 1 A4-210x297.
HV Switchboard Data sheet

Unit : GTS s/s Bus current rating : 1600A (single bus) Fault level : 40 kA (1 sec)
Extension Panel No : HT-227A/ LHS Voltage rating : 11kV Auto-transfer: Not applicable
Location : GTS s/s Execution : Single front, Drawout New Switchboard/Extension to existing Swbd.
S Feeder Nameplate Inscription Bus Section Breaker Rating / CT Primary current rating Max Cable Size Reference Remarks
No Feeder (A) ** (mm²) Data Sheet
Panel Feeder Description Rating Scheme Left Right Designation Metering & # (6970-302-
No No (kW/A) No side side Protection 16-50-DS-
9007)
Incomer from
1 upstream isolation 800A 1 800A VCB feeder 800/5 2Rx3Cx300 Sht.1
XMFR (ISOL#3)
Outgoing plant feeder
2 for new water intake 800A 1 800A VCB feeder 800/5 2Rx3Cx300 Sht.3
S/S
3. Line PT - 1 - - - Sht.1
4 Bus Coupler 1600A 1
Outgoing plant feeder Sht.3

5 for CSS-7, CSS-8, 3 800A VCB feeder 800/5 2Rx3Cx300
construction power
Sht.3
6 Spare plant feeders 1 800A VCB feeder 800/5 2Rx3Cx300
Note: ** CT primary current ratings indicated are tentative and shall be finalized during drawing approval stage. There shall not be implication due to the
same.
# All cables mentioned shall be XLPE insulated, AL cond cable. However, cable sizes mentioned are tentative and the final cable size shall be provided to
the vendor during detailed engineering stage.
REV DATE PURPOSE BY CHKD APPD DATA SHEET Rev
ENGINEERS INDIA LIMITED B 18.04.17 Issued with Bid Package CS MKS MKS SWITCHBOARD B001-302-16-50-DS-
(FEEDER DETAILS ) B
NEW DELHI A 20.12.16 Issued with Bid Package JM MKS MKS 9013
Sheet 1 of 5
Page 1614 of 2065

limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1650-682, Rev 1 A4-210x297.

Unit : New Intake Well s/s Bus current rating : 630A (single bus) Fault level : 40 kA (1 sec)
Switchboard No : HT-240 Voltage rating : 11kV Auto-transfer: Not applicable
Location : New Intake Well s/s Execution : Single front, Drawout New Switchboard/Extension to existing Swbd.
S Feeder Nameplate Inscription Bus Section Breaker CT Primary current rating Max Cable Size Reference Remarks
No Rating / (A) ** (mm²) Data Sheet
Feeder # (6970-302-
Designation 16-50-DS-
Panel Feeder Description Rating Scheme Left Right Metering & 9007)
No No (kW) No side side Protection
1. Incomer 1 630A VCB 600/5 2Rx3Cx300 Sht.1
11/6.9KV
2. 2.5MVA 1 630A VCB 200/5 1Rx3Cx300 Sht.4
Transformer feeder
11/6.9KV
3. 2.5MVA 1 630A VCB 200/5 1Rx3Cx300 Sht.4
Transformer feeder
2.5MVA,
4. Spare 2 630A VCB 200/5 1Rx3Cx300 Sht.4
0.63MVA
5. Line PT - 1 - - Sht.1
6. Bus PT - 1 - - Sht.5
11/0.433KV
7 0.63MVA 1 630A VCB 200/5 2Rx3Cx50
Transformer feeder
11/0.433KV
8 0.63MVA 1 630A VCB 200/5 2Rx3Cx50
Transformer feeder
Note: ** CT primary current ratings indicated are tentative and shall be finalised during drawing approval stage. No price implication on account of change of
CT ration in later date.

FEEDER DETAILS 9013 B
NEW DELHI
Sheet 2 of 5
Page 1615 of 2065

# All cables mentioned shall be XLPE insulated, AL cond cable. However, cable size mentioned are tentative and the final cable size shall be provided to

Switchboard No : HT-265 Voltage rating : 6.6kV Auto-transfer: Applicable
Designation # (6970-302-
16-50-DS-
9007)
Panel Feeder Description Rating Scheme Left Right Metering &

No No (kW) No Protection
1. Incomer # 1 1 630A VCB 200/5 3Cx120 Sht.8
2. Incomer # 2 630A VCB 200/5 3Cx120 Sht.8
3. Bus coupler - 630A VCB 200/5 - Sht.6

4. Line PT # 1 - - 1 - - - Sht.8
5. Line PT # 2 - - 1 - - - Sht.8
6. Bus PT # 1 - - 1 - - - Sht.10
7. Bus PT # 2 - - 1 - - - Sht.10
8. Intake well Motor # 1 300 - 1 630A VCB 50/5 3Cx50 Sht.7
9. Intake well Motor # 2 300 - 1 630A VCB 50/5 3Cx50 Sht.7

NEW DELHI
Sheet 3 of 5
Page 1616 of 2065


Switchboard No : HT-265 Voltage rating : 6.6kV Auto-transfer: Applicable
Designation # (6970-302-
16-50-DS-
9007)
Panel Feeder Description Rating Scheme Left Right Metering &

10. Spare motor feeder 300 - 1 630A VCB 50/5 3Cx50 Sht.7
Note: ** CT primary current ratings indicated are tentative and shall be finalised during drawing approval stage. No price implication due to change in CT ratio at later date.

NEW DELHI
Sheet 4 of 5
Page 1617 of 2065

MV Switchboard Data sheet

Switchboard No : MV-RW Voltage rating : 415V Auto-transfer: Not applicable
S Feeder Nameplate Inscription Bus Section Breaker CT Primary current rating Max Cable Size Reference Remarks
No Rating / (A) ** (mm²) Data Sheet
Feeder # (1202-00-
Designation XB-DS-
0012)
Panel Feeder Description Rating Scheme Left Rigt Metering &

1
1. Incomer # 1 1250A VCB 1250/5 3Rx3.5Cx300 Sht.11
1
2 Incomer # 2 1250A VCB 1250/5 3Rx3.5Cx300 Sht.11
As per
3. SFU feeder 125A - - Sht.12
requirement
SFU feeder with
As per
4. contactor+ELCB & 63A - Sht.13
requirement
CBCT & timer
5. As per
SFU feeder 63A - - Sht.12
requirement
Note: ** CT primary current ratings indicated are tentative and shall be finalized during drawing approval stage. No price implication due to change in CT ratio
at later date.
# All cables mentioned shall be XLPE insulated, AL cond cable. However, cable sizes mentioned are tentative and the final cable size shall be provided to

NEW DELHI
Sheet 5 of 5
Page 1618 of 2065

Page 1619 of 2065
Page 1620 of 2065
Page 1621 of 2065
Page 1622 of 2065
Page 1623 of 2065
EIL DWG NO : B001-302-16-50-DS-9014E REV-A

Dated 20.12.2016
Note:-
8 metre height lattice type pole shall be
considered.(See the pole drawings)
Datasheet No.
DATA SHEET
B001-302-16-50-DS-9015
HIGH VOLTAGE SQUIRREL CAGE
Rev.No. A
INDUCTION MOTOR
Page 1 of 1
PURCHASER's DATA
A. Site conditions
1 Ambient temperature, minimum: 47 °C 3 Atmospheric condition: Humid & highly corrosive
maximum: 10 °C 4 Altitude: < 1000 m
design: 47 °C 5 Location: Outdoor
2 Relative humidity: 85 % 6
B. Technical particulars
1 Motor tag no.: By contractor 17 Hazardous area classification: Safe Area
2 Driven equipment name: Intake well pump 18 Gas group:
3 Voltage: 6.6. kV ±10% 19 Type of explosion protection:
4 Phase: Three 20 Type of ingress protection: IP 55
5 Frequency: 50 Hz ±3% 21 Reacceleration:
6 Fault level: 20 kA 22 Diff. protection CTs:
7 Fault duration: 1 sec. CT specs.:
8 System earthing: Resistance 24 Color shade: 632 as per IS 5
9 Duty: Continuous 25 Thermisters:
10 Method of starting: D.O.L. 26 RTD:
11 Cable size: 3Cx50 mm² 27 BTD:
12 Cable type: Al. cond. XLPE insulated 28 RTD/BTD monitoring device:
13 Temperature rise: 73 °C
14 Cooling: IC611
15 Insulation class: F 29 Applicable specification: EIL spec. 6-51-0031
16 Temperature rise limit B
DRIVEN EQUIPMENT MANUFACTURER's DATA
1 Suggested motor rating: kW 9 Coupling type:
2 Manufacturer: 10 Torque required, starting: mkg
3 Type of driver mounting: 11 maximum: mkg
4 Driven equipment: 12 GD2 of eqpt., including flywheel: kgm2
5 Shaft kW: kW excluding flywheel: kgm2
6 kW at maximum load: kW 13 Maximum thrust: kg
7 Speed: RPM 14 Pulsation rate:
8 Rotation of eqpt. from coupling end: 15 Starting condition:
MOTOR MANUFACTURER's DATA
1 Rating: kW
2 Manufacturer: 19 Space heater - voltage & power:
3 Frame designation: 20 Moment of inertia, GD2: kgm2
4 No. of poles: 21 DE/NDE bearing type & no.:
5 Full load speed: RPM 22 Type of lubrication:
6 Mounting: 23 Type of main terminal box:
7 Full load torque (FLT): mkg 24 Type of neutral terminal box:
8 Starting torque: % of FLT 25 No. of Terminals
9 Break down or pull out torque: % of FLT 26 Weight of motor: kg
10 Full load current (FLC): A 27 Thermisters, quantity: no.
11 Starting current at 100% voltage: % of FLC make: type:
12 Rotation viewed from coupling end: 28 RTD, quantity: no.
13 Starting time at 80%/100% voltage: sec. make: type:
14 Locked rotor withstand time (cold/hot) at, 29 BTD, quantity: no.
80% voltage: sec. make: type:
100% voltage: sec. 30 Shaft voltage: V
15 Time (Te) for Increased Safety Motor sec. 31 Critical speed, 1st/2nd stage: RPM
at 100% Voltage 32 Pressurization panel:
16 Efficiency at 75%/100% Load: % make: type:
17 Power factor at 75%/100% load: 33 Canopy:
18 Heating/Cooling Time Const. (min.) min 34 Fan rotation Design Universal/Fixed/Can be changed
1. Recommended list of maintenance spares for two years operation shall include the follwing as minimum:
a) Bearing DE/NDE one set b) Terminal box cover with screws c) Fan d) Terminal block
2. Starting time calculations shall be based on operating conditions specified in Material Requisition eg. open valve condition/closed

Format No. EIL-1650-687H Rev.3 Copyrights EIL - All rights reserved
Page 1624 of 2065

Atmospheric condition Altitude Location
Humid & highly corrosive < 1000 m Outdoor
> 1000 m Indoor
Voltage Voltage Duty Fault level Starting method Earthing No.of terminals
3.3 kV ±6% Continuous 20 kA D.O.L. Direct 3
6.6. kV ±10% 25 kA V.S.D. Resistance 4
11 kV 40 kA Star-delta 6
N.A. Auto transformer
Insulation Class Area Class Gas group Area Classification IP

B Zone 1 IIA Ex(n) IP 23
F Zone 2 IIB Ex(e) IP 44
H Divn. 1 IIC Ex(d) IP 55
C Divn. 2 IIB/IIC
A
B
C
D
Std. Spec. color C&D RTD/BTD
EIL spec. 6-51-0031 632 as per IS 5
Frequency Frequency2 Cooling Cable Type

±3% 50 Hz IC401 Al. cond. XLPE insulated
±5% 60 Hz IC511 Cu. cond. XLPE insulated
IC611
Format No. EIL-1650-687H Rev.3 Copyrights EIL - All rights reserved
Page 1625 of 2065

DOCUMENT No.
DATA SHEET B001-302-16-50-DS-9016
LIGHTING FIXTURE SCHEDULE Rev.A
Page 1 of 6
DATASHEET
LIGHTING FIXTURE SCHEDULE
Rev. Prepared
Date Purpose Checked by Approved by
No by
Page 1626 of 2065

DOCUMENT No.
DATA SHEET
LIGHTING FIXTURE SCHEDULE B001-302-16-50-DS-9016
Rev.A
Page 2 of 6
Type of fixtures Description Watt

INDIX Mounting rail type fixture suitable for 1x36W 1x36W
fluorescent lamp made of MS sheet steel
housing
IND2X Similar to IND1X but suitable for 2x36W lamps 2x36W
IND3X Industrial type fixture suitable for 1x36W 1x36W
fluorescent lamp made of MS sheet steel
housing and vitreous enamel reflector
IND4X Similar to IND3 but suitable for 2x36W 2x36W
fluorescent lamps.
OUTDOOR TYPE FIXTURES

ST2X Street lighting fixture suitable for 2x18W
fluorescent lamps with MS sheet housing stove
enameled grey outside and white inside, a pair
of stainless steel reflectors and highly
transparent clear acrylic sheet cover with hinge
and toggle fastening, neoprene gaskets and
integrated prewired ballasts etc.
ST3X Street lighting fixture suitable for 70W HPSV 1x70W
lamps with MS sheet housing stove enameled
grey outside and white inside, a pair of
stainless steel reflectors and highly transparent
clear acrylic sheet cover with hinge and toggle
fastening, neoprene gaskets and integrated
prewired ballasts etc.
ST10X Single piece die-cast MS sheet steel body 1x150W
street light with bowl type stainless steel
reflector and with clear acrylic cover suitable
for 150W SON tubular lamp
BK3X Industrial well glass fixture with cast iron 1x100W
painted body with high grade epoxy paint with
grey outside and white inside having cast iron
mounting piece, sheet steel vitreous enameled
reflector with white inside and grey outside with
heat resistant glass and wire guard suitable for
upto 100W GLS/160W MLL
BK4X Similar to BK3X but suitable for 70W HPSV 1x70W
lamp with necessary control gear and housing
attachment with reflector
FD1 Flood lighting fixture suitable for 250W HPMV 1x250W
lamp comprising of anodized aluminum
housing and reflector with adjustable lamp
holder, heat resistant front glass cover fixed to
reflector by aluminum ring and rubber gasket
(IP-54 enclosure)
FD1X Same as FD1 but suitable for lamp of 150W 1x150W
HPSV body of MS (asymmetrical) MS powder
coated reflector and fixture suitable for NaOH
atmosphere.
FD10 Similar to FD8 but suitable for 1x250W SON 1x250W
tubular lamp
Page 1627 of 2065

DOCUMENT No.
DATA SHEET
Rev.A
Page 3 of 6
Notes:
1. All fixtures shall be complete with lamps.

2. All fluorescent/Mercury vapour/ Sodium Vapour fixtures shall be high power factor
type.
3. All fixtures shall be fitted with low loss type (i.e. limited to 9W loss) vacuum
pressure impregnated technology copper ballast (VPIT).
4. All fixtures of HPMV/HPSV shall be with integral control gear.
5. All mirror optics luminaires should be epoxy powder coated.
6. All fixtures shall be supplied with cast iron enclosures with stainless steel reflector
only.
Page 1628 of 2065

DOCUMENT No.
DATA SHEET
Rev.A
Page 4 of 6
Particular Specifications for Lighting fixtures and accessories
1.0 General
The fixtures shall be suitable for use in Alumina refinery. Certain fixtures in Alumina
plant shall be suitable for use in atmosphere, which has corrosive gases like sodium
hydoxide and acid vapours in different degree of saturation in the plant.
Since the corrosion of Aluminium metal is very rapid in the presence of Sodium
Hydroxide, it is of utmost importance not to use aluminium components and if not
absolutely possible the to provide special protection to all aluminium components used
in lighting fixtures such as starters, lamp caps of fluorescent and incandescent lamps.
2.0 Supply system

All lighting fixtures shall be suitable for 240V+6%, single phase, 3 wire, 50Hz+3%
supply system derived from 415V, 3 phase, 4 wire supply system having solidly
earthed neutral. All fixtures with incandescent lamps shall also be suitable for 110V
+10% DC supply.
3.0 Constructional features
3.1 All lighting fixtures shall be supplied with lamps, chokes, starters, capacitors (wherever
required) with complete inside wiring and hardwares. Fixtures with sodium vapour
lamps shall be supplied with suitable external electronic ignitors.
3.2 All hardwares shall be of stainless steel
3.3 Clear/Opal Acrylic sheet covers wherever used shall be of very high quality. Thickness
for plain sheet shall be 2.5mm and that of moulded version be 3.0mm Cast Acrylic
sheet shall not be used.
3.4 Lamp holders for lamps other than fluorescent shall be screw type and shall be of
internationally acceptable standards and so constructed as to cause no ill effect to the
electrical contact due to vibration impact etc.
3.5 All terminals shall be clamping type suitable for terminating 1.5 mm 2 PVC insulated
copper wire of 2.5mm2 PVC insulated copper armoured cable. The terminals shall be
such that they do not produce arc or spark under normal condition of operation.
3.6 Control gearboxes for all high bay (HB type), flood ligh fixtures (FD type) and bulk head
fixtures (BK type) shall be non integral. Each control gear box shall be complete with
three nos. of 3/4'” ET threaded cable entries and shall also be provided with double
compression nickel plated brass cable glands.
3.7 All lighting fixtures suitable for discharge lamps shall be provided with one ¾” ET
threaded entry and supplied with double compression nickel plated brass cable glands.
3.8 All lighting fixtures suitable for incandescent lamps shall be provided with two ¾” ET
threaded entries and supplied with double compression nickel plated brass cable
glands.
3.9 The top of all well glass lighting fixtures shall be identically drilled/threaded to facilitate
the installation on pole/column or ceiling.
3.10 Each fixture shall be provided with one earth terminal.
3.11 The temperature rise of the parts of the fixtures shall be limited to the maximum
allowable temperature as per Indian standards.
Page 1629 of 2065

DOCUMENT No.
DATA SHEET
Rev.A
Page 5 of 6
3.12 Fixtures shall be provided with antivibration/padding at suspension. fixing point. These
paddings shall be made of corrosion resistant high density synthetic rubber (Applicable
for high bay fixtures and totally enclosed anticorrosive type fixtures).
3.13 The stove enamel/epoxy/vitreous enamel colour shade shall be light grey as per IS 5
4.0 Fluorescent fixtures for indoor area (IND1X, IND2X, IND3X, IND4X)
4.1 The channel body of fluorescent fixtures shall be made of heavy gauge sheet steel
(22SWG) and it shall be provided with epoxy paint (on both inside and outside).
4.2 The choke boxes and other auxiliaries of the fluorescent lamps shall be housed on the
channel itself.
4.3 The pin holders of the fluorescent lamps shall be of die cast porcelain with synthetic
rubber gasket to cover the lamp caps so as to prevent ingress of dust in the holders.
4.4 The reflectors of the fluorescent fixtures shall be of high quality vitreous enameled
sheet steel of heavy guage (20SWG), white inside and grey outside.
5.0 Weather proof Well glass Fixtures for corrosive atmospheres (BK4X/BK3X)
Construction of weatherproof well glass fixture shall comprise of cast iron body with
high finish epoxy paint with vitreous enamel reflector made of heavy gauge steel (20
SWG). The fixture shall be provided with aminimum 3 mm dia. duly painted with anti
corrosive paint steel wire cage meshing.
Glass used shall be slear and suitable for use under the conditions involving
exceptional risk of mechanical strength. Perfect gasketing shall be done with neoprene
ti ensure weather proofness.
5.1 Housing of Control gears: -

The capacitor capsule shall be housed in MS box with hinged door with proper slot for
cable entries through brass brushing and cable gland.
The box shall be fabricated with 16SWG MS sheet steel duly pretreated and painted
with epoxy paint. Proper gasketing shall be provided on the door leaf to prevent the
entry of dust and corrosive vapours. The size of the box should be sufficient to take
care of heat dissipation.
6.0 Street lighting fixture (ST3X & ST10X)

Fixture shall be integral type suitable for sodium vapour/mercury vapour (the wattage
required). The body shall be rugged type made of MS.Front cover shall be of moulded
clear acrylic sheet fitted in the groove with neoprene gasket for perfect weather
proofness. The reflector shall be made of stainless steel.
7.0 Flood light fixtures for corrosive areas (FD1X, FD2X)

The flood light fixtures shall be suitable for use in corrosive and dusty atmosphere. The
body shall be of mild steel and painted with epoxy. The reflector shall be made of MS
with epoxy powder coating with high reflectance surface and gasketted toughened
front glass cover. Cable entry to the fixture shall be from the side and through non-
metallic glands to make it weather and dust proof.
The control gear capsule shall be housed in mild steel enclosure and shall be suitable
for weatherproof execution.
10.0 Accessories
10.1 Ballast for all discharge lamps shall be of copper wound and filled with polyester.
Ballasts for HPMV/HPSV lamps shall have atleast two voltage tappings capable of
connection to 20/240V single-phase 50Hz supply.
Page 1630 of 2065

DOCUMENT No.
DATA SHEET
Rev.A
Page 6 of 6
10.2 The capacitors of appropriate value shall be used for fluorescent HPMV and HPSV
lamps and shall be of high power factor type (0.9). These shall be provided with
discharge resistors for electrical safety.
10.3 Lamp holders for HPMV and HPSV lamps

The lamp holders shall be made of high quality porcelain and shall be suitable for use
with HPMV/HPSV lamps of 150 to 1000W. The holders shall be provided with spring
lock so that the lamp does not get unscrewed due to vibration. The center contact of
the lamp holders shall be of chromium plated brass strip supported by stainless steel
spring, which can withstand temperature rise upto 300C.
‘Phase’ and ‘Neutral’ marking shall be provided on the lamp holder.
10.4 Holders and starters for Fluorescent lamps

The holders shall be made of high quality thermo setting material for optimum utility.
The starter capsule shall be made of aluminium with brass pins.
Page 1631 of 2065

DOCUMENT No.
B001-302-16-50-DS-9017
Rev. A
Page 1 of 4
DATA SHEET - HIGH MAST LIGHTING SYSTEM

Part-I (Data to be filled in by purchaser)
A. Site Conditions
1. Ambient temp. : 47 OC
2. Design ambient temp. : 47 OC
3. Humidity : 100 %
4. Atmosphere : Dusty, tropical & corrosive
5. Altitude above MSL : Less than 1000 m
6. Location : Damanjodi, Odisha
B. System conditions
The equipment and materials to be supplied by the contractor shall be designed for the following power
supply conditions
1. Input supply Voltage : 415V ± 10% TPN

2. Lighting fixture voltage : 240V Phase-Neutral
3. Frequency : 50Hz ± 3%
4. Fault level : 50 KA for 1 second
5. Neutral grounding : Solidly grounded
C. General requirements
1. Height of the mast : 30 Meter

2. Method of operation winch : Both manual and electrical
3. Type of fixture : HPMV/HPSV
4. Fixture wattage : 1 x 400 W (Type-FD-8)
5. No of fixtures on each mast : 12 nos. fixtures, each fixture with 1x400W
tubular lamp
6. No. of layer for fixture arrangement : 1/2
7. No. of fixtures in each layer : 12 nos.
8. No. of aviation fixtures on each mast : 2 nos.
9. Type and rating of aviation fixture : Medium intensity flashing LEDs
11. Feeder pillar loop in loop out facility : Yes/No
12. Area classification : Safe
13. Lightning protection down conductor : Yes
D. Structural design data (To be selected by contractor based on site data)

1. Maximum basic wind speed :
2. Maximum gust speed time :
3. Dynamic loading of high mast for :
wind load

Date Purpose
No by by by
Format No. EIL 1650-2065 Rev.0 Copyright EIL – All rights reserved
Page 1632 of 2065

DOCUMENT No.
HIGH MAST LIGHTING SYSTEM B001-302-16-50-DS-9017

Rev. A
Page 2 of 4
4. Factor of safety for foundation:

a. Overburden in offsite area shall be considered as 50%, if area is unpaved.
b. Factor of Safety for (Dead + Live Load):
c. Factor of Safety for (Dead + Live + Seismic Load):
5. Soil load bearing capacity: To be calculated by contractor
NOTE:
1. For make of equipments/components refer vendor list attached with the MR.
2. Contractor to note that scope of work also includes providing one no. dedicated earth electrode for
each of the high mast lighting system as per enclosed EIL standard no. 7-51-0102 Rev. 4.
3. Synchronous timer with contactor shall be provided in marshalling box of High Mast Lighting System.
4. Contractor to note that in some of the areas hard rocks may be encountered. Contractor shall
accordingly take this into account for carrying out all related civil/structural works.
5. Provision shall be made to enable owner to feed emergency power to the aviation lighting fixtures in
the future. For this purpose the mast shall be complete with cable with min. 2 cores dedicated to the
emergency lighting.
6. One set of recommended tools, tackles and special equipment required for the maintenance of the high
mast lighting system shall be supplied with the equipment.
7. FD-8 type fixture description: Flood light fixture of cast iron housing and spun aluminum reflector
heat resistant glass cover and adjusting facility suitable for 1x400W HPSV lamp. (IP-55 enclosure).
8. Reference model nos. of FD-8 type fixture : Philips MNF-14/400, Crompton FBD-14 & Bajaj BJEF
215.
Page 1633 of 2065

DOCUMENT No.

Rev. A
Page 3 of 4
DATA SHEET FOR HIGH MAST LIGHTING SYSTEM

PART-II (to be filled in by vendor and submitted with bid)
1.0 HIGH MAST STRUCTURE

a) Height of mast : Meters
Type :
Make :
b) Material of construction :
c) Cross section of mast : Polygonal
d) Length of individual section : Top Middle Bottom
e) Thickness of individual section : Top Middle Bottom
f) Base and top diameter :
g) Type of joints :
h) Length of overlap joint :
i) Type of metal protection : Hot dip Galvanized treatment
j) Thickness of galvanization :
k) Size of door opening :
l) Thickness of base plate : mm
m) Size of anchor plate and thickness :
n) Weight of mast including base plate, : Kgs
door, head frame etc.
o) Lightning protection final : Yes
2.0 LANTERN CARRIAGE

a) Material of construction :
b) Diameter of carriage ring (mm) :
c) Buffer arrangement between carriage :
and masts.
d) Load carrying capacity :
e) Total weight of assembly with fittings :
3.0 WINCH
a) Make of winch :
b) Number of drums per winch :
c) Gear ratio/materials :
d) Capacity :
e) Operating speed :
f) Time to raise/lower :
g) Method of operation :
h) Type of Lubrication arrangement :
i) Type of lubricants :
j) Tested load per drum (kg.) :
k) Factor of safety :
l) Positive locking
4.0 STAINLESS STEEL WIRE ROPE

a) Make :
b) Grade :
c) Number of ropes :
d) Material and Construction :
e) Diameter (mm) :
f) Braking load capacity :
Page 1634 of 2065

DOCUMENT No.

Rev. A
Page 4 of 4
g) Factor of safety :
5.0 HIGH MAST TRAILING CABLE

a) Type :
b) Make :
c) Conductor size and insulation :
d) Reference code :
e) Current carrying capacity :
f) No. of cores :
g) No. of circuits :
h) Earthing conductor size :
6.0 POWER TOOL #

a) Model :
b) Make :
c) Input supply :
d) Power rating :
e) Operating speed :
f) Remote control switch PB station :
g) Size and Length of control cable :
h) Time taken for Raising /Lowering :
# EACH HIGH MAST SHALL BE PROVIDED WITH A DEDICATED POWER TOOL.
7.0 TORQUE LIMITER

a) Model :
b) Make :
c) Lifting capacity :
d) Type of tripping device :
8.0 Expected designed life of the mast in years :
9.0 Proven track record for the offered mast : Furnished / Not Furnished
Page 1635 of 2065

DOCUMENT NO.
TECHNICAL COMPLIANCE FORMAT
(ELECTRICAL) B001-302-16-50-TC-9001
Rev. A
Page 1 of 5
TECHNICAL COMPLIANCE (ELECTRICAL)
PROJECT : 2ND RAW WATER INTAKE

PUMPHOUSE & PIPELINE AT DAMANJODI , NALCO
OWNER : NALCO
JOB NO. : B001

Date Purpose
No by by by
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved
Page 1636 of 2065

DOCUMENT NO.
(ELECTRICAL) B001-302-16-50-TC-9001
Rev. A
Page 2 of 5
TECHNICAL COMPLIANCE
DISCIPLINE : ELECTRICAL
DOCUMENT NO. : B001-302-16-50-TC-0001
PROJECT : 2ND RAW WATER INTAKE PUMP
HOUSE & PIPELINE AT DAMANJODI ,
NALCO
OWNER : NALCO
EIL JOB NO. : B001
Notes: -
1. The Bidder shall indicate his reply in the space provided in the
Technical Questionnaire. In case space provided is not adequate,
the reply may be furnished separately under suitably numbered
annexure / attachments duly referred against the comment /
query.
2. The Compliance Statements / Queries are required to be
categorically confirmed / answered by the bidder and the
completely filled in Tech questionnaire shall be submitted together
with the Bid.
Bidder’s Signature and

Stamp
Page 1637 of 2065

DOCUMENT NO.
(ELECTRICAL) B001-302-16-50-TC-9001
Rev. A
Page 3 of 5
Bidder must furnish answers/clarifications/ confirmations of all the following queries and submit
along with offer.
Sl. No. COMPLIANCE STATEMENT / QUERY BIDDER’S CONFIRMATION/ANSWER

1. Confirm that the scope of work shall be
complete in all respects as specified in the
tender document and all other equipment,
materials and work not explicitly mentioned
but nevertheless required to fulfil the
functional requirements shall be deemed to
be included in the scope of Contractor with no
additional cost and times implication to the
owner.
2. Contractor is informed that the detailed offers

from the equipment manufacturer for all
equipment is not required to be furnished in
the Contractor’s proposal at this stage. If any
such details are furnished by the Contractor
in their proposal, these shall not be reviewed
or taken cognisance of at this stage. These
details shall be treated as preliminary and for
reference and record purpose only and shall
not be contractually binding.
Confirm compliance.
3. This Technical Questionnaire with categorical

confirmation against each of the clauses shall
be furnished along with the bid. Deviation, if
any, against the, applicable specifications
and codes duly consolidated at one place.
(Under Exceptions / Deviation list Form).
Please note that Vendor specific deviations
will not be considered .In case no deviations
are furnished, it will be presumed that all
requirements are fully met. Any deviations/
deletions/corrections made by the Contractor
elsewhere will not be taken cognisance of
and all such deviations shall deemed to have
been withdrawn by the Contractor.
Confirm compliance.
4. Confirm that the equipment and components

supplied shall be from one of the approved
vendors given in the in the bid document.
Page 1638 of 2065

DOCUMENT NO.
(ELECTRICAL) B001-302-16-50-TC-9001
Rev. A
Page 4 of 5
along with offer.

5. Confirm that major and critical electrical
equipment shall be ordered on the Vendors
only ensuring equipment meeting the
acceptance criteria wherever specified in the
bid document by furnishing experience record
and type test certificates which shall be
subject to Owner / EIL’s approval.
Confirm Compliance.
6. Duly filled in equipment data sheets,

characteristic curves for the selected
vendor/equipment model shall be subject to
Owner / EIL’s approval to ensure compliance
to bid specification during detailed
engineering stage.
Confirm compliance.
7. Confirm that obtaining approval of CEA /

Electrical inspectorate of state / Other
statutory authorities as applicable for
energisation of electrical installation is
included in the scope of bidder.
8. Confirm that copies of valid type test

certificates, applicable for the offered HV, MV
switchboards are available. If valid certificates
are not available, confirm that type tests
would be conducted on switchboards before
delivery without time and cost implication
9. Confirm that all Inspection & acceptance,

type Tests as required for each equipment,
as per the Engineering Design basis and as
per specification and Codes attached and
referred to have been included by the
Contractor in his proposal.
10. Confirm that Operation and Maintenance

spares required for the two years of normal
operation for all equipment along with unit
prices and quantities as recommended by the
equipment manufacturer has been quoted.
11. Confirm that commissioning spares, as

required for each equipment, have been
included in the proposal.
Page 1639 of 2065

DOCUMENT NO.
(ELECTRICAL) B001-302-16-50-TC-9001
Rev. A
Page 5 of 5
along with offer.

12. Confirm that Special Tools and Tackles, as
required for each Equipment, have been
13. Confirm that substation of adequate size has

considered by you, considering the
dimensions of equipment such as
switchgears, transformers, etc. In case size of
buildings needs to be increased, the same
shall be considered during detail engineering
by the Contractor without any cost and time
implication to Owner.
14. Furnish the average and maximum power

consumption(normal & emergency)
requirement for the package with break up of
electrical loads.
15. Confirm that all consumables for initial

charge and for commissioning have been
16. Confirm that all Drawings / Data

requirements as per scope of work and as
per specifications and codes attached and
referred to have been included.
17. Rating and number of equipment as shown in

the single line diagram are indicative and are
minimum. Confirm that required numbers of
adequately rated equipment with spare
capacity, quantities of feeders etc. including
spare feeders as per specifications shall be
provided without price and time implication to
Owner/ EIL. However minimum number of
equipment and their rating shall be as per
single line diagrams (enclosed with the
package) shall be maintained.
Page 1640 of 2065

DOCUMENT No.
SCOPE OF WORK
(CP SYSTEM) B001-000-16-50-CPS-01 Rev. A
Page 1 of 16
SCOPE OF WORK
(CP SYSTEM)
2ND RAW WATER INTAKE PIPELINE
PROJECT : 2nd RAW WATER INTAKE PUMPHOUSE AND
PIPELINE
OWNER : M/S NALCO
PMC : ENGINEERS INDIA LTD.
JOB NO. : B001
A 21.12.16 Issued for Comments PTR NSB NSB
Rev.
Date Purpose Prepared by Checked by Approved by
No
Page 1641 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 2 of 16
INDEX OF CONTENTS
SL. NO. DESCRIPTION
1.0 INTRODUCTION
2.0 SCOPE OF WORK FOR CP SYSTEM
2.1 SCOPE OF WORK FOR TEMPORARY CP SYSTEM (TCP)
2.2 SCOPE OF WORK FOR PERMANENT CP SYSTEM (PCP)
2.3 SCOPE OF DESIGN & ENGINEERING
3.0 SCOPE OF SUPPLY
4.0 AS BUILT DRAWING & DOCUMENT
5.0 OWNER’S SCOPE OF SUPPLY
6.0 LIST OF ATTACHMENTS
ANNEXURE-I: IDENTIFICATION OF DIFFERENT CABLES
ANNEXURE-II: QUALITY ASSURANCE PLANS/ PROCEDURE
ANNEXURE-III: COATING CONDUCTANCE TEST
ANNEXURE-IV: PIPELINE SCHEMATIC DIAGRAM REFERS DRG.NO. B001-000-83-41-

30001 Rev A
Page 1642 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 3 of 16
ABBREVIATION
AC : Alternating Current
A/G : Above Ground
ACDB : Alternating Current Distribution Board
AJB : Anode Junction Board

CP : Cathodic Protection
CPTR : Cathodic Protection Transformer Rectifier
CTSU : Computerized Test Station
CJB : Cathode Junction Box
CPL :Close Potential Logging
CAT ;Current Attenuation Test
DCVG :Direct Current Voltage Gradient
DCDB : Direct Current Distribution Board
DC : Direct Current
DT : Dispatch Terminal
ER :Electrical Resistance
GCC :General Condition of Contract
GSM : Global System for Mobile communications
HV : High Voltage
HVDC : High Voltage Direct Current
HDPE :High Density Polyethylene
HMWPE : High Molecular Weight Polyethylene
IPS : Intermediate Pigging Station
MMO : Mixed Metallic Oxide
PCP :Permanent Cathodic Protection
PE : Polyethylene
PVC : Polyvinyl Chloride
RFP ;Request For Purchase
ROU : Right of use
RT : Receipt Terminal
RTU : Remote Transmission Unit
SCC : Special Condition of Contract
SCADA :Supervisory control and Data Acquisition
SV : Sectionalizing Valve
TCP :Temporary Cathodic Protection
Page 1643 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 4 of 16
1.0 INTRODUCTION
M/s National Aluminium Company Ltd. (NALCO) proposes to lay 17 km* (approx.) long
raw water pipeline from proposed new 2nd water intake at Kerandi river to existing
storage reservoir at treatment plant, as an additional water of approx. 580 m3/hr or
3MGD is required to meet the water supply demands for various purposes of the refinery
& its township at Damanjodi in the state of Odisha. This required quantity is proposed to
be tapped from Kerandi River by constructing second Intake System (Intake Well) there
at.
* The pipeline length shall be decided upon route survey to be executed by Pipeline
Laying Contractor. Approximate margin of ±10% of asserted length of 17km shall be
considered as part of this present tender. Any deviation of pipeline length beyond the
prescribed limit shall be executed on a pro-rata basis.
1.1 Cathodic protection system shall be provided for the above mentioned pipeline.
Enclosed elsewhere: Refer to Schematic Arrangement of Pipelines - Drawing No. B001-

000-83-41-30001.Rev A
1.2 This document covers details of work tendered, Scope of Work, and Scope of Supply
pertaining to Cathodic Protection System for the pipeline. All works and clauses of this
document shall be applicable to all spreads, unless specifically mentioned otherwise.
1.3 This document shall be read in conjunction with Schedule of Rates, List of Attachments,
Specifications, Standards, Drawings and other Documents/ Drawings forming part of
Tender Document.
2.0 SCOPE OF WORK FOR CP SYSTM
i. The CP System contractor shall be Owner/ Consultant approved contractor who shall
carryout the complete Temporary and Permanent Cathodic Protection strictly as per the
scope of work defined in this document and Quality Assurance Plans/ Procedure as per
ANNEXURE –II of this document while the pipeline laying works are going on.
The CP System contractor shall carryout the design, engineering, procurement, supply,
installation, testing, commissioning and survey of TCP and PCP system for pipeline.
The CP System contractor shall also include the services of Owner/ Consultant
approved agency for carrying out interference survey and implementing mitigation
measures against DC, AC interference on pipeline due to proximity of foreign DC
source, AC source/ HV line, etc. Contractor shall follow the standard “BS EN
15280:2013 - Evaluation of A.C. corrosion likelihood of buried pipelines applicable to
cathodically protected pipelines”.
ii. The make of the equipment / materials shall be strictly as per the EIL approved vendor
list.
iii. Contractor shall be responsible for the following:
 The works related to TCP/ PCP such as connection of cables to the pipeline,
installation of sacrificial anodes, laying of polarization coupons, reference cells,
CTSU etc. and laying of HDPE sheets between the pipeline under the scope of
Page 1644 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 5 of 16
work and other foreign pipelines at the crossing locations for providing electrical
isolation for minimizing the pickup and discharge of the CP System current
between the pipelines shall be completed before backfilling of the trench.
 The CP contractor shall carryout the CIPL survey, CAT with ‘A’ frame & DCVG
survey and identify the chainage locations of coating defects / holidays. The
physically verification of the coating defects and repairing of the same shall be
done by the pipeline contractor at no extra cost to the Company.
 The pipeline material required for fabrication of polarization coupons shall be

arranged by the pipeline contractor/ OWNER.
 CP contractor shall submit the TCP design document immediately after award of
contract and shift the required material as per reviewed/ approved design
document as per project schedule.
 The work shall be performed in conformity with the scope and specifications for CP
System mentioned in this tender document. In case of any conflict, the following
shall be the priority:-
a) Scope of work
b) Design basis
c) Data sheets
d) Job specification/ codes/ standards
 Protection current densities for both TCP & PCP for pipeline shall be considered as
follows:
Minimum Protection Current Density
Temporary CP Permanent CP for 30-Year

(µ A/m2) Design Life
(µ A/m2)
25 250
The above current density values for temporary CP system are applicable for
CP system design life up to two years.
 Wherever operating temperatures of U/G pipeline is above 30 deg.C, protection

Current Density shall be increased in minimum by 25% for every 10 °C rise in
temperature over 30 °C up to a temperature of 60 deg.C.
2.1 SCOPE OF WORK FOR TEMPORARY CP SYSTEM (TCP)
2.1.1 a) Corrosion survey, Design, detailed engineering, Supply, installation, testing and
commissioning of the temporary cathodic protection system using galvanic anodes to
protect the external surface of the pipelines mentioned in item (1) above against
corrosion for minimum 24 months or till commissioning of permanent CP system
whichever is later.
b) Within 60 days of lowering of each continuous segment of pipe, it should be protected at

minimum -850mV potential level by Mg anode as part of TCP.
c) Where soil resistivity is 150 ohm-m or more, achievement of -850mV potential level shall
not be mandatory. However, minimum acceptable shift of potential level over and above
Page 1645 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 6 of 16
natural potential at such locations (where soil resistivity is 150 ohm-m or more) shall be
decided by Consultant/ Owner on the case to case basis. For the soil resistivity profile
for the Trunk line & Spur line attached elsewhere in the tender, at locations where soil
resistivity is more than 100 ohm-m, those locations shall be treated as high soil resistivity
areas.
(d) Laying of HDPE sheets between the OWNER’s pipeline and the other foreign pipelines
at the crossing locations for providing electrical isolation for minimizing the pickup and
discharge of the CP System current between the pipelines.
(e) Measurement of soil resistivity along the ROU at TCP anode bed locations, collection of
cathodic protection related data along ROU as per specifications.
(f) AC & DC interference detection using data logger and mitigation of the same due to
proximity of foreign AC & DC source, CP protected foreign pipelines, etc.
(g) Installation of independent sacrificial type CP System considering suitable number of

Magnesium anode (20 Kg net each) at all River crossings/ HDD/ Road/ Railway/
Nallah crossing (in addition to the ICCP system, each 20 Kg Pre packed Magnesium
anode shall be designed for five years design life considering ICCP System is not
existing).
(h) Providing test stations along the pipeline route as per the specifications.
(i) Maintaining and safe keeping of test stations and monthly monitoring of the temporary
cathodic protection system including monitoring of AC and DC voltages till
commissioning of the permanent cathodic protection system.
(j) All work shall be carried out conforming to the Scope of work, Design Basis, Data
Sheets, specifications, standards, drawings, etc., as per the list of attachments for the
CP System documents provided elsewhere in the tender document and provisions of
GCC, SCC.
2.1.2 The following particular requirements shall be considered as additional points in

specification no. 6-45-0027 and 6-45-0028
i) At saline soil Ag/ AgCl reference electrode shall be used and not Zinc electrode.
ii) Zinc ribbon anodes to be installed for protection of carrier pipe inside the casing
pipe along with Bentonite filling at the annular space between casing and carrier.
Discrete Mg anode (quantity as required to achieve -850mV potential level), shall
be connected to casing pipe at the cased crossings in case casing and carrier
pipe is shorted (i.e become in mechanical contact with each other) and the short
is not cleared after filling of Bentonite.
iii) Wherever discrete Magnesium anode shall be considered for the temporary
cathodic protection, average separation distance between each consecutive
anode location along the pipeline route shall be 1Km.
iv) Sacrificial Zinc Ribbon anode of approx size 15mm X 22mm laid in backfill of
Gypsum, Bentonite & Sodium sulphate minimum 100mm on all the sides of
anodes, shall be provided for grounding at HV line crossings/ parallel run at the
high soil resistivity areas, where as for grounding at HV line crossings/ parallel run
at the low resistivity areas discrete 20 Kg Sacrifical Zinc anode with backfill of
Gypsum, Bentonite & Sodium sulphate shall be considered.
Page 1646 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 7 of 16
Number of anodes and length of each type of anode shall be decided as per soil
resistivity values to limit the grounding resistance to 5 ohms max. at each
installation.
v) Test station shall be installed at one side of the road crossing where casing pipe is
not considered for the crossing. In case more than one such road crossing occurs
within 1Km, then only one such road crossing shall be provided with test station.
vii) All TCP cables shall be HMWPE insulated and HMWPE sheathed in place of PVC.
viii) Cable from AJB to TR unit shall be laid in HDPE duct only and for acquisition of
ROU for cable route shall be made as per M/S NALCO sale deed agreement.
2.2 SCOPE OF WORK FOR PERMANENT CP SYSTEM (PCP)
a) Corrosion survey, design, detailed engineering, supply, installation, testing and

commissioning of the permanent cathodic protection system by impressed current
method to protect the external surface of the pipelines mentioned in item (1) above
against corrosion for minimum for 30-35 years.
b) The scope shall include complete permanent cathodic protection system, including
cathodic protection related data collection along the ROU, carrying out the soil
resistivity measurement for anode ground beds.
c) Design of anode ground beds considering size / rating of anode bed not less than
the minimum requirements specified.
d) Providing new CP stations for the pipeline at locations as indicated in data sheet for
impressed current CP system No. B001-000-16-50-CDS-02, and bonding provision
with the existing foreign pipeline,
e) Detection using data logger and mitigation of DC, AC interference due to proximity
of foreign DC source, HV transmission lines, cables, AC ground current, etc. Both
AC & DC interference survey including mitigation to be done for proposed new
pipeline and existing old pipeline along the ROU (if any)
f) Close interval potential logging survey for entire lines and additional survey of CAT
with ‘A’ frame survey at selected locations decided from the abnormally and under
protected areas noticed during close interval potential logging survey, DCVG survey
shall be conducted to identify coating defects/ holiday at the probable defective
areas indicated by CAT survey.
The interference surveys and mitigation shall be carried out for both the pipelines i.e.
proposed and existing. Other CP related surveys for existing pipeline is not
applicable. For proposed new pipeline all CP related survey to be carried out.
g) Conducting coating resistance/ conductance test & current measurement test at

selected locations of pipeline provided with current measurement test stations as per
procedure given vide Annexure-IV of this document,
h) Preparation of commissioning report and as built drawings etc. All work shall be
carried out conforming to the Scope of work, Design Basis, Data Sheets,
specifications, standards, drawings, etc., as per the list of attachments for the CP
System documents provided elsewhere in the tender document and provisions of
GCC, SCC. Also the entire work shall be executed through approved Contractors
only.
Page 1647 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 8 of 16
i) The scope shall include acquisition of land in the name of M/S NALCO by CP
System contractor for anode ground bed & anode junction box, acquisition for right to
use of land in the name of M/S NALCO for 45 years for laying of cables from anode
ground bed to CP station and transfer the title of the same to M/S NALCO by the CP
System contractor. The relocation of others / foreign anode bed causing interference
to M/S NALCO Pipeline (if required) with the approval of foreign pipeline Owner shall
be done by CP System contractor
j) The scope shall also include:
 Disconnection of all the sacrificial anodes before PCP commissioning. After PCP
commissioning TCP may be reconnected, if required at some locations in the
event of detection of localized areas of inadequate protection (hot spot).This will
be only as a temporary measure, till the permanent measures are implemented
by the Contractor to increase the CP potential level at hot spot areas.
 Supply, laying , termination of all the cables of CP System, including all incoming
and outgoing cables from CPTR units, permanent reference cables,
measurement cables, computerized test stations cables, etc as require.
 Supply, installation, testing and commissioning of CPTR units at the CP stations

as indicated in the Design basis No. B001-000-16-50-CDB-01, etc.
k) Provisions for direct/ resistance bonding between the pipelines in the common ROU,
where applicable, shall be provided in the test stations along the pipeline route at an
average interval 1Km and at additional locations wherever required for interference
mitigation.
At all possible locations, the test stations for new pipeline need to be installed
matching with the test station of existing pipeline, for bonding purpose.
l) CPTR units to be installed shall be provided with facilities for sending and receiving
digital and analogue input/ output signals for remote SCADA/ RTU monitoring/
controlling system. Supply, installation and termination of copper conductor PVC
insulated screened cable for sending analogue signals and copper conductor YFY
cable for sending digital signals between CPTR & SCADA system I/O rack shall be
in the contractor’s scope.
m) The CP System contractor shall include the services of Owner/ Consultant approved
agency for carrying out interference survey and implementing mitigation measures
against DC, AC interference on pipeline due to proximity of foreign DC source, AC
source/ HV line, etc.
n) It shall be CP System contractors’ responsibility to verify and ascertain the types of

power supply available at site at CP station location during detail engineering stage.
No change in the quoted price due to change in the types of power supply unit during
the execution of the project shall be admissible.
Proposed total no. of CP stations/ anode ground beds: 02
 Proposed location of CP stations/ anode ground beds for the Pipelines is

as following:
Page 1648 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 9 of 16
Proposed
CP Rating of CPPSM/
location of CP Proposed location of CP
station CPTR unit
station Chainage station
No. V/A DC
(km)
Near proposed Intake
1 0.00
0
Facilities 50V/50A
Storage Reservoir
2 15.00
,NALCO 50V/50A
o) Where soil resistivity is lower at higher depth, deep well type anode ground beds
shall be provided. The soil resistivity values taken both by soil box method and using
Wenner's 4-pin method at 2M interval up to the proposed deep well depth shall be
furnished for deep well type anode ground beds. For each deep well anode bed
minimum 10 Nos. MMO tubular anode (each of 25mm dia. X 1000mm long) shall be
provided. Minimum depth of deep well anode bed shall be 50M & diameter of deep
well shall be 250/ 150mm. Adequate length of top portion of the anode bed shall be
made inactive to achieve remoteness of ground bed to pipeline. In case design
calculations based on soil resistivity at the anode bed or the life of anode bed or
ground bed current output works out to be of higher depth or higher No. of anodes
than the minimum requirement specified, the higher requirements shall be provided.
The unarmored anode tail cables shall be laid in PE conduits.
p) Where soil resistivity is lower at shallow depth, there horizontal type anode ground
bed shall be preferred. Irrespective of the life of anode bed or anode bed resistance
worked out by the design calculations, each anode bed shall contain minimum 10
Nos. MMO tubular anode (each of 25mm dia. X 1000mm long). In case the design
calculations based on soil resistivity at the anode bed or the life of anode bed or
anode bed current rating works out to be of higher no. of anodes than the minimum
requirement specified, the higher requirements shall be provided. Continuous coke
breeze backfill shall be provided for the entire length of anode bed trench of cross-
section 300mm x 300mm. Chain link fencing shall be provided around the ground
bed for all types of anode bed. For deep well anode bed minimum cross section 5mx
5m x 2m chain link fencing to be provided.
q) Three plots shall be identified for each anode bed and investigated individually and
best one of these shall be selected based on the observations/ data. Ground water
depth data shall be collected from Geographic survey of India to ensure that the
anode bed location is appropriate and is in perennially moist environment. The
anode ground bed loop resistance shall be restricted to 1 ohm (max) as specified in
spec.6-45-0028. However, in case of very high soil resistivity at anode ground bed
location, the upper acceptance limit of anode bed resistance may be increased at the
sole discretion of Consultant/ Owner. Any combination of the following alternative
measures may be adopted to limit anode bed loop resistance within 1 ohm limit.
r) The anode tail cable up to AJB shall be Halar/ KYNER type with HMWPE sheathed
and PVDF 1100 volt grade insulated, 7 strands, 10mm2 copper conductor, single
core, unarmored type. This shall be in place of 1x 10 sq.mm PVC insulated and
sheathed cable mentioned in spec.6-45-0029. The unarmored anode tail cables shall
be laid in PE conduits.
In high resistivity areas:
Page 1649 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 10 of 16
 Anode ground bed length may be increased for horizontal type ground beds
and depth of the deep well may be increased in case of deep well type
ground bed.
 Number of MMO Tubular anodes may be 10 No. of 1000mm x 25mm (8A), or

16 No. of 1000mmx16mm (5A), or 20 No. of 500mmx25mm (4A), or 32 No.
of 500mmx16mm (2.5A).
s) In addition to the requirement of Current measurement test station mentioned

elsewhere in the specifications, it shall be installed at all the SV cum CP Station for
measurement of the upstream and downstream pipeline current as well as coating
resistance.
t) In case anode ground bed for foreign pipeline is existing within 100M of the
proposed pipeline ROU and cause interference to proposed pipeline, the ground bed
shall be relocated by the contractor with the consent of the OWNER of the foreign
pipeline.
u) Each CPTR units shall have GPS synchronized current interrupter with 0-99.9
second programmable timer and antenna for synchronized current interruption.
v) For observing various parameters/ indications without opening the door, a

transparent glass cover shall be provided at each CPTR units.
w) The polarization cells shall be of solid state type.
x) Minimum distance between the anode ground bed and the pipeline shall be
considered as 100m. In case design calculations based on soil resistivity of the
anode bed and anode bed current indicates that remoteness of the anode bed shall
be achieved at a distance more than 100M, the same shall be provided within
maximum limit up to 500M. Where land availability for horizontal ground bed with
clear distance of min 100M from pipeline is restricted, deep well type ground bed
with suitable active and inactive lengths may be provided.
y) Supply and installation of the AC / DC power supply cable from the outgoing
terminals of the feeder in the MCC / ACDB/ DCDB of the Electrical substation/
Electrical room/ control room to CPTR at each CP stations shall be included in CP
System contractor’s scope.
z) Computerized test station unit (CTSU) shall have the following feature:
 Simultaneous recording of 3 No. analogue channels.

 Shall be able to generate +ve & -ve sign for recorded PSP values.
 Portable Laptop readers shall be supplied with CTSU for Field downloading
of Data.
 Spare Battery Pack shall be supplied.
 The CTSU shall provide Battery Low alarm.
The CTSU shall be housed in a PVC enclosure of dimensions 130mm X 130mm
aa) At saline soil Ag/ AgCl reference electrode should be used and not Zinc electrode.
bb) All CP System cables for PCP except anode lead cables & SCADA signal cables
shall be HMWPE insulated and HMWPE sheathed.
Page 1650 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 11 of 16
cc) The reference cell and measurement cables between test station and reference
cell, pipeline shall be PVC insulated, aluminium backed by mylar/ polyster tape
shielded, PVC sheathed, armored.
dd) The layout of switchgear/ control room indicating CPTR units/ CPPSMs and
layout of cables inside the switchgear/ control room and inside the SV station/
terminal station areas shall be furnished as part of detailed engineering
document.
ee) Identification scheme need to be provided for the CP System cables as

mentioned vide ANNEXURE-I.
ff) For local monitoring of PSP at the CPTR units, Permanent Ref. cell &
measurement cables HMWPE insulated,, aluminium backed by mylar/ polyster
tape shielded, HMWPE sheathed, armoured need to be supplied and installed
from CJB to CPTR units.
gg) Supply, installation, testing and commissioning of CTSU shall be Contractor

scope. Location shall be decided in consultation with OWNER/ CONSULTANT
during detail engineering.
hh) CP System contractor shall provide current measurement provision along with
PSP measurement at all SV station (where CP station is not available). Also
required Converter for PSP and current output for SCADA connectivity along
with cable to be provided by contractor.
2.3 SCOPE OF DESIGN & ENGINEERING
The scope of design and engineering shall include preparation and submission for
review of CP system design & detailed engineering package, specification for
procurement of CP System equipment/ materials, equipment drawing/ document,
preparation of site engineering drawings and details for installation work wherever
applicable or required by the Owner/ Consultant, and submit to the Owner/ Consultant
for approval.
3. SCOPE OF SUPPLY
All the equipment and materials required for both the temporary and permanent CP
system shall be in the CP System contractor’s scope of supply. All equipment and
materials including cables as required for both Temporary & Permanent cathodic
protection of the pipeline shall be in line with the specifications (specification no. 6-45-
0026, 6-45-0027, 6-45-0029, standard specification, design basis and data sheets.) of
the tender.
4. AS BUILT DRAWING & DOCUMENT
After completion of work CP System contractor shall prepare commissioning report as

well as hard and soft copy of as built drawings & documents both for TCP & PCP. Six
copies of the commissioning report and as built drawings & documents shall be
submitted to Owner and one copy to Consultant for record.
5. OWNER’S SCOPE OF SUPPLY
Nil
Page 1651 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 12 of 16
6. LIST OF ATTACHMENTS
For List of attachment, refer technical section: Attachments/ CP System in this tender
document.
Sl.
Data Sheet No. Rev. Title
No.
B001-000-16-50-CDS-01 Data sheet Sacrificial anode cathodic
1. A
protection system for pipelines
B001-000-16-50-CDS-02 Data sheet Impressed current cathodic
2. A
protection system for pipelines
B001-000-16-50-CDS-03 A Data sheet cathodic protection transformer
3.
rectifier unit (CPTRU)
B001-000-16-50-CDS-04 A Data Sheet for Cathodic Protection Power
4.
Supply Module
B001-000-16-50-CDS-05 A Data sheet computerized Test Station unit
5.
(CTSU)
Sl.
Standard Spec. no. Rev. Title
No.
6-45-0025 Specification for cathodic protection
1.
0 transformer rectifier unit.
6-45-0026 Specification for corrosion survey.

2. 0
6-45-0027 Specification for sacrificial anode cathodic
3.
1 protection system for pipelines.
6-45-0028 Specification for impressed current cathodic

4.
0 protection system for pipelines.
6-45-0029 Specification for eqpt. /material for cathodic

5.
0 protection system for pipelines
Sl. No. Drawing No. Rev. Title

7-45-0601 Pre packed zinc anode
1. 0
7-45-0602 Pre packed magnesium anode
2. 0
7-45-0603 Magnesium ribbon anode
3. 0
7-45-0604 Test station with foundation details
4. 0
7-45-0605 Test station connection schemes
5. 0
7-45-0606 Galvanic anode installation.
6. 0
7-45-0607 Zinc ribbon anode for cased crossing with
7.
0 coated/ painted casing
Page 1652 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 13 of 16
Sl. No. Drawing No. Rev. Title

7-45-0610 Typical construction details of high silicon cast
8.
0 iron anode.
7-45-0612 Shallow anode ground bed (PCP)

9. 0
7-45-0613 Anode lead junction box.
10. 0
NOTES:
1. CP System contractor shall note that the exact cable routing shall be decided at site
based on actual site conditions. Exact cable sizes/ quantities shall be based on electrical
load and actual measured route lengths at site which shall be finalized by CP System
contractor in coordination with Engineer-in-Charge/ OWNER. CP System contractor
shall ensure that there is no shortage of cables at site and procure cables accordingly
and avoid cable straight through joints.
2. CP System contractor shall furnish total bill of materials for both TCP and PCP system
during detail engineering stage for our review and record.
Page 1653 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 14 of 16
ANNEXURE-I
IDENTIFICATION OF DIFFERENT CABLES
Alphabetic & numeric PVC ferrules and following colour cable sleeve need to be
considered at termination for identification of different cables terminated inside Test
Station, AJB, CJB, TR/ CPPSM unit:
SL.NO. DESCRIPTION COLOUR
1. Anode tail and anode cable (Positive header cable) Red
2. Cathode cable, Drainage cable & Negative header Blue

cable
3. PSP measurement cable from pipe Green
4. Reference cell cable Yellow
5. All cable from foreign pipeline (Bonding or PSP Pink

Measurement cable)
6. Grounding cell cable Brown
7. Balance all cable Black
Page 1654 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 15 of 16
ANNEXURE-II
Quality Assurance Plans/ Procedure:
1.1 The CP System contractor shall establish document and maintain an effective Quality
Assurance system as outlined in recognized codes etc. and Quality Assurance Plans
included in Specifications etc. to ensure that the work is performed in a planned,
systematic manner to the best quality standards and properly documented to provide
confidence that materials supplied and/ or work executed and services performed by him
conform to the applicable specifications and all the requirements of contract document
and work executed by him shall perform satisfactorily over the entire period of its life.
The Quality Assurance Systems Plans/ Procedures of the CP System contractor shall
generally cover the following aspects/ details, which shall be furnished by CP System
contractor along with, his detail-engineering package.
i) A Quality Assurance Organogram with curriculum vitae of key personnel

responsible for the Quality Assurance at site and design office.
ii) Complete details pertaining to the responsibility authority and accountability of

the Quality Assurance Organization of the CP System contractor at site.
iii) Equipments, material, Erection, Installation, Testing and commissioning control

plans for quality testing/ inspection etc.
iv) Quality Control of processes such as Pin brazing, anode to cable jointing etc.
v) Control Procedures/ Plans for calibration and safe up-keep of instruments,

gauges and similar testing equipments etc.
vi) Quality audit & Maintenance/ records/ procedures etc.
vii) Other relevant details.
1.2 Quality Assurance System Plans/ Procedures of the CP System contractor shall be
furnished in the form of a QA manual. CP System contractor shall be required to provide
explanation pertaining to the details furnished by him in accordance with provisions
contained in this clause and any further details, as sought for by OWNER/
CONSULTANT. In addition, all the Quality Assurance Programs/ Plans as per
specifications enclosed with the Contract shall be fully complied with by the contractor.
- Precautionary measures to be taken to prevent fire hazard during Pin Brazing to

pipeline for the purpose of cable to pipeline joint as well as during installation,
operation & maintenance of CP System.
- All other information as required in individual job specifications shall be furnished

by the CP System contractor in his detail-engineering package.
Page 1655 of 2065

DOCUMENT No.
SCOPE OF WORK
Page 16 of 16
ANNEXURE-III
Coating conductance test:
1. Post commissioning of the PCP system, Coating conductance survey shall be

done as per procedure given below:
For evaluation of the electrical strength of the coating, after one month of commissioning
of the CP system, Coating Conductance Surveys shall be conducted, to serve as
reference for future comparison. Although the same coating specifications are used
throughout the length of the pipeline, effective electrical strength thereby its ability to
resist flow of current would reasonably vary on account of terrain, construction defects,
soil resistivity along the pipeline length.
For conducting Coating Conductance Surveys, potential (∆V) & current (∆I) shall be
measured at two consecutive current measurement type test stations w.r.t remote earth,
both with current interrupter ‘on ‘ & ‘off” at each measurement point.
The difference of the two (∆I) will be the CP current being collected by this section of the
pipeline. The difference of two (∆V) will be the average change in pipeline potential within
the test section owing the current received from CP system.
The above procedure shall be repeated for all current measurement type test stations for
evaluating coating conductance value for different sections along the pipeline. All the
data obtained shall be handed over to the CONSULTANT/ OWNER & will form part of
technical documentation for commissioning report.
ANNEXURE-IV
PIPELINE SCHEMATIC DIAGRAM: REFER DRG. NO. B001-000-83-41-30001, Rev. 0
Page 1656 of 2065

DOCUMENT NO.
ENGINEERING DESIGN BASIS B001-000-16-50-CDB-01
(CP SYSTEM) Rev. A
Page 1 of 11
CP SYSTEM ENGINEERING DESIGN BASIS

(ELECTRICAL DEPARTMENT)
PIPELINE
OWNER : M/S NALCO
JOB NO. : B001
(M/s NALCO) (M/s EIL)
A 14-12-2016 Issued for Comments PTR NSB NSB
Page 1657 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 2 of 11
CONTENTS
SLNO. DESCRIPTION
1. CP SYSTEM DESIGN BASIS
1.1 TEMPORARY CP SYSTEM (TCP)
1.2 PERMANENT CP SYSTEM (PCP)
2. AVERAGE DISTANCE BETWEEN CONSECUTIVE

CP STATIONS AND THEIR MONITORING SYSTEM
2.1 SPECIAL REQUIREMENT FOR SCADA SYSTEM
ANNEXURE-I: SPECIFICATION FOR COLD INSTALLED PETROLEUM JELLY CASING FILLER
Page 1658 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 3 of 11
1.0 CP SYSTEM DESIGN BASIS

This design basis defines the design requirements applicable for this project in addition to the
specification for sacrificial anode cathodic protection system 6-45-0027, specification for
impressed current cathodic protection system 6-45-0028. NACE SP-0169- 2007 & NACE SP-
0177- 2007 and all applicable PNGRB & OISD regulations. In case of conflict, the requirements
mentioned in this document or stringent shall be considered.
1.1 Temporary cathodic protection (TCP) : Within 60 days of lowering of each continuous
segment of pipe, it should be protected at
minimum -850mV potential level by Mg anode as
part of TCP. Where soil resistivity is 150 ohm-m or
more, achievement of -850mV potential level shall
not be mandatory. However, minimum acceptable
shift of potential level over and above natural
potential at such locations (where soil resistivity is
150 ohm-m or more) shall be decided by EIL/
OWNER on the case to case basis. For the soil
resistivity profile for the Trunk line & Spur line
attached elsewhere in the tender, at locations
where soil resistivity is more than 100 ohm-m,
those locations shall be treated as high soil
resistivity areas.
A. Type : Sacrificial magnesium anode

B. Design life : 2 Years or till commissioning of PCP
whichever is later
C. Pipeline coating : External :Three Layer Polyethylene
D. Protective current density at 300C :
Minimum Protection Current Density
Temporary CP Permanent CP for 30-Year

(µ A/m2) Design Life
(µ A/m2)
25 250
The above current density values for temporary CP system are applicable for CP
system design life up to two years.
Where operating temperatures of U/G pipeline is above 30 deg. C, such as CP Stations located
near Compressor stations, protection Current Density shall be increased in minimum by 25% for
every 10 °C rise in temperature over 30 °C up to a temperature of 60 deg.C.
E. Anode material (for sacrificial CP system): Zinc (1.1 V) / low potential

Magnesium (1.55 V)
F. Polarisation coupons : Shall be provided as per

spec.6-45-0027 (pre-determined
locations)
Page 1659 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 4 of 11
a. Size of exposed area of : 100mm x 100mm

coupon
b. No. of coupons: Three and Location in consultation with

OWNER/ EIL ( 1 no. Each for each
section)
c. No. of magnet devices for : -DO-

operation of magnetic reed switch
G. Polarisation cell : Solid state type
H. Additional tests to evaluate the : Shall not be conducted for TCP

coating defects
I CPL survey : Shall not be conducted during TCP.
J DC interference & AC induced

voltage survey : Shall be conducted during TCP stage for
DC interference areas and HT crossings
(33 kV and above), reading shall be taken
for 24 hrs at 60 seconds interval.
K. Test stations : Test stations shall be provided at an

average distance of 1Km interval along the
pipeline ROW for monitoring the
performance of the cathodic protection
system. The following locations shall also
be considered for Test stations:
a) At the locations of TCP anodes.
b) At both sides of metalled road crossings where cased crossing is considered for
the crossing. At one side of the road crossing where casing pipe is not considered
for the crossing. In case more than one such uncased road crossing occurs within
1Km, then only one such uncased road crossing shall be provided with test station
within 1Km.
c) At all insulating joints.
d) At locations of reference cells, surge diverters, polarisation coupons, Electrical

Resistance probes, pipeline grounding through polarisation cells, zinc and
magnesium anodes.
e) At both sides of railway line crossings & both sides of Canal in case width greater
than 50 meter.
f) At both sides of major river crossings.
g) At EHV/ HV AC/ DC overhead line crossings and along routes where EHV/ HV
overhead line are running in parallel.
h) In the vicinity of DC networks or grounding systems and HVDC grounding
systems where interference problems are suspected.
i) At crossings of other pipelines/ structures.
Page 1660 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 5 of 11
j) Locations where interference is expected.

k) At locations of (SV/ IP/ DT/ RT) stations.
l) Current measurement test station for each leg of each SV cum CP stations.
m) At any other locations considered necessary by OWNER/ OWNER's
representative.
The test station locations mentioned above shall override the same mentioned vide
cathodic protection system standard 6-45-0027.
1.2. Permanent Cathodic Protection System (PCP)
A. Type : Impressed current type
B. Design life of protection : 30-35 Years
C. Pipeline coating : Three Layer Polyethylene
D. Design protection current density : Refer item D of TCP
E. Current drainage & coating

resistance measurement survey : Shall be carried out
F. Type of Anodes for anode ground : Tubular Mixed Metal Oxide (MMO) Titanium
bed
G. Computerised test stations (CTSU) : Shall be provided
a. No. of computerised test stn : 1 no.s CTSU

(And location of CTSU in consultation
with OWNER/ EIL by CP Contractor)
b. No. of computerised test : One for each CTSU

station readers/ portable data
collection & storage
instruments.
c. Interval for data acquisition/ : Once every day

storing
H Polarisation coupons : Refer item F of TCP
I Polarisation cell : Solid State Type
J. Acquisition of land for : By CP system contractor

Anode ground bed in the name of Owner
including installation of anode junction
boxes (AJB) and ROU for anode ground
bed cable laying between AJB & TRU
Page 1661 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 6 of 11
K. Chain link fencing around the ground: Shall be provided as per anode ground bed size.
bed
L. Close interval potential logging survey: Shall be carried out by CP contractor
M. Additional tests to be conducted for : CAT survey followed by DCVG

identifying pipe coating defects/
holidays
N. Proposed location of Anode Ground

bed (For impressed current CP System)
at proposed CP stations/ : To be decided by CP system contractor
based on detailed engineering, EIL
specification and at availability of power
source & land. At each CP Station
location soil resistivity shall be measured
up to 50m depth for 3 plots, for selection
of the anode bed for the lowest resistivity
plot. Horizontal shallow depth anode bed
shall be considered where soil resistivity
up to 2m depth is lower compared to
higher than 2m depth, deep well anode
bed shall be considered where soil
resistivity at higher than 2m depth is
lower compared to surface soil resistivity
up to 2m depth.
O. Proposed location of : To be decided by CP contractor

Computerised test stations/ during detail engineering based
Polarisation Coupons on EIL specifications and in
consultation with the Client.
Q. CP stations/ anode ground bed for Impressed current system:-

a) CP stations shall be located coinciding with SV/ IP/ DT/ RT stations, as far as
possible.
b) At dispatch terminals & Receipt Terminal, SV cum CP stations, IP cum CP
stations, power supply to PCP system shall be through transformer rectifier unit
fed from UPS. However, for locations where grid power is not available,
cathodic protection power supply module (CPPSM) will be provided with solar
& battery as power source.
R. Additional requirements (if any):

i) External Corrosion Sensing probe and reader should be very sensitive even to read
minute corrosion rates to a tune of 1 mil per year.
ii) For each IP,SV,DT/RT stations, insulating joint (IJ) shall be provided by EPC contractor
for isolating the incoming Trunk line / Spurline, outgoing Trunk line / Spurline, including
Compressor stations, existing consumer tapping (whichever is applicable) from the
station piping, earthing grids/ pits etc.
Page 1662 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 7 of 11
iii) For protection of the carrier pipe inside casing pipe, any one of the following two
alternative options shall be considered by the pipeline CP system contractor. The
selection of any of the alternative options shall be as per sole discretion of EIL/
OWNER:
 Zinc ribbon anodes to be installed for protection of carrier pipe inside the casing pipe
along with Bentonite filling at the annular space between casing and carrier. Discrete
Mg anode (quantity as required to achieve -850mV potential level), shall be connected
to casing pipe at the cased crossings in case casing and carrier pipe is shorted (i.e
become in mechanical contact with each other) and the short is not cleared after filling
of Bentonite.
 Petroleum jelly (as per ANNEXURE-I or equivalent) filling at the annular space between
casing and carrier without installation of zinc ribbon & discrete Mg anode.
iv) At alternate SV station, current measurement provision along with PSP

measurement to be provided. Converter for PSP and current output for SCADA
connectivity along with cable to be provided by CP contractor.
v) The pipeline shall be grounded through polarization cell with Zinc galvanic anode,
wherever the pipeline is either crossing or running in parallel with overhead EHV/ HV
transmission lines of voltage grade 33 KV and above.
vi) Further additional requirements (if any) shall be included during detailed
engineering stage, if required.
2. Average distance between consecutive CP Stations and their monitoring

system:
Average distance between consecutive CP Stations shall be considered between
15-20 Km for the entire CP System project. All CP Stations & CTSU shall be
centrally monitored from pipeline SCADA system.
2.1. Special requirements for SCADA input:

(I) For CPPSM UNIT:
SL. DESCRIPTION MONITORING (M) DIGITAL (D) / NO. OF TAG NO.

No. / CONTROL (C) ANALOGUE A) SIGNALS
1 CPPSM OUT PUT VOLTAGE M AI 1 CPPSM-V
2 CPPSM OUT PUT CURRENT M AI 1 CPPSM-A
3 PIPELINE OVER PROTECTED M DI 1 PL-OV

PIPELINE UNDER
4 M 1
PROTECTED DI PL-UV
Page 1663 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 8 of 11
SL. DESCRIPTION MONITORING (M) DIGITAL (D) / NO. OF TAG NO.

No. / CONTROL (C) ANALOGUE A) SIGNALS
ALL REFERENCE CELLS
5 M DI 1 REFC-F
FAILED
REFERENCE CELL-1
6 M AI 1 REFC1-V
VOLTAGE
REFERENCE CELL-2
7 M AI 1 REFC2-V
VOLTAGE
8 CPPSM IN AUTO MODE M DI 1 CPPSM-AU
CPPSM-
9 CPPSM IN MANUAL MODE M DI 1
MAN
CURRENT INTERRUPTER
10 C DO 1 CI-ST
START
CURRENT INTERRUPTER
11 C DO 1 CI-STP
STOP
CURRENT INTERRUPTER
12 C DO 1 CI-RST
RESET
(II) For CPTRU:
SL. DESCRIPTION MONITORIN DIGITAL (D) NO. OF

No. G (M) / SIGNALS TAG NO.
/CONTROL ANALOGUE
(C) (A)
1 CPTR OUT PUT VOLTAGE M AI 1 CPTR-V
2 CPTR OUT PUT CURRENT M AI 1 CPTR-A
3 PIPELINE OVER PROTECTED M DI 1 PL-OV

PIPELINE UNDER
4 M 1
PROTECTED DI PL-UV
ALL REFERENCE CELLS

5 M DI 1 REFC-F
FAILED
REFERENCE CELL-1
6 M AI 1 REFC1-V
VOLTAGE
REFERENCE CELL-2
7 M AI 1 REFC2-V
VOLTAGE
8 CPTR IN AUTO MODE M DI 1 CPTR-AU
9 CPTR IN MANUAL MODE M DI 1 CPPSM-MAN
CURRENT INTERRUPTER
10 C DO 1 CI-ST
START
CURRENT INTERRUPTER
11 C DO 1 CI-STP
STOP
CURRENT INTERRUPTER
12 C DO 1 CI-RST
RESET
Legend:
1 AI :Analogue monitoring signal from Equipment to PLC/ Telemetry

interface cabinet (TIC)
Page 1664 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 9 of 11
2 AO: Analogue control signal from PLC/ (TIC) to Equipment
3 DI: Digital Monitoring signal from Equipment to PLC/ (TIC)
4 DO: Digital control signal from PLC/ (TIC) to Equipment
Notes:
1 For any control signal the signal shall be available from SCADA for
less than 2 seconds only.
2 The rating of the potential free contact for digital input and output
signals from Equipment/ PLC/ RTU shall be 24 V DC, 1.5 A DC.
Analogue signals shall be 4-20 mA, galvanically isolated.
3 Provision for minimum two nos analogue and two nos of digital input
signal to SCADA System shall be available for future use.
4 Provision for monitoring of current measurement with PSP

measurement at alternate SV station to SCADA System.
Page 1665 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 10 of 11
ANNEXURE-I
Specification for Cold Installed Petroleum Jelly

Casing Filler
Page 1666 of 2065

DOCUMENT NO.
(CP SYSTEM) Rev. A
Page 11 of 11
Petroleum wax-based corrosion preventive compound, to be considered to fill the pipeline

casing annulus, It shall be specifically designed for pumping at the casing annulus at
ambient temperature. It should remain in a firm gel condition at ground temperature. It
should displace the existing water (if any) present inside the casing also it should prevent
water from re-entering, for mitigating galvanic and atmospheric corrosion for the carrier
pipe inside the casing pipe at the cased crossings.
Specifications:
Color........................................ ......................dark brown.

Specific Gravity @ 60°F...................................80 to 90
Pour Point.........................................................80 to 100°F
Flash Point........................................................300°F
Dielectric constant............................................2.1 to 2.5
Page 1667 of 2065

DATA SHEET FOR DOCUMENT No.
SACRIFICIAL ANODE CATHODIC B001-000-16-50-CDS-01 Rev A
PROTECTION SYSTEM FOR PIPELINES Page 1 of 8
DATASHEET FOR
SACRIFICIAL ANODE CATHODIC PROTECTION
SYSTEM FOR PIPELINES
(CP SYSTEM)
PIPELINE
OWNER : M/S NALCO
JOB NO. : B001
Rev.
No
Format No. EIL 1641-1924 Rev. 1 B001-000-16-50-CDS-01 RA Copyright EIL – All rights reserved
Page 1668 of 2065

SACRIFICIAL ANODE CATHODIC B001-000-16-50-CDS-01
PROTECTION SYSTEM FOR Rev A
PIPELINES Page 2 of 8
DATA SHEET
SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES

PART I
(PURCHASER SPECIFIED DATA)
1. Type of coating for the pipelines : 3 Layer Polyethylene/ Coal tar enamel with 3 coat,
2 wrap / Fibre bonded epoxy /
2. Type of CP system : Permanent / Temporary using sacrificial anodes
3. Design life of protection :
- Temporary CP system : 2 years or till commissioning of PCP, whichever
is later
4. Design protection current density : As per cathodic protection system standards
6-45-0027 & 6-45-0028.
5. Corrosion survey data : Enclosed / Corrosion survey shall be conducted by
contractor
6. Type of sacrificial anode : Zinc / Magnesium low potential type (-1.55V) /
magnesium high potential type (1.75V)
7. Electrical Resistance Probes : Shall be provided for marshy areas and water
logged areas / Not required.
7.1 Quantity of E/R Probes : Please refer to Design Basis for CP system No.
B001-000-16-50-CDB-01(see note No. vi. below)
7.2 No. of E/R probe reading : Please refer to Design Basis for CP system No.
instrument B001-000-16-50-CDB-01
8. Polarisation coupons : Shall be provided
8.1 Size of exposed area of coupon : Please refer to Design Basis for CP system No.
B001-000-16-50-CDB-01 (also see note No. vi.
below)
8.2 No. of coupons : -Do-
8.3 No. of magnets for operation : -Do-
9.0 Close interval ‘ON’/‘OFF’ potential : Shall not be carried out / not be carried
Survey out during TCP
At DC interference prone areas and high induced voltage areas at EHV/HV transmission
lines (33KV & above) crossing/running in parallel / foreign pipeline either crossing
readings shall be taken using data logger for 24 hours at 1 minute interval or as required.
10.0 Additional tests to be conducted : Pearson survey / CAT with ‘A’ frame or
for identifying pipe coating DCVG survey / Not required
defects /holidays during TCP
11.0 Indicative Design data for sacrificial anodes ground bed (see note ‘v’ below)
Page 1669 of 2065

11.1 To be filled by CP contractor

Chainage Pipeline Pipeline Type of Anode material Anode type Anode ground No. of
S.No Dia Wall coating Zinc / Solid/Ribbon bed spacing anodes per
From To thickness Magnesium (clear) from ground bed
KM KM M mm pipeline Nos.
11.2 Details of anodes (By CP Contractor)

- Type : Zinc Magnesium
- Net weight : _ _ _ Kg _ _ _ Kg
- Size :
- Bare : _ _ x _ _ x _ _ mm. __ x __ x __ mm.
min. Min.
- Prepacked : _ _ x _ _ x _ _ mm. __ x __ x __ mm.
min. Min.
11.3 Type of anode installation : Horizontal / Vertical
11.4 Clear distance between individual anodes: ___M
11.5 Clear distance between edge of : 5000 mm min for magnesium anodes / 2000
Pipeline and prepacked anode mm min. for zinc anodes
11.6 Clear distance between edge of : 5M min

Pipeline and Zinc ribbon anode at
HV OH line crossings/parallel running
Notes:
i. Where sacrificial anode system is specified as temporary cathodic protection system,
unless otherwise specified, monitoring of the sacrificial anode cathodic protection
system till the commissioning of permanent CP system shall be carried out by TCP
contractor.
ii. In cases where sacrificial anode CP system is specified as temporary and where both
temporary, permanent cathodic protection works are being executed by the same
agency, activities of permanent CP system which are common to temporary CP system
shall be completed as part of temporary CP system. In cases where temporary and
permanent cathodic protection works are being executed by different agencies, the
contractual scope of work shall be referred for further details.
Page 1670 of 2065

iii. All civil works associated with the complete cathodic protection system are included in
the scope of Contractor. This shall include providing cable trenches and foundations for
all equipment, all test stations, etc.
iv. The design data for anode ground beds and anodes shall be decided by TCP contractor
depending on the protection current requirement of the pipeline as laid.
v. Contractor shall fill up all the data asked for in the ‘Data sheet sacrificial anode cathodic
protection system for pipelines, part-II (to be filled in by the contractor)’ and submit the
same for EIL’s review.
vi. Location of E/R probes and Polarization coupons shall be decided by CP sub contractor
as per specification requirement and in consultation with Owner/EIL during detailed
engineering)
vii. Contractor shall supply necessary instruments, tools and tackles necessary for proper
operation and maintenance of complete cathodic protection system and associated
equipment.
Page 1671 of 2065

DATA SHEET
SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES
PART-II
(TO BE FILLED IN BY THE VENDOR)
1.0 E/R probes

1.1 Make and model no. of E/R probes :
1.2 Material of E/R probes :
1.3 size of the exposed area of the probe :
1.4 Make and model no. of E/R probe :

reading instrument
2.0 Permanent reference electrodes

2.1 Type :
2.2 Make & model no. :
2.3 Design life of electrode under burial : _ _ _ Years

Condition
3.0 Polarisation cells

3.1 Type :
3.3 Maximum DC leakage current at

400 C at
- 1V DC across the Polarisation cell : _ _ _ mA
- 1.5V DC across the Polarisation cell : _ _ _ mA
3.4 50 Hz AC current rating at 400 C

- Continuous : ___A
- Short time : _ _ _ KA for _ _ _ Sec
3.5 No. of operations over life time
under maximum ratings : _ _ _ Nos.
4.0 Polarisation Coupons
4.1 Exposed size of metal :
4.2 Metal type :
4.3 Make and model no. of reed switch :

operator magnet
4.5 Rating of reed switch

4.5.1 Continuous current rating : _ _ _ A DC, at _ _ _ V DC
4.5.2 Breaking current : _ _ _ A DC, at _ _ _ V DC
5.0 Surge Diverters
Page 1672 of 2065

5.1 Type :
5.2 Ratings :
5.2.1 Current, 8/20 micro second wave :
5.2.2 AC spark over voltage
-50 Hz AC :
-Impulse (1.2/50 micro second) :
5.3 Make :
6.0 Cables
6.1 Type :
6.2 Voltage grade :
6.3 Make :
7.0 Cable to pipe connection

-For charged pipeline :
- For non charged pipeline :
7.1 Make and model number of

- CAD weld Material :
- Pin brazing equipment :
8.0 Details of anodes
8.1 Prepacked type
- Anode material : Zinc Magnesium
- Net weight : _ _ _ Kg min. _ _ _ Kg min.

- Size :
- Bare : _ _ x _ _ x _ _ mm. min. __ x _ _ x _ _ mm. Min.
- Prepacked : _ _ x _ _ x _ _ mm. min. __ x _ _ x _ _ mm. Min.
- Make : ___ ___
8.2 Ribbon type

- Anode material : Zinc Magnesium
-Net weight : _ _ _ Kg min per metre _ _ _ Kg min per metre

- Size : _ _ x _ _ x _ _ mm. min _ _ x _ _ x _ _ mm. min
- Make : ___ ___
9.0 Makes
9.1 Test stations:
9.2 Special Backfill for sacrificial anodes :
Page 1673 of 2065

Page 1674 of 2065
FORM-IA
DETAILS OF SPECIFIC EXPERIENCE OF BIDDER* / HIS NOMINATED SUB-CONTRACTOR FOR SACRIFICIAL ANODE CP SYSTEM
(SEPARATE SHEETS SHALL BE FILLED UP FOR EACH JOB/PROJECT HANDELED)
Name of CP sub contractor:
EXPERIENCE DETAILS OF HYDROCARBON HANDLING CROSS COUNTRY PIPELINES
Format No. EIL 1641-1924 Rev. 1

SL. DESCRIPTION LENG- DIAM TYPE TYPE OF NO. OF NAME OF WORK DATE OF DATE OF NAME OF EXPERIENCE
NO. (For Sacrificial TH OF ETER OF PIPE ANODES ANODE PROJECT ORDER COMMEN- COMPL- BACK-UP OF BACK-UP
PIPE OF COAT- GROUND AND NO. (**) CEMENT ETION AGENCY AGENCY
anode CP LINE PIPE ING BEDS FOR OWNER OF WORK OF
System) CONSIDER
LINE THE WORK.
PIPELINE ED
(**)
1 Design and
engineering
experience
PIPELINES
2 Supply of CP
DATA SHEET FOR
equipment/mat
erial
PROTECTION SYSTEM FOR
SACRIFICIAL ANODE CATHODIC
3 Installation of
CP system
4 Testing and
commissioning
Rev A
Page 7 of 8
DOCUMENT No.
Copyright EIL – All rights reserved

B001-000-16-50-CDS-01
* Strike out which ever is not applicable

** Copy of the work order and completion certificate shall be attached
Page 1675 of 2065
FORM-II
*
DETAILS OF SPECIFIC EXPERIENCE OF BIDDER / HIS NOMINATED SUB-CONTRACTOR FOR CP SYSTEM/ BACK UP AGENCY FOR
INTERFERENCE DETECTION AND MITIGATION (SEPARATE SHEET SHALL BE FILLED FOR EACH JOB/PROJECT HANDELED)
NAME OF THE SUB-CONTRACTOR FOR CP SYSTEM:

NAME OF THE BACKUP AGENCY FOR INTERFERENCE DETECTION & MITIGATION:
Format No. EIL 1641-1924 Rev. 1

EXPERIENCE DETAILS OF HYDROCARBON HANDLING CROSS COUNTRY PIPELINES
SL. CAUSE OF LENG- DIAM- TYPE NO. OF CP NAME OF WORK DATE DATE OF DETAILS OF BACK-UP AGENCY, IF
NO. INTERFERENCE TH OF ETER OF STATIONS PROJECT ORDER OF COMPL- HIRED FOR CP INTERFERENCE/
PIPE OF PIPELI- FOR THE AND NO. (**) COMM- ETION MITIGATON
NE OWNER OF
LINE PIPE PIPELINE ENCEM-
COATI- WORK NAME OF EXPERIENCE OF
LINE NG ENT OF BACK UP
(**) AGENCY
WORK AGENCY(***)
1 Cathodically protected
foreign pipelines
crossing/ parallel
running
2 Cathodically
PIPELINES
unprotected foreign
DATA SHEET FOR
pipelines/ structures
crossing/ parallel
PROTECTION SYSTEM FOR
running
3 High voltage line

AC/DC (66KV and
above) crossing &
parallel running
4 AC/DC electrified
traction
Rev A
5
Page 8 of 8
DOCUMENT No.
* STRIKE OUT WHICH EVER IS NOT APPLICABLE

** COPY OF WORK ORDER AND COMPLETION CERTIFICATE SHALL BE ATTACHED
B001-000-16-50-CDS-01
*** LIST OF INTEREFERENCE DETECTION, MITIGATION JOBS DONE ALONG WITH WORK ORDER AND COMPLETION CERTIFICATE SHALL BE ATTACHED
IMPRESSED CURRENT CATHODIC B001-000-16-50-CDS-02
PROTECTION SYSTEM Rev A
Page 1 of 8
DATASHEET FOR
IMPRESSED CURRENT CATHODIC PROTECTION
SYSTEM FOR PIPELINES
(CP SYSTEM)
PROJECT : 2nd RAW WATER INTAKE PUMPHOUSE AND PIPELINE
OWNER : M/S NALCO
JOB NO. : B001
A 21.12.16 ISSUED FOR COMMENTS PTR NSB NSB
Rev.
No
Page 1676 of 2065

IMPRESSED CURRENT CATHODIC
B001-000-16-50-CDS-02 Rev A
PROTECTION SYSTEM
Page 2 of 8
DATA SHEET
IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES

PART-I
(PURCHASER SPECIFIED DATA)
1. Pipeline coating : 3 layer Polyethylene coating

2. Type of CP system : Permanent / Temporary
3. Design life of protection : 30 Yrs
4. Design protection current density : as per cathodic protection system standards
6-45-0027 & 6-45-0028
5. Current drainage & coating : Shall be conducted after PCP commissioning
resistance measurement where current measurement type test stations
are provided along pipeline.
6. Corrosion survey data : Enclosed / Corrosion survey shall be conducted
by CP system contractor
7. Integration of permanent CP with : In the scope of the CP system contractor / Not in
the Temporary & existing CP scope of the contractor.
8. Type of Anodes for anode ground : MMO coated Tubular titanium anode,
bed canistered with petroleum coke breeze
9. Electrical resistance probes : Shall be provided for marshy areas and water
(E/R Probes) logged area as part of TCP activity (Ref to
Design Basis doc No. B001-000-16-50-CDB-01)
10. Computerized test stations : Required
10.1 No. of computerized test stations : Ref to Design Basis doc No. B001-000-16-50-CDB-01
10.2 Data collection interval : -Do-
10.3 No. of computerized test station : -Do-
readers/Data retrieval computer of
portable type for data collection.
11. Polarization coupons : Required / Not required shall be provided as
part of TCP activity
12. Surge diverter across insulation joints: Shall be provided as part of TCP activity / NA
13. Grounding with galvanic anodes : Shall be provided at each 33KV & above HV
through Polarization cells line crossings and at regular intervals of
maximum 1km where EHV/HV transmission
lines run parallel with the pipeline; and at
locations where the AC induced voltage
of 15V or more is observed.
14. Acquisition for right of use of land for : By Contractor
anode ground bed, anode junction
boxes and anode ground bed cable
laying
15. Chain link fencing around the ground : Shall not be provided
bed.
16. Close interval potential logging survey : Shall be carried out
17. Additional tests to be conducted for : Shall be carried out (Also refer Note (xiv)
identifying pipe coating defects/ holidays below)
18. Interference detection & mitigation : Shall be done by CP system contractor for each
Page 1677 of 2065

B001-000-16-50-CDS-02 Rev A
PROTECTION SYSTEM
Page 3 of 8
pipeline
19. Proposed location of new CP stations/ : As per. B001-000-16-50-CPS-01, R0
NB: The proposed location of CP stations shall be confirmed by CP system contractor during
bidding stage.
20. Output of the Existing impressed : NA

current CP stations which shall be
connected/ extended to the new spur
pipelines by bonding with the respective
existing pipelines.
21. Proposed location of Computerized test stations / Polarization coupons:

Location of Computerized test stations, Polarization coupons shall be decided by CP
system contractor as per specification requirement and in consultation with Owner/EIL
during detailed engineering stage)
S.No Locations of Computerized Locations of

test stations polarization coupons
Notes:
i) Unless otherwise specified in project specifications/data sheet, integration of the
permanent impressed current CP system with the sacrificial anode temporary CP
system (whether provided by a different contractor or included along with the
impressed current CP system) shall be the responsibility of the impressed current CP
system contractor whose scope shall include disconnection of sacrificial anodes
wherever required.
ii) The permanent CP system includes certain activities, which are common with the
temporary protection facilities. In cases where temporary and permanent cathodic
protection works are being executed by the same agency, the common activities of
temporary and permanent cathodic protection system shall be completed as part of
temporary cathodic protection system. In cases where temporary and permanent
cathodic protection works are being executed by different agencies, the contractual
scope of work shall be referred for further details.
iii) Obtaining approval certificate from electrical inspectorate for electrical installation
and carrying out any modifications as per the requirement of electrical inspectorate
shall be included in CP system contractor scope.
iv) All civil works associated with the complete cathodic protection system are included
in scope of CP system contractor. This shall include providing cable trenches and
foundations for all equipment, kiosks, anode lead junction boxes, all test stations,
deep well ground beds, etc.
Page 1678 of 2065

B001-000-16-50-CDS-02 Rev A
PROTECTION SYSTEM
Page 4 of 8
v) CP system contractor shall supply necessary instruments, tools and tackles

necessary for proper operation and maintenance of complete cathodic protection
system and associated equipment as per Cl. 23 below.
vi) Contractor shall clearly bring out during bidding stage, the requirement of additional
CP stations/higher rated ground bed, if any, over and above those specified in clause
19 above.
vii) Vendor shall fill up all the data asked for in the ‘Data sheet Impressed current
cathodic protection system for pipelines, part II (to be filled in by the vendor)’ and
submit the same for EIL’s review.
viii) Necessary coordination with pipeline laying contractor shall also be in the scope of
CP system contractor.
ix) Reference cell and measurement signal cables between test stations and TR units
shall be laid in a separate cable trench other than for power/anode/cathode cables.
x) The make of equipment, materials shall be as per EIL approved vendor list.
xii) For specific requirements, refer Design Basis document no. B001-000-16-50-CDB-01
xiii) Anode Ground Bed shall preferably be horizontal type, however type of anode
ground bed finally selected shall be as per soil resistivity data by CP system
contractor.
xiv) CAT and DCVG survey shall be carried out along the route of pipeline where under
protection is found during CPL survey, to identify coating defects/holidays and
complete report shall be submitted to Owner/ EIL. All the identified coating defects
shall be rectified by the pipeline laying contractor.
22. LIST OF ATTACHMENTS
For List of attachment, refer document no B001-000-16-50-CLL-01 attached elsewhere in
this tender document
23. O&M CP Spares:

23.1 O&M CP Spares for TR unit:
Sl. No Description Unit Qty
1. DC Voltmeter Nos. 1
2. DC Ammeter Nos. 1
3. AC Voltmeter Nos. 1
4. AC Ammeter Nos. 1
5. Diodes Nos. 2
6. SCR’s Nos. 2
7. DC Fuses for output side Nos. 6
8. HRC fuse for Diodes Nos. 6
9. AC fuses for input side Nos. 6
10. DC Lightening arrestor Nos. 1
11. AC Circuit breaker(MCB/MCCB) Nos. 1
12. Electronic Control Cards each type Nos. 1
13. Filter circuit capacitor Nos. 2
14. Signal light assembly for annunciation Nos. 2
15. RC Surge Diverter Nos. 1
16. Control transformer Nos. 1
17. voltage control switch Nos. 2
Page 1679 of 2065

B001-000-16-50-CDS-02 Rev A
PROTECTION SYSTEM
Page 5 of 8
18. current control switch Nos. 2

19. Auto Manual Mode selector switch Nos. 1
20. Toggle switches Nos. 1
21. Assorted Glass cartridge fuses Nos. 12
23.2 O&M CP Spares/ Tool / Tackles for CP system :
Sl. No Description Qty

1 4½ Digital multimeter (Fluke make/approved 4 no.
equivalent)
2 Portable Cu CuSO4 ref cells (Mc miller/approved 4 no.
equivalent)
3 AC/DC Clamp ON meter 02 no.
Page 1680 of 2065

B001-000-16-50-CDS-02 Rev A
PROTECTION SYSTEM
Page 6 of 8
DATA SHEET
IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES
PART-II
(TO BE FILLED IN BY THE VENDOR)
1.0 E/R probes NA

1.2 Material of E/R probe :
1.3 Size of the exposed area of the probe :

reading instrument

2.2 Design life of electrode under burial : _ _ _ Years

condition.
3.0 Polarisation cells

3.1 Type :
3.3 Maximum DC leakage current at 400 C at

- 1V DC across the Polarisation cell : _ _ _ mA
3.4 50 Hz AC current rating at 400 C

- Contnuous : ___A
- Short time : _ _ _ KA for _ _ _ sec
3.5 Rated no. of operations over life time

under maximum ratings : _ _ _ Nos.

4.1 Exposed area of metal :
4.2 Metal type :

Page 1681 of 2065

B001-000-16-50-CDS-02 Rev A
PROTECTION SYSTEM
Page 7 of 8
operator magnet
4.5 Rating of reed switch :

-Continuous current rating : _ _ _ A DC, at _ _ _ V DC
-breaking current : _ _ _ A DC, at _ _ _ V DC
5.0 Surge Diverters

5.1 Type :
5.2 Ratings :
5.2.1 Current, 8/20 micro second wave :
5.2.2 AC spark over voltage

-50 Hz AC :
-Impulse (1.2/50 micro second) :
5.3 Make :
6.0 Cables
6.1 Type and voltage grade
-For anode tail cables : ___ /___V
-For other CP cables : ___ /___V
6.2 Make
-For anode tail cables :
-For other CP cables :
7.0 Cable to pipe connection
- For charged pipeline :
- For non charged pipeline :
7.1 Make and model number of
- Cad weld Material :
- Pin brazing equipment :

8.0 Anode type and make
8.1 Impressed current anodes
- Type :
- Make :
Page 1682 of 2065

B001-000-16-50-CDS-02 Rev A
PROTECTION SYSTEM
Page 8 of 8
8.2. Sacrificial anodes make

-Zinc anodes :
-Zinc ribbon anodes :
9.0 Make of
9.1 CPTR unit :
9.2 CPPSM :
9.3 Test stations :
9.4 Anode junction box :
9.5 Cathode junction box :
9.6 Calcined petroleum coke breeze :

-CuCuSO4 type :
-AgAgCl type :
9.8 Special Backfill for sacrificial anodes :
Page 1683 of 2065

DOCUMENT No.
DATA SHEET FOR
CP TRANSFORMER RECTIFIER B001-000-16-50-CDS-03
UNIT (CP SYSTEM, ELECTRICAL) Rev A
Page 1 of 4
DATASHEET FOR
CATHODIC PROTECTION TRANSFORMER RECTIFIER
UNIT (CP SYSTEM)
PIPELINE
OWNER : M/S NALCO
JOB NO. : B001
Rev.
No
Page 1684 of 2065

C P TRANSFORMER RECTIFIER B001-000-16-50-CDS-03 Rev A
UNIT (CP SYSTEM, ELECTRICAL) age 2 of 4
DATA SHEET
CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT
PART - I (TO BE FURNISHED BY PURCHASER)
1. Input power supply * 230V/240 V ± 10 %, 50 Hz ± 3 %, 1 Phase

2. Input power supply fault level Indicated elsewhere in the tender
3. Number of output circuits One/two as required
4. Output voltage (+ve earthed) 0.5 V (min.) DC, 50V (max.) DC
5. Rated output current 50A
6. Pipe to soil potential setting range (Vps) -0.85V - to -2.5V
7. Minimum set potential range (Vrs) -0.4V to -0.9V
8. Maximum pipeline potential range (Vpm) -1.1V to-2.5V
9. Minimum pipeline potential range (Vpn) -0.7V to -1.0V
10. Number of reference cells for control Two
11. Equipment design temperature (IS 9676) 450C
12. Shade of final paint Vendor Standard
13. Commissioning at site By CP system contractor
14. Remote monitoring and control Required (Refer SCADA I/O elsewhere)
15. Type of Control
- Auto Close loop control with PSP of reference
cells in feedback loop (as per clause no. 6.4
of spec. no. 6-51-0025).
- Manual Constant voltage and constant current
mode (CVCC) (as per clause 6.4 of spec. 6-
51-0025.
16 Current Interrupter Required
16.1 Type of current interrupter Mounted in CPTR unit (GPS based timer
interrupters for measuring ON & OFF
potentials shall be provided)
16.2 Interrupter controls (for start, stop, reset) Auto (operation through SCADA) and
Manual
17 Specific requirement (if any)
* CP system contractor shall take confirmation from EIL/Owner regarding the exact voltage of power
supply after placement of order.
NOTE:
1. All Pipe to soil potentials (PSP) measured/set values specified are w.r.t. copper-copper
sulphate half cell.
2. CPTR unit shall be provided with a door having transparent glass cover for viewing various
parameters/indications without opening the door. The type of indicating lamps shall be
minimum 10mm dia. LED type.
3. Separate data shall be furnished for each rating of CPTR unit.
4. The incomer power supply cable shall be sized to limit the max voltage drop in the cable to
5% max subject to min size of 3 X 4 sq.mm copper.
Page 1685 of 2065

PART - II (TO BE FILLED BY CONTRACTOR/VENDOR)
1. Rating of each CPTR unit along ROU
S. Location along CPTR unit output Installation in Size of incomer cable

ROW substation
No rating
building/ in an
outdoor kiosk
Voltage Current
2. Guaranteed technical particulars of CPTR unit.
2.1 Efficiency at 10 % load *

at 25 % load *
at 50 % load *
at 75 % load *
at 100 % load *
2.2 Voltage regulation (Manual mode) * _______ %
(from zero to100 % load variation

and
throughout the output voltage range
(Refer clause 6.4.3 of spec. no. 6-
51-0025)
2.3 Current regulation (Manual mode) * _______ %
(from 0.5 V to100 % output voltage

variation and
throughout the output current range
(Refer clause 6.4.3 of
spec. no. 6-51-0025)
2.4 Closed loop PSP regulation in auto ± ________ mv
mode (refer clause 6.4.3 of spec.
no. 6-51-0025)
2.5 Output ripple at full load current: Auto mode Manual mode
At 10% output voltage * *
51-0025)
3. Technical particulars of Current interrupter
Page 1686 of 2065

3.1 Type of interrupter Mounted with CPTR unit
3.2 Power supply voltage *

3.3 Detail of output Contractor *
Make *
Current rating * A, DC, suitable for the interruption duty.
Voltage rating of coil * V, AC/DC suitable for the interruption duty.
3.4 Timer Details
Make *
Timing range
On 0.1 - 99.9 Sec
Off 0.1 - 99.9 Sec
Timing Accuracy *
* Separate data shall be furnished for each rating of CPTR unit.
Page 1687 of 2065

CATHODIC PROTECTION POWER B001-000-16-50-CDS-04, Rev. A
SUPPLY MODULE Page 1 of 5
DATASHEET FOR
CATHODIC PROTECTION POWER SUPPLY MODULE
(CP SYSTEM)
PIPELINE
OWNER : M/S NALCO
JOB NO. : B001
Rev.
No
Page 1688 of 2065

DATA SHEET FOR CATHODIC DOCUMENT No.
PROTECTION POWER SUPPLY B001-000-16-50-CP-DS-04, Rev. A
MODULE Page 2 of 5
DATA SHEET
CATHODIC PROTECTION POWER SUPPLY MODULE
PART - I
(TO BE FURNISHED BY PURCHASER)
1 Input power supply (-)48V ± 10%,

2 Input power supply fault level Refer elsewhere
3 Number of output circuits One/two as required
4 Output voltage (+ve earthed) 0.5 V (min.) DC, 50V (max.) DC

(see note 2)
5 Rated output current 50 A (see note 2)
6 Pipe to soil potential setting range (Vps) -0.85V - to -2.5V
7 Minimum set potential range (Vrs) -0.4V to -0.9V
8 Maximum pipeline potential range (Vpm) -1.1V to-2.5V
9 Minimum pipeline potential range (Vpm) -0.7V to -1.0V
10 Number of reference cells for control Two /
11 Equipment design temperature (IS 9676) 450C
12 Shade of final paint Vendor Standard /
13 Commissioning at site By CP system contractor

14 Remote monitoring and control Required (Refer SCADA I/O elsewhere)
15 Type of Control
- Auto Close loop control with PSP of

reference cells in feedback loop
(as per clause no. 6.4 of spec. no. 6-51-
0025).
- Manual Constant voltage and constant current

mode (CVCC) having regulated output
voltage at set value of constant voltage
and constant current with current limit
features (as per clause 6.4 of spec. 6-51-
0025.
16 Current Interrupter Required
16.1 Type of current interrupter Mounted in CPPSM unit(GPS based
timer interrupters for measuring OFF
potentials shall be provided)
Page 1689 of 2065

MODULE Page 3 of 5
16.2 Interrupter controls Auto (operation through SCADA)

(for start, stop, reset) and Manual
17 Specific requirement (if any)
NOTE:
1. All Pipe to soil potentials (PSP) measured/set values specified are w.r.t. copper-copper
sulphate half cell.
2. The output voltage, current ratings of CPPSM units and their location along the ROU of
the pipe line shall be as per CP system contractor/vendor data in S.No.1 of Part II of the
data sheet.
3. CPPSM unit shall be provided with a door having transparent glass cover for viewing
various parameters/indications without opening the door. The type of indicating lamps
shall be minimum 10mm dia. LED type.
4. *Separate data shall be furnished for each rating of CPPSM unit.
5. The CPPSM unit will have Built-in Galvanic Isolator to provide complete Electrical
Isolation between Input & Output of the CPPSM unit to enable use of common
Battery Bank for CPPSM and other utilities in the CP station. The CPPSM unit will
also have facility for step-up of voltage output from the CPPSM unit using suitable
DC – DC converter inbuilt in the CPPSM unit, so that it shall be possible to have 0
to 40V DC output from the CPPSM even when operating from a 24 Battery supply.
Page 1690 of 2065

MODULE Page 4 of 5
PART - II (TO BE FILLED BY CONTRACTOR/VENDOR)
1. Rating of each CPPSM unit along R.O.U.
S. Location along CPPSM unit Installation in Size of incomer cable

ROW substation
No output rating
building/ in an
outdoor kiosk
Voltage Current
2. Guaranteed technical particulars of CPPSM unit.
2.1 Efficiency at 10 % load *

at 25 % load *
at 50 % load *
at 75 % load *
at 100 % load *
2.2 Voltage regulation (Manual mode) * _______ %
(from zero to100 % load variation

and
throughout the output voltage range
51-0025)
2.3 Current regulation (Manual mode) * _______ %
(from 0.5 V to100 % output voltage

variation and
throughout the output current range
(Refer clause 6.4.3 of
spec. no. 6-51-0025)
2.4 Closed loop PSP regulation in auto ± ________ mv
mode (refer clause 6.4.3 of
spec. no. 6-51-0025)
2.5 Output ripple at full load current: Auto mode Manual mode
Page 1691 of 2065

MODULE Page 5 of 5

51-0025)
3. Technical particulars of Current interrupter
3.1 Type of interrupter Mounted with CPPSM unit
3.2 Power supply voltage *

3.3 Detail of output by CP system *
contractor
Make *
Current rating * A, DC, suitable for the interruption duty.
Voltage rating of coil * V, AC/DC suitable for the interruption duty.
3.4 Timer Details
Make *
Timing range
On 0.1 - 99.9 Sec
Off 0.1 - 99.9 Sec
Timing Accuracy *
* Separate data shall be furnished for each rating of CPPSM unit.
Page 1692 of 2065

DOCUMENT No.
DATA SHEET FOR
COMPUTERIZED TEST STATION B001-000-16-50-CDS-05
UNIT (CTSU) Rev A
Page 1 of 3
DATASHEET FOR
COMPUTERIZED TEST STATION UNIT
(CP SYSTEM)
PROJECT : 2nd RAW WATER INTAKE PUMPHOUSE AND PIPELINE
OWNER : M/S NALCO
JOB NO. : B001
Rev.
No
Format No. EIL 1641-1924 Rev. 1 B001-000-16-50-CDS-05, RA Copyright EIL – All rights reserved
Page 1693 of 2065

COMPUTERIZED TEST STATION B001-000-16-50-CP-DS-05 Rev A
UNIT (CTSU) age 2 of 3
DATA SHEET
COMPUTERIZED TEST STATION
UNIT (CTSU) (TO BE FURNISHED BY PURCHASER)
Unit : Micro controller based intelligent CP Test Station Data

Monitoring Logger.
Analog Inputs : Logger will have 4 Nos. High accuracy, High Input Impedance,
16- bit resolution Analog channels with high common mode
rejection
ratio (CMRR), as under:
CH-1 : -4V to +4V DC (for DC PSP)
CH-2 : 0V to 25 V AC (for AC PSP Interference Monitoring)
CH-3 : 0A to 100A DC (for Pipeline Current Monitoring)
CH-4 : Battery Level ( For Internal Battery Monitoring)
The typical accuracy of each channel should be ± 1.0% of
F.S.±1 digit.
The PSP Input channels should have Input Impedance of 10
Meg Ohm minimum.
Isolation : All the four channels of the Data Logger should be fully Isolated
from each other.
Local Display : The CTSU Data Logger will have a 2 Line 16 x 2 LCD display for
entering local settings and viewing Test Station parameters
locally.
The LCD Display will display the following Parameters
 DC Reference Potential (PSP)
 AC Reference Potential (AC PSP)
 Pipeline Current
 Battery Level
Following Local settings should be done using the Laptop:
Setting Date/ Time
Setting Start Time for logging .
Setting Periodic logging Interval
Setting field ID of the Data Logger
Programmable : The Periodic Data Logging interval should be programmable

Logging Interval from 1 data sample per Hour to 1 data sample per day. The
logger should log the readings of all four channels
simultaneously.
Data Storage : The CTSU Data Logger should have built-in Non volatile memory
for local storage of Data. It should be possible to store about
250,000 Data readings for each channel i.e. a Total One Million
readings for all four channels in the Local memory of the Data
Logger. Locally stored data should be retained up to 10 years
Page 1694 of 2065

COMPUTERIZED TEST STATION B001-000-16-50-CP-DS-05 Rev A
UNIT (CTSU) age 3 of 3
without any external power.
The locally store data could be downloaded on a field Laptop

reader using the USB communication port provided on Data
Logger. The Data Logger will be supplied with Data downloading
software. The logger software should download the Data in
standard MS Excel sheet
Time Stamping : The Data Logger unit should have a precise and accurate Real
Time Clock (RTC) for exact time stamping of data.
Protection : The Input channels of Data Logger should have full protection
against high voltage surges and continuous over voltages of up
to 500V AC & DC.
Power Supply : The CTSU Data Logger will be a battery operated device and
will
have built-in Internal rechargeable Lithium Battery.
Battery Life : The CTSU Data Logger will be capable of functioning for
inimum
One Year at the logging rate of one log per day on the Internal
Battery, without any need of changing/ re-charging the battery.
A Discharged battery should be fully recharged in 2-4 hours by

means of the rapid charger to be supplied with the CTSU.
Enclosure : The CTSU Data Logger unit should be housed in a compact &
study
non corroding enclosure.
Overall dimensions : 130mm x 130mm x 75mm (Maximum)
Mounting : Wall mounting inside C.P. Test Station
Cable Entry : From Bottom
The above indicated Enclosure Size is including the Internal
Battery.
It should be possible to install the Data Logger inside the
existing Test Station at site.
Operating Temp : -10 degree C to 70 degree C and humidity of 95% (RH)
Data Download : The internally stored data should be downloadable on a Field

Laptop computer through a USB port provided in the logger unit
using the software provided with the logger. The logger software
will display and store this data in the Laptop in the standard MS
EXCEL sheet, which can be used for generating reports for
further analysis of the structure under protection.
Page 1695 of 2065

VENDOR LIST
DOCUMENT No.
FOR
CP SYSTEM B001-000-16-50-VN-0001, Rev. A
Page 1 of 6
VENDOR LIST FOR CP SYSTEM MATERIAL
PIPELINE
OWNER : M/S NALCO
JOB NO. : B001

Prepared Approved
Rev. No Date Purpose Checked by
by by
Format No. EIL 1641-1924 Rev. 1 B001-000-16-50-CVN-01 RA PIPELINE Copyright EIL – All rights reserved
Page 1696 of 2065

VENDOR LIST
DOCUMENT No.
FOR
Page 2 of 6
CATHODIC PROTECTION SYSTEM
a) SUGGESTED LIST OF CONTRACTORS FOR ON-SHORE CATHODIC PROTECTION SYSTEM SURVEY, DESIGN,
ENGINEERING, SUPPLY AND INSTALLATION, TESTING & COMMISSIONING WORKS:
1. M/S CORROSION CONTROL SERVICES (BOMBAY) PVT. LTD.,

405, Arun Chambers, Tardeo Road,
Bombay-400034.
Fax: 91-22-4934570
Attn: Mr.V.G. Kulkarni, Managing Director
( T.No. 4974593/4974564 )
2. M/S CORRTECH INTERNATIONAL PVT. LTD.

22, Dhara Centre, Vijay Char Rasta,
Navrangpura, Ahmedabad-380009.
Fax : (079) 26431615,
Attn: Mr. Amit Mittal, Director
Ph. No.(079) 26563443, 26568639(Off)
3. M/S RAYCHEM RPG LIMITED

Sun Magnetica
A- Wing, 3rd Floor,Unit No.301-303.,
Near LIC Building, Eastern Express Highway,
Thane (W) – 400 604.
Ph No.-022 - 64577800 - 831
Fax No - 022- 25826041
Attn: Mr.Prashant Naik
E-mail: pnaik@raychemrpg.com
4. M/S CORROSION TECHNOLOGY SERVICES INDIA PRIVATE LIMITED

(Enlisted with 30 KM, 2 CP Stations)
E-110, 1St Floor, “Crystal Plaza” New Link Road,

Andheri (W), Mumbai – 400053. India
Ph No.: 022-26733421/26732966/65
Fax No.: 022-26733420
Attn: Mr Anand V. Nadkarni
Email: avnadkarni@cts-middleeast.com
5. M/SARK EPC Projects pvt. Ltd

(Enlisted with 27 KM, 2 CP Stations)
307-Apollo Arcade, R.C. Technical Road,

Off S. G. Highway-Ghatlodiya,
Ahmadabad-380061,
Phone: 079-27774147
E-Mail: sweta@sarkprojects.com
Web: www.sarkprojects.com
6. M/s JSW Infrastructure Pvt.Ltd

(Enlisted with 83.96 Km length, 3 CP Stns)
4, Astt Mitre Estate,
Nr.Vadilal Factory, Dudheshwar Road,
Gandhinagar, Ahmadabad-380004
Gujrat, tel no. 079-23971327,
08164004158, 09825377791
Page 1697 of 2065

VENDOR LIST
DOCUMENT No.
FOR
Page 3 of 6
b) SUGGESTED LIST OF SPECIALIST AGENCIES FOR DOING THE INTERFERENCE SURVEY AND
IMPLEMENTING MITIGATION MEASURES AGAINST INTERFERENCE FOR CP SYSTEM OF HIGH
INDUCED VOLTAGE IN PIPELINE DUE TO PROXIMITY OF HT LINES NEAR PIPELINE.
 M/S VANDERVELDE, HOLLAND

 M/S SSS GERMANY
 M/S BALSLEV (Denmark)
 M/s SAFE ENGINEERING SERVICES & TECHNOLOGIES LTD., Canada
 MATCOR, USA
c). MIXED METAL OXIDE ANODES:
1) MMO WIRE ANODES (WITH FACTORY PRE-PACKED COKE BREEZE):
SL. NO. VENDOR NAME

1 M/S MATCOR (USA)
2 COVALENCE (USA)
3 BERRY PLASTICS (USA)
2) MMO WIRE ANODES (WITHOUT FACTORY PRE-PACKED COKE BREEZE):
SL. NO. VENDOR NAME

1 M/S GROUPPO DENORA, GOA, INDIA
2 M/S CERANODE TECHNOLOGIES, USA
3 M/S TELPRO, USA
3) MMO TUBULAR/ STRIP/ RIBBON ANODES:
SL. NO. VENDOR NAME

1 M/S GROUPPO DENORA, GOA, INDIA
2 M/S ORANZIO DE NORA, ITALY
3 M/S MAGNETOCHEMIE, HOLLAND
4 M/S ACTEL LTD., U.K.
5 M/S ELTECH SYSTEMS CORPORATION, USA
6 M/S CERANODE TECHNOLOGIES, USA
7 M/S MATCOR (USA)
d) JUNCTION BOXES (CLASSIFIED TYPE)
SL. NO. VENDOR NAME

1 FLAME PROOF EQUIPMENT PVT. LTD.(FEPL), BOMBAY . INDIA
2 BALIGA LIGHTING, CHENNAI , INDIA
3 CEAG FLAME PROOF CONTROL GEARS, BOMBAY ,INDIA
4 FLEXPRO ELECTRICALS, NAVSARI, GUJARAT, INDIA
5 SUDHIR SWITCHGEARS PVT.LTD., BOMBAY, INDIA
Page 1698 of 2065

VENDOR LIST
DOCUMENT No.
FOR
Page 4 of 6
e) CABLES
SL. NO. VENDOR NAME

1 M/S VICTOR CABLES , INDIA
2 M/S FORT GLOSTER CABLES , INDIA
3 M/S UNIVERSAL CABLES , INDIA
4 M/S NETCO CABLES, INDIA
5 M/S FINOLEX CABLES , INDIA
6 M/S ASIAN CABLES , INDIA
7 M/S RADIANT CABLES, INDIA
8 M/S CCI CABLES
9 M/S NIXUS,USA
10 M/S YUXI ,CHINA
11 M/S TRINITY CABLES ,UK
12 M/S ICON CABLES ,INDIA
13 M/S GEMSCAB, INDIA
14 M/S KEI, INDIA
f) PERMANENT REFERANCE ELECTRODES
SL. NO. VENDOR NAME

1 M/S PERMACELL/ HARCO (USA)
2 M/S BORIN MANUFACTURER, USA
3 M/S M.C.MILLER, USA
4 M/S CORRTECH (ZULU), INDIA
5 M/S TINKER RASOR, USA
6 M/s SILVION, UK
g) MCCB/ MCB FOR POWER DISTRIBUTION BOARD
SL. NO. VENDOR NAME

1 M/S SIEMENS, INDIA
2 M/S L&T , INDIA
3 M/S MERLIN GERIN, INDIA
4 M/S MDS,INDIA
5 M/S INDO ASIAN, INDIA
6 M/S AEG , GERMANY
7 M/S HAGER , GERMANY
8 M/S HAVELL’S ,INDIA
9 M/S ABB , INDIA
Page 1699 of 2065

VENDOR LIST
DOCUMENT No.
FOR
Page 5 of 6
h) HEAT SHRINK CAP FOR ANODE TO CABLE JOINT
SL. NO. VENDOR NAME

1 M/S RAYCHEM, USA
2 M/S MATCOR (USA)
i) ANODE BACKFILL MATERIAL
SL. NO. VENDOR NAME

1 M/S LORESCO, USA
2 M/S GOA CARBON (GOA), INDIA
3 M/S INDIA CARBON (CALCUTTA) , INDIA
4 M/S PETROCARBON & CHEMICAL COMPANY (HALDIA) ,INDIA
j) MAGNESIUM & ZINK ANODES FOR ON-SHORE PIPELINE
SL. NO. VENDOR NAME

1 M/S CORRPRO INTERNATIONAL , SARJAH
2 M/S NAKABOHTEC, JAPAN
3 M/S NIPPON CORROSION, JAPAN
4 M/S AFIC, KSA
5 M/S WILSON TAYLOR ASIA PACIFIC, SINGAPORE
6 M/S XIANG METAL, CHINA
7 M/S SHUNRUI, CHINA
8 M/S PLATT BROS. AND COMPANY, USA
9 M/S YUXI, CHINA
10 M/S SCIENTIFIC METAL , INDIA
11 M/s CATHODIC CONTROL CO., BANGALORE, INDIA
12 M/s ELECTRO PROTECTION SERVICES, INDIA
13 CTS, SARJAH, UAE
k) HI-SI-CR CAST IRON ANODE
SL. NO. VENDOR NAME

1 M/s DURICHLOR 51 SOLID ROD CAT IRON ANODE, USA
2 M/s SCIENTIFIC METALS, INDIA
3 M/s METAL FOUNDERS, INDIA
4 M/s CATHODIC CONTROL CO, BANGALORE, INDIA
l) COMPUTERIZED TEST STATION UNIT (CTSU)
SL. NO. VENDOR NAME

1 M/ S KRISTRON SYSTEMS, LOWER PAREL, MUMBAI, INDIA
Page 1700 of 2065

VENDOR LIST
DOCUMENT No.
FOR
Page 6 of 6
m) TRANSFORMER RECTIFIER UNIT (TRU) AC INPUT DC OUTPUT, & CPPSM

SL. NO. VENDOR NAME
1 M/S RAYCHEM RPG LTD(CANARA ELECTRIC), INDIA
2 M/S KRISTON SYSTEM , INDIA
n) PIN BRAZING
SL. NO. VENDOR NAME
1 M/s. SAFETRACK , SWEDEN
2 M/s BAC, UK
o) THERMITWELD
SL. NO. VENDOR NAME
1 M/S. ERICO, USA
2 M/S THERMOWELD, USA
3 M/S. ERICO, EUROPE
p) SURGE DIVERTORS - EXD

SL. NO. VENDOR NAME
1 M/s DEHN GmbH, GERMANY
2 M/S OBO , BETTERMANN, GERMANY
q) SOLID STATE POLARIZATION CELLS

SL. NO. VENDOR NAME
1 M/s DAIRYLAND ELECTRICAL INDUSTRIES , USA
2 M/s METRICORR, DENMARK
3. B) RUSTROL, USA/ CANADA
Page 1701 of 2065

SPECIFICATION STANDARD SPECIFICATION NO.
k31 ENGINEERS FOR
INDIA LIMITED CATHODIC PROTECTION POWER 6-45-0024 REV. 0
51gZ:1122eg
IA Govt ol lnJia Undertaking)
#z1~êSC81f Yfdâ kiLcieni

(*.t.t."W.'qq.) fffq fqr-4-4r
SPECIFICATION
FOR
CATHODIC PROTECTION POWER
SUPPLY MODULE (CPPSM)
ISSUED AS STANDARD SPECIFICATION

0 17.07.14 NSB RC PPL1 17Pti SC
(OLD DOC. NO.: 6-51-0024, REV. 4)
Standards Standards
Committee Bureau
Rev. Date Purpose
Prepared Checked
Convenor Chairman
No by by
Approved by
Page 1702 of 2065

(5-11 ENGINEERS
fa~0 87= INDIA FOR
LIMITED CATHODIC PROTECTION POWER 6-45-0024 REV. 0
1.11271 2.17(.12 0..YRA1 IA Govl ot maia undertaking)
Abbreviations:

CPPSM Cathodic Protection Power Supply Module
CVCC Constant Voltage and Constant Current
IS Indian Standard
MOSFET Metal Oxide Semiconductor Field Effect Transistor
MOV Metal Oxide Varistor
MTBF Mean Time Between Failure
MTTR Mean Time to Repair
PCB Printed Circuit Board
PO Purchase Order
PSP Pipe to Soil Potential
SCADA Supervisory Control and Data Acquisition
SMMS Standards Committee
Convenor: Mr. P.P. Lahiri
Members: Mr. R. Chaudhury

Mr. S. Mukherjee (Construction)
Mr. R. Muthu Ramalingam (Inspection)
Mr. Amit Prakash (HMTD)
Mr. Raj Kishore (Pipeline)
Mr. A.R. Purushottam (POSD)
Mr. B.R. Bhogal (Electrical)
Mr. Ratan Lal Kanaujia (Project)
Mr. R. Nanda (Piping)
Page 1703 of 2065

ENGINEERS FOR
fg-af 02eg INDIA LIMITED CATHODIC PROTECTION POWER 6-45-0024 REV. 0
IA Govt of lnd.a Undertakeg)
CONTENTS
1.0 SCOPE 4
6.0 EQUIPMENT DESCRIPTION 7
7.0 TESTS AND ACCEPTANCE 13
Page 1704 of 2065

rOtll61 ENGNEERS FOR
$1g-ar Oegl INDIA LIMITED CATHODIC PROTECTION POWER 6-45-0024 REV. 0
I 451.30,5711 IA Go. of maia undertak.g)
1.0 SCOPE
This specification covers the requirements for the design, manufacture and testing of Cathodic
Protection Power Supply Module (CPPSM) working on controlled switch mode principle
intended to supply power to cathodic protection system for underground pipelines/ structures.
2.1 The system design, performance and materials to be supplied shall conform to the requirements
of the latest revision of following standards:
IS: 1248 Direct acting indicating analogue electrical measuring instruments and
(Parts-1, 2, 8 & 9) accessories
IS: 3700 Essential rating and characteristics of semiconductor devices

(Parts-1 to 11)
IS: 3715 Letter symbols for semiconductor devices

(Parts-1 to 4)
IS: 4411 Code of designation of semiconductor devices
IS: 5469 Code of practice for the use of semiconductor junction devices
(Parts-1 to 4)
IS: 6619 Safety code for semiconductor rectifier equipment
IS:7204 Stabilised power supplies DC output

(Parts-1 to 4)
IS: 12021 Control transformers for switchgear and control gear for voltages not
(Parts-1 to 4) exceeding 1000 V AC
IS: 13703 Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC
(Parts-1 to 4)
IS/ IEC: 60947 : Specification for low voltage switchgear and control gear
IS/ IEC: 60079 : Electrical apparatus for explosive gas atmosphere
IS/ IEC: 60529 : Classification of degree of protection provided by enclosures
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory
2.4 In case of any contradiction between various referred standards/ specifications/data sheet and
Page 1705 of 2065

k7111~21 ENGINEERS FOR
fszrrf812-&-g
1.4.71 e-12cnre,af137¢.11
INDIA LIMITED
(A Goot of India Undeltalong)
CATHODIC PROTECTION POWER 6-45-0024 REV. 0
- Statutory Regulations
- Data Sheets
- Job Specification
- This Specification
- Codes and Standards
3.0 SITE CONDITIONS
The CPPSM shall be suitable for installation in non air-conditioned room with restricted
ventilation or in outdoor kiosk (as specified in data sheet), in locations having generally
corrosive, warm, humid and dusty atmosphere. Service conditions shall be as specified in the data
sheet. If not specifically mentioned therein, a design ambient temperature of 40°C and an altitude
not exceeding 1000 m above mean sea level shall be considered.
equipment for at least for 15 years from the date of supply.
services.
5.1 Fabrication and General Details
5.1.1 CPPSM shall be housed in sheet steel enclosure. The front, rear walls and doors shall be made by
using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.6 mm thick
sheet steel. Wherever required, suitable stiffeners shall be provided. The Unit shall be
freestanding type. Hinged doors shall be provided at the front and back as required. The unit shall
be natural cooled type. Louvered openings with wire mesh for natural ventilation may be
provided. Degree of protection for the panel shall be minimum IP-41. The CPPSM panel shall,
preferably, not need rear access for operation, maintenance and shall be suitable for mounting
flushed to the wall.
5.1.2 Suitable hooks shall be provided for lifting the panel. These hooks when removed shall not leave
any hole in the panel or imperfection in the paint finish.
5.1.3 All instruments shall be panel mounted type and back connected. All fuses shall be provided
inside the panel and shall be of link type. 660 V grade PVC insulated BIS approved wires with
stranded copper conductor of size minimum 2.5 mm z shall be used for power and auxiliary
wiring. Control wiring for electronic circuits shall be through flat ribbon cable or through copper
wire of minimum 0.5 mm diameter. All wirings shall be ferruled with PVC ferrules at both ends
for ease of identification. Clamp type terminals suitable for termination up to 10 mm2 conductor
shall be provided for all control cable connection. Suitable power terminals shall be provided for
power cables. Minimum 20% spare terminals shall be provided. The terminal blocks shall be
mounted minimum 300 mm above the gland plate.
Page 1706 of 2065

("ENGINEERS FOR
~viti
or,,
lwoINDIA
1.1271 2170517
LIMITED
Ga. of Indle Undertaiong)
5.1.4 A11 live parts shall be properly shrouded. This shall ensure complete safety to personnel intending
routine maintenance by opening the panel doors.
5.1.5 CPPSM shall be suitable for bottom cable entry unless otherwise specified in the data sheet and
shall be supplied complete with crimping type tinned copper lugs and cable glands. Cable glands
shall be of brass, nickel plated, single compression type for indoor installations and double
compression type for outdoor installations. The space in the terminal chamber shall be adequate
for termination of required number and sizes of cables as specified in the data sheet.
5.1.6 The CPPSM shall be field proven. The design, internal component layout and rating of
component shall ensure high MTBF and low MTTR. Prototype equipment shall not be
acceptable. Layout of panel components shall enable easy access to the components for
maintenance.
5.1.7 All the control equipment like switches, push buttons, potentiometers etc. shall be located at a
convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.
5.1.8 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB tracks shall
be tinned and solder masked. The PCB shall be coated with suitable lacquer to make it immune to
dust, moisture and fungal growth. Where plug in type of PCBs are used gold plated male-female
connectors shall be used for the purpose.
5.1.9 If required the panel shall be provided with space heater to prevent moisture condensation. The
space heaters shall be located at the bottom of the panel and shall be provided with a manually
operated switch and HRC fuse. The space heater shall have porcelain-insulated connectors.
Where space heater is not provided the electronic PCBs/components and other control devices
shall be made immune to moisture condensation.
5.1.10 Panel shall be provided with integral base frame channel. The integral base frame of panel shall
be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack
welding to purchaser's insert plate/flat/channel embedded in the floor. Amply dimensioned
oblong holes shall be provided at the bottom of the panel for its bolting to the embedded insert
plate/channel.
5.1.11 An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminium shall be provided
throughout the length of the panel. Provision shall be made for connecting this earth bus at two
ends with the plant earth grid by means of (40x5) mm2 GI flat. All non-current carrying metallic
parts of the panel and mounted equipment shall be connected to the panel earth bus. All doors
and movable parts shall be connected to the earth bus by flexible copper cables.
5.1.12 A11 panel mounted equipments (e.g. lamps, push buttons, switches, meters, PCBs, etc.) shall be
provided with suitable nameplates. Nameplates shall be engraved out of 3-ply (black-white-
black) lamicoid sheets or anodised aluminium. Back-engraved perspex sheet nameplates may
also be acceptable. Engraving shall be done with groove cutters. Hard paper or self-adhesive
plastic tape nameplates shall not be acceptable. Nameplates shall be fastened by screws and not
by adhesive.
Labels shall be provided for every component on the cards, connecting wires as well as for the
terminals in the terminal strip inside the panel.
Page 1707 of 2065

ENGINEERS FOR
Og-ar f&12- g INDIA LIMITED
IA Go, of India Undertaking)
5.1.13 Where specified in the data sheet the CPPSM shall be housed in an outdoor kiosk. The kiosk
shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and
external surfaces. Hinged lockable doors shall be provided at the front and back. Acrylic
transparent glass window shall be provided on the front door of the kiosk so that the meters,
indications and positions of the control switches on the CPPSM can be seen without opening the
door of the kiosk. The kiosk shall be suitable for outdoor mounting and shall give proper
protection to the CPPSM against rain, other harsh weather conditions. Necessary ventilation
arrangement with louvers and wire mesh shall be provided for proper operation of the CPPSM.
The cable entry to the kiosk shall be from bottom through cable glands. Suitable canopy shall be
provided on the top of the kiosk.
5.1.14 Painting
All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease
and dirt.
Fabricated structures shall be pickled and then rinsed to remove any trate of acid. The under
surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. The undersurface shall be made free from all imperfections before undertaking
the finishing coat.
After preparation of the under surface, the panel shall be spray painted with two coats of final
paint or shall be powder coated. Colour shade of final paint shall be approved by the purchaser
before final painting is started. The finished panels shall be dried in stowing ovens in dust free
atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off
paint, etc.
All unpainted steel parts shall be cadmium plated or suitably treated to prevent corrosion. If these
parts are moving elements, then they shall be greased.
6.0 EQUIPMENT DESCRIPTION
The CPPSM shall be complete with following main sections:
Input controls.
Power converter and filters.
Out put protections
System controls
Current interrupter
Control, indication and metering
6.1 Input Controls
6.1.1 A moulded case circuit breaker with thermal over load and short circuit release (rated for the
input power supply short circuit current) shall be provided at the input for power supply control.
6.2 Power Converter and Filters
6.2.1 The CPPSM shall convert and control the input DC power supply voltage/current into variable
DC output voltage/current through switching power semiconductor devices (Thyristor/power
transistor/power MOSFET, etc.). The variation in the output voltage/current shall be achieved
through control of duty cycle of conduction of the switching power semiconductor devices. The
Page 1708 of 2065

ENGINEERS FOR
$11g-ar 015eg INDIA LIMITED CATHODIC PROTECTION POWER 6-45-0024 REV. 0
Govt of Intha undertaking)
current and voltage ratings of the power semiconductor devices shall be at least two times the
maximum device current and min. two times the maximum voltage coming across it respectively.
The voltage rating of the power semi-conductor devices shall be co-coordinated with the break
down voltage of lightning arrestor provided at the output so that the power semiconductor
devices are protected from any voltage surge coming from the pipeline. Shunt zeners / MOV
shall be provided across the power semiconductor devices for protection. The power
semiconductor devices shall have humidity/moisture resistant finish and mounted in sufficiently
sized heat sink designed to provide adequate cooling under worst conditions of operation. The
power semiconductor devices shall have adequate protection against high dv/dt and di/dt.
6.2.2 Where specified in the data sheet, the converter shall electrically isolate the input power to
CPPSM from its out put so that the grounding of the positive out put of the CPPSM through
anode ground bed shall not affect the grounding system of the input power supply. Alternatively,
a separate DC to DC converter having electrical isolation between input and out put power supply
shall be provided at the input of the CPPSM.
6.2.3 The power semiconductor devices shall be protected by semiconductor fuses or the system shall
have instantaneous short circuit-current limit feature to protect the devices against output short
circuits. An adjustable output over current limit feature shall be provided.
6.2.4 Filter shall be provided in the input power supply circuit to minimise the AC injected into the DC
input power supply system.
6.2.5 Adequate filtering shall be provided on the DC output of the converter to limit the ripple content
in the output to less than 5% at rated output.
6.2.6 The converter system shall be of natural air cooled type.
6.2.7 For CPPSMs with multiple output circuits, each output circuit shall have independent output
converter and output filters.
6.3 Output Protections
Two pole moulded case circuit breaker or miniature circuit breaker rated for the DC output
current, short circuit current and having thermal over load, short circuit release shall be provided
in the output. A lightning arrestor rated for minimum 10KA impulse current discharge capacity
and rated voltage & max. spark over voltage rating suitable to protect the CPPSM components
against lightning and switching surges shall be provided at the output. For CPPSMs with multiple
output circuits, each output circuit shall have independent protections.
6.4 System Controls
6.4.1 The CPPSM shall have two distinct modes of operation (independent for each output circuit) as
below:
a) Constant Voltage - Constant Current Mode (CVCC)
In this mode the output voltage (Vos) of CPPSM shall be continuously adjustable from
0.5V DC to the rated output voltage specified on the data sheet. Current limit feature
shall be provided in this mode of operation. The current limit (Ios) shall be continuously
adjustable from zero to rated output current.
Page 1709 of 2065

ENQNEERS FOR
- Og-ar s
otventVattarotot
v INDIA LIMITED
IA Govt d InUia Unetertalong)
For constant voltage mode of operation the output current limit shall be set at maximum
and output voltage setting shall be varied. Irrespective of output current demand the
chosen value of the output voltage shall be maintained by the control system till the
current limit is reached. After that the output current limit shall be maintained and output
voltage shall decrease to keep the current constant.
For constant current mode of operation the output voltage shall be set at maximum and
output current shall be varied through varying the setting of output current limit.
Irrespective of output voltage requirement the control system shall maintain the output
current to the set current limit value till the voltage limit is reached. After that the output
voltage limit shall be maintained and output current shall decrease to keep the voltage
constant.
b) Auto PSP Mode
In this mode of operation the output of the CPPSM shall operate in an external closed
loop with pipe-to -soil potential (PSP) in feed back loop. The CPPSM control shall adjust
the output voltage such that the PSP as measured by reference cell always remains equal
to the set potential on the unit. The set potential (Vps) shall have high long time stability
and minimum temperature drift. The set potential shall be continuously adjustable over
the range specified in data sheet. An adjustable over current limit shall be provided to
limit the maximum output current.
The unit shall be designed to operate with the number of reference cells connected to it
(to be provided by others) as specified in data sheet. In case of more than one reference
cell being specified, CPPSM shall have feature to automatically select the reference cell
having less negative potential than the others and use the same for auto control of the unit
(e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be provided in
selecting the less negative potential reference cell, to avoid hunting between the reference
cells at change over conditions.
In case of open circuit or short circuit of the reference cell or potential being less
negative than a minimum set potential (Vrs), for the controlling reference cell, the unit
shall sense these conditions as reference cell failure and shall automatically switch over
to the other healthy reference cell for control. Should fault occur in all the reference cells,
the output voltage or current of the CPPSM shall adjust automatically to a preset value
(Vas/Ias), which shall be adjustable.
In both CVCC and auto PSP modes of operation the electronic over current limit shall be
fast enough to protect the active devices of the unit and fast enough to act before tripping
of MCCB/MCB or blowing of fuse.
6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shall be provided in case
of PSP either exceeding the specified maximum limit (Vpm ) or remaining lower than the
specified minimum limit (Vpn).
6.4.3 The output voltage regulation for no load to full load variation with input voltage variation from
maximum to minimum shall not be more than 2.5 % of rated voltage through out the range of
output voltage and over the specified ambient temperature variation as specified in data sheet, in
CVCC- constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation for
Page 1710 of 2065

Ir= ENQNEERS FOR
5g-ar 22-&-g
1.01, eoraffer an.yrorof
INDIA LIMITED
IA Govt of Indie Undeftalongf
no load to full load variation with input voltage variation from maximum to minimum shall be
within 20mV through out the PSP setting range specified.
In CVCC- constant current mode of operation, the current regulation for minimum to maximum
output voltage and minimum to maximum variation in input voltage, shall not be more than 2.5%
through out the range of output current.
6.4.4 The output of the unit shall be ungrounded and shall allow grounding of positive terminal of the
output through the anode ground bed.
6.4.5 For CPPSMs with multiple output circuits, each output circuit shall have independent control
system.
6.5 Current Interrupter
6.5.1 If specified on the data sheet a current interrupter for CPPSM output current interruption shall be
provided.
6.5.2 The current interrupter shall have an output contactor with current rating minimum 125% of the
output current rating of the CPPSM and a digital timer to operate it.
6.5.3 The timer shall have ÒN' and ÒFF' timings. When the timer is turned on the ÒN' timing shall
start and shall close the output contactor till the end of the ÒN' timing. At the end of the ÒN'
timing the ÒFF' timing shall start and keep the contactor open till the end of the ÒFF' timing.
At the end of the ÒFF' timing the ÒN' timing shall start again. This process of ÒN' and ÒFF'
timing shall continue.
6.5.4 The ÒN' and ÒFF' timings of the timer shall be settable by separate 2 digit thumbwheel
switches, each settable from 1 to 99 seconds. The timing error of the timer shall be less than 5
parts per million. In case of microprocessor based system keypad with display may be provided
in place of thumbwheel switches.
6.5.5 Whenever the timer is switched on it shall always start with ON `timing'. A timer-reset push
button shall be provided. On pressing this push button during operation of the timer, the timer
shall get reset and upon release of the button the timer shall restart with ÒN' timing.
6.5.6 The power required for operation of the timer and contactor shall be derived from the main power
supply to the CPPSM.
6.5.7 The following controls and indications shall be provided for current interrupter. The controls
shall be housed in a lockable cover, so that normally they are not accessible. The indications shall
be mounted on the door.
a) Controls
Timer power ÒN' / ÒFF'

Timer reset
Thumb wheel switch for ÒN' timing
Thumb wheel switch for ÒFF' timing
Page 1711 of 2065

ENGINEERS FOR
- Og-ar 18t151 -g
tmwr Cle•ant ,M370,-.1)
INDIA LIMITED
Govt of India UnOertakng)
In case of microprocessor based system keypad with display may be provided in place of
thumbwheel switches.
b) Indications (LED)
Timer power ÒN'

ÒN' timing
ÒFF' timing
6.5.8 The output contact of the current interrupter contactor shall be wired in the positive DC output of
the CPPSM. A link shall be provided for shorting these terminals whenever the current
interrupter is not in use.
6.5.9 If specified in the data sheet the current interrupter shall be an independent unit of portable type.
The interrupter unit shall have terminals for input power supply and terminals of the contactor in
the timer output. The input power supply and the rating of the timer output contactor shall be as
specified on the data sheet.
6.5.10 Where the current interrupter is not specified with CPPSM or is specified as portable type
external to the CPPSM, then the CPPSM shall have provision for connection of input power
supply terminals and out put contacts of external current interrupter for current interruption test.
A link shall be provided for shorting the out put terminals provided in CPPSM for current
interruption, whenever the current interrupter is not connected.
6.5.11 For CPPSMs with multiple output circuits, each output circuit shall have independent current
interrupter.
6.6 Controls, Indication and Metering
6.6.1 Following controls shall be provided on CPPSM front door:
a) ON/OFF control for input through MCCB

b) ON /OFF control for output through MCCB/MCB
c) Auto/CVCC mode selector switch
d) Potentiometers for Vos, Vps and Ios settings
e) Selector switch for selecting indication of PSP set and PSP actual for all the reference
cells
6.6.2 Following controls shall be provided inside the module at user accessible common location:
a) Potentiometer for Vrs, Vpm, Vpn and Vas/Ias settings.

b) Controls for current interrupter:
Timer reset
Thumb wheel switch for ÒFF' timing
6.6.3 CPPSM shall have following indicating lights (lamps or minimum 5 mm dia LEDs):
a) CPPSM ON/OFF
b) Unit in auto/CVCC (2 lamps)
Page 1712 of 2065

Ir= ENGINEERS FOR
5fgzfr181~ INDIA LIMITED
IA Goot of inOfa Undertakng)
c) Reference cell controlling the closed loop control of the CPPSM (number of lamps same
as number of reference cells).
d) Reference cell faulty (number of lamps same as number of reference cells).
e) Pipeline over protected.
f) Pipeline under protected
g) Indications for current interrupter:
Timer power ÒN'

ÒN' timing
ÒFF' timing
It shall be possible to switch-off all the indication lamps by a single switch. In case of LED
indication lights this facility may not be provided.
6.6.4 Following meters having min cl. 1.5 accuracy shall be provided on the CPPSM:
a) Digital meter for output voltage

b) Digital meter for output current
c) Digital voltmeter to measure PSP set (Vps) and PSP actual for all the reference cells. The
meter shall have range from (-) 4 V to 0 V and shall have cl. 0.5 accuracy.
e) Digital meters for measuring Vrs, Vpm, Vpn and Vas/Ias settings.
f) Meters for input voltage and current
It shall be possible to switch-off all the digital meters preferably by a single switch.
6.6.5 If specified in data sheet, CPPSM shall incorporate provision for remote monitoring of the unit
through SCADA system as below:
a) Potential free contacts for the following:
A11 the reference cells failed. (Contact open on alarm condition)

Pipeline overprotected. (Contact open on alarm condition)
Pipeline under protected. (Contact open on alarm condition)
System in auto-mode. (Contact close in auto condition)
System in CVCC mode. (Contact close in CVCC mode)
b) 4 to 20 mA electrically isolated signal for the following:
PSP (-4V to OV)

CPPSM output voltage
CPPSM output current
The transducers shall have electrical isolation between input and output. The isolation insulation
shall withstand 2 kV, 50 Hz for minimum 1 minute. The accuracy class of the transducer shall be
0.5. The transducers shall be protected against input and output voltage surges. The transducer
shall be suitable for driving up to 600 ohms load impedance located up to 500 m away and wired
with 0.5 mm2 copper conductor cable. The transducers shall be suitable for minimum 125%
continuous over load in the input voltage/current parameter.
Page 1713 of 2065

ENGINEERS FOR
Of54
17.112,1 ,i2C1572a51 3.7MA .1
INDIA LIMITED
(A GoN of India Undertakng)
6.6.6 For units having multiple outputs, each output circuit shall have independent controls, indication
and metering.
7.0 TESTS AND ACCEPTANCE
7.1 During fabrication, the equipment shall be subjected to inspection by owner or his authorised
representative to assess the progress of the work as well as to ascertain that only quality raw
materials are used for the same. He shall be given all assistance to carryout the inspection.
7.2 Final acceptance test shall be carried out at manufacturer's works under his care and expense.
Instruments and equipments required for testing shall be arranged by manufacturer. Owner's
representative shall be given minimum 2 weeks prior notice for witnessing the tests. Test
certificates indicating test results shall be furnished by the manufacturer. Acceptance tests shall
include but not be limited to the tests listed below.
7.2.1 Visual Inspection
This shall include-
Completeness of the equipment in line with specification.

Checking of all settings.
All labels provided and satisfactory.
Dimensional checking.
Proper mounting of components and neatness of wiring etc.
Model number.
The voltage specified in the table below shall be applied for one minute to the circuits indicated:
Control electronics Power electronics Auxiliary circuits

Withstand voltage
<60V Un i Un2
To earth 700V D.C. 2xUn1 + 1000V 2xUn2 + 1000V
To control electronics - 2xUn1 + 1000V 2xUn2 + 1000V
To power electronics 2xUn1 + 1000V 2xUn1 + 1000V
To auxiliary circuits 2xUn2 + 1000V 2xUn1 + 1000V -
(Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits respectively).
D.C. test voltages may be applied instead of A.C. The magnitude of D.C. test voltages to be
applied shall be 2 times the above-mentioned A.C. (r.m.$) Values.
Insulation resistance test shall be conducted before and after heat run test.
7.2.3 Heat Run Test
All CPPSMs shall be subjected to a heat run test performed at rated voltage for period not less
than 16 hours prior to execution of functional tests.
Page 1714 of 2065

ENGINEERS FOR
$1gzir INDIA LIMITED CATHODIC PROTECTION POWER 6-45-0024 REV. 0
.271. vwcove OtliJattost, IA Govt of ioau Undertaiong)
At least one CPPSM of each rating shall be loaded to its rated output through out 16 hour test
period. A11 other CPPSMs shall be energized under partial load or zero load current condition
through out the test period.
Functional tests as below shall be performed on each CPPSM. If during execution of functional
tests, any electronic component of the unit is required to be replaced e.g. due to malfunction or
failure of the unit to fulfill the performance requirements of the specification, then the load test
shall be repeated at rated current following which functional tests shall be carried out.
7.2.4.1 CVCC Mode Operation Testing
a) Constant Voltage Operation
During the test current limit shall be set to rated output current. Performance testing shall
be carried out for various out put voltage settings and load varying from zero to
maximum. The verification of operation of the control functions, measurement of output
voltage, current, input voltage, current, ripple in the output, input, evaluation of output
voltage regulation and efficiency of the unit shall be carried out during the testing.
b) Constant Current Operation
During the test voltage limit shall be set to rated output voltage. Performance testing shall
be carried out for various out put current limit settings and load resistance varied to
achieve output voltage from minimum to maximum. The verification of operation of the
control functions, measurement of output voltage, current, input voltage, current, ripple
in the output, input, evaluation of output current regulation of the unit shall be carried out
during the testing.
7.2.4.2 Auto PSP Mode Operation
Suitable set up shall be arranged for out put loading and reference cell feed back. The closed loop
performance and regulation shall be checked with the PSP set voltage varied from 0.85V to 1.2V.
Disconnecting the reference cell feed back connection in the above set up shall simulate the
reference cell failed condition. The output voltage/current of the unit shall go to the value set on
the potentiometer Vas/Ias provided inside the CPPSM. The settings on Vas/Ias shall be varied
and the output voltage/current shall be observed.
7.2.4.3 Operation of sensors for pipeline over protection, under protection, reference cell failure and
reference cell selection logic in auto PSP mode shall be verified by connecting variable external
voltage sources to reference cell inputs of the CPPSM. The number of external voltage sources
shall be same as number of reference cell inputs specified for the CPPSM.
7.2.4.4 The unit shall be checked for operation of the current limit by over loading the unit in both
CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not provided
for protection of the power semiconductor device, the protection of same shall be tested as below:
A switch rated for making and carrying CPPSM output short circuit current shall be connected to
the output terminals of the unit. The output voltage and the output current limit settings of the
Page 1715 of 2065

ei ENGINEERS FOR
ICIaès
làir, ,wenre,LIR .TRISTI,
INDIA LIMITED
IA Govl of India Undettekng)
unit shall be set to the maximum rated values. The switch connected in the output shall be shorted
quickly.
The unit shall go to current limit mode and shall not damage any active component of the unit.
7.2.4.5 The current interrupter shall be tested for time interval settings and specified operation.
The equipment shall be properly packed for selected mode of transportation i.e. by ship/ rail or
trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent
damage to finish. Crates shall have skid bottom for handling. Special notations such as `Fragile',
`This side up', `Center of gravity', ` Weighe etc., shall be clearly marked on the package together
with Tag nos., P.O. Nos. etc.
completely suitable for outdoor storage in areas with heavy rains/ high ambient temperature.
Page 1716 of 2065

©!Z ENGINEERS FOR
51gZIE f8'12-&g INDIA LIMITED CATHODIC PROTECTION 6-45-0025 REV. 0
CA Govt of InO. Undertalung)
TRANSFORMER RECTIFIER UNIT Page 1 of 15
:1<kIIT "cifUNT
tlii fffg "r~
SPECIFICATION
FOR
CATHODIC PROTECTION
TRANSFORMER RECTIFIER UNIT

0 17.07.14 NSB RC PPL 4Ili tt SC
(OLD DOC. NO.: 6-51-0025, REV. 4)
Standards Standards
Committee Bureau
No by by
Approveci by
Page 1717 of 2065

• ENGINEERS
It FOR
5gar f&I~
,xrrn
INDIA LIMITED
Govt ol India Undertalong)
CATHODIC PROTECTION 6-45-0025 REV. 0
Abbreviations:

CVCC : Constant Voltage and Constant Current Mode
MOV : Metal Oxide Varistor
MTBF : Mean Time Between Failure
MTTR : Mean Time to Repair
PCB : Printed Circuit Board
PSP : Pipe to Soil Potential
PO : Purchase Order

Page 1718 of 2065

ENGINEERS FOR
af&Jr1M2-c5
' INDIA LIMITED
IA GoA of India Undertakmg)
CONTENTS
1.0 SCOPE 4
6.0 EQUIPMENT DESCRIPTION 7
7.0 TESTS AND ACCEPTANCE 13
Page 1719 of 2065

t_71 ENGINEERS FOR
gz.ji INDIA LIMITED CATHODIC PROTECTION 6-45-0025 REV. 0
ariJaSis".11 (A Govt of India Undertalong)
1.0 SCOPE
This specification covers the requirements for the design, manufacture and testing of Cathodic
Protection Transformer Rectifier units (CPTR units) working on controlled rectification
principle intended to supply power to cathodic protection system for underground pipelines/
structures.
2.1 The system design, performance and materials to be supplied shall conform to the requirements
of the latest revision of following standards:
IS: 1248 : Direct acting indicating analogue electrical measuring instruments and
(Parts-1, 2, 8 & 9) accessories
IS: 3700 : Essential rating and characteristics of semiconductor devices

(Parts-1 to 11)
IS: 3715 : Letter symbols for semiconductor devices

(Parts-1 to 4)
IS: 4411 : Code of designation of semiconductor devices
IS: 5469 : Code of practice for the use of semiconductor junction devices
(Parts-1 to 4)
IS: 6619 : Safety code for semiconductor rectifier equipment
IS: 7204 : Stabilised power supplies DC output

(Parts-1 to 4)
IS: 12021 : Control transformers for switchgear and control gear for voltages not
(Parts-1 to 4) exceeding1000 V AC
IS: 13703 : Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC
(Parts-1 to 4)
IS/ IEC: 60947 : Specification for low voltage switchgear and control gear
IS/ IEC: 60079 : Electrical apparatus for explosive gas atmosphere
IS/ IEC: 60529 : Classification of degree of protection provided by enclosures
2.4 In case of any contradiction between various referred standards/ specifications/data sheet and
Page 1720 of 2065

Itrru ENGINEERS FOR
Og-z-z 22-eg
..rwm eznre, en, JTErr+1)
INDIA LIMITED
IA Govl of Incha Undertaking)
CATHODIC PROTECTION
6-45-0025 REV. 0
- Statutory Regulations
- Data Sheets
- Job Specification
Codes and Standards
3.0 SITE CONDITIONS
The CPTR unit shall be suitable for installation in non air-conditioned room with restricted
ventilation or in outdoor kiosk (as specified in data sheet), in locations having generally
corrosive, warm, humid and dusty atmosphere. Service conditions shall be as specified in the
data sheet. If not specifically mentioned therein, a design ambient temperature of 40°C and an
altitude not exceeding 1000 m above mean sea Level shall be considered
equipment for at least for 15 years from the date of supply.
services.
5.1 Fabrication and General Details
5.1.1 CPTR unit shall be housed in sheet steel enclosure. The front, rear walls and doors shall be
made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.6
mm thick sheet steel. Wherever required, suitable stiffeners shall be provided. The Unit shall be
freestanding type. Hinged doors shall be provided at the front and back as required. The unit
shall be natural cooled type. Louvered openings with wire mesh for natural ventilation may be
provided. Degree of protection for the panel shall be minimum IP-41. The CPTR unit panel
shall, preferably, not need rear access for operation, maintenance and shall be suitable for
mounting flushed to the wall.
5.1.2 Suitable hooks shall be provided for lifting the panel. These hooks when removed shall not
leave any hole in the panel or imperfection in the paint finish.
5.1.3 All instruments shall be panel mounted type and back connected. All fuses shall be provided
inside the panel and shall be of link type. 660 V grade PVC insulated BIS approved wires with
stranded copper conductor of size minimum 2.5 mm 2 shall be used for power and auxiliary
wiring. Control wiring for electronic circuits shall be through flat ribbon cable or through
copper wire of minimum 0.5 mm diameter. All wirings shall be ferruled with PVC ferrules at
both ends for ease of identification. Clamp type terminals suitable for termination up to 10 mm2
conductor shall be provided for all control cable connection. Suitable power terminals shall be
provided for power cables. Minimum 20% spare terminals shall be provided. The terminal
blocks shall be mounted minimum 300 mm above the gland plata.
Page 1721 of 2065

fr= ENGINEERS FOR
$'2..111C12eg INDIA LIMITED CATHODIC PROTECTION 6-45-0025 REV. 0
(0, Go. ol Incha Undertaking)
5.1.4 All live parts shall be properly shrouded. This shall ensure complete safety to personnel
intending routine maintenance by opening the panel doors.
5.1.5 CPTR unit shall be suitable for bottom cable entry unless otherwise specified in the data sheet
and shall be supplied complete with crimping type cable termination lugs and cable glands.
Cable glands shall be of brass, nickel plated, single compression type for indoor installations
and double compression type for outdoor installations. The space in the terminal chamber shall
be adequate for termination of required number and sizes of cables as specified in the data
sheet.
5.1.6 The input power factor of the unit at rated load shall be 0.8 lag or better.
5.1.7 The CPTR unit shall be field proven. The design, internal component layout and rating of
component shall ensure high MTBF and low MTTR. Prototype equipment shall not be
acceptable.
5.1.8 All the control equipment like switches, push buttons, potentiometers etc. shall be located at a
convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.
5.1.9 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB tracks
shall be tinned and solder masked. The PCB shall be coated with suitable lacquer to make it
immune to dust, moisture and fungal growth. Where plug in type of PCBs are used gold plated
male-female connectors shall be used for the purpose.
5.1.10 If required the panel shall be provided with space heater to prevent moisture condensation. The
space heaters shall be located at the bottom of the panel and shall be provided with a manually
operated switch, HRC fuse and link for phase and neutral respectively. The space heater shall
have porcelain connectors. Where space heater is not provided the electronic PCBs/components
and other control devices shall be made immune to moisture condensation.
5.1.11 Panel shall be provided with integral base frame channel. The integral base frame of panel shall
be suitable for directly bolting with the help of foundation bolts and shall also be suitable for
tack welding to purchaser's insert plate/flat/channel embedded in the floor. Amply
dimensioned oblong holes shall be provided at the bottom of the panel for its bolting to the
embedded insert plate/channel.
5.1.12 An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminium shall be provided
throughout the length of the panel. Provision shall be made for connecting this earth bus at two
ends with the plant earth grid by means of (40x5) mm2 GI flat. All non-current carrying
metallic parts of the panel and mounted equipment shall be connected to the panel earth bus.
All doors and movable parts shall be connected to the earth bus by flexible copper cables.
5.1.13 All panel mounted equipments (e.g. lamps, push buttons, switches, meters, PCBs, etc.) shall be
provided with suitable nameplates. Nameplates shall be engraved out of 3-ply (black-white-
black) lamicoid sheets or anodised aluminium. Back-engraved Perspex sheet nameplates may
also be acceptable. Engraving shall be done with groove cutters. Hard paper or self-adhesive
plastic tape nameplates shall not be acceptable. Nameplates shall be fastened by screws and not
by adhesive.
Labels shall be provided for every component on the cards, connecting wires as well as for the
terminals in the terminal strip inside the panel.
Page 1722 of 2065

,31
-1P.Jt4 frr,) (--- s ENQNEERS
FOR
g-z,..r,irewax,
02- d g `,..._.-, INDIA LIMITED 6-45-0025 REV. 0
on,Ylas., IA Govl of Ind. Undertalong) CATHODIC PROTECTION
5.1.14 Where specified in the data sheet the CPTR unit shall be housed in an outdoor kiosk. The kiosk
shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and
external surfaces. Hinged lockable doors shall be provided at the front and back. The kiosk
shall be suitable for outdoor mounting and shall give proper protection to the CPTR unit against
rain, other harsh weather conditions. Necessary ventilation arrangement with louvers and wire
mesh shall be provided for proper operation of the CPTR unit. The cable entry to the kiosk
shall be from bottom through cable glands. Suitable canopy shall be provided on the top of the
Kiosk.
5.1.15 Painting
All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease
and dirt.
Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under
surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. The undersurface shall be made free from all imperfections before
After preparation of the under surface, the panel shall be spray painted with two coats of final
paint or shall be powder coated. Colour shade of final paint shall be approved by the purchaser
before final painting is started. The finished panels shall be dried in stowing ovens in dust free
atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off
paint, etc.
All unpainted steel parts shall be suitably treated to prevent corrosion. If these parts are moving
elements, then they shall be greased.
6.0 EQUIPMENT DESCRIPTION
The CPTR unit shall be complete with following main sections:

- Transformer and input controls.
Rectifier and filter
Out put protections
System controls
- Control, indication and metering
6.1 Transformer and Input Controls
6.1.1 The transformer shall be natural cooled dry type with separate primary and secondary windings.
An intermediate earth screen shall be provided between primary and secondary windings. CPTR
Units having multiple output circuits shall have separate secondary windings for each output
circuit. Transformer shall be vacuum impregnated with epoxy varnish and baked. The safety
factor for transformer rating shall be minimum 125%.
6.1.2 Single-phase transformers may be provided up to 50V, 50A DC output rating of the CPTR
units. Beyond this rating 3 phase transformers shall be provided.
A moulded case circuit breaker with thermal over load and short circuit release shall be
provided at the input of the transformer. Miniature circuit breaker with thermal overload and
short circuit release in place of moulded case circuit breaker inay be provided, where the
Page 1723 of 2065

ENGINEERS FOR
.11 INDIA LIMITED CATHODIC PROTECTION 6-45-0025 REV. 0
1.1,1 ,wm,1151.307,70 IA Govt of InOia Underta.g)
miniature circuit breaker rated for the incoming AC supply short circuit current indicated in the
data sheet is available.
6.2 Rectifier and Filters
6.2.1 The rectifier shall be made of thyristors and diodes as basic components. The CPTR unit shall
be suitable for 415 V AC, 3-ph power supply. Rectifier shall be 3 phase full wave type and
controlled type. For CPTR units rated 50V, 50A DC or less, the unit may be suitable for 240V
AC, 1 ph power supply and the rectifier shall be full wave type and controlled type.
Alternatively, for single phase AC CPTR units, diode rectifier of full wave type in the
secondary of the transformer and triac or back to back connected thyristors in the transformer
primary AC supply circuit may be provided. The current and voltage ratings of thyristors,
diodes shall be at least two times the actual maximum device current and minimum two times
the actual maximum voltage coming across the device respectively. The thyristors/ triac/
rectifier elements shall be protected against voltage surges coming from the incoming power
supply and from out put side from the pipeline. Required shunt zeners / MOV shall be provided
across the rectifier elements for protection.
The rectifier elements shall have humidity/moisture resistant finish and mounted in sufficiently
sized heat sink designed to provide adequate cooling under worst conditions of operation. The
rectifier elements shall have adequate protection against high dv/dt and di/ dt.
6.2.2 The thyristors/triacs shall be protected by semiconductor fuses. For units rated 50V, 50A DC or
less, if the thyristors or triacs are adequately over rated and system has enough inductance so
that in case of sudden output short circuit the over current limit feature comes into action before
short circuit current rises beyond the rating of the thyristors/triacs, then the semiconductor fuses
may not be provided. This feature shall be demonstrated during testing of the unit at works.
6.2.3 Adequate filtering shall be provided on the DC output of the rectifier to limit the ripple content
in the output to less than 5% at rated output.
6.2.4 The rectifier system shall be of natural air cooled type.
6.2.5 For CPTR units with multiple output circuits, each output circuit shall have independent
rectifier and filter.
6.3 Output Protections
Two pole moulded case circuit breaker or miniature circuit breaker (if available) rated for the
DC output current, short circuit current and having thermal over load, short circuit release shall
be provided in the output. A lightning arrestor rated for minimum 10KA impulse current
discharge capacity and rated voltage & maximum spark over voltage rating suitable to protect
the CPTR unit components against lightning and switching surges shall be provided at the
output. For CPTR units with multiple output circuits, each output circuit shall be provided with
circuit breaker and lightning arrestor.
6.4 System Controls
6.4.1 The CPTR unit shall have two distinct modes of operation (independent for each output circuit)
as below:
Page 1724 of 2065

kil R_1t4 ENGINEERS FOR
af
1.72,
, 2 05139,M1
r221,
INDIA LIMITED
IA Go. al Incha unoerta.9)
a) Constant Voltage and Constant Current Mode (CVCC)
In this mode the output voltage of CPTR unit shall be continuously adjustable from 0.5V
DC to the rated output voltage specified on the data sheet. The set output voltage (Vos)
shall remain constant irrespective of output current. Current limit feature shall be
provided. The current limit (Ios) shall be continuously adjustable from zero to rated
output current.
For constant voltage mode of operation the output current limit shall be set at maximum
and output voltage setting shall be varied. Irrespective of output current demand the
chosen value of the output voltage shall be maintained by the control system till the
current limit is reached. After that the output current limit shall be maintained and output
voltage shall decrease to keep the current constant.
For constant current mode of operation the output voltage shall be set at maximum and
output current shall be varied through varying the setting of output current limit.
Irrespective of output voltage requirement the control system shall maintain the output
current to the set current limit value till the voltage limit is reached. After that the output
voltage limit shall be maintained and output current shall decrease to keep the voltage
constant.
b) Auto PSP mode
In this mode of operation the output of the CPTR unit shall operate in an extemal closed
loop with pipe to soil potential (PSP), measured by reference cell, in feed back loop. The
CPTR unit control shall adjust the output voltage such that the PSP as measured by
reference cell always remains equal to the set potential on the unit. The set potential
(Vps) shall have high long time stability and minimum temperature drift. The set
potential shall be continuously adjustable over the range specified in data sheet.
The unit shall be designed to operate with number of reference cells connected to it (to be
provided by others) as specified in data sheet. In case of more than one reference cell
being specified, CPTR unit shall have feature to automatically select the reference cell
having less negative potential than the others and use the same for auto control of the unit
(e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be provided in
selecting the less negative potential reference cell, to avoid hunting between the reference
cells at change over conditions.
In case of open circuit or short circuit of reference cell or potential being less negative
than a minimum set potential (Vrs), the unit shall sense these conditions as reference cell
failure and shall automatically switch over to the other healthy reference cell for control.
Should fault occur in all the reference cells, the output voltage or current of the CPTR
unit shall adjust automatically to a preset value (Vas/Ias), which shall be adjustable.
In both CVCC and auto PSP modes of operation a fast acting electronic over current limit
protection shall be provided. This protection shall be fast enough to protect the active
devices of the unit and fast enough to act before tripping of MCCB/MCB or blowing of
fuse.
6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shall be provided in
case of PSP either exceeding the specified maximum limit (Vpm) or remaining lower than the
specified minimum limit (Vpn).
Page 1725 of 2065

-

(31 ENQNEERS FOR
Ofjleg
eve•me• ,151,34C.,
INDIA LIMITED
IA Govt of Indo Undettalong
6.4.3 The output voltage regulation for no load to full load variation with input voltage variation from
maximum to minimum shall not be more than 2.5 % of rated voltage through out the range of
output voltage and over the specified ambient temperature variation as specified in data sheet, in
CVCC- constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation
for no load to full load variation with input voltage variation from maximum to minimum and
PSP feedback varying over the specified range shall be within 20 mV.
In CVCC- constant current mode of operation, the current regulation for minimum to maximum
output voltage and minimum to maximum variation in input voltage shall not be more than
2.5% through out the range of output current.
6.4.4 The DC output of the CPTR unit shall be floating (ungrounded) in the Unit. However the
CPTR Unit shall allow grounding of positive output terminal through the anode ground bed.
6.4.5 For CPTR units with multiple output circuits, each output circuit shall have independent control
system.
6.5 Current Interrupter
6.5.1 If specified on the data sheet a current interrupter for CPTR Unit output current interruption
shall be provided.
6.5.2 The current interrupter shall have an output contactor with current rating minimum 125% of the
output current rating of the CPTR unit and a digital timer to operate it.
6.5.3 The timer shall have ÒN' and ÒFF' timings. When the timer is turned on the ÒN' timing
shall start and shall close the output contactor till the end of the ÒN' timing. At the end of the
ÒN' timing the ÒFF' timing shall start and keep the contactor open till the end of the ÒFF'
timing. At the end of the ÒFF' timing the ÒN' timing shall start again and close the output
contactor. This process of ÒN' and ÒFF' timing shall continue.
6.5.4 The ÒN' and ÒFF' timings of the timer shall be settable by separate 2 digit thumbwheel
switches, each settable from 1 to 99 seconds. The timing error of the timer shall be less than 5
parts per million. In case of microprocessor based system keypad with display may be provided
in place of thumbwheel switches.
6.5.5 Whenever the timer is switched on it shall always start with ON `timing'. A timer-reset push
button shall be provided. On pressing this push button during operation of the timer, the timer
shall get reset and upon release of the button the timer shall restart with ÒN' timing.
6.5.6 The power required for operation of the timer and contactor shall be derived from the main
power supply to the CPTR unit.
6.5.7 The following controls and indications shall be provided for current interrupter. The controls
shall be housed in a lockable cover, so that normally they are not accessible. The indications
shall be mounted on the door.
a) Controls

Timer reset
Page 1726 of 2065

ENGINEERS FOR
g-a f INDIA LIMITED CATHODIC PROTECTION 6-45-0025 REV. 0
.11-tn e■renotasT.,:nma, IA co. of ■ndia Underca.g)
- Thumb wheel switch for ÒN' timing

- Thumb wheel switch for ÒFF' timing
In case of microprocessor based system keypad with display may be provided in place of
thumbwheel switches.
b) Indications (LED)
- Timer power ÒN'

ÒN' timing
- ÒFF' timing
6.5.8 The output contact of the current interrupter contactor shall be wired in the positive DC output
of the CPTR unit. A link shall be provided for shorting these terminals whenever the current
interrupter is not in use.
6.5.9 If specified in the data sheet the current interrupter shall be an independent unit of portable type.
The interrupter unit shall have terminals for input power supply and terminals of the output
contactor. The input power supply and the rating of the output contactor shall be as specified on
the data sheet. Terminals shall be provided in the CPTR unit for taking power supply to the
current interrupter.
6.5.10 Where the current interrupter is not specified with CPTR unit or is specified as portable type
external to the CPTR unit, then the CPTR unit shall have provision/ terminals for connection of
input power supply and out put contacts of external current interrupter, for current interruption
test. A link shall be provided for shorting the out put terminals provided in CPTR unit whenever
the current interrupter is not connected.
6.5.11 For CPTR units with multiple output circuits, each output circuit shall have independent current
interrupter.
6.6 Controls, Indication and Metering
6.6.1 Following controls shall be provided on CPTR unit front door.
a) ON/OFF control for input through MCCB/MCB.

b) ON /OFF control for output through MCCB/MCB.
c) Auto/CVCC mode selector switch.
d) Potentiometers for Vos, Vps and Ios settings.
e) Selector switch for selecting indication of PSP set and PSP actual for all the reference
cells.
6.6.2 Following controls shall be provided inside the module at user accessible common location:
a) Potentiometer for Vrs, Vpm, Vpn and Vas/Ias settings.

b) Controls for current interrupter:
- Timer reset
- Thumb wheel switch for ÒFF' timing
Page 1727 of 2065

‘31 ENGINEERS FOR
$11g-ar 02-'
dg
171,1 ,mcnr, an~
INDIA LIMITED
GoN of Ind. und~ng)
6.6.3 TR unit shall have following indicating lights (lamps or minimum 5 mm dia LEDs):
a) CPTR unit ON/OFF

b) Unit in auto/CVCC (2 lamps)
c) Reference cell controlling the closed loop control of the CPTR unit (number of lamps
same as number of reference cells).
d) Reference cell faulty (number of lamps same as number of reference cells).
e) Pipeline over protected.
f) Pipeline under protected
g) Indications for current interrupter:
Timer power ÒN'
- ÒN' timing
ÒFF' timing
It shall be possible to switch-off all the indication lamps by a single switch. In case of LED
indication lights this facility may not be provided.
6.6.4 Following meters having min c1.1.5 accuracy shall be provided on the CPTR unit:
a) Digital meter for output voltage

b) Digital meter for output current
c) Digital voltmeter to measure PSP set (Vps) and PSP actual for all the reference cells. The
meter shall have range from -4 V to 0 V and shall have c1.0.5 accuracy.
e) Digital meters for measuring Vrs, Vpm, Vpn and Vas/Ias settings.
f) Meters for input voltage and current
It shall be possible to switch-off all the digital meters preferably by a single switch.
6.6.5 If specified in data sheet, CPTR unit shall incorporate provision for remote monitoring of the
unit through SCADA system as below:
a) Potential free contacts for the following:
- All the reference cells failed. (Contact open on alarm condition)

Pipeline overprotected. (Contact open on alarm condition)
- Pipeline under protected. (Contact open on alarm condition)
- System in auto-mode. (Contact close in auto condition)
System in CVCC mode. (Contact close in CVCC mode)
b) 4 to 20 mA electrically isolated signal for the following:
- PSP (-4V to OV)

- CPTR unit output voltage
- CPTR unit output current
The transducers shall have electrical isolation between input and output. The isolation insulation
shall withstand 2kV, 50Hz for minimum 1 minute. The accuracy class of the transducer shall be
0.5. The transducers shall be protected against input and output voltage surges. The transducer
shall be suitable for driving up to 600 ohms load impedance located up to 500 m away and
wired with 0.5 mm2 copper conductor cable.
Page 1728 of 2065

-

ENGINEERS FOR
INDIA LIMITED CATHODIC PROTECTION 6-45-0025 REV. 0
IA Govl of Intha UnclertaNing)
6.6.6 For units having multiple outputs, each output circuit shall have independent controls,
indication and metering.
7.1 During manufacture, the equipment shall be subjected to inspection by owner or his authorised
representative to assess the progress of the work as well as to ascertain that only quality raw
materials are used for the same. He shall be given all assistance to carryout the inspection.
7.2 Final acceptance test shall be carried out at manufacturer's works under his care and expense.
Instruments and equipments required for testing shall be arranged by manufacturer. Owner's
representative shall be given minimum 2 weeks prior notice for witnessing the tests. Test
certificates indicating test results shall be furnished by the manufacturer. Acceptance tests shall
include but not be limited to the tests listed below.
7.2.1 Visual Inspection
This shall include-
Completeness of the equipment in line with specification.

Checking of all settings.
All labels provided.
Dimensional checking.
Proper mounting of components and neatness of wiring etc.
Model number.
The voltage specified in the table below shall be applied for one minute to the circuits indicated:
Control electronics Power electronics Auxiliary circuits

Withstand voltage
<60V Uni Un2
To earth 700V D.C. 2xUni + 1000V 2xUn2 + 1000V
To control electronics - 2xUni + 1000V 2xUn2 + 1000V
To power electronics 2xUni + 1000V - 2xUn i + 1000V
To auxiliary circuits 2xUn2 + 1000V 2xUn1 + 1000V -
(Uni and Un2 are nominal voltage rating of power electronics and auxiliary circuits
respectively).
D.C. test voltages may be applied instead of A.C. The magnitude of D.C. test voltages to be
applied shall be 2 times the above-mentioned A.C. (r.m.$) Values.
Insulation resistance test shall be conducted before and after heat run test.
7.2.3 Heat Run Test
A11 CPTR units shall be subjected to a heat run test performed at rated voltage for period not
less than 16 hours prior to execution of functional tests.
Page 1729 of 2065

(r;\ ENGINEERS
rz" INDIA FOR
22Cg LIMITED CATHODIC PROTECTION 6-45-0025 REV. 0
(A GoN of Intlia UnderlakIng
At least one CPTR unit of each rating shall be loaded to its rated output through out 16 hour test
period. All other CPTR units shall be energized under partial load or zero load current condition
through out the test period.
Functional tests as below shall be performed on each CPTR unit. If during execution of
functional tests, any electronic component of the unit is required to be replaced e.g. due to
malfunction or failure of the unit to fulfil the performance requirements of the specification,
then the load test shall be repeated at rated current following which functional tests shall be
carried out.
7.2.4.1 CVCC Mode Operation Testing
a. Constant Voltage Operation
During the test current limit shall be set to rated output current. Performance testing shall
be carried out for various out put voltage settings and load varying from zero to
maximum. The verification of operation of the control functions, measurement of output
voltage, current, input AC voltage, current, power factor, ripple in the output, evaluation
of output voltage regulation and efficiency of the unit shall be carried out during the
testing.
b. Constant Current Operation
During the test voltage limit shall be set to rated output voltage. Performance testing shall
be carried out for various out put current limit settings and load resistance varied to
achieve output voltage from minimum to maximum. The verification of operation of the
control functions, measurement of output voltage, current, input AC voltage, current,
power factor, ripple in the output, evaluation of output current regulation of the unit shall
be carried out during the testing.
7.2.4.2 Auto PSP Mode Operation
Suitable set up shall be arranged for out put loading and reference cell feed back. The closed
loop performance and regulation shall be checked with the PSP set voltage varied from 0.85V to
1.2V.
Disconnecting the reference cell feed back connection in the above set up shall simulate the
reference cell failed condition. The output voltage/current of the unit shall go to the value set on
the potentiometer Vas/Ias provided inside the CPTR UNIT. The settings on Vas/Ias shall be
varied and the output voltage/current shall be observed.
7.2.4.3 Operation of sensors for pipeline over protection, under protection, reference cell failure and
reference cell selection logic in auto PSP mode shall be verified by connecting variable external
voltage sources to reference cell inputs of the CPTR unit. The number of external voltage
sources shall be same as number of reference cell inputs specified for the CPTR unit.
7.2.4.4 The unit shall be checked for operation of the current limit by over loading the unit in both
CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not provided
for protection of the thyristors/triacs, the protection of same shall be tested as below:
Page 1730 of 2065

k31 ENGINEERS FOR
5g-L;IT Of5Er
1.41, a31.30,4:1)
INDIA LIMITED
IA Go. of InCia Under~9)
A switch rated for making and carrying CPTR unit output short circuit current shall be
connected to the output terminals of the unit. The output voltage and the output current limit
settings of the unit shall be set to the maximum rated values. The switch connected in the output
shall be shorted quickly.
The unit shall go to current limit mode and shall not damage any active component of the unit.
7.2.4.5 The current interrupter shall be tested for time interval settings and specified operation.
The equipment shall be properly packed for selected mode of transportation i.e. by ship/ rail or
trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent
damage to finish. Crates shall have skid bottom for handling. Special notations such as
`Fragile', `This side up', `Center of gravity', `Weight' etc., shall be clearly marked on the
package together with Tag nos., P.O. Nos. etc.
completely suitable for outdoor storage in areas with heavy rains/ high ambient temperature.
Page 1731 of 2065

ENGINEERS FOR
INDIA LIMITED 6-45-0026 REV. 0
rItrrAl JWITA Govt of inoia Undeftakng) CORROSION SURVEY Page 1 of 7
wur ~fr fq-Nkr
SPECIFICATION
FOR
CORROSION SURVEY
tfk Nt".
0 17.07.14 NSB RC PPL g SC
(OLD DOC. NO.: 6-51-0026, REV. 3)
Standards Standards
Date Purpose by Convenor Chairman
No by
Approved by
Page 1732 of 2065

r= ENGINEERS
O FOR
INDIA LIMITED 6-45-0026 REV. 0
IA Go. of Inthe undertalong)
CORROSION SURVEY Page 2 of 7
Abbreviations:
CP Cathodic Protection
DC Direct Current
EHV Extra High Voltage
HV High Voltage
HVDC High Voltage Direct current
NACE National Association for Corrosion Engineers
ROU Right of Use

Page 1733 of 2065

ENQNEERS
5sZII 22eg INDIA LIMITED FOR 6-45-0026 REV. 0
.177/ ,I,cnre,D7 3W/,
A/ IA Govt ol Indol Undertaiong)
CONTENTS
1.0 SCOPE 4
3.0 GENERAL 4
4.0 SOIL RESISTIVITY SURVEY 4
5.0 TESTS ON SOIL SAMPLES 5
6.0 ADDITIONAL DATA COLLECTION 5
7.0 REPORT 7
Page 1734 of 2065

-

E.3 ENQNEERS
C.
24[22-eg INDIA LIMITED
IA Go. of InOia Urulellak,ng)
FOR 6-45-0026 REV. 0
1.0 SCOPE
The specification covers the requirements for corrosion survey including measurement of soil
resistivity, chemical analysis of soil/ water and collection of other cathodic protection related
data along ROU of the pipelines.
Equipment and measurement techniques shall unless otherwise specified, conform to the
requirement of latest revisions of following applicable standards:
BIS specifications
BS specifications and codes of practice
NACE publications
The work shall be carried out in compliance with all applicable local laws and regulations.
In case of any contradiction between various referred standards/ specifications/ data sheet and
Statutory Regulations
Data Sheets
Job Specification
This Specification
Codes and Standards
3.0 GENERAL
This specification defines the basic guidelines for carrying out the corrosion survey. Contractor
shall be responsible for providing necessary data interpretation based on corrosion survey
measurements, which is intended to form a basis for design of cathodic protection system for
the pipeline.
4.0 SOIL RESISTIVITY SURVEY
4.1 Unless otherwise specified the soil resistivity measurements shall be carried out at intervals of
approximately 1000 m along the ROU. Where soil resistivity is less than 100 ohm-m and two
successive readings differ by more than 2:1 then additional soil resistivity readings in between
the two locations shall be taken.
4.2 To carryout the soil resistivity measurement, Wenner's 4 pin method or approved equal shall be
used. The depth of resistivity measurement at each location shall be at around 1 m and at the
burial depth of the pipeline accounting for the cuttings/ fillings or 2 m approximately which
ever is higher. At locations where multi layer soil with large variation in resistivity/
corrosiveness is expected and/or locations specifically advised by OWNER or his
representative, resistivity measurements at additional depth of up to 3 m (approx.) or more shall
be taken. In general the resistivity of soil, which shall be surrounding the pipe, shall be
measured. Hence the depth of measurement/ electrode spacing may vary depending on
topography and strata at the area.
Page 1735 of 2065

k31 ENGINEERS
$igu OfM- g INDIA LIMITED FOR 6-45-0026 REV. 0
,rrerrween.yrars0 IA Go. ol heba Unden.kM)
4.3 At places where ROU has not yet been cleared, measurements shall be made right over the
centre line of pipeline route surveyed accounting for the cuttings/ fillings also.
4.4 Observations shall be made enclosing the soils adjoining the trench wherever pipeline trenching
has already been done.
4.5 The observations shall be made enclosing the soil immediately surrounding the pipeline route
where ROU has been cleared but trenching has not been done.
4.6 All measurements shall be taken at right angles to the ROU unless otherwise asked by OWNER
or his representative at site.
4.7 At places in ROU where other pipelines are already existing care shall be taken to precisely
locate such pipes line and take such precautions that observations are not adversely affected by
presence of such pipelines.
4.8 Care shall also be taken that the observations are not influenced by presence of other earth
currents in the area especially in the vicinity of EHV/HV lines and plants using earth return in
their source of power etc.
4.9 Wherever possible/ advised by OWNER or his representative, depth of water table shall be
determined by resistivity observations.
4.10 All measurements shall be made and recorded in metric units. While recording the data
reference to the nearest intersecting point shall be made. To provide visual representation of
variations in the resistivity along ROU, values shall be plotted on semi log graph sheets. The
resistivity graph shall also indicate the resistivity at additional depths measured at various
locations and depth of water table.
5.0 TESTS ON SOIL SAMPLES
Soil/ water samples shall be collected along the ROU for analysis. Samples shall be collected on
an average at one location for every 10 km along ROU with minimum at approximate two
equidistant locations. Exact locations shall be decided at site depending on the type of soil, soil
resistivity and in consultation with OWNER or his representative. At each location the soil
samples shall be collected at 1 m, 2 m depth and at scheduled/ designed depth of pipeline if it is
more than 2 m at the location.
The collected soil/ water samples shall be analysed to determine presence and percentage of
corrosive compounds including carbonates, bicarbonates, nitrates, chlorides, oxygen activity,
moisture content and pH value.
6.0 ADDITIONAL DATA COLLECTION
The following data shall be collected with a view to generate design data for evaluation of
cathodic protection interaction possibilities due to presence of other services in ROU and its
vicinity:
6.1 Following information regarding foreign service/ pipeline in or around the ROU (for existing
and those, which are likely to come up during contract execution):
Page 1736 of 2065

ENGINEERS
f812Cg INDIA LIMITED FOR 6-45-0026 REV. 0
1.17,1 ‘4,151.1 451,1053:11 (A GoN ol Intha uncien"ng)
6.1.1 Types of service/ pipeline and year of laying
6.1.2 Diameter and pipeline coating in case of pipeline
6.1.3 Parallel running/ crossing
6.1.4 Year of laying/ commissioning
6.1.5 Depth of laying
6.1.6 Type of existing cathodic protection systems (impressed current / sacrificial)
6.1.7 Location and type (Deep well / surface) of anode ground bed
6.1.8 Rating of impressed current type of anode ground bed
6.1.9 Location of existing CP power supply units and their output voltage, current, pipe to soil
potential readings
6.1.10 Location of existing test stations
6.1.11 Remedial measures existing on foreign service/ pipeline to prevent interactions
6.1.12 Graphical representation of existing structure/ pipe to soil potential records
6.1.13 Possibility of integration/isolation of CP system of the foreign service/ pipeline with that of the
proposed pipeline, which may involve negotiations with owner's of foreign services
6.1.14 Where pipeline is likely to pass close to any existing ground bed (with in 100 m approx), anode-
bed potential gradient survey shall be carried out to verify possible interference with the CP
system of the pipeline covered under this project.
6.2 Voltage rating, phases and sheathing details of cables running parallel or crossing the ROU.
6.3 Existing and proposed DC/AC power sources and systems using earth return path such as
HVDC substations/ earthing stations, fabrication yards with electric welding etc. in the vicinity
of the entire pipeline route.
6.4 Crossing and parallel running of electrified and non-electrified traction (along with information
regarding, operating voltage, AC/DC type etc.) as well as abandoned tracks near ROU having
electrical continuity with the tracks in use.
6.5 Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power lines
along with details of voltage, AC/DC type etc.
6.6 Voltage rating, phases, sheathing details of underground power cables along ROU or in its
vicinity.
6.7 Any other relevant information that may be needed in designing and implementing of proper
cathodic protection scheme for the proposed pipeline.
Page 1737 of 2065

t.71 , ENGINEER.S
laWg INDIA LIMITED
Govt of India Undert~g)
FOR 6-45-0026 REV. 0
7.0 REPORT
On completion of all the field and laboratory work an interim report incorporating results
generated from surveys, additional data collected, results of test carried out etc. shall be
submitted for comments/ approval. The report shall also highlight any adverse impact on
performance of sacrificial anodes due to the percentage of corrosive compounds including
carbonates, bicarbonates, nitrates, chlorides present in the soil and pH value of the soil noticed
during the survey. The final report incorporating comments/ missing data shall be furnished for
records. The report along with various drawings, graphs etc. prepared in connection with the
work shall be submitted along with six prints by the contractor.
Page 1738 of 2065

ENGINEERS FOR SACRIFICIAL ANODE
INDIA LIMITED CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
Go. of Indta Unelerlaog)
FOR PIPELINES Page 1 of 18
rehrt4licti
mulicen fffq "Nr-44T
SPECIFICATION
FOR
PROTECTION SYSTEM
FOR PIPELINES
SPECIFICATION NO. 6-51-0027 REVISED,

0 21.05.12 RENUMBERED AND ISSUED AS GSH BC PPL DM
STANDARD SPECIFICATION
Standards Standards
Prepared Checked Committee Bureau
Rev. Date Purpose Convenor Chairman
by by
Approved by
Page 1739 of 2065

IND1A LIMITED CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
IA Govt of Intha Undertakog)
Abbreviations:-
AC : Alternating Current
ASTM : American Society for Testing and Materials
BS : British Standards
CMRI : Central Mining Research Institute
CPPSM : Cathodic Protection Power Supply Module
CTE : Coal Tar Enamel
DC : Direct Current
EHV : Extra High Voltage
FBE : Fusion bonding Epoxy
HDD : Horizontal Directional Drilling
HV : High Voltage
HVDC : High Voltage Direct Current
IS : Indian Standards
MOV : Motor Operated Valve
j, A/mm2 : Micro-Ampere per square millimeter
NACE : National Association of Corrosion Engineers
PE : Polyethylene
ROU : Right of Use
SV : Sectionalizing Valve

Format No. 8-00-0001-F1 Rev. 0 Copydght EIL — All rights reserved
Page 1740 of 2065

Og-a l
wan .3v0,1)
INDIA LIMITED CATHODIC PROTECTION SYSTEM
IA GoN of Ind. Uncleeta.g)
6-45-0027 REV. 1
CONTENTS
1. SCOPE 4
2. APPLICABLE CODES AND STANDARDS 4
3. SYSTEM IMPLEMENTATION 5
4. CORROSION SURVEY 5
5. CATHODIC PROTECTION DESIGN PARAMETERS 6
6. CATHODIC PROTECTION DESIGN CRITERIA 8
7. SYSTEM DETAILS 8
8. INSTALLATION 14
9. FIELD TESTING AND COMMISSIONING 15
10. INTERFERENCE MITIGATION 17
11. SYSTEM MONITORING 17
12. CLOSE INTERVAL POTENTIAL LOGGING SURVEY 18
Page 1741 of 2065

kil 'i ENGINEERS FOR SACRIFICIAL ANODE
Og-af la2eg INDIA LIMITED CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
4.117/1 eYrcrxe,■171.3POSTO IÀ GoN of India Undettabong)
1. SCOPE
1.1 This specification defines the requirements of design, engineering, installation, testing and
commissioning of sacrificial anodes cathodic protection system for external surface of cross
country onshore underground pipelines/ structures including supplementing of corrosion
survey, investigation for interference/ interaction problems and mitigation of the same.
1.2 This specification defines the basic guidelines to develop a suitable sacrificial anode cathodic
protection system for the pipelines/ structures required to be protected. All data required in
this regard shall be taken into consideration to develop an acceptable design and for proper
engineering of the system.
1.3 Compliance with these specifications and/or approval of any of the contractor's documents
shall in no case relieve the contractor of his contractual obligations.
2. APPLICABLE CODES AND STANDARDS
2.1 The system design, performance and materials to be supplied shall conform to the
requirements of the latest revision of following standards as a minimum:
- NACE Standard SP0169 : Control of External Corrosion on Underground or

Submerged Metallic Piping Systems
- NACE Standard SP0177 : Mitigation of Alternating Current and Lightning

Effects on Metallic Structures and Corrosion
Control Systems
- NACE Standard SP0207 : Performing Close-Interval Potential Surveys and

DC Surface Potential Gradient Surveys on Buried or
Submerged Metallic Pipelines
- NACE Standard SP0286 : The Electrical Isolation of Cathodically Protected

Pipelines
- BS 7361, Part I : Cathodic Protection- Code of Practice for Land and

Marine Applications
- VDE 0150 : Protection against Corrosion due to Stray Current

from DC Installations
- IS 8062 : Code of Practice for Cathodic Protection of Buried

Pipeline/ Structure for Transportation of Natural
Gas, Oil and Liquids
- IS 1554, Part I : PVC Insulated (Heavy Duty) Electric Cables: For

Working Voltages up to and Including 1100V
- IS/ IEC: 60079 : Electrical Apparatus for Explosive Gas Atmosphere
- IS/ IEC: 60529 : Classification of Degree of Protection Provided by

Enclosures
2.2 In case of imported equipments standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable lndian Standards.
Page 1742 of 2065

-

gelflafjles INDIA LIMITED CATHODIC PROTECTION SYSTEM
GoN of InCia Undertak.ng)
6-45-0027 REV. 1
2.4 In case of any contradiction between various referred standards/ specifications/ data sheet
and statutory regulations the following order of priority shall govern:
- Data Sheets
Job Specification
3. SYSTEM IMPLEMENTATION
All work to be performed and supplies to be effected as a part of contract shall require
specific review by Owner or his authorised representative. Major activities requiring review
shall include but not be limited to the following:
a) Corrosion survey data interpretation report and design basis for CP system
b) CP system design package
c) Detailed engineering package
d) Field testing and commissioning procedure
e) Procedures for interference testing and mitigation
f) Close interval potential logging survey procedure and report
g) CAT/ DCVG survey procedure and report
h) System monitoring procedures
i) As built documentation
4. CORROSION SURVEY
4.1 The details of corrosion survey including soil resistivity data along ROU and other data
required for CP design if available with the Owner shall be included as part of project
specification/ data sheet. However, verification of its veracity and adequacy shall be the
entire responsibility of the contractor. In addition, contractor shall collect additional data as
per clause 4.2 below required for proper implementation of the protection system. Contractor
shall also carry out soil resistivity survey at sacrificial anode ground bed locations for proper
design of ground beds. Wenner's 4-pin method or approved equal shall be used for such
measurements. Survey instruments shall have maximum AC and DC ground current rejection
feature.
Care shall be taken to ensure that the resistivity observations are not influenced by the
presence of foreign pipelines/ structures, and earth currents in the vicinity of EHV/HV lines
and installations using earth return in their power system etc.
Where specified in the project specification/ data sheet, the contractor shall carry out
corrosion survey along the ROU of the pipeline conforming to the specifications included in
the tender document.
4.2 Additional Data to be Collected
The following data shall be collected to generate design data for evaluation of interaction/
interference possibilities due to presence of other services in ROU/ vicinity. Owner shall
provide assistance for liaison work to the extent possible:
Page 1743 of 2065

ENQNEERS FOR SACRIFICIAL ANODE
51g-ar 02&-g
1.71271,,,m1,01.3421,-.11
IA Gos1 of India Underta.g)
6-45-0027 REV. 1
i) Route and types of foreign service/ pipeline in and around or crossing the right of use
(including those existing and those which are likely to come up during contract
execution).
ii) Diameter, wall thickness, pressure, soil cover, and coating scheme used, type of
cathodic protection system provided, if any, and year of laying/ commissioning in case
of foreign pipelines.
Details of the existing cathodic protection systems protecting the services i.e. type of
protection system, location (distance from the proposed pipeline), type, rating of anode
beds, test station locations and their connection schemes. Present output current and
voltage readings of the CP power supply units.
iii) Remedial measures existing on foreign pipelines/ services to prevent interaction.
iv) Graphical representation of existing structure/ pipe-to-soil potential records.
v) Possibility of integration/ isolation of CP systems, which may involve negotiations

with owners of other services.
vi) Crossing and parallel running of electrified and non-electrified traction (along with
information regarding, operating voltage, AC/DC type etc.) as well as abandoned
tracks near ROU having electrical continuity with the tracks in use.
vii) Information on existing and proposed DC/AC power sources and systems using earth
return path such as HVDC substations/ earthing stations, fabrication yards with electric
welding etc. in the vicinity of the entire pipeline route.
viii) Crossing or parallel running of any existing or proposed 11 KV and above AC/DC
overhead power lines along with details of voltage, AC/ DC type etc.
ix) Voltage rating, phases, sheathing details of underground power cables running along
ROU or in its vicinity.
x) Any other relevant information that may be needed in designing and implementing
proper protection scheme for the proposed pipeline.
Contractor shall conduct necessary potential gradient surveys for any existing anode ground
beds that may interfere with the CP system of the pipelines covered under this project.
4.3 Report
On completion of all fieldwork, a report incorporating all the results generated from surveys
and details of additional data collected shall be prepared. The report shall also contain soil
resistivity data and detailed interpretation of survey results, probable interference prone areas
etc. to form design basis for the cathodic protection system. This report shall also include
various drawings prepared in connection with the above work. The soil resistivity values
shall be plotted on semi-log graph sheets.
5. CATHODIC PROTECTION DESIGN PARAMETERS
Unless otherwise specified in the data sheet, following parameters shall be used for design of
cathodic protection system.
Where the cathodic protection system is specified for temporary protection, those parts of
sacrificial anode cathodic protection system which will be integrated with the permanent CP
system shall be designed based on permanent CP parameters.
Page 1744 of 2065

$}g-arRfcg INDIA LIMITED CATHODIC PROTECTION SYSTEM
IAGovt of Ind. Undertakingt
6-45-0027 REV. 1
5.1 Protection Current Density
i) Pipe lines having Coal Tar Enamel (CTE) coating with two/ three layers of
reinforcement:
Minimum Protection Current Density*
Permanent CP for 30-Year

Temporary CP
Design Life
0.1 A/m2)
(1.1 A/m2)
40 500
ii) Pipe lines having Dual Layer Fusion Bonded Epoxy (DLFBE) coating or 3-Layer
Polyethylene (3LPE) coating:

Temporary CP
Design Life
(p. A/m2) (3. Ahn2)
25 250
The above current density values for temporary CP system are applicable for CP system
design life up to two years.
*Actual current density to be adopted shall be decided based upon soil and other
environmental conditions, current drainage survey data (where included in contractor's
scope), proximity of foreign pipe lines/ structures and other interference areas affecting the
installation. Where considered necessary for satisfactory protection of pipeline the current
density shall be suitably increased by contractor.
5.2 The pipe protection Current Density indicated in the clause 5.1 above shall be applicable
where the temperature of the fluid transported by the pipeline/ the surface temperature of the
buried portion of the pipeline does not exceed 30 °C. Where this temperature exceeds 30 °C,
the protection Current Density shall be increased in minimum by 25% for every 10 °C rise in
temperature over 30 °C.
5.3 For all pipeline sections which are having intermediate HDD (Horizontal Directional
Drilling) crossings, the nearby T/R units should have adequate provision of D.C. output
current to cater to the extra protection current demand at the HDD crossings.
5.4 Safety factor for current density 1.3
5.5 Anode utilisation factor 0.85 for solid anodes

• 0.6 for ribbon anodes
5.6 Pipeline natural potential (-) 0.45V
5.7 Unless otherwise specified in data sheet the design life for temporary CP system shall be one
year and that for permanent CP system shall be 30 years.
5.8 Unless otherwise specified in the project specification/ data sheet, temporary CP for the
pipeline may not be provided along the ROU where soil resistivity is higher than 150 Ohm-m.
Page 1745 of 2065

k31 ENGINEERS FOR SACRIFICIAL ANODE
zat Wieg INDIA LIMITED CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
1.17-rt ..-lemr1an IAGo vt o1 I ncha
undenaking)
6. CATHODIC PROTECTION DESIGN CRITERIA
Cathodic protection system shall be designed to meet the following criteria:
6.1 The pipe to soil potential measurements shall be between (-) 0.95 V (ON) and (-) 1.5 V (ON)
for polyethylene coated pipe lines, between (-) 0.95 V (ON) and (-) 1.7 V (ON) for fusion
bonded epoxy/coal tar coated pipe lines with respect to a copper/copper sulphate reference
electrode.
Where polarisation coupons are provided along the pipeline the coupon to soil potential
measurements shall be between (-) 0.9V (OFF) and (-) 1.18V (OFF) with respect to a
copper/copper sulphate reference electrode.
6.2 A positive potential swing of 100 milli volts or more shall be considered sufficient to indicate
the presence of an interaction/ interference situation requiring investigation and incorporation
of mitigation measures by the Contractor.
7. SYSTEM DETAILS
The system shall include the following major equipment/ sub-systems unless otherwise
specified in project specifications.
Sacrificial anodes and anode ground beds

- CP system at cased crossings
Test stations
- Polarisation coupons
- Surge diverter and polarisation cell
Permanent reference cells
Interconnecting cables
- Cables to pipe connections
All equipment shall be new and procured from approved manufacturers. Equipment offered
shall be field proven. Equipment requiring specialised maintenance or operation shall be
avoided as far as possible. Prototype equipment shall not be accepted.
Equipments shall conform to the relevant specifications enclosed with the tender document.
All equipment including test stations, etc. shall be located in safe non-hazardous areas.
Where it is essential to install electrical and electronic instrument enclosures and its
accessories in hazardous area, such equipment shall be flame proof type and shall meet the
requirements as per IS/ IEC: 60079 and shall be weather proof to IP-65 also as per
IS/IEC:60529.
A copy of approval from local statutory authority, as applicable such as Petroleum &
Explosives Safety Organization (PESO)/ Chief Controller of Explosives (CCE), Nagpur or
Director General of Mines Safety (DGMS) in India, for the electronic instruments installed in
electrically hazardous area along with:
i) Test certificate from recognized test house like Central Institute of Mining and Fuel
Research (CIMFR)/ Electronics Regional Testing Laboratory (ERTL) etc. for
flameproof enclosure/ intrinsic safety, as specified in the data sheet, as per relevant
standard for all Indian manufactured equipments or for items requiring Director General
of Mines Safety (DGMS) approval.
Page 1746 of 2065

IND1A LIMITED CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
1.7?1,-Iroxlas,347.0 in co. of Incha Undertaking)
ii) Certificate of conformity from agencies like Laboratorie Central Des Industries
Electriques (LCIE), British Approval Service for Electrical Equipment in Flammable
Atmospheres (BASEEFA), Factory Mutual (FM), Physikalisch-Technische
Bundesanstalt (PTB), Canadian Standards Association (CSA), Underwriters
Laboratories (UL) etc. for compliance to ATEX directives or other equivalent standards
for all equipments manufactured outside India.
7.1 Anode Ground Beds
Along ROU, where soil resistivity is within 10 Ohm-m and pH value is within 9, either Zinc
anodes or Magnesium anodes shall be provided.
In case of Zinc anodes, anode of type I as per ASTM B418 standard shall be used for
seawater, brackish water having resistivity not exceeding 10 Ohm-m and for grounding/
earthing of pipelines. Anode of type II as per ASTM B418 standard shall be used for ribbon
anodes for protection of carrier pipes inside casing or for application in saline soil having
resistivity less than 10 Ohm-m.
7.1.1 Along ROU, where soil resistivity exceeds 10 Ohm-m, Magnesium anodes shall be provided.
7.1.2 Anodes shall be installed along the pipeline at suitable intervals as per pipeline protection
voltage attenuation calculations and ground bed resistance/ current output of anode
installations. At high resistivity area the Magnesium ribbon anodes shall be installed all along
the pipeline by the side of the pipeline in the pipeline trench.
7.1.3 Suitability for proper operation of the selected type of sacrificial anodes for the soil
conditions with particular attention to carbonates, bicarbonates, phosphates and nitrates shall
be checked by the contractor. The anodes shall be laid in proper type of back fill, such that
the effect of soil is minimum on the anode performance and life. Suitable safe guards against
anode passivation in prevailing soil shall be taken by the contractor.
7.1.4 Each electrically continuous section of pipeline shall be protected totally by single type of
anode to avoid inter-anode circulation currents.
7.1.5 The anodes shall be installed at sufficient depth to reach moist soil and shall be separated
from the pipeline by at least 5 m and 2 m for Magnesium and Zinc anodes respectively. The
Magnesium ribbon anode shall be separated from the pipeline by at least half a meter. The
anode connections to pipe line shall be routed through test stations.
7.1.6 At the temporary CP anode ground bed, the leads of all the anodes shall be joined together in
a junction box filled with epoxy and buried. A single cable shall be routed from the junction
box to test station.
7.1.7 For sacrificial anode ground bed which is intended for permanent CP system and/or which is
to be integrated with permanent CP system, the leads of all the anodes shall be brought up to
the test station and shall be terminated individually.
7.1.8 The number of anodes at each ground bed shall be sufficient for providing the specified pipe
protection current density taking into consideration the ground bed resistance, cable
resistance etc. For permanent cathodic protection system, contractor shall prepare a table for
number of anodes required at different soil resistivity to produce the specified protection
current for the specified designed life. For temporary cathodic protection system, an
indicative design data for sacrificial anodes ground bed in tabular form is given in data sheet.
The number of anodes at each anode ground bed, spacing of anode ground beds based on the
applicable soil resistivity, size of pipeline, type of coating for the pipeline shall be chosen
from the table after necessary verification by the CP contractor.
Page 1747 of 2065

Of51- g
,wenr1M1.37-tn-fil
inGoN of India Undertakong)
6-45-0027 REV. 1
For temporary protection of pipelines, Magnesium anodes shall be installed at 1 Km interval
along the pipeline. At each location suitable number of anodes shall be installed in parallel,
so as to achieve the desired current output for the given soil resistivity and pipeline
protection current density or coating resistivity. Minimum separation of the nearest anode
from the pipeline shall be 5 m. The group of anodes at each location shall be laid in a single
row perpendicular to the pipeline. Each anode shall be of minimum 2.5 Kg. net weight
(excluding backfill). Anode cable from each anode shall be terminated inside the test station.
Individual cable ends at the test station shall be linked through a Copper bus bar. Above 150
Ohm-m soil resistivity, the installation of sacrificial anodes may not be required for
temporary protection of the pipeline unless otherwise specified in the project specification/
data sheet.
7.1.9 For the portion of the pipeline for which the CP system has been specified based on the
permanent CP system parameters, the contractor shall ascertain the requirement of the
cathodic protection current density indicated in clause 5.1 above. Where specified in the
project specification/ data sheet the requisite current requirement/ drainage survey shall be
conducted by the contractor to establish the adequacy of CP current requirement and number
of anode ground beds.
7.2 Test Stations
7.2.1 Test stations shall be provided along the pipeline ROU for monitoring the performance of the
cathodic protection system at the following locations. Test stations shall be provided at
additional locations, if required, so that distance between any two adjacent test stations does
not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like
forest/deserts:
a) At the locations of anode ground beds.
b) At both sides of metalled road crossings where cased crossing is considered for the
crossing. At one side of the road crossing where casing pipe is not considered for the
crossing. In case more than one such uncased road crossing occurs within lKm, then
only one such uncased road crossing shall be provided with test station within 1Km.
c) At all insulating joints.
d) At vulnerable locations with drastic changes in soil resistivity.
e) At locations of reference cells, surge diverters, polarisation coupons, pipeline grounding

through polarisation cells, Zinc and Magnesium anodes.
f) At railway line crossings and at selected locations along railway lines running parallel to
the pipeline.
g) At both sides of major river crossings.
h) At EHV/HV cable crossings or along routes where EHV/HV cables are running in
parallel.
i) At EHV/HV AC/DC overhead line crossings and along routes where EHV/HV
overhead line are running in parallel.
j) In the vicinity of DC networks or grounding systems and HVDC grounding systems

where interference problems are suspected.
k) At crossings of other pipelines/ structures.
1) Locations where interference is expected.

Page 1748 of 2065

-

(
rriz ENGINEERS
Th INDIA FOR SACRIFICIAL ANODE
$ifg-
ar iffleg LIMITED CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
1.41, 370r. IA Govtof Indla Undeltakfng)
m) At locations of Sectionalising Valve (SV) stations.
n) At any other locations considered necessary by Owner/ Owner's representative.
7.2.2 Test stations used for sacrificial anodes shall have shunt for measurement of anode current,
provision for resistance insertion to limit the anode current output and anode-disconnecting
link.
7.2.3 Test stations for bonding shall be provided with a link and shunt, resistor as a means to
monitor and control current flow between the pipeline and foreign pipelines or structures that
may exist in common ROU.
7.2.4 Unless otherwise specified in the project specification/data sheet, Test station with current
measuring facility shall be provided at interference prone areas, on both sides of major river
crossings, and minimum one for every 10 km max. along the pipeline and at SV, IP, RT, DT
locations where CP Stations shall be considered.
7.2.5 The test stations shall be installed with the face of the test station facing the pipeline. The
nameplate of test stations shall carry the following minimum information:
Chainage in km.
Test station connection scheme
Distance from pipeline in metres.
Direction of product flow.
7.2.6 Terminals and different schemes of wiring shall be provided as per the test station connection
scheme. Minimum twenty percent spare terminals shall be provided in each test station.
7.2.7 Minimum two cables shall be provided from the pipeline at any test station.
7.2.8 The location of all the test stations shall be marked with their connection schemes and other
relevant information on alignment sheets. A detailed test-station schedule shall be prepared.
7.3 Polarization Coupons
7.3.1 Unless otherwise specified in the project specification/data sheet steel coupons of pipeline
material shall be provided along the pipeline to monitor the adequacy of the CP system to
polarize/protect coating holidays. Coupon shall be installed at permanent CP station drainage
points, predicted cathodic protection mid points along the pipeline, at locations where the
pipeline is bonded to foreign pipeline/structures, interference prone areas, marshy areas, At
every 10 km approximate along the pipe line etc.
7.3.2 Coupons shall be installed at bottom 1/3rd portion of the pipeline and 200 mm approx away
from the pipe surface.
7.3.3 The coupons shall be constructed from the pipeline material and shall have one side uncoated
surface area of 100 mm x 100 mm exposed to soil. Two cables one for connection to pipeline
for coupon protection and other for coupon potential measurement shall be provided for each
coupon. The coupon protection cable shall be connected through a vacuum sealed magnetic
reed switch inside the test station to enable measurement of coupon ÒFF' potential.
7.3.4 A permanent reference electrode shall be installed adjacent to the coupon in a manner so as
to measure the representative potential of the coupon.
7.3.5 Magnets for operation of reed switch shall be provided as specified in the project
specification/data sheet.
Page 1749 of 2065

ENQNEERS FOR SACRIFICIAL ANODE
Og-ar fafJleg
rwcm,
INDIA LIMITED
IA GoN of Ind. Urbertakrtgl CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
7.4 Permanent Reference Cells
7.4.1 High purity copper-copper sulphate permanent reference cells with proven high reliability
shall be provided for stable coupon to soil potential measurement at the locations of
polarisation coupons.
7.4.2 The reference cells shall be of silver/silver chloride type in place of copper/copper sulphate
cells, at locations where chloride ion concentration is more than 300 ppm.
7.4.3 The life of reference cells shall be minimum 8 years under burial conditions.
7.4.4 The test station connection scheme inside the test station shall clearly indicate the type of
reference cell (Cu CuSO4/ Ag AgC1).
7.5 Surge Diverter
7.5.1 Explosion proof solid state surge diverter shall be connected across each insulating joint to
protect it from high voltage surges.
7.5.2 The total system including surge diverters, cables, cable termination, etc shall be suitable for
the anticipated fault current at the location of installation.
7.5.3 The surge diverter shall be suitable for the design life of permanent CP system.
7.6 Polarisation Cell
7.6.1 Wherever the pipeline is either crossing or running in parallel with overhead EHV/HV
transmission lines of voltage grade 66kV and above, it is mandatory that the pipeline shall be
grounded to discharge any accumulated potential/ surge that may appear in case of
transmission line faults, as per below:
The pipeline shall be grounded through polarization cell with Zinc galvanic anodes of
either block anode or ribbon type. Sizing and quantity of anode shall be decided so as to
achieve maximum total earth resistance of 5 Ohm for each location where pipeline
crosses EHV/HV transmission lines.
The pipeline shall be grounded at regular intervals of maximum lkm where EHV/HV
transmission lines run parallel within 25m of the pipeline. Also, where EHV/HV
transmission lines run parallel beyond 25 m of the pipeline and it is expected from
calculations/ software simulations that surge would appear in case of transmission line
faults or any abnormal operating conditions.
7.6.2 Locations along pipeline where continuous induced over-voltage due to overhead
transmission lines/ underground cables is expected or observed by calculation/ software
simulations or observed during commissioning, the pipeline shall be grounded through
polarisation cell to the earth system of the transmission tower causing the voltage induction
or to a separate earthing system of Zinc anodes through polarisation cell.
7.6.3 The solid state type polarization cell shall be installed inside test station.
7.6.4 Areas where soil resistivity is higher than 50 Ohm-m Zinc ribbon anodes installed in
carbonaceous backfill instead of 20kg net prepacked Zinc solid anodes may be provided for
grounding.
7.6.5 The total system including cable, cable termination, polarisation cells and anodes shall be
suitable for the anticipated fault current at the location of its installation.
Page 1750 of 2065

~-it4 ENGINEERS FOR SACRIFICIAL ANODE
OgZif laf51ft. INDIA LIMITED CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
INT,,,oronlOTI,AffrAl IA GoN ol Ind. UndertaMing)
7.6.6 The polarisation cell and anode system shall be suitable for the design life of permanent CP
system. The grounding system shall have minimum resistance to earth to restrict the pipeline
voltage as per NACE/ VDE criteria but shall not exceed 5 Ohms.
7.6.7 The anodes shall be pre packed with special backfill adequately so that the performance of
the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In
any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.
7.7 Motor operated valves where located on the cathodically protected portion of the pipeline
shall be grounded by a Zinc or Magnesium anode of 20 kg net where the type of anode
provided for the CP system of the pipeline is Zinc or Magnesium respectively. The MOV
power supply cable armour shall be insulated (by cutting and taping with insulation tape) at
MOV end to avoid armour carrying CP current.
7.8 The above ground cathodically unprotected pipeline at intermediate SV stations, pigging
stations, etc. and terminals shall be earthed with GI earth electrodes. The resistance to earth
of grounding shall be limited to 5 Ohms max.
7.9 CP at cased crossing
7.9.1 At cased crossings where casing will have coating on its external surface, it shall be protected
by sacrificial anode installations provided at both ends of casing. The anode installation shall
be sized based on the permanent CP design parameters and design life of permanent CP
system.
7.9.2 The carrier pipe inside the externally coated casing shall be protected by Zinc ribbon anodes
piggy backed longitudinally on the carrier pipe between 4 and 8 O'clock position. Anode
shall be tied with carrier pipe using Nylon rope at close intervals and weld connected at the
ends. The quantity/ no. of ribbon anodes shall be based on the permanent CP design
parameters for marshy area and design life of permanent CP system.
7.10 Reference Cell Access Points
Reference cell access points shall be provided over the pipe near insulating joint locations
and at SV stations, where the ground is paved, for measurement of pipe to soil potentials. A
perforated PVC pipe filled with native soil and buried at the location shall be provided for the
purpose. The length of the PVC pipe shall be adequate to reach the native soil below the
paving.
7.11 Cables
7.11.1 Cables shall be with annealed high conductivity, stranded copper conductor, HMWPE
insulated, 650/1100V grade, armoured, HMWPE sheathed. The size of the copper conductor
shall be 6 sq.mm. for anode tail cable from anode to buried junction box, 10 sq.mm. from
buried junction box to test station and 10 sq.mm. from test station to pipeline. The size of
cable for bonding, polarisation cell, grounding anodes and surge diverter connections shall be
suitable for the maximum fault current subject to minimum 25 sq.mm. The length of anode
tail cable shall be sufficient for routing from anode to buried junction box or test station for
anodes for temporary CP or permanent CP respectively.
7.11.2 The cables for reference cells, pipeline potential measurements and polarisation coupon
potential measurements shall be of 4 sq.mm copper conductor, HMWPE insulated,
Aluminium backed by mylar/ polyester tape shielded, HMWPE sheathed, armoured,
HMWPE over all sheathed type.
Page 1751 of 2065

fg2:11 fdifeg
i
1.17-01,,,cm10,34-41,
+11
(A Govt ol Ind. Undertakng)
6-45-0027 REV. 1
8. INSTALLATION
8.1 Cable Laying
8.1.1 Cables shall be laid in accordance with the layout drawings to be prepared by the contractor.
No straight through joint shall be permitted. Cable route shall be carefully measured and
cables cut to required length. Minimum half metre cable slack shall be provided near anodes,
pipeline and test stations to account for any settling.
8.1.2 All cables inside station/ plant area shall be laid at a depth of 0.75 M. Cables outside
station/plant area shall be laid at a depth of minimum 1.5 m. Cables shall be laid in sand
under brick cover and back filled with normal soil. For cables laid outside the station/plant
area, polyethylene warning mats shall placed at a depth of 0.9 m from the finished grade, to
mark the route. Inside plant area cable routes shall be marked by means of cable markers
located at maximum intervals of 30 M and at locations of changes in direction of cable route.
8.1.3 In case of above ground cable, all unarmoured cables shall be laid in GI conduits of
sufficiently large size, up to accessible height for protecting against the mechanical damage.
8.1.4 All underground unarmoured cables including anode tail cables shall run through PE sleeves.
The cables routed along the pipeline shall be carried at the top of the carrier pipe by securely
strapping it at intervals with adhesive tape or equivalent as required.
8.1.5 PVC pipes of proper size shall be provided for all underground cables for road crossings.
8.1.6 Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and
final take-off to equipment is facilitated.
8.1.7 The cables for reference cells and pipeline potential measurement shall be routed in a
separate trench other than the trench provided for the rest of the CP system cables, AC/DC
power supply cables for CPTR units/ CPPSM etc.
8.1.8 The armour of all the cables from pipeline to test station (potential measurement, current
measurement, reference cell cables, cathode cables, bonding cables, grounding cables, etc)
and test station to ground bed (anode cable) shall be earthed only at test station end of the
cable to avoid armour carrying CP current. The armour of the bonding cables between test
stations shall be earthed at any one end of the cable only. The cable armour shall be insulated
by cutting and taping with insulation tape.
The permanent reference cells shall be installed with special backfill material and as per the
recommendations of the cell manufacturer. Installations in highly acidic/ alkaline soil and
soil contaminated by hydrocarbons shall be avoided.
8.3 Cable to Pipe Connections
All cable connections of other than cathode drainage cables to the new pipeline shall be made
by an approved exothermic process or by pin brazing. However, cable connection to charged
pipelines shall be made by pin brazing. Approved exothermic welding may be adopted for
pipelines carrying water. Coating shall be repaired after connection of cable conductor to
pipeline. The coating repair material shall be compatible with the original coating and shall
prevent ingress of water along the cable surface and at the interface of coating repair with the
original pipe coating.
Page 1752 of 2065

--1 ENGINEERS FOR SACRIFICIAL DE
$1g-ar g INDIA LIMITED CATHODIC PROTECTIONANOYSTEM
S 6-45-0027 REV. 1
IA Govt of Inda Undeltak.ng)
8.4 Ground Bed Fencing
Where specified in project specifications/ data sheet chain link fencing shall be provided
around the location of each ground bed designed based on the permanent CP design
parameters.
9. FIELD TESTING AND COMMISSIONING
9.1 System Testing at Site
9.1.1 Field tests as per the reviewed field testing and commissioning procedures prepared by the
Contractor shall be carried out on the equipment/systems before these are put into service.
Acceptance of the complete installation shall be contingent upon inspection and test results.
9.1.2 Before the CP system facilities are put into operation, necessary tests shall be carried out to
establish that all equipment, devices, wiring and connection have been correctly installed,
connected and are in good working condition as required for the intended operation.
Owner/Owner's representative may witness all tests. Intimation shall be given at least one
week before commencing the tests.
9.1.3 A11 tools, equipment and instruments required for testing shall be provided by Contractor.
9.1.4 Generally, the following minimum tests shall be carried out and recorded.
a) Visual Inspection : Comparison with drawings, specifications, detailed

physical inspection.
b) Testing : Simulation tests of equipment to determine its

operational fitness.
i) Cables
- Cable No.
- Voltage grade.
- Conductor cross section.
Continuity check.
- Voltage test.
- Insulation resistance values between each core & earth, between cores.
A11 cables shall be tested by 500 V megger.
ii) Insulating Joint
Location.
- Pipe to soil potential of both protected and non-protected sides of the insulating
joint before and after energisation of CP system.
iii) Surge Diverter
- Location/identification number.
Rating
- Type
- Explosion proof enclosure.
Check for healthiness.
- Check for proper connection.
iv) Polarisation Cell
- Location/Identification number.
Page 1753 of 2065

~'i71n~ILl~ ENGINEERS FOR SACRIFICIAL ANODE
$1g-ar 02eg
1.177,(....ficorl 4171 Joorsil
of InOa Unctertak,o9)
IA Govt
6-45-0027 REV. 1
- Type.
Ratings.
Check for wiring.
- Check standby current drain after CP system energisation.
- Details of grounding provided for the polarisation cell.
v) Polarisation Coupon
- Location/Identification number.
- Exposed area/size of coupon.
- Depth and distance from pipeline of coupon
- Type of reference cell
- Distance of reference cell from coupon
- Magnetic reed switch rating
- Operation of magnetic reed switch with magnet
- Check for wiring.
- Coupon On and OFF potentials.
vi) Reference Cell
Location
- Type of cell
- Depth and distance from pipeline of reference cell
- Potential reading
vii) Anode Ground Bed
- Location/ Station
- Horizontal/ Vertical
Check for actual layout and compliance with drawings.
- Current output of ground bed.
- Current output of each anode (in case of permanent CP anode ground beds)
9.2 Commissioning
9.2.1 Natural pipe to soil potential for the complete pipeline and casing pipelines at the locations of
cased crossings shall be measured at all the test station locations and recorded prior to
connecting anodes to pipe line and casing pipelines.
9.2.2 The anodes shall be connected to pipeline in the test station and the pipe to soil potential
observation shall be made after allowing sufficient time for polarisation. The current output
of each anode at permanent CP anode ground bed or the total current output of anode bed at
temporary CP anode ground bed shall also be measured to ensure that it does not exceed the
output current capacity of the anodes. In case the anode output current exceeds the rated
capacity, it shall be controlled by insertion of resistance element in the anode circuit inside
test station and the pipe to soil potential shall be rechecked for adequacy of protection. At
locations of polarisation coupons the coupon ÒFF' potential shall be measured by switching
off the reed switch. Additional anodes shall be provided where required to achieve desired
Level of protection and to keep the anode output current within the rated value. In case pipe to
soil potential exceeds the specified value, suitable resistance shall be inserted in the anode
circuit to limit the potential.
9.2.3 Anode installation shall become individually operational as above.
9.2.4 At the locations of cased crossings where anode installations are provided for the protection
of the casing pipe, these anode installations shall be commissioned as per the procedure
detailed in ciause 9.2.2 above.
Page 1754 of 2065

(31 ENGINEERS FOR SACRIFICIAL ANODE
tg"-at t&f5l&g INDIA LIMITED CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
(AGo. of India Underta.9)
9.2.5 After connecting all the anode ground beds to the pipe line, measurement of pipe to soil
potentials shall be taken at each of the test stations to ensure conformity to protection criteria.
9.2.6 In case of insufficient protection as per the CP design criteria, on any portion of the pipeline/
casing pipeline (at cased crossings where casing is cathodically protected) Contractor shall
carry out necessary additions/modifications to the provided protection in consultation with
the Owner/ Owner's representative.
9.2.7 Healthiness of the insulating joints provided on the pipeline shall be checked by measuring
the pipe to soil potentials on both protected and non protected sides of the IJs.
10. INTERFERENCE MITIGATION
10.1 Investigations shall be made for stray current electrolysis of the pipeline, mutual interference
between the pipeline and foreign pipelines/ structures, interference on foreign
pipelines/structures due to the CP of the pipeline and ground bed, AC induction on pipeline
due to 11 KV and above overhead HV/EHV line, interference due to high voltage DC line,
HVDC groundings, electric traction, DC mining, DC welding operations, impressed current
anode ground beds on other pipelines, etc.
10.2 Where transmission lines cross the pipeline or run in parallel within 25m from the pipeline,
AC voltage measurements shall also be made on the pipeline to find out continuous induction
of voltage. In case of induced voltage being beyond safe limits, the pipeline shall be
grounded in line with clause no.7.6 above. Where transmission lines run in parallel more than
25m from the pipeline, however, continuous induced AC of voltage beyond safe limits are
noticed on the pipeline the same shall be mitigated by grounding the pipeline in line with
clause no.7.6 above.
10.3 Measurements including pipe/ structure to soil potential and pipeline/ structure current etc. on
the pipeline/ structure being CP protected and on foreign pipelines/ structures shall be made
to investigate the current discharge and pickup locations. In case of fluctuating stray current,
investigations shall be made continuously over a period of time and if required
simultaneously at different locations to find out the stray current source(s). For measurements
over longer durations, recorders shall be used.
10.4 Where foreign pipelines (unprotected or protected by independent CP system) run in parallel
to the pipeline in same trench or very near to the pipeline, and are not bonded to the pipeline
then investigation shall be made for current discharge points on both the pipelines.
10.5 Mitigation measures shall be provided depending on type of stray current electrolysis/
interference. These shall include installation of bond with variable resistor, diodes,
installation of galvanic anodes for auxiliary drainage of current, adjustment/ relocation (if
possible) of offending interference source, provision of electrical shield etc. depending on the
type of interference.
10.6 Bonding with foreign pipeline/ structure, as a mitigation measure shall be provided where the
owner of the foreign pipeline/structure have no objection, otherwise alternative mitigation
measure shall be provided. Where bonding is provided for mitigation, the bonding resistor
shall be adjusted for optimum value for minimum/no interference. Galvanic anodes installed
as a mitigation measure shall be sized for the design life specified for permanent CP system.
11. SYSTEM MONITORING
Where the CP system provided is temporary, the CP system shall be monitored at all test
stations once in a month for healthiness/ adequacy of protection till commissioning of
permanent CP system or for design life of temporary CP system specified, whichever is less.
Page 1755 of 2065

Ir ENGINEERS FOR SACRIFICIAL ANODE
laW'g INDIA LIMITED CATHODIC PROTECTION SYSTEM 6-45-0027 REV. 1
1.1271 an 051 3,
1,157,11 in G. of lntha Undeefa.9)
During this period if any deficiency/ interference in protection system is noticed, the same
shall be rectified/ augmented by providing additional anodes as required. The monitoring
report shall be submitted regularly to owner for his review/ information.
12. CLOSE INTERVAL POTENTIAL LOGGING SURVEY
Where specified in project specification/data sheet, contractor shall carry out a close interval
potential survey over the entire length of pipeline by computerised potential logging method
and identify the under protected/ over protected area, any major coating damage on the
pipeline, after the back-filling has been consolidated sufficiently and CP system has
stabilized. Contractor shall provide required mitigation measures and rectify the
under/overprotected zones, identify if any, the major pipeline coating defects required to be
repaired. During the survey the reference cell shall be calibrated minimum once in 24 hours.
Where specified in the project specification/ data sheet, additional tests for detailed
identification of coating defects shall be conducted by the contractor.
Page 1756 of 2065

SPECIFICATION FOR STANDARD SPECIFICATION NO.
ENGINEERS IMPRESSED CURRENT
5szu &g INDIA LIMITED
22-2131.3(.71) CATHODIC PROTECTION 6-45-0028 REV. 0
10171 IA Go. of Indm Unde/talong)
SYSTEM FOR PIPELINES Page 1 of 22
41q9(1144 et;k1-
#-(vErr wiji(41 fffq fqr-4-4-r
SPECIFICATION
FOR
IMPRESSED CURRENT
FOR PIPELINES

0 17.07.14 NSB RC PPL ■ SfNM SC
(OLD DOC. NO.: 6-51-0028, REV. 2)
Standards Standards
Prepared Checked Committee Bureau
Rev. Date Purpose Convenor Chairman
by by
Approved by
Page 1757 of 2065

ENGINEEFZS IMPRESSED CURRENT
rIrcr, asr3crom, (A Govt ol Incha Undertaking)
Abbreviations:
CP Cathodic Protection
CMRI Central Mining Research Institute
CPTR Cathodic Protection Transformer Rectifier
CTE Coal tar enamel
DC Direct Current
EHV Extra High Voltage
FBE Fusion Bonding Epoxy
HDD Horizontal Directional Drilling
HV High Voltage
HVDC High Voltage Direct Current
IS Indian Standards
A/mm2 Micro-ampere per square millimeter
MMO Mixed Metal Oxide
MOV Motor Operated Valve
NACE National Association of Corrosion Engineers
PE Polyethylene
ROU Right of Use
SV Sectionalizing Valve

Page 1758 of 2065

IA Govt ol Intlia Undertalfing)
CONTENTS
1.0 SCOPE 4
2.0 APPLICABLE CODES AND STANDARDS . 4
3.0 SYSTEM IMPLEMENTATION 5
4.0 CORROSION SURVEY 5
5.0 CATHODIC PROTECTION DESIGN PARAMETERS .7
6.0 CATHODIC PROTECTION DESIGN CRITERIA 9
7.0 SYSTEM DETAILS 9
8.0 INSTALLATION 16
9.0 FIELD TESTING AND COMMISSIONING 17
10.0 INTERFERENCE MITIGATION 21
11.0 CLOSE INTERVAL POTENTIAL SURVEY 22
Page 1759 of 2065

(c= ENGINEERS
j INDIA IMPRESSED CURRENT
Idf56
wr,of Fiari anyiprall
LIMITED
IA Go. ol Inclia Unclenal.ng)
1.0 SCOPE
1.1 This specification defines the requirements of system design, engineering, installation, testing
and commissioning of an Impressed Current Cathodic Protection System for cross-country
onshore underground pipelines/ structures including supplementing of corrosion survey, close
interval potential logging survey, investigations for interaction/interference problems and
mitigation of the same.
1.2 This specification provides the basic parameters to develop a suitable impressed current
cathodic protection system for the pipelines/ structures requiring protection. All data required
in this context shall be taken into consideration to develop an acceptable design and for
proper engineering of the system.
1.3 Compliance with these specifications, and/or approval of any documents submitted by
contractor shall in no case relieve the contractor of his contractual obligations.
2.0 APPLICABLE CODES AND STANDARDS
2.1 The system design, performance and materials to be supplied shall conform to the
requirements of the latest revision of following standards as a minimum:
i) NACE Standard SP0169 Control of External Corrosion on Underground or

ii) NACE Standard TM0497 Measurement Techniques Related to Criteria for

Cathodic Protection on Underground or
iii) NACE Standard SP0177 Mitigation of Alternating Current and Lightning

Effects on Metallic Structures and Corrosion
Control Systems
iv) NACE Standard SP0286 Electrical Isolation of Cathodically Protected

Pipelines
v) NACE Publication No. 54276: Cathodic Protection Monitoring for Buried

Pipelines
vi) NACE Standard SP0572 Design, Installation, Operation and Maintenance of

Impressed Current Deep Ground beds
vii) IS 8062 Recommended Practice- ICCP for Underground

Piping
viii) BS 7361 Part I Cathodic Protection- Code of Practice for Land

and Marine Applications
ix) VDE 0150 Protection against Corrosion due to Stray Current

from DC Installations
x) IS 1554 Part I PVC Insulated (Heavy Duty) Cables
xi) IS/ IEC: 60079 Electrical Apparatus for Explosive Gas Atmosphere
Page 1760 of 2065

■
31 ENGINEERS IMPRESSED CURRENT
Og-ar .3.79.11
INDIA LIMITED
IA Govt of Intha Uncleetakug)
xii) IS/ IEC: 60529 Classification of Degree of Protection Provided by

Enclosures
2.4 In case of any contradiction between various referred standards/ specifications/ data sheet and
Data Sheets
- Job Specification
Codes and Standards
3.0 SYSTEM IMPLEMENTATION
All work to be performed and supplies to be effected as a part of contract shall require
specific review by Owner or his authorised representative. Major activities requiring review
shall include but not be limited to the following:
i) Corrosion survey data interpretation report and plot plans for land acquisition
ii) Conceptual system design
iii) Basic engineering package
iv) Detailed engineering package
v) Field testing and commissioning procedures
vi) Procedures for interference testing and mitigation
vii) Close interval potential logging survey procedure
viii) As built documentation
4.0 CORROSION SURVEY
4.1 General
4.1.1 The details of corrosion survey including soil resistivity data along ROU and other data
required for C.P design if available with the Owner shall be included as part of project
specification/ data sheet. However, verification of its veracity and adequacy shall be the entire
responsibility of the contractor. In addition, contractor shall have to generate/ collect
additional data as per clause 4.4 below required for completeness of the job.
Contractor shall carry out soil resistivity survey at anode ground bed locations for design of
ground bed. Where specified in the data sheet, Contractor shall carry out corrosion survey
along the ROU of the pipeline conforming to the specifications included in the tender
document.
Page 1761 of 2065

(-51- ENGINEERS
Irg.J IMPRESSED CURRENT
$1g-zir laa&g
1711,1 ,wes,r1,
T51.3.7".
INDIA LIMITED
Govl of intha undeetak.g)
4.1.2 To carry out soil resistivity measurement Wenner's 4-pin method or an equivalent method
approved by Owner/ Owner's representative shall be used. Survey instruments shall have
maximum AC and DC ground current rejection feature.
Care shall be taken to ensure that the resistivity observations are not influenced by the
presence of foreign pipelines/ structures, and earth currents in the vicinity of EHV/ HV lines
and installations using earth return in their power system etc.
4.2 Soil Resistivity Survey at Impressed Current Anode Ground Bed Plot
4.2.1 Each selected anode bed plot shall be sub-divided into sub-plots. Sizes of sub-plots shall
depend upon the expected depth for soil resistivity investigations. Each of these sub-plots
shall be investigated for resistivity data individually. Sufficient observations shall be taken at
each of these sub-plots as required and desired by Owner/ Owner's representative to obtain
sufficient information about sub-soil stratification and, wherever possible, to establish the
depth of water table. The number of subplots at each ground bed plot shall be decided at site
in consultation with Owner/ Owner's representative.
4.2.2 Number, location, demarcation and size of sub-plots and number of sets of resistivity
observations required for each sub-plot shall be individually decided for each ground bed plot
location.
4.2.3 One or more ground bed plots may be required to be selected and surveyed at each CP station
to form a suitable ground bed.
4.3 Topographic Surveys
Cathodic protection stations consisting of anode ground bed, CP station etc. as applicable,
along with all associated cabling up to pipeline and any other related equipment and
accessories for CP station shall be demarcated on the ground. Ground plots so demarcated
shall be surveyed for all other topographical and cadastral features and topo-sheets shall be
developed by the CONTRACTOR, which shall be suitable for use in land acquisition etc.
4.4 Additional Data to be collected
The following data shall be collected to generate design data for evaluation of
interaction/interference possibilities due to presence of other services in ROU or in its
vicinity. OWNER shall provide assistance for liaison work to the extent possible.
i) Route and types of foreign service/ pipeline in and around or crossing the right of use
(including those existing and those which are likely to come up during contract execution).
ii) Diameter, wall thickness, pressure, soil cover, and coating scheme used, type of cathodic
protection system provided, if any, year of laying/ commissioning in case of foreign pipelines.
iii) Details of the existing cathodic protection systems protecting the services i.e. type of
protection, location, type, rating of anode beds, test station locations and their connection
schemes. Present output current and voltage readings of the CP power supply units.
iv) Remedial measures existing on foreign pipelines/ services to prevent interaction.
v) Graphical representation of existing structure/ pipe-to-soil potential records.
vi) Possibility of integration/ isolation of CP systems, which may involve negotiations with
owners of other services.
Page 1762 of 2065

t.71 ENGINEERS IMPRESSED CURRENT
latMeg INDIA LIMITED CATHODIC PROTECTION 6-45-0028 REV. 0
1.1277 2,45r2 an,Fiml (A Govt ol Intha undenakng)
vii) Existing and proposed DC/AC power sources and systems using earth return path such as
HVDC substations/ earthing stations, fabrication yards with electric welding etc. in the
vicinity of the entire pipeline route.
viii) Crossing and parallel running of electrified and non-electrified traction (alongwith
information regarding, operating voltage, AC/DC type etc.) as well as abandoned tracks near
ROU having electrical continuity with the tracks in use.
ix) Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power
lines along with details of voltage, AC/DC type etc.
x) Voltage rating, phases, sheathing details of underground power cables along ROU or in its
vicinity.
xi) Any other relevant information that may be needed in designing and implementing proper
cathodic protection scheme for the proposed pipeline.
Contractor shall conduct necessary potential gradient surveys for any existing anode ground
beds that may interfere with the CP system of the pipelines covered under this project.
4.5 Report
On completion of all field work, a report incorporating all the results generated from surveys
and details of additional data collected shall be prepared. The report shall also contain
detailed interpretation of survey results and resistivity data, probable interference prone areas,
selected locations for anode ground beds etc., to form a design basis for the scheme of
cathodic protection. This report shall also include various drawings prepared in connection
with the above work. Soil resistivity values shall be plotted on semi-log graph sheets.
5.0 CATHODIC PROTECTION DESIGN PARAMETERS
A distinctly independent impressed current cathodic protection system shall be provided to

protect the external surfaces of the complete pipeline/ structure installation as specified.
Unless otherwise stated in the data sheets, the following parameters shall be used for design
of permanent cathodic protection system:
5.1 Protection Current Density Range
i) Pipe lines having Coal Tar Enamel (CTE) coating with two/ three layers of
reinforcement.

Temporary CP Design Life
(i_t A/m2) (i.t A/m2)
40 500
Page 1763 of 2065

k31
'--12-.1t4 ENGINEERS IMPRESSED CURRENT
1.11-
,n erlasrearIJO-prA, IA Go. of Ind. Undertalong)
ii) Pipe lines having Dual Layer Fusion Bonded Epoxy (DLFBE) coating or 3-Layer
Polyethylene (3LPE) coating:

Temporary CP
(p. A/m2) Design Life
(i A/m2)
25 250
The above current density values for temporary CP system are applicable for CP system
design life up to two years.
*Actual current density to be adopted shall be decided based upon soil and other
environmental conditions, current drainage survey data, proximity of foreign
pipelines/structures and other interference areas affecting the installation. Where considered
necessary for satisfactory protection of pipeline the current density shall be suitably increased
by contractor. Also refer to clause 7.1 (iv) below.
For all pipeline sections which are having intermediate HDD (Horizontal Directional Drilling)
crossings, the nearby T/R units should have adequate provision of D.C. output current to cater
to the extra protection current demand at the HDD crossings.
5.2 The pipe protection Current Density indicated in the clause 5.1 above shall be applicable
where the temperature of the fluid transported by the pipeline/ the surface temperature of the
buried portion of the pipeline does not exceed 30 °C. Where this temperature exceeds 30 °C,
the protection Current Density shall be increased in minimum by 25% for every 10 °C rise in
temperature over 30 °C.
5.3 Safety factor for current density 1.3
5.4 Anode utilisation factor

(For High Silicon Cast Iron Anode) 0.85 for centre connected anode
0.6 for end connected anode
5.5 Anode surface current density

(For High Silicon Cast Iron Anode 15 Amp./sq.m for shallow anode for ground
continuous operation) bed
10 Amp./sq.m for deep well anode ground
bed
(For MMO Coated Titanium Anode 70 Amp./sq.m in coke backfill

for continuous operation) 30 Amp./sq.m in soil without coke backfill
5.6 Anode consumption rate
(For High Silicon Cast Iron Anode) 0.2 kg./Amp-yr

(For MMO Coated Titanium Anode) 2.0 mg./Amp-yr (In Coke Backfill)
5.7 Pipeline natural potential (-) G.45 V
Page 1764 of 2065

5gar 02eg
rwmr, MI.3,74:1173,
INDIA LIMITED
IA Go. ot Incka Undettabung)
5.8 Design life of CP system 30 years, unless specified otherwise in

the data sheet
5.9 Anode ground bed loop resistance 1 Ohm (max.)

including anode to ground resistance,
anode and cathode cable resistances
(The output voltage rating of the CPTR unit/ CPPSM shall in minimum be adequate to drive
the specified end of life cathodic protection current with safety factor, considering the total
anode ground bed loop resistance as the sum of the resistance specified in this clause and pipe
to earth resistance).
6.0 CATHODIC PROTECTION DESIGN CRITERIA
Cathodic protection system shall be designed to meet the following criteria:
i) The pipe to soil potential measurements shall be between (-) 0.9V (OFF) and (-) 1.18V
(OFF) with respect to a copper/copper sulphate reference electrode.
ii) In rare circumstances, a minimum polarization Shift of (-) 100 millivolts may be accepted as
an adequate level of cathodic protection for the pipeline with the approval of Owner.
iii) A positive potential swing of 100 millivolts or more shall be considered sufficient to indicate
the presence of an interaction/ interference situation requiring investigation and incorporation
of mitigation measures by the Contractor.
7.0 SYSTEM DETAILS
The system shall include the following major equipment/ sub-systems unless otherwise
specified in project specifications:
- CP stations
- CPTR units/ cathodic protection power supply modules (CPPSM).
Anode ground beds and anodes
Anode junction box
Cathode junction box
Test stations
Permanent reference cells
Polarisation cell and surge diverter
- Polarisation coupons
CP system at cased crossing
- Bond Stations
Cables
A11 equipment shall be new and procured from EIL approved manufacturers. Equipment
offered shall be field proven. Equipment requiring specialized maintenance or operation shall
be avoided as far as possible. Prototype equipment shall not be accepted.
Page 1765 of 2065

laWg INDIA LIMITED
(A GoN of India Undertakmg)
A11 equipment/ materials shall conform to the relevant specifications included in the tender
document.
All equipment including CPTR unit, CPPSM, test stations, anode lead junction boxes etc.
shall be located in safe non-hazardous areas.
Where it is essential to install electrical and electronic instrument enclosures and its
accessories in hazardous area, such equipment shall be flame proof type and shall meet the
requirements as per IS/ IEC: 60079 and shall be weather proof to IP-65 also as per
IS/IEC:60529.
Director General of Mines Safety (DGMS) in India, for the electronic instruments installed
in electrically hazardous area along with:
Research (CIMFR)/ Electronics Regional Testing Laboratory (ERTL) etc. for
flameproof enclosure/ intrinsic safety, as specified in the data sheet, as per relevant
standard for all Indian manufactured equipments or for items requiring Director General
of Mines Safety (DGMS) approval.
Atmospheres (BASEEFA), Factory Mutual (FM), Physikalisch-Technische
Bundesanstalt (PTB), Canadian Standards Association (CSA), Underwriters
Laboratories (UL) etc. for compliance to ATEX directives or other equivalent standards
for all equipments manufactured outside India.
7.1 Cathodic Protection Stations
The number and exact locations of CP stations shall be worked out based on the corrosion
survey data collected. In addition, the following guidelines shall be followed for selecting the
locations:
i) Number of CP stations and their selected locations shall ensure that these remain valid and are
adequate for the full design life of the system after considering all foreseeable factors.
ii) As far as possible, the availability of nearby low resistivity areas for location of associated
ground beds must be ensured while selecting the locations of CP stations.
iii) As far as possible, locations of intermediate CP stations shall coincide with the locations of
SV stations.
iv) The proposed locations of CP stations and anode ground bed current ratings are detailed in
project specifications/ data sheets. The same shall be verified for adequacy by the contractor.
The requisite current drainage tests/ survey shall be conducted by the contractor to establish
the adequacy of CP current requirement indicated in clause 5.0 above and adequacy of
number, ratings of CP stations for permanent CP system indicated in the data sheet. The
minimum end of life pipe protection current requirement shall be considered as the current
requirement indicated in the clause 5.0 above or 3 times the current density value measured
by the current drainage survey for polyethylene coated pipeline and 4 times the current
density value measured by the current drainage survey for fusion bonded epoxy, coal tar
enamel with reinforcement coated pipeline, whichever is maximum.
Page 1766 of 2065

ENGNEERS IMPRESSED CURRENT
2.1r1Mffleg. INDIA LIMITED
IA Go. of Incha unaena.9)
7.2 CP Transformer Rectifier Unit/ CPPSM
If specified in project specifications/ data sheet, the supply, installation, testing and
commissioning of cathodic protection power supply module (CPPSM)/ indoor type Cathodic
Protection Transformer Rectifier Unit (CPTR unit)/ outdoor type CPTR unit installed in kiosk
along with kiosk shall be included in contractor's scope. The CP TR units shall be provided at
CP stations where reliable AC power supply is available. CPPSM shall be provided at other
CP stations where reliable DC power supply instead of reliable AC power supply is available.
The CPTR unit/ CPPSM shall be installed in non-hazardous (safe) area as specified in data
sheets.
7.3 Anode Ground Beds
i) Each CP station shall have an independent anode ground bed, which may be of shallow or
deep well construction depending upon the data collected by the contractor. Deep well ground
beds may also be used in the congested locations where availability of suitable land for spread
out ground beds is restricted.
ii) Ground bed shall be located electrically remote from the pipeline and foreign pipeline/ other
buried metallic structures. Nearest part of the anode bed shall at least be 100 meters away
from the pipeline and foreign pipeline/ other buried metallic structures. The anodes installed
in the ground shall be located in perennially moist strata, wherever possible. Horizontal
ground beds shall be at right angles to the pipeline, as far as possible.
The location of ground bed shall be checked and ensured for remoteness from the pipeline
and other buried foreign pipelines/ structures, building foundations, switchyards, electrical
earthing systems, etc.
iii) Unless otherwise agreed, anodes shall be of high silicon cast iron type or mixed metal oxide
coated titanium anodes.
iv) Sheet steel anode canisters of adequate size shall be provided for each anode. Anode canisters
shall be filled with petroleum coke breeze. In case of deep well ground beds non-canistered
anodes with petroleum coke breeze in the well surrounding the anodes shall be provided.
v) Each shallow anode-bed shall contain anodes with canisters positioned horizontally or
vertically in the soil with suitable backfill. The depth of anodes (depth of top of anode in case
of vertically laid anodes) shall not be less than 2 meter from grade level.
vi) Layout of anode installation in anode bed shall be detailed out in drawings showing anode
installation details, anode grouping, anode wiring, anode cable routing, etc. The deep well
anode ground bed details shall include the details of anodes, deep well casing, anode
positioning, anode cable supporting, deep well gas venting, active, passive portions of the
ground bed etc.
vii) Anodes shall be supplied complete with tail cables, which shall be long enough for
termination on their associated anode lead junction boxes without intermediate joints. Exact
lengths and termination details shall be indicated in construction drawings.
viii) Potential gradient around the anode bed shall be within safety requirements with regard to
interference on foreign structures and its effective boundary shall be defined.
ix) In case of two parallel pipelines running in the same ROU, the anode ground beds of the
respective pipelines shall be located on the respective sides of the pipelines.
Page 1767 of 2065

r= ENGINEERS
(O IMPRESSED CURRENT
02e
— g INDIA LIMITED CATHODIC PROTECTION 6-45-0028 REV. 0
imrtn ,-1,:xtan.yros.0 Go. of InEia Undertaking,
7.4 Anode Junction Box
Depending on the size and configuration of anode ground beds, one or more anode junction
boxes shall be provided at each ground bed. All cable tails from individual anodes shall be
terminated onto the respective anode junction boxes, which shall be further connected to the
main anode junction box (where applicable). The main anode junction box shall be connected
to the cable coming from CP power source. Each outgoing circuit in main junction box
(where applicable) and each anode circuit in junction shall have provision for measurement
and control of individual circuit/anode current.
7.5 Cathode Junction Box
Where output of the CP power supply unit is connected to multiple pipelines a cathode
junction box shall be provided near the pipelines at the location of connection of the negative
drainage cable to the pipelines.
The negative of the CP power source shall be connected to the incoming circuit of the cathode
junction box. The junction box shall have separate out gong circuit one for each pipeline to
collect the negative drainage currents from each of the parallel pipelines.
The incoming circuit shall have a current measurement facility. Each out going circuits shall
have provision for measurement and control of current.
7.6 Test Stations
7.6.1 Test stations shall be provided along the pipeline ROU for monitoring the performance of the
cathodic protection system at the following locations. Test stations shall be provided at
additional locations, if required, so that distance between any two adjacent test stations does
not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like
forest/deserts:
i) At all insulating joints
ii) At both sides of metalled road crossings
iii) At vulnerable locations with drastic changes in soil resistivity
iv) At locations of surge diverters, pipeline grounding through polarisation cells, Zinc
and Magnesium anodes
v) At EHV/HV AC/DC overhead line crossings and selected locations where EHV/HV
overhead line is in the vicinity of the pipeline
vi) At railway line crossings and at selected locations along lines running parallel to the
pipeline
vii) At both sides of major river crossings
viii) At EHV/HV cable crossings or along routes where EHV/HV cables are running in
parallel
ix) In the vicinity of DC networks or grounding systems and HVDC grounding systems
where interference problems are suspected
Page 1768 of 2065

-

lair1P17:f7x1Wen.340., (A Go. of India unaenalony t
x) At crossings of other pipelines/ structures
xi) At the locations of reference cell and polarization coupon installation
xii) At both sides of cased crossings
xiii) Locations where interference is expected
xiv) At locations of sectionalizing valve (SV) stations
xv) At any other locations considered necessary by Owner/ Owner's representative
7.6.2 Test stations for bonding shall be provided with shunt and resistor as a means to monitor and
control current flow between the pipeline and foreign pipelines or structures that may exist in
common ROU.
7.6.3 Test stations with current measuring facility shall be provided at each CP station drainage
point (to measure pipeline current on any one side of pipeline from drainage point at
intermediate CP station and towards protected side of the pipeline at starting, end point CP
stations), at interference prone areas, on both sides of major river crossings, near marshy areas
and minimum one for every 10 km max. along the pipeline.
7.6.4 Test stations shall be installed with the face of the test station facing the pipeline. The
nameplate of test stations shall carry the following minimum information:
Chainage in km.
Test station connection scheme
Distance from pipeline in meter.
Direction of product flow.
7.6.5 Number of terminals and different schemes of wiring shall be as per the test station
connection scheme. Minimum twenty percent spare terminals shall be provided in each test
station.
7.6.6 Minimum two cables from the pipeline shall be provided at any test station.
7.6.7 The location of all the test stations shall be marked with their connection schemes and other
relevant information on alignment sheets. A detailed test-station schedule shall be prepared.
7.7.1 High purity copper/copper sulphate reference cells with proven high reliability shall be
provided for stable pipe to soil potential measurement at CP stations and polarization coupons
along ROU.
7.7.2 Silver/Silver Chloride reference cells in place of copper/copper sulphate cells shall be
provided at marshy area locations, where water table is high and chloride concentration is
more than 300 ppm. For marshy area in saline soil, high purity Zinc may be considered as an
alternative to silver/silver chloride. The test station connection scheme shall clearly indicate
the type of the reference electrode (Cu CuSO4/Ag AgC1) at these locations.
7.7.3 The life of the reference cells shall be minimum 8 years under the installed conditions.
Page 1769 of 2065

zit4 ENGINEERS IMPRESSED CURRENT
Offleg
c9renrlan,crils.
I. Go,of Ind. Und..k.9)
7.7.4 The cable from reference cells shall be provided up to CP power source at CP stations and up
to test stations at the locations of polarization coupons. The cable up to CP power source shall
be routed through test stations near pipeline.
7.8 Polarisation Cell and Surge Diverter
7.8.1 Polarisation Cell
i) Wherever the pipeline is either crossing or running in parallel with overhead EHV/HV
transmission lines of voltage grade 66kV and above, it is mandatory that the pipeline shall be
grounded to discharge any accumulated potential/ surge that may appear in case of
transmission line faults, as per below:
The pipeline shall be grounded through polarization cell with Zinc galvanic anodes of
either block anode or ribbon type. Sizing and quantity of anode shall be decided so as to
achieve maximum total earth resistance of 5 Ohm for each location where pipeline
crosses EHV/HV transmission lines.
The pipeline shall be grounded at regular intervals of maximum 1 km where EHV/HV

transmission lines run parallel within 25m of the pipeline. Also, where EHV/HV
transmission lines run parallel beyond 25 m of the pipeline and it is expected from
calculations/ software simulations that surge would appear in case of transmission line
faults or any abnormal operating conditions.
ii) Locations along pipeline where continuous induced over-voltage due to other overhead
transmission lines/ underground cables of voltage grade below 66kV is expected or observed
during commissioning, the pipeline shall be grounded through polarisation cell to the earth
system of the EHV/HV tower causing the voltage induction or to a separate earthing system
of Zinc anodes through polarisation cell.
iii) Polarisation cell shall be installed inside test station of suitable size.
iv) Type of polarization cell shall be as specified in data sheet.
7.8.2 Surge Diverter
Explosion proof spark gap surge diverter shall be provided across each insulating joint to
protect it from high voltage surges. Surge diverters shall be suitable for installation in
classified areas.
7.8.2 The total system including cables, cable termination, anodes/ surge diverters, polarisation cell
shall be suitable for the anticipated fault current at the location of installation.
7.8.3 The surge diverter and polarisation cell system shall be suitable for the design life of
permanent CP system. The grounding system shall have minimum resistance to earth to
restrict the pipeline voltage as per NACE/VDE criteria but shall not exceed 5 Ohms.
7.8.4 The anodes shall be pre packed with special backfill adequately so that the performance of the
anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any
case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.
7.9 Motor operated valves where located on the cathodically protected portion of the pipeline shall
be grounded by a Zinc anode of 20 kg. net Magnesium anodes grounding, if any, provided
during temporary CP system shall be disconnected. The MOV power supply cable armour shall
Page 1770 of 2065

ENGINEER.S IMPRESSED CURRENT
O&IIIM141eg
-'
I Nr271 7,12,512 7331,7,11,4
INDIA LIMITED
IA GoN of InUla Undertaking)
be insulated (by cutting and taping with insulation tape) at MOV end to avoid armour carrying
CP current.
7.10 The above ground cathodically unprotected pipeline at terminals, intermediate SV stations,
pigging stations etc. shall be earthed with GI earth electrodes. The resistance to earth of
grounding shall be limited to 5 Ohms (Max.).
Where specified in the project specification/data sheet steel coupons of pipeline material shall
be provided along the pipeline to monitor the adequacy of the CP system to polarize/ protect
coating holidays. Coupon shall be installed at CP station drainage points, predicted cathodic
protection mid points along the pipeline, at locations where the pipeline is bonded to foreign
pipeline/ structures, interference prone areas, marshy areas and at other locations as specified in
the project specification/ data sheet, along the pipe line.
Coupons shall be installed at bottom 1/3rd portion of the pipeline and 250 mm away from the
pipe surface.
The coupons shall be constructed from the pipeline material and shall have one side uncoated
surface of 100 mm x 100 mm exposed to soil. Two cables one for connection to pipeline for
protection and other for potential measurement shall be provided for each coupon. The
protection cable shall be connected through a magnetic reed switch inside the test station to
enable measurement of coupon ÒFF' potential.
A permanent reference electrode shall be installed adjacent to the coupon in a manner so as to

measure the representative potential of the coupon.
Magnets for operation of reed switch shall be provided as specified in the project
specification/data sheet.
7.12 CP at Cased Crossing
7.12.1 At cased crossings where casing will have coating on its external surface, it shall be protected
by sacrificial anode installations provided at both ends of casing. The anode installation shall be
sized based on the permanent CP design parameters and design life of permanent CP system.
7.12.2 The carrier pipe inside the externally coated casing shall be protected by Zinc ribbon anodes
piggy backed longitudinally on the carrier pipe between 4 and 8 O'clock position. Anode shall
be tied with carrier pipe using Nylon rope at close intervals and weld connected at the ends. The
quantity/ no. of ribbon anodes shall be based on the permanent CP design parameters for
marshy area and design life of permanent CP system.
7.13 Reference Cell Access Points
Reference cell access points shall be provided near insulating joint locations and at SV stations,
where the ground is paved, for measurement of pipe to soil potentials. A perforated PVC pipe
filled with native soil and buried at the location shall be provided for the purpose. The length of
the PVC pipe shall be adequate to reach the native soil below the paving.
7.14 Cables
7.14.1 Cables shall be with annealed high conductivity stranded copper conductor, PVC insulated,
650/1100 V grade, armoured, PVC sheathed conforming to IS 1554 part-I, except for the cables
Page 1771 of 2065

6M ENGINEERS
0 IMPRESSED CURRENT
Ogz;1122- 5 INDIA LIMITED CATHODIC PROTECTION 6-45-0028 REV. 0
44<r",” evamwonao".0 in Govt of Incha Underlaiong)
for anode tail, reference cells and pipeline for potential measurements. The size of the copper
conductor shall be minimum 35 sq. mm. for anode and cathode cables, 6 sq.mm. for current
measurement, 10 sq.mm. for anode tail cables and polarization coupon protection cables. The
size of cable for bonding, polarization cell, grounding anodes and surge diverter connections
shall be suitable for the maximum fault current subject to minimum 25 sq mm.
7.14.2 The anode tail cables shall be PE insulated, 650V grade, unarmoured, PVC sheathed and length
shall be sufficient for termination on anode lead junction box without any joint in between.
7.14.3 The cables for reference cells, coupon and pipeline potential measurements shall be of 4 sq.mm
copper conductor, PVC insulated, Aluminium backed by mylar/ polyster tape shielded, PVC
sheathed, armoured, PVC over all sheathed type.
7.14.4 The CPTR unit incomer cable shall be minimum 4 sq.mm. Copper conductor, 650/1100 V
grade, PVC insulated, armoured, PVC sheathed. The cable shall be of 3 core type for single
phase CPTR units and of 4 core type for 3 phase CPTR units.
7.14.5 The cables for connecting various transducers from CPTR unit/CPPSM to telemetry interface
junction box shall be twisted pair with individual pair shielded and overall shielded with
aluminium backed by mylar/ polyster tape, PVC sheathed, armoured, PVC over all sheathed
type.
8.0 INSTALLATION
8.1 Cable Laying
i) Cables shall be laid in accordance with layout drawings to be prepared by the contractor. No
straight through joint shall be permitted. Cable route shall be carefully measured and cables
cut to required length. Minimum half metre cable slack shall be provided near anodes, anode
junction box, pipeline and test stations to account for any settling.
ii) All cables inside station/plant area shall be laid at a depth of 0.75 metre. Cables outside
station/ plant area shall be laid at a depth of minimum 1.5 metres. Cables shall be laid in sand
under brick cover and back filled with normal soil. For cables laid outside the station/plant
area, polyethylene warning mats shall be placed at a depth of 0.9 metre from the finished
grade, to mark the route.
iii) In case of above ground cables, all unarmoured CP cables shall be laid in GI conduits of
sufficiently large size, up to accessible height for protecting against the mechanical damage.
iv) All underground unarmoured cables including anode tail cables shall run through PE sleeves.
Distant measurement cables and permanent reference cell cables routed along the pipeline
shall be carried at the top of the carrier pipe by securely strapping it at intervals with adhesive
tape or equivalent as required.
v) PVC pipes of proper size shall be provided for all underground cables for road crossings.
vi) Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and
final take-off to equipment is facilitated.
vii) The cables for reference cells and pipeline potential measurement shall be routed in a separate
trench other than the trench provided for the rest of the CP system cables, AC cables for
CPTR Units etc.
Page 1772 of 2065

k3i
`- 12«.1L4 ENGINEERS IMPRESSED CURRENT
Ogzx INDIA LIMITED CATHODIC PROTECTION 6-45-0028 REV. 0
laff-rn rwer»,a573qpn.0 IA Go. of Ineka Undertak.g)
viii) The armour of the cables from CP station to test station (potential measurement, reference cell
& drainage cables etc.), CP station to ground bed (anode cable) and test station to pipeline
shall be earthed only at CP station end and test station end respectively of the cables. The
cable armour shall be insulated (by taping with insulation tape) to avoid armour carrying CP
current.
The permanent reference cells shall be installed in natural soil conditions as per the
recommendations of the cell manufacturer. Installations in highly acidic/ alkaline soil and soil
contaminated by hydrocarbons shall be avoided.
8.3 Cable to Pipe Connections
All cable connections of other than cathode drainage cables to the new pipeline shall be made
by an approved exothermic process or by pin brazing. However, cable connection to charged
pipelines shall be made by pin brazing. Exothermic welding shall be adopted for water
pipelines. The resistance of the cable to pipe at the pin brazing connection point shall not
exceed 0.1 Ohm.
The cathode drainage cable shall be connected to a bolt welded to a metal plate, which is weld
connected to the pipeline. The material of the plate shall be same as that of the material of the
pipeline.
Pipe coating shall be repaired after connection of cable to pipeline. At cathode drainage point
the cable joint including the bolt, metal plate and the exposed portion of the pipeline shall be
covered by the coating repair material against ingress of water/moisture. The coating repair
material shall be compatible with the original coating and shall prevent ingress of water along
the cable surface and at the interface of coating repair with the original pipe coating.
8.4 Ground Bed Fencing
Where specified in project specifications/data sheet chain link fencing shall be provided
around the location of each ground bed/anode lead junction box.
9.0 FIELD TESTING AND COMMISSIONING
9.1 System Testing at Site
Field tests as per the reviewed field testing and commissioning procedures prepared by the
Contractor shall be carried out on the equipment/ systems before these are put into service.
Acceptance of the complete installation shall be contingent upon inspection and test results.
Field testing shall include but not be limited to the following:
i) Contractor shall carry out pre-commissioning operations after completion of installation of

the system including all pre-commissioning checks, setting of all equipment, control and
protective devices. A11 site tests, reliability and performance tests shall be carried out by
Contractor.
ii) Before the electrical facilities are put into operation, necessary tests shall be carried out to
establish that all equipment and devices have been correctly installed, connected and are in
good working condition as required for the intended operation. Owner/Owners representative
may witness all tests. At least one week's intimation notice shall be given before commencing
the tests.
Page 1773 of 2065

it ENGINEERS IMPRESSED CURRENT
eaes
u<rrov swan1on,ross“
INDIA LIMITED
IA Govt of Incha undertak.g)
iii) All tools, equipment and instruments required for testing shall be provided by Contractor.
iv) Generally, the following minimum tests must be carried out and results shall be recorded:
- Visual Inspection Comparison with drawings, specifications, detailed physical

inspection and, if necessary, by taking apart the component
parts.
- Testing Simulation tests of equipment to determine its operational

fitness.
a) Cables
Cable No.
- Voltage grade.
- Conductor cross section
Continuity check
Voltage test.
Insulation resistance values between each core & earth, between cores (between
core and earth for single core cable). All cables shall be tested by 500 V megger.
b) Reference Cell
- Location
Type of cell
Potential reading
- Installed on top/ bottom level of pipeline
c) Insulating Joint
- Location
Pipe to soil potential of both protected and non-protected sides of the insulating
joint before and after energisation of CP system
d) Surge Diverter
- Location/ Identification Number

Rating
Type
- Check for healthiness.
e) Polarisation Cell
- Location/ Identification Number

- Rating
- Check for wiring
- Check standby current drain after CP system energisation (Current drain with
respect to voltage across the cell shall be recorded)
Page 1774 of 2065

k31 ENGINEERS IMPRESSED CURRENT
Ogzir fa~ INDIA LIMITED
IA Govt of Indo Undedakng)
- Details of grounding provided for the polarisation cell.
f) Anode Ground Bed
Location/ Station
- Check for actual layout and compliance with drawings
- Resistance of each individual anode
- Current dissipation by each individual anode
Total resistance of complete anode bed
- Mutual interference
g) Polarisation Coupons
- Location
- Exposed area/ size of coupon
- Coupon to soil ÒN' and ÒFF' potentials
- Type of reference cell
- Magnetic reed switch rating
- Operation of magnetic reed switch with magnet
9.2 CP Commissioning Procedure
A model commissioning procedure for a three stations CP system of a pipeline is given below
for general guidance. Contractor shall develop detailed commissioning procedure as per this
guideline.
i) On completion of installation of anode beds and other systems as envisaged in this

specification, they shall be individually checked, tested and compared against the agreed
specifications and procedure.
ii) Electrical continuity of the entire pipeline shall be verified in conformity with design.
iii) Input resistance of the pipeline at all the drainage points shall be checked and recorded.
iv) All current measuring test stations shall be calibrated and recorded using portable battery,
variable resistances, voltmeters, ammeters, etc. as required.
v) Temporary protection facilities provided (if any) which do not form part of permanent CP
shall be disconnected from the system & removed unless agreed otherwise.
vi) Anodes provided for grounding at the MOVs on cathodically protected portion of the pipeline
shall be disconnected. Sacrificial anode where provided for the protection of the casing pipe
at cased crossings shall be disconnected.
vii) The pipeline shall be allowed to depolarize for at least 72 hours after switching ÒFF' the
protection (if any) of all other pipelines in the common ROU.
viii) Before the pipelines are put on charge by switching ÒN' any of the CP stations, natural
pipeline to soil, casing pipe to soil and coupon to soil potential values at all the test stations of
Page 1775 of 2065

(.31 ENGINEERS IMPRESSED CURRENT
Og-ar IMeg INDIA LIMITED CATHODIC PROTECTION 6-45-0028 REV. 0
1ff, rwax,..3.mszo in ~oH Of .tha Unde...n9)
the system (coupon to soil potential at the locations of the coupon installations) shall be
measured with respect to Copper/Copper Sulphate half cell.
ix) CP station no.1 shall be energised with out put potential adjusted to achieve a maximum pipe
to soil potential (PSP) as specified, at the test station nearest to the drainage point.
Observations on either spread of protected portion of pipeline and coupons under this CP
station shall be taken for PSP 'ON' and PSP 'OFF' values at each of the installed test stations
(coupon to soil potential at the locations of the coupon installations). The typical switching
cycle of current interrupter shall be 12 seconds 'ON' and 3 seconds 'OFF'. The pipeline
current values across the cross section of the pipeline shall also be determined at all the
intended test stations influenced by this station.
x) CP station no.1 shall now be switched ÒFF', CP station no. 3 shall be switched 'ON' and
measurement procedure as detailed in clause ix) above shall be repeated.
xi) Similarly CP station no. 1 and 3 shall now be switched ÒFF', CP station no.2 shall be
switched ÒN' and measurement procedure as detailed in clause ix) above shall be repeated.
xii) All the CP stations of the system shall be switched 'OFF' and the pipelines shall be allowed to
depolarize. All the three CP stations in the system shall then be simultaneously switched 'ON'
and PSP values at the drainage points of pipeline shall be brought to a value of maximum PSP
as specified and a complete set of observations shall be taken.
Another complete set of pipe to soil and coupon to soil observations shall be taken after lines
have stayed on charge for 48 hours. If there are appreciable differences in these observations
as compared to those of earlier set, a third set of observations shall be taken after 72 hours.
Maximum drainage point protective potentials shall not be allowed to go beyond the
maximum PSP values as specified, in any case.
Coupon to soil ÒFF' potential shall be measured at all locations of coupon installations by
operation of magnetic reed switch in the test station. The PSP of the coupons shall be within
the PSP range specified in clause 6 of this document.
The output of CP stations shall then be so adjusted that the sites of occurrence of least
negative protective potentials are not less negative than (-) 0.95V (OFF) and sites of
occurrence of the most negative protective potential are not more negative than (-) 1.18V
(OFF). A full set of pipe to soil, coupon to soil observations shall again be taken 72 hours
after the adjustment of potentials and the protection system shall be left in this state of
operation.
xiii) Care shall be exercised to ensure that power supply remains uninterrupted during the period
of commissioning. In case of an interruption, the test in progress shall be repeated after
allowing time for polarisation. More sets of observations shall be taken in any of the steps
specified above, if advised by the Owner/Owner's representative.
xiv) The Zinc anodes for grounding of MOVs at the locations of MOVs on cathodically protected
portion of the pipeline shall be reconnected to the MOVs.
xv) At cased crossings where casing is protected, sacrificial anodes provided for the casing shall
be connected to the casing pipe. The casing to soil potential and anode out put current shall be
measured and recorded. Where casing pipe protection is inadequate or the out put current of
the anode is more than the designed current, then additional anodes shall be provided as
required.
Page 1776 of 2065

Og-a[21-kg
iaar ,9,cnr1L111.3.70.71
INDIA LJMITED
1A Go. of Intha Unclertaiong)
xvi) PSP values at each of the test stations of the existing pipelines shall be measured, plotted,
where existing pipelines run in parallel to the new pipeline, mutual interference situations
between the pipelines shall be identified and necessary mitigation measures shall be provided.
Interference situations shall also be identified and mitigated by comparing different sets of
readings taken at same test stations at different intervals of time under identical conditions
where positive potential swing is 100 mV or more.
xvii) Current readings at all the current measuring test stations shall be measured and recorded.
xviii) Final records of testing and commissioning including graphical representation of final pipe to
soil potential readings shall be compiled with interpretation in consultation with
Owner/Owner's representative and submitted.
xix) If any deficiencies are found in the system, the same shall be rectified by the contractor, at no
extra cost or time schedule impact, to the complete satisfaction of Owner/ Owner's
representative. Such deficiencies shall include mitigation of stray current electrolysis and
interference problems that may be found existing in the course of testing and commissioning.
A set of PSP observations shall also be taken during the peak of the first dry season after
commissioning the system into regular operation. Any deficiency found in the protection of
the pipeline shall be rectified by the contractor at his own cost.
xx) If it is found during commissioning that the sites of occurrence of least negative or most
negative protective potentials are less negative than (-) 0.95V (OFF) or more negative than (-)
1.18V (OFF) respectively even after 72 hours of operation, then the drainage point potentials
shall be adjusted depending upon anode ground bed currents in consultation with
Owner/Owner's representative. In any case, the protective 'OFF' potential values of pipeline
and polarization coupons shall not exceed the PSP value range specified in clause 6 of this
document, at any location on the pipeline.
xxi) The reference cell shall be calibrated minimum once in 24 hours during the commissioning.
xxii) The current dissipated by individual anodes shall be measured from the anode lead junction
box and corrected for equal dissipation to the extent possible keeping the total ground bed
current same.
10.0 INTERFERENCE MITIGATION
10.1 Investigations shall be made for stray current electrolysis of the pipeline, mutual interference
between the pipeline and foreign pipelines/ structures, interference on foreign
pipelines/structures due to the CP of the pipeline and ground bed, interference on metallic
structures which lie in between pipeline and ground bed or near to ground bed, AC induction
on pipeline due to overhead EHV/HV lines, interference due to high voltage DC lines, HVDC
earthing system, electric traction etc.
10.2 Measurements including pipe/ structure to soil potentials and pipe/ structure currents etc. on
the pipeline/ structure being CP protected and on foreign pipelines/ structures, and ground
potential gradient etc. shall be made to investigate the current discharge and pickup locations.
In case of fluctuating stray currents, investigations shall be made continuously over a period
of time and if required simultaneously at different locations to find out the stray current
source(s). Recorders shall preferably be used for long time measurements.
10.3 Wherever foreign pipelines which may or may not be protected by an independent CP system
run in parallel to the protected pipeline, either in the same trench or very near to the protected
pipeline and are not bonded to it, investigations shall be performed for current discharge
points on both the pipelines.
Page 1777 of 2065

oi
`72_Jt4 10
f ■ ENGINEERS IMPRESSED CURRENT
IM~
i ,+aftraxlonJ.7,5-41 i
INDIA LIMITED
I Go. of India Undertalong)
10.4 Mitigative measures shall be provided depending upon the type of stray current
electrolysis/interference. These shall include installation of bond with variable resistor,
diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment/
relocation (if possible) of offending interference source, provision of electrical shield etc.
depending on the type of interference.
10.5 Bonding with foreign pipelines/ structures as a mitigation measure shall be provided where
the owners of the foreign pipelines/ structures have no objection. Otherwise alternative
mitigation measures shall be provided. Wherever bonding is provided for mitigation, the
bonding resistor shall be adjusted for optimum value for minimum/ no interference. Galvanic
anodes installed as a mitigation measure shall be adequately sized for the life specified for
permanent CP system.
10.6 Where overhead EHV/HV transmission lines/underground electric cables cross the pipeline or
run in parallel with in or more than 25m from the pipeline, A.C. Voltage measurements shall
also be made on the pipeline to find out continuous induction of voltage. In case of the
induced voltage being beyond the safe limits, the pipeline shall be grounded in line with
clause no.7.8 above.
11.0 CLOSE INTERVAL POTENTIAL SURVEY
Where specified, contractor shall carry out a close interval `01\17ÒFF' potential survey over
the entire length of pipeline by computerised potential logging method and identify the under
protected/ over protected area, any major coating damage on the pipeline, after the backfilling
has been consolidated sufficiently and CP system has stabilized. Contractor shall provide
required mitigation measures and rectify the under/ over protected zones, identify if any, the
major pipeline coating defects, required to be repaired. During the survey the reference cell
shall be calibrated minimum once in 24 hours. Detailed procedures for running this survey
shall be submitted for review.
Additional tests for detailed identification of coating defects shall be conducted by the
contractor, if specified in the project specification/ data sheets.
Page 1778 of 2065

(E7,-4 ENGINEERS EQUIPMENT/ MATERIAL FOR
6-45-0029 REV. 0
$.1g--arl~ INDIA LIMITED
evran, a513qar. (A Goot of incha Uncfortaiong)
CATHODIC PROTECTION
.4frXW 'WkciT ul
4R4Kvi fffqfq?"4-47
SPECIFICATION
FOR
EQUIPMENT / MATERIAL FOR
FOR PIPELINES
r-4
AI
0 17.07.14 NSB RC PPLATCtii SC
(OLD DOC. NO.: 6-51-0029, REV. 1)
Standards Standards
Committee Bureau
No by by
Approved by
Page 1779 of 2065

5g-ar 22- g O INDIA LIMITED
kwcWas.3o,...1
rl; ENGINEERS
IA Govt of Indha Undettalonw
EQUIPMENT/ MATERIAL FOR
Abbreviations:
CMRI : Central Mining Research Institute
CPPSM: Cathodic Protection Power Supply Module
DC : Direct Current
HV High Voltage
IS : Indian Standards
MMO : Mixed Metallic Oxide
MOV : Motor Operated Valves
NACE : National Association of Corrosion Engineers
PE : Polyethylene
ROU : Right of Use

Page 1780 of 2065

ENQNEERS EQUIPMENT/ MATERIAL FOR
g-ar fM2C'g
0,3W1.11
INDIA LIMITED
IA GoN of Inda Undertalung)
CONTENTS
1. SCOPE 4
2. CODES AND STANDARDS 4
3. SITE CONDITIONS 5
4. EQUIPMENT/ MATERIAL SPECIFICATIONS 5
5. EQUIPMENT FOR CLASSIFIED AREAS 14
6. TESTS AND ACCEPTANCE 14
7. PACKING AND DESPATCH 17
Page 1781 of 2065

ENGINEERS EQUIPMENT/ MATERIAL FOR
$ifgzu fal51- g INDIA LIMITED CATHODIC PROTECTION 6-45-0029 REV. 0
1441, 2taX2+1,3,
10,A, IA Gov1 of India Undeftalung)
1.0 SCOPE
This specification covers the requirements for the design, manufacture, supply and testing of
various equipment and materials for Cathodic Protection System for underground
pipelines/structures.
These equipment and materials shall broadly include:

Sacrificial Anodes
- Test Stations
- Anodes for impressed current CP system
Anode junction boxes
- Cathode junction boxes
- Permanent reference cells
Polarisation cells and surge diverters/grounding cells
Polarisation coupons
Cables
Requirement of cathodic protection TR units (CPTR unit) and cathodic protection power
supply modules (CPPSM) are covered in separate specifications.
2.1 All equipment and material covered in this specification shall conform to the requirements of
the latest revision of following standards:
IS 3043 Code of Practice for Earthing
NACE standard SP0169 Control of External Corrosion on Underground or Submerged

Metallic Piping Systems
BS 7361, Part-I Cathodic Protection- Code of Practice for Land and Marine
Applications
ASTM A518 M Corrosion Resistant High Silicon Iron Castings ASTM B418
Cast and Wrought Galvanic Zinc Anodes
ASTM B338 Specification for Seamless and Welded Titanium and

Titanium Alloy Tubes for Condensers and Heat Exchangers
ASTM B843 Magnesium Alloy Anodes for Cathodic Protection
IS 1554, Part-I PVC Insulated (Heavy Duty) Cables
IS/ IEC: 60079 Electrical Apparatus for Explosive Gas Atmosphere
IS/ IEC: 60529 Classification of Degree of Protection Provided by

Enclosures
Page 1782 of 2065

5gar ffleg INDIA LIMITED CATHODIC PROTECTION 6-45-0029 REV. 0
o■rcort,friJOOM, IA GoN of India undenak.g)
2.4 In case of any contradiction between various referred standards/ specifications/ data sheet and
Data Sheets
- Job Specification
This Specification
3.0 SITE CONDITIONS
The equipment and materials shall be suitable for installation in locations having generally
corrosive, warm and humid or dusty atmosphere. Service conditions shall be as specified in
the project specification/ data sheet. If not specifically mentioned therein, a design ambient
temperature 40°C and an altitude not exceeding 1000 M above mean sea level shall be
considered.
4.0 EQUIPMENT/ MATERIAL SPECIFICATIONS
All equipments/ materials shall be brand new with state of art technology and proven field
Make and construction of all equipments/ materials shall be subject to approval by

Owner/Owner's representative.
4.1 Sacrificial Anodes
4.1.1 Magnesium Anode
The anode shall conform to the requirements of ASTM B843 standard. The anode shall be of
high manganese, Magnesium alloy packed with special back fill. The metallurgical
composition, potential and capacity of anode shall be as below:
i) Composition
Element Weight
Manganese 0.15 - 0.7%
Copper 0.02% max.
Silicon 0.1% max.
Zinc 2.5% - 3.5%
Aluminium 5.3% - 6.7%
Iron 0.003% max.
Nickel 0.002% max.
Calcium
Other metallic elements (Total) 0.3% max
Magnesium Balance
Page 1783 of 2065

056
13W7, rwon, CIRJWIM,
INDIA LJMITED
(A co. of India undenak.g) CATHODIC PROTECTION 6-45-0029 REV. 0
ii) Anode open circuit Potential 1.55 volts

(Cu/CuSO4 Reference)
iii) Anode Capacity 1050 - 1200 AH/Kg.
4.1.2 Zinc Anode
The anode shall conform to the requirements of ASTM B418 standard. The metallurgical
composition of anode, potential and capacity of anodes shall be as below. Anode of type I shall
be used for seawater, brackish water having resistivity not exceeding 10 Ohm-m and for
grounding/ earthing of pipelines. Anode of type II shall be used for ribbon anodes for
protection of carrier pipes inside casing or for application in saline soil having resistivity less
than 10 Ohm-m. The anode (other than ribbon anode) shall be packaged with special backfill.
i) Composition:
Element Weight Weight

(Type I) (Type II)
Aluminium 0.1% to 0.5% 0.005% max.
Cadmium 0.025-0.07% 0.003% max.
Copper 0.005% max. 0.002% max.
Iron 0.005% max. 0.0014% max.
Lead 0.006% max. 0.003% max.
Others (Total) 0.1% max.
Zinc Remainder Remainder
ii) Anode open circuit Potential -1.1 volts -1.1 volts

(Cu/CuSO4 Reference)
iii) Anode Capacity 790 - 810 AH/Kg. 790 - 810 AH/Kg.
4.1.3 The anodes shall be provided with cable tail of sufficient length to reach test station/ buried
junction box, as applicable without any intermediate joint in the cable and with minimum of
0.5m cable slack provided at each anode and test station ends.
4.1.4 The anodes for grounding/ earthing or for saline soil application shall be pre packed with
special backfill adequately so that the performance of the anode is not affected by the
carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill
shall not be less than 50mm on all the sides of the anode or minimum 20 Kg. net, whichever is
higher.
4.1.5 The other details of anodes shall be as shown in the applicable EIL standard drawings.
4.1.6 The anodes for grounding of cathodically protected above ground pipelines at intermediate SV
stations, pigging stations etc., grounding of motor operated valves on cathodically protected
portion of the pipeline, grounding of pipeline through polarisation cell at EHV/HV line
crossings or running in parallel etc., shall be either of block anode or ribbon type. Sizing and
quantity of anode shall be decided so as to achieve maximum total earth resistance of 5 Ohm
Page 1784 of 2065

g1-110156 INDIA LIMITED CATHODIC PROTECTION 6-45-0029 REV. 0
iaams rwem, am,yrasR, f A Govt of Ind. Underte/ong)
for each location. The anode and cable terminations shall be suitable for the anticipated fault
current at the location of installation.
4.1.7 Special Backfill
The composition of special back fill for anodes shall be as below:
Gypsum (Commercial Purity) 75%

Bentonite (Commercial Purity) 20%
Sodium Sulphate (Commercial Purity) : 5%
4.2 Test Stations
Test stations shall be provided along the pipeline ROU for monitoring the performance of the
cathodic protection system.
i) Test station enclosure shall be made of sheet steel of at least 3 mm thickness and shall
be suitable for GI pipe post mounting. Test stations shall have weather proof enclosure
having degree of protection IP-55 and hinged lockable shutter. The inner and outer
surfaces of test stations shall be Epoxy painted.
ii) The resistors for control of current provided in the test stations, anode/ cathode
junction box etc. shall be of variable, grid coil type. The resistors shall be suitable for
operation over the design life for the permanent CP system specified in the project
specification/ data sheet.
iii) Number of terminals and different schemes of wiring shall be as per the applicable
EIL standard drawing. Minimum twenty percent spare terminals shall be provided in
each test station.
iv) At locations where solid state polarisation cells are provided, the test station size shall
be suitable for mounting the polarisation cell inside the test station.
v) A nameplate of Anodised Aluminium with black back ground and white letters shall
be fixed to the inner side of the test station. The nameplate shall carry the following
minimum information:
- Chainage in km
- Test station connection scheme
Distance form pipeline in metres
Direction of product flow
vi) The constructional features of test stations shall be as per the applicable EIL standard
drawings.
4.3 Anodes for Impressed Current CP System
4.3.1 High Silicon Cast Iron Anodes
i) High silicon cast iron type anodes shall be center-connected hollow type or end
connected solid type. Cable to anode joint shall be reliable and long lasting for total
Page 1785 of 2065

(5-1
1 ENGINEERS EQUIPMENT/ MATERIAL FOR
5gar 18tW'g INDIA LIMITED CATHODIC PROTECTION 6-45-0029 REV. 0
lattOPt vtrovet 41573OOttt I A Govt of Intha UndettakIng)
design life of anode. Composition of anodes shall be as below and shall also conform
to ASTM A518 M-86 Gr. III.
Element Weight
Silicon 14.2 - 14.75 %
Manganese 1.5% max.
Carbon 0.7% - 1.1 %
Chromium 3.25 - 5.0 %
Copper 0.5% max.
Molybdenum 0.2% max.
Iron Remainder
ii) Surface current density rating of the anode for continuous operation shall be
15 Amp./sq.m for shallow anode ground bed and 10 Amp./sq.m for deep well anode
ground beds.
iii) Anode consumption rate shall not be more than 0.2 kg./Amp-Yr
iv) The design life of anode under burial condition, at the design operating current shall
be in minimum the design life of the CP system specified in the project
specifications/data sheet.
v) For shallow anode ground bed sheet steel anode canisters of adequate size shall be
provided for each anode. Anode canisters shall be filled with petroleum coke breeze
with following specification conforming to IS: 8502, Grade-A type.
a) Chemical Composition
- Fixed carbon content by mass 99% min.

- Ash by mass 0.5% max.
- Moisture by mass 0.1% max.
Volatile matters by mass 0.5% max.
b) Bulk density 800 kg./M3 to 1200 kg./M3

c) Real density 2.03 kg/litre (min.)
d) Particle size 1 mm max, dust free
e) Resistivity 0.1 ohm cm max at 150 PSI
vi) For deep well ground beds, anodes shall be non canistered type. Calcined petroleum
coke breeze slurry conforming to clause 4.3.1 v) above shall be supplied along with
the anodes.
4.3.2 Mixed Metal Oxide Coated Titanium Anode
i) Mixed metal oxide coated titanium anodes shall be of pure titanium having substrate
composition of titanium of ASTM B-338, Grade I/ Grade II, over laid with mixed
oxide of noble metals (MMO coated). These anodes shall be dimensionally stable. The
anodes shall be centre connected sealed tubular type. The design life of anode under
burial condition, at the design operating current in minimum be the design life of the
CP system specified in the project specifications/ data sheet.
Page 1786 of 2065

‘31
(fErj- ENGINEERS EQUIPMENT/ MATERIAL FOR
OgL
ar Of5leg INDIA LIMITED CATHODIC PROTECTION 6-45-0029 REV. 0
14,,71 e-wern, a>t3VVWl IA Go. of Inclw undertak.g)
Maximum allowable anode current 100 A/m2 (in coke backfill)

density 50 A/m2 (soil without backfill)
100 A/m2 (Fresh Water)
Allowable anode current density 70 A/m2 (in coke backfill)

for continuous operation 30 A/m2 (soil without backfill)
70 A/m2 (Fresh Water)
Maximum coating consumption 2 mg./A-Yr in coke backfill

(wear) rate at maximum anode 6 mg./A-Yr in fresh water
current density
The guaranteed design parameters of anode regarding current density, consumption

rate, design life, rated current output, dimensions, shape, noble metal oxide coating
thickness (gm./square meter), their physical and mechanical properties shall be
substantiated by manufacturer's published catalogues and backed up by type test
reports. Each anode shall be supplied with anode lead cable connected to it.
ii) The anodes shall be provided with sheet steel canisters and coke breeze as per clause
No. 4.3.1 (v) & (vi) above.
4.3.3 Each anode shall be supplied with anode tail cable connected to it, which shall be long enough
for termination on their associated anode lead junction box without intermediate joint. Anode
cable tail shall be connected/ jointed to the anode and the joint insulated at the anode
manufacturer's shop before despatch of anode.
4.3.4 For deep well ground beds steel pipe casing for active portion of the ground bed and non
metallic pipe casing for the top inactive portion of the ground bed shall be provided. The top
non metallic casing and the lower metallic pipe casing shall have threads for jointing each
other. Anode supporting pipe, anode centralisers and gas venting pipes shall be provided for
the ground bed.
4.4 Anode Junction Box
Depending on the size and configuration of anode ground beds, requisite main and sub anode
junction boxes (where required) shall be supplied for each ground bed.
i) Each junction box shall have provision of termination of cable tails from individual
anodes of the ground bed and provision of connection of anode cable coming form
main anode junction box (in case of sectionalised ground bed) or from CP station
power source.
ii) Junction boxes shall have sheet steel enclosure of minimum 3 mm thickness and hinged
lockable shutters. Junction boxes shall be weather proof with degree of protection IP-
55. It shall be epoxy painted on inside and outside surface. Junction boxes shall have
anode bus of copper with nickel/ silver plated or tinned. Provision shall be made for
measurement and control of individual out going circuit/ anode current by providing
suitable shunt and resistors of grid coil type. Disconnecting links shall be provided for
each out going/ anode circuit. 30% spare out going circuits shall be provided in each
anode junction box. Terminals shall be of anti loosening type and provided with
Page 1787 of 2065

©
f=t1 ENGINEERS EQUIPMENT/ MATERIAL FOR
yrs1.27, on,3,ram,
INDIA LIMITED
IA Govt of India Undertalongt
identification labels. Each outgoing circuit shall be labelled clearly to indicate the
circuit/ sub anode junction box to which it is connected.
iii) The constructional features of junction boxes shall be as per the applicable EIL
standard drawing enclosed with the data sheet for impressed current cathodic protection
system for pipelines.
iv) A nameplate of anodised aluminium with black back ground and white letters shall be
fixed to the inner side of the junction box. The nameplate shall carry the following
- Ground bed current rating

- Ground bed resistance
- Connection scheme
- Distance form pipeline in metres
- Distance form CP station in metres
4.5 Cathode Junction Box
Where output of the CP power supply unit is connected to multiple pipelines a cathode
junction box shall be supplied for providing near the pipelines at the location of connection of
the negative drainage cable to the pipelines.
i) The junction box shall have a bus bar with an incoming circuit for connecting to
negative of the CP power source and separate out going circuits for collection of
negative drainage current from each of the pipelines.
ii) The incoming circuit shall have a current measurement shunt. Each out going circuits
shall have isolation link, variable resistance of grid coil type and a current measurement
shunt. One number spare outgoing circuit shall be provided.
iii) Junction box shall have sheet steel enclosure of minimum 3 mm thickness and hinged
lockable shutters. Junction box shall be weatherproof with degree of protection IP-55.
The inside and outside surfaces of the junction box shall be epoxy painted. The
terminals shall be of anti loosening type. Proper identification labelling shall be
provided for each terminal. Each outgoing circuit label shall clearly indicate the size
and identification of the pipeline to which it is connected.
iv) A nameplate of anodised aluminium with black back ground and white letters shall be
fixed to the inner side of the junction box. The nameplate shall carry the following
- Chainage in km
Connection scheme
Distance form the nearest pipeline in metres
- Direction of product flow
4.6 GI Earth Electrodes
For earthing of above ground cathodically unprotected pipelines at intermediate SV stations,

pigging stations etc. and at terminals GI earth electrodes shall be supplied. Earth electrodes
shall be 100 mm dia, 3000 mm long and 13 mm thick conforming to IS 3043.
Page 1788 of 2065

ENGINEERS
k311 EQUIPMENT/ MATERIAL FOR
$'2e4~ INDIA LIMITED CATHODIC PROTECTION 6-45-0029 REV. 0
Govt of Intha unclen..9)
High purity copper/copper sulphate reference cells as specified in project specification/data

sheets, with proven high reliability shall be supplied for providing stable pipe to soil potential
measurement reference at CP stations and at locations of polarisation coupons along ROU.
Silver/Silver Chloride/Saturated Potassium Chloride type reference cells shall be supplied for
marshy area/ brackish water/ saline soil locations where water table is high and chloride ion
content is more than 300 ppm.
i) The reference cells shall have high accuracy and stability and maintain the same over
its design life.
ii) The permanent reference cells shall have a minimum design life of 8 years under
installed/ buried condition.
iii) The reference cell for high resistivity areas shall be suitable for the prevailing dry soil
conditions to give maximum service life.
iv) The reference cells shall be provided with cable tail long enough for connection to test
station without any joint in between.
4.8 Polarisation Cell and Surge Diverter
4.8.1 Polarisation Cell
Polarisation cell shall be a electrolytic type or solid state device as specified in project
specification/ data sheets, designed to simultaneously provide isolation for DC current and low
resistance path for AC current. The device shall require minimum maintenance. The solid state
device shall have weather proof enclosure and shall be suitable for mounting inside a test
station.
Unless other wise specified in project specification/ data sheet the DC blocking voltage shall
not be less than 1.2 volts. The DC leakage current at 1.2 volt shall not be more than 0.5 mA.
The device shall be suitable for continuously conducting maximum AC steady state current
and short time AC short circuit current expected to flow through the pipeline under the normal
operating condition/ any kind of fault on the EHV/HV line at respective sites, subject to
minimum ratings as indicated in clause 4.9.3 below.
4.8.2 Surge Diverter
The surge diverter when connected in parallel across the insulating joints shall protect the
insulating joint against surges coming across it due to lightening strikes, electrical faults, etc,
on the above ground portion of the pipeline. The surge diverter shall be of spark gap type. The
device shall have weatherproof enclosure suitable for out door mounting. The surge diverters
shall be of explosion proof type.
4.8.3 The minimum ratings of polarisation cells and surge diverters shall be as below unless
otherwise specified in the project specification/ data sheet.
Page 1789 of 2065

~_Je? 0" ENGINEERS
=1 EQUIPMENT/ MATERIAL FOR
fa2- g
rwcr»,«Jotrfso
INDIA LIMITED
CA Govt of meia underta.,9) CATHODIC PROTECTION 6-45-0029 REV. 0
i) Polarisation Cell
a) Type Solid state type/Electrolytic type

b) Description Rating
- Minimum rated 50 Hz steady : 30A min at 28° C and min 2V DC
state current (RMS symmetrical)
- AC fault current 5 kA min for 1 cycle
(RMS symmetrical)
- Ac voltage under maximum
rated AC fault current Less than 10 V peak to peak
ii) Surge Diverter
a) Type Spark gap, explosion proof type

b) Current, 8/20 micro Second wave: 100 Kilo Amp
c) Spark - over AC voltage
-50 Hz 1 KV
-Impulse (1.2/50 micro Second): 2.2 KV
iii) The polarisation cells, surge diverters, anodes, connecting cables, cable joints, etc,
shall be adequately sized and suitable for the design life of permanent CP system. The
anodes shall be pre packed with special backfill adequately so that the performance of
the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the
soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides
of the anode.
The Polarisation Coupons shall be made from the material of the pipeline. The coupon shall
have one side exposed area of 100 mm x 100 mm unless other wise specified in project
specification/ data sheet. Cable connection of 10 mm2 and 4 mm2 shall be provided to the
coupon for connecting it to pipeline for cathodic protection and potential measurements
respectively.
Connection of coupon to pipeline shall be through a vacuum sealed magnetic reed switch
housed inside the test station. The magnetic reed switch shall be rated to carry and break
minimum 50 mA at 50 V DC.
Magnet for operation of reed switches shall be provided as specified in project

specificationidata sheet.
4.10 Miscellaneous Requirements
i) The sheet steel used for fabrication shall be thoroughly cleaned and degreased to
remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then
rinsed to remove any trace of acid. The under surface shall be prepared by applying a
coat of phosphate paint and a coat of yellow zinc chromate primer. The under surface
shall be free from all imperfections before undertaking the finishing coat. After
Page 1790 of 2065

(r, ENGINEERS
'INDIA EQUIPMENT/ MATERIAL FOR
Q'Q III G LIMITED CATHODIC PROTECTION 6-45-0029 REV. 0
.1.771 rwcrr, 7:157 co. of Intha Unclenmong)
preparation of the under surface, final spray painting with two coats of epoxy based
paint shall be done. Panel finish shall be free from imperfections like pinholes, orange
peels, runoff paint etc.
ii) All unpainted steel parts shall suitably treated to prevent rust formation. Copper bus
bars, interconnection copper link shall be tinned or nickel/silver coated.
iii) Test station/ junction box cabling

Adequate space shall be provided inside the test station/junction box for termination of
cables. Termination shall be performed using crimped lugs. The lugs shall be of tinned
copper. Requisite cable lugs shall be supplied.
4.11 Cables
4.11.1 Cables shall be of annealed high conductivity stranded copper conductor, 650/1100V grade
PVC insulated, armoured, PVC sheathed conforming to IS-1554 part-I, except for reference
cell, potential measurement and impressed current CP anode tail cables. The size of the copper
conductor of the cables shall be as below:
i) Minimum 4 mm2 for potential measurement, reference cells, 6 mm2 for current
measurement and 25 mm2 for bonding/grounding.
ii) For sacrificial anode CP system the cable size shall be minimum 6 mm2 copper for
anode tail cable from anode to buried junction box and 10 mm2 copper from buried
junction box to test station in case of temporary CP anodes. In case of sacrificial anodes
for permanent CP system the size of anode tail cable from anode to test station shall be
minimum 6 mm2 copper.
iii) For impressed current CP system the size of conductor of cables shall be based on the
current to be carried, ground bed loop resistance and shall be minimum 35mm2 copper
for positive, negative drainage cables and 10 mm2 copper for anode tail cables. The size
of CPTR unit AC incomer cables shall be of minimum 4mm2 copper conductor.
4.11.2 Impressed current CP anode tail cables shall be of minimum 10 mm2, annealed high
conductivity stranded copper conductor, single core, 650 voltage grade PE insulated,
unarmoured, PVC sheathed. Contractor may suggest cables with alternative
insulation/sheathing having proven track record for impressed current anode ground bed
application, for Owner's approval.
4.11.3 The cables for reference cells and pipeline potential measurements shall be of 4 mm2 copper
conductor, PVC insulated, Aluminium backed by mylar/ polyster tape shielded, PVC sheathed,
armoured, PVC over all sheathed type. The tape shield shall be helically applied with metallic
side down, with either side 25% overlap and 100% coverage. The minimum shield thickness
shall be 0.05 mm.
4.11.4 Cables for connecting various transducers from CPTR Unit/CPPSM to telemetry interface
junction box shall be copper conductor, PVC insulated, twisted pair with individual pair
shielded and overall shielded with Aluminium backed by mylar/ polyster tape, PVC sheathed,
armoured, PVC over all sheathed type.
Page 1791 of 2065

Og-ar faf51-dg InJnir.
1.4,1rwanc,
INDIA LIMITED
Govt o, Ind. Undertakng)
4.11.5 Cable conductor sizes indicated above are minimum only and where necessary for proper
operation of the CP system higher sized cables shall be provided.
4.11.6 Length of anode tail cables shall be sufficient for routing and terminating the cable inside
anode junction box/buried junction box/test station as applicable without any intermediate
joint.
5.0 EQUIPMENT FOR CLASSIFIED AREAS
All electrical and electronic instrument enclosures and its accessories for hazardous area shall
be flame proof type.
The flame proof equipment shall meet the requirements as per IS/ IEC: 60079 and shall be
weather proof to IP-65 also as per IS/IEC:60529.
Director General of Mines Safety (DGMS) in India, for the electronic instruments installed in
electrically hazardous area along with:
Research (CIMFR)/ Electronics Regional Testing Laboratory (ERTL) etc. for flameproof
enclosure/ intrinsic safety, as specified in the data sheet, as per relevant standard for all
Indian manufactured equipments or for items requiring Director General of Mines Safety
(DGMS) approval.
Atmospheres (BASEEFA), Factory Mutual (FM), Physikalisch-Technische Bundesanstalt
(PTB), Canadian Standards Association (CSA), Underwriters Laboratories (UL) etc. for
compliance to ATEX directives or other equivalent standards for all equipments
manufactured outside India.
6.1 Unless other wise agreed by the Engineer-in-Charge, all the equipment/ material shall be
subject to inspection by Owner/ EIL or by an agency authorised by the Owner/ EIL. A11
necessary information concerning the supply shall be furnished to EIL/ Owner's inspector.
Two weeks notice shall be given to Owner/ EIL for witnessing the final testing.
6.2 Routine tests and final acceptance tests shall be carried out at manufacturer's works under his
care and expense. Instruments and equipment required for testing shall be arranged by the
manufacturer. Final acceptance shall be subject to successful testing. Type test certificates
instead of conducting the tests may be accepted where specified in the project specifications.
6.3 Sacrificial Anodes
i) Inspection
a) Visual inspection shall be carried out on all the anodes regarding surface finish
excessive shrinkage, cracks, cable joint to anode cone, etc.
Page 1792 of 2065

$11gzir fafai-eg
1.12PIrwoWan..3froff,0
INDIA LIMITED
(A Govt of Intha Undertalung)
b) Minimum 10% of number of anodes from each heat for conformity to

dimensions and weight.
c) The anode surface shall be free from cracks, which may reduce the performance
of the anode.
Any cracks which follow the longitudinal direction of elongated anodes shall
not be acceptable.
Small cracks in the transverse direction of elongated anodes and in anodes of

other shapes may be accepted provided the cracks would not cause any
mechanical failure during service of the anode considering that the combination
of cracks and lack of bond to the anode core is detrimental.
For transverse cracks the acceptable limits shall be furnished by the bidders
along with the offer.
d) The anode shall be free from excessive shrinkage. The following limits shall be
used:
Maximum 10% of the depth of anode or 50% of the depth of the anode core
whichever is less. The depression may be measured for the edges of one side.
The surface of the anodes shall be free from coatings and slag/ dross inclusions
etc.
The maximum deviation from straightness shall not exceed 2%.
The weight tolerance of individual anode may be taken as + 5%. The total
weight of the anodes shall not have negative tolerance.
Recommended dimensional tolerance shall be as follows:
Length + 2.5%
Width/thickness + 5%
ii) One anode per heat shall be subjected to radiographic test completely to evaluate
cracks, voids, slag inclusion etc.
iii) Destructive Testing
At least one anode per heat shall be subject to close inspection by destructive testing
for slag inclusions, bond between the anode material and steel inserts. If the anode
fails the test, two more anodes shall be tested. If the second lot of anodes also fails the
test, all the anodes of the heat shall be rejected.
iv) Chemical Analysis
One anode sample per heat shall be subject to chemical analysis by spectrography.
Sample shall be taken in the beginning for first heat, at the end for the second heat, at
the beginning for the 3rd heat and so on.
Page 1793 of 2065

k31 ENGINEERS EQUIPMENT/ MATERIAL FOR
$1@zu INDIA LIMITED CATHODIC PROTECTION 6-45-0029 REV. 0
I.Vrt rwern, ori,ran,) (A Go. ot Ind. Und.nak,n9)
In case the chemical compositions of the tested anode do not meet the requirements of
this specification, all the anodes of the heat shall be rejected. Vendor shall indicate
specific method of spectrography for each element (e.g. atomic absorption/ emission/
photometrics etc.).
v) Electrochemical Tests
- Open circuit potential, closed circuit potential and anode capacity test shall be
carried out for one anode per heat for a duration of 96 hours as per DNV-RP-
B401 in the synthetic sea water conforming to ASTM D1144
- Consumption rate by weight loss method
Visual examination of corrosion pattern (uneven consumption, inter granular
attack etc.)
The anode open circuit potential shall lie within (+) 10 MV and (-) 50 MV of the
guaranteed value. The anode consumption rate shall not be less than the specified
value. In case of anode closed circuit potential and/or the anode consumption rate do
not meet the acceptance criteria, all the anodes of the heat shall be rejected.
vi) Manufacturer's test reports regarding reference cell calibration shall be furnished. The
report shall also indicate the month and year of manufacture of reference cell.
6.4 Impressed Current Anodes
6.4.1 High silicon Cast Iron anode
i) Visual inspection
Visual inspection regarding surface finish, surface cracks & craters, shrinkage, cable
joint, measurements of dimension, weight, radiographic tests etc. shall be conducted
as Yer clause 6.3 i) above. The anode acceptance criteria shall be as specified in the
clause except that no crack in the anode shall be acceptable unless the cracks are only
superficial.
ii) Destructive testing

Destructive testing and acceptance criteria shall be as per clause 6.3 iii) above.
iii) Chemical analysis

Chemical analysis test and acceptance criteria shall be as per clause 6.3 iv) above.
iv) Electrochemical tests

Electrochemical tests for anode consumption, visual examination of corrosion pattern
and the anode acceptance criteria shall be as per clause 6.3 v) above.
v) Spectrographic analysis
The anodes from each heat shall be tested for chemical composition by spectrographic
analysis and for homogeneity, dross inclusion, voids etc. by radiography. Destructive
tests shall be carried out where asked by owner based on the radiographic test results.
Page 1794 of 2065

fa51- g
1.17N r1,15■ C
INDIA LIMITED
IA GoN of Incha Undeltakmg)
6.4.2 Mixed Metal Oxide Coated Titanium Anode
Contractor shall furnish list/ details of the tests that will be conducted by manufacturer of
anode and their acceptance criteria.
6.4.3 Petroleum coke breeze and special back fill
The petroleum coke breeze material shall be tested for chemical composition, bulk density,
real density, particle size and resistivity and test certificate shall be furnished.
The special back fill material for the sacrificial anodes shall be tested for composition and test
reports shall be submitted.
All equipment/ material for CP system along with one set of final drawings shall be
dispatched to site packed in wooden crates.
All the equipment shall be divided in to several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for transportation by ship/ rail
or trailer. The equipment shall be wrapped in polyethylene sheets before being placed in
crates/ cases to prevent damages to finish. Crates/ cases shall have skid bottom for handling.
Special notations such as `Fragile', `This side up', `Centre of gravity', Weighe, Òwners
particulars', `PO nos.' etc. shall be clearly marked on the package together with other details
as per purchase order.
The equipment may be stored out doors for long periods before installation. The package
shall be completely suitable for out door storage in areas with heavy rain/ high ambient
temperature unless otherwise agreed.
Page 1795 of 2065

STANDARD No.
ENGINEERS PREPACKED ZINC
7-45-0601 Rev. 1
IIAI«11111111113•11~ (A Govt. of Indio Undertoking)
ANODE
c D(0)
SILVER SOLDERJNUT & BOLT CONNECTION

COTTON BAG MS CORE ZINC ANODE
SEE DETAIL—X BACK FILL

ANODE TAIL CABLE
ELEVATION
CHEMICAL COMPOSITION OF ANODE (% WEIGHT):—
CHEMICALS TYPE—I TYPE—II

Al :0.1%-0.5% 0.005%MAX
MS CORE Cd :0.025%-0.07% 0.003%MAX
Cu :0.005%MAX 0.002%MAX
_L_ Fe
Pb
:0.005%MAX
:0.006%MAX
0.0014%MAX
0.003%MAX
OTHERS :0.1%MAX
Zn :REMAINDER REMAINDER
SECTION-AA ARMOUR
(SHALL NOT HAVE BACK FILL COMPOSITION
ELECTRICAL CONNECTION
EPDXY TO ANODE) GYPSUM :75%
COMPOUND —MS CORE BENTONITE :20%
SODIUM SULPHATE :5%
ZINC
ANODE
ANODE TAIL
CABLE SILVER SOLDER CONNECTION
PVC INSULATION
DETAIL-X
NOTES: —
1. ANODE COMPOSITION, NET WEIGHT, GROSS WEIGHT, PREPACKED ANODE WEIGHT AND DIMENSIONS
(A,B,C,D,E & F) SHALL BE FURNISHED BY CONTRACTOR.
2. ANODE TAIL CABLE SHALL BE HIGH CONDUCTIVITY, STRANDED, COPPER CONDUCTOR, 650V GRADE, PVC
INSULATED, PVC SHEATHED & ARMOURED.
1 17.07.14 REVISED AND REISSUED NSB RC • PPL SC
0 14.03.13 ISSUED AS STANDARD NSB RC PPL DM

(OLD DOC. NO. 7-51-0601 Rev. 3)
No. by by
Approved by
Page 1796 of 2065

STANDARD No.
INGNEERS PREPACKED MAGNESIUM
MIA LIMITED 7-45-0602 Rev. 0
Pow rumairawra (A Govt. of India Undertaking)
ANODE
C D(0)
SILVER SOLDER/NUT & BOLT CONNECTION

MS CORE ANODE
COTTON BAG
SEE DETAIL—X BACK FILL
ANODE TAIL CABLE (SEE NOTE-3
ELEVATION
CHEMICAL COMPOSITION OF ANODE (%WEIGHT):-
ELEMENT %WEIGHT
MS CORE
C Al 5.3-6.7(max)
Mn 0.15-0.7
Cu 0.02(max)
Fe 0.003(max)
F
Ni 0.002(max)
SECTION-AA Zn 2.5-3.5
Si 0.1(max)
ARMOUR (SHALL NOT HAVE
Ca
ELECTRICAL CONNECTION
EPDXY
COMPOUND TO ANODE) OTHER METALLIC ELEMENTS
—TOTAL 0.3(max)
MS CORE Mg BALANCE
ANODE TAIL BACK FILL COMPOSITION

CABLE SILVER SOLDER CONNECTION
GYPSUM :75%
MAGNESIUM
ANODE BENTONITE : 20%
DETAIL-X : 5%
PVC INSULATION SODIUM SULPHATE
NOTES:-
1. ANODE COMPOSITION, NET WEIGHT, GROSS WEIGHT, PREPACKED ANODE WEIGHT AND DIMENSIONS
(A,B,C,D,E & F) SHALL BE FURNISHED BY CONTRACTOR.
2. ANODE TAIL CABLE SHALL BE HIGH CONDUCTIVITY, STRANDED, COPPER CONDUCTOR, 650V GRADE, PVC
INSULATED, PVC SHEATHED & ARMOURED.
3. THICKNESS OF BACK FILL SHALL BE ADEQUATE TO SAFEGUARD THE ANODES AGAINST EFFECT OF
CARBONATES, BICARBONATES, NITRATES etc. IN SOIL. ANODES SHALL BE PROVIDED WITH MIN. 50mm.
THICK BACK FILL ON ALL THE SIDES OF THE ANODE OR MIN. 20k NET, WHICHEVER IS HIGHER.
ISSUED AS STANDARD uo.tak- 41 r4(

0 14.03.13 (OLD DOC. NO. 7-51-0602 Rev. 3) NSB RC PPL DM

Rev.
No. by by
Approved by
Page 1797 of 2065

STANDARD No.
ENGNEERS MAGNESIUM RIBBON
Oitz~bINDIA LIMITED 7-45-0603 Rev. 1
IfIRPMENROW/WOO (A Govt. of Indla UndortokIng)
ANODE
L
M.S WIRE CORE
T
i
CABLE
AJ
SEE DETAIL -'A' SECTION-À A'
\\ MAGNESIUM RIBBON ANODE
SILVER SOLDER GRADE LEVEL

PVC INSULATION CONNECTION
CABLE ///" ///"
1-.-75(TY .) M.S. WIRE CORE
—TRENCH
•
ARMOUR PIPE LINE

(SHALL NOT
HAVE ELECT.
CONNECTION io(Typ.) 1-.35(TYP)1
TO ANODE)
HEAT SHRINK
SLEEVE OR 500(min.)
EPDXY COMPOUND
IN PVC CONDUIT
ANODE INSTALLATION
DETAIL À'

Al 5.3-6.7
Mn 0.15-0.7
Cu 0.02(max)
Fe 0.003(max)
Ni 0.002(max)
Si 0.1 (max)
Zn 2.5-3.5
Ca
OTHER METALLIC ELEMENTS
-TOTAL 0.3(max)
Mg BALANCE
NOTES :-
1. ALL THE DIMENSIONS ARE IN MM.
2. ANODE COMPOSITION, ALL DIMENSIONS, NET WEIGHT & GROSS WEIGHT SHALL BE FURNISHED BY
CONTRACTOR.
3. CABLE CONNECTION TO ANODE SHALL BE DONE AT SITE.
4. CABLE SHALL BE HIGH CONDUCTIVITY, STRANDED, COPPER CONDUCTOR, 650V GRADE, PVC INSULATED,
PVC SHEATHED & ARMOURED.
tkktsi...
1 17.07.14 REVISED AND REISSUED NSB RC PPL ‘9A.114 sc
ISSUED AS STANDARD
0 06.03.13 NSB RC PPL DM
(OLD DOC. NO. 7-51-0603 Rev. 3)
No. by by
Approved by
Page 1798 of 2065

TEST STATION STANDARD No.
WITH
OtailMOINDIA
lRNRl1(A
LIMITED Govt. of India Undertaking)
7-45-0604 Rev. 0
FOUNDATION DETAILS
Page 1 of 1
25 25 50
CANOPY WITH
15* (APPRX.)
SLOPE ANGLE
TERMINAL
SHUTER WITH
z PLATE
H NEOPRENE GASKET
CONCEALED
LOCK
FRONT
100 MM 0,4.5MM THICK MS PIPE

(EPDXY PAINTED)
FOUNDATION
FOUNDATION PLATE BOLT (TYP.)
WITH STIFFNER
(6 THICK)
0
4 0 0
CV GRADE LVL.
PCC (M-15) //A\
FOUNDATION ••
•
600 .%
•.•••• • i% •• --THE ENTYRY
50—r- • • SHALL BE SEALED
T25 WITH BITUMEN
(Typ.)"
1 COMPOUND AFTER
LAYING CABLE TO
5
50T PREVENT WATER
CONCRETE 600
600 ENTRY.
FRONT ELEVATION SIDE ELEVATION
NOTES :-
1. THE SHUTTER SHALL BE HINGED TYPE WITH CONCEALED LOCK & SHALL HAVE DOOR GASKET TO
MAKE THE TEST STATION WEATHER PROOF (IP:55)
2. THE INNER & OUTER SURFACE OF THE TEST STATION SHALL BE EPDXY PAINTED.
3. THE NAME PLATE SHALL BE OF ANODISED ALUMINIUM WITH BLACK BACKGROUND & WHITE LETTERS
& SHALL BE FIXED TO THE INNER SIDE OF SHUTTER.
4. TEST STATION SHALL BE ERECTED WITH THEIR SHUTTERS PARALLEL TO THE LINE OF AXIS & FACING
THE PIPE LINE.
5. THE CHAINAGE OF TEST STATION SHALL BE WRITTEN WITH BLACK PAINT ON THE OUTER SIDE OF
THE FRONT SHUTTER.
6. HEIGHT OF THE TEST STATION SHOWN ABOVE GROUND LEVEL IS MINIMUM ONLY. THE
ACTUAL HEIGHT SHALL BE DECIDED BASED ON LOCAL FLOOD LEVELS TO BE ASCERTAINED.
7. CONTRACTOR SHALL FURNISH ALL THE DIMENSIONS OF THE TEST STATION.
0 06.03.13 ISSUED AS STANDARD NSB RC DM

(OLD DOC. NO. 7— 51— 0604 Rev. 3)

No. by by
Approved by
Page 1799 of 2065
STANDARD No.
TEST STATION
MATED
7-45-0605 Rev. 0
Mel ellegrIPIZal/W) (A Govt. of Indio Undertaking)
CONNECTION SCHEMES SHT. 1 OF 4
TEST STATION
(TYP.)
TERMINALS
(TYP.)
2
6MM CABLE
4MM 2 CABLE
PIN BRAZING
IIII1
(Typ 6
4MM2 CABLE CASING
(TYP.) 6011
1
1 =
CARRIER
POTENTIAL MEASUREMENT CURRENT MEASUREMENT CASED CROSSING WITH
(CONNECTION SCHEME-A) (CONNECTION SCHEME-B) UNCOATED/UNPAINTED CASING
(CONNECTION SCHEME-C)
VARIABLE LINK
RESISTOR
VARIABLE
RESISTOR
SHUNT
2
25MM
4MM2 CABLE CABLE
FOREIGN 4MM2 INSULATING

25MM2 CABLE
PIPELINE JOINT
ZINC GALVANIC
ANODE 25MM2 SURGE
CARRIER CASING CABLE DIVERTOR
FOREIGN PIPELINE
CASED CROSSING WITH
CROSSING INSULATING JOINT
COATED CASING
(CONNECTION SCHEME-E) (CONNECTION SCHEME-F)
(CONNECTION SCHEME-D)
2
35MM (MIN.) CABLE
TO CPTR UNIT/CPPSM
TO CPTR UNIT/CPPSM
7 8 09 01 08 9 —010 011 012 013 014
02 03 04 05 Q3 r 05
25MM2
6011
('fYP.) CABLE
4MM2CABLE
6MM2CABLE INSULATING
JOINT
35104 2(41N.) CABLE
REFERENCE CELL (TYP.)

FOR AUTO PSP CONTROL SD
BOLT CONNECTION TO 25MM 2CABLE
PLATE WELDED TO CATHODICALLY SURGE DIVERTOR
PIPELINE (TYP.) PROTECTED SIDE
INTERMEDIATE CP STATION (WITHOUT
IJ ON PIPE LINE AT THE STATION) TERMINAL STATION IMPRESSED
IMPRESSED CURRENT DRAINAGE POINT CURRENT DRAINAGE POINT
(CONNECTION SCHEME-G) (CONNECTION SCHEME-H)
ISSUED AS STANDARD Nkro.ok,,tk

0 06.03.13 (OLD DOC. NO. 7-51-0605-1 Rev.3) NSB DM
Prepared Stds. Committee Stds. Bureau

Rev. Checked
No. by by
Approved by
Page 1800 of 2065
STANDARD No.
ENGINEERS TEST STATION
INDIA UMITED 7-45-0605 Rev. 0
Plan ellellIsCaellna (A Govt. of India Undertaking) CONNECTION SCHEMES
SHT.2 OF 4
TEST STATION 1-1 TEST STATION 1-2
{ TO CPTR UNIT/CPPSM
TO CPTR UNIT/CPPSM
LINK VARIABLE
VARIABLE SHUNT 35MM1 (MIN.) CABLE
RESISTOR RESISTOR
LINK
0 1 15 1 8 1 _12 _13 _14 SHUNT
0 4ioomito
13 14 35MM2(MIN.) CABLE TO STN.
TO STATION EARTHING
02 03
2 03 4 05/6 77 8 EARTHING SYSTEM
25MM2CABLE t 05 06 07
SYSTEM
UNPROTECTED SIDE 2C
25MM ABLE
25MM2CABLE
4MM2CABLE
SURGE DIVERTOR
6MM2CABLE
INSULATING JOINT
2
35 MM (MIN.)
25MM2 CABLE CABLE
PIN BRAZING (TYP.) >-
I
O
lD
BOLT CONNECTION TO PLATE

WELDED TO PIPELINE (TYP.)
ISSUED AS STANDARD qi\%J.DIX

0 06.03.13 (OLD DOC. NO. 7- 51-0605-2 Rev.3) NSB
Rev.
No. by by
Approved by
Page 1801 of 2065
STANDARD No.
TEST STATION
7-45-0605 Rev. 0
MUT IMOSIVOINSOWO (A Govt. of Indio Undertaking) CONNECTION SCHEMES
SHT.3 OF 4
CATHODE JUNCTION BOX TEST STATION

VARIABLE SHUNT LINK 35mm2(MIN.) CABLE
RESISTOR (TIP.) (TYP.) (TYP.) TO CPPSM/
CPTR UNIT J ^0
0.
>-
Z
0
13 14 15 16 18
PIN BRAZING (TYP.)

co -J °
0\ 0 0 0
U 11)
0-
N ckk O9
E 10 1 012 0
Z
E Lai
-04=13Y-`-0=0 02 06 CC 41
3 Lai
La. IX
La 0
IX La.
TO CPPSM/CPTR UNIT
..L
BOLT CONNECTION TO PLATE 60M (TIP.)
WELDED TO PIPE UNE (TIP.) ilk AN. al. /Ilk ilk
INTERMEDIATE CP STATION MULTIPLE PIPELINES (TYP. FOR TWO PIPE LINES)

IMPRESSED CURRENT DRAINAGE POINT (WITHOUT Us ON LINE PIPES AT THE STATION)
(CONNECTION SCHEME—J)
TEST STATION
2 TO CPPSM/CPTR UNIT
2 6mm CABLE
35mm (MIN.)
CABLE 4mm2 CABLE
CATHODE JUNCTION BOX
VARIABLE SHUNT LINK
RESISTOR (TYP.) (TYP.) (Tip.)
2 ;322 02 c)2 02
016 0 ---0—
X7 18 19 020
0 0 Qi 5
011 ,12 13 14
06 ,7 08
09 _/°10
2
01 03— 05 25mm
2 CABLE
SURGE 2
DIVERTOR(TYP.) 25mm
CABLE(TYP.)
INSULATING
JOINT(TYP.) UNPROTECTED TERMINAL SIDE
REFERENCE CELL (TYP.)
FOR AUTO PSP CONTROL
TERMINAL STATION MULTIPLE PIPELINES (TYP. FOR TWO PIPELINES)

IMPRESSED CURRENT DRAINAGE POINT.
(CONNECTION SCHEME—K)

(OLD DOC. NO. 7-51--0605-3 Rev.3)

Page 1802 of 2065

STANDARD No.
ENGNEERS TEST STATION
MIA LIMITED 7-45-0605 Rev. 0
own "WM WW1) (A Govt. of Indio Undertaking) CONNECTION SCHEMES SHT.4 OF 4
LINK SHUNT
5 6 7 8
0 0 0
VARIABLE
1 2_3r1=04 RESISTOR
1 OMM2 CABLE
GALVANIC ANODES
4MM2CABLE
BURIED JUNCTION BOX (SEE NOTE-3)
-
TCP GALVANIC ANODE INSTALLATION
(CONNECTION SCHEME-L)
25MM2 (MIN.) PVC

INSULATED
ZINC GALVANIC PVC SHEATED
ANODES (TYP.)
(EACH 20KG NET
ARMOURED
CABLE
LINK
(TYP.) 1
8
5 SOUD STATE
POLARISATION CELL
4MM2PVC INSULATED PVC

TEST STATION SHEATHED ARMOURED CABLE
2
25MM (MIN.) PVC INSULATED
SHUNT
PVC SHEATHED ARMOURED CABLE
PIPE LINE
PIPELINE GROUNDING THROUGH POLARISATION CELL AND GALVANIC ANODE

CONNECTION SCHEME-M
NOTES:-
1. NUMBER OF TERMINALS FOR TEST STATION OF DIFFERENT CONNECTION SCHEME SHALL BE AS SHOWN ON
THE RESPECTIVE SCHEME DRAWING. TEST STATION FOR ANY OTHER SCHEME SHALL PREFERABLY BE
SIMILAR TO ANY OF THE ABOVE TYPES.
2. ELECTRICAL CONNECTIONS SHALL BE CLEANED TO BRIGHT SURFACE & TIGHTENED WITH NON—OXIDE GREASE
APPLIED ON MECHANICALLY MATED SURFACE.
3. FOR SECRIFICIAL ANODE GROUND BED WHICH IS INTENDED FOR PERMANENT CP SYSTEM AND/OR TO BE
INTEGRATED WITH PERMANENT CP SYSTEM, THE LEADS OF ALL ANODES SHALL BE BROUGHT UP TO THE
TEST STATION AND SHALL BE TERMINATED INDIVIDUALLY. ACCORDINGLY, THE NUMBER OF TERMINALS FOR
TEST STATION SHALL BE DECIDED BASED ON NUMBER OF ANODES.
4. WHERE INSULATING JOINT (IJ) ON THE PIPELINE IS BURIED, THE SURGE DIVERTER MOUNTED ACROSS THE
IJ SHALL BE HOUSED SUITABLY SO THAT OPERATION OF THE SAME IS NOT AFFECTED.
5. THE DISTANCE BETWEEN TWO SUCCESSIVE PIN BRAZING POINTS SHALL BE MIN. 300MM.
ISSUED AS STANDARD I 'I

76
'
0 06.03.13 NSB RC PL DM
(OLD DOC. NO. 7-51-0605-4 Rev. 3)
No by by
Approved by
Page 1803 of 2065

STANDARD No.
ENGNEIRS GALVANIC ANODE
min maw magma (A Govt. of India Undertaking) INSTALLATION
Page 1 of 1
TEST STATION FRONT
PIPE LINE
BURIED JUNCTION BOX
FOR CABLE JOINT
(EPDXY FILLED)
(SEE NOTE-5)
ANODE TAIL CABLE
I )
ELEVATION
PREPACKED GALVANIC
ANODE (SEE NOTE-2) 10MM2CABLE PVC INSULATED
TEST STATION ARMOURED
(SEE NOTE-5)
PIPELINE
1—ANODE TAIL CABLE
BURIED JUNCTION BOX 6MM2 PVC INSULATED
(SEE NOTE-5) ARMOURED
TO TEST
STATION
)
4MM2 PVC INSULATED
PLAN ARMOURED
5000 MM MIN. FOR

MAGNESIUM ANODE
2000 MM MIN. FOR
NOTES:- ZINK ANODE
1. THE PREPACKED GALVANIC ANODE SHALL BE INSTALLED AT A MINIMUM DEPTH, EQUAL TO BOTTOM
LEVEL OF THE PIPELINE.
2. THE ANODES ARE SHOWN HORIZONTALLY LAID. ALTERNATIVELY THE ANODES MAY BE VERTICALLY
INSTALLED WITH TOP OF THE ANODE AT A MINIMUM DEPTH EQUAL TO BOTTOM LEVEL OF THE PIPE LINE.
3. ALL NATIVE BACKFILL SOIL SHALL BE FREE OF ROCKS, GARBAGE, PAPERS, PLASTICS ETC.
4. CABLE SHALL BE LAID WITH ENOUGH SLACKNESS TO AVOID DAMAGE TO CABLES DURING BACK
FILLING ETC.
5. THIS DRAWING SHOWS TYPICAL ANODE INSTALLATION ARRANGEMENT FOR TEMPORARY CATHODIC
PROTECTION SYSTEM. ANODES FOR PERMANENT CATHODIC PROTECTION SYSTEM SHALL BE INSTALLED
IN A SIMILAR MANNER, BUT ANODE TAIL CABLES OF EACH ANODE SHALL BE BROUGHT INDIVIDUALLY
UPTO TEST STATION & TERMINATED. NO BURIED JUNCTION BOX SHALL BE USED FOR PERMANENT
CP SYSTEM.
6. ANODE TAIL CABLE SHALL NOT BE USED FOR LIFTING THE ANODE. ROPE SLINGS SHALL BE USED
FOR LIFTING THE ANODE DURING INSTALLATION INTO GROUND BED.
ISSUED AS STANDARD 1 ■4043.-n

0 06.03.13 (OLD DOC. NO. 7-51-0606 Rev. 3) NSB

Rev.
No. by by
Approved by
Page 1804 of 2065

ZINC RIBBON ANODE FOR STANDARD No.
LIMITED CASED CROSSINGS WITH 7-45-0607 • Rev. 0

eueswaratiwo (A Govt. of India Undertaking)
COATED/PAINTED CASING
CASING PIPE (COATED/PAINTED)
THERMITT WELDING (TYP.)
8 0' CLOCK POSITION O'CLOCK POSITION (120')

(2401
ZINC RIBBON ANODE (SEE NOTE-1)
CASING PIPE COATED PAINTED

SEE NOTE-21
CARRIER PIPE
BOTTOM VIEW
CHEMICALS TYPE—I TYPE—II

Al :0.1%-0.5% 0.005%MAX
Cd :0.025%-0.07% 0.003%MAX
Cu :0.005%MAX 0.002%MAX
Fe :0.005%MAX 0.0014%MAX
Pb :0.006%MAX 0.003%MAX
OTHERS -- :0.1%MAX
Zn :REMAINDER REMAINDER
NOTES:-
1. STEEL CORE TO BE THERMITT WELD DIRECTLY TO CARRIER PIPE WITHIN CASINGS AT 4 & 8 '0' CLOCK
POSITIONS. FOR CARRIER PIPE OF LESS THAN 4 INCH DIA, ANODES MAY BE PROVIDED ALONG THE
LENGTH OF THE CARRIER PIPE LINE AT THE BOTTOM LEVEL.
2. SIZE OF ANODE & SPACING BETWEEN ANODES SHALL BE DECIDED BASED ON DESIGN CRITERIA.
HOWEVER MINIMUM ONE NUMBER ANODE SHALL BE PROVIDED BETWEEN TWO PIPE SPACERS/
CENTRALISERS PROVIDED BETWEEN CARRIER AND CASING PIPES.
3. PIPE SPACERS/CENTRALISERS ARE NOT SHOWN.
4. ANODE COMPOSITION, DIMENSION, NET & GROSS WEIGHT PER UNIT LENGTH SHALL BE FURNISHED BY
THE CONTRACTOR.
5. CASING PIPE, WHERE COATED AGAINST CORROSION OF EXTERNAL SURFACE, SHALL BE PROTECTED BY
GALVANIC ANODES INSTALLED AT BOTH THE ENDS OF THE CASING PIPE.
6. ANODE TYPE—I SHALL BE USED FOR SEA WATER, BRACKISH WATER OR SALINE ELECTROLYTE APPLICATION
AND ANODE TYPE—II SHALL BE USED FOR WATER, SOIL APPLICATION.
ISSUED AS STANDARD 1■ NLIA-

0 06.03.13 (OLD DOC. NO. 7-51-0607 Rev. 3) NSB
Checked Stds. Committee Stds. Bureau
Rev. Prepared
No. by by
Approved by
Page 1805 of 2065
TYPICAL CONSTRUCTION STANDARD No.
ZO
ellOWSIONIWO
MINERS
NDIA UMTE)
DETAILS OF HIGH SILICON
CAST IRON ANODE
7-45-0610 Rev. 0
20 SWG SHEET STEEL

CANISTER END CAP CANISTER
BOLT WITH NUT
& WASHER BACK FILL ANODE BRAZED JOINT
10MM2ANODE-
TAIL CABLE IN
PE CONDUIT
GAS VENT
BRAZED SPACE RING
L
PREPACKED CANISTERED ANODE
TINNED COPPER LUG
EXPOSY RESIN FILLING
MS INSERT
BRASS WASHER
WITH TREADING
ANODE TAIL
CABLE
SOLDER
FILLING
HEAT SHRINK POLYETHYLENE HIGH SILICON
SLEEVE & ANODE CAP WASHERS I IRON ANODE
4
ANODE DETAILS
CHEMICAL COMPOSITION OF ANODE (% WEIGHT): —
CARBON 317%-1.1%
MANGANESE .5%max.
SILICON .14.2%-14.75%
CHROMIUM :3.25%-5%.
MOLYBDENUM ---:0.2%max.
COPPER- :0.5% max.
IRON :REMAINDER
NOTES:-
1. ANODE FOR SURFACE AND DEEP GROUND BED APPLICATION SHALL BE IDENTICAL EXCEPT FOR
BACK FILL PREPACKING.
2. SHEET STEEL ANODE CANISTERS SHALL BE FILLED WITH PETROLEUM COKE BREEZE CONFORMING TO
IS:8502 GRADE-A TYPE. ANODES SHALL BE PROVIDED WITH MIN. 50mm. THICK BACK FILL ON ALL THE
SIDES OF THE ANODE OR MIN. 20kg NET, WHICHEVER IS HIGHER.
3. PETROLEUM COKE BREEZE SLURRY BACKFILL SHALL BE PROVIDED IN THE WELL, SURROUNDING ANODES
IN DEEP WELL GROUND BEDS.
4. ANODE TAIL CABLE SHALL BE 10 SQ. MM. HIGH CONDUCTIVITY, STRANDED COPPER CONDUCTOR,
650V GRADE, PE INSULATED, PVC SHEATED & UNARMOURED.
5. ALL THE DIMENSIONS, NET WEIGHT, GROSS WEIGHT OF THE ANODE AND ALL THE DIMENTIONS, WEIGHT
OF PREPACKED CANISTERED ANODE SHALL BE FURNISHED BY THE CONTRACTOR.
6. THE ACTIVE LENGTH `la' OF ANODE SHALL BE CONSIDERED FOR CALCULATING THE SIZE/ WEIGHT
OF ANODE.
1■
.1
(OLD DOC. NO. 7-51-0610 Rev. 3)

No. by by
Approved by
Page 1806 of 2065

STANDARD No.
SHALLOW ANODE
ditaTZONDIA WIRD 7-45-0612 Rev. 0
OVETWROMMUFWO (A Govi of India Undertaking) GROUND BED (PCP)
ANODE
LEAD ALL OPENINGS SHALL BE SEALED
JUNCTION WITH BITU MIN COMPOUND AFTER
BOX LAYING OF CABLE
GRADE LEVEL A
///\\\
ANODE TAIL CABLE 0 0-
>- O ›-
o_ O
O POLYETHYLENE CABLE
0 0
>- rn
0
co
WARNING MAT
0
O T
0
Cs( 200(TY P.) / BRICK COVER
PIPELINE
1S)1
. oz
........:I •
:•:•:- : : : : : : : . : . ... • • •
ELEVATION CABLE LAID IN A

SAND BED (TIP.)
CANISTERED ANODE PIPE LINE
(LAID HORIZONTALLY
SEE NOTE-7) ANODE LEAD JUNCTION BOX
f
_ 3000 L(MIN.) MIN
(SEE NOTE-1)
CABLEWARNING MAT
BRICK COVER
100(TYP.)
CABLE LAID
IN SAND BED
NATIVE 500
BACKFILL CANISTERED ANODE
SOIL (MIN.)
500
SECTION-AA ANODE BED MARKER POST
NOTES:-
1. THE ANODE GROUND BED SHALL BE LOCATED ELECTRICALLY REMOTE FROM THE PIPE LINE WITH
MINIMUM 100 MTR. AWAY FROM THE NEAREST POINT ON THE PIPE LINE.
2. NO SPLICING SHALL BE ALLOWED FOR THE CABLES.
3. CONTRACTOR SHALL FURNISH THE DIMENSIONED DRAWING SHOWING ACTUAL QUANTITY OF ANODES FOR
EACH GROUND BED.
4. ALL UNARMOURED CABLES SHALL BE RUN THROUGH PE SLEEVES.
5. ANODE BED MARKER SHALL BE FIXED ON BOTH SIDES OF GROUND BEDS.
ETC.
6. NATIVE BACKFILL SOIL SHALL BE MOIST, FREE OF ROCKS, GARBAGE, PAPERS, PLASTICS
7. ANODES MAY BE LAID VERTICALLY IN CASE OF VERTICAL SHALLOW ANODE GROUND BED DESIGN.
0 06.03.13 ISSUED AS STANDARD

(OLD DOC. NO. 7-51-0612 Rev. 3)
No. by by
Approved by
Page 1807 of 2065

STANDARD No.
16iNzeilliENGNEERS
#gziefflegmerNDIAUMMD ANODE LEAD JUNCTION BOX 7-45-0613 Rev. 0
osentworwrawo (A Govt. of Indio Undertaking)
TO ANODE 150 MM STEEL C—CHANNEL

WELDED TO VERTICAL
C—CHANNEL FOR MOUNTING
JUNCTION BOX (TYP.)
\\+ L= 5A, VARIABLE RESISTOR (TYP.)
ar=30==0=0- +
SHUNT (TYP.)
0 0 c:,
REMOVABLE LINK (TYP.)
ANODE LEAD JUNCTION BOX
g1-10 0
L (SHEET STEEL OF MIN. 3MM THICK)
. _
--
mr7=D_YTh_0= o-_/Th-oct_ro
COPPER BUS BAR
BAKELITE BOARD
7 FROM POSITIVE OF RECTIFIER
+ +
F
150 MM STEEL C—CHANNEL

(JUNCTION BOX SUPPORT)
0
0
0 G.I STEEL CONDUIT FOR
CABLE ROUTING
200
PCC FOUNDATION (M15 GRADE)
GRADE LEVEL 600(W)(MIN.)X600(L)(MIN.)
/A% X800(H)(MIN.)
THE ENTRY SHALL BE

SEALED WITH BITUMEN
600 COMPOUND AFTER
LAYING CABLE TO
PREVENT WATER ENTRY
125
0 600
NOTES:-
1. SHUTTER SHALL BE HINGED TYPE WITH CONCEALED LOCK. THE DOOR SHALL BE PROVIDED
WITH GASKET TO MAKE THE BOX WEATHER PROOF (IP:55)
2. INSIDE & OUTSIDE OF THE BOX SHALL BE 125 tI GALVANIZED AND 300 'u EPDXY TOP COATED.
3. THE HEIGHT OF THE JUNCTION BOX ABOVE GROUND LEVEL, INDICATED IN THIS STANDARD IS
MINIMUM. THE ACTUAL HEIGHT SHALL BE DECIDED BASED ON LOCAL FLOOD LEVELS.
4. NUMBER OF ANODE CIRCUITS SHOWN IN THIS STANDARD ARE INDICATIVE ONLY. CONTRACTOR
SHALL FURNISH DRAWING WITH ACTUAL DIMENSIONS & NUMBER OF ANODE CIRCUITS.
5. THE SIZE OF THE CONCRETE FOOTING SHOWN IS MINIMUM ONLY. CONTRACTOR SHALL PROVIDE
ADEQUATELY SIZED FOUNDATION BASED ON SOIL CONDITION AND DIMENSIONS OF ANODE LEAD
JUNCTION BOX.
0 06.03.13 ISSUED AS STANDARD

(OLD DOC. NO. 7-51-0613 Rev. 3)
Rev.
Page 1808 of 2065

REV DATE REVISIONS BY CHKD APPD PEM/PC
Page 1809 of 2065

SCALE JOB NO. UNIT DEPT. SECT. DWG. NO. REV.
Page 1810 of 2065
Page 1811 of 2065
 DOCUMENT NO.
MANDATORY SPARES LIST
(ELECTRICAL) B001-302-16-50-MS-0001
Rev. A
Page 1 of 2

MANADATORY SPARES LIST

(ELECTRICAL)
PROJECT : 2nd RAW WATER INTAKE

PUMPHOUSE & PIPELINE AT
DAMANJODI , NALCO
OWNER : NALCO
JOB NO. : B001
Rev Prepared Checked Approved

Date Purpose
No by by by

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Page 1812 of 2065

 DOCUMENT NO.
MANDATORY SPARES LIST
(ELECTRICAL) B001-302-16-50-MS-0001
Rev. A
Page 2 of 2

MANDATORY SPARE PARTS - ELECTRICAL
S. No. PART DESCRIPTION QUANTITY REQUIRED

Power Transformer (one set of spare for each power
1.0 Quantity is per transformer
transformer)
1.1 Gasket one set
1.2 Gauge glass 2 Nos of each rating & type.
11 kV & 6.6 Switchgear (one set of spare for each
2.0 Quantity is per switchboard.
switchgear)
2.1 Closing coil 1
2.2 Shunt trip coil 1
2.3 control fuses(all type & rating ) 10 Nos. each rating & type.
415 V Switchboard
3.0 Quantity is per switchboard.
(one set of spare for each Switchboard)
3.1 Closing coil 1
3.2 Shunt trip coil 1
3.3 control fuses(all type & rating ) 10 Nos. each rating & type.
4.0 DC System(one set of spare for each DC System)
4.1 All fuse 10 nos. of each rating & type.
All cards such as input & output cards, power supply
4.2 1 no. of each rating & type.
cards, processor cards etc.
4.3 Thyristors 1 no. of each rating & type.
4.4 fuse link 10 nos. of each rating & type.
4.5 BLOCKER DIODE Two nos.
HV induction motors (one set of spare for each rating
5.0
& type)
5.1 Bearing ( DE & NDE ) one each
5.2 Terminal studs/bushing assembly one no.
MV induction motors 37 kW & above (one set of spare
6.0
for each rating & type)
6.1 Bearing set (DE & NDE) one no of each type
6.2 Terminal/ bushing one set each
NOTES:
1. The word ‘TYPE’ means the Make, Model no., Type, Range, Size/ Length, Rating, Material
as applicable.
2. Wherever % age is identified, Contractor shall supply next rounded figure.
3. The terminology used under ‘Part Description’ is the commonly used name of the part and
may vary from manufacturer to manufacturer.
4. Mandatory spares as indicated above do not cover commissioning spares.
5. Mandatory spares as indicated above do not cover two year O&M spares.
6. Mandatory spares shall be applicable for electrical items of motors / sub-packages as per
mandatory spares philosophy specified elsewhere in the bid document.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Page 1813 of 2065

DOCUMENT N0.
VENDOR DATA REQUIREMENT B001-302-16-50-VR-9001
FOR PACKAGE Rev. A
Page 1 of 2
PROJECT: 2nd RAW WATER INTAKE PUMPHOUSE & PIPELINE AT DAMANJODI ,

NALCO
CLIENT : NALCO
Post order
With Final
Sr.No. Description For For
Bids Documents
Review Records
1. Schedule of Vendor Documents *
2. List of deviations to MR requirements *
Motor start up study & voltage drop
3. calculation for finalization of XMFR * *
impedence & ACSR conductor size
4. Single line diagram (Overall) * * *
5. Single line diagram (switchboard wise) * *
6. Electrical load data * * *
7. Equipment layout * *
Cable/lighting/earthing/lightning protection
8. * *
layout
Technical details/Data sheets/GA for each
9. electrical equipments as envisaged in * *
project
Transmission line layout/route survey/pole
10. * *
drawings
GA and internal arrangement drg. for
11. * *
panels
12. Schematic/Logic diagrams * *
Interconnection/Wiring diagrams/cable
13. * *
schedules
14. Bill of material * *
15. List of recommended maintenance spares * *
16. Type Test certificates * *
17. Test certificates * *
18. Catalogues and brochures * *
19. Installation manual *
20. Operation/maintenance manual *

Date Purpose
No by by by
Format No. 1650-EIL 1650-5193 Rev. 1 Copyright EIL – All rights reserved
Page 1814 of 2065

DOCUMENT NO.
VENDOR DATA REQUIREMENT B001-302-16-50-VR-9001
PACKAGE EQUIPMENT Rev. A
Page 2 of 2
Post order
With Final
Sr.No. Description For For
Bids Documents
Review Records
21. QA Plan of Vendor * *
22. Inspection Plan & Testing Procedure * *
23. Equipment storage procedure at site *
24. Sag tension calculation * *
 DATA REQUIRED
Notes :
1. Unless otherwise agreed, the number of copies of various drawings and documents
shall be as follows:
a. With bids : Same as the number of copies of bids
b. Post order submission : For Review/Records - Four copies
c. Final document : Six prints and two sets of CDs
Vendor shall furnish soft copy of all drawings in AutoCad and all documents in MS
Office as part of final documentation
2. Vendor shall furnish Schedule of Vendor Drawings and Documents (Format EIL 1641-
1923) within 15 days after placement of FOI/TOI.
3. All technical details and documents furnished with bids shall be treated as data for
engineering. These shall however be subject to Purchaser’s review after order
placement and bidder shall comply to MR/Tender requirements without any cost &
time implication to EIL/Owner.
Format No. 1650-EIL 1650-5193 Rev. 1 Copyright EIL – All rights reserved
Page 1815 of 2065

JOB SPECIFICATION No.
WELDING SPECIFICATION FOR
RAW WATER INTAKE PUMP B001-000-02-42-WSP-0001
HOUSE AND PIPELINE, NALCO REV.0
Page 1 of 41

RAW WATER INTAKE PUMP HOUSE
AND PIPELINE,
NALCO
0 3.01.2017 Issued for Tender S K Mishra P Chowdhary A Roy
Page 1816 of 2065

Page 2 of 41
CONTENTS
1.0 SCOPE 3
2.0 APPLICABLE CODE AND STANDARDS 3
3.0 BASE MATERIAL 4
4.0 WELDING CONSUMABLES 4
5.0 EQUIPMENT AND ACCESSORIES 5
6.0 WELDING PROCESSES 5
7.0 BEVEL CLEANING/BEVEL INSPECTION 5
8.0 ALIGNMENT AND SPACING 6
9.0 WEATHER CONDITIONS 7
10.0 WELDING 7
11.0 HEAT TREATMENT 8
13.0 REPAIRS OF WELDS 13
ANNEXURE – 1: Destructive Testing of Welded joint (Butt welds) 14
ANNEXURE-3: RADIOGRAPHY INSPECTION 21
EXHIBIT – A: ELECTRODE QUALIFICATION TEST RECORD 26
EXHIBIT-B: STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION 29
EXHIBIT – C: RECORD FORM FOR WELDING PROCEDURE QUALIFICATION TEST 30
EXHIBIT – D: RECORD FORM FOR WELDER QUALIFICATION TEST 33
EXHIBIT – E: WELDER’S IDENTIFICATION CARD 34
EXHIBIT – F: RADIOGRAPHIC PROCEDURE FOR PIPE WELDING 35
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1.0 SCOPE
The requirements stated herein shall be followed for the fabrication of all types of welded
joints of carbon steel piping systems connected with the pipeline and related facilities.
The welded pipe joints shall include the following:
a) All line pipe joints of the circumferential butt welded and socket welded types.
b) Attachments of castings, forgings, flanges and other supports to pipes.
c) Welded manifold headers and other sub-assemblies.
d) Welded branch connections.
e) Joints in welded/fabricated piping components.
f) The attachments of smaller connections for vents, drain drips and other instrument
tappings.
Any approval granted by the OWNER shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
The Welding Specification Charts specified in this document shall refer to B001-000-02-42-
WSC-0001.
2.0 APPLICABLE CODE AND STANDARDS

All welding work, equipment, equipment for welding, heat treatment, other auxiliary functions
and the welding personnel shall meet the requirements of the latest editions of the codes,
standards and specification listed below:
a) ANSI B 31.4: Code for Transportation System for Hydrocarbons, Liquid Petroleum
Gas, Anhydrous Ammonia and Alcohols.
b) API 1104 (2013): Standard for welding of Pipelines and Related Facilities.
c) ASME Sec. II part C (2015): Specification for welding Electrodes and filler Materials.
d) ASME Sec. V (2015): Non Destructive Examination.
e) B001-000-02-42-WSC-0001: Welding Specification Chart for Raw Water Intake
Pump House and Pipeline.
f) BS EN ISO 6892-1(2009) Metallic materials. Tensile testing. Method of test at
ambient temperature.
g) ASTM E3 (2011): Standard guide for preparation of metallographic specimens.
h) ISO 6507-1 (2005): Metallic Materials-Vicker’s Hardness test-Part 1: Test method.
i) ISO 6507-2 (2005):- Metallic Materials-Vicker’s Hardness test-Part 2: Verification &
Calibration of testing machines.
j) BS EN ISO 148-1(2009): Metallic materials. Charpy pendulum impact test.
k) ASTM A 370 (2012a): Standard Test Methods and Definitions for Mechanical Testing
Of Steel Products
l) ASTM E 1815 (2008): Standard Test Method for Classification of Film for Industrial
Radiography
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2.1 Abbreviations:
ANSI: American National Standards Institute
API: American Petroleum Institute
ASME: American Society of Mechanical Engineers
BS: British Standard
CRT: Cathode Ray Tube
CTOD: Crack Tip Opening Displacement
GMAW: Gas Metal Arc Welding
GTAW: Gas Tungsten Arc Welding
HAZ: Heat Affected Zone
HV: Vickers Hardness
IIW: International Institute of Welding
IQI: Image Quality Indicator
ISO: International Organization for Standardisation
MPI: Magnetic Particle Inspection
PQR: Procedure Qualification Record
SMAW: Shielded Metal Arc Welding
UT: Ultrasonic Testing
UTS: Ultimate Tensile Strength
WPS: Welding Procedure Specification
3.0 BASE MATERIAL

In general carbon steel is used in this specification. The details of material specification are
given in the Welding Specification Charts attached along with other project data sheets.
The CONTRACTOR will arrange and maintain the record of test certificates of all the
materials for the reference of the welding engineer.
4.0 WELDING CONSUMABLES

a) The CONTRACTOR shall provide at his own expense all the welding consumables
necessary for the execution of the job such as electrodes, oxygen, acetylene etc. and
these shall bear the approval of the OWNER.
b) The welding electrodes/filler wires supplied by the CONTRACTOR shall conform to

the class specified in the welding specification chart attached along with other project
data sheets. The materials shall be of the make approved by the OWNER.
c) The electrode shall be suitable for the welding process recommended and base metal
used. Physical properties of the welds produced by an electrode recommended for the
welding of a particular base metal shall not be lower than the minimum values
specified for the base metal unless otherwise specified in Welding Specification Chart
and shall correspond to the physical properties of the class of electrode adopted. The
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choice of electrode shall be made after conducting the required tests on the electrodes
as per relevant standards, and shall be the sole prerogative of the OWNER.
d) The CONTRACTOR shall submit batch tests certificates from the electrode
manufacturers giving details of physical and chemical tests carried out by them for
each batch of electrodes to be used.
e) Electrode Qualification test records shall be submitted as per the Exhibit-A (attached)
in respect of the electrodes tested by the CONTRACTOR for obtaining the approval of
the OWNER.
f) All electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration. The electrodes removed from the containers (except cellulosic
electrodes) shall be kept in holding ovens, at the temperature recommended by the
electrode manufacturer. Ovens shall be used for low hydrogen electrodes only. Out-
of-the oven time of electrodes before they are consumed shall not exceed the limits
recommended by the electrode manufacturer. The electrodes shall be handled with
care to avoid any damage to the flux covering.
Different grades of electrodes shall be stored separately. Cellulosic electrodes used

shall however be used as per specific recommendations of manufacturer.
g) The electrodes used shall be free from rust, oil, grease, earth and other foreign matter
which affect the quality of welding.
5.0 EQUIPMENT AND ACCESSORIES
5.1 The CONTRACTOR shall have sufficient number of welding and cutting equipment,
auxiliaries and accessories of sufficient capacities to meet the target schedules.
5.2 All the equipment for performing the heat treatment, including transformers, thermocouples,
pyro-metres, automatic temperature recorders with suitable calibration arrangements, etc. shall
be provided by the CONTRACTOR, at his own expense and these shall bear the approval of
the OWNER. Adequate means of measuring current and voltage shall be available.
5.3 Redoing of any work necessitated by faulty equipment or operation used by the
CONTRACTOR, will be done at his own expense.
6.0 WELDING PROCESSES
6.1 The welding processes to be employed are given in the welding specification chart attached
along with other project data sheets. Any deviation desired by the CONTRACTOR shall be
obtained through the express consent of the OWNER.
6.2 A combination of different welding processes or a combination of electrodes of different

classes/makes could be employed for a particular joint only after duly qualifying the welding
procedures to be adopted and obtaining the approval of the OWNER.
7.0 BEVEL CLEANING/BEVEL INSPECTION

Before welding, all rust and foreign matter shall be removed from the bevelled ends by power
operated tools. This shall be effected inside and outside and for a minimum distance of 25
mm from the edge of the weld bevel. The bevels shall be thoroughly inspected at this stage.
If any of the ends of the pipe joints are damaged to the extent that, in the opinion of OWNER,
satisfactory weld spacing cannot be obtained and local repair by grinding cannot be
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successfully done, the damaged ends shall be cut and bevelled to the satisfaction of the
OWNER, with an approved bevelling machine. Manual cutting and weld repairs of bevels is
not allowed. Should laminations, split ends or inherent manufacturing defects in the pipe be
discovered, the lengths of pipe containing such defects shall be removed from the line to the
satisfaction of OWNER. On pipes which have been cut back, a zone extending 25 mm back
from the new field bevel, shall be ultrasonically tested to the requirement of the line pipe
specification to ensure freedom from laminations. The new bevel shall be 100% visual and
100% dye penetrant/MPI tested . A report shall be written for all testing and records kept.
8.0 ALIGNMENT AND SPACING

8.1 Line pipes
Immediately prior to line-up CONTRACTOR shall inspect the pipe ends inside and outside for
damage, dents, lamination etc. Pipe for welding shall be set up, correctly spaced, allowing for
temperature changes during welding, in correct alignment and shall in no circumstances be
sprung into position. Temporary attachments of any kind shall not be welded to the pipe.
Welds joining the sections of the pipeline, valve installation or similar welds classified as tie-in
welds shall be made in the trench. Otherwise the alignment and welding shall be made along
side the ditch with the pipe supported on skids and pack pads or other suitable means approved
by OWNER, at least 500 mm above the ground unless approved by the OWNER in specific
cases.
Seam orientation of welded pipe shall be selected to ensure that at the circumferential welds, the
longitudinal welds shall be staggered in the top 90" of the pipeline, or 250 mm whichever is the
lesser. A longitudinal joint shall pass an appurtenance of a structural element at a minimum
distance of 50 mm. Should a section of the line containing uncompleted welds fall from the
skids, the CONTRACTOR shall immediately inform OWNER.
Every effort shall be made to reduce misalignment by the use of the clamp and rotation of the
pipes to the best fit. For pipe of same nominal wall thickness the off-set shall not exceed 1.6
mm. The off set may be checked from outside using dial gauges. Any branch connection
sleeve, etc. shall be at least 150 mm from any other weld. The welds for fittings shall be so
located that the toe of the weld shall not come within 50 mm of any other weld. Cold dressing is
permissible only in cases of slight misalignment and may only be carried out with a bronze
headed hammer. Hot dressing shall not be permitted. When welding pipes of different wall
thickness (as directed by OWNER) a special transition piece shall be used. This shall have a
minimum of 1:4 taper. The welds shall be subject to both ultrasonic and radiographic
inspections.
The root gap shall be accurately checked and shall conform to the qualified welding procedure.
The use of internal line-up clamps is mandatory for pipe diameters 10" and above. However, in
some case (tie-in welds, flanges, fittings, diameter of pipe 10" and below etc.) Where it is
impossible to use internal clamps, an external line-up clamp may be used.
The internal line-up clamp shall not be released before the entire first pass has been completed.
When an external line-up clamp is used, all spaces between bars or at least 60% of the first pass
shall be welded before the clamp is released and the pipe remaining adequately supported on
each side of the joint. segments thus welded shall be equally spaced around the circumference of
the pipe. Slag, etc. shall be cleaned off and the ends of the segments shall be prepared by
grinding, so as to ensure continuity of the weld bead.
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9.0 WEATHER CONDITIONS

The parts being welded and the welding personnel shall be adequately protected from rain and
strong winds. In the absence of such a protection no welding shall be carried out. The
completed welds shall be suitably protected in case of bad weather conditions.
10.0 WELDING
10.1 Root Pass for Line Pipe Welding
a) Root pass shall be made with electrodes/filler wires recommended in the welding
specification chart attached along with other project data sheets. The size of the
electrodes used shall be as per the approved welding procedure.
b) Position or roll welding may be permitted. Separate procedures shall be submitted and
qualified for up hill, down hill, vertical down and roll welding. The vertical up method of
welding shall be used for the root pass of the tie-ins, special crossings, fittings and special
parts, fillet welds, repairs and when an external line up clamp is used. The down hill
welding may be used for root run welding of tie-ins and special crossings when (a) the
edges are machined or have equivalent preparation (b) internal line up clamps are used
and the fit up is geometrically and mechanically similar to one of the ordinary line
welding without misalignment or unevenness.
c) The root pass of butt joints shall be executed properly so as to achieve full penetration
with complete fusion of the root edges. Weld projection inside the pipe shall not exceed 3
mm wherever not specified by the applicable code.
d) Any deviations desired from the recommended welding technique and electrodes indicated
in the welding specification chart shall be adopted only after obtaining express approval
of the OWNER.
e) Welding shall be continuous and uninterrupted during a pass.
f) On completion of each run, craters, welding irregularities, slag etc., shall be removed by
grinding and chiselling.
g) While the welding is in progress care shall be taken to avoid any kind of movement of the
components, shocks, vibration and stresses to prevent occurrence of weld cracks.
h) Fillet welds shall be made by shielded metal arc welding process using low hydrogen
electrodes only irrespective of the thickness and class of piping. Electrode size shall not
exceed 3.25 mm diameter for socket joints. At least two passes shall be made on socket
weld joints.
i) Peening shall not be used.
Joint Completion for Line Pipe Welding

a) In case of manual welding, the first pass shall be carried out by a minimum of two
welders, working simultaneously and so placed as to cause minimum distortion of the
pipe.
b) The number of welders and the allowable welding sequences shall be as those laid down
in the qualified welding procedure specification. Once the deposit of the first pass has
been started, it must be completed as rapidly as possible, reducing interruptions to the
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minimum. The welding and wire speed shall be approximately same as that established in
the qualified weeding procedure specification.
c) The pipe shall always be adequately supported and must not be bumped or shaken during
welding. The clamp shall be removed, as indicated in clause 8.0 above. Before starting
the second pass, the first pass shall be cleaned and flattened with rotating grinders.
d) The interruption between completion of the first pass and starting the second pass shall be
as stated in the procedure specification, normally not exceeding four minutes.
e) For crack prevention a top and bottom reinforcement of at least one electrode shall be
applied before lowering the pipe on the skid.
f) The welding speed selected shall enable production of a bead which is sufficiently thick
and which shows no undercutting.
g) The time lapse between second and third pass shall be as stated in the procedure
specification, normally not exceeding five minutes. After completion of the third or
following passes, welding operations may be suspended, so allowing the joint to cool
down, provided that the thickness of the weld metal deposited is equal to at least 50% of
the pipe thickness. Upon restarting, depending on the materials, wall thickness and
welding process, a preheating to atleast 100˚ C shall be carried out. Subsequent passes up
to weld completion shall be protected to avoid rapid cooling, if meteorological conditions
to dictate. Cleaning between passes shall be done carefully so as to reduce the possibility
of inclusions.
h) Electrode starting and finishing points shall be staggered form pass to pass. Arc-strikes
outside the bevel on the pipe surface are not permitted. Arc-strike or arc-burn on the pipe
surface outside the weld, which are caused accidently by electrical arcs between the
electrode, electrode holder, welding cable or welding cable round and the pipe shall be
removed by grinding in accordance with a procedure approved by OWNER and the repair
checked by ultrasonic, radiographic, magnetic particle or dye penetrant tests which the
OWNER feels necessary. The pipe wall thickness after grinding shall not be less than the
minimum thickness limit permitted for the pipe. Repair of arc strikes by welding is
prohibited.
i) The completed weld shall be carefully brushed and cleaned and shall appear free from
spatters, scales, etc. These requirements apply not only to completed welds but also to the
bare strip at least so wide as to allow full skid examination at both ends of the pipe to
allow a good ultrasonic inspection when it is required.
11.0 HEAT TREATMENT

11.1 Preheating
a) Preheating requirements for the various materials shall be as per the welding
specification chart attached along with other project data sheets.
b) Pre-heating may be done using a propane gas burner ring with prior approval from
OWNER. The contractor may be asked to demonstrate the effectiveness of the
arrangement.
c) Preheating shall extend uniformly to atleast three times the thickness of the joint, but
not less than 50mm, on both sides of the weld.
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d) Preheating temperature shall be maintained over the whole length of the joint during
welding. Temperature indicating crayons or other temperature indicating devices shall
be provided by the CONTRACTOR to check the temperature.
11.2 Post Weld Heat Treatment
a) Post weld heat treatment, wherever required for joints between pipes and fittings, pipe
body and supports shall be carried out by the CONTRACTOR at his expense as per
the relevant specifications, applicable standards and the instructions of the OWNER.
b) The heat treatment of welded joints shall be carried out as per the requirements laid
down in ANSI B31.4 and other special requirements mentioned in welding
specification charts.
c) The CONTRACTOR shall submit for the approval of the OWNER, well before
carrying out actual heat treatments the details of the post weld heat treatment
procedure as per Exhibit-B attached, that he proposes to adopt for each of the
materials/assembly/part involved.
d) Post weld heat treatment shall be done in a furnace or by using an electric resistance or
induction heating equipment, as decided by the OWNER.
e) While carrying out local post weld heat treatment, technique of application of heat
must ensure uniform temperature attainment at all points of the portion being heat
treated. Care shall be taken to ensure that width of heated band over which specified
post weld heat treatment temperature is attained is atleast as that specified in the
relevant applicable standards/codes.
The width of the heated band centered on weld shall at least be equal to the width of
weld plus 2" (50mm). The temperature gradient shall be such that the length of the
material on each side of the weld, at a temperature exceeding half the heat treatment
temperature, is atleast 2.5 rt where ‘r’ is the bore radius and ‘t’ is the pipe thickness at
the weld.
f) Throughout the cycle of heat treatment, the portion outside the heat band shall be
suitably wrapped under insulation so as to avoid any harmful temperature gradient at
the exposed surface of pipe. For this purpose temperature at the exposed surface of
the pipe shall not be allowed to exceed 400˚C.
g) The temperature attained by the portion under heat treatment shall be recorded by
means of thermocouple pyrometer. Adequate number of thermocouples shall be
attached to the pipe directly at equally spaced locations along the periphery of the pipe
joint. The minimum number of thermocouples attached per joint shall be 2 upto 10"
dia and 3 for 12" dia and above. However, the OWNER can increase the required
minimum number of thermocouples to be attached if found necessary.
h) Automatic temperature recorders which have been suitably calibrated shall be

employed. The calibration chart of each recorder shall be submitted to the OWNER
prior to starting the heat treatment operation and its approval shall be obtained.
i) Immediately on completion of the heat treatment, the post weld heat treatment
charts/records along with the hardness test results on the weld joints (whenever
required as per the welding specification chart) shall be submitted to OWNER for its
approval.
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j) Each joint shall bear an identification number which shall be maintained in the piping
sketch to be prepared by the CONTRACTOR. The joint identification number shall
appear on the corresponding post weld heat treatment charts. The same identification
numbers shall also be followed for identification of corresponding radiographic films.
The chart containing the identification number and piping sketch shall be submitted to
the OWNER in suitable folders.
k) Vickers hardness/Brinell hardness of the heat affected zone as well as of the weld
metal, after heat treatment shall be measured using a suitable hardness tester and shall
not exceed the maximum hardness specified in the welding specification chart. The
weld joint shall be subjected to reheat treatment, when hardness measured exceeds the
specified limit, at the CONTRACTOR's expense.
l) The CONTRACTOR shall arrange for the hardness testing and shall maintain the
records of all the joints tested. These records shall be checked by the plant owner's
inspector.

12.1 General
a) The OWNER's Inspector shall have free access to all concerned areas, where the
actual work is being performed. The CONTRACTOR shall also afford the OWNER's
inspector all means and facilities necessary to carry out inspection.
b) The OWNER is entitled to depute its own inspector to the shop or field where
prefabrication and erection of pipelines are being done, with (but not limited to) the
following objectives:
i) To check the conformance to relevant standards and suitability of various

welding equipment and the welding performance.
ii) To supervise the welding procedure qualification.
iii) To supervise the welders' performance qualification.
iv) To check whether shop/field welding being executed is in conformity with the
relevant specifications and codes of practice followed in pipe construction.
c) CONTRACTOR shall intimate sufficiently in advance the commencement of
qualification tests, welding works and acceptance tests, to enable the OWNER’s
inspector to be present to supervise them.
12.2 Welding Procedure Qualification
a) Welding procedure qualification shall be carried out in accordance with the relevant
requirements of ASME Section IX and other job requirements by the CONTRACTOR
at his expense. The CONTRACTOR shall submit the welding procedure
specifications in format as per Exhibit-C (attached) immediately after the receipt of
the order.
b) OWNER's inspector will review, check and approve the welding procedure submitted
and shall release the procedure for procedure qualification tests. The procedure
qualification test shall be carried out by the CONTRACTOR under field conditions at
his own expense. A complete set of test results in format as per Exhibit-C (attached)
shall be submitted to the OWNER”s Inspector for approval immediately after
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completing the procedure qualification test and atleast 2 weeks before the
commencement of actual work. Standard tests as specified in the code shall be carried
out in all cases. In addition to these tests, other tests like radiography, macro/micro
examination, hardness tests, dye penetrant examination, charpy V-notch etc. shall be
carried out on specimens. It shall be the responsibility of the CONTRACTOR to
carryout all the tests required to the satisfaction of the OWNER's Inspector. The
destructive testing of welded joints shall be as per Annexure-1.
12.3 Welder's Qualification
a) Welders shall be qualified in accordance with the ASME Section IX by the

CONTRACTOR at his expense. The butt weld test pieces of the qualification test
shall meet the radiographic test requirements specified in clause 12.5 and Annexure-3
of this specification. The OWNER's inspector shall witness the test and certify the
qualification of each welder separately. Only those welders who have been approved
by the OWNER's inspector shall be employed for welding. CONTRACTOR shall
submit the welder qualification test reports in the standard format as shown in Exhibit-
D and obtain express approval, before commencement of the work. It shall be
responsibility of CONTRACTOR to carryout qualification tests of welders.
b) The welders shall always have in their possession the identification card as shown in
Exhibit-E and shall produce it on demand by the OWNER's Inspector. It shall be the
responsibility of the CONTRACTOR to issue the identity cards after it has been duly
certified by the OWNER.
c) No welder shall be permitted to work without the possession of identify card.
d) If a welder is found to perform a type of welding or in a position for which he is not

qualified, he shall be debarred from doing any further work. All welds performed by
an unqualified welder shall be cut and redone by a qualified welder at the expense of
the CONTRACTOR.
12.4 Visual Inspection

Inspection of all welds shall be carried out by OWNER as per the latest editions of the
applicable codes and specifications. All finished welds shall be visually inspected for parallel
and axial alignment of the work, excessive reinforcement, concavity of welds, shrinkage,
cracks, under-cuts, dimensions of the weld, surface porosity and other surface defects as per
EIL Standard, 6-44-0016. Undercutting adjacent to the completed weld shall not exceed the
limits specified in API 1104-2013.
12.5 Non destructive Examination
12.5.1 Line pipe girth welds:
The non destructive examination shall mainly consist of examination using x-ray radiography
as detailed in Annexure-3.
Radiographic examination of one hundred percent (100%) girth welds will be required by the
OWNER. Welds shall meet the standards of acceptability as set forth in API 1104 and as well
as the requirements laid in subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the radiographic examination of
work covered by the specification at his expense.
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The OWNER will review all the radiographs of welds and inform the CONTRACTOR
regarding unacceptable welds. The decision of the OWNER shall be final and binding in this
regard.
All requirements mentioned in the specification shall be arranged and executed by the
CONTRACTOR through his own resources. In addition, for pipes, ultrasonic inspection is
required in the following cases as per Annexure 2 of this Specification.
a) When 25 mm or more are cut from the pipe end as supplied, the ends shall be
ultrasonically inspected for an additional length of 25mm to assure no lamination
exist.
b) When welds are repaired.
c) When in the opinion of OWNER, ultrasonic inspection is required to confirm or

clarify defects indicated by radiography.
d) Welding of Transition piece of pipe.
Line Pipe - Tie-in weld Joints, welding of valves, flanges, Golden joints etc.
Radiographic examination shall be required for certain critical welding of the pipeline (i.e. tie-
ins, welding of valves, flanges etc.) which have not undergone pressure testing (this is to
ensure soundness of the total pipeline). All fillet and groove welds other than those
radiographed shall be subjected to dye penetrant/MP inspection. The non-destructive test
system used for inspecting welds must be approved by the OWNER.
12.5.1 Acceptance Criteria
Weld quality as judged on the basis of the acceptability criteria mentioned below:
i) Any weld, which as a result of radiographic and/or ultrasonic examination in the

opinion of OWNER exhibits imperfections greater than the limits, stated in API 1104
latest edition or as superseded in this article shall be considered defective and shall so
be marked with an identification point marker.
ii) In addition to the API 1104 requirements, the welds containing cracks including crater
cracks regardless of size or location are unacceptable.
Lack of fusion and lack of root penetration may be permitted only up to a maximum individual
length of t, where t is nominal pipe wall thickness. Cumulative length of the defect shall not
exceed 25 mm in any 300 mm length of weld. For welds less than 300 mm length, the
aggregate length shall not exceed 8 percent of the weld length. Defects situated in line and
separated by less than the length of the shortest defect shall be considered as one defect.
However, no Lack of fusion or lack of root penetration is permitted at any intersections of
welds.
Suitable records shall be maintained by the CONTRACTOR as desired by the OWNER on the
day to day work done on welding radiography, ultrasonic testing. The CONTRACTOR shall
present the records to the OWNER on day-to-day basis and whenever demanded, for approval.
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12.6 Destructive Testing

The OWNER has the authority to order the cutting of up to 0.1% of total welds completed for
subjecting to destructive tests at no extra cost to OWNER. The destructive testing of joints
shall be made as per Annexure-I.
In addition, welds already cut out for defects for any reason may also be subjected to
destructive testing. The sampling and the re-execution of welds shall be carried out by the
CONTRACTOR at his own expense.
If the results are unsatisfactory, welding operations shall be suspended and may not be
restarted until the causes have been identified and the CONTRACTOR has adopted measures
which guarantee acceptable results. If it is necessary in the OWNER's opinion the procedure
shall be re-qualified. The weld joint represented by unsatisfactory welds shall stand rejected
unless investigation prove otherwise.
13.0 REPAIRS OF WELDS
13.1 With the prior permission of OWNER welds which do not comply with the standards of
acceptability shall be repaired or the joint cut out and re-welded.
A separate welding procedure specification sheet shall be formulated and qualified by

CONTRACTOR for repair welds simulating the proposed repair to be carried out. Separate
procedures are required to be qualified for (a) through thickness repair (b) external repair and
(c) internal repair. Welders shall be qualified in advance for repairs. The root pass, for repairs
opening the root, shall be replaced by the vertical uphill technique. The procedure shall be
proven by satisfactory procedure tests to API 1104 including the special requirements of the
specification, and shall also be subjected to metallographic examination, hardness surveys and
Charpy test to determine the effects of repair welding on the associated structure.
Root sealing or single pass repair deposit shall not be allowed. Internal root defects shall be
ground thoroughly and welded with a minimum of two passes. However, while grinding for
repairs, care shall be taken to ensure that no grinding marks are made on the pipe surface
anywhere.
The repair shall be subjected, as a minimum requirement, to the same testing and inspection
requirements as the original weld. After the repair of the circumferential weld, re-radiography
of the full joint shall be carried out. A 100% ultrasonic test shall be done at the repaired area
externally. Any repaired area that is wide, irregular or rough shall be rejected and a full cut
out shall be done.
Repairs are limited to a maximum 30% of the weld length. Welds containing cracks shall be
cut out and rebevelled to make a joint. OWNER shall authorise all repairs.
13.2 Weld Rejected by Accumulation of Defects

Where a weld is rejected by accumulation of defect clause, as defined by API 1104 and this
specification, repairs within these limitations are permitted. Defects in the filling and capping
passes shall be repaired preferentially.
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ANNEXURE – 1: Destructive Testing of Welded joint (Butt welds)
1.0 Destructive Testing of Welded joint - Butt welds

1.1 Preparation
Having passed the visual and the non-destructive inspection, the test weld shall be subjected to
mechanical test.
After satisfactory completion of all visual and non-destructive testing the procedure test weld
shall be set aside for a period not less than 24 hours. No further work on the test weld and no
cutting of test specimens from the weld shall be performed until a period of at least 24 hours
has expired.
Weld specimens shall be taken from the positions indicated in Figure 1 of this specification
from areas as free from defects as possible; for this reason it is necessary to take the previous
non-destructive tests into account. The minimum number of tests to be carried out is given in
Table - 1 of this specification.
The test shall be carried out at laboratories approved by the OWNER. The specimens shall be
prepared in accordance with the figures given in the paragraphs which refer to the individual
test.
1.2 Tensile Strength

Specimens shall be taken from the position indicated in Figure 1 & 1A of this specification.
Two ISO type specimens and two API-type specimens shall be taken.
The ISO test specimens are shown in Figure 2of this specification.
1.2.1 Method
The test shall be carried out in accordance with BS EN ISO 6892-1:2009.
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TABLE 1
Type and Number of Test Specimens for Procedure Qualification Test and Production Welds
PIPE SIZE, OUT
SIDE DIAMETER NUMBER OF SPECIMENS
INCHES TENSILE TENSILE NICK ROOT FACE SIDE MACRO HARDNESS IMPACT TOTAL
API ISO BREAK BEND BEND BEND
WALL THICKNESS ½ INCH (12.7 mm) AND UNDER
UNDER 2 0 0 2 2 0 0 0 0 0 4
2 TO 4½ 0 0 2 2 0 0 0 0 0 4
INCLUDING
OVER 4½ LESS 2 0 2 2 2 0 2 2 12 24
THAN 12¾
12¾ AND OVER 2 2 4 4 4 0 2 2 24 44
WALL THICKNESS OVER ½ INCH (12.7 mm)
4½ AND 0 2 0 0 0 2 0 0 0 4
SMALLER
OVER 4½ LESS 2 0 2 2 2 0 2 2 12 24
THAN 12¾
12¾ AND OVER 2 2 4 0 0 8 2 2 24 44
1.3 Nick-Break Test

1.3.1 Preparation
Specification for nick-break test with notches thus worked can break in the base metal, instead
of in the fusion zone; therefore an alternative test piece may be used after authorization by the
OWNER with a notch cut in the reinforcement of outside weld bead to a maximum depth of
1.5mm, measured from the surface of the weld bead.
1.4 Macroscopic Inspection
1.4.1 Preparation
Specimens shall be taken from the positions indicated in Figure 1 of this specification and
shall be prepared in accordance with ASTM E3-11.
The width of the macrosection has to be at least three times the width of the weld. The section
is to be prepared by grinding and polishing and etched to clearly reveal the weld metal and
heat effected zone.
1.4.2 Method
Specimens shall be carefully examined under the microscope, with a magnification of atleast
25 times (25:1). The OWNER may ask for a macrograph with 5 times (5:1) magnification, for
DOCUMENTATION purposes.
1.4.3 Requirements
Under macroscopic examination, the welded joints shall show good penetration and fusion,
without any defect exceeding the limits stated in the evaluation criteria of the nick break test.
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1.5 Hardness Test

1.5.1 Preparation
The prepared macro section is to be used for hardness testing using the vickers method with 10
kg load indentations are to be made along tranverse direction each approximately 1 mm below
the surface at both side of the weld.
In the weld metal a minimum of 6 indentations equally spaced along the traverses are to be
made. The HAZ identations are to be made along the traverses for approximately 0.5mm each
into unaffected material, and starting as close to the fusion line as possible.
One indentation at each side of the weld along each traverse has to be made on parent metal.
Reference is made to Figure 3 of this specification. The indentations are to be made in the
adjacent region as well as on the opposite side of the macro section along the specified
traverses.
1.5.2 Method
The test shall be carried out in accordance with recommendation of ISO 6507-1:2005, Vickers
hardness, using a laboratory type machine controlled as pre-recommendation ISO 6507-
2:2005 and using a diamond pyramid penetrator set at 2.37 rad (136") with a load of 10 kg.
1.5.3 Requirements
Hardness value shall not exceed the limit specified in welding specification chart. In case of a
single reading strictly ( +10HV) higher than the specified limit, further indentations shall be
made to check if the high value was an isolated case.
All the hardness values contained from the heat affected zone shall not exceed 100 HV with
respect to the average hardness of the values obtained for the base metal. If these additional
tests give a hardness within the specification limit the slightly higher value may be accepted.
1.6 Charpy-V-Notch Impact Test

1.6.1 Specimens shall be taken from the position indicated in Fig. 1 of this specification. The test
specimens will be prepared in accordance with BS EN ISO 148-1:2009.
Three test specimens shall be taken from each sample and they shall be cut and worked so that
their length is transversal and perpendicular to the weld bead with the notch position as shown
in Figure 4 of this specification. The notch shall be perpendicular to the roller surface. The
test specimen width shall depend upon the pipe wall nominal thickness as following:
Nominal wall thickness in mm Test specimen width in mm

Over 12 10
Over 9.5 and upto 12 7.5
From 7 upto 9.5 5
Less than 7 2.5
1.6.2 Test Method

The test shall be carried out as indicated in BS EN ISO 148-1:2009 or ASTM A 370-12a.
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Test pieces shall be immersed in a thermostatic bath and maintained at the test temperature for
at least 15 minutes. They shall then be placed in the testing machine and broken within 5
seconds of their removal from the batch. The test temperature shall be as per Welding
Specification Chart.
1.6.3 Requirements (Note 1)
The impact energy shall be as per the values given in the Welding Specification Charts, for full-
size test pieces. If subsize test pieces are used, the required minimum average (set of three test
pieces) absorbed energy values shall be the required values for full-size test pieces times the
ratio of the specified width of the subsize test piece to the specified width of the full-size test
piece, with such derived values rounded to the nearest joule.
Note :
(1) These values are specified for resistance to brittle fracture only. Where additional
requirements are specified in project data sheet (Ex. pipeline materials with arrest
properties i.e. a higher upper shelf charpy V energy for resistance against propagating
ductile fractures) the same shall be followed.
(2) Only one value is permitted to be lower than average value upto the value specified.
1.7 Bend Test Requirements
The Bend test Specimens shall be made and tested as per the requirements of API 1104. The
acceptance criteria shall however be as per para 5.6.4.3 and 5.6.5.3 of API 1104.However, the
dimensions of the Jig for guided bend test in Figure 8 (of API 1104) shall be modified as
specified below:
Radius of the Plunger À' = 2t
Radius of the die. `B' = 3t + 1.6 mm
Width of the die. `C' = 50.8
Where t = thickness of the specimen
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ANNEXURE – 2: ULTRASONIC INSPECTION
1.0 ULTRASONIC INSPECTION

In addition to the radiographic inspection, ultrasonic inspection is required as per conditions
listed in paragraph 12.5 of this specification. This section concerns manual ultrasonic
inspection. However ultrasonic inspection by automatic equipment may be used if approved
by the OWNER.
1.1 General:
The CONTRACTOR who carries out the ultrasonic inspections shall have sufficient no. of
qualified personnel, equipment and instruments at his disposal to be able to affect the tests
without hindering or delaying the pipeline assembly operations.
The CONTRACTOR appointed to carry out ultrasonic inspections shall supply all the
instruments necessary for their execution on site.
1.2 Specification for Ultrasonic Testing Procedure Qualification
Before work begins, the CONTRACTOR shall present a specification describing the proposed
UT procedure qualification.
This specification shall state, all the parameters described in API 1104 and the following
information:
a) Type of UT equipment used;
b) Type and dimensions of transducers;
c) Frequency range;
d) Details for calibration;
e) Coupling medium;
f) Inspection technique;
g) Record details;
h) Reference to the welding procedure where it is intended to adopt the specification;
i) Temperature range of the joints to be inspected.
1.3 Qualification of Ultrasonic Inspection Procedure
The ultrasonic inspection procedure shall be approved by the OWNER. Before inspection
begins, the OWNER may require the qualification test of the ultrasonic inspection procedure.
This specification test consists in testing (under normal operating conditions) some
CONTRACTOR welds made according to the same production procedure, where there are
typical defects the test intends to detect.
This test shall be conducted in the presence of the OWNER.
1.4 Test Procedure
Circumferential welds shall be inspected from both sides using angle probes.
The surface with which the probe comes into contact shall be free of metal spatter, dirt, iron
oxide, and scales of any type; therefore it shall be necessary to clean a strip at least 50 mm
wide on both sides of the weld with steel-wire brushes and anyhow the cleaned strip must be at
least wide enough to allow one and a half skip examination.
If, during the test, echoes of doubtful origin appear, it shall be necessary to inspect a
convenient area on the pipe surface, close to the weld, with a straight beam transducer in order
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to check whether any manufacturing defects are present which could have interfered with the
ultrasonic beam.
By way of an example, the equipment shall include but not be limited to the following:
a) Ultrasonic equipment and coupling medium
b) Sample sections for calibration of instruments
c) Equipment for cleaning of surface to be examined
d) Rules calibrated in centimeters for exact location of the position of defects.
The characteristics of the above listed instruments and equipment shall guarantee:
a) That the required standards of the inspection procedure, as previously established an
approved by the OWNER, are satisfied.
b) Continuous operation
All the instruments and equipment shall be approved by the OWNER before being used. The
OWNER has the authority to reject any item that is considered unsuitable. The decision of the
OWNER is final. The CONTRACTOR appointed to carry out ultrasonic inspections shall also
ensure the operational efficiency and maintenance of the instruments and equipment, and shall
immediately substitute any item rejected by the OWNER.
All the instruments and equipment necessary for carrying out ultrasonic inspection on site shall
satisfy the requirements laid down by the public boards of institutions that regulate `safety at
work`.
1.5 Ultrasonic Instruments
The ultrasonic instrument:
a) shall be pulse echo type, able to generate, receive and display, on the screen a
Cathode Ray Tube (CRT), pulse at frequencies between 1 and 6 MHz. The useful part
of the CRT screen shall be at least 70mm wide and at least 50mm high.
shall have variable amplification, with steps of 1 or 2 dB over a range of a least 60 dB.
b) the regulation control shall be accurate to within ±1 dB and this accuracy shall be
certified by the instrument manufacturer.
c) may be powered by a battery or an electric generator. In the first case, the autonomy
of operation (endurance) of the instrument shall be sufficient to carry on working
without frequent interruptions, and the instrument shall be equipped with an automatic
switch which switches if off when the battery runs down; in the second case, there
must be a voltage stabilising device with a tolerance of ±2 Volts.
1.6 Probes
The probes used shall have dimensions, frequencies, and a refraction angle suited to the type
of steel, the diameter, and the thickness of the pipeline and to the joint design.
1.7 Reference Sample Pieces
The efficiency of the equipment used, the effective refraction angle of the probe, and the beam
output point, shall be checked using a V1 and V2 sample block, IIW type or the calibration
block ASTM E-428-08.
For manual ultrasonic testing and automated ultrasonic testing the reference sample pieces
shall be as described in API 1104.
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1.8 Calibration
The calibration, qualification of the testing procedure shall be done as provided in API 1104.
1.9 Regulation of Amplification during Production Testing
Scanning sensitivity shall be as provided in API 1104.
1.10 Qualification of Ultrasonic Testing Operators
Before the inspection begins or during the same inspection, the OWNER may require a
qualification test for the ultrasonic equipment operators.
The operators shall be fully qualified as per a recognized standard (ASME Sec V or
equivalent) and they shall have as minimum level II as described in para 11.4.3, API 1104.
The operators shall be able to:
a) calibrate the equipment;
b) perform an operational test under production conditions;
c) interpret the screen picture;
d) evaluate the size and location of reflectors;
e) interpret the type of defects detected;
The OWNER has the option of checking the ability of personnel employed for ultrasonic
testing by means of qualification tests.
1.11 Evaluation of indications given by Ultrasonic Tests
Each time that echoes from the weld bead appear during production testing, the instrument
amplification shall be altered to coincide with the reference amplifications and the probe shall
be moved until maximum response is obtained, paying attention all the time to the probe-tube
coupling.
If, under these conditions, the height of the defect echo is equal to or greater than that of the
reference echo, the defect shall be evaluated according to clause 12.5 of this specification. If
the defect has also been detected by the radiographic and/or visual examination, the
dimensions shall be judged according to the type of examination which detects the greater
defect. Returns that are less than 50% of the reference echo will not be considered. If returns
are above 50% but lower than 100% of the reference echo, and if the operator has good
reasons to suspect that the returns are caused by unfavorably oriented cracks, he shall inform
the OWNER. Moreover, when there is a defect to be repaired, such defect shall be removed
for a length corresponding to the one where no more return echo is given.
1.12 Other Equipment
The use of rules calibrated in centimetres, attached if possible to the probe, for the precise
location of the position of welding defects, is recommended. Defect location is effected by
measuring the projection distance between the probe output and the reflecting surface.
The operators carrying out the tests shall have, besides the probing instrument, tools for
cleaning the pipe surface (files, brushes, etc.) as well as the coupling liquid or paste appropriate
for the temperature of the section to be examined.
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ANNEXURE-3: RADIOGRAPHY INSPECTION

1.0 SCOPE
This annexure covers the radiographic inspection of all types of welded joints of the main
pipeline.
The welded joints shall include the following:
i) Full girth welds on the mainline construction including double jointing of pipe, if
adopted.
ii) Welds for installation of block valves, insulating joints and other appurtenances and
tie-ins.
iii) Welds at scraper launching and receiving barrels.
iv) Terminal Piping
2.0 APPLICABLE STANDARDS

This specification shall apply in conjunction with the following (all latest edition):
i) API 1104, Standard for welding Pipelines and Related Facilities.
ii) ASME B 31.4, Code for Transportation System for Hydrocarbons, Liquid Petroleum
Gas, Anhydrous Ammonia and Alcohols.
iii) ASTM E94 - 04(2010) Standard Guide for Radiographic Examination.
iv) The American Society for Nondestructive Testing. Recommended Practice No. SNT-
TC-1A Supplement A.
3.0 PROCEDURE
3.1 The radiographic examination procedure to be adopted shall be submitted by the
CONTRACTOR as per Exhibit-F.
3.2 The procedure of radiographic examination shall be qualified to the entire satisfaction of
OWNER prior to use. It shall include but not be limited to the following requirements:
i) Lead foil intensifying screens, at the rear of the film shall be used for all exposures.
ii) Type 2 and 3 films as per ASTM E94-04(2010) shall be used.
iii) A densitometer shall be used to determine film density. The transmitted film density
shall be between 2.0 and 3.5 throughout the weld. The unexposed base density of the
film shall not exceed 0.30.
iv) Radiographic identification system and documentation for radiographic interpretation
reports and their recording system.
3.3 The CONTRACTOR shall qualify each procedure in the presence of the OWNER prior to use.
3.4 The procedure of radiographic examination shall produce radiographs of sufficient density,
clarity and contrast so that defects in the weld or in the pipe adjacent to the weld, are clearly
discernible.
3.5 One Check shot of the full joint on main line welds shall be taken per 100 circumferential welds
or one per day of the production which ever is more for cross checking the correctness of the
radiographs of weld joints executed by the contractors. For taking check shots on
completed/accepted sections, contractor has to separately mobilize either internal
crawler/external X-ray unit, as appropriate.
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3.6 All the girth welds of mainline shall be subjected to 100% radiographic examination. The
CONTRACTOR shall furnish all the radiographs to the OWNER, immediately after
processing them, together with the corresponding interpretation reports on approved format.
The details of the radiographs along with the joint identification number shall be duly entered
in a register and signed by the CONTRACTOR and submitted to the OWNER for approval.
3.7 When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each exposure
shall not exceed the values given of API 1104. The minimum film overlap, in such cases,
shall be 40mm. The ellipse exposure technique may be used on nominal pipe sizes of 2 inch
and smaller provided that the source to film distance used is a minimum of 12 inch.
3.8 Three copies of each acceptable radiographic procedure (as per Exhibit-F) and three copies of
radiographic qualification records, shall be supplied to OWNER. One set of the qualifying
radiographs on the job shall be kept by the CONTRACTOR's authorized representative to be
used as a standard for the quality of production radiographic during the job. The other two
sets shall be retained by OWNER for its permanent record.
3.9 Three copies of the exposure charts relating to material thickness, kilo voltage, source of film
distance and exposure time shall also be made available to OWNER by the CONTRACTOR.
3.10 The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiograph's
number, (2) approximate chainage of weld location, (3) whether or not the welds meet the
specified acceptance standards and (4) the nature and approximate location of unacceptable
defects observed. It must be possible to relate back to a particular butt weld and welder on
piping drawing and pipe line alignment drawing.
3.11 Each day's production of processed radiographs shall be properly packaged separately,
identified by at least the (1) date, (2) radiographic unit, (3) job locations, (4) starting and
ending progress survey stations and (5) shall include original and three copies of the daily
radiographic record. The package shall be submitted to the OWNER daily when possible, but
in no event later than noon of the following day.
3.12 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room with
controlled temperature, film viewer etc. to enable the OWNER to examine the radiographs.
3.13 The CONTRACTOR, if found necessary, may modify the procedure of radiographic
examination suiting to the local conditions prevailing. This shall, however, be subject to the
approval of the OWNER.
3.14 OWNER shall have free access to all the CONTRACTOR's work facilities in the field.
3.15 Any approval granted by the OWNER shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
4.0 RADIATION SOURCE
4.1 Radiography examination shall be carried out using X-radiations. Radiography examination by
Gamma rays using slow speed films may be allowed, at the discretion of the
CONSULTANT/OWNER in case of inaccessible joints. Radiography by Gamma ray for tie-
in-joints shall be acceptable provided Type I of ASTM E1815-08 film or equivalent is used
and the required sensitivity obtained.
4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source inside the
pipe, on the pipeline axis, with a radiation of 6.28 red. (360 ).
If it is impossible to place the radiation source inside the pipe, the weld will be inspected with
the source on the outside. An overlap of at least 40 mm at the ends of each film shall be
required to ensure that the first and last location increment numbers are common to successive
films and to establish that no part of a weld has been omitted.
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5.0 LEVEL OF QUALITY

The quality level of Radiographic sensitivity required for radiographic inspection shall be at
least equivalent to the values in Figure-5.
6.0 PENETRAMETERS
6.1 The Image Quality Indicator (abreviation:IQI) shall be used for the qualification of the
welding procedure and during normal line production. Radiographic sensitivity shall be
measured with the wire image quality indicator (Penetrameter). The Penetrameter shall be
selected according to DIN EN 462-1:1994-03 or ISO 19232-1:2004. For radiographs made
with the source on the outside, a Penetrameter shall be placed on each side of the film with the
smaller wire of the Penetrameter turned towards the end of the film itself. When a complete
weld is radiographed in a single exposure using a source inside the piping, four pentrameters
approximately equally spaced around the circumference shall be used. During the procedure
qualification, IQI shall be placed both on the source side and on the film side. The sensitivity
obtained with IQI on the source side shall not be less than the values shown in Fig. 5 of this
specification.
The sensitivity limit may be considered to have been reached when the outline of the IQI, its
identification number and the wire of the required diameter show up clearly on the radiograph.
The OWNER may authorise use of types of IQI other than those planned, provided that they
conform with recognised standards and only if the CONTRACTOR is able to demonstrate that
the minimum sensitivity level required is obtained. For this demonstration, a test shall be
carried out comparing the IQI specified and the CONTRACTOR's to show up the
identification number and other details of the proposed IQI, which must be visible in the test
radiograph.
7.0 FILM IDENTIFICATION MARKERS
All films shall be clearly identified by lead numbers, letters, and/or markers. The image of the
markers shall appear on the films, without interfering with the interpretation. These markers
positions shall also be marked on the part to be radiographed and shall be maintained during
radiography.
8.0 PROTECTION AND CARE OF FILM
8.1 All unexposed films shall be protected and stored properly as per the requirements of API
1104 standard and ASTM E94-04(2010).
8.2 The exposed and unexposed film shall be protected from heat, light, dust and moisture.
Sufficient shielding shall be supplied to prevent exposure of film to damaging radiation prior
to and following the use of the film for radiographic exposure.
9.0 RE-RADIOGRAPHY
9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the radiographs, at
the expense of the CONTRACTOR.
9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the OWNER in the
same manner as that followed for the original welds. In addition, the repaired weld areas shall
be identified with the original identification number plus the letter R to indicate the repair.
9.3 When evaluating repair film, radiographers shall compare each section (exposure) of the weld
with the original film to assure repair was correctly marked and original defect removed.
9.4 The OWNER will review prior to any repair of welds, all the radiographs of welds which
contain, according to the CONTRACTOR's interpretation, unacceptable defects. The final
disposition of all unacceptable welds shall be decided by the OWNER.
10.0 QUALIFICATION OF RADIOGRAPHERS
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10.1 Pipeline radiographers shall be qualified in accordance with the requirement of API 1104 and
to the full satisfaction of OWNER.
10.2 Certification of all the radiographers, qualified as per 10.1 above, shall be furnished by the
CONTRACTOR to the OWNER before a radiographer will be permitted to perform
production radiography. The certificate record shall include:
i) Background and Experience Record
ii) Training Course Record
iii) Technical Examination Record
iv) Doctor's report on radiographer's Oaecuer 0-1 acquity eye test
v) Date of qualification
10.3 The radiographers shall be required to qualify with each radiographic procedure they use, prior
to performing the work assigned to him in accordance with the specification.
11.0 PRESERVATION OF RADIOGRAPHS
11.1 The radiographs shall be processed to allow storage of films without any discoloration for at
least three years. All the radiographs shall be presented in suitable folders for preservation
along with necessary documentation.
11.2 All radiographs shall become property of the OWNER.
12.0 EQUIPMENT AND ACCESSORIES
12.1 CONTRACTOR shall make necessary arrangements at his own expense, for providing the
radiographic equipment, radiographic films and all the accessories for carrying out the
radiographic examination for satisfactory and timely completion of the job.
12.2 For carrying out the mainline radiographic examination the CONTRACTOR shall be equipped
with suitable mobile/stationary type dark rooms.
These shall have all the required facilities for film processing. Film viewer used shall be
equipped with the film illuminator that has a light source of sufficient intensity and suitably
controlled to allow viewing film densities upto 4.0 without damaging the film.
13.0 RADIATION PROTECTION
13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of every
man with or near radiation sources.
13.2 The protection and monitoring shall comply with local regulations.
13.3 In view of visual hazards in the handling of Radioactive source of material, CONTRACTOR
shall be solely responsible for complying with all rules and regulations set forth by Atomic
Energy Commission or any other Government agencies of India in this regard and OWNER
shall not be responsible and shall be kept indemnified by the CONTRACTOR for default (s) of
whatever nature by the CONTRACTOR. Safety equipment as considered adequate by the
OWNER for all necessary personnel shall be made available for use and maintained for
immediate and proper use by the CONTRACTOR.
14.0 DISPLAY OF SAFETY INSTRUCTIONS
14.1 The safety provisions shall be brought to the notice of all concerned by display on a notice
board at prominent place at the work spot. The person responsible for the “Safety” shall be
named by the CONTRACTOR.
15.0 ENFORCEMENT OF SAFETY REGULATIONS
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15.1 To ensure effective enforcement of the rules and regulations relating to safety precautions, the
arrangement made by the CONTRACTOR shall be open to inspection by OWNER or its
representatives.
16.0 FIRST AID AND INDUSTRIAL INJURIES
16.1 CONTRACTOR shall maintain first aid facilities for its employees and those of sub-
contractors.
16.2 CONTRACTOR shall make outside arrangements for ambulance service and for treatment of
industrial injuries. Names of those providing these services shall be furnished to OWNER
prior to start of work and their telephone no. shall be posted prominently in CONTRACTOR'S
field office.
16.3 All critical industrial injuries shall be reported promptly to the OWNER and a copy of
CONTRACTOR's report covering each personal injury requiring the attention of physician
shall be furnished to the OWNER.
17.0 NO EXEMPTION
17.1 Notwithstanding the above there is nothing in these to exempt the CONTRACTOR from the
operation of any other act or rules in force.
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EXHIBIT – A: ELECTRODE QUALIFICATION TEST RECORD

Sheet 1 of 3
A: Tested at (Site name) Date :

Manufacturer’s Name :
Brand Name :
Batch Number & Size tested :
Classification & Code :
Intended for welding in position :
In combination with (if any) :
Code of Reference (used for testing) :
Special Requirements (if any) :
B: All-weld Tensile Test

Base Material used :
Pre-heat temperature :
Post weld heat treatment details :
Visual examination :
Radiographic examination results :
Tensile test results :
Identification No. U.T.S. Yield Point Elongation Remarks
1.
2.
C. Impact Test Results
Test Temperature : Notch in :
Type of Specimens (Charpy) : Size of Specimens :
Specimen No. Impact Value Average

1
2
3
4
5
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EXHIBIT - A
Sheet 2 of 3
D. Chemical Analysis Results
Electrode Size Result :
Batch No. :
%C %S %P % Si % Mn % Cr % Ni % Mo Other
E. Fillet Weld Test Results :
Welding Positions :
Base Materials :
Size of electrode used :
Visual Inspection Results : 1)
2)
3)
Macro Test Results :
Fracture Test Results :
Remarks :
F. Other Test Results :
1. Transverse tensile test :
In combination with :
Base material used :
Position of welding :
Preheat temperature :
Post weld heat treatment :
Radiography :
Identification No. U.T.S. Fracture in Remarks
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EXHIBIT - A
Sheet 3 of 3
2. Guided Bend Test :
Position Identification No. Root, Face or Side Bend Remarks

1
2
3
4
5
Any other tests :
Conclusions :
--------------------- -------------------- -------------------------

PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (OWNER)
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EXHIBIT-B: STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
Sheet 1 of 1
Name of the Heat-treater:
Name of the Project : Specification Reference No.
1. General Details : 2. Furnace Details
Name of the : Type of Heating : Gas/Oil/Elec.
Equipment Res./Induction
Name of the : Type of Heating : (Tick mark)
Assembly/Part
Assembly/Part : Capacity (Size) :
Drawing No.
Material : Maximum Temp.( C) :
Method of temp. :
Measurement
Atmosphere Control :
3. Heat Treatment Cycle Details :
Changing Temp. C
Rate of heating, C/Hr
Soaking Temp. C
Soaking Time, hrs.
Rate of Cooling, C/Hr.
Mode of Cooling
4. Other Details, if any :
Notes:
The following documents shall be furnished along with the specifications :
i) Material test certificates
ii) Assembly/Part Drawing.
--------------------- -------------------- -------------------------

PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (OWNER)
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EXHIBIT – C: RECORD FORM FOR WELDING PROCEDURE QUALIFICATION TEST

Sheet 1 of 3
Project/Contract Contractor
Pipe and fitting material
Process
Outside
diameter
Pipe
thickness
Joint design (Sketch attached)
Make and type of Diameter Current Voltage
filler metal
Root
Second run
Other runs
Other electrical a.c/d.c Electrode negative/Positive
characteristics
Shielding gas
Type of mixture
Flow
Shielding flux
Position
Direction of welding :
Root : Vertical up*/ Vertical down
Second run : Vertical up*/ Vertical down
Other runs : Vertical up*/ Vertical down
Number of welders :
Root
Second run
Other runs
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EXHIBIT - C
Sheet 2 of 3
Time lapse between commencement of second

run and commencement of other runs
Minimum number of runs before joint allowed
to cool
Maximum time between commencement and
completion of weld
Type of line-up clamp
Removal of clamp after run
Lowering off after run
Cleaning
Preheating
Minimum temperature, ˚C Ambient temperature, ˚C
Type of heater to be used
Interpass temperature
Minimum, ˚C Maximum, ˚C
Post weld heat treatment
Speed of travel
Test Results
State acceptable ‘non-acceptable (with
reasons) or give numerical results
Non-destructive tests
Visual
Radiograph
Page 1846 of 2065

Page 32 of 41
EXHIBIT – C
Sheet 3 of 3
Destructive tests 1 2 3 4
Transverse tensile
Tensile strength (with units)
Fracture location
Test temperature
Macro-examination
Fillet weld fracture
Hardness survey :
Type Load Location of hardness measurements (Sketch)
Hardness range :
Parent metal
Heat affected zone
weld
Charpy V-notch impact tests
Specimen location and size
Notch location
Test temperature
Results (with units)
Additional test(s) and results. e.g. chemical analysis, micro-examination, CTOD tests, Bend tests,
Nick Break test.
The statements in this record are correct. The test joints were prepared, welded and tested in
accordance with the requirements of specification.
Contractor Inspector
Position Witnessed by
Date Date
Page 1847 of 2065

Page 33 of 41
EXHIBIT – D: RECORD FORM FOR WELDER QUALIFICATION TEST
Sheet 1 of 1
Welder test certificate Test no.
Project/Contract Date
Contractor Inspector
Welder’s name
Address
Pipe material
Pipe thickness
Pipe outside diameter

Welding process Root Fill and cap
Electrode/wire
Root Current Voltage

Second run Current Voltage
Full and cap Current Voltage

Direction of travel Root : Vertical up*/ Fill and cap :
Vertical down Vertical up*/
Vertical down
Reason for failure
Visual
Non-destructive testing
Butt joint
Fillet weld
Number of attempts
Comments
Accepted date Time Signed by Contractor Signed by Inspector
* Delete as necessary
Page 1848 of 2065

Page 34 of 41
EXHIBIT – E: WELDER’S IDENTIFICATION CARD
Name :
Identification : Photograph
Date of Testing :
Valid till :
Approval of Welding :
Welding Position :
Material :
Diameter :
Diameter range approved :
Wall thickness :
Thickness range approved :
Type of welding consumables :
Approved by : Employers’ Signature with seal
Page 1849 of 2065

Page 35 of 41
EXHIBIT – F: RADIOGRAPHIC PROCEDURE FOR PIPE WELDING
Sheet 1 of 1
1. Location
2. Date of Testing
3. Name of Supervised Contractor
4. Material
5. Dia & Thickness
6. Type of weld joint
7. Radiation Source (X-ray, iridium)
8. Type of equipment (External/Internal)
9. Intensifying screens and material
10. Filter type and placement mask, Diaphragm Lead screen etc. adjacent to radiation source
or specimen.
11. Geometric relationship (Source local spot size, max and min source strength, object to film
distance, radiation angle with respect to weld and film).
12. Limit of film coverage
13. Film type and make
14. Exposure Time
15. Processing (time temperature for development stop bath or rinse, fixation, washing, drying
etc.)
16. Density
17. Sensitivity
18. Type of pentameter
Approval of the OWNER Signature of CONTRACTOR

with seal
Page 1850 of 2065

Page 36 of 41
Page 1851 of 2065

Page 37 of 41
Page 1852 of 2065

Page 38 of 41
Page 1853 of 2065

Page 39 of 41
Page 1854 of 2065

Page 40 of 41
Page 1855 of 2065

Page 41 of 41
Figure 5
Page 1856 of 2065

WELDING SPECIFICATION JOB SPECIFICATION No.
CHART FOR RAW WATER B001-000-02-42-WSC-0001
INTAKE PUMP HOUSE AND Rev. 0
PIPELINE, NALCO Page 1 of 2
WELDING SPECIFICATION CHART FOR

RAW WATER INTAKE PUMP HOUSE AND
PIPELINES
NALCO
0 3.01.2017 Issued for Implementation S K Mishra P Chowdhary A Roy
Rev. No.
Page 1857 of 2065 Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
WELDING SPECIFICATION JOB SPECIFICATION No.
CHART FOR RAW WATER B001-000-02-42-WSC-0001
INTAKE PUMP HOUSE AND Rev.0
PIPELINE, NALCO Page 2 of 2
20" LINE PIPE FROM RADHEYPUR TO NTPC JHANORE

PIPES API 5L GR.X-52 (THK.: 6.4 mm/7.1 mm)
MATERIAL FITTINGS -
SPECIFICATIONS FLANGES -
OTHERS -
BASE METAL `P’ NO 1

GROOVE JOINTS
WELDING PROCESS
BUTT OTHER THAN BUTT
ROOT PASS: SMAW
FILLERPASS: SMAW ROOTPASS: - FILLER PASS: -
FILLET JOINTS/ SOCKET JOINTS: -NOTE-1
GROOVE JOINTS
BUTT OTHER THAN BUTT
ROOT PASS:AWS SFA 5.1
FILLER PASS: AWS SFA 5.5
WELDING MATERIALS E6010 (NOTE-2) ROOT PASS: FILLER PASS:
E7010-P1 (NOTE-2)
FILLER JOINT/SOCKET JOINT:

BACKING RING: NA CONSUMABLE INSERT: NA
JOINT PREPARATION ASME B31.4
GASES PURGING: - SHIELDING: -

GAS COMPOSITION PURGING: - SHIELDING: -
PREHEATING PREHEAT TEMP: +10°C MIN. POST HEATING: -
CONTINUITY OF WELDING AND PREHEAT: REFER TO SPECIFICATION
HOLDING TEMP: - HOLDING TIME: -
POST WELD HEAT TREATMENT RATE OF HEATING: - MIN. HOLDING TIME: -
METHOD OF COOLING: - RATE OF COOLING: -
MECHANICAL PROPERTY CHARPY `V’ NOTCH VALUE: (NOTE-3) MIN: --- AVERAGE: ---
REQUIREMENTS
AT TEMPERATURE: ---
HARDNESS: 250HV10 MAX.
CODE OF FABRICATION ASME SECTION IX/API 1104
TECHNICAL NOTES:
1. FILLET JOINTS/SOCKET JOINTS SHALL BE MADE BY SMAW PROCESS USING LHE ONLY.
2. THIS WELDING SPECIFCATION CHART SHALL BE REFERRED ALONG WITH DOCUMENT NO. B001-000-02-
42-WSP-0001.

Page 1858 of 2065 Format No. 8-00-0001-F1 Rev. 0
Document No.
CENTRIFUGAL PUMP B001-000-80-42-DS-0001
(VERTICAL) Rev. No. A
Page 1 of 3
1 GENERAL
2 Project: 4th Stram Upgradation of Alumina Refinery EIL Job No.: B001
3 Owner: M/s NALCO Site:
4 Purchaser: Unit: Unit No.:
5 Max./Min.
Item No.: Service:
Ambient
6 No. Reqd: Working: Standby: Parallel Operation Required:  Yes  No
7 One
Applicable to  Proposal  Purchase  As Built
8  Scope, option & Info. specified by purchaser  Info. Required from & option left to vendor. Vendor to cross  the selected option.
9 Driver: Working: Driver Supplied & Mounted By:  Pump Mfr.  Other
10 OPERATING CONDITIONS (Refer Process Package)
11 Liquid Handled Capacity (m3/hr): Min/Nor/Rated:
12 Pumping Temperature (°C) Min./Nor./Max: Discharge Pressure (kg/cm²,A):
13 Specific Gravity at P.T./15°C: Suction Pressure: Nor./ Max. (kg/cm²A):
14 Vap. Pressure at P.T. (kg/cm²,A): Diff. Pressure (kg/cm²) @ Rated Capacity:
15 Viscosity at P.T. (cSt): Diff. Head (m) @ Rated Capacity:
16 Corr./Eros. Caused by: NPSH Available (m):
17 MANUFACTURER'S SPECIFICATIONS
18 Pump Manufacturer: Model No.:
19 CONSTRUCTION Bowl Head Calculations: (m) (Rem.-8)
20 Pump Type: Differential Head at Discharge Flange:
21  Vertical Sump  Turbine  Submerged Motor Diff. Between Min. Liquid Level / Min.
22  Vertical Double Casing Submergence Level (Whichever is higher):
23  Single Volute  Double Volute  Diffuser And bottom of support plate
24 Casing  Vent  Drain  Gauge Thickness of Support Plate:
25 Connections:
Line Shaft: Diff. Between Support Plate Level and
26  Open  Enclosed Discharge. Flange Centreline/Top of Flange:
27 Shaft Dia. (mm): No. of Shaft Segments: Friction losses in Suction Strainer:
28 Spacing between Shaft Guide Bushing (mm): Friction losses in Column/Discharge Pipe:
29 Coupling: Make Total (Bowl) Differential Head (m):
30 Type: Flexible metallic
31 Non-spark Guard:  Yes  No PERFORMANCE
32 Line Shaft Coupling Type: Proposal Curve No.
33  Threaded  Muff-Type Visc. Corr. Factor: C CQ CH
34 Column Type:  Threaded  Flanged NPSH Reqd. (Water) (m): F/L Speed (rpm):
35 Column NB (mm): No. of Col. No. of stages:
36 Nozzles Size ANSI Rating Segments:
Facing Position Efficiency (%):
37 Suction Rated BKW(0% Tol.) (kW):
38 Discharge Max. BKW rated. Imp. (kW):
39 Imp.(m Max Rated: Min: Type:
40 m) :
Guide Bushing: Material: No. Rec. Driver Rating (kW):
41 Guide Bushing Lubrication: Max. head rated imp.(m):
42  Pumpage / Self  Oil  Other Cap @ BEP(m3/hr):
43  No Pre-lubrication Required MCF (m3/hr):Stable Thermal
44 Driver Half cplg. mtd. by:  Pump Mfr.  Others M.A.W.P @ 15°C/P.T./Design
45 Packing: Size: No. of rings: Temp.(kg/cm²,G):
Hydrostatic Test pressure (kg/cm²,G):
46 Mech. Seal: Make Rotation facing coupling end:  CW  CCW
47 Model: API Code: Seal flush/ Quench plan: Material:
48 Mounting Plate:  Yes  No Fnd. Bolts:  Yes  C.W. Plan: Material:
49 Mtg Plate Gasket:  Yes  No Mntg. Bolts:  Yes  No Ext. seal flush fluid: LPM: kg/cm²G/ °C
50 Motor Mtg Stool:  Yes  No No Seal Barrier fluid: LPM: kg/cm²G/ °C
@
51 Balancing  Yes  No Ext. quench fluid: LPM: kg/cm²G/ °C
Device: @
52 Suction Strainer:  Yes  No Material: C.W. Reqmt. LPM: kg/cm²G/ °C
@
53 Type: Mesh Size: Thrust (kg) Up: Max. Min.
@
54 Thrust (kg) Down: Max. Min.
55 NOTES: WEIGHT DATA:
56 Weight of the Pump (kg):
57 Weight of the Mounting. Plate (kg):
58 Weight of the Mounting. Stool (kg):
59 Weight of the Driver (kg):
60 Total Weight of the Pump Unit (kg):
61
Format No. 1645-DS-105 Rev. 0 Copyrights EIL – All rights reserved
Page 1859 of 2065

Document No.
Page 2 of 3
62 INSPECTION & TESTS (EACH PUMP)
63 Witness Observe Witness Observe
64  Shop Test / Inspection    NPSH Test As Reqd. Per Spec.  Mandatory  
65  Material Certificates    Dismantle Inspection & Reassembly after Test  
66  Hydrostatic    Unitisation/Dimensional Check  
67  Performance/Sound Level    Check for dirn. of rotation of pump & driver  
68 Materials Class:
69 Materials: MOC ASTM Grades AUXILIARY PIPING INTERFACE
70 Casing (External) (All interface conn. shall be termntd. with a flng. block valves)
CONNECTIONS
71 Impeller Size Rating(ANSI) Facing
72 Inner Case parts Lantern Ring Inlet/Outlet
73 Sleeve Packed / Stuffing Box Ext. flush fluid Inlet/Outlet
74 Sleeve Seal Seal Quench fluid Inlet
75 Casing wear ring -BHN Seal pot vent/ drain
76 Impeller wear ring 50(Min.) Casing vent/ drain
77 Shaft Driver C.W Inlet/ Outlet
78 Shaft Intermediate Base plate drain (only
79 Shaft Pump flanged)
80 Column / Column Flange Steam Inlet/Outlet for Jacket

81 Mounting Plate
82 Discharge Pipe
83 Throttle Bush
84
85 Legend: I-Cast Iron; B-Bronze; S-Carbon Steel; C-11 to 13% Chr Stl; h-Hardened; f-Faced; K-SS 304; L-SS 316; X-AISI 410
86  Driver suitable for Pump starting with open Discharge Valve condition.
87 Applicable Specification: 6-41-0003
88 REMARKS:- 1) Maximum allowable casing working pressure shall not be less than kg/cm²,g @ °C.
89 2) Down Stream Design Pressure is kg/cm²,g. The same shall not be exceeded in any circumstance.
90 3) This pump item is to be installed in sump (Sump item no. ___________).
91 4) Accessories & Instrumentation shall be as per approved makes only.
92 5) Unitization of pump & driver shall be done in the pump manufacturer’s shop.
93 6) Pump vendor shall furnish the Dimensional Details along with the pump data sheet.
94 7) The pump mounting plate shall be of standard thickness.
95 8) Discharge pressure is supposed to be indicated at the pump discharge flange located above mounting plate. Vendor should calculate
96 the bowl head based on the installation depth of the pump. Calculations for arriving at the bowl head shall be furnished along with the
97 data sheet.
98 9) Performance / Characteristics curves of the pumps shall be furnished by the bidder along with proposal.
99 10) MOC shall be as specified in process package.
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
Page 1860 of 2065

Document No.
Page 3 of 3
Date Rev Job Engineer Rev. & Approved By
Page 1861 of 2065

DOCUMENT No.
DATA SHEET
FOR B001-000-80-42-DS-0002
HOT CRANE Rev A
Page 1 of 5
DATA SHEET
FOR
HOT CRANE

Date Purpose Approved by
No by by
Page 1862 of 2065

DOCUMENT No.
DATA SHEET
FOR B001-000-80-42-DS-0002
HOT CRANE Rev A
Page 2 of 5
1.0 GENERAL
1.1 Project : NALCO 4th Stream 1.2 Job No . : B001

Upgradation Project
1.3 Customer : NALCO 1.4 Location :
1.5 Item No. : 1.6 Quantity :
1.9 Manufacturer: 1.10 Service :
2.0 PURCHASER'S REQUIREMENTS
2.01 Shop/Building : *
2.02 Quantity : *
2.03 Main hoist capacity (tonnes) : *
2.04 Auxiliary hoist capacity (tonnes) : *
2.05 Span (Centre-centre runway rails)M : *
2.07 Highest position of main hook from ground floor ( M ): *
2.08 Type of crane (Single/Double girder) : *
2.09 Class of Duty (As per IS 807 & 3177) : *
2.10 Max.lift of main hook (M) : *
2.12 Hoisting CP block type/rope drum type : CP Block
2.13 Maximum lifting pull at full load : *
2.14 Maximum LT & CT pull at full load : *
2.15 Bay length (M) : *
2.16 Location (Indoor/outdoor) : *
2.17 Area classification : *
2.18 Gantry (Runway) rails size mm : *
2.19 Special Requirements (if any) : None
MANUFACTURER'S SPECIFICATIONS
(Bidder to fill up completely and submit after order)
3.0 PERFORMANCE DATA
3.01 Name of Supplier : *

3.02 Class of Duty
3.03 Main hoist/Auxiliary hoist capacity (tonnes) : *
3.04 Span (metres) : *
3.05 Max.lift of main/Auxiliary hook metres) : *
3.06 Max.vertical deflection : *
3.07 Lifting pull at full load kgs. : *
3.08 Traverse pull at full load kgs. : *
3.09 No. of girders : *
3.10 Test load : *
3.11 Underslung type : Yes/No
3.12 WEIGHT OF EQUIPMENT

3.12.1 Wt.of complete crane kgs. : *
3.12.2 Wt. of trolley kgs. : *
3.12.3 Wt. of each girder kgs. : *
3.12.4 Wt. of each end carriage kgs : *
3.12.5 Max.wheel load kgs : *
3.13 CRANE GIRDERS

Page 1863 of 2065

DOCUMENT No.
DATA SHEET
FOR B001-000-80-42-DS-0002
HOT CRANE Rev A
Page 3 of 5
3.13.1 Girder Particulars

a) Type of girder construction : *
b) Size : *
c) Number : *
d) Material : *
e) Weight, each girder, kg : *
3.13.2 Platform
a) Type of construction : *
b) Material : *
c) Width : *
d) Length : *
e) Hand rail : *
f) Mattress material : *
3.13.3 Trolley rail
a) Type and size : *
b) Material : *
3.13.4 Bearings for wheels
a) Type & Make : *
b) Number : *
c) Lubrication particulars : *
d) Plummer block details : *
3.13.5 Bridge Wheels
a) Type : *
b) Size : *
c) Number per end carriage : *
d) Material : *
e) Hardness no. (H.B.) : *
f) Diameter : *
g) Wheel base centre : *
3.13.6 Bridge Travel Buffers
b) Location : *
c) Material : *
d) Number : *
e) Type of stops to engage the buffers : *
3.13.7 Runway Rail Sweep
b) Location : *
c) Material : *
3.13.8 End Carriage
b) Size : *
c) Number : *
d) Material : *
e) Weight Kg. : *
f) Length : *
3.13.9 Runway Rails
a) Type and size : *
b) Length : *
c) Material : *
d) Accessories : *
3.14 TROLLEY
3.14.1 Frame particulars
b) Material : *
Page 1864 of 2065

DOCUMENT No.
DATA SHEET
FOR B001-000-80-42-DS-0002
HOT CRANE Rev A
Page 4 of 5
3.14.2 Trolley Wheels

a) Type : *
b) Size and number : *
c) Arrangement : *
d) Material : *
e) Hardness No. (H.B.) : *
f) Diameter : *
g) Wheel base : *
3.14.3 Trolley Wheel Bearing
a) Type and make : *
b) Number : *
c) Lubrication particulars : *
3.15 HOIST-ROPE DRUM TYPE CRANE

Drum size L X W : *
Drum Material : *
Rope dia./rope construction : *
Rope strength : *
No. of falls : *
Sheave dia./material : *
Type of brake : *
3.16 HOIST-CHAIN PULLEY BLOCK TYPE

Type of block : *
Capacity/Lift : *
Velocity ratio : *
No. of falls : *
3.17 LOAD CHAIN

a) Type and material : *
b) Standards followed : *
c) Total length of chain : *
d) Pitch : *
e) Outside width : *
f) Load chain guide provided : *
g) Load chain stripper provided : *
3.18 HAND CHAIN

a) Type and material : *
b) Standard followed : *
c) Length : *
d) Pitch : *
e) Outside width : *
f) Method of attachment : *
3.19 BRAKE (HAND OPERATED HOIST)

a) Type of brake provided for manually operated hoist : *
b) Material of pawl : *
c) Hardness of the tip : *
d) Whether it is spring loaded : *
e) Ratchet wheel diameter : *
f) Material of Ratchet wheel : *
g) Method of attachment : *
3.20 HOOK
a) Name of manufacturer : *
Page 1865 of 2065

DOCUMENT No.
DATA SHEET
FOR B001-000-80-42-DS-0002
HOT CRANE Rev A
Page 5 of 5
b) Conforms to code/standard No. : *

c) Type : *
d) Material : *
e) Type of hook suspension block : *
f) Type of bearing at hook suspension : *
g) Method of lubrication : *
h) Type of locking device for swivel motion : *
i) Design load : *
j) Proof test load : *
k) Factor of safety : *
3.21 PAINTING
a) Primer : *
i) Type of primer : *
ii) Number of coats of primer : *
b) Finish Painting
i) Type of finish paint : *
ii) Colour of finish paint : *
iii) Number of coats of finish paint: : *
Note: “*” Vendor to fill the above data and submit.
Page 1866 of 2065

EXPERIENCE RECORD PROFORMA Document No.
CENTRIFUGAL PUMP (VERTICAL) B001-000-80-42-ERP-9001
Rev. No. A
Page 1 of 4
EXPERIENCE RECORD - CENTRIFUGAL PUMP (VERTICAL)
ITEM :
ITEM NUMBER. :
VENDOR :
INSTRUCTIONS TO BIDDERS:
1. This proforma duly filled in shall be submitted for each item separately, alongwith the bid.
2. Since the information requested in this proforma will be utilised to assess provenness of offered model, it is in the interest of the
equipment manufacturer to pick up those cases out of total list of references which most closely match with the offered model. The
equipment manufacturer shall also ensure that each & every information asked for is furnished and the same is correct and complete in
all respects. Incorrect information furnished in this proforma shall render the bid liable for rejection.
3. While furnishing the materials, where asked for, the equipment manufacturer shall furnish ASTM equivalents also.
4. For the referred installations, the equipment manufacturer shall indicate the name of the person (alongwith his address, telephone no.,
fax no./email-id etc.) who may be contacted by the Purchaser / his representative, if felt necessary.
5. The equipment manufacturer shall also furnish along with the bid his standard reference list for the offered equipment model
manufactured and supplied by him.
6. The equipment manufacturer shall clarify the meaning of each letter / digit used in the model designation below:
Description of Model designation system:
Format No. 1645-ERP-105 Rev. 0 Copyrights EIL – All rights reserved
Page 1867 of 2065

Rev. No. A
Page 2 of 4
SL. PARAMETER INFORMATION ON INFORMATION ON REFERRED EXISTING INSTALLATIONS REMARKS

NO. PROPOSED MODEL Ref.- 1 Ref.-2 Ref.-3
1. 2. 3. 4. 5. 6. 7.
1 GENERAL
1.1 Cross reference to manufacturer's Standard Reference list ----
1.2 Make
1.3 Model Number
1.4 Number of units supplied
1.5 Type of driver

(Electric Motor / Steam Turbine / Gas Turbine / IC Engine)
1.6 Drive Arrangement (Direct coupled/Gear/Belt driven)
1.7 Type of Drive (Fixed Speed/Variable speed /Variable frequency)
1.8 Driver rated kW / Speed(rpm)
1.9 Shop where pump is designed, manufactured, packaged, tested

& supplied with address
2 OPERATING CONDITIONS
2.1 Fluid Handled
2.2 Pumping temperature (Min / Max) °C
2.3 Capacity (m3/hr)
2.4 Suction pressure (kg/cm²,a) (Normal/Max.)
2.5 Differential Pressure(kg/cm²) / Differential head (m)
2.6 Minimum Submergence Required (mm)
2.7 Setting depth (mm)(distance between bottom face of the

mounting flange and first stage impeller suction eye)
2.8 Efficiency (%)
2.9 BKW, Rated (kW)
Page 1868 of 2065

Rev. No. A
Page 3 of 4

1. 2. 3. 4. 5. 6. 7.
2.10 Minimum Continuous Stable Flow, (m 3/hr)
2.11 Rated Speed (rpm)
2.12 Speed range for variable speed drive
2.13 MAWP casing (kg/cm²G) @ 15°C / @ pumping temperature
3 CONSTRUCTION
3.1 Type of Pump Discharge

(discharge through column / separate discharge )
3.2 Type of line shaft (open / close)
3.3 Line shaft lubrication (pumping medium / separate lubricant)
3.4 Start-up pre-lubrication required (yes / no)
3.5 No. of stages (single / two)
3.6 Impeller diameter - Rated/ Maximum / Minimum (mm)
3.7 Whether the proposed model and reference models have

identical hydraulic design (for impeller / diffuser / volute)
3.8 Sealing Element (Packing / mechanical seal)
4 MATERIAL OF CONSTRUCTION
4.1 Casing / Column
4.2 Impellers
4.3 Pump Shaft / Line Shaft / Driver Shaft
4.4 Shaft Sleeve / Line Shaft bearing
5 OTHER INFORMATION ON INSTALLATIONS
5.1 Date of supply of entire unit
Page 1869 of 2065

Rev. No. A
Page 4 of 4

1. 2. 3. 4. 5. 6. 7.
5.2 Date of commissioning of entire unit
5.3 No. of operating hours completed as on the date of issue of

material requisition
5.4 Major Problems encountered
5.5 Name of plant
5.6 Purchaser's Name and Address
Name (Company / Organization)
Name of Contact Person
Address/ Telephone No. /Fax No.
email-id
Page 1870 of 2065

JOB SPECIFICATION DOCUMENT No.
(STATIC & MACHINERY EQPT.) B001-000-80-42-SP-9001
RAW WATER INTAKE & ASSOCIATED Rev. A
PIPELINE FACILITIES Page 1 of 6
JOB SPECIFICATION
(STATIC & MACHINERY EQUIPMENT)
RAW WATER INTAKE &
ASSOCIATED PIPELINE FACILITIES
PROJECT : NALCO 4th STREAM UPGRADATION
CLIENT : M/s NALCO
CONSULTANT : M/s ENGINEERS INDIA LTD.
JOB NO. : B001
A 28.12.16 Issued with Tender PG MKA NK

Rev.
No
Page 1871 of 2065

1.0 GENERAL
1.1 Scope
This Specification covers the design criteria for the purpose of carrying out
Engineering for Procurement of rotating equipment and maintenance equipment required and
their requirements with regard to spare parts & special tools. This Job Specification shall be
applied for RAW WATER INTAKE & ASSOCIATED PIPELINE FACILITIES and any other
rotating equipment defined in contractor’s scope vide process package.
The Contractor shall use data sheets / proformas as enclosed in this section of the bid
package, for carrying out engineering for procurement at his end.
For the equipment, for which no such data sheets / proformas are furnished by PMC/Owner,
the Contractor may use his standard data sheets / proformas or of Equipment Manufacturer’s
standard data sheets/ proformas.
1.2 Selection of Rotating Equipment

Selection of Rotating Equipment shall be based upon the following considerations:
- Suitability for the specified duty conditions.
- Standard Models under vendor's regular range of manufacture.
- Proven Track record in similar service as specified under acceptance criterion.
- Optimum operating and maintenance costs.
- Maximum Interchangeability of parts.
- Ease of operation and maintenance.
1.3 Order of Precedence

The design, manufacturing, testing etc. for the above equipment shall be as per the following
documents applicable to these equipment and shall be in the same order of precedence:
a) Process data sheet/ Design data
b) This specification
c) Equipment Data sheets
d) P & IDs
e) Other International/National codes and standards referred to.
However, in case of any conflict, contractor shall bring out the same to the notice of
Owner/PMC. The stringent requirement shall prevail and Owner/PMC’s decision shall be
final.
1.4 UNIT RESPONSIBILITY

In addition to the overall responsibility of the LSTK Contractor, the unit responsibility shall rest
with the driven equipment manufacturer, who shall also be the SPRV (Single Point
Responsibility Vendor) for the complete equipment unit including driver, driven equipment &
all other associated auxiliary systems, instrumentation & controls etc. All Rotating Equipment
drivers shall be procured, from the respective driven equipment manufacturers, complete with
all associated auxiliary systems.
1.5 UNITISATION
All rotating equipment shall be unitized with respective drivers at the manufacturer’s shop
before dispatch to check fit up of equipment, alignment, location of bolt holes, interface
locations / dimensions etc.
1.6 EQUIPMENT SUPPLIERS

The equipment supplier shall be one from the approved list of vendors provided
elsewhere in the bid package and shall be approved by NALCO.
Page 1872 of 2065

1.7 ASSOCIATED ACCESSORIES AND AUXILIARY SYSTEMS
1.7.1 All rotating equipment, drivers, auxiliary systems, instrumentation and control
systems, shall be provided with all necessary electrical and safety devices as applicable or
required for safe and reliable operation of the unit
The Contractor in his scope of supply and work shall also include the hardware required over
and above what is specified, for safe and satisfactory operation of the equipment package.
1.7.2 Motors, electrical/instrument components and electrical/instrument installations shall be

suitable for the area classification specified by the purchaser, and shall meet the
requirements as defined in the electrical/instrument specification attached with the relevant
sections of the bid package /order.
1.8 DRIVE ARRANGEMENT

All equipment shall be direct driven.
1.9 COUPLINGS & COUPLING GUARDS
1.9.1 Unless otherwise specified, Couplings shall be of metallic, non-lubricated, flexible

element type (i.e. either diaphragm or discs) with spacer, for all equipment. All coupling
models shall be selected for a minimum service factor of 1.5.
1.9.2 Removable coupling guard shall be provided which shall be fabricated from non-
sparking material, and shall be open at the bottom to permit manual shaft rotation. The
guard shall be sufficiently rigid to withstand deflections as a result of bodily contact of
nominally 100 kgs.
1.10 ALLOWABLE NOISE LEVEL
1.10.1 Equipment noise level (Driver + Driven equipment train + auxiliaries) shall not exceed 88
dBA when measured at One-meter distance from the equipment skid in any direction.
1.11 EQUIPMENT STORAGE

All rotating equipment shall be packed for an outside storage period of at least 12 months.
1.12 INITIAL FILL

The initial fill of lubricants, sealing fluid & other consumables for start-up & commissioning
shall be included in the scope of supply of the Contractor for LSTK packages. The grades
of lubricants and consumables used shall be as specified by the equipment manufacturer
and shall be of same grade, brand as used by NALCO in their existing plant.
1.13 INSTALLATION CRITERIA
1.13.1 Pumps
All pumps shall be suitable for outdoor installation. No equipment shelter is envisaged.
1.13.2 General
1.13.2.1 All other rotating equipment shall be suitable for outdoor installation and shall be
installed on ground floor (i.e. on finished floor level). No equipment shelter is envisaged.
1.13.2.2 All rotating equipment base plates shall have jacking provision for leveling and screws
for alignment.
Page 1873 of 2065

1.13.2.3 Only Stainless Steel shims shall be used for equipment alignment. Shim thickness shall
be minimum 3mm.
1.14 MAINTENANCE FACILITIES
1.14.1 Equipment layout shall incorporate adequate maintenance platforms, support structures,
hand rails, material handling facilities for operational access, inspection and maintenance
of equipment, which shall be provided by Contractor. (All platform gratings, handrails, steps
etc. shall be of galvanized steel).
1.14.2 Where the equipment are installed in open area, no permanently installed maintenance
facility shall be provided.
1.14.3 For all equipment located on grade level, the height of foundation shall be minimized for
easy accessibility, when it is not possible to do so suitable working platform shall be
provided around the equipment for ease of operability and maintenance.
1.15 MATERIALS
The material of construction of the wetted parts of rotating equipment shall be as
specified in the process package.
1.16 SAFETY
1.16.1 Equipment design and engineering shall incorporate adequate safety features (as per
applicable specifications of respective equipment as well as Health, Safety and Environment
Codes & Standards applicable for the subject project) to provide protection to operating
personnel, equipment and environment.
1.16.2 Thermal relief valves shall be provided for components that may be blocked in by
isolation valves (including any cooling water return circuit piping of a cooler or a jacket).
1.16.3 All electrical components & installations, instruments shall be suitable for the electrical area
classification and grouping in which the equipment is installed.
1.17.1 Inspection and test specified in the bid package shall be carried out by the Equipment Vendor
at his works. The Contractor shall conduct inspection and witness tests of all equipment at
vendor’s works and furnish inspection and test reports to the owner.
1.17.2 Owner and/or his Consultant may participate along with the Contractor’s inspectors in any
inspection and tests. The Contractor shall notify to owner of all inspection and tests at-
least four weeks before the scheduled date of inspection and test and reconfirm the
same at least one week before the date of inspection and testing.
1.18 ERECTION OF EQUIPMENT

Erection of all rotating equipment shall be carried out by the contractor under the
supervision of equipment vendor.
1.19 VENT & DRAINS

All vents shall be taken to flare or a safe location, depending upon the properties of fluid to be
vented. All drains shall be terminated with a flanged valve at the equipment battery limit.
1.20 Maximum allowable working pressure and temperature of the equipment shall not be less
than the design pressure and temperature specified in the data sheet nor less than those
specified in specifications, codes and standards.
Page 1874 of 2065

1.21 Driven equipment & drivers (including gear units and couplings if any) shall be
designed to perform satisfactorily under specified start up conditions, part load operation,
maximum differential pressure operation and relief valve set pressure and up to full speed.
2.0 SPECIAL REQUIREMENTS FOR CENTRIFUGAL PUMPS (GENERAL WATER SERVICE /

LARGE CAPACITY WATER SERVICE):
2.1 Pump shall be as per Standard Specification for Centrifugal Pumps (Water Service) (6-41-
0003 Rev.4) attached elsewhere in the bid package.
3.0 SPECIAL REQUIREMENTS FOR MAINTENANCE EQUIPMENT
3.1 HOT Cranes
3.1.1 These cranes are to be installed in intake well for handling pump machinery for
maintenance or replacement. Other applications involving use of cranes during other
operation may also exist.
3.1.2 The bridge structure of overhead traveling cranes may be of box section/(double web)
fabricated plate or fabricated from rolled sections. The structure can be single girder or
double girder type. The single girder bridge is typically limited to lifting capacities upto 5T and
span lengths upto 10 meters. In case either of these values is exceeded, the double girder
bridge should be used.
3.1.3 For cranes which are to operate in areas classified as hazardous, besides ensuring that all
electrical components are certified for use in the specified hazardous areas as envisaged in
the electrical design basis/ electrical specification, materials of construction for rubbing non
lubricated metallic parts should be specified in such a way that the possibility of sparking
during operation is eliminated. This is normally done by having one part in every such pair
made from a suitable non-ferrous material such as phosphor/aluminum bronze or gun
metal. The parts thus specified are the wheels (or wheel rims) for the cross and long travel
motions and chain wheels in case of manual drives as per Standard Specifications.
3.1.4 Maintenance walkways shall be provided on both sides along the bridge girders.
3.1.5 The minimum capacity of the crane shall be the weight of the largest component to be lifted
plus design margin of ten percent as a minimum.
3.1.6 Painting shall be as per applicable painting specification enclosed with bid package
3.1.7 HOT Cranes shall be as per EIL Standard Specification for HOT Cranes (6-48-0003 Rev.4)
attached elsewhere in the bid package.
4.0 SPARES & SPECIAL TOOLS
4.1 Commissioning Spare Parts

Commissioning Spare Parts, as per equipment manufacturer’s recommendations, shall be
procured along with the main equipment. The list of such recommended spares shall be
obtained along with the offer. Any commissioning spare consumed over and above the
recommended commissioning spares, during commissioning shall be supplied free of cost by
the equipment vendor.
4.2 Special Tools / Tackles

Special tools & tackles (as recommended by equipment manufacturer) shall form part of the
supply of main equipment. As per equipment manufacturer’s recommendations, special tools
Page 1875 of 2065

and tackles required shall be procured along with the main equipment. The list of such
special tools & tackles shall be obtained along with the offer.
4.3 Spare Parts for One Year Normal Operation

As per rotating equipment manufacturer’s recommendations, a quotation for spare parts for
one year normal operation along with unit price shall be furnished with the proposal or post-
order for customer to order the same separately. Customer shall indicate, in case these
spares are required to be ordered along with the equipment or to be ordered separately.
Page 1876 of 2065

SCOPE OF SUPPLY / WORKS DOCUMENT No.
(Static & Machinery Equipment) B001-000-80-42-SS-9001
RAW WATER INTAKE & Rev. A
ASSOCIATED PIPELINE FACILITIES Page 1 of 4
SCOPE OF SUPPLY / WORKS

STATIC & MACHINERY EQUIPMENT
RAW WATER INTAKE &

CLIENT : M/s NALCO
JOB NO. : B001

Date Purpose
No by by by
Page 1877 of 2065

SCOPE OF SUPPLY / WORKS
Contractor shall refer the bid package and note the following:
1. Contractor scope of supply / work shall include but not limited to the following rotating and
maintenance equipment coming in the Raw water intake & associated pipeline:
Sno. Description Process Specifications

1 Vertical Centrifugal Pumps Refer Process Package
2 Any other rotating equipment envisaged in Refer Process Package
the contractor’s scope vide Process Package
3 Maintenance Equipment (as required for
maintenance within the scope of contractor as
defined in process package) e.g. HOT etc.
All rotating equipment & maintenance equipment shall meet the requirements specified in the
process data sheets, job specifications, etc. as enclosed elsewhere in the bid package.
Contractor shall procure the complete rotating equipment package from the respective driven
equipment vendors. The package as defined herein means as a minimum of the driven
equipment, its driver, couplings, coupling guards, common base plate, foundation bolts, local
instruments, local gauge board (as required), local control panel (as required) and other
associated auxiliaries / accessories, as specified in the bid package and as required to make
the package ready for safe & smooth operation.
2. Contractor shall procure all the equipment from the list of approved vendors as attached with
the bid package elsewhere.
3. Contractor shall carry out the following activities for procurement of Rotating
Equipment & Maintenance equipment:
3.1 Contractor shall prepare the enquiry specifications/documents for each Rotating Equipment,
maintenance equipment and materials to be purchased including spare parts for erection &
commissioning, as applicable, spare parts for one-year normal operation and special tools
and tackles.
3.2 Contractor shall fill all the required data/information in the partially filled in Equipment data
sheets formats forming part of the bid package for preparation of enquiry specifications/
documents.
3.3 Contractor shall prepare the detailed Purchase Requisition / specification for each equipment
package. Purchase Requisition / specification shall contain the following:
- Filled in Equipment Data Sheet along with performance curves (as applicable) along
with a copy of approved process data sheet (for reference)
- List of deviations (if any) to the MR specifications, specific to the equipment
- Filled in Experience Record Proforma & General reference List (to justify meeting
vendor’s & equipment’s past experience in line with inquiry requirements)
- Equipment Manufacturer’s Latest Catalogue, General Arrangement Drawing, Cross
Sectional Drawing & Schematic drawing / P&ID for the proposed model shall also be
submitted along with the above documents.
3.4 Contractor shall prepare the detailed Purchase Requisition / specification for each equipment
package.
Page 1878 of 2065

4. Contractor shall carry out the detailed review and approval of data sheets,
engineering & fabrication drawings and other technical data furnished by the
respective Equipment Vendors to ensure a safe, smooth and reliable operation at site.
5. Contractor shall submit to the Owner/PMC, all engineering drawings/ documents/ data as
specified in “Documents/drawings for Owner/PMC review”.
6. Contractor shall ensure that, all inspection and tests are conducted for all equipment at
Vendor’s shops/site as specified in bid package. Contractor shall also submit the schedule of
witnessed tests of all rotating equipment well in advance.
7. Contractor shall furnish a list of spares recommended by the equipment vendor for one-year
normal operation along with firm unit prices and ensure that the Spare parts for one-year
normal operation, if ordered by the Owner, are procured from equipment vendor and
supplied to the Owner.
8. Contractor shall include all the Commissioning spares as required in the equipment vendor’s
scope. Contractor shall procure the same from the equipment vendors and make it available
well before commissioning of Plant/Equipment. In case, any additional spares are consumed
during commissioning the same to be provided by the contractor at no additional cost to the
Owner.
9. A list of special tools and tackles required for all rotating equipment are to be included in
vendor’s scope of supply. Such tools/tackles shall be supplied by the vendor and shall form
part of supply by Contractor to Owner.
10. Contractor’s scope shall include complete supply, transportation of equipment package from
vendor’s shop to site, Receipt of material at site, Handling at site and arrangement for
storage at site shall be as per the requirements indicated in the Bid Document.
11. Equipment, which is transported by sea, shall have sea-worthy packing. The Contractor shall
strictly follow the recommended preservation procedures during the period of storage for all
equipment.
12. Contractor shall carry out the erection of rotating & maintenance equipment at the specified
location on the properly designed & cast foundation as per bid document.
13. Contractor shall carry out the inter-connections at all interface points such as main process
and all utility connections.
14. Contractor shall note that consumables, lubricants etc. required during erection,
commissioning & running of Rotating Equipment & Maintenance equipment, as specified
elsewhere in the bid document, shall be in Contractor’s scope. A consolidated list for
all equipment shall be provided indicating type of lubricant, grease, oil etc. giving
specifications, quantities, brand name and their Indian equivalent.
15. Contractor shall supply & install all maintenance facilities sized for handling the
heaviest single piece of equipment for maintenance. The contractor shall provide
maintenance facilities like cranes, chain pulley blocks and monorails (as deemed necessary)
for Rotating equipment. Contractor shall provide sufficient space for maintenance,
dismantling and platforms for maintenance.
16. Contractor shall carry out the pre-commissioning and commissioning activity at site for all
Rotating Equipment & Maintenance equipment.
Page 1879 of 2065

17. Contractor shall ensure the presence of equipment manufacturer (Vendor) at site for
checking of equipment erection and hook-up & supervision of commissioning of all Rotating
Equipment & Maintenance equipment.
18. Other rotating equipment:

Vendor’s scope for other rotating equipment included in the package shall be as defined in
the tender document.
Page 1880 of 2065

TECHNICAL COMPLIANCE Document No.
(Static & Machinery Equipment) B001-000-80-42-TC-9001
TECHNICAL COMPLIANCE
(Static & Machinery Equipment)
RAW WATER INTAKE &

CLIENT : M/s NALCO
JOB NO. : B001

Notes:-
1. This Technical Compliance is a general compliance and is required to be furnished ,duly completed,
by the bidders along with the proposal. The Bidder shall indicate his reply in the space provided in
this Technical Compliance. In case space provided is not adequate, the reply may be furnished
separately under suitably numbered annexes / attachments duly referred against the comment /
query.
2. The Compliance Statements / Queries are required to be categorically confirmed / answered by
the bidder and the completely filled in Tech Compliance shall be submitted together with the Bid.
Bidder’s Signature &

Stamp

Rev.
No
Page 1881 of 2065

S.No. COMPLIANCE STATEMENT / QUERY BIDDER’S CONFIRMATION /

ANSWER
STATIC & MACHINERY EQUIPMENT
1 General
1.1 Bidder to note that this Compliance statement/query
pertains to rotating equipment & maintenance related
equipment required for Raw Water Intake & Associated
Pipeline Facilities.
1.2 Bidder to note that the detailed offer for any rotating
equipment, i.e. filled-in equipment data sheets, performance
curves, vendor's selected equipment models etc. is
not required at this stage of bidding and shall not be
reviewed or taken cognisance of at this stage.
2. Documents Required with the Bidder’s Technical
Proposal
Bidder shall furnish only the following documents
along with the proposal:
a) This Technical compliance statement duly completed
with categorical confirmation to each
of the clauses of the same.
b) List of deviations, if any, duly consolidated at one place
(under exceptions/ deviation list).
Note:
1. In case no deviations are furnished, it shall be construed that
bidder’s proposal is in total compliance to bid package
requirements.
2. Bidder shall note that vendor specific deviations to specified
design codes (API/ISO/IS/BS etc.) and related Process
Specifications shall not be considered at this stage and shall
be subject to review and approval of Owner/PMC during
detail engineering. However bidder shall note that only those
deviations to specified standards & codes (if any), shall be
permitted which are technically infeasible to meet, provided
suitable justification for the same is furnished. Deviations,
which can be complied with extra cost and or time
implication, shall not be permitted.
3. Any deviations/deletions/corrections made elsewhere in the
body of the Bidder’s proposal will not be taken cognizance of
and all such deviations shall be deemed to have been
withdrawn by the bidder.
Confirm compliance.
3 Bidder’s Categorical Confirmation
3.1 Equipment Supplier
Confirm that all rotating equipment shall be procured from
the approved vendors listed in the bid package.
3.2 Requirements to be met prior to placement of
Purchase order
Confirm that Contractor shall ensure the following
requirements while placing the orders of rotating equipment
& maintenance equipment:
(a) Ensuring that equipment meets the specified
operating conditions and meets the stipulated
technical specifications, enclosed with the bid
package.
(b) Ensuring equipment meeting the equipment
qualification criteria (EQC) as specified in the
bid package and obtaining approval of the same.
Note:
1. Bidder shall note that vendor specific deviations to specified
design codes (API/ISO/IS/BS etc.) and related Process
Page 1882 of 2065

S.No. COMPLIANCE STATEMENT / QUERY BIDDER’S CONFIRMATION /

ANSWER
Specifications shall be subject to review and approval of
Owner/PMC during detail engineering stage prior to
placement of order. Bidder shall note that only those
deviations to specified standards & codes (if any) shall be
permitted which are technically infeasible to meet, provided
suitable justification for the same is furnished. Deviations,
which can be complied with extra cost and or time
implication, shall not be permitted.
2. Filled in Experience Record Proforma shall be submitted
along with all supporting information as specified in the bid
package, for Owner / PMC’s approval.
Confirm Compliance.
3.3 Scope of supply and Work
Confirm that the Scope of supply and work considered
in the Bidder’s proposal is in total compliance to the Bid
Package-requirement including Scope of Work/Supply, Job
specification, Process Package etc. with respect to all
Rotating Equipment.
3.4 Inspection & Tests
Confirm that all Inspection & Tests as required for each
equipment, as per the Job specifications and other
documents forming part of the bid package, have been
included by the bidder, in his proposal.
3.6 Spares required for One Year Normal Operation Confirm
that the list of Operation and Maintenance spares
required for One Year Normal Operation (indicatingthe
price against each spare) as
recommended by the respective Equipment
Manufacturers have been included in the Bidder’s
proposal.
3.7 Commissioning Spares
Confirm that Commissioning Spares as required for each
equipment have been included by the bidder in his proposal.
Further in case any spare is consumed over and above the
quoted commissioning spares during start-
up/commissioning, the same shall be supplied free of cost.
3.8 Special Tools & Tackles
Confirm that Special Tools & Tackles, as required for each
Rotating Equipment, have been included by the Bidder in his
proposal.
3.9 Consumables
Confirm that first fill of all consumables, chemicals,
lubricants etc. required during erection, commissioning and
performance guarantee run of Rotating Equipment have
been included in the Bidder’s proposal.
3.10 Documents/Data required during Detailed
Engineering
Confirm that all Drawings / Data requirements as specified in
VDR attached elsewhere in the bid package shall be
furnished for review/approval/records of Owner / PMC
during detailed engineering.
Page 1883 of 2065

DOCUMENTS / DRAWINGS FOR DOCUMENT NO.
OWNER’S / PMC REVIEW B001-000-80-42-VD-9001
(Static & Machinery Equipment) Rev A
RAW WATER INTAKE & ASSOCIATED
Page 1 of 3
PIPELINE FACILITIES
DOCUMENTS / DRAWINGS FOR

OWNER’S / PMC REVIEW
(Static & Machinery Equipment)
RAW WATER INTAKE &

CLIENT : M/s NALCO
JOB NO. : B001

Rev.
No
Page 1884 of 2065

Page 2 of 3
PIPELINE FACILITIES
SNO. DESCRIPTION REVIEW RECORDS REMARKS

1 Document Control Index (DCI) / Drawing Multi-disciplinary
√ review (Note-1)
submission schedule
2 Equipment Package Details: For main equipment
- Filled in Equipment Data Sheet along (Note-2, 3)
with performance curves (as applicable)
along with a copy of approved process data
sheet (for reference)
- List of deviations (if any) to the bid package √
specifications, specific to the equipment
- Filled in Experience Record Proforma(s)
- Equipment Manufacturer’s general reference
list along with Equipment Manufacturer’s
latest Catalogue (for reference)
3 General arrangement drawing (certified Multi-disciplinary
dimensional outline drawings including details
√
of foundation where required) of Pumps, Main
Motor Driver, Couplings, auxiliaries etc.
4 Equipment layout showing main as well all Multi-disciplinary
associated equipment/skids (pumps, motors,
instrumentation, electrical & piping with
√
associated accessories & valves etc.) with
interface piping connection, maintenance
space, cable trays etc.
5 Foundation layout showing foundation details of Multi-disciplinary
main as well all associated equipment / skids
(pumps, motors, instrumentation, electrical & √
piping with associated accessories & valves
etc.)
6 Electric load data, Utility consumption list
(start up, normal operation, shutdown & √
emergency) & Lubricant schedule
7 Cross-sectional drawings with bill of materials √
8 Shop test procedures including mechanical
running test, performance test as applicable √
for pumps
9 Inspection & test reports (all tests) √
10 ELECTRICAL
10.1 Refer Electrical document for Vendor data
requirement attached elsewhere
11 INSTRUMENTATION
11.1 Refer Instrumentation document for Vendor
data requirement attached elsewhere
12 PURCHASE REQUISITIONS √ (Note-5)
13 FINAL DOCUMENTATION
Mechanical Catalogue containing the following: (Note-6)
i) All certified & “As built” documents as per
applicable codes & as mentioned above
ii) All inspection & test records
iii) Installation, Operation and maintenance
√
manuals
iv) Spare parts manual
v) List of Tools & Tackles
vi) Manufacturer’s Catalogue for all main sub
items of an equipment package.
* Only critical drawings/ documents identified by EIL from contractor’s schedule shall be reviewed.
# Drawings/ documents other than those identified for review or EIL shall be submitted for records.
Page 1885 of 2065

Page 3 of 3
PIPELINE FACILITIES
NOTES:
1) Section-wise Document Control Index (DCI) is to be submitted in the prescribed format, before the kick-off meeting
(Post Order stage) for finalization of the same during kick off meeting.
DCI shall be periodically updated w.r.t. submission of drawings, review of drawings & drawings remaining for
submission etc. and shall be submitted by contractor.
Requirements indicated in respective department’s (i.e. Electrical, Instrumentation, Piping, Structural, Architecture,
General Civil, Process, Inspection etc.) vendor data forms (as enclosed with the requisition) shall be governing &
shall be the basis of formation of section-wise DCI.
2) Each vendor Drawing/Data (listed under Review & Record) shall have been reviewed by the Contractor for ensuring
strict compliance to the Bid Specification requirements and shall carry the Reviewer’s signature/seal of the
Contractor, prior to submission for PMC’s Review/Records and as Final Documentation. Drawings submitted
without Contractor’s review shall be returned.
3) Documentation pertaining to auxiliary equipment of main rotating equipment shall not be reviewed & shall form part
of the Final Documentation.
4) Comments of Client to be incorporated by contractor/vendor.
5) As a minimum, Purchase Requisitions shall contain the following:

a) List of applicable EIL documentation
b) Detailed Vendor’s scope of supply / work
c) Equipment Data sheets – Process, Mechanical, Electrical & Instrumentation (approved copy)
d) Performance curves (approved copy)
e) List of Agreed Deviations with respect to bid package requirements (approved copy)
f) Completely filled in Experience record format (approved copy)
g) List of Spare parts: Commissioning spares, Special tools / tackles, Quotation for O&M spares
h) Detailed Vendor Data Requirements
Copies of only approved documents by EIL, as mentioned above, shall be attached to the PR before submission for
EIL’s records.
6) Contractor shall furnish hard/ soft copies to Owner directly, however only soft copy shall be submitted to EIL.
7) Ensuring compliance to the requirements of bid package specifications is the responsibility of the Contractor.
Contractor to follow the requirements stipulated in 6-78-0001 & 0002.
8) For balance requirements of documentation / data, VDR’s of respective disciplines shall be referred to & shall be
governing.
Page 1886 of 2065

STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS FOR CENTRIFUGAL PUMPS
$1g-41 kitReg INDIA LIMITED 6-41-0003 Rev. 4
71V MI3R01747
1.2, A Govi at ■nda Undenek.g) (WATER SERVICE) Page 1 of 21
tirof Fml Hfrich fq1

-4
- F
(5-kri ()cm)
STANDARD SPECIFICATION FOR

CENTRIFUGAL PUMPS
(WATER SERVICE)
Qs/
4 18/10/13 M TK DB SC
SPECIFICATION
3 20/03/08
SPECIFICATION NK AKN VKM VC
2 04/09/02 NK KDS VJN GRR
SPECIFICATION
1 18/02/98 NK KDS SKG AS
SPECIFICATION
0 26/08/86 ISSUED AS STANDARD SPECIFICATION VK MR SNG
Standards Standards
Committee Bureau
No by by
Approved by
Page 1887 of 2065

0 el ENGINEERS
FOR CENTRIFUGAL PUMPS
tif54eg e,,ygnoz■
141,
—, :AMR", IA GoN of India Underl4kng, (WATER SERVICE) Page 2 of 21
Abbreviations:
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
CG Centre of Gravity
EQC Equipment Qualification Criteria
GA General Arrangement
IC Internal Combustion
ISA Instruments Society of America
MAWP Maximum Allowable Working Pressure
MCF Minimum Continuous Flow
MCR Maximum Continuous Rating
MCS Maximum Continuous Speed
NPSH Net Positive Suction Head
NPSHA Net Positive Suction Head Available
NPSHR Net Positive Suction Head Required
OD Outside Diameter
P&ID Piping and Instrumentation Diagram
PTR Proven Track Record
VDR Vendor Data Requirements
Rotating Equipment Standards Committee

Convenor: Mr Dinesh Bhatia
Members: Mr Nalin Kumar

Mr Tarun Kumar
Mr Anukul Mandal
Mr.Rakesh Mishra
Mr JS Duggal
Mr KVK Naidu (Projects)
Page 1888 of 2065

atztelel. ENGINEERS FOR CENTRIFUGAL PUMPS
iEtWetg INDIA UMITED 6-41-0003 Rev. 4
tA QM of haw UntlertaNog)
(WATER SERVICE) Page 3 of 21
CONTENTS
Page No.
SECTION 1 - GENERAL 4
1.1 SCOPE 4
1.2 CONFLICTING REQUIREMENTS 4
1.3 DEFINITION OF TERMS 4
1.4 EQUIPMENT QUALIFICATION CRITERIA 5
SECTION 2 - BASIC DESIGN 6

2.1 GENERAL 6
2.2 PRESSURE CASING DESIGN 7
2.3 IMPELLER, SHAFTS AND SHAFT SLEEVES 8
2.4 WEAR RINGS 8
2.5 DYNAMICS 8
2.6 MECHANICAL SEAL/PACKING 8
2.7 BEARINGS 9
2.8 MATERIALS 9
2.9 PUMPS FOR FIRE WATER APPLICATION 9
SECTION 3 - ACCESSORIES 10
3.1 DRIVERS 10
3.2 GEARS 10
3.3 COUPLING 11
3.4 BASEPLATE 11
3.5 STRAINERS 12
SECTION 4 - INSPECTION, TESTING AND PREPARATION FOR SHIPMENT 12

4.1 GENERAL 12
4.2 TESTS 12
SECTION 5 - VENDOR'S DATA 15

5.1 PROPOSALS 15
5.2 CONTRACT DATA 16
Page 1889 of 2065

01c4zrel ENGINEERS
Sig-ar 201-ez INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
e771156.7 IA Go,1 oi India Undertsionso
SECTION 1 - GENERAL
1.1 SCOPE
This specification together with the attendant Data Sheets and other specifications/attachments
to inquiry/order defines the minimum requirements for vertical and horizontal centrifugal
pumps and their accessories/auxiliaries for use in Water service. DM water, Water injection
pump, boiler feed water pumps and pumps for sea water services are not covered by this
specification.
ii. Vendor shall make all possible efforts to comply strictly with the requirements of this
specification and other specifications/attachments to inquiry/order.
In case deviations are considered essential by the vendor (after exhausting all possible efforts)
these shall be separately listed in the vendor's proposal under separate section titled as "List of
deviations/exceptions to the inquiry document". Deviation shall be listed separately for each
document with cross reference to Page No./Section/Clause No./Para etc. of the respective
document supported with proper reasons for the deviation for purchaser's consideration. Any
deviation not listed under the above section, even if reflected in any other portion of the
proposal shall not be considered applicable.
No deviation or exception shall be permitted without the written approval of the purchaser.
iii Compliance with this specification shall not relieve the vendor of the responsibility of
furnishing equipment and accessories/auxiliaries of proper design, materials and workmanship
to meet the specified start up and operating conditions.
In case the vendor considers requirement of additional instrumentation, controls, safety

devices and any other accessories/auxiliaries essential for safe and satisfactory operation of the
equipment, he shall recommend the same along with reasons in a separate section along with
his proposal and include the same in his scope of supply.
1.2 CONFLICTING REQUIREMENTS

In case of conflict between this specification and the attendant data sheets, job specifications
(if any) and other attached specification the following order of precedence shall govern:
1. Equipment Technical Data Sheets.
2. Job Specifications (if any)
3. P&ID's (if any)
4. This specification
5. Other specifications
6. Other referred codes and standards
1.3 DEFINITION OF TERMS
1.3.1 The Normal operating point is the point at which usual operation is expected.
1.3.2 The Rated operating point is the point at which the vendor certifies that performance is
within the tolerances stated in this specification.
1.3.3 Maximum allowable working pressure (MAWP) is the maximum continuous pressure for
which the manufacturer has designed the equipment (or any part to which the term is referred)
when the equipment is operating at the maximum allowable temperature.
1.3.4 Maximum allowable temperature is the maximum continuous temperature for which the
Page 1890 of 2065

ifaae? ENGINEERS
42,4jf EtReg INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
1.2e
-r ,vitve 1151.3.704 (Govt ■ntlia Undettatoom (WATER SERVICE) Page 5 of 21
manufacturer has designed the equipment (or any part to which the term is referred) when
handling the specified liquid at the specified pressure.
1.3.5 Minimum continuous stable flow is the lowest flow at which the pump can operate
continuously without exceeding the noise and vibration limits imposed by this specification.
1.3.6 The Pressure casing is the composite of all stationary pressure containing parts of the unit,
including all nozzles, glands and other attached parts.
1.3.7 The Vendor means the manufacturer of the pump.
1.3.8 Net positive suction head (NPSH) is the total absolute suction head, in meters of liquid,
determined at the suction nozzle and referred to the datum elevation minus the vapour pressure
of the liquid in meters absolute. The datum elevation is the shaft centerline for horizontal
pumps, the suction nozzle centerline for vertical in-line pumps and the top of foundation for
other vertical pumps.
1.3.9 Net positive suction head available (NPSHA) is the NPSH in meters of liquid, determined by
purchaser for pumping system with the liquid at the rated flow and normal pumping
temperature.
1 .3 . 1 0 Net positive suction head required (NPSHR) is the NPSH in meters, determined by vendor
testing with water. NPSHR is measured at the suction flange and corrected to the datum
elevation. NPSHR at rated and other capacities is equal to the NPSH that produces a 3 percent
head drop (first stage head in multistage pumps) due to cavitation within the pump.
1 .3 . 1 1 Minimum Submergence required is the liquid level with respect to pump suction flange
face, in millimeters, determined by the vendor when testing with water for vertical pumps.
This is the level required to prevent vortex formation/ingress of air/vapour into the pump
suction resulting in loss of flow/head.
1.4 EQUIPMENT QUALIFICATION CRITERIA
1.4.1 Unless otherwise specified elsewhere, the Equipment Qualification Criteria (EQC) specified
vide para 1.4.2 to 1.4.3 of this specification shall be applied for acceptance of the offered
pump model.
1.4.2 a) The vendor shall be an established manufacturer of centrifugal pumps having adequate
design, engineering, manufacturing and testing facility for pumps and shall be the single point
responsibility vendor for the complete centrifugal pump package.
b) The vendor shall have designed, engineered, packaged, tested and supplied in the last TEN
(10) years from the proposed manufacturing plant, at least ONE (1) centrifugal pump package
with same type of driver having similar drive power.
As minimum, this package shall have completed ONE (1) year of satisfactory operation at site
as on bid due date.
1.4.3 a) The centrifugal pump model offered shall be from the existing pump model series and shall
be from the regular manufacturing range of the vendor. The mechanical as well as the
hydraulic performance (including NPSHR) for the complete range of operation of the offered
model shall have been established in the shop test. The offered pump model shall meet the
minimum service and manufacturing experience requirements specified in clause 1.5.3 b)
below.
Page 1891 of 2065

ei ENGINEERS
1g-a Wes*v.INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
NOW (A C., of 00.0 Undertak.ng, (WATER SERVICE) Page 6 of 21
b) Pumps shall be identical in terms of Hydraulics and similar in terms of Power rating, Inlet
flow, Differential Head, Operating Pressure & Temperature, Speed, Number & Type of
Impellers, Mechanical Design, Materials, Bearing Span(applicable for between bearing
pumps), Column Length (applicable for vertically suspended pumps) etc. as compared to at
least ONE(l) unit of the proposed model designed, engineered, manufactured, tested and
supplied from the proposed manufacturing plant in the last TEN(10) years and the reference
unit shall have completed ONE(1) year of satisfactory operation at site as on bid due date.
In case all the above parameters are not available from single past reference, more than one
reference can be cited/considered to satisfy the above qualification requirement.
1.4.5 PROVEN TRACK RECORD (PTR)
Pump Vendor shall complete the Experience Record Proforma's enclosed with the inquiry
document to amply prove that the offered equipment meet the EQC for technical acceptance.
Vendor may furnish additional information to justify that the EQC is being met. In addition,
manufacturer's catalogue and general reference list for Centrifugal Pumps shall also be
furnished alongwith the proposal.
SECTION 2 - BASIC DESIGN
2.1 GENERAL
2.1.1 The vendor shall assume the Unit Responsibility for equipment and auxiliary system(s)
included in his scope.
2.1.2 Pumps with constant speed drivers shall be capable of atleast 5 percent head increase at rated
condition and pump rated speed by replacing with a new impeller or impellers. Offered
impeller shall in no case be less than the minimum diameter impeller.
2.1.3 Horizontal pumps of the close-coupled, the two stage overhung, or the single stage double
suction overhung, type shall not be furnished.
2.1.4 Pumps where difference between NPSHA and NPSHR from quoted minimum flow to rated
flow is less than 1 meter (for pumps with driver rating <55KW) & 0.6 meter(for pumps with
driver rating >55KW) are not acceptable. The said NPSHR value shall correspond to the
maximum value of NPSHR from rated flow down to the recommended minimum stable flow
specified by the vendor.
2.1.5 Pumps that have stable head/capacity curves (continuous head rise to shut-off) are preferred
for all applications and are required when parallel operation is specified.
2.1.6 The pumps for parallel operation shall have characteristics suitable for capacity sharing. The
shut off head in such cases shall not be less than 110 percent of the rated head and no more
than 120 percent of the rated head in horizontal pumps and 140 percent in the case of vertical
turbine pumps.
2.1.7 The best efficiency point for the furnished impeller is preferred between the rated point and
the normal point. However in no case the rated point shall be beyond 110 percent of the best
efficiency point of the rated impeller.
2.1.8 The maximum permissible sound pressure level of the pump driver train shall not exceed 88
dBA measured at 1 meter from pump surface for the recommended range of operation.
Page 1892 of 2065

q.JENGINEERS
42e.ff telPeg INDIA UMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
I MN, AVM?? entautnvo
IA Govt of ■nclo UnderUk.9) (WATER SERVICE) Page 7 of 21
2.1.9 For vertical pumps, not provided with non-reverse ratchet, vendor shall describe the
precaution taken, to prevent damage due to reverse rotation.
2.1.10 Pump-Driver train shall be designed to be suitable for outdoor installation without a roof.
2.1.11 Lifting lugs/eye hooks shall be provided for ease of lifting of complete pump as well as the
heavy maintenance components of the pump (e.g. Top half casing cover of axially split pump).
2.1.12 The guaranteed parameters shall be demonstrated during shop test without any coating on
impellers or casings.
2.1.13 Pumps with variable speed drivers shall be capable of operating continuously upto 105 percent
of rated speed as well as operating briefly upto driver trip speed.
2.1.14 Casing vents alongwith vent valves, as per manufacturer standards, for all pumps shall be
provided. For all horizontal pumps, casing drain with isolation valve and flanged piping
terminated at the skid edge shall be provided. Baseplate shall also be provided with flanged
drain connection.
2.1.15 Horizontal between bearing pumps, pumps with rated flow above 500m3/h(horizontal) and
pumps with rated flow above 100m3/h(vertical) shall be considered as Large Capacity in
LCWS.
2.2 PRESSURE CASING DESIGN
2.2.1 Maximum allowable working pressure (MAWP) for all pressure containing parts e.g. casing,
bowl, discharge head, discharge pipe, column pipe, stuffing box etc. shall in no case be less
than the maximum discharge pressure produced by the pump at shut-off (including tolerances),
at the maximum suction pressure, for the maximum impeller diameter and the maximum
continuous speed.
MAWP shall also not be less than the specified downstream design pressure.
These pressure containing parts shall be suitable for hydrostatic test pressure of 11/2 times the
MAWP.
Note: MAWP shall not be less than 10 kg/cm2G for pumps with 125# flanges (i.e. with Cast Iron
casing) & 16 kg/cm2G for pumps with 150# flanges (i.e. with Carbon Steel or Alloy Steel casing).
2.2.2 Pumps shall have suction and discharge flanges designed for same rating. Unless otherwise
stated, flanges shall be machined and drilled conforming to ANSI B16.5 standard.
2.2.3 Pumps shall be provided with Flanged nozzles.
2.2.4 Unless otherwise specified, all pumps shall be supplied with companion flanges with rating
conforming to applicable specification of ANSI, drilled and faced in accordance with pump
suction and discharge flanges alongwith gaskets and fasteners.
For pumps with casing material as cast iron (CI), the companion flanges shall be of slip-on
(SO) type [for flange sizes 50 mm (2 inches) & above] or socket welded (SW) type [for
flanges of size 15 mm (0.5 inches) to 40 mm (1.5 inches)] with flat face (FF) & of carbon steel
material. The gasket shall be of full face type.
Page 1893 of 2065

l ,2J ENGINEERS STANDARD SPECIFICATION
sigar faOrdu
441-
,a 7,4:1,13
INDIA LIMITED
IA Govf of IntAA Undertaiong,
(WATER SERVICE)
6-41-0003 Rev. 4
Page 8 of 21
For pumps with casing material other than cast iron, the companion flanges shall be of weld
neck (WN) type with raised face (RF) & of the material compatible with piping material.
2.3 IMPELLER, SHAFTS AND SHAFT SLEEVES
2.3.1 Impellers shall be cast as one piece.
2.3.2 Shaft shall be provided with sleeves under the packing/seal and shall be locked to the shaft.
The material of sleeve shall be 12 percent chrome steel (hardened).Where the size of pump
makes the use of shaft sleeve impracticable, the shaft shall be constructed of 12 percent
chrome steel (hardened). For vertical pumps, shaft material shall be 12 percent chrome steel.
2.4 WEAR RINGS
Unless otherwise specified, renewable wear ring shall be furnished at least on the casings.
Mating wear surfaces of hardenable materials shall have a difference in Brinell hardness
number of at least 50. Integral impeller wear surfaces shall have higher hardness than that of
the casing wear rings, when only casing wear rings are provided.
2.5 DYNAMICS
The following vibration limits shall be applied at rated speed and at flow of ±10 percent of
rated flow.
2.5.1 Horizontal pumps
Unfiltered vibration velocity for horizontal pumps upto 3000 rpm with antifriction bearing or
sleeve bearings when measured at the bearing housing in horizontal or vertical direction shall
not exceed 4.0 mm/sec (0.16 inch/sec).
Bearing housings shall be suitable to permit measurement of vibration.
2.5.2 Vertical Pumps
Unfiltered vibration velocity for vertical pumps with antifriction and or sleeve bearings when
measured at the top bearing housing of pump or top bearing housing of motor or mounting
flange for measuring points upto 3 meters above the mounting base shall not exceed the
following limit:
Pumps greater than 1500 rpm = 7.0 mm/sec (0.28 inch/sec)
Pumps upto & including 1500 rpm = 5.1 mm/sec (0.20 inch/sec)
2.5.3 The vibration limits specified vide clause. 2.5.1 and 2.5.2 above shall be applied for pumps
only. The vibration limits for the drivers shall be as per their respective applicable standards.
Where respective applicable standards do not specify such limits for the associated drivers, the
driver manufacturer's recommendation shall be applied for acceptance of the driver. Such
acceptable limits shall be indicated by the vendor in their proposal.
2.6 MECHANICAL SEAL/PACKING
2.6.1 Unless otherwise specified, the pump shall be supplied with packings. Stuffing box shall have
minimum five packing rings plus lantern ring. Packing ring size shall be 3/8" or larger.
Page 1894 of 2065

15if5i-zreq ENGINEERS
$'2e..1TEtWe.0 INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
I NWT fA JRNZO IA Govt o India UM/N.1*mm (WATER SERVICE) Page 9 of 21
2.6.2 The mechanical seal shall be of a make, duly approved by the purchaser.
2.6.3 Seal manufacturers specific recommendation shall be obtained and submitted alongwith the
proposal.
2.6.4 All auxiliaries for flushing of mechanical seal shall be in vendor's scope of supply.
2.7 BEARINGS
2.7.1 Antifriction bearings shall be of standard type and shall meet minimum L-10 rating life of
either 25000 hours with continuous operation at rated conditions or 16000 hours at maximum
axial and radial loads and rated speed.
2.7.2 The rise in bearing grease/oil temperature with continuous running of the pump shall be within
the allowable limits which shall not exceed 30°C for grease and 39°C for oil lubricated
bearings above ambient. Cooling arrangements shall be provided if required. Bearings shall be
equipped with constant level oilers, vent breather & drain point for oil lubricated
arrangements.
2.7.3 Unless otherwise specified, for vertical pumps with open shaft, the intermediate bearings /
bushings shall be suitable for operation without any lubrication during start / shut-down or
during normal operation (i.e. bearing bush material shall be of self lubricating type). Details of
line shaft bearings shall be furnished with the proposal.
2.7.4 Unless otherwise specified, for vertical pumps, thrust from the pump shall not be transferred to
the electric motor.
2.8 MATERIALS
2.8.1 The material of construction of parts shall be as specified. Vendor shall furnish the equivalent
material as per ASTM.
For impellers in cast iron or bronze construction, the tip speed shall be limited to 40
meters/sec. Unless otherwise specified, for tip speeds exceeding 40 meters/sec, the material of
impellers shall be stainless steel.
As an alternate, vendor may suggest suitable material proven for higher impeller tip speeds.
2.8.2 Unless otherwise specified in the data sheet, material test certificates (chemical and
mechanical properties) shall be supplied for impeller, shaft, shaft sleeve, wearing rings and
casings.
2.8.3 The repair of pressure castings by peening, plugging, impregnating or by the use of plastic or
cement compound is prohibited. The Inspector's prior approval shall be obtained for the repair
of castings. When authorised, repair shall be carried out in accordance with applicable ASTM
Specification. Weld repair of pressure containing parts of Cast Iron construction is not
permitted.
2.9 PUMPS FOR FIRE WATER APPLICATION
Pumps for Fire Water Application shall also meet the following additional requirements:
2.9.1 Pumps shall meet the requirements of TAC (Tariff Advisory Committee), NFPA (National
Fire Protection Association) etc. as specified in the data sheet. The vendor shall also be
Page 1895 of 2065

ENGINEERS
$igeAr 0151-dg INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
I 7.111$7 ,7,57517 71,17.17 IA (.,0,4 Enda undertakmg)
responsible for obtaining the necessary approvals as specified in inquiry.
2.9.2 Pumps shall be direct-coupled except in the case of engine-driven vertical turbine pumps
wherein gear drives shall be used. Belt driven pumps are not acceptable.
2.9.3 Parts of pumps like impeller, shaft sleeve, wearing ring etc. shall be of non-corrosive metal
preferably brass or bronze unless the quality of water dictates the use of special metals/alloys
which shall be insisted upon.
2.9.4 Pumps shall be capable of furnishing not less than 150 percent of rated capacity at a head not
less than 65 percent of the rated head.
2.9.5 Difference between NPSHA and NPSHR at 150 percent of the duty point shall not be less than
0.6 meters.
2.9.6 The electrical motor shall be of continuous rating type and the rating shall be 110 percent of
the power at rated point or equal to maximum BKW rated impeller whichever is higher.
2.9.7 For Diesel engine drivers, the net continuous site power available after considering the
deration due to site condition and power losses, due to other parasitic loads and engine driven
auxiliaries shall be higher of the following two values:
(a) 20 percent in excess of the maximum BKW required to drive the pump at rated condition.
(b) Maximum BKW rated impeller as indicated by the manufacturer in the pump data sheets.
SECTION 3 - ACCESSORIES
3.1 DRIVERS
3.1.1 Electric motor drivers shall have a maximum continuous rating (MCR) (i.e. service factor
equal to 1) not lower than the following unless higher rating is dictated by the Note 1.
Motor Name plate Rating Motor MCR (% of Pump Rated BKW)
Less than 22 kW To suit maximum BKW indicated on pump data
sheet or 125% of rated pump BKW, whichever is
higher.
22 kW - 55 kW 115% of rated pump BKW.
Higher than 55 kW 110% of rated pump BKW.
Note :
1. The motor namelpate rating for pumps under parallel operation shall not be less than the
max. BKW indicated on pump data sheet (the power at End of the curve for the rated
impeller) or shall have the specified margin as per this clause whichever is greater. The
pump motors shall also be suitable for start-up under open discharge valve condition.
3.1.2 Steam Turbine rating shall be at-least 110% of rated pump BKW (unless higher rating is
dictated by Note 1 above) at the rated speed with coincident minimum inlet & maximum
exhaust steam conditions. As a minimum, steam turbine rating shall be equal to motor rating
(IS).
3.2 GEARS
The type of gears shall be as specified in the inquiry document.

Unless otherwise specified, gear box shall be selected with a minimum of AGMA service
factor of 1.75 over the driver rating.
Page 1896 of 2065

ENGINEERS
ttMeg INDIA litv1ITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
IOW, FIVAAP +7,1,100.49 rn
Govt. of ,ndo UndertakIng)
Wherever right angle gear box are required the same shall be supplied non-reversible ratchet
and shall allow for vertical adjustment of the impeller. Further the gearbox shall be suitable
for absorbing the maximum thrust under any case of operation.
3.3 COUPLING
3.3.1 Unless otherwise specified, connection between pump and driver shall be made by a flexible
metallic coupling.
A spacer (127 mm minimum normal length), shall be used to permit the removal of coupling,
bearings, seal and/or rotor as applicable without disturbing the driver, the suction and
discharge piping, or the casing top cover, for all horizontal pumps.
It shall be the responsibility of the pump vendor to obtain purchaser's approval for the selected
coupling, its make and rating.
However, unless otherwise specified, the coupling shall be rated using a service factor of not
less than 1.25 for flexible element coupling.
3.3.2 Whether or not pump vendor is required to supply the driver, he shall still deliver the fully
machined coupling assembly alongwith the pump. The driver shaft dimensions and tolerances
shall be furnished by the Purchaser to the pump vendor.
3.3.3 Removable coupling guard shall be provided which shall be fabricated from non-sparking
material, and shall be open at the bottom to permit manual shaft rotation. The guard shall be
sufficiently rigid to withstand deflections as a result of bodily contact of nominally 100 kgs.
3.4 BASEPLATE
3.4.1 Baseplates for Horizontal Pumps
3.4.1.1 Baseplate shall extend under the pump, gear box and motor/turbine driver and shall be fully
machined for mounting the above equipment. Baseplate shall be steel fabricated and shall have
sufficient rigidity to avoid vibration and distortion. Baseplate shall be so designed as to
facilitate proper grouting (Vent holes where required shall be provided). Baseplate shall be
cleaned (sand blasted) inside and outside and coated with suitable anticorrosion paint.
3.4.1.2 The baseplate shall be provided with lifting lugs for at-least a four point lift. Lifting the
baseplate complete with all equipment mounted shall not permanently distort or otherwise
damage the baseplate or machinery mounted on it.
3.4.1.3 For driver trains over 75 kW, alignment positioning screws shall be provided for each drive
element to facilitate longitudinal and transverse horizontal adjustments. The lugs holding these
positioning screws shall be attached to the baseplate so that they do not interfere with the
installation or removal of the drive element.
3.4.1.4 Vertical leveling screws, spaced for stability shall be provided on the outside perimeter of the
baseplate. These shall be numerous enough to carry the weight of the baseplate, pump, gear-
box (if any) and driver without excessive deflection.
Page 1897 of 2065

tn~ ENGINEERS
ligai fag& INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
,0151V c151 P.1,117,
3.4.2 Baseplate / Mounting Plate for Vertical Pumps
3.4.2.1 Vertical pumps shall have the manufacturer's standard mounting arrangement.
3.4.2.2 Alignment positioning screws shall be provided for 18.5 kW and above and as per
manufacturer's standard practice for lower ratings.
3.4.2.3 Unless otherwise specified, mounting plate for vertical pumps shall be made from
IS:2062/IS:2002 plate material with a thickness of 48 mm. Mounting plate shall be supplied
with gaskets & fasteners.
3.4.2.4 Alignment positioning screws shall be provided for all motors.
3.5 STRAINERS
Unless otherwise specified, all vertical pumps shall be provided with suction strainers of SS-
316 material.
SECTION 4 - INSPECTION, TESTING AND PREPARATION FOR SHIPMENT
4.1 GENERAL
4.1.1 Unless otherwise specified, all pumps shall be inspected and all tests shall be witnessed by the
Purchaser or by the Purchaser's authorised representative.
4.1.2 Purchaser's or their authorised representative shall have access to the plant including sub
vendors plants where work on or testing of equipment is being performed.
4.1.3 No surfaces of parts of pumps are to be painted until the inspection is completed.
4.1.4 Vendor shall give to the purchaser atleast 15 days notice prior to commencement of testing.
Vendor shall carry out all running tests and mechanical checks and satisfy himself prior to
purchaser's arrival for inspection and shall maintain desired log of tests.
4.1.5 Acceptance of shop test shall not constitute a waiver of requirement to supply equipment as
per specification and/or to meet field test under operating condition, nor does inspection
relieve the manufacturer of his responsibility in any way whatsoever.
4.2 TESTS
As a minimum following tests shall be performed. The basic reference standard shall be the
latest edition of Hydraulic Institute Standard or IS:5120.
4.2.1 Hydrostatic Test
4.2.1.1 Pressure casings including column pipe and discharge head shall be hydrostatically tested with
water at ambient temperature at 11/2 times the maximum allowable working pressure specified
in the data sheet.
4.2.1.2 Jackets for bearing, stuffing box, coolers, etc, shall be tested at 8 Kg/cm2g or 11/2 times the
maximum allowable jacket working pressure whichever is higher.
4.2.1.3 Hydrostatic test shall be maintained for a minimum period of 30 minutes.

Page 1898 of 2065

k.71 ei ENGINEERS
LJI tIfireg INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
.1101 AFAR> VI% fA Govt of India Unclettatong)
4.2.1.4 Hydrostatic test is under non-witness category & only review of manufacturer's shop test
reports is required.
4.2.2 Performance Test
4.2.2.1 Unless otherwise specified, performance test for Horizontal pumps for General Water
Services GWS shall be carried out as per following:-
Pumps with drivers upto 55KW Non witnessed. Only review of
manufacturer's shop test reports are
required
Pumps with drivers from 55KW to One pump per tag/item no. to be witnessed
160KW
Pumps with drivers above 160 KW All pump units in an item to be witnessed
However, in case of vertical pumps & for pumps for Large Capacity Water Services(LCWS) ,
all pumps in a tag needs to undergo witnessed performance test.
4.2.2.2 Unless specifically agreed upon, pump shall be tested at the rated speed specified in the data
sheet with calibrated motors, at least for four hours. During the four hour run test, complete
data including pressure, capacity, power, vibration levels, bearing temperatures and noise
levels shall be recorded and guaranteed parameters verified.
Prior to start of test, manufacturer shall furnish the certificate of latest calibration / re-
calibration of driver and measuring instruments. Unless electrical or mechanical failure occurs,
driver used for shop testing need not be recalibrated and original calibration certificate shall
remain valid. Duration of recalibration for all measuring instruments shall be as per the
recommendations of HI Standards and/or relevant standards of the country of origin of the
pump manufacturer.
4.2.2.3 The pump shall be tested with water at ambient temperature. Suitable rust inhibitor shall be
added in the water used during any internal testing / performance testing of the pumps, to
prevent rusting of pump internals.
4.2.2.4 The performance test for the pumps shall be in accordance with Indian Standard IS:5120
latest edition and the tolerance of the guaranteed parameters shall be as follows:
Rated head Zero negative tolerance.

Shut-off head Positive tolerance permitted so long as it does not exceed
downstream design pressure. Negative tolerance
permitted so long as the curve is
continuously rising to shut off without any drooping &
min 110% head rise to shut off shall be available for
pumps in parallel operation.
NPSH(r)/
Min Submergence Reqd. Zero Positive Tolerance.
Rated BKW Zero positive tolerance (However pumps may be
accepted upto 104 percent of Guaranteed BKW subject to
Penalties as defined elsewhere)
At least four to six values between duty point and shut off and two values on the right of duty
point including one point with discharge valve fully open, shall be measured and recorded
during tests. All the instruments used for conducting the tests shall be calibrated before tests
and calibration certificates furnished from a recognised testing institution to the Inspector.
Page 1899 of 2065

101 el ENGINEERS
$1gar 0154-ft INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
74, e.1,75, 7.51 as Go, of 4-0.3 Undertakog) (WATER SERVICE) Page 14 of 21
4.2.2.5 For fire water application all engine driven horizontal and vertical pumps shall be subjected to
a 4 hour complete unit string test at the pump vendor's works during which mechanical
performance of the train shall be verified, in terms of vibration, bearing/oil temperature,
engine parameters and controls.
In case multiple units are ordered, only one number of diesel engine and gear box unit (if
used) may be brought to the pump vendor shop for complete unit (string) test for the fire water
pump unit. For the remaining pumps, complete unit (string) need not be done. However, any
modification required to be done on the first unit shall be uniformly done on the remaining
units also for proper unitization of the same at site.
4.2.3 NPSH Test / Min. Submergence Test

Unless otherwise specified, NPSH test for Horizontal pumps for General Water
Services(GWS) shall be carried out as per following :
For pumps with driver rating upto 55KW Not Applicable

For pumps with driver rating between 55KW One pump tag/item to be witnessed
to 160KW
For pumps with driver rating above 160KW All pump units to undergo witness test
Additionally, in case of vertical pumps, all pumps in a tag needs to undergo minimum
submergence test in addition to NPSH test.
Also for all pumps in LCWS, all pumps in a tag needs to undergo NPSH test if required as per
specification.
4.2.4 Vibration Measurement

During performance test vibration shall be measured on the bearing housing for the capacity
range of ±10 percent of rated capacity.
4.2.5 Dismantling Inspection

Dismantle Inspection of pump after performance test shall be applicable only in case of
abnormality in mechanical behaviour (such as excessive noise & vibration, bearing
temperature rise etc.) during performance test.
4.2.6 Final Inspection

After the performance/dismantle test the pump and the job driver shall be unitised on the job
base plate, aligned and coupled to make a complete unit. The pump will then be checked for
visual inspection to confirm compliance to the GA drawings, nozzle dimension, elevations,
anchor bold position, direction of rotation etc.
4.3 If it is necessary to dismantle a pump after the performance test for the sole purpose of
machining impellers to meet the tolerances for differential head, no re-test will be required
unless the reduction in diameter exceeds 5 percent of the original diameter. The diameter of
the impeller at the time of shop test, as well as the final diameter of the impeller, shall be
recorded on a certified shop test curve that shows the operating characteristics after the
diameter of the impeller has been reduced.
4.4 If it is necessary to dismantle a pump for some other correction, such as improvement of
power, NPSH, or mechanical operation, the initial test will not be acceptable, and the final
performance test shall be run after the correction is made.
Page 1900 of 2065

larael&ft ENGINEERS FOR CENTRIFUGAL PUMPS
Igelf titReg W.. INDIA LIMITED 6-41-0003 Rev. 4
13,741
1.11P71 AMR +3513, IA Govt of InOla Undettakmg) (WATER SERVICE) Page 15 of 21
4.5 PREPARATION FOR SHIPMENT
4.5.1 After all tests are completed and after inspection is made, all exposed mechanical surfaces and
all internal parts shall be thoroughly coated with a rust preventive. All exterior parts of the unit
except machined surfaces shall receive one prime coat and one coat of vendor's standard
enamel.
4.5.2 All flanges, nozzles shall be blanked off. All untapped openings shall be provided with
substantial wood or metal closure. The ends of small piping may be sealed with tape.
4.5.3 The pump shall be supplied with a nameplate containing the following information:
-Purchaser's Item No.
-Manufacturer's Name
-Type and Serial No
-Speed.
The nameplate shall be of stainless steel and relevant information shall be punched into the
same.
4.5.4 All auxiliary, dismantled and packed separately shall be properly marked with the Item No. for
which it is intended by means of metal tag.
4.5.5 Pump with auxiliary shall be suitably packed, fastened to avoid damage during transit and
crated for shipment and storage for a period of 12 months. Lifting, unpacking and handling
instructions shall be securely attached to the exterior of the largest packing in a well marked
weather proof container. The upright position of lifting points, gross weights and dimensions
be clearly marked on each package. Each package shall clearly identify the equipment
contained therein. If any extra precaution is to be taken by the Purchaser for storage beyond 12
months the same shall be explicitly indicated in the operation and maintenance manuals.
SECTION 5 - VENDOR'S DATA

5.1 PROPOSALS
The vendor's proposals shall as a minimum include the following:

a) All data sheets, drawings and documents listed under "PRINTS WITH QUOTE" in the
enclosed Vendor Data Requirement Form.
b) Vendor's confirmation/comments on post-order Vendor Data Requirements (Type of
Documents, no. of prints and date needed) indicated in Vendor Data Requirement forms
data sheets and specs.
c) List of recommended commissioning spares included in the offer.
d) List of mandatory spares (where specified by the purchaser) included in the offer.
e) List of Vendor's standard Spare Parts for Two Years Normal Operation
This list shall be made separately for each items including auxiliaries and drivers in the
form of a table & shall show :
i) Part name, description and number.
ii) Quantity installed in one unit.
iii) Quantity recommended per unit for 2 years normal operation.
iv) Quantity recommended for number of units of an item as specified in the inquiry.
v) Quantity recommended as insurance for the number of units of an item specified
in the inquiry.
f) An itemised list of special tools included in the offer.
g) Any start-up, shutdown or operating restrictions required to protect the integrity of the
equipment.
h) Any limitations of vendor's test-facility to carryout the specified tests.
Page 1901 of 2065

-

ftfazi-& ENGINEERS
fat5reg
eae,M1, 1,1,30a).1
INDIA LIMITED
IA Gout of India Undertaiunq)
(WATER SERVICE)
6-41-0003 Rev. 4
Page 16 of 21
i) A specific statement that the scope of supply, the offered equipment/systems and all its
components are in strict accordance with the data sheets, job specifications, this
specifications and all other attachments, except for specific deviations as listed in the
proposal.
5.2 CONTRACT DATA
5.2.1 General
5.2.1.1 Drawings and data as required after purchase order has been specified in Vendor Data
Requirement. Vendor to note that the drawing/document descriptions/titles as given in the
Vendor Data Requirement are generic in nature. It is possible that against one
drawing/document specified there are several drawings to be furnished by the vendor or vice
versa.
Vendor shall complete & forward a document "DOCUMENT CONTROL INDEX" to the
purchaser (Destination & contact person as per order).
This document shall list out in consolidated form all drawings and documents required by
purchaser (As specified in Data Sheets, Specifications and Vendor Data Requirement forms
enclosed with the order).
Against each drawing/document vendor shall indicate the vendor's drawing numbers, titles,
Rev. No., category (whether for information or approval) and schedule of submission.
This shall be the first document to be submitted by vendor within two weeks of order.
No drawing shall be taken up for review till DCI for the inquiry/order is finalized by
vendor.
5.2.1.2 All transmittal letters (covers), drawings and data shall have a title block (in addition to
vendor's standard title block) which shall as a minimum contain the following contract
information:
i) Purchaser's and Consultant's Corporate Name
ii) Project Name.
iii) Equipment Name and Item No.
iv) Purchase Order No.
v) Purchase Requisition No.
Title Block on drawings shall be placed on the lower right hand corner.
5.2.1.3 All vendor data/drawings/documents shall be in English Language and in Metric Systems.
5.2.1.4 Data specified in the VDR is the minimum requirements of Purchaser. Any additional
document/data required or requested by Purchaser for engineering or construction shall also be
made available by the vendor.
5.2.1.5 Whether or not specified the vendor shall furnish the following, before shipment:
As built running clearances and when applicable; thrust bearing, radial bearing and
seal running clearances.
A supplementary list of spare parts other than those included in his original proposal.
The supplementary list shall include recommended spare parts, cross-sectional or
assembly type drawings, parts numbers, materials, prices and delivery period. The
vendor shall forward this supplementary list to the purchaser promptly after receipt of
the reviewed drawings and in time to permit order and delivery of parts before field
start-up.
- A parts list for all equipment supplied. The list shall include pattern, stock, or
production drawing numbers and materials of construction. The list shall completely
identify each part so that the purchaser may determine the interchangeability of the
Page 1902 of 2065

zac9 ENGINEERS
zir kitfaes. INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
1411p7f AIIPITAF A Govt of ,n0oa Undertalon9) (WATER SERVICE) Page 17 of 21
parts with other equipment furnished by the same manufacturer. Standard purchased
items shall be identified by the original manufacturer's name and part number.
At least 8 weeks before shipment, the vendor shall submit his preservation, packaging
and shipping procedures to the purchaser's for his review.
5.2.3 Co-ordination Meeting

When specified, a co-ordination meeting shall be held at Purchaser's office, preferably within
4 weeks of order.
An agenda shall be prepared for this meeting and would include the following points related to
technical aspects.
a. Any clarifications required by the vendor on purchaser's order.
b. Document Control Index(DCI).
c. Vendor Data Review/approval modalities.
d. Sub-vendor lists proposed by vendor.
e. Utility requirements.
f. Preliminary General Arrangement & layout drawings & purchaser's interface drawings.
5.2.4 Drawings
5.2.4.1 The number of prints and/or reproducible required and the times within which these are to be
submitted by vendor are specified in Purchaser's inquiry/order.
If specified, drawing review may be through EDMSNDOCS in soft as per the details provided
elsewhere in the inquiry document.
5.2.4.2 The purchaser's review of the vendor's drawings shall not constitute permission to deviate
from any requirements in the purchase order/specifications unless specifically agreed upon in
writing. After the drawings have been reviewed, the vendor shall furnish certified copies in
the quantity specified. All drawings must be clearly legible and shall be folded to 216 mm x
279 mm (8'/2" x 11") size. All transparencies shall be rolled.
5.2.4.3 Drawings/documents with following titles shall contain as a minimum the following
information:
a) General Arrangement Drawing
A general arrangement drawing shall indicate:
i) Outline dimensions (minimum three views) (All principal dimensions).
ii) Allowable forces and moments on suction and discharge nozzles.
iii) Location (in all three planes), size, type, rating and identification of all purchaser's
interface connections including those of vents, drains lubricating oil, sealing fluid,
cooling water, steam & Electrical/Instrumentation.
Direction of rotation viewing from the driving end.
Weight of each assembly/component.
The weight & location of center of gravity of the heaviest assembly/components
that must be handled for erection.
Identification and weight, dimensions of the heaviest assembly / subassembly /
component required to be handled for maintenance.
Maintenance clearances and dismantling clearances.
Speeds of Driven Equipment and driver and driver rating. Location of driver
terminal box (in case of Electric Driver)
Layout of auxiliary equipment and operating platform.
Make, Type and Size of couplings and the location of guards and their coverage.
A list of reference drawings if any.
A list of any special weather-protection and climatic features.
Page 1903 of 2065

401 ENGINEERS
Og-ar lal5leg INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
lir, rWriTgr, 1,1,111.1 to Govt of ,r..11.3 Undertaiong} (WATER SERVICE) Page 18 of 21
b) Foundation Drawings
A foundation drawing shall indicate complete information required for foundation design
by purchase including the following:
i) Foundation bolt sizes, pipe sleeve details, pocket sizes and locations and also
distance between the first/ nearest anchor bolt and pump suction and discharge
nozzle centrelines.
ii) Grouting thickness and other necessary technical details.
iii) Static weight of each skid/independently grouted item and location of center of
gravity of each of such skid/items in all three planes.
iv) Weight distribution for each bolt/subsole plate location and total static weight.
v) Dynamic loading caused due to various items grouted independently.
vi) The direction and magnitude of unbalance forces and moments generated by each
such item at the worst operating condition and short circuit moments of motor
drivers at the C.G. of the pump-motor baseplate.
vii) GD2 value of each item resolved to driver speed.
viii) Maximum permissible amplitude of vibration on the foundation at base level.
ix) Total mass of rotating parts.
x) Total mass of reciprocating parts.
xi) Suggested dynamic factor and ratio of foundation weight to weight of
skid/equipment as per vendor experience.
c) Layout Drawing (For multi-skid packages)

This drawing shall include atleast the following:
i) Layout of all skid/equipment and their auxiliaries, vessels, control panels,
exchangers etc. Vendor shall furnish an optimised layout (considering the space
allocated, site wind conditions, area classification, the type of equipment located
in the vicinity etc.) indicating elevation and dimension of skids/equipment.
ii) Minimum spacing required between the various skids/equipment and between the
skids and the walls/columns/roof for an easy accessibility and maintenance.
iii) Layout for water piping, trenches for water piping, cable tray/trenches layout.
iv) Piping arrangement and piping support arrangement/location for piping in
vendor's scope.
v) Layout for auxiliary equipment and operating platform details.
vi) Specification for crane/mono rail (including suggested mono rail layout)
recommended for maintenance and height of the lifting hook from the centerline
of equipment.
d) Field Alignment Diagram

The diagram shall indicate the relative displacement to be kept between the centrelines of
various equipments at the time of installation, so that under normal running conditions the
equipments get fully aligned. This relative displacement should be decided on the basis of
centerline temperature rise data of driver, gear box/transmission system, driven
equipment.
e) Heat Exchanger Drawings

Heat exchanger drawing and data shall include heat and mass balance data, details of
provisions for separating and withdrawing the condensate, construction details, cross
sections & general arrangement drawings of heat exchangers, vendors recommendations
regarding provision for support and piping expansion.
Page 1904 of 2065

101 elczl ENGINEERS
sigz.,r i INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
1.FR qii97.71,1,341,1741 A Govt ol Ingha Undettakm9)
5.2.4.4 P&I Diagrams (with Bill of Materials)

Vendor shall supply P&I Diagrams along with Bill of Materials of each system in the vendor's
scope of supply or specified in the order. P&I Diagram shall indicate the system details,
location of various auxiliaries, instruments, controls and safety devices as required. Line
sizes, piping class, valve sizes and class shall be clearly marked on the P&ID. Vendor's scope
and purchaser's scope shall be clearly demarcated. Each item shall be identified by an item
No./item tag no., which shall correspond to the item no. shown on the bill of materials. The
bill of materials shall include items number, normal value, set value, range, quantity per unit,
make and other specifications as applicable.
Legends adopted shall be indicated either at the bottom of drawing or on a separate drawing.
The legends shall be as per ISA.
5.2.4.5 Cross-sectional Drawing(with Bill of Materials)

The vendor shall supply cross-sectional or assembly type drawings for all equipment furnished
showing all parts, design assembly and running clearances, and balancing data required for
erection and maintenance. Each part shall be numbered which shall correspond to the part
number on the bill of materials. The bill of materials shall include the part no., name of
component, materials quantity installed per unit & sizes where applicable (say for bolts, nuts,
rings, gaskets etc.). All boughtout items shall also be indicated with make and brief
specifications.
A separate cross-sectional drawing showing installation and setting dimensions for the seals
shall be furnished.
5.2.5 Performance Characteristic Curves
5.2.5.1 The vendor shall provide complete performance curves to encompass the map of operations,
with any limitations indicated thereon.
5.2.5.2 All curves submitted prior to final performance testing shall be marked "PREDICTED". Any
set of curves resulting from a test shall be marked "TESTED".
5.2.5.3 Certified test curves and data shall be submitted within 15 days after testing and shall include
head, power recalculated to the proper specific gravity and efficiency plotted against capacity.
If applicable, viscosity corrections shall be indicated. If NPSHR test is specified, the water
NPSHR curve (drawn upto minimum continuous flow) shall also be included. The curve sheet
shall include the maximum and minimum diameters of the impeller design supplied, the eye
area of the first stage impeller, the identification number of the impeller or impellers and the
pump serial number.
5.2.6 Data Sheet
5.2.6.1 The Vendor shall provide completely filled in data sheets, first for "as purchased" and then for
"as built". This shall be done by the vendor correcting and filling out the data sheets and
submitting copies to the purchaser.
5.2.7 Technical Data Manual/Mechanical Catalogues
5.2.7.1 Technical Data Manual/Mechanical Catalogue is a compilation of "as built" drawings and
data, manufacturing and test records, installation, operating and maintenance instructions.
5.2.7.2 Not later than two weeks after successful completion of all specified tests, the vendor shall
furnish the required number of Technical Data Manual/Mechanical Catalogues for the
equipment, any auxiliaries and instruments that the vendor is providing. The Technical Data
Manual/Mechanical Catalogue shall include the following documents as a minimum:
Page 1905 of 2065

el ENGINEERS
51g-ar tttateg INDIA LIMITED FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
0.51,1,75331 i GOV: Of ■rtl. Undertakig,
i) All drawings and data as listed in the vendor data index & schedule. (For drawings, where
purchaser's approval is required, the final certified drawings shall be attached.)
Sections shall be organised in a manner that data & drawings related to one subject is
grouped together such as Mechanical, Electrical, Instrumentation etc.
ii) All manufacturing, inspection and test data and records.
iii) Installation and Instruction Manual
The vendor shall provide sufficient written instructions, including a cross-reference list of
all drawings, to enable the purchaser to correctly install the equipment and prepare the
equipment for start-up. It shall include any special information required for proper
installation that is not on the drawings, special alignment or grouting procedures, utility
specifications (including quantity) and all installation data. It shall also contain the
following information:
(a) Instructions for erecting, piping, aligning (including the expected thermally
induced shaft centerline shift between normal site ambient temperature position
and that at normal equipment operating temperature).
(b) A description of rigging procedures, including the lifting of the assembled
equipment, and methods of disassembly, repair, adjustment, inspection and
reassembly of the equipment and auxiliaries.
(c) Pre-commissioning/commissioning/functional test procedures and acceptance
criterion.
iv) Operation and Maintenance Manual
This manual shall provide sufficient written instructions and data to enable purchaser to
correctly operate and maintain the equipment ordered. It shall include a section to cover
special instructions for operation at extreme environmental and/or extreme operating
conditions. The following shall be included in this manual:
(a) Instructions covering start-up, normal shutdown, emergency shutdown, operating
limits and routine operational procedures.
(b) A description of equipment construction features and the functioning of
component parts or systems (such as control, lubrication, sealing systems etc.).
(c) Outline and sectional drawings, schematics and illustrative sketches in sufficient
details to identify all parts and clearly show the operation of all equipment and
components and the methods of inspection and repair. Standardised sectional
drawings are acceptable only if they represent the actual construction of the
equipment.
(d) The following maintenance information:
i. Maximum and minimum bearing, labyrinth and seal clearances including
any other clearance between moving and stationary parts of the
equipment affecting proper running and maintenance of the equipment.
ii. Instructions for measuring and adjusting cold clearances, shaft runout,
concentricity etc.
iii. Rotor float allowance.
iv. Interference fits on parts that are required to be removed or replaced for
maintenance of normally consumable spares.
v. Balancing data with permissible tolerances.
vi. Lubricating schedules indicating recommended grades of oil, their
properties, replacement period etc.
vii. Normal maintenance procedure.
viii. Preventive maintenance schedules and criterion for replacement of parts.
ix. Trouble - shooting procedures.
(e) The following reassembly information:
1. Bolting sequence and torque values for all bolts affecting equipment
performance/integrity/safety.
2. Reassembly sequences together with required inspection checks.
Page 1906 of 2065

NGINEERS
$°2111 1Weg ENDIA
N MITED
LI FOR CENTRIFUGAL PUMPS 6-41-0003 Rev. 4
aRrrt7,51 34:11.0 (A Gov( of hata Undettakmq)
3. Adjustment procedures to achieve required positions, clearances, float

and so forth.
4. Detailed procedures for pre-operational checks, including settings and
adjustments.
5. Seals and coupling installation procedures.
6. Parts list indicating cross-sectional drawings of various assemblies and
sub-assemblies, part numbers, materials of construction (ASTM) etc.to
facilitate identification of parts and for procurement of spares.
v) Following information shall also be included in the Technical Data Manual/Mechanical

Catalogue:
1. Storage instructions for storing and preserving the equipment (including driver
and all the auxiliary units) at the plant site before installation of the same.
2. Instructions for preserving the equipment after it has been installed. This is
particularly required in cases where a long time gap is expected between
equipment installation and commissioning.
3. Field performance test procedures and acceptance criterion.
5.2.7.3 Technical Data Manual/Mechanical Catalogue shall be in Hard board folder(s) of size 265 mm
x 315 mm (10Y2" x 12'/2") and shall not be more than 90 mm thickness; it may be of several
volumes and each volume shall have a volume number, index of volumes & index of contents
of that particular volume.
5.2.7.4 Title sheet (Top sheet) of each volume of Technical Data Manual/Mechanical Catalogue shall
contain the contract informations as defined under 5.2.1.2 besides the volume number.
5.2.7.5 In case order contains more than one item, separate dedicated mechanical catalogues shall be
submitted for each item.
5.2.7.6 Two (2) sets of Final / "As Built" drawings & documents shall also be submitted as electronic
files on secondary storage media (i.e. CD-ROM / DVD-ROM disk).
Page 1907 of 2065

lalfMa-e? =1.) ENGINEERS FOR 6-48-0003 Rev. 4
$fa 051-eg INDIA LIMITED
H.O.T. CRANE
10 s IA Goo of Indo Underlakong)
Page 1 of 9
vwatit. tR. *FA-Q- aTrww fe4-41TR-
STANDARD SPECIFICATION FOR

H.O.T. CRANE
3 13/08/10 REVISED AND REISSUED SPC PB MK/DM ND
2 31/07/06 REVISED AND REISSUED PPP AK SMA VJN
1 05/08/99 REVISED AND REISSUED AK SMA NN AS
0 28/12/94 ISSUED AS STANDARD SPECIFICATION AK SSC DKD AS

Standards Standards
Committee Bureau
No by by
Approved by
Page 1908 of 2065

■_7itti ENGINEERS FOR 6-48-0003 Rev. 4
$ig-ar acs INDIA LIMITED H.O.T. CRANE
aitE, el0000 +151,plira11 (A Govt of India Gneleitalong) Page 2 of 9
Abbreviations:
CI Cast Iron
CS Cast Steel
CT •. Cross Travel
HTB •. High Tensile Brass
IS •. Indian Standard
LT Long Travel
QA •. Quality Assurance
SWL •. Safe Working Load
Machinery Equipment Standards Committee
Convenor : Mr. R.K Trivedi
Members Mr P.Bhattacharjee
Mr Sanjay Mazumdar
Mr P.P Pandey
Mr Nalin Kumar
Mr Tarun Kumar
Mr Anukul Mandal
Mr Shishupal Choudhary
Mr R R Srivastava
Mr J S Duggal
Mr KC Paikar
Mr A Natarajan
Mr K V K Naidu (Projects)
Page 1909 of 2065

ENGINEF_RS
NE FOR 6-48-0003 Rev. 4
ogeir vtordg
eletfAZ f013,10.0
INDIA LI
(A Govt Of India undertaiong) H.O.T. CRANE Page 3 of 9
CONTENTS
1.0 GENERAL 4
3.0 TECHNICAL REQUIREMENT 4
5.0 PROTECTION AND PAINTING 8
6.0 PACKAGING AND IDENTIFICATION 9
7.0 SPARE PARTS 9
Copyright EIL — AU rights reserved

Page 1910 of 2065

a
. loi ei ENGINEERS FOR
err 0151-eg
1.2712:1271517M,7717.11
INDIA LIMITED
IA Govt of India Undertaking) H.O.T. CRANE
6-48-0003 Rev. 4
Page 4 of 9
1.0 GENERAL
This specification outlines the minimum requirements under which the manufacturer shall
design, manufacture, test and supply the Hand Operated Overhead Travelling (H.O.T.)
Crane, complete with all accessories.
2.1 This standard is based on the following Indian Standard, and the standards referred therein,
which shall be deemed to be part of this standard:
IS 28 : Phosphor Bronze Ingots and Castings
IS 304 : High Tensile Ingots and Castings
IS 305 : Aluminium Bronze Ingots and Castings
IS:807 : Code of Practice for Design, manufacture, erection and testing

(structural portion) of cranes and hoists.
IS:3177 : Code of Practice for Electric Overhead Travelling Cranes and

Gantry Cranes other than Steel Work Cranes. (As applicable)
IS:3443 : Crane Rail Sections.
IS:3832 : Hand-operated Chain Pulley Block-Specification.
IS: 15560 : Specification for Point hooks with shank up to 160 Tonne.
EIL Std.-7-76-0103 : Instructions to vendor for site performance guarantee

requirements for packaged units.
Latest revision of the above-mentioned standards as on the date of enquiry shall be

applicable. For hazardous area application, following additional standards shall also govern.
2.2 Other international standards may also be acceptable subject to their being equivalent or
superior with prior approval of purchaser.
2.3 For provisions not covered by the above codes & standards, applicable good engineering
practices and norms of the industry shall be applicable.
2.4 National Laws and statutory provisions together with any local bylaws for the state wherein
package is required to be installed shall be complied with.
3.0 TECHNICAL REQUIREMENT
Technical requirements of H.O.T Crane shall be as per Indian Standards referred in clause2.1
above, subject to the following additions, deletions and modifications:
3.1 Addition / Deletion / Modifications to IS-3177: 1999 (Reaffirmed 2006)
i) Clause no..4.2.b (Deletion): Clause deleted.
ii) Clause no..4.2.f (Deletion): The part "such as motors" from sentence deleted.
iii) Clause no. 7.4.8 (Deletion): Clause deleted.
iv) Clause no. 8.1.2 (Modification): Hook latch shall be provided on all hooks.
v) Clause no. 8.3 (Deletion): Clause deleted.
Page 1911 of 2065

ENGINEERS
ei FOR
igejr 051as'' INDIA LIMITED 6-48-0003 Rev. 4
OtriO1 2 2 I 2'MI J‘105.1 (A Govt of India UnOntalong) H.O.T. CRANE Page 5 of 9
vi) Clause no. 8.4 (Deletion): Clause deleted.

vii) Clause no. 8.5 (Deletion): Clause deleted.
viii) Clause no. 8.6.1 (Addition): Wheels for Bridge shall be double flanged with tread and
flange machined accurately to size and flanges tapered and radiused. The wheels shall
be of single piece type. However for cranes working in hazardous area, wheels with
tyre of non ferrous metallurgy as specified in cl. no. 3.6 below shall be provided.
ix) Clause no. 8.6.3 (Modification): Wheel hardness shall not be applicable for hazardous
area Cranes having HTB/Aluminium bronze tyred wheels.
x) Clause no. 8.6.4 (Modification): For Cranes working in hazardous areas, wheels shall
be provided with HTB/Aluminium bronze tyres. The minimum thickness of tyres shall
be 30 mm at the tread.
xi) Clause no. 8.6.6 (Addition): For wheels with HTB/Aluminium bronze tyres, the
minimum tread diameter of the wheel on which the HTB/Aluminium bronze tyre is
shrunk, shall be calculated as per the formula given in IS-3177.
xii) Clause no. 8.6.11 (Addition): The width of wheel tread shall be 40mm and 20mm
greater than the rail head, for Long travel and Cross travel wheels respectively, unless
specified otherwise.
xiii) Clause no. 8.7.1 (Modification): Only anti-friction bearings shall be used. Bearing
enclosure shall be dust tight. All bearing make shall be of SKF/FAG/NTN make only.
Bearing caps/nipples shall be provided with fittings for lubrication.
xiv) Clause 8.7.3 (Deletion): Clause deleted.
xv) Clause 8.8.3 (Deletion): Clause deleted.
xvi) Clause 8.11.2 (Modification): Buffers shall be made from resilient plastic , rubber or
polyurethane.
xvii) Clause 8.12 (Deletion): Clause deleted.
xviii) Clause 9.1 (Deletion): From second paragraph the sentence "suitable guards shall be
provided on the down shop lead side to prevent accidental contact between wire ropes
or hook block or lifting attachments and live conductors" shall be deleted.
xix) Clause 9.2 (Deletion): The term "electrical" deleted.
xx) Clause 9.3 (Deletion): The term "electrical" deleted.
xxi) Clause 11.2.b (Deletion): Clause deleted.
xxii) Clause 11.4.f (Deletion): Clause deleted.
xxiii) Clausel2 to 25 (Section 3) (Deletion): Clause deleted.
xxiv) Clause 26.2 (Deletion): The term "electrical" deleted.
xxv) Clause 26.3.10 to 26.3.17 (Deletion): Clause deleted.
xxvi) Clause 28.1 & 2(Deletion): Clause deleted.
xxvii) Clause 28.3 (Modification): Load test shall be carried out to the extent applicable for
H.O.T crane.
3.2 Addition / Deletion / Modification to IS 807: 2006
i) Clause no. 24.1 (Addition): End carriage shall be made from rolled steel sections
welded together to form a box. The design shall be such that the load is uniformly
distributed. For the attachment of end carriages to the main girders, gusset plates or
diagonal bracings shall be employed to provide lateral strength.
Page 1912 of 2065

a

ENGINEERS FOR
ligarfa41--eg . .-1 1NDIA LIMITED 6-48-0003 Rev. 4
I .1R7f,E2bri• MIORI,31) IA Govt ot India Undertaiong) H.O.T. CRANE Page 6 of 9
End carriages shall be designed so as to enable the track wheels to be withdrawn

readily. Jacking pads shall be provided for jacking up the crane for changing crane
wheels.
ii) Clause no. 24.2 (Addition): Square bar type rail may be provided for LT motion, if
specified in data sheet.
3.3 Addition / Deletion / Modification to IS 3832: 2005 (along with Amendment no. 1,
December 2005)
i) Clause no. 4.2.1 (Modification): Mechanism class 2 shall be considered for design of
chain pulley Block unless otherwise specified in the data sheet.
ii) Clause no. 11.2 (Modification): The chain pulley block shall carry ISI (BIS) stamp.
iii) Clause no.5.1 (Addition): The frame shall be built from steel plates with
bolted/welded construction.
iv) Clause no. 5.2 (Addition): All gears shall be machine cut.
v) Clause no. 5.5 (Addition): Only anti friction bearing shall be used.
vi) Clause no. 5.6 (Modification): The block shall be provided with adequate facilities for
lubrication and same shall be clearly indicated in the maintenance manual.
vii) Clause no. 5.7.1 (Addition): Hooks (both top and bottom) shall be provided with
safety latches to prevent accidental unhooking unless otherwise stated.
viii) Clause no. 5.7.1.2 (Modification): First line to be modified as "Bottom hook shall be
provided with thrust bearing to enable it to rotate freely under load so as to prevent
twisting of the load chain.
ix) Clause no. 5.10.3 (Modification): The length of hand chain shall be such that the
lowest point of the suspended loop shall be 400 mm above operating level.
x) Clause no. 5.11 (Addition): The trolley for the chain pulley block shall be geared type,
fabricated construction, 4 wheeled, driven by hand chain and shall have provision for
mounting the chain pulley block. Trolley shall be designed to suit the suitable joist
size and the hoisting capacity.
3.4 Addition requirements
i) The Crane may be under slung type if specifically asked in data sheet. For under slung
cranes, geared type four wheeled trolley shall be provided. The wheels/runner shall be
suitable for the flange of the I sections used for the girders.
ii) The bridge drive assembly shall consist of reduction gear assemblies with shaft
extensions and couplings to connect the bridge cross shaft extensions to truck wheels.
The travelling motion shall be communicated by endless hand chain wheel to a steel
cross shaft, positively driving one travelling wheel in each end carriage. The cross
shaft shall be suitably supported. The wheels and cross shaft shall have roller/ball
bearings.
iii) Cross traversing motion shall be transmitted through suitable gearing by an endless
hand chain and chain wheel.
3.5 The following material shall be used for construction of various parts of the crane.
SL
Name of Part Material
No.
1. Girder CS weldable quality as per IS 2062 (100% Radiography to
be taken on all Butt welded joints)
2. End carriage CS weldable quality as per IS 2062
Page 1913 of 2065

15digtTre? ENGINEERS FOR 6-48-0003 Rev. 4
laWeg
Mn5retalaclirail
INDIA LIMITED
IA Govt of India undenalongl H.O.T. CRANE Page 7 of 9
SL
Name of Part Material
No.
3. Hand chain wheel for CI grade 25 of IS 210, or fabricated steel or pressed steel
trolley metal.
4. Hand chain for LT Grade L3 as per IS 2429
and Trolley
5. CT trolley CS weldable quality as per IS:2062
6. Rails for LT Crane rails as per IS: 3443 or Square Bar as per IS: 2062,
as applicable.
7. Wheels for LT 55C8 (Old designation:C55Mn75) as per IS:1570 (part
2/sec 1)
8. Gears 45C8 (Old designation :C45) as per IS:1570 (part 2/sec 1)
9. Pinions 50C4 (Old designation:C50 ) as per IS:1570 (part 2/sec 1)
10. Shafts 3008 (Old designation :C30) as per IS:1570 (part 2/sec 1)
11. Axles 45C8 (Old designation :C45) as per IS:1570 (part 2/sec 1)
12. Couplings Forged steel as per IS:1570
13. Suspension pin in the 50C4 (Old designation:C50 ) as per IS:1570 (part 2/sec 1)
trolley
All materials shall be of tested quality and shall conform to the standards as mentioned
above.
3.6 Special Requirements for Hazardous Area Cranes
3.6.1 For H.O.T. Crane to be located in hazardous area, non sparking type design features shall be
incorporated. Basic approach for such application calls for use of non-ferrous material for
one out of two mating parts for a non lubricated mating/striking pair.
3.6.2 The suggested materials for such components are as follows
Part/Component Material of Construction
A Lifting Mechanism
Ratchet wheel, chain guides Solid construction in Aluminium Bronze/ High
Tensile Brass
Hand chain wheel Solid construction of Aluminium Bronze/
Phosphor Bronze/ High Tensile Brass
Load chain wheel Solid construction in Aluminium Bronze/ High
Tensile Brass
Hook (Top & bottom) Bronze coated forged alloy steel/Forged
Stainless Steel
B Trolley Mechanism
Hand chain wheel guides Solid construction in Aluminium Bronze/
Hand chain wheel Solid construction of Aluminium Bronze/
Ungeared and geared wheels Solid construction in Aluminium Bronze/ High
or tyres, as appilcable Tensile Brass
Page 1914 of 2065

ENGINEERS /—•
fge.J1 fdf5teg 0 INDIA LIMITED T-7 FOR 6-48-0003 Rev. 4

1.1t-r ■ kolstE• 3otot.0 (A Govt India UnOettaking) H.O.T. CRANE Page 8 of 9
C LT Mechanism
Tyres of LT wheels Solid construction in Aluminium Bronze/ High
Tensile Brass
3.6.3 Phosphor Bronze, High Tensile Brass and Aluminium Bronze shall conform to IS 28, IS 304
and IS 305 respectively.
4.1 Equipment shall be subjected to stagewise expediting, inspection and testing at vendor's/sub-
vendor's works by purchaser/its authorised inspection agency. Approved Quality Assurance
(QA) plan shall form the basis for equipment inspection.
4.2 Testing at Works
4.2.1 Vendor shall perform tests and inspection necessary to ensure that the material and
workmanship confirm to the requirement of this specification.
4.2.2 Testing at vendors works shall be carried out in accordance with IS:3177 and 3832 and shall
include following tests as minimum:
Full load and 125% overload test for hoist & cross travel motions at works (chain
pulley block shall be separately tested for operational proof as per cl. No. 9.2 of IS
3832).
Deflection Test at Works.
4.2.3 Any or all the tests, at purchaser's option, shall be witnessed by purchaser/its authorised
inspection agency. However, such inspection shall be regarded as check-up and in no way
absolve the vendor of his responsibility.
4.3 Performance Testing and Guarantees
4.3.1 A field performance test shall be conducted by the vendor to demonstrate the performance
of the equipment after commissioning in accordance with test procedure prepared as per EIL
Standard 7-76-0103.
4.3.2 Testing at site shall be carried out in accordance with IS: 3177. Following parameters shall
be guaranteed and demonstrated during the performance testing.
i) SWL of Hoist
ii) Deflection of bridge girder
4.3.3 All parts of the crane shall operate satisfactorily with no undue friction, noise or display of
any other unfavourable characteristics during the performance test.
4.3.4 All equipment and component parts shall be guaranteed by the vendor against defective
material and design for a period as specified in Purchaser's general purchase conditions.
4.3.5 If any defect occurs during the guaranteed period the Vendor shall make all necessary
alterations, repairs and replacement at their own cost.
4.3.6 Necessary instruments for the performance testing shall be arranged by the vendor, and shall
be tested and calibrated before undertaking the performance test. Only test load shall be
provided by purchaser near test site.
5.0 PROTECTION AND PAINTING
5.1 Surface preparation and painting shall be done as defined in Job Specification.
5.1 Stainless steel surfaces, both inside and outside, shall be pickled and passivated.
Page 1915 of 2065

t311 ENGINEERS FOR 6-48-0003 Rev. 4
51gat tateg INDIA LIMITED
omn maw 7:1513WITA) IA Govt of India Undertaking) H.O.T. CRANE Page 9 of 9
5.2 Machined and bearing surfaces shall be protected with varnish or thick coat of grease.
6.0 PACKAGING AND IDENTIFICATION
6.1 All packaging shall be done in such a manner as to reduce the volume. The equipment shall
be dismantled into major components, suitable for shipment and shall be properly packed to
provide adequate protection during shipment. All assemblies shall be properly match marked
for site erection.
6.2 Attachments, spare parts of the equipment and small items shall be packed separately in
wooden-cases. Each item shall be appropriately tagged with identification of main
equipment, item denomination and reference number of the respective assembly drawing.
6.3 Detailed packing list in water-proof envelope shall be inserted in the package together with
equipment.
6.4 Each equipment shall have an identification plate giving salient equipment data, make, year
of manufacture, equipment number, name of manufacturer etc.
6.5 Vendor shall furnish procedure for prolonged storage of supplied equipment/ material at site.
7.0 SPARE PARTS
7.1 Vendor shall submit list of spare parts with recommended quantities and itemised prices for
first two years of operation of the equipment. Proper coding and referencing of spare parts
shall be done so that later identification with appropriate equipment is facilitated.
7.2 Recommended spares and their quantities should take into account related factors of
equipment reliability, effect of equipment downtime upon production or safety, cost of parts
and availability of vendor's service facilities around the proposed location of equipment.
7.3 Vendor shall also submit a list of commissioning spares with quantities. The commissioning
spares shall be sufficient for trouble free commissioning of the system at site. Any
commissioning spares required during commissioning, over and above, the commissioning
spares supplied, shall be made available by the vendor without any cost and time implication
to purchaser. If for any reason, during commissioning, vendor needs to utilise spares from 2
years' operation spares, the same shall be replenished by vendor within a reasonable time
without any cost implication to purchaser. Any unused commissioning spares shall be handed
over to owner.
Page 1916 of 2065

COSTRUCTIONSUPERVISION & Document No.
MANAGEMENT BY PACKAGE CONTRACTOR
BOO1-00-000-19-41-0001
2nd RAW WATER INTAKE PUMP HOUSE AND
PIPELINE PROJECT AT DAMANJODI, Rev 0
NALCO Page 1 of 23
CONSTRUCTION SUPERVISION AND

MANAGEMENT
PROJECT : 2nd RAW WATER INTAKE PUMP HOUSE

& PIPELINE PROJECT
OWNER : M/s NALCO, DAMANJODI
PMC : ENGINEERS INDIA LIMITED
JOB NO. : B001
0 19.12.2016 ISSUED FOR BIDS PKR RK GM(C)

Rev.
No
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B001-00-000-19-41-0001
NALCO Page 2 of 23
TABLE OF CONTENTS
____________________________________________________________________
CLAUSE NO. TITLE PAGE NO.
_____________________________________________________________________
1.0 General 3
2.0 Execution on works 5
3.0 Execution Plans 7
4.0 Temporary Facilities 8
5.0 Construction Planning, Scheduling, Monitoring 9
& Reporting
6.0 Quality assurance and Quality Control (QA/QC) 9
7.0 Warehouse Management & Material Control 9
8.0 Field Engineering 10
9.0 Field Tendering 10
10.0 Field Purchase 10
11.0 Health, Safety and Environment (HSE) Management 11
12.0 House Keeping 11
13.0 Industrial Labour Relations 11
14.0 Construction Equipments 12
15.0 Construction Manpower 13
16.0 Interface with other CONTRACTORS 14
17.0 Colour Coding of Piping Material 14
APPENDIX - A QUALITY ASSURRANCE AND QUALITY CONTROL MANAGEMENT DURING

CONSTRUCTION
APPENDIX - B HEALTH, SAFETY AND ENVIRONMENT (HSE) MANAGEMENT DURING

CONSTRUCTION
List of Attachments:
Attachment-I Inspection & Test Plans (ITPs) for Cross country 6-82-1900 Rev.2
pipeline works
Attachment-II Standard Specification for Colour Coding of Piping 6-82-0003, Rev.2
Materials
Attachment-III Observation on Quality Aspect B001-00-000-19-41-0001 F1
Attachment-IV Observation on Safety Aspect B001-00-000-19-41-0001 F2
Copyrights EIL – All rights reserved
Page 1918 of 2065

B001-00-000-19-41-0001
NALCO Page 3 of 23
1.0 GENERAL
1.1 The Contractor shall construct Pipeline Facilities in accordance with the requirements of the
Technical Standards/ Specifications, with proven/good engineering practices and
procedures. Such Facilities shall be safe, reliable and suitable for their intended purpose.
1.2 The Contractor shall provide all supervision, labour, construction equipments, tools &
tackles, materials and consumables, temporary facilities, etc. and render all support
services necessary for the construction. Provision of construction power and water shall be
as per Special Conditions of Contract (SCC)/ General Conditions of Contract (GCC).
1.3 The Contractor shall plan, execute, manage and control all the construction activities for the
Facilities forming a part of this contract.
1.4 The Contractor shall arrange insurance coverage for all the personnel engaged by him for
the work as per statutory rules, regulations and local laws.
1.5 The Contractor shall insure all the materials and equipments against fire, flood, earthquake,
theft, etc. as per SCC/ GCC brought for the job till the Plant/Facilities are commissioned
and handed over to the OWNER.
1.6 The Contractor to ensure mechanizing the construction activities to the maximum.
1.7 The Contractor is deemed to have full knowledge of the applicable laws and regulations,
conditions of labour, local conditions, the SITE conditions, environmental aspects and shall
comply with the requirements thereof.
1.8 The Contractor is required to organize and mobilize Construction Management Services in
a systematic and sequential manner to ensure that the Plant installation is carried out in
accordance with the approved engineering drawings, specifications, standards, QA/QC
procedures etc. and its mechanical completion is achieved within targeted time schedule.
Construction Management and Supervision is to be carried out by the Contractor himself by
deploying persons on his rolls and this activity is not to be sub-contracted in any case.
For this purpose, the Contractor shall deploy a Construction Management Team headed by
a qualified & experienced person at site. The Construction Management team shall include
engineers/ specialists in QA/QC, Project Control (Planning, scheduling, monitoring),
contracts, construction supervision, welding & NDT, progress measurement/billing, safety,
warehousing, purchasing etc. Key personnel including the Head should have sufficient
experience and should not be changed without concurrence from Owner/PMC.
Curriculum vitae of all key Construction Personnel shall be submitted to Owner/PMC for
approval before deployment. Owner/PMC reserve the right to interview these personnel
before their mobilization.
1.9 The Contractor shall ensure delegation of adequate and sufficient powers (including
financial) to the Head of his Construction Team for effective and smooth functioning of the
construction management. HO support shall be provided to the Head of Construction Team
at site during construction on all matters of project execution including the following:
- Field engineering.
- Vendor specialists required during construction.
- Rectification/replacement of defective supplies, if any, noticed during construction.
- Expediting replacement of imported items found short/damaged.
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B001-00-000-19-41-0001
NALCO Page 4 of 23
- Required documentation for the material inspection at site

- Compilation and submission of Field Inspection documents in requisite copies as
per contract
- Documentation to meet statutory requirements.
1.10 The construction supervision, co-ordination and management activities shall be carried out
by the Contractor in accordance with the construction procedures developed and submitted
by the Contractor and approved by Owner/PMC. Contractor shall prepare construction
schedules within the framework of overall contract schedule and submit to Owner/PMC for
approval. Contractor shall plan, execute, monitor and control construction activities as per
the approved construction schedule.
Contractor shall depute a project team at site during construction phase under a project
coordinator for providing above-mentioned support to the Head of Construction Team.
1.11 Most of the civil construction materials like cement, reinforcement bars, aggregates, bricks,
and structural steel are available locally. Cement/rebars/structural materials shall be
procured from approved suppliers only. The Contractor shall establish and maintain a
material testing laboratory for carrying on field tests during execution of contracts under
different disciplines by sub-contractor’s, at no extra cost to OWNER. The entire test
equipments deployed shall have valid test/calibration certificates traceable to relevant
national/ international standards. Such material tests, for which testing facility at site is not
established, shall be carried out by Contractor at testing laboratories approved by Owner/
PMC at no extra cost. Contractor shall maintain the test records and the same shall be
made available for review/ inspection of Owner/ PMC. Further, Owner/PMC reserves the
right to witness/ inspect testing at the laboratory at no extra cost to Owner/PMC.
1.12 All electrodes/filler wires and other consumables like argon/oxygen cylinders etc shall be
arranged by main contractor from the approved suppliers/manufacturers in order to
exercise proper control on the fabrication of works.
1.13 Construction supervision and management functions to be performed by the Contractor shall
include the following as key functions for effective execution, monitoring and control:
- Planning, scheduling, monitoring & reporting.

- Construction supervision, discipline wise.
- Quality assurance and quality control, discipline wise.
- Perform and Control of Welding & NDT activities
- Procurement and expedition of bought out items
- Shipping, custom clearances, inland transportation
- Warehouse management and material control including Dump sites.
- Field engineering/Purchase.
- Health, Safety and Environment (HSE) Management
- Statutory clearances and enforcement of statutory rules/ regulations and Labour
Laws
- Personnel/administration/Industrial Relations
- Finance and Accounts
- Security
1.14 Whenever the hookup is being taken with the facilities of operating Fire water network,
efforts shall be made by the Contractor to complete the work and restore the system
expeditiously. If required the work shall be continued round the clock.
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NALCO Page 5 of 23
1.15 Any modification, dismantling, re-routing etc. of the permanent / temporary facilities
belonging to Owner, private parties, public / government facilities including provision of
ramps at bridges to enable the ODC movement are in Contractor’s scope.
1.16 Restoration of the all the modified, dismantled facilities to original condition is in the scope
of the Contractor. Contractor shall obtain no claim certificates from such parties.
2.0 EXECUTION OF WORKS
The Contractor’s work during construction shall include but not be limited to the following:
i) Prepare and submit all the Plans, Procedures and documents to Owner/PMC as
specified in the contract.
ii) Establish requisite site organization staffed by competent and experienced
specialists, supervisors and inspectors.
iii) Supervise, Coordinate and manage the activities performed at site by him and by
his sub-contractors for execution of work and render all technical/specialist services.
v) Plan and schedule the construction work monitor and take timely corrective action
when required to adhere to approved execution schedule.
vi) Plan, allocate and mobilize required resources, manpower, and construction
equipment/materials, commensurate with construction plan/schedule.
vii) Provide all temporary facilities required for Construction including Power,DG sets,
Construction water, drinking water, lighting, office space, dump sites, camp facilities,
electronic transmission of drawings & documents, printing facilities, rest rooms,
crèches, first-aid, fire protection system, toilets, canteen facilities, labour hutments
and transport facilities for the workers and staff.
viii) Prepare & implement approved Quality Control and Quality Assurance plan.
ix) Prepare & implement approved Health, Safety & Environment (HSE) plan.
x) Report beforehand and take approval from Owner/PMC regarding use of any
equipment and/or material not conforming to the contract, drawings and
specifications.
xi) Execute and supervise all additional works and modification works as required or
suggested by Owner/PMC as a part of approved change orders.
xii) Erect and install the equipments and materials according to the approved
specifications and procedures.
xiii) Establish required Field Inspection and Testing Laboratories at site to carryout tests
as specified in the standards/specifications of the contract.
xiv) Organize and obtain all applicable clearances/approvals from statutory
bodies/authorities, as required by the laws of land for the work executed at site by
the Contractor under the contract.
xv) Obtain approval of Owner/ PMC for Welding Procedure Specifications (WPS)/
Procedure Qualification Records (PQR) as required. Carry out inspection, non-
destructive tests and analyze and certify acceptability of all welds and materials in
accordance with specified Technical Standards. Carry out inspection and testing of
incoming materials as per agreed procedures.
xvi) Organize and conduct Weekly Project Review meeting related to site construction
activities.
xviii) Provide daily work progress reports and detailed weekly and monthly progress
reports summarizing percentage completion of the work including status of
drawings, materials and effects on approved schedule, areas of concern and
corrective actions required thereof. Contractor shall also identify any foreseeable
delays in any aspect of the work and take corrective actions to eliminate/minimize
the effect on Overall Completion Schedule. All progress shall be quantified.
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B001-00-000-19-41-0001
NALCO Page 6 of 23
xix) Take photographs and video recording of Project Construction Progress on regular
basis and submit the same to Owner/PMC on monthly basis along with the Monthly
Progress Report.
xx) Prepare and submit records of all site meetings and any other related documents to
all parties concerned within two (2) days of the meeting.
xxi) Prepare and submit safety and labour relation procedures in line with all applicable
codes, regulations and Owner’s requirements.
xxii) Supervise and monitor all safety and labour relation functions as per agreed
procedures and applicable laws of the land and report to Owner immediately for any
violations and injuries.
xxiii) If any part of the facilities is completed and is under operation, while other parts of
the facilities are under construction, or work is to be carried in existing running
Plant, it is essential that rigid safety rules be prepared and maintained for all works
in accordance with the requirements of Owner/PMC.
xxiv) Maintaining all the records generated during project execution up-to-date and made
available to Owner/PMC whenever requested. These records shall be handed over
to Owner on completion of the work at no extra cost to Owner.
xxv) Carryout warehouse management and material control in accordance with approved
procedure.
xxvii) Take all necessary precautions and required actions to protect construction work
and materials from damage by local weather conditions and ongoing construction
activities in the vicinity, theft and pilferage etc. till handing over of the plant to
Owner.
xxviii) Take insurance policies for materials in transit and storage-cum-erection risk and
other insurance covers required for men and materials at site as per SCC/ GCC in
consultation with Owner.
xxviii) Undertake housekeeping including sweeping, clean up to maintain cleanliness,
sanitation, removing excess materials, temporary facilities, scaffolding, etc. on
regular basis till hand over to Owner.
xxix) Prepare and submit to Owner/PMC the following daily reports for construction
activities covering the following:
a. Weather
b. Manpower deployment category wise
c. Construction Equipments
d. Work Progress
xxx) Ensure the control of all works with regard to its impact on the surrounding
environment.
xxxi) Ensure all hot works are performed outside hazardous areas and in compliance
with Owner’s Safety Permit System requirements wherever applicable.
xxxii) Arrange and coordinate the visits of supplier’s representatives/specialists at site.
xxxiii) All material handling equipment, tools, tackles, hoisting and lifting equipments/
machineries should be subjected to required load test initially and then periodically,
to ensure safe/stable operation.
xxxiv) Organize field engineering work, wherever required and ensure timely resolution of
interface problems / site constraints in consultation with Owner/PMC.
xxxv) Prepare and certify material reconciliation statement on completion of work to
enable Owner to take over the surplus materials, as applicable.
xxxvi) Organize the codification and handing over of surplus materials (as applicable) and
spares/ tools and tackles to the Owner on completion of work.
xxxvii) Provide weekly/daily activity plan for site inspection.
xxxviii) Develop a phased mechanical completion program to facilitate sequential Pre-
commissioning/Commissioning activities in a logical manner to meet the Overall
Project Schedule.
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xxxix) Remove / demolish all temporary structures/ establishments/ facilities created by the
Contractor / his sub-contractors during the execution of the work and restore the site
to its original condition.
xl) Estimate monthly consumption of following utilities (if provided by Owner):
a. Industrial water
b. Drinking water
c. Electricity
xli) Carry out tightening of flange joints by using hydraulic tensioner/ torque wrench as
per specifications. Contractor shall ensure that stud bolts are ordered extra long to
facilitate tensioning.
xlii) Develop colour coding scheme (to avoid mix up during fabrication and erection) for
piping material and get it approved from Owner/PMC.
xliii) Organize safety induction programme for their manpower before deployment on
work and at regular intervals thereafter.
xliv) Carryout survey of pipeline in ROU, scour levels at sea bed areas etc, in order to
maintain minimum depth requirements for anti-buoyancy measures.
3.0 EXECUTION PLANS
Contractor shall submit detailed construction execution/methodology for Pipeline laying

work as per the scope of the work.
After award of the works, the contractor shall submit Construction Execution Plan to
Owner/PMC for review/approval during kick-off meeting. The Plan shall detail the
execution methodology of the Contractor during construction phase of the Project covering
following aspects as minimum –
3.1 Construction Management Plan
Contractor shall submit Construction Management Plan to Owner/PMC for approval during
kick-off meeting. The Plan shall detail the management methodology to be applied during
the construction phase of the Project, along with a list of procedures to be utilized in
undertaking the work.
All reference procedures and detail work plans referred to in this document must be
submitted for review and approval by Owner/PMC at least (4) four weeks in advance of
actual commencement of the activity concerned.
3.2 Construction Execution Plan:
It shall include
3.2.1 Contractor’s manpower and man-hour histogram by major section and discipline and their
manpower deployment schedule on monthly basis.
3.2.2 Major equipment mobilization plan on monthly basis with short description. Contractor to
develop this plan with due consideration to maximize the mechanization of construction
activities.
Other plans of Contractor and procedures to be submitted at least four (4) weeks prior to
start of respective activity at site include the following as a minimum:
a. Develop/ prepare construction/erection plan/job procedures and submit to Owner/ PMC

for approval
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b. Execution Methodology /Plan for Laying of pipeline, crossings & hookup with HDD as
applicable.
c. Schedule for opening of ROU
d. WPS/PQR submission schedule
e. Temporary facilities, etc
f. Piling plan (if applicable)
g. Barricading Plan
h. Scaffolding plan
i. Excavation and underground work plan
j. Pre-fabrication plan
k. Other activity plans e.g. piping, equipment and structural steel erection plan
l. Monsoon counter measures and preparation
m. Emergency Evacuation Procedure
n. Storm Management Plan
o. Schemes to carry out works in inclement weather
Contractor shall ensure that lay down area given to him shall be utilized optimally.
3.3 Sub-Contracting Plan
If Contractor proposes to engage sub-contractor(s) for the execution of some of the

activities at site, a preliminary sub-contracting plan along with the identified scope of
work for each sub-contract shall be furnished by the Contractor to the Owner/PMC at the
time of bid submission. However, the credentials of proposed Sub-contractor(s)’s shall be
submitted by the Contractor on award of work, which shall be evaluated by Owner/PMC at
Site for acceptance. Contractor shall not be permitted to change the sub- Contractor under
any circumstances without prior approval of Owner/PMC. Non-compliance of the above
shall be strictly dealt within relevant provision(s) of the contract. However, main contractor
shall be responsible for overall implementation of works being done by sub-contractor by
deploying competent engineers of respective areas/disciplines.
The sub-contracting plan shall cover
i) Sub-contracting philosophy
ii) List and scope of work of each subcontract
iii) Subcontract administration plan
iv) Organization chart of each sub-contractor.
The list and major scope of each subcontract shall not be changed from those of the
Contractor’s plan unless specially approved by Owner.
4.0 TEMPORARY FACILITIES
The Contractor shall arrange the following temporary facilities at the minimum (including for
his sub-contractors also):
1) Exact location of temporary work area, access and general layout inside the
operational area.
2) Planning and description of the temporary facilities such as:
a. Identification of borrow earth area (if required)/excess earth dumping yards

b. Dump site for storage of line pipes, as applicable
c. Site office and Fabrication yards, Open storage area and Warehouse
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B001-00-000-19-41-0001
NALCO Page 9 of 23
d. Covered areas for maintaining fabrication works in rainy season(contractor

to indicate size)
e. Miscellaneous workshops including maintenance area for construction
equipments.
f. Temporary roads including access road to Plant, fencing and gates
g. Security, watch & ward, security gates, etc.
h. Utility supply systems viz. Construction power with DG Sets, construction
water, drinking water etc.
i. Area lighting
j. Fire fighting equipments
k. Drainage and Sanitation
l. Camp Accommodation
m. Field Testing Laboratory
n. Radiography Source Pit as per BARC Guidelines
o. Film processing and viewing labs
p. Communication facilities viz. Telephone, Fax, E-mail, electronic transmission
of drawings./ documents, etc.
q. Hutments, transport, Pantry and Canteen for staff and workers. Hutments/
labour colony shall not be allowed inside the refinery area.
r. Vehicle parking area including construction equipments.
s. First aid arrangement/ medical and health care facilities
t. Gate pass for workmen/officials/ vehicles as per Owner’s security system.
u. Work Permits as per Owner’s prevailing system.
Contractor shall develop the temporary facilities layout for approval of Owner/PMC.
5.0 CONSTRUCTION PLANNING, SCHEDULING, MONITORING & REPORTING
The Contractor shall be responsible for construction Planning, Scheduling, Monitoring and
Reporting activities at site in line with the overall master schedule and details stipulated
elsewhere in the bid document.
6.0 QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC)
The Contractor shall be responsible for ensuring quality of construction (including materials)
carried out by him/his approved sub-contractors in accordance with the requirements given
in Appendix-A for Quality Assurance / Quality Control (QA/QC) during construction
including all documents referred therein.
7.0 WAREHOUSE MANAGEMENT & MATERIAL CONTROL
The Contractor shall construct/ build warehousing facilities (both covered and open)
appropriate for storing materials required for the job. The facilities shall include proper
lighting, fire protection system, office/rest rooms/toilets for warehouse personnel.
The Contractor shall obtain all statutory approvals from concerned authorities for all
warehouse equipment, instruments etc. The Contractor shall comply with statutory
regulations for storage of any material covered under Explosives rules.
The Contractor shall be responsible for carrying out the Warehouse Management and
Material Control in accordance with the approved warehousing procedure and material
control procedure, which is to be submitted by the Contractor during kick-off meeting. The
activities shall include but not limited to:
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B001-00-000-19-41-0001
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- Transport Liaison, both for imported materials as well as materials procured

indigenously, from the time of dispatch up to receipt at site.
- Transportation Plan (i) from source to site (ii) site to erection location.
- Filing of insurance Claims and follow up.
- Documentation for control and accounting of materials.
- Generation and upkeep of Traceability Records for materials.
- Materials Control & Issue.
- Inventory Checks.
- Field Requisition and Purchase.
- Spare & Tools including handing over of mandatory Spares/Tools to the Owner as
per the terms of the contract.
- Material Appropriation and Handing Over of all items to Owner with Owner’s
codification system.
- Security.
- Taking up with suppliers on short supplied items and placing replacement orders for
lost/damaged items.
- Intimating short/lost/damaged items received at site and further replacement action,
as applicable.
- Handing over of surplus materials to Owner as per the contractual provisions
Contractor shall generate and issue following reports:
- Fortnightly statement of consignments in transit.

- Daily report of material received.
- Material receipt status and inventory status w.r.t. material delivery schedule
- Material Inspection Report with respect to materials received at site
- Report on Over/Short/Reject/Damage (OSRD) receipts against each consignment
on receipt at warehouse.
- Weekly status of consignments, Material Receipt Report (MRRs)
- Monthly status of field purchase.
- Monthly status of over, short, reject & damage (OSRD) settlement.
- Monthly status of piping material MTO V/s Actual receipt.
- Log Register of Rotating Equipments maintenance
- Daily Stock Position of Cement
- Any other report as desired by Owner/PMC.
8.0 FIELD ENGINEERING
Contractor shall be responsible for controlling and issue of technical drawings and
documents, Alignment sheets, crossing drawings, preparation of field sketches, field
modifications, checking/preparation of as built drawings, etc. Contractor should have
adequate facilities for incorporating field changes, preparation of As-built drawings, Printing
machines and Drawing & Document Control System.
9.0 FIELD TENDERING
Contractor shall be responsible for carrying out field tendering activities, as required from
the site itself.
10.0 FIELD PURCHASE
Contractor shall be responsible for carrying out field purchase activities, as required.
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Field Purchase items are restricted to those required for running and maintenance of the
field offices, items required to expedite construction work and items found short, missing or
damaged against the main order when received at the site. Any material purchased from
field for usage in the plant should have proper inspection certificate and should be
purchased from Owner/PMC approved suppliers. If required by Owner/ PMC, check testing
of the material samples selected by Owner/PMC shall be carried out by Contractor without
any extra commercial implication.
11.0 HEALTH, SAFETY AND ENVIRONMENT (HSE) MANAGEMENT
The Contractor shall be responsible for Health, Safety and Environment (HSE)
Management at construction site for the construction activities to be carried out by the
him/his approved sub-contractors in accordance with the requirements mentioned in
Appendix-B for Health, Safety and Environment Management during construction.
12.0 HOUSE KEEPING
It is the responsibility of the Contractor to maintain general cleanliness and proper

housekeeping at work site. Contractor shall organize disposal of excavated earth /garbage/
rubbish/scrap, etc. on day to day basis to identified disposal areas/safe areas and forward
daily report for the same indicating the details of men and machinery deployed for the
purpose; if asked by Owner/PMC.
Wastage and serviceable/ unserviceable scrap generated during dismantling and regular
works shall be segregated and dumped in designated locations in consultation with
Owner/PMC. Earth and landfill materials shall be dumped at locations identified by
Owner/PMC, otherwise outside the Project Site and the required fees charged by the local
authorities shall be borne by the Contractor without any extra cost to Owner.
13.0 INDUSTRIAL LABOUR RELATIONS
Contractor shall be responsible for industrial relation functions and implementation of labour
laws at site. Contractor’s staff shall be suitably trained and experienced in Labour Relation
functions so as to ensure a good relationship with labour and to prevent the occurrence of
industrial disputes resulting in subsequent delays or work stoppages. In particular,
Contractor shall maintain close liaison with Owner/PMC.
Contractor shall maintain proper liaison with Statutory Authorities and local bodies and shall
be responsible to implement and observe all statutory laws at site. Contractor must have in
his staff; a well experienced Labour Relation Officer.
Contractor shall maintain the records of wages paid in a wage register, PF, Gratuity,
contribution towards building of construction works act etc. as per statutory regulations.
Contractor shall report immediately to Owner/PMC any problems including labour disputes,
fight, and work stoppages. A written report shall be submitted to Owner/PMC within 24
hours of the incident.
Contractor must submit a Labour Relation Plan including their sub-contractor(s) prior to the
start of the work/within one month of award of the contract, whichever is earlier, mentioning
as a minimum:
a. A detailed estimate of the number of labour, indirect and direct, sorted by craft.
b. Outline recruiting plans for all manpower requirements.
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c. Identify personnel involved with labour relations and outline procedures to mitigate
labour disputes & problems.
d. Labour welfare plan.
Contractor shall hold labour relations meeting twice a month with their work force as well as
a separate meeting with the Owner.
14.0 CONSTRUCTION EQUIPMENTS
The Contractor is required to organize and mobilize the construction equipments and other
tools/tackles in a sequential manner and ensure that plant/ Pipeline installation is carried
out in a mechanized manner to the extent possible and its mechanical completion is
achieved within targeted time schedule. Contractor shall ensure deployment of the key
construction equipments as per Annexure to SCC.
Contractor shall confirm that the above equipments in requisite no are available with him in
good working condition and shall be timely mobilized on this project site. Contractor has the
option to hire some of these equipment from hiring agencies also. Owner/EIL reserve the
right to physically check & verify the availability of these equipments prior to award of the
work. Contractor shall replace any defective/damaged equipments promptly to complete the
work without time & cost implication to the Owner/EIL.
For the purpose of Pipeline laying, the Contractor shall deploy a Pipeline team comprising
of civil/mechanical and electrical engineers and foreman’s for ROW clearing and Grading,
Stringing, welding, trenching, lowering, tie-in and backfilling etc., reporting to Spread in-
charge. Spread in charge should be well conversant with methods and techniques of
pipeline laying works.
Contractor shall prepare erection schedule in line with the overall project schedule in
phased manner with erection schemes of various equipments, vessels and submit to
Owner/PMC for approval, Monitoring and control of erection schedule and erection
activities shall be carried out by the Contractor as per the approved construction
procedures.
For efficient working and maintenance of construction aids, Contractor shall establish and
maintain crane yard / workshop equipped with regular maintenance facilities for various
construction aids for carrying out routine field maintenance during performance of the
contract. Temporary approach road and hard stands, wherever required for the movement
of the Cranes and other vehicles for equipment erection and transportation of material shall
be properly planned and made by the Contractor. Weekly/fortnightly maintenance shall be
planned in such a way that the same does not hamper the erection schedule.
During performances of the work, Contractor must ensure that structures, materials and
equipments are adequately braced with Guys, Struts or any other means as deemed fit &
approved by Owner/PMC. Such means shall be supplied and installed by the Contractors
as required till the erection works is satisfactorily completed. Such guys, shoring, bracing,
strutting, planking supports etc. shall not interfere with the work of other agencies and shall
not damage or cause distortion to works executed by other agencies. All lifting tools,
tackles and cranes shall be tested periodically by statutory/ competent authorities for their
load carrying capacity. Such relevant valid/test certificates shall be submitted to
Owner/PMC for review before actual use of the tools, tackles and cranes.
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Contractor shall submit the construction equipment deployment schedule in the Performa
attached elsewhere in the bid. Daily construction equipment deployment report will also be
submitted by the Contractor to Owner/PMC along with DPR.
Contractor shall ensure the timely augmentation of the men, equipments and machinery
depending upon the exigencies of the work to meet the overall project schedule and as per
instructions of Owner/PMC.
15.0 CONSTRUCTION MANPOWER
The CONTRACTOR is required to organize and mobilize construction staff/ manpower in a

sequential manner (Refer Annexure to SCC for List of key construction manpower to be
deployed by the contractor) to ensure that the work is carried out in accordance with the
construction schedule. Mobilization of construction staff should be such that the progress
achieved in phased manner should match with the overall Project Schedule. The key
construction Personnel identified shall be well qualified & having adequate relevant
experience, as specified in document no 7-82-0003. The other man power shall also be
qualified and experienced with their assigned work.
For this purpose, the Contractor shall clearly indicate in his construction methodology
whether work shall be done departmentally or by engaging sub-contractor or the combina-
tion of both. Contractor shall prepare detailed methodology for the work to be carried out
departmentally as well as through sub-contractors clearly, defining the scope and re-
sponsibility of Contractor and his sub-contractors.
The works of all sub-contractors shall be managed by the construction staff of the main
Contractor who shall perform the duties of construction management and shall administer,
coordinate, and inspect the works of the sub-contractor(s) and be responsible for the
Quality and timely completion of respective works. The Contractor shall establish the
pre-requisites for successful completion of sub-contractor (s) work. However, by deploying
the sub-contractor (s), as approved by Owner/PMC for any discipline, does not absolve the
Contractor of his total responsibility under the subject contract.
The Contractor must note that in case of any sub-contractors' failure to execute the works
as per standards/specifications/drawings and/or negligence & disobedience in carrying out
any order or instruction of Owner/PMC, the same shall be viewed very seriously and any
action as deemed fit in accordance with provision(s) of the contract shall be taken by
Owner/PMC.
Contractor must submit the construction manpower deployment schedule. Daily

construction manpower deployment report shall also be submitted by the Contractor to
Owner/PMC on approved format. Any additional manpower of any category required to be
deployed during the actual execution of the work to meet the Project time schedule and as
instructed by Owner/PMC, shall be mobilized by the Contractor within a reasonable time.
Mobilization of such additional manpower by the Contractor shall not entitle him for any
additional compensation at all.
All construction supervision, coordination and management activities shall be carried out by
the Contractor in accordance with the construction procedures approved by Owner/PMC.
Contractor shall prepare construction schedules based on the Overall Project Schedule of
the PLANT and submit the same to Owner/PMC for approval. Monitoring and control of the
construction activities shall be carried out as per the approved construction schedule &
procedures.
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During the execution of works at site, if the Contractor engages sub-contractor (s) for
execution of works at site as per approval obtained from Owner/PMC in line with contract
provision(s) and in the event sub-contractor complains in writing to the OWNER with regard
to the non-payment of their dues from the Contractor for the works executed by them
(excluding final payments and payments due after termination of sub-contractors' services
by the main Contractor), Owner/PMC reserves the right to make such payment to the sub-
contractors directly based on approved measurements with due notice to the Contractor.
Owner/PMC shall release such payments to sub-contractor at the cost and risk of the
Contractor in order to ensure smooth execution of work at site. All such payments made by
Owner/PMC to the sub-contractor(s) shall be deducted from the running account bills or
any other payments due to the Contractor.
The above provisions shall also be applicable in case of construction materials procured at
site by the Contractor from the suppliers.
16.0 INTERFACE WITH OTHER CONTRACTORS
Contractor shall ensure that his interface with other Contractors is smooth and cordial. In
case of any dispute, Owner/PMC decision shall be binding.
Owner/PMC may arrange weekly/fortnightly/monthly interface meetings. The Contractor
shall depute concerned personnel to attend these meetings.
Generally, the following interfaces may be present:
• Contractor shall allow movement of persons/ material/ equipment/ vehicles

belonging to other Contractors or Owner/PMC through the roads constructed by
him.
• Contractor shall resolve issues raised by land owners (except Land compensation
settled by Owner) during the period from ROU handing over to ROU restoration and
till obtaining No Objection Certificate from the concerned land owners.
• Contractor shall coordinate with ‘neighboring’ contractors for maintaining
elevations/levels of various interconnecting services.
• Contractor shall not dump his earth, scrap or any material in other Contractors’
area. He shall cooperate with Owner/PMC in maintaining good housekeeping
throughout the complex.
• Contractor shall ensure proper drainage and no water logging in his area/other
areas.
• If requested by the Owner/PMC, Contractor shall allow testing of materials of other
Contractors in his laboratory, in case of emergency.
• Contractor shall clearly define in the interface meeting with other contractors their
erection / construction interface at their Battery limits.
17.0 COLOUR CODING OF PIPING MATERIAL
Specification for colour coding of Stored Piping Material No. 6-82-0003 shall be uniformly
followed for the entire facilities.
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APPENDIX - A
QUALITY ASSURANCE
AND
QUALITY CONTROL
DURING CONSTRUCTION PHASE
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TABLE OF CONTENTS
_____________________________________________________________________
CLAUSE NO. TITLE PAGE NO.
____________________________________________________________________________
1.0 PURPOSE 17
2.0 SCOPE 17
3.0 RESPONSIBILITY 17
4.0 METHODOLOGY 17
4.1 PROCUREMENT OF MATERIALS REQUIRED 17

FOR THE CONSTRUCTION WORKS
4.2 EXECUTION OF WORKS 18
4.3 DOCUMENTATION 19
4.4 QA/ QC AUDITS 20
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1.0 PURPOSE
The purpose of this document is for uniform understanding and implementation of quality
management and quality control by contractor during construction to produce the product
by combination of various activities and role of Owner/EIL in verification. The management
of quality shall also cover co-ordination, review, approval audit and proper documentation
of the works performed. Indicative Inspection and Test Plans (ITPs) are forming part of this
document as attachments.
2.0 SCOPE
This document shall be applicable to all construction works to be executed by Contractor’s.
3.0 RESPONSIBILITY
It is Contractor’s prime responsibility to arrange/produce the product conforming to contract

specifications and inspect all equipment, materials and works at various stages of
execution as per the approved QA Plans. In addition, they have to coordinate all efforts in
this regard directly with the Owner/ PMC and other involved agencies to give adequate
confidence that the activities are performed as per agreed ITPs and necessary
documentation are available. Verification by Owner/PMC or his representative at any stage
shall not relieve Contractor of his responsibility towards quality of the product.
The Contractor shall comply with all statutory rules & regulations in force during execution
of work and interface with such authorities as required.
4.0 METHODOLOGY
The management of construction quality control is divided into the following categories:-
(1) Procurement of materials required for the construction work.

(2) Execution of work
(3) QA/QC Audits
4.1 PROCUREMENT OF MATERIALS REQUIRED FOR THE CONSTRUCTION WORK
The Contractor shall develop list(s) defining the items to be procured along with proposed
Vendors for approval of the Owner/PMC. The list shall comprise of all items except
vessels, equipments, pumps, electrical/ instrumentation panels etc. which may be available
directly ready for installation or requiring small fabrication as per requirement. The vendor
list shall be in line with the contract document. In case, no vendor list exists in the contract
for a particular item, the Contractor shall propose a list of Vendors to Owner/PMC.
Contractor has to satisfy himself with the capability of the vendor to deliver the product in
time with quality before proposing him as a prospective vendor. Contractor shall submit
the QA/QC plans for all major items and carry out their procurement in line with the
approved plans. The categorization plan shall be submitted by contractor in line with the
contract requirement. The Contractor can either provide his own adequate qualified staff for
inspection or employ a separate third- party inspection agency with prior approval to carry
out these functions. Involvement of Owner/PMC in the quality control plan, if required, shall
be defined during approval of the same.
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4.2 EXECUTION OF WORK
(i) The QA plans for execution shall be developed by the Contractor. Owner/ PMC’s
approval for the same shall be taken well before start of the work. The final
Inspection & Test Plans (ITPs), based on the indicative ITPs enclosed in document
Nos. 6-82-1900 shall be developed by the Contractor as per contract specifications
for approval by Owner/ PMC. For the activities which are identified as Witness or
Hold Point, specific inspection call shall be raised by the Contractor with Owner/
PMC in the requisite format well in advance.
The indicative ITPs and Formats enclosed in the feed package are for guidance to
the Contractor and may not cover some of the activities to be performed during
execution of works under the scope of this contract. The Contractor shall develop
Inspection & Test Plans and Formats for all such activities also and submit the
same to Owner/ PMC for approval, before actually undertaking such activities.
Contractor shall be completely responsible for management of approved quality

plans and Owner/PMC involvement will be only of Surveillance in nature to
randomly check the works at selective/critical junctures. Their role shall be to
monitor that the Contractor is executing the quality plans as per the approved
drawings, employing adequately qualified staff and other resources for various items
of works. Any deviation to the specifications shall be brought to the notice of
Owner/ PMC in prescribed formats by Contractor for approval.
(ii) It is likely that the Contractor may engage sub-contractor(s)/vendors for

performance of the work. Contractor shall be responsible for ensuring the
implementation of approved QA plan, contract specifications and contract conditions
through their sub-contractors to achieve the quality during all stages of construction.
It shall be the responsibility of the Contractor to ensure proper coordination between
his sub- contractor(s) and other agencies working at site.
The sub-contractor(s)/vendors selection shall be done after evaluation by the

Contractor in line with contract requirements and shall be got approved by
Owner/PMC before engaging them for the works.
(iii) Storage
All the materials procured shall be stored/stacked as per the standard norms and as
recommended in various clauses of relevant codes and contract document. The
storage of material shall be such as to avoid damage to life/properties (physical and
chemical) of the materials. The storage shall not cause deterioration, rusting, mix-
up etc. and hamper the other related works in any way. Contractor shall submit his
detailed warehouse plan for Owner/ PMC approval to manage the above in
open/covered areas.
The materials susceptible to fire shall be kept away in a separate protected place.
In general, the materials shall be kept systematically in order of their class, batch
number and identification number, so that they are accessible for the inspection by
Owner/ PMC whenever required and to avoid the mix up in those materials.
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(iv) Use
The materials shall be stacked in such a way that the lot, which is procured first, will
be consumed first. For materials which are having specific expiry date/ shelf life
shall not be used beyond that date and shall be removed from site. Wherever there
is any doubt about the change in properties of the materials, such materials shall be
sent to reputed approved laboratory for testing and acceptance.
(v) Inspection
The Contractor shall be responsible for carrying out inspection of the materials
brought at site and conducting tests/ checks (at site or in approved laboratories) at
predefined frequencies as per contract. It is the responsibility of the Contractor to
ensure that the materials used at site shall conform to relevant codes/ standards
and Manufacturer Test Certificates are available for correlation as and when
required. The Contractor shall maintain the records of all materials brought at site
and tests conducted on them.
(vi) In process and final Inspection
Contractor shall be responsible to arrange verification of products during in- process

and final inspection. Relevant checks and tests shall be arranged for the works
performed and records maintained. Tolerances achieved with respect to contract
specification and execution drawings for various activities/processes shall be
ascertained and submitted to Owner/ PMC for approval. Efforts shall be made to
keep checks and controls in such a way that a non-conforming product is avoided.
However, if in an isolated case, the tolerances are beyond the acceptable values
given in the contract/execution drawings/codes, non-conformance
resolution/Deviation permit need to be raised by the Contractor and got
approved/resolved from Owner/ PMC.
The Contractor shall arrange verification of ingredients used and validation of the
software used at the batching plant(s). Owner/ PMC reserve the right to inspect the
working of batching plant including validation of the software used and calibration of
measuring & monitoring devices any time. The Contractor shall ensure the quality
of the concrete delivered by the transit mixers, as applicable and maintain verifiable
records.
vii) Any Observation on quality aspects , Owner/PMC shall raise observation in attached
OQA format which has to be acknowledged & compliance to be done by the
contractor within the agreed time period.
viii) The contractor shall follow the requirements given for control of monitoring and
measuring devices (Refer Document no. 7-82-0002).
4.3 DOCUMENTATION
All the necessary documentation & records shall be maintained by Contractor till completion
of project and handed over to Owner/ PMC in requisite copies as a part of completion
documents. Wherever Owner/ PMC personnel were directly involved particularly in witness
and hold point, the copies of the records shall also be provided to personnel on completing
inspection of those activities. The documentation & records shall include the following as a
minimum but not limited to:
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i) Approved Quality Assurance Plan

ii) Approved Inspection and Test Plans
iii) Inspection and test documents covering
a) Manufacturer Test Certificate
b) Material Receipt Report including Inspection Release Note, if applicable and

Site Inspection and acceptance Report on quality and quantity of material
c) Site test/laboratory test Report reviewed by Contractor for acceptance vis-à-

vis to contract/code requirements for materials/including PMI report at
warehouse
d) In process Verification reports of Contractor representative and Owner/ PMC

as applicable
e) Final verification report including any test checks done for compliance
f) As-built vis-à-vis to contract/drawings including tolerances
g) As-built for erection
h) Non conformance resolution raised by Contractor / Owner/ PMC
i) Concession/Deviation approval by Owner/ PMC
j) Change order approval by Owner/ PMC in case there is variation from

contract
k) QA/QC Audit Reports and compliance Reports thereof
l) Mechanical Completion formats
4.4 QA/QC AUDITS
During the execution of the works, Contractor shall carry out periodical Quality Audits at
least quarterly in all areas of work. These audits will be conducted by a team of specialists
in the respective areas. The auditors shall not be directly involved in the jobs being
audited.
The Contractor shall prepare an Audit Plan and Procedure and submit the same to Owner/
PMC for approval.
A copy of the Audit Report containing the findings of the Audit team will be submitted to
Owner/ PMC. After completion of rectification/modifications/corrective actions on the issues
indicated in Audit Report, Compliance Report shall be submitted by the Contractor to
Owner/ PMC for review.
Over and above the Contractor’s Internal QA/QC Audits outlined above, Owner/ PMC shall
also reserve the right to conduct QA/QC audits at the frequency decided by them.
Contractor shall participate and provide full support to the Audit Team and furnish all
documents / reports / records as desired by the Audit Team. The Contractor shall take all
actions required to comply with the findings of the Audit Report and issue regular
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Compliance Reports for the same to Owner/ PMC till all the findings of the Audit Report are
fully complied.
In case major Non conformities are observed during execution of the works Owner/ PMC
reserve the right to appoint an independent person/Third Party Agency to conduct QA/QC
Systems Audit for full/part of the facilities being executed by the Contractor. This audit
will be in addition to the audits described above and may be carried out
intermittently/continuously for all or part of the facilities being executed by the Contractor.
Contractor shall bear the total cost of such audits and shall participate & provide full support
to the Audit Team and ensure compliance of the audit observations.
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APPENDIX-B
HEALTH, SAFETY AND
ENVIRONMENT (HSE) MANAGEMENT
DURING CONSTRUCTION
Page 1938 of 2065

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GENERAL REQUIREMENTS
1.0 Specification for Health, Safety and Environment (HSE) Management (Spec. No. 6-82-
0001) is required to be followed by Contractor during Construction Phase at site.
2.0 Contractor shall have a documented HSE policy to cover commitment of the organization to
ensure Health, Safety and Environment aspects in the line of operation.
3.0 It is the responsibility of the Contractor to ensure that safe construction procedures are
complied with. Contractor will also ensure that adequate First Aid medical facilities are
available and effectively operative for emergency purpose and that safety practices as per
the approved safety procedure are followed by his sub-contractors also.
Contractor to ensure all necessary & relevant safety measures at the minimum like:
a) The use of safety gadgets, viz. safety goggles, helmets, safety shoes, full body
harness, provision of safety net for construction at higher elevations and provision of
toe boards in scaffolding platforms, etc.
b) All hot works must be performed by ensuring compliance to the requirements as
specified by the Owner from time to time.
c) Barricading of crane movement areas / Radiography areas
d) Proper earthing of equipments.
e) Proper shoring / strutting of Excavated Areas, as applicable.
f) Cylinders of inflammable gases to be stacked upright.
In addition to above Contractor shall study the working conditions of the specific site and
assess hazards / risks corresponding to various activities in order of sequence and shall
carry out detailed “ Risk Analysis vis a vis Method Statement ” to deal with anticipated risks
and dangers during the course of work operations. The aforesaid exercise shall be
reviewed by Owner/PMC and after incorporating suggestions if any physical work shall be
carried out implementing requisite measures on work spots. The documents thus generated
(Hazard Identification and Risk Assessment) shall be utilized to develop corresponding
accident prevention curriculum.
The responsibilities of the Contractor shall include but not limited to:
- Coordination and supervision of the details of the job safety program.

- Preparation and review of HIRA (Hazard Identification & Risk Analysis).
- Periodical review / Safety audit (internal& external).
- Initiation of accident reporting, investigation and follow-up actions.
- Review of periodic accident summaries / analysis.
- Safety inspection of the job and submission of summary inspection report to OWNER
/ PMC indicating course of corresponding action taken.
- Obtaining work permits from the Owner, wherever applicable.
- Check the fitness of cranes and other hoisting equipments on periodic basis/before all
major lifts and submit to Owner/PMC valid/latest test certificates of tackles used for
lifting.
- Submission of any other report required by Owner / PMC.
- Cooperate and adhere with safety systems & arrangements as & when advised by
Owner / PMC.
4.0 Any Observation on Safety aspects , Owner/PMC shall raise observation in attached OSA
format, which has to be acknowledged & compliance to be done by the contractor within
the agreed time period.
Page 1939 of 2065

ATTACHMENT – I
Page 1940 of 2065

lafazid ENGINEERS FOR CROSS COUNTRY PIPELINE
Oge.if0151-
ziornfo
ez INDIA LIMITED
1.1ferf flo3o4off0 IA Govt Al India UnOeflaiong) WORKS
6-82-1900 Rev. 2
Page 1 of 106
tR wi LIIVICIIVI chlea ara7

19-Nrur tffikaiur el) All OTriat)
INSPECTION & TEST PLAN (ITP)

FOR CROSS COUNTRY PIPELINE
WORKS
A2(
IN 1
p
2 09/11/2015 Revised And Reissued DJ MKG TKS SC
1 29/03/2010 Revised And Reissued SM SM RKD ND
0 10/10/2005 Issued as Standard Specification MPJ MPJ VNP VJN

Standards Standards
No by by
Approved by
Page 1941 of 2065

.3111a_it4 ENGINEERS
la5rdg INDIA LIMITED FOR CROSS COUNTRY PIPELINE 6-82-1900 Rev. 2
rir,ort 011JOOrAO IA Go. of India Undeflaloo9) WORKS Page 2 of 106
Abbreviations:
AFC Approved for Construction

CPTR Cathodic Protection Transformer Rectifier
CS Carbon Steel
ER Electrical Resistance
HDPE High Density Poly Ethylene
HV High Voltage
HDD Horizontal Directional Drilling
IMIR Incoming Material Inspection Report
IP Intermediate Point
KM Kilo Meter
L-Seam Longitudinal Seam
MIV Material Issue Voucher
MOV Motor Operated Valves
MT Magnetic Particle Test
MR Material Requisition
MS Mild Steel
NDT Non Destructive Testing
NOC No Objection Certificate
OFC Optical Fibre Cable
P/L Pipeline
PO Purchase Order
PQR Procedure Qualification Record
PR Purchase Requisition
PSP Pipe to Soil Potential
PT Liquid Penetrants Test
ROU Right of Use
ROW Right of Way
TBM Temporary Bench Mark
TPIA Third Party Inspection Agency
TP Turning Point
U/G Under Ground
UT Ultrasonic Testing
WPS Welding Procedure Specification
Convenor: Sh. T.K. Sen GM (VC) (Construction)
Members: Sh. S N Bhatnagar, GM (Construction)

Sh. MK Garg, GM (Construction)
Sh. Janak Kishore , DGM (Projects)
Sh. Rajeev Jain, DGM, (C&P)
Sh. Udayan Chakravarty, AGM (Piping)
Sh. Ravindra Kumar , AGM (Construction)
Page 1942 of 2065

FOR CROSS COUNTRY PIPELINE 6-82-1900 Rev. 2
WORKS Page 3 of 106
CONTENTS
S. DOCUMENT PAGE
DESCRIPTION
NO NO. NO.
ITPs FOR Cross Country Pipeline works
1. Dump yard maintenance by coating contractor and 1901 8
Handing Over/Taking over of line pipes at dump yard
2. Incoming material Checking for Contractor’s Supplied 1902 9-11
Materials
3. ROU Survey, Clearing & Grading 1903 12
4. Trenching 1904 13
5. Rock Blasting for Trenching / foundation 1905 14
6. Line Pipe Handling, Hauling & Stringing 1906 15
7. Cold Field Bending of Pipes 1907 16
8. Concrete Coating 1908 17
9. Welding (including Tie In and SV installation) 1909 18
10. Field Joint Coating & Repair 1910 19
11. Lowering of Pipeline Section & OFC Cables / Duct 1911 20

laying
12. Back Filling 1912 21
13. Cased Crossings 1913 22-23
14. Major Water Crossings by Open Cut 1914 24-25
15. Crossings by Horizontal Directional Drilling (HDD) 1914A 26-27
16. Installation of Pipe Line Markers 1915 28
17. Hydrostatic Testing & Dewatering 1916 29-30
18. Final Cleanup & Restoration 1917 31
19. Calibration of instruments 1918 32
20. Laying of OFC Including Laying in Separate Trench 1919 33
21. OFC Jointing & Testing 1920 34
22. Cathodic Protection 1921 35-37
FORMATS
23. Inspection report for handing over taking over of line P-01 38
pipes at dump yard.
24. Material issue voucher P-02 39
25. Material return voucher P-03 40
26. Incoming material inspection report P-04 41
27. Inspection report for Handing over of ROU/ Clearing, P-05 42

Grading of ROW
Page 1943 of 2065

WORKS Page 4 of 106
S. DOCUMENT PAGE
DESCRIPTION
NO NO. NO.
28. Inspection report for trenching P-06 43
29. Inspection report for Rock blasting P-07 44
30. Inspection report for stringing P-08 45
31. Inspection report for cold field bending P-09 46
32. Inspection report for concrete weight coating of pipes P-10 47
33. Crushing strength testing results of concrete cubes P-11 48
34. Record of approval of source(s) for aggregates P-12 49
35. Sieve analysis report P-13 50
36. Pour card-I (programme of concreting) P-14 51
37. Pour card-II (observations during concreting P-15 52
38. Line up and welding visual inspection report P-16 53
39. Inspection report for tie-in welding P-17 54
40. Inspection report for radiography P-18 55
41. Inspection report for welding repair P-19 56
42. Inspection report for liquid penetrant examination P-20 57

report
43. Inspection report for ultrasonic testing P-21 58
44. Inspection report for field joint coating P-22 59
45. Inspection report for Holiday Testing and lowering P-23 60
46. Inspection report for Holiday Testing and Pulling of P-23A 61

HDD String
47. Inspection record or level record after lowering P-24 62
48. Inspection report for backfilling P-25 63
49. Inspection report for cased crossing P-26 64
50. Inspection report for open cut road/minor water P-27 65

crossing
51. Inspection report for major river crossing by open cut P-28 66
52. Inspection report for major river crossing / other P-28A 67

crossings by HDD
53. Hydrostatic pre-test cum evaluation report P-29 68
54. Temperature and pressure recording log for pre-hydro P-30 69

testing
55. Hydrostatic post-test cum evaluation report P-31 70
56. Installation of markers P-32 71
Page 1944 of 2065

WORKS Page 5 of 106
S. DOCUMENT PAGE
DESCRIPTION
NO NO. NO.
57. Clearance certificate of pipeline section for hydro P-33 72
testing
58. Safety checklist for pipeline section hydro testing P-34 73
59. Inspection report for air pigging of pipeline section P-35 74

during hydro testing
60. Inspection report for gauging of pipeline section during P-36 75
hydro testing
61. Inspection report for water filling of pipeline section P-37 76
62. Inspection report for thermal stabilization of pipeline P-38 77
section during hydro testing
63. Inspection report for air volume calculations during P-39 78
pressure test of pipeline section
64. Inspection report for pressurization of pipeline section P-40 79
65. Inspection report for dead wt. Pr. pipe temp & soil P-41 80
temp. during pressure test of pipeline section
66. Inspection report for calculation and evaluation of P-42 81
hydrostatic test for pipeline section
67. Inspection report for dewatering during hydrostatic test P-43 82
for pipeline section
68. Inspection report for swabbing of pipeline section P-44 83
69. Inspection report for SV installation P-45 84
70. Inspection report for restoration P-46 85
71. Inspection report for calibration of instruments P-47 86
72. Recording of site data for preparation of as built of P-48 87

OFC
73. Inspection report for OFC laid in crossings P-49 88
74. Inspection report for OFC drum testing P-50 89
75. Inspection report for OFC jointing & splicing P-51 90
76. Inspection report for OFC link testing P-52 91
77. Pipe book format P-53 92
78. Inspection report for Cathodic Protection System P-54 93-94
79. Inspection report for anode connection and sealing P-55 95
80. Inspection report for zinc ribbon anode installation P-56 96
81. Inspection report for anode junction box installation P-57 97
82. Inspection report for CPTR and CPPSM installation P-58 98
83. Inspection report for ER probe installation P-59 99
84. Inspection report for horizontal anode bed installation P-60 100
Page 1945 of 2065

WORKS Page 6 of 106
S. DOCUMENT PAGE
DESCRIPTION
NO NO. NO.
85. Inspection report for commissioning of anode bed P-61 101
86. Inspection report for vertical anode bed installation P-62 102
87. Inspection report for polarization cell installation P-63 103
88. Inspection report for surge diverter installation P-64 104
89. Inspection report for permanent reference cell P-65 105

installation
90. Inspection report for polarization coupon installation P-66 106
Page 1946 of 2065

WORKS Page 7 of 106
GENERAL NOTE
1. The enclosed ITPs are indicative and shall be followed for developing the job specific ITPs for
the works to be performed by the contractor. The provisions indicated for stage wise
inspection by EIL and Owner (For specific activities) are the minimum and the Engineer-In-
Charge may decide to increase Hold Points/ Witness Points, while approving the job specific
ITPs. Activities for which ITPs are not provided in this specification, contractor to develop
and get the same approved by EIL/Owner before start of the work. In general role of EIL has
been specified in the document. The role of owner to be specified during preparation of site
specific ITPs.
2. Contractor to submit job specific reporting formats with the aid of enclosed sample reporting
formats and job procedures for the jobs for which ITPs are attached and submit to EIL/Owner
for approval, before commencement of the activity. If the contractor has to deviate from the
given ITP for a valid reason, he shall obtain prior written approval of EIL/Owner. Contractor
to carry out 100% examination of all activities.
LEGEND
HP : Hold Point;
A point which requires witnessing/ inspection/ verification and acceptance by Owner/EIL

before any further processing is permitted.
The Contractor shall not process the activity/item beyond a Hold Point without written
approval by Owner/EIL except where prior written permission for further processing is
available.
W : Witness Point;
An activity which requires witnessing/inspection/verification by Owner /EIL when the

activity is performed.
After proper notification has been provided (notification modalities and period shall be
finalized before hand), the Contractor is not obliged to hold further processing if
Owner/EIL is not available to witness the activity or does not provide comments before
the date notified. In such cases, basis of acceptance shall be review of Contractor
generated report/document as per relevant technical specification.
Rw : Review of Contractor’s documentation.
S : Surveillance Inspection by Owner/ EIL.

Monitoring or making observations to verify whether or not material/items or services
conform to specified requirements. Surveillance activities may include audit, field
inspections, witness of testing, review of quality documentation & records, personnel
qualifications, etc.
WC : 100% Supervision and Examination by Contractor.
Responsibility for execution of the inspection/testing is with the Contractor; Owner/EIL only
verifies examination or testing done by the Contractor at relevant important stages
Page 1947 of 2065

WORKS Page 8 of 106
ITP No : 1901
DUMP YARD MAINTENANCE BY COATING CONTRACTOR
AND HANDING OVER/TAKING OVER OF LINE PIPES AT
DUMP YARD
Contractor Records to be
Sl.
Activity EIL Submitted/
No. Coating Laying
Format No.
Submission & approval of work
Approved
1 procedure including proposed WC - Rw
procedure
dumpsite layout.
Grading, leveling, and stripping, of
dumpsites with arrangement of Approved
2 WC - S
stacking as per relevant Records.
specification
Preparation of sand rows for
stacking of coated pipes and
Approved dump
fencing with gate barrier, lighting
3 WC - S site acceptance
arrangements, drainage systems etc.
report
as per approved layout of
dumpsites.
Holiday checking of line pipes,
Internal gauge plate run, pipe dia.
and thickness, internal cleaning,
Pipe identification nos like pipe no,
4 WC WC - P-01
coat no, heat nos, bevel edges. &
other markings correlating with
Inspection Release Note by laying
contractor
5 Coating Repairs, if any WC WC - P-01
Segregation and repair of pipes

6 WC WC Rw P-01
having Parent metal damage
Signing of Joint Record for handing

7 WC WC Rw P-01/ P-02
over/ taken over based on MIV
Review test and inspection

WC - Rw
documents
Note:
The above activities will be under EIL if warehousing is in EIL scope of work
*S for coating repair works / holiday repairs. W for pipe damage repair, if any.
Page 1948 of 2065

WORKS Page 9 of 106
ITP NO : 1902
INCOMING MATERIAL CHECKING FOR CONTRACTOR’S
SUPPLIED MATERIALS (Sheet 1 of 2)
EIL /Owner ($) Records to be
Sl.
Activity Contractor Submitted/
No. CAT 1 CAT 2 CAT 3
Format No.
A. Document Checking
1. Check whether vendor/source is approved WC HP Rw Rw P-04
2. Availability of QAP/ITP duly approved by TPIA WC Rw Rw Rw P-04

Availability of MTC / IRN (Availability of stage
wise Inspection Reports/certificates in case of
3. WC HP Rw Rw P-04
inspection by TPIA, Inspection reports of
Contractor, if applicable)
Availability of certificates from statutory bodies,
4. WC HP Rw Rw P-04
if applicable
5. Delivery challan /LR WC Rw S - P-04
B. Physical Verification
Checking for Inspection stamp/Identification
1. WC W* S S P-04
mark, if applicable
Correlation of MTC w.r.t. Heat nos/ Batch no /lot
2. WC HP W* W* P-04
no, as applicable
3. Physical assessment of Qty WC S S - P-04
4. Certification of condition of material WC W S S P-04

Sampling for Field tests / tests from approved
C WC W W W P-04
laboratories, if applicable
Review of Field Test reports/Lab Test reports if
D WC Rw Rw Rw Test Report
applicable
Review & Endorsement on MTC/IRN/Lab test MTC/IRN/ Lab
E WC Rw Rw Rw
report etc. Report
F Endorsement on IMIR WC HP HP HP P-04
NOTE:
 ($)A generic categorization plan could be firmed based on following guideline and as per Table A:-
 (* )Sampling plan for checking of bulk items shall be as per discretion of EIL
 General :
1) EIL/OWNER and contractor shall jointly finalize the list of incoming materials and categorize in line
with inspection categorization plan for bought out items. The items not covered in Table A shall be
finalized by Engineer In charge /Owner.
2) In general Sl no of the ITP: A(1,3,4 &5) B, E and F shall be applicable to both (#)and (@) i.e. Items
with and without TPI/EIL inspection
3) In general Sl no of the ITP: A (2), shall be applicable to (@) ie. Items with TPI/EIL inspection
4) In general Sl no. of ITP : C and D shall be applicable to (#) ie. Items without TPI/EIL inspection.
5) All items to be procured from approved vendors / source as per list enclosed in the contract / approved
vendor list. Prior approval for the source / vendor to be taken for items not listed in the contract /
approved vendor list.
6) Anodisation / galvanization shall be ensured in shops having proven track record and samples are to
be tested to check galvanizing / anodizing prior to dispatch to sites.
Page 1949 of 2065

WORKS Page 10 of 106
ITP NO : 1902
INCOMING MATERIAL CHECKING FOR CONTRACTOR’S
SUPPLIED MATERIALS (Sheet 2 of 2)
CAT 1 CRITICAL: The materials requiring long time impact to meet the stipulation of end user. Completely
engineered and inspected as per the contract.
CAT 2 MAJOR: The materials requiring lesser impact on end user. Specified to Industry standards, lower
design category (not fully reviewed of detailed Engg but all interfaces checked) and with complete
compliance with code but requiring limited inspection.
CAT 3 MINOR: Standard items, fit for the purpose with minimal Engg review.
TABLE: A
Sl CAT 1 CAT 2 CAT 3
No (Critical) (Major) (Minor)
Items without TPIA/EIL inspection (#)
1  Cement  Coarse aggregate  Anti-Corrosion coating
 Reinforcement steel  Fine aggregate materials
 Structural steel  Stone aggregate for road work  Water
 Filling soil  AC sheets/CGI sheets
 Murrum sand, etc  Particle board
 Brick and tile brick  Stone for stone masonry
 Asphalt(bitumen), Paint  Glazing glass
 Sanitary wares, sanitary fittings (pipes  All galvanized /
& fittings) anodized items like GI
 Chemicals for ATT, pipes
 Acid resistant tiles and mortar, marble  Door/window frames
and marble chips  Pre-coated sheets
 Mechanical hardener for flooring  Steel doors
 Grouting compound  Aluminum doors
 Wood for doors and windows  Rolling shutters
 Ventilator  Cable ducts/trays
 Flush door  Lightning arrestors
 Paneled door  Street light poles
 Roof treatment materials  Earthing items.
 False ceiling & flooring materials
 RCC Hume pipes
 Refractory
 Anchor Fasteners
Items with TPIA/EIL inspection (@)
1  All process  All types of compressors and pumps  Hoists
Compressor except under category1  Pipes and piping
 Process Pumps  EOT crane materials (other than
 Gas and Liquid Filters category 2)
 Pipes  Gauges Glass
 Piping material including Valves  Meter-flow-annubar
(AS, SS, LT)  Solenoid valve
 HT switch gear  Pressure gauges and
 Neutral Grounding resistor Receiver gauges
 Fire alarm system  Draft Gauges
 CO2 Flooding system  Pressure switches
 HT / LT Motors  Flow switches
 DC System  Level switches
 Batteries & battery Charges (explosion Proof)
 Plant communication system  Annunciators
 UPS  Temperature sensing
Element-RTD’s
Page 1950 of 2065

 HT / LT Switchgear  Thermowell and

 Transformer thermocouple
 Variable speed drives  Temperature Gauges
 Ball valves, check valves, Plug valves  Gratings
 Tank level indicator / Instruments  Insulation materials
 Control valve, Pressure relief valves  All fasteners
 Breather valve  Gaskets
 Self actuating pressure control valve  Sacrificial anodes
 Analysers-H2S  Test lead points
 Analyser-Moisture vapour ambient  Anode Junction Boxes
 Analyser- Chromotographs Process Gas  Casing Insulators
 LEL Detectors  End seals
 Level Instruments/Transmitters  Warning mats
 Flame arrestors
 Thermocouple Extension Cable
 Transmitters –Electronic
 Panel Control and accessories
 All HV/HT and LV/LT cables and
control cables
 All types of flameproof fittings &
fixtures
 Solar Panels etc.
 LR Bends
 Corrosion Monitoring System
 HDPE duct
Note: For any material not covered above, the inspection requirement shall be decided
by EIC based on the criticality
Page 1951 of 2065

ITP NO : 1903
ROU SURVEY, CLEARING & GRADING
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
1 Taking over ROU from client/owner WC Rw P-05
Calibration/testing of survey equipment

2 a) Review of certificates WC Rw Manufacturer’s
b) Rechecking , if any WC Rw calibration cert.
Approved
3 Submission & approval of work procedure WC Rw
procedure
Staking markers for ROU Boundary, IPs, TPs, Km

4 WC S P-05
thickness change and others
5 Availability of approved AFC alignment sheets WC HP P-05
6 Centre line of pipeline and location of turning points WC S P-05
Existence of structure/obstruction& providing safety

7 warning signs for overhead electric HT power line WC S P-05
crossing
8 Restricted ROU WC S P-05

Review test and inspection documents WC Rw
Page 1952 of 2065

ITP NO : 1904
TRENCHING
Records to be
Sl.
No.
Format No.
Approved
1 Submission and approval of work procedure WC Rw
Procedure
Center line/dimensions of trench w.r.t established
2 markers & stacks or existing U/G line (in case of WC S P-06
existing ROU)
3 Measurement of trench depth WC S P-06
Detail of under-ground structures encountered and its

4 WC S P-06
safety
5 Provision of warning signs & safety regulation WC S P-06
6 Maintenance of motor able road WC S P-06
7 Separate stacking of arable soil WC S P-06
8 Level and width of excavated trenches WC S P-06
9 Bottom padding in trench, if required WC S P-06
10 Profile survey of trench at TP/crossing WC S P-06
Page 1953 of 2065

ITP NO : 1905
ROCK BLASTING FOR TRENCHING / FOUNDATION
Records to be
Sl.
No.
Format No.
Submission & approval of work procedure by geologist Approved
1 WC Rw
engaged by contractor / by competent authority procedure
Availability and submission of valid license for
possessing as well as use of explosive materials from License for
2 WC HP
concerned statutory authority and notice to all blasting
concerned authorities
Availability of licensed blaster / other competent
3 personnel as per requirement of statutory authority and WC Rw Valid license
examining blasting material before use
Trial blasting
4 Trial blast & vibration recording WC S
records
5 Recording of all safety regulations in checklist. Form WC Rw P-07
Ensure firing of all spots, misfires to be brought to

6 WC Rw P-07
notice
Profile of trench to suit vertical and horizontal bends in

7 WC S P-07
rocky area
Page 1954 of 2065

ITP NO : 1906
LINE PIPE HANDLING, HAULING & STRINGING
Records to be
Sl.
No.
Format No.
Approved
procedure
Stringing of correct dia./thickness of pipes in ROW on

2 WC S P-08
sand bags
Verification of pipe dia./ length/ orality/ inside
cleanliness, damage during transportation/ pipe no./
3 heat no./ yard coating no., holiday checking etc. & its WC S P-01/P-08
documentation during taking over of pipes from dump
yards
4 Marking for repair of damaged coating WC S P-08
Transfer of Pipe details like Pipe No., Heat No, Coat

5 No, Length etc. from inside to outside at appropriate WC S P-16/ P-17
location
Return of surplus pipe / cut pieces to owner after
6 WC S P-03
completion
Page 1955 of 2065

ITP NO : 1907
COLD FIELD BENDING OF PIPES
Records to be
Sl.
No.
Format No.
Approved
procedure
2 Bending procedure qualification and approval WC HP P-09
Alignment sheet
3 Survey check WC S and field survey
report
4 Setting up of pipe orientation for L-Seam WC S P-09
5 Bending operation; degree/pull etc. WC S P-09
6 Pull Through, Holiday check & Visual checking WC S P-09
Disbondment check of coating by wooden mallet on

7 WC S P-09
bend areas.
8 Numbering for identification w.r.t. TP WC Rw P-09
Page 1956 of 2065

ITP NO : 1908
CONCRETE WEIGHT COATING
Records to be
Sl.
No.
Format No.
Approved
procedure
Approved Mix
2 Approval of concrete mix design WC Rw
design report
Approved PQR
3 Concrete weight Coating procedure qualification WC HP for concrete
coating
4 Raw material inspection & testing wherever required WC Rw P-04, P-12, P-13
Visual check and Holiday test of pipes before placing

5 WC W P-10
of reinforcement wires etc./ repair
6 Wire mesh application WC S P-10
7 Preparation of concrete mix & pouring WC S P-14, P-15
Transfer of heat No. Pipe details like Pipe No., Coat

8 WC -
No, Length etc. from outside to inside of pipe
9 Curing with water/ curing compound WC -
10 Cube testing WC W P-11
11 Electrical Continuity checking WC W P-10
Marking of completed pipes, cleaning & fixing of end

12 WC -
caps
Page 1957 of 2065

ITP NO : 1909
WELDING (INCLUDING TIE IN AND SV
INSTALLATION)
Records to be
Sl.
No.
Format No.
Approved
1 Submission & approval of work procedures WC Rw
Procedure
Electrode / Filler wire P-04
a) Review of batch test certificates/documents from
WC Rw
manufacturer
2
b) Electrode / Filler wire Testing, as required
WC W
c) All weld tensile test and bend tests for each batch of Approved lab test
WC Rw
electrodes (as required ) reports
WPS/PQR
a) Review of proposed WPS WC Rw
3 Approved
b) Procedure Qualification Test WC HP
WPS/PQR
c) Approval of final WPS & PQR WC HP
Welders
a) Performance qualification test WC W Approved welder
4
b) Review of radiographs of qualification test piece WC HP ID card and
c) Final approval of welders WC HP Certificates.
NDT Procedure Qualification
5 a) Review of proposed procedure WC Rw Approved NDT
b) Procedure Qualification Test WC W PQR
Bevel inspection / Pipe facing / Bevel cutting) & inside
6 WC S P-16, P-17
cleaning of pipes
7 Line-up/pre heating & root welding WC S P-16, P-17
Weld visual & writing welder nos. beside completed

8 WC S P-16, P-17
welds
Repair of Arc burns on pipes/Arc Strikes
9 a) Visual Inspection WC S
P-16, P-17
b) Final acceptance WC Rw
P-18
10 Interpretation of weld radiographs WC HP
P-17
Other NDT’s like PT & UT on new cut bevels, UT on
11 WC W*/Rw P-17
golden tie-in welds, MT as specified etc.
12 Visual check of repaired welds WC S P-19
Destructive Testing of production welds, if required by Approved lab test

13 WC HP
specification reports
14 Confirmation check of radiography of weld joints WC HP P-18
Review inspection & test documents WC Rw
*UT on Golden tie in shall be witness point.
Page 1958 of 2065

ITP NO : 1910
FIELD JOINT COATING AND REPAIR
Records to be
Sl.
No.
Format No.
Approved
procedure
Approved PQR
2 Coating Procedure Qualification WC HP
for coating
3 Approval of coating materials WC Rw P-04
Approved
Qualification of applicators/application in presence of
4 WC HP applicator ID
Manufactures representative of coating material
card
5 Visual check for irregularities, overlap, thickness, etc. WC S P-22
Holiday check (For main line section holiday check

6 WC S P-22
shall be reconfirmed before lowering)
Peel test, as per approved frequency for acceptance of
7 WC W P-22
daily coating done (as per relevant specification)
8 Repairs and Holidays WC W P-22
Coating integrity test (Holiday) after pulling of HDD

9 WC HP P-28A
string
Page 1959 of 2065

ITP NO : 1911
LOWERING OF PIPE LINE SECTION & OFC
CABLES
Records to be
Sl.
No.
Format No.
Approved
1 Submission and approval of work procedure WC Rw
procedure
Clearance for lowering (Preparation of Pipe Book for

2 WC HP P-53, P-23
Part A for covering activities up to lowering.
Inspection of trench for depth , debris etc.(before

3 WC Rw P-23
lowering)
Soft soil/sand padding in rocky/hard soil area/ non-
4 cohesive material in seismic zone, station approach etc. WC W* P-23
as required
Holiday check (including field joints and repairs) prior
5 WC W* P-23
to /during Lowering after removing end caps
Calibration of Holiday detector by Zeep meter before
use and during use (in case of doubt) after attaching
6 WC W* P-23
grounding wire/ground cable with alligator clip
attached to the bare metal
Tests on optical fibre cable/HDPE duct & approval of
7 WC Rw P-50, P-04
OFC warning mat as applicable (before laying)
Lowering of optical fibre cable/HDPE duct, padding &

8 WC S P-50, P-23
placing of warning mat.
9 Checking of levels WC Rw P-24
10 Post padding to cover pipeline and OFC cable WC S P-24
* Owner shall also be informed for association in this critical activity.
Page 1960 of 2065

ITP NO : 1912
BACK FILLING
Records to be
Sl.
No.
Format No.
Approved
procedure
Provision of slope breakers, concrete boulder layer

over backfill in water crossings & Concrete slab/plastic
2 WC W P-25
grating at crossing of P/L’s and HT line crossings, as
applicable
3 Proper backfilling with crown WC S P-25
4 Compaction of backfilling at crossings etc. WC S P-25
5 Replacement of aerable soil, as applicable WC -
Special backfill / Sand Fill at specified locations as per

6 WC S P-25
alignment sheet / station approach drawings
Page 1961 of 2065

ITP NO : 1913
CASED CROSSINGS (Sheet 1 of 2)
Records to be
Sl.
No.
Format No.
Approved
1 Submission & approval of Work Procedure WC Rw
procedure
Approval from competent authority before start the
2 work (in case of obtaining approval from the concerned WC Rw
authority is in the scope of the contractor)
Preparation of construction drawing and schedule for

3 WC Rw
boring as per contract/specs.
Approved
Approval of construction drg. from concerned
Construction
authority having jurisdiction, for length & depth of
4 WC Rw drawing for
casing pipe (in case of approval of boring is in
cased crossing
contractor’s scope)
from CA
5 Preliminary survey & marking of P/L centre line WC S
6 Preparation of boring pit & level check WC S P-26
Fitness check of casing pipe (out of roundness, dent

7 WC S P-26
etc.)
Visual checks of casing pipe after welding (during

8 WC W P-26
fabrication)
Visual check of inside of the casing pipe & carrier pipe
9 WC S P-26
prior to installation of carrier pipe.
10 Boring operation WC S P-26
11 Installation of casing vent and drain pipes WC S P-26
12 Coating/Painting of vent and drain pipes WC S P-26
13 Fabrication of carrier Pipe string WC * P-26, P-18, P-16
14 NDT WC * P-18, P-21
15 Pre hydro test of carrier pipe WC HP P-26, P-29
16 Field joint coating & holiday check WC * P-26, P-22
Approval of casing insulators, spacing of insulator &

17 WC Rw P-04
tightness etc.
Page 1962 of 2065

ITP NO : 1913
CASED CROSSINGS (Sheet 2 of 2)
Records to be
Sl.
No.
Format No.
18 Installation of insulators WC W P-26
19 Welding of nose piece to carrier pipe WC S
20 Insertion of Carrier Pipe WC W P-26
21 Electrical continuity& resistance checks before tie-in WC W P-26
22 Installation of end seals WC W P-26
Boring completion reports & preparation of As Built

23 WC Rw As build Drg
Drawings.
Obtaining/submission of NOC from concerned

24 WC Rw NOC from CA
authority having jurisdiction
* as per Main Line activities .
Page 1963 of 2065

ITP NO : 1914
MAJOR WATER CROSSINGS BY OPEN CUT (Sheet 1 of 2)
Records to be
Sl.
No.
Format No.
Approved
procedure
Approval of concerned authority having jurisdiction to Copy of written
2 WC Rw
start the work approval letter
3 Preliminary survey, marking reference line & TBM WC S
Crossing drawings duly approved by Engineering. or Approved

4 WC Rw
statutory approvals, wherever required drawing by CA
P-08, P-16,
5 Fabrication of string WC * P-17, P-28,
P-23
P-18, P-21,
6 NDT WC *
P-28, P-27
7 Trenching WC S P-06
8 Pre Testing of sections/strings (ex-situ ),

Calibration certificate for pressure / temperature
a) WC Rw P-47
gauges
Welding of pretested test headers by qualified
b) WC S -
welders/WPS.
c) Water filling & venting WC S P-29
d) Pressurization WC S P-29
e) Hold period as per specification WC W P-29
f) Visual inspection of weld/ pipe, wherever feasible WC Rw P-29
g) Compilation of test records WC S P-29, P-30
Draining of hydro test water from the pipeline & fixing

h) WC S P-29
of end caps
As per ITP
9 Field joint coating WC
1910
Page 1964 of 2065

ITP NO : 1914
MAJOR WATER CROSSINGS BY OPEN CUT (Sheet 2 of 2)
Records to be
Sl.
No.
Format No.
10 Holiday testing of the entire string WC W P-23, P28
P-23, P-24,
11 Lowering & Level Checking WC W
P-28, P-27
12 Concrete coating , if required WC *
Laying of HDPE conduit in trench or in CS pipe for P-48, P-49,

13 WC S
OFC P-28
14 Paddings & backfilling WC S P-25, P-28
P-31, P-28,
15 Gauging & Post - hydro test ( in –Situ ) WC HP
P-36
16 Tie in with Mainline WC * P-18
17 Bank protection and restoration WC S P-28
18 Post laying survey/As Built Drawings WC Rw As built drawing
19 Crossing completion report WC S P-28
20 Warning marker WC S P-32
21 Obtaining & Submission of NOC from CA WC Rw
* As per Main Line Activities.
Page 1965 of 2065

ITP NO : 1914 A
CROSSINGS BY HORIZONTAL DIRECTIONAL DRILLING
(HDD) (Sheet 1 of 2)
Records to be
Sl.
No.
Format No.
Approved
procedure
2 Preliminary survey, marking reference line & TBM WC S
Geotechnical Survey and Reports thereof, Collection of

3 WC S
Hydrological Data
Approved
4 HDD Profile drawings duly approved by Engineering WC Rw
Profile drawing
5 Copy of written
Approval of competent authority to start the work WC Rw
approval letter
P-08, P-16,
6 Fabrication of string WC * P-17, P-23A,
P-28A
P-18, P-21,
7 NDT WC *
P-23A, P-28A
8 Pre Testing of sections/strings (ex-situ )
Calibration certificate for pressure / temperature

a) WC Rw P-47
gauges
Welding of pretested test headers by qualified

b) WC S -
welders/WPS.
c) Water filling & venting WC S P-29
d) Pressurization WC S P-29
e) Hold period as per specification WC W P-29
f) Visual inspection of weld/ pipe, wherever feasible WC Rw P-29
g) Compilation of test records WC S P-29, P-30
Draining of hydro test water from the pipeline & fixing

h) WC W P-29
of end caps
P-22,
9 Field joint coating including fixing of end closures WC W
P-28A
Page 1966 of 2065

ITP NO : 1914 A
CROSSINGS BY HORIZONTAL DIRECTIONAL DRILLING
(HDD) (Sheet 2 of 2)
Records to be
Sl.
No.
Format No.
10 Holiday testing of the entire string WC W P-23A, P28A
Pilot hole for carrier and CS conduit (for laying HDPE

11 WC W P28A
duct and OFC)
Reaming and Clean passes (Check for excessive load

12 WC S
on the HDD Rig)
13 Placement of pre tested string on roller WC S
14 Welding of Pull Head WC S
P-23A,
15 Pulling of Pipe String WC W
P-28A
16 Pulling of CS conduit with HDPE duct for OFC WC W P28A
17 Coating integrity check after Pulling WC W P-23A, P-28A
P-31, P-28A,
18 Gauging & Post - hydro test ( in –Situ ) WC W
P-36
19 Tie in with Mainline WC * P-18
20 Bank protection / Restoration WC S P-28A
21 Disposal pf Bentonite WC S
22 Post Pulling survey/As Built Drawings WC Rw As built drawing
23 Crossing completion report WC S P-28A
24 Warning marker WC S P-32
25 Obtaining & Submission of NOC from CA WC Rw
* As per Main Line Activities.
Page 1967 of 2065

ITP NO : 1915
INSTALLATION OF PIPELINE MARKERS
Records to be
Sl.
No.
Format No.
Approved
procedure
Approval letter
2 Approval of " Sample " markers including painting WC HP
for sample.
Fabrication of pipe line / OFC markers as per drawing

3 WC S P-04
in fabrication shop
Surface preparation & primer application in fabrication

4 WC S
shop.
5 Pre -casting of markers ( ROU boundary marker ) WC S P-11 to P-15
Installation of correct type marker at correct location as

6 WC W P-32
per drawing
7 Primer touch-up, finish painting & stenciling WC S P-32
Page 1968 of 2065

ITP NO : 1916
HYDROSTATIC TESTING & DEWATERING (Sheet 1 of 2)
Records to be
Sl.
No.
Format No.
1 Submission & approval of work procedure WC Rw Approved procedure
Clearance of the pipe section

2 WC HP P-33
(Part “B” of pipe book)
Submission of water test laboratory report including Approved lab test
3 recommendations for corrosion inhibitor and its testing WC Rw reports for water &
(if reqd.), oxygen scavengers and bactericides corrosion inhibitor.
Valid manufacture’s
Calibration certificates for dead weight tester, pressure
calibration
4 gauges, pressure/temperature recorders temp. sensor, WC Rw
certificates/lab test
water meter etc.
reports.
Installation of temporary piping, equipment, filters,
5 WC S
provisions for launching and receiving pigs etc.
Installation of water holding devices or piping from
6 WC S
water sources etc.
7 Ensuring communication system WC S
8 Ensuring safety requirements WC S P-34
9 Review of filling pump & pressurizing pump data WC Rw
10 Cleaning by air pigging WC W P-35
11 Gauging pig run and gauge plate inspection WC HP P-36
12 Flushing by water driven pigs WC S
13 Installation of temperature sensors WC S
14 Installation of launching and receiving WC S
headers and pigs
15 Filling operations and corrosion inhibitor dosing
a) Filling rate WC S P-37
b) corrosion inhibitor injection rate as approved WC S
c) Back pressure control to avoid air entrapment WC S
16 Thermal stabilization WC HP P-38
17 Air volume confirmation test WC HP P-39
Page 1969 of 2065

ITP NO : 1916
HYDROSTATIC TESTING & DEWATERING (Sheet 2 of 2)
Records to be
Sl.
No.
Format No.
18 Pressurization
a) Rates as per approved procedure WC S P-40
b) Recording of temperature & pressure at every two

WC S/ HP * P-41
hours during 24 hours hold period
c) Bleed off water measurement WC W P-41
Detection of leaks if any and extension of hydro test

19 WC HP
duration
20 Rectification & stocking/marking of damaged pipes WC W P-08, P-16
21 Evaluation and acceptance of recorded data WC HP P-42
22 Depressurization and de-watering WC W P-43
23 Swabbing operation WC S P-44
24 Acceptance after swabbing operation and drying WC HP P-44
25 Reinstatement & golden tie –in. WC W P-17
*Temperature and Pressure reading at the beginning and end of the test shall be HP
Page 1970 of 2065

ITP NO : 1917
FINAL CLEAN UP & RESTORATION
Records to be
Sl.
No.
Format No.
Approved
procedure
Restoration of water ways, roads, land structures,

2 WC S P-46
ecology etc.
Restoration of water way banks and check protections

3 WC S P-46, P-28
as per approved drawings
Sorting and grouping of surplus piping material for

4 WC S
returning to the owner and for scrapping
Transporting all scrap and disposable from ROU

5 WC S
including surplus rock / earth etc.
6 Inspect restoration of ROU to the condition as per spec. WC W* P-22
*This activity shall be witnessed by owner’s representative
Page 1971 of 2065

ITP NO : 1918
CALIBRATION OF INSTRUMENT
Records to be
Sl.
No.
Format No.
Approved
procedure
2 Physical verification of instruments WC W P-47
3 Review of calibration certificates for test equipment WC Rw P-47
4 Field calibration of instruments wherever required WC W P-47
Page 1972 of 2065

ITP NO : 1919
LAYING OFC INCLUDING LAYING IN SEPERATE TRENCH
Records to be
Sl.
No.
Format No.
Approved
procedure
Approved
Review and approval of OFC alignment sheets/drum
2 WC Rw alignment sheet
schedule.
for OFC laying
Review of manufacturer test certificate of HDPE
3 WC Rw P-04
conduit & cable and clearance through IMIR
4 Trench inspection WC S P-49
5 HDPE conduit installation WC S P-48
6 C.S. piping installation (boring / HDD) WC S P-49
7 Cable laying/blowing WC S P-48, P-49
8 Padding / warning mat WC S P-25
Route markers – Mechanical & Electronic joint pit

9 WC S P-49
markers
11 Installation of joint pit markers, electronic markers ,etc WC W
As built
12 As-Built drawings WC Rw
drawing.
Page 1973 of 2065

ITP NO : 1920
OFC JOINTING AND TESTING
Records to be
Sl.
No.
Format No.
Approved
- Submission & approval of work procedure WC Rw
procedure
1 Drum Testing
1a Physical inspection WC S P-50
1b Measurement of fibre attenuation WC Rw P-50
2 Jointing
2.1 Before splicing (after laying)
a) Record fibre attenuation of both the fibre being spliced WC W P-51
2.2 Measurement of splice loss WC W P-51
3 Link Testing
Measurement of link loss from either side OFC
3.1 WC W P-52
between two stations after jointing
Page 1974 of 2065

ITP NO : 1921
CATHODIC PROTECTION (Sheet 1 of 3)
Records to be
Sl.
No.
Format No.
Check for availability of approved Design document for
1 WC HP
Cathodic protection
2 Incoming Material check WC HP P-04
Availability of Approved procedure for execution of Approved
3 WC Rw
Cathodic protection Procedure
Demonstration of application of Thermit weld, Pin
Record of
4 brazing, etc. and conformity by pull / hammer test and PT WC HP
demonstration
etc.)
5 Pipe to cable Connection
Check location for Lead connection and expose pipe
a) WC S P-54
surface
Connection of cable to pipe as per demonstrated procedure
b) WC S P-54
(pin brazing, thermit welding etc.)
c) Bonding tightness test of cable WC S P-54
d) Continuity test WC Rw P-54
e) Epoxy filling after thermit welding/pin brazing WC S P-54
f) Holiday testing WC W P-54
g) Backfilling WC S P-54
6 Anode connection and sealing
a) Anode surface preparation WC S P-55
b) Continuity Test WC Rw P-55
c) Encapsulation WC S P-55
7 Anode installation
a) Check for Depth of anode, dimension, air/water tightness WC S P-56
b) Open circuit potential measurement WC S P-56
c) Natural PSP measurement WC W P-54
d) PSP measurement WC W P-54
8. Test Station or Test Lead Point Installation
a) Location of TS in ROW WC S P-54
Check for Concrete foundation: size, Concrete Mix and
b) WC S P-54
curing
c) Installation of Test Station above Foundation WC S P-54
d) Termination of Cables in the Test Station WC S P-54
e) Check proper sealing of Cable entry at Foundation WC S P-54
Ensure Galvanic earthing through polarization cells in
f) WC W P-54
Test stations at HV transmission line crossings as required
g) Name plate on Teat Station WC S P-54
Page 1975 of 2065

ITP NO : 1921
CATHODIC PRTECTION (Sheet 2 of 3)
Records to be
Sl.
No.
Format No.
9. Anode Junction box Installation
a) Check Pit Dimension and location WC S P-57

b) Concrete foundation size, Grade & 7 day curing WC S P-57
c) Check foundation level and height above ground WC S P-57
d) Check connection of anode Tail cable and tagging WC S P-57
e) Anode header cable connection and tagging WC S P-57
10 CPTR and CPPSM installation

a) Inspection of TRU/CPPSM WC W P-58
b) Verification of location WC S P-58
c) TR/CPPSM unit installation WC S P-58
d) Cable termination and tagging WC S P-58
e) Inspection /Testing report WC W P-58
11 ER Probe Installation
Visual Inspection of ER probe & supply manufacturer
a) WC Rw P-04/P-59
TC
Verification of location, pipe to ER probe clearance &
b) WC S P-59
level
c) ER probe installation and backfilling WC S P-59
d) Cable termination and Tags WC S P-59
e) Final Inspection/Acceptance report WC W P-59
12 Horizontal /vertical anode Bed installation
Inspection of anode bed WC S P-60/P-61/P-62
Individual anode to ground resistance measurement WC W P-60/P-61/P-62
Ground bed resistance measurement WC W P-60/P-61/P-62
Total circuit resistance WC W P-60/P-61/P-62
13 Polarisation Cell Installation
Check for proper connection to pipe WC S P-63
Electrolyte level checking WC S P-63
Installation WC W P-63
14 Surge diverter installation
a) Bolt Tightness WC S P-64
Polarity checking WC S P-64
Encapsulation WC S P-64
Earthing of unprotected side WC S P-64
Final Inspection/acceptance report WC W P-64
Page 1976 of 2065

ITP NO : 1921
CATHODIC PROTECTION (Sheet 3 of 3)
Records to be
Sl.
No.
Format No.
Permanent Reference cell installation/ Polarisation
15
coupon installation
Verification of location, pipe to reference cell/

a) WC W P-65/P-66
Polarisation coupon in clearance and level
Reference cell / Polarisation coupon installation and

b) WC S P-65/P-66
backfilling
c) Cable termination and tags WC S P-65/P-66

16 Cable laying
a) Trench depth and clearance WC S P-65/P-66

b) Soft soil padding (pre and post), as required WC S P-65/P-66
c) Warning mat and brick protection WC S P-65/P-66
17 Ensure Galvanic Earthing of protected Actuated

Valves/ MOVs WC S
18 Pre Commissioning Interference Surveys WC S
19 Commissioning of PCP System
a) Disconnection of sacrificial anodes WC S

b) 24 Hours depolarisation WC S
c) Measuring natural PSP WC S P-65/P-66
d) Energising PCP system WC S
e) On off Potential Measurement WC S
f) Final Commissioning WC S
20 Post Commissioning Surveys
a) Interference Survey WC S*
b) CIPL Survey WC S*
c) CAT Survey (As required) WC S*
d) DCVG Survey (As required) WC S*
*Note: The interpretation of survey data and recommendations for mitigation measures shall
be vetted by Engineering
Page 1977 of 2065

Format no : P-01
INSPECTION REPORT FOR HANDING OVER TAKING OVER
OF LINE PIPES AT DUMP YARD
Project Name: Job No:

Client: Consultant:
Contractor Report No: Date:
DUMP SITE : PIPE DIA : MIV No.: MIV Dt.:
PIPE DIA: SPECIFICATION: GRADE:
Release Note No.:

Wall Thk. (mm):
Holiday check
for coating /
S. Coating Repairs
Pipe No. Heat No. Length internal gauge
No. No. (if any)
plate run /
visual check
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
The pipes mentioned above are coated (externally cleaned, primed and coated), tested and inspected in
accordance with the contract.
Visual Check includes mechanical damages, pipe bevels and proper securing with bevel protectors etc
Certified damage free handing over and receipt of above Line pipes.
TAKEN OVER BY LAYING

HANDED OVER BY COATING CONTRACTOR
CONTRACTOR
Sign.: Sign.:
Name: Name:
Date: Date:
EIL (Verified & retained for information)
Sign.:
Name:
Date:
Page 1978 of 2065

Page 1979 of 2065

Format no : P-02
MATERIAL ISSUE VOUCHER
CLIENT :
JOB DESCRIPTION :
REQUISITION NO : INDENT NO : MIV NO :
REQUISITION DATE : MIV DATE :
CONTR.NAME : CONTR. CODE : FREE/LOAN/CHARGEABLE
DRG NO:/LINE NO :
COST CENTRE : MATL.CARD NO:
ALLOCATION DATE : ALLOCATION RUN NO: VALID DATE
SL EIL ITEM CODE MATERIAL DESCRIPTION QUANTITY

UNIT RATE VALUE IRN NO & DATE
NO: CLIENT CODE (With Tag No as applicable) INDENTED ISSUED
NOTE : For line pipes (coated / bare), the copy of IRN of the pipes, indented quantity shall be attached with MIV for identification & certification of
pipe No, Coating No& pipe length issued and received by contractor.
IDENTED RECEIVED RECOMMENDED PROCESSED ISSUED POSTED AUTHORISED
CONTRACTOR CONTRACTOR SITE ENGR./AREA PLANNING STORE KEEPER INCHARGE

CORDINATOR (WAREHOUSE)
Name: Name: Name: Name: Name: Name:
Date: Date: Date: Date: Date: Date:

Page 1980 of 2065

FOR CROSS COUNTRY PIPELINE 6-82-1900 Rev.2
Format No : P-03
MATERIAL RETURN VOUCHER
Project : ______________________________________ MRV No: Date :____________

Client : ____________________________________
Contractor : _______________________________
Name of Work : ____________________________ Job No. : _________________
Work Order/Scope of work : _______________________ Cost Centre
MIV No. : _________________________
Sl. Material Materials Description with Return Type Quantity For Account Deptt.
Unit Location
No. Code No. Tag No as applicable / category Returned Accepted Rate Value
Remarks Category
A – Unused & Serviceable
B – Used & Serviceable
C - Repairable
D – To be returned to Vendor
E - Scrap
Returned By Authorised By Accepted & Data Entered Approved
CONTRACTOR’S SIGNATURE EIL STORE KEEPER/ In-charge (Warehouse)

& STAMP STORE OFFICER

Page 1981 of 2065

FOR CROSS COUNTRY PIPELINE 6-82-1900 Rev.2
Format No : P-04
INCOMING MATERIAL INSPECTION REPORT
Report No. :
Date :
Project : Unit : Name of Work :

Contractor : Consultant : Job No. :
Work order No. : P.O. No. & Date : LR No. :
MTC No./
SOR Material IRN No. Heat/
Sl. Date of Qty. Qty. Manufacturer/ Ref. Invoice/ Observation/Remarks/
Item description/Tag with Batch
No. Receipt Received Accepted Vendor Challan No. Storage Instruction
No. Date/Sampling No.
no for field test, etc
Notes :
INSPECTION ACTIVITY AT SITE (Tick as applicable)

1. Quantity verified and found in order 2. Material condition appears to be good 3. Heat/Batch/Tag No. mentioned on the material
4. Color coding done as applicable 5. Site identification mark on material 6. Correlation w.r.t. IRN/MTC/Lab Tests report
7. TC verification w.r.t. IRN/Spec/QAP, etc. 8. Check forVendor/Source approval 9. Special Requirement if any.
Based on above, materials are accepted. _____________________ __________________________

Contractor Field Engineer Contractor RCM / Site In charge
Name: Name:
__________________ _______________________________________________________________
EIL Field Supervisor (Countersigned) EIL Lead Engineer / Area Coordinator/ Spread In Charge
Name: Name:

Format No : P-05
INSPECTION REPORT FOR HANDING OVER OF ROU/
CLEARING, GRADING OF ROU
PART A : INSPECTION REPORT FOR HANDING OVER OF ROU

Client: Consultant:
Contractor: Date:
From: To: Report No.:
Section: Alignment Sheet No.:
Weather:
Chainage Markers Progress in meters
S Section Type of for IP
Remarks
No From To Length Ground nos/TP Today Previous Cum
Nos.
Details of Structure In/Across

ROU such as Pipeline, HT etc.
Name Of Structure Chainage Details
CONTRACTOR CLIENT
Sign Sign
Name Name
Date Date
PART B: CLEARING, GRADING OF ROU
Chainage Markers Progress in meters
S Section Type of
for IP nos/ Remarks
No From To Length Ground Today Previous Cum
TP Nos.
Details Of Structure In/Across

ROU such as Pipeline, HT etc.
Name Of Structure Chainage Details
Provision of safety warning sign in ROU for electrical HT line X-ing(30 m on either side): Yes/No
Manpower
Machineries
CONTRACTOR EIL / OWNER
Sign Sign
Name Name
Date Date
Page 1982 of 2065

Format No : P-06
INSPECTION REPORT FOR TRENCHING
Client: Consultant:
Contractor: Date:
Section: Alignment .Sheet No.:
Weather:
S Chainage Section Width Terrain

Depth Remarks
No From To Length Top Bottom classification
Details Of Structure : In/Across ROU such as Pipeline, HT , U/G Structure etc.
Availability of minimum cover ( From Top of Pipe/ Weight coating ) : Yes / No

Separation of Arable soil : Done / Not Applicable
Suitability of trench profile for bends :Yes / Not Applicable
Provision of warning signs & safety signs :Yes/No
Verification of minimum depth w.r.t. padding in rocky area / Sign. Of
Contractor
Seismic zone and cover requirements by Contractor. Checker
PROGRESS
PREVIOUS TODAY CUMULATIVE
CONTRACTOR EIL
sign Sign
Name Name
Date: date
Page 1983 of 2065

Format No : P-07
INSPECTION REPORT FOR ROCK BLASTING

Client: Consultant:
Contractor: Date:
Section: Align. Sheet No.:
Weather: Blaster Name / License details
Suitability for bend profile (Horizontal / Sag & Over bends) : YES / NA
Chainage Section Type of
S. No. Depth Width Remarks
From To Length Ground
Details of Structure/U/G : In/Across ROW such as U/G

utility Pipeline, overhead HT line etc.
Name of Chainage Details
Structure/UG/utility
 Provision of all safety waning sign, cordoning off, etc and
Checking of all safety precautions as per procedure/checklist
/ Standard HSE Specification (6-82-0001) attached in tender : Yes/No
 Firing of all spots : Yes/No
PROGRESS PREVIOUS TODAY CUMMULATIVE

IGN SIGN
NAME NAME
DATE DATE
Page 1984 of 2065

Format No : P-08
INSPECTION REPORT FOR STRINGING

Owner: Consultant:
Contractor: Date:
Section: Align. Sheet No.:
Weather: Line Pipe Spec & Grade
Type of corrosion coating : CTE/PE Concrete weight coating : Yes /NA

P-01
Wall Damage
S Pipe Report
Heat No. Yard Coating No. Thick in Length of coating Remarks
No. No. No. &
mm (if any)
Date
Additional Stringing if required (Crossing Locations)
Stringing Progress
To Chainage Length Previous Today Cum Remarks
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 1985 of 2065

Page 1986 of 2065

Format No : P-09
INSPECTION REPORT FOR COLD FIELD BENDING.
SPREAD : Date :
FROM : TO : Report No. :
WEATHER :
Type
Sl. Coating Visual Wall Length Pull Through Holiday Disbondment
Chainage / TP No Pipe No. Heat No. Degree of
No. No. Inspection Thickness (m) Check Check Check
Bend
No. of Bends Today Previous Cumulative Remarks :

a) Orientation of L seam as per spec
b) Maintaining limit for Degree / pull as per spec
Manpower
Machineries
Contractor EIL
Sign Sign
Name Name
Date Date

Format no : P-10
INSPECTION REPORT FOR CONCRETE WEIGHT COATING
OF PIPES
Owner: Consultant:
Contractor: Date:
Section: Alignment .Sheet No.:
Weather: Location: Shop / Field

Progress in resistivity
Concrete Coating meters value in
M-ohm
Wire
S Pipe Heat Coating Length Holiday after
Mesh Remarks
No. No No No (m) Test concrete
fixing Length Thickness Cumm
Today coating
(m) (mm) ulative
(Pass /
Fail)
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 1987 of 2065

Page 1988 of 2065

Format No : P-11
CRUSHING STRENGTH TESTING RESULTS OF CONCRETE CUBES
Project : Job No :
Client : Contractor :
Name of Work :
Grade of Concrete : Type of Cement :
W/C Ratio : Max. size of Aggregate :
Id. Date of Vol. Wt.

Type & Dimensions of Cube Unit Surface Crushing Crushing
Cube Mark Age of of Remarks
Location WT. Area Load Strength
No. on (days) L B H Cube Cube
of Structure Casting Testing (Kg/m3) (Cm2) (Kg) (Kg/Cm2)
cube (Cm) (Cm) (Cm) (m3) (Kg)
_____________________________ ________________ _____

( TESTED BY)/LAB-IN-CHARGE (CONTRACTOR ) ( EIL )
SIGN SIGN SIGN

NAME NAME NAME
DATE DATE DATE

FORMAT NO. : P-12

RECORD OF APPROVAL OF SOURCE(S) FOR
AGGREGATES
Project : Job No :
Name of Work :
1. Reference :
2. Material :
3. Location of Source :
4. Approx. distance from the site :
5. Physical Properties
a) Colour :
b) Shape : Rounded/Irregular
c) Texture : Glossy/Smooth/Granular
6. Tests conducted at :
7. Code of Conformance : IS : 383
8. Test Report Reviewed : Satisfactory/Un-satisfactory
9. Remarks : The source is approved/not approved
10. Explanation if any :
Enclosures : a) Reviewed Test Reports

b) Request of contractor, if available
COMMITTEE MEMBERS :
APPROVED : i) EIL :
ii) Client :
Signature of the contractor :
Date :
Place :
Page 1989 of 2065

Page 1990 of 2065

FORMAT NO. : P-13

SIEVE ANALYSIS REPORT
Project : Job No : Name of Work :
Wt. of Sample taken : Date on which sample taken :
FINE AGGREGATE
Cumulative Fineness Zone
S. No. Sieve Size Weight Retained (gm) Percentage Retained % Passing Remarks
% Retained Modulus (As per IS:383)
1. 4.75mm
2. 2.36mm
3. 1.18mm
4. 600 u
5. 300 u
6. 150 u
7. Pan
COARSE AGGREGATE/ROAD METAL Wt. of Sample taken :
Passed/ Failed Remarks
(As per IS:383/EIL Spec 6-65-0018)
1. 125mm
2. 90mm
3. 80mm 90-45 (Gr-I),
4. 63mm 63-45 (Gr-II),
5. 53mm 13.2mm (screening) for
6. 45mm
7. 40mm road work
8. 22.4mm
9. 20mm
10. 16mm 40mm down for PCC
11. 13.2mm
12. 12.5mm 20mm down for RCC
13. 11.2mm
14. 10mm
15. 5.6mm
16. 4.75mm
17. 2.36mm
18. 180 u
________________________ _______________ ____

(TEST BY/LAB-IN-CHARGE) (CONTRACTOR) (EIL)

FORMAT NO. : P-14

POUR CARD-I (PROGRAMME OF CONCRETING)
Contractor : Client :
Name of work :
1. Reference document :
2. Type of structure : Location :
3. Levels From : To :
4. Grade of concrete/ Approved Design Mix
5. Brand name, Grade and Consignment no. of cement
6. Estimated volume of concrete :
7. Quantity of cement required :
8. Reinforcement checking details :
No. Dia. Length
a) Laps
b) Separators
c) Chairs
d) Any other
Remarks
9. Pre pour inspection details Checked NA

a) Survey/ Layout
b) Sub soil compaction
c) Completion of underground works
d) Cleanliness
e) Cover to reinforcement
f) Anchor bolts
g) Sleeves/ pockets
h) Water stops
i) Formwork
j) Slopes
k) Construction/ Expansion joints
l) Admixtures
m) Any other
Remarks
10. Clearance for Electrical/ Mechanical Electrical Mechanical

works required/ not required :
11. The above structure is finally inspected on at AM/PM and found/ not found
satisfactory for concreting.
Remarks, if any
(Contractor) (EIL)
Sign Sign
Name Name
Date Date
Page 1991 of 2065

FORMAT NO. : P-15

POUR CARD-II (OBSERVATIONS DURING CONCRETING)
Contractor : Client :
Name of work :
1. a) Quality of coarse aggregates
Satisfactory Not satisfactory
b) Quality of fine aggregates

c) Bulkage of sand taken into account

Yes No
2. Quality of water
3. Machinery mobilization Nos. Stand by

a) Mixture machine
b) Ready mixed concrete dumpers
c) Vibrators
d) Pumps
e) Hoists
4. Pour start time : AM/PM ; Date :
5. Slump
6. W/C Ratio
8. Type of weather
Normal Abnormal
Details of abnormality :
(Precautions taken for <50C and >400C, rainy season)
10. Number of cubes taken :
11. Quantity of concrete poured :
12. Pour completion time : AM/PM ; Date :
13. Curing method :
Traditional Curing compound
Blankets/ foils/ gunny bags Others (specify)
14. Period for removal of form work :

15. Any defect(s) observed during concreting :
(Contractor) (EIL)
Signature Signature
Name Name
Date Date
Page 1992 of 2065

Page 1993 of 2065

Format No : P-16
LINE UP AND WELDING VISUAL INSPECTION REPORT

Owner: Consultant:
Contractor: Date:
Weather:
PIPE Dia Batch No: of Electrode:
Yard Welder Numbers

S Pipe Heat Joint WPS Fit up Visual
Coating Thickness Length Subsequent
No No. No. No. Adopted Inspection Root Hot Filler 1 Capping Inspection Remarks
No. fillers
Progress
Manpower: Joint No. Lining up Welding Completed
Remarks
From To Previous Today Cum Previous Today Cum
Machineries:
Internal Cleaning of Pipes: OK / Not OK Pull Through Pass :

Arc Strike removal by grinding DP& MP test & thickness check: Done/NA
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE

Format No : P-17
INSPECTION REPORT FOR TIE-IN WELDING

Owner: Consultant:
Contractor: Date:
Weather:
PIPE Dia Batch No: of Electrode:
WPS No;
Visual
Field
S Pipe Heat Fit Up Welder Inspection
Thickness Length Joint Remarks
No No. No. Inspection No. (including
No.
Arc Strike*)
Welded Today Previous Day Till Date
CUT PIPE DETAILS:
Pipe No. Length Removed/Added Remarks Note: Schematic sketch of tie in

joints with direction w.r.t. flow to be
attached.
RT Report No.: Coating of Tie-in Joint:

UT Report No.: Date of Commencement of Tie in:
Backfill Report No.: Date of Completion of all activities:
* Removal of Arc strike by grinding & thickness check : Done/NA
Removal / Retrieval of cut pipe from ROU – Done / Not Done
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 1994 of 2065

Format No : P-18
INSPECTION REPORT FOR RADIOGRAPHY
PROJECT NAME: JOB NO:

OWNER: CONSULTANT:
CONTRACTOR: DATE:
FROM: TO: REPORT NO.:
SECTION: ALIGNMENT SHEET NO.:
WEATHER:
PIPE THK.: ________

PIPE MATERIAL:
SOURCE : INTERNAL X-RAY/EXTERNAL X-
PIPE DIA:
RAY /GAMMA RAY
TYPE OF FILM: PENETRAMETER:
SENSTIVITY:_______________ TECHNIQUE: DWSI / SWSI
DENSITY:_________________
S JOINT RESULT
SEGMENT OBSERVATIONS REMARKS
NO. NO. CONTRACTOR EIL
LEGENDS: A-ACCEPTABLE, RT-RETAKE, R- REPAIR, C/S- SURFACE CHECK IN FIELD,

RS-RE SHOOT.
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE:
Page 1995 of 2065

FORMAT NO : P-19
INSPECTION REPORT FOR WELDING REPAIR

OWNER: CONSULTANT:
CONTRACTOR: DATE:
SECTION: ALIGNMENT .SHEET NO.:
WEATHER:
PIPE DIA BATCH NO: OF ELECTRODE:
WPS NO:
S. JOINT LOCATION WELDER VISUAL

REMARKS
NO. NO OF DEFECT NUMBERS INSPECTION
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE:
Page 1996 of 2065

Format No : P-20
INSPECTION REPORT FOR LIQUID PENETRANT
EXAMINATION REPORT

OWNER: CONSULTANT:
CONTRACTOR: DATE:
SECTION: ALIGN.SHEET NO.:
WEATHER:
DESCRIPTION MANUFACTURER BATCH NO.
PENETRANT :
REMOVER :
DEVELOPER :
PENETRANT DWELL DEVELOPER DWELL
SURFACE TEMP.:
TIME:______ Minutes TIME :____Minutes
DESCRIPTION
LINE JOINT OBSERVATIONS
SL.NO. OF TYPE SIZE REMARKS
NO. NO. / RESULTS
PART/SKETCH
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE:
Page 1997 of 2065

Format No : P-21
INSPECTION REPORT FOR ULTRASONIC TESTING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
PIPE DIA
S NO. JOINT NO. OBSERVATION ACC / REJ REMARKS
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 1998 of 2065

Page 1999 of 2065

Format No : P-22
INSPECTION REPORT FOR FIELD JOINT COATING
PROJECT NAME: JOB NO: REPORT NO.:

OWNER: PIPE DIA: DATE :
CONSULTANT: TYPE OF COATING : BATCH NO OF
CONTRACTOR: WEATHER: SLEEVE. :
RELATIVE HUMIDITY : PROFILE GUAGE DETAILS: PRIMER PART A : PRIMER PART B :
HUMIDITY METER DETAILS: DIGITAL PYROMETER DETAILS: HOLIDAY TESTER DETAILS:
SURFACE PREPARATION
CHECK THICKNESS MEASUREMENT
SL. JOINT WFT OF HOLIDAY ON BODY
DUST VISUAL ON WELD SEAM
NO. NO. ROUGH PRIMER TEST
CONTAMINAN- VISUAL D/S U/S
NESS
TION TEST 3 6 9 12 3 6 9 12 AVG. 3 6 9 12 AVG.
PEEL TEST : Joints Marked for Peel Test: Value: On Joint On Overlap: Accepted / Rejected
FIXING OF END CLOSURE PATCH (IN CASE OF HIGH TENSILE SLEEVES IN HDD): YES / NO Repair of Peel Test Location: OK / Not OK
MANPOWER: MACHINERIES:
CONTRACTOR EIL / OWNER:
SIGNATURE : SIGNATURE :
NAME : NAME :
DATE : DATE :

Format No : P-23
INSPECTION REPORT FOR HOLIDAY TESTING AND
LOWERING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
PIPE DIA AND GRADE
Dewatering :Completed / Not Applicable PADDING: PROVIDED/NOT APPLICABLE
Select Padding material for seismic zone :Provided / Not Applicable

Approved part A of pipe book for pipeline section as per format P-53 is available : Yes/No
Lowering Clearance: Yes / No
Chainage Padding over

Section HOLIDAY
S No OFC Trench Start Time End Time Remarks
From To Length CHECKING
Cleaning
Note: 1) Pipe top Level record after lowering as per format P24 is to be attached.
Previous Today Cumulative

Progress
Holiday Detector Details :

1. Make / Model :
2. Test Voltage : _______________
3. Routine Calibration Done On : _______________
4. Repair of Coating Damages : Completed / Not Applicable
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2000 of 2065

Format No : P-23A
INSPECTION REPORT FOR HOLIDAY TESTING AND
PULLING OF HDD STRING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER: CHAINAGE:
PIPE DIA AND GRADE CROSSING DETAILS
Approved part A of pipe book for pipeline section as per format P-53 is available : Yes/No
Pulling Clearance: Yes / No
Chainage
Section Holiday Details of Events Remarks (Details
S No
From To Length Checking of Break down)
Activity Start End
Pilot Hole *
(Carrier)
Reaming*
Clean Pass*
Pilot Hole *
(CS Conduit
for HDPE
Duct)
CS conduit
Pulling
Previous (Mtrs) Today (Mtrs) Cumulative (Mtrs)
Progress
Holiday Detector Details :

1. Make / Model :
2. Test Voltage : ______________
3. Routine Calibration Done On : _______________
4. Repair of Coating Damages : Completed / Not Applicable
 Drilling Log Sheet for each pass to be attached
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2001 of 2065

Format No : P-24
INSPECTION RECORD OR LEVEL RECORD AFTER
LOWERING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
PIPE DIA
Chainage @ 25mtr. &

at vertical bends Natural Ground
S No Pipe Top Level Remarks
Level (NGL)
From To
Pipe top Natural Ground

S No Chainage TP NO. Remarks
Level Level (NGL)
Certified that 500mm backfilling/post padding (if applicable) to cover pipeline & OFC cable is done immediately
after lowering of P/L and recording of levels as above.
REMARKS:
CONTRACTOR EIL/ OWNER
SIGN SIGN
NAME NAME
DATE DATE
Page 2002 of 2065

Format No : P-25
INSPECTION REPORT FOR BACKFILLING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
PIPE DIA AND GRADE
SL Joint No Chainage Length

Remarks
No From To From To Today Previous Till date
SOFT PADDING BEFORE BACKFILLING : OK / NOT REQUIRED
SPECIAL BACKFILL MATERIAL AS PER ALIGNMENT SHEET: OK / NOT REQUIRED
SL Chainage Slope Plastic Anti

Remarks
No From To Breakers Grating Buoyancy
Progress
Today Previous Cumulative Remarks
Padding (Post)
MANPOWER
MACHINERIES
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2003 of 2065

Format No : P-26
INSPECTION REPORT FOR CASED CROSSING
OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER: CHAINAGE:
CARRIER PIPE DIA / GRADE / THICKNESS CROSSING DETAIL
Type of Crossing :- Road / Rail / Canal Chainage :-
A) CASING PIPE DETAIL
Material specification:- Total length : _____________ Visual Check (Out of roundness / dents etc.) OK / Not
OK
Painting
Weld visual
Dia. Thick Length Joint No. Casing pipe internal Casing pipe Remarks
after welding
DFT external DFT
B) CASING VENT AND DRAIN SKETCH:

Size and length of vent pipe :____________________
Size and length of drain pipe :____________________
Pipe grade :___________________
Coating / Painting of vent& drain : A/G__________________ U/G ______________
C) OFC Steel Conduit details
Size & Length: HDPE duct & sealing details:
Pipe Grade: Size:
DFT of external paint: Rating:
End seals details:
D) CARRIER PIPE DETAIL Dia.:______ Thk.:_________ Length:_________
Pre-Hydro Holiday
Welding RT UT Field Joint
Stringing test Checking
Sl No. Pipe No Joint No. Report Report Report Coating
Report No. Report Report
No. No. No. Report No.
No. No.
Checked By
OTHER DETAILS:- Contractor Owner/EIL Boring Operation:-
Bottom Level of Casing Pipe Start-Date/Time:-
Installation of Zinc Ribbon Anode, if applicable Completed-Date/Time:-
Installation of Insulators, Nos, and Spacing. Carrier Pipe Insertion:-
Installation of End seals Start-Date/Time:-

Electrical continuity Resistance check(Before backfilling and
tie-in) Completed-Date/Time:-
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2004 of 2065

Format No : P-27
INSPECTION REPORT FOR OPEN CUT ASPHALT ROAD
/ LISTED MINOR WATER CROSSING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
PIPE DIA
Joint Holiday Remarks

Sl Pipe Bending Stringing Weld Welding
RT Report Coating Report
No No Report Report Jt No Report
Report
GENERAL
DATE OF
CHAINAGE
COMMENCEMENT
ALIGNMENT SHEET NO. DATE OF COMPLETION
TYPE OF XING (ROAD/CANAL) ACTUAL NO. OF DAYS
CARRIER PIPE DETAILS
OPERATION STARTED
GRADE X WALL THK
ON
OPERATION FINISHED
PIPE INSTALLED ON
ON
CARRIER WELD REF REPORT NO.
SKETCH (IF REQUIRED, SEPARATE SHEET MAY BE ATTACHED)
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2005 of 2065

Format No : P-28
INSPECTION REPORT FOR MAJOR RIVER CROSSING BY
OPEN CUT

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
PIPE DIA AND GRADE
S
ACTIVITY REPORT NO. DATE: REMARKS
NO
1 TRENCHING
2 STRINGING
3 WELDING
4 NDT
JOINT COATING / CONCRETE
5
WEIGHT COATING
6 PREHYDRO TESTING
7 LOWERING
8 BACKFILLING WITH PADDING
9 GAUGING
10 POST HYDRO TESTING
11 RESTORATION AND CLEANUP
12 TIE-IN
GENERAL TRENCHING
CHAINAGE DATE OF COMMENCEMENT
ALIGNMENT SHEET NO. DATE OF COMPLETION
RIVER XING ACTUAL NO. OF DAYS
OPEN CUT
LOWERING BACKFILLING
OPERATION STARTED ON OPERATION STARTED ON
OPERATION FINISHED ON OPERATION FINISHED ON
PIPE LINE BOTTOM CONTOUR
INSPECTION AFTER LOWERING :
Diver Report attached
AS BUILT SKETCH : __________________ Attached as Annexure
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2006 of 2065

Format No : P-28 A
INSPECTION REPORT FOR MAJOR RIVER CROSSING /
OTHER CROSSINGS BY HDD

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
PIPE DIA AND GRADE
S
ACTIVITY REPORT NO. DATE: REMARKS
NO
1 TRENCHING
2 STRINGING
3 WELDING
4 NDT
5 PREHYDRO TESTING
6 JOINT COATING
7 HOLIDAY AND PULLING
8 GAUGING
9 POST HYDRO TESTING
10 TIE IN
11 RESTORATION AND CLEANUP
GENERAL DRILLING DETAILS
CHAINAGE DATE OF COMMENCEMENT
ALIGNMENT SHEET NO. DATE OF READINESS FOR PULLING
RIVER XING ACTUAL NO. OF DAYS
PULLING
OPERATION STARTED ON COATING INTEGRITY CHECK OK / NOT OK
OPERATION FINISHED ON
BENTONITE DISPOSAL
RESTORATION ON: CROSSING COMPLETED ON:
MARKER INSTALLATION ON:
AS BUILT DRAWING : __________________ Attached as Annexure
REMARKS:
SIGN SIGN
NAME NAME
DATE DATE
Page 2007 of 2065

Format No : P-29
HYDROSTATIC PRE - TEST CUM EVALUATION REPORT
OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
Testing Duration
Start Date Finish Date
Start Time Finish Time
No of pipes in String : Length of pre-tested String :
Details of Tested Pipes and Weld Joints ( if any)
Pipe No./Section From- Weld joint NDT
Wall thickness Length of pipe Remarks
To no. Clearance
Volume of Water filled :

Test Pressure :
Pressurization : Start Time Finish Time
Pressure Hold Period : Start Time Finish Time
Variation in temperature, °C Format P-30
Initial measured pressure Format P-30
Final measured pressure Format P-30
Theoretical pressure change as calculated Format P-30
Inference and acceptance.
Hydro test Accepted & Section released for depressurization / Hydro test not Accepted.
Section dewatered & end cap fixed on date:……………..
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2008 of 2065

Format No : P-30
TEMPERATURE AND PRESSURE RECORDING LOG FOR
PRE HYDROTESTING
OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
S. NO. TIME PRESSURE TEMPERATURE REMARKS

1
3
4
5
6
7
8
9
10
11
12
13
14
15
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2009 of 2065

Format No : P-31
HYDROSTATIC POST - TEST CUM EVALUATION REPORT

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
Testing Duration
Start Date: Finish Date
Start Time: Finish Time
Length of String : Test Pressure :
Volume of Water filled :
Pressurization : Start Time Finish Time
Pressure Hold Period : Start Time Finish Time
Variation in temperature, °C
Initial measured pressure
Final measured pressure
Mano thermograph
Inference and acceptance.
Hydro test Accepted & Section released for depressurization / Hydro test not Accepted.
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2010 of 2065

Format No : P-32
INSTALLATION OF MARKERS

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
S Location Listed Type of Marker No of Orientation Remarks

No. (Chainage) Crossing, if Markers
any Installed
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2011 of 2065

Format No : P-33
CLEARANCE CERTIFICATE OF
PIPELINE SECTION FOR HYDROTESTING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
O D (mm) Wall Thk. (mm) I.D.(mm) Grade Length (km) Volume (m3)
Min. : Min. : (excluding test headers)
Max. : Max. :
Wall Thickness
Length (Mtr) Number of Welds :
(mm)
Length of not back filled section :
CONSTRUCTION PERIOD :
Start Date :
Total Length End Date :

This is to certify that all welds of the above test section have been accepted and the pipeline section
has been laid and backfilled according to the specifications. All activities up to part-B of pipe book is
completed.
REMARKS ( Exceptions if any)

CONTRACTOR EIL OWNER
SIGN : SIGN : SIGN :
NAME: NAME : NAME :
DATE : DATE : DATE :
Page 2012 of 2065

Format No : P-34
SAFETY CHECKLIST FOR PIPELINE SECTION
HYDROSTESTING
SL
CHECK POINTS YES NO
NO.
1 The test section has been isolated from all other pipeline sections.
2 Is a copy of the hydro test pack available in the area ?
3 Is adequate water disposal arrangement made?
Check Housekeeping standards are acceptable at the filling end and receiving
4
end.
5 Check the conditions of the tools and tackles to be used.
Check that the lighting arrangements are adequate and the condition of the
6
electrical wiring circuit boards, conduit etc. is acceptable and safe.
Check that test areas at each end of the test section have been cordoned off
7
with stakes and bunting tape.
Check that emergency equipment are adequate and are working condition-
8 standby vehicle, communication system, first aid boxes, medical facilities,
stretcher etc.
9 Check the condition of tools to be used.
All temporary piping test heads and other equipment connected to the test
10
section have been pre tested to a pressure of at least 1.1 times the test pressure.
Ensure; complete bolting on cleaning /Batching Pigs are properly tightened
11
before insertion in the test Headers.
12 The test section has been completely filled with water and the air vented off.
13 All instruments and gauges which are used have valid calibration certificates.
All warning notices, marker tapes, protective barriers and other safety
14
equipment have been positioned and all the concerned informed.
15 All persons who may be affected by the operations are informed of the activity.
Communication system is tested and ensured that this is working properly.

16
Backup instruments are available.
Informed the person operating the pressuring equipmets of the maximum test
17
pressure which shall be applied to the test section.
Joint inspection of the entire facilities by the hydro test engineer and HSE
18
officer to ensure all the safety measures have been undertaken before the test.
Note : Hydro test engineer/ HSE officer to add any other safety points to this list as per the site
circumstances if deemed necessary.
HYDROTEST ENGINEER HSE OFFICER
Sign : Sign :
Name : Name :
Date : Date :
Page 2013 of 2065

Format No : P-35
INSPECTION REPRT FOR AIR PIGGING OF PIPELINE
SECTION DURING HYDROTESTING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
No of welds:
Compressor Location Km ________ Make : Model :
Out Put : ________ Max. Pressure : _________ kg/ sqcm
Pigging Direction From : Ch __________ To : Ch__________
Remarks (Abnormal
Start End
quantity of water /
Run No Pig Type
debris or any
DATE TIME DATE TIME interruption)
REMARKS :
Acceptance of Cleaning : Yes / No
Sign : Sign : Sign :
Name: Name : Name :
Date : Date : Date :
Page 2014 of 2065

Format No : P-36
INSPECTION REPORT FOR GAUGING OF PIPELINE
SECTION DURING HYDROTESTING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
No of welds:
Compressor Location Ch ________ Make : Model :
Out Put : ________ Max. Pressure : _________ kg/ sq cm
Pigging Direction From : KM __________ To : KM __________
Gauge Plate Start End

Remarks
Dia ( mm ) Thk. ( mm) Material Date Time Date Time
Enclosure : - The Photograph of Gauge Plate After Run (Front, back and side views – 3 snaps)
Detail of Gauge Plate Damage ( if any ) :
REMARKS :
Acceptance of Gauging : Yes / No
Sign: Sign : Sign :
Name: Name : Name :
Page 2015 of 2065

Format No : P-37
INSPECTION REPORT FOR WATER FILLING OF
PIPELINE SECTION DURING HYDROTESTING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
No of welded joints:
Test Medium : Water Source : ______________ Location :_Km_________
Inhibition : Y/N Type : ______________ Dosage :__________ mg/l (ppm)

MTC No & Date : Batch No. : TPL Rpt No & Dt.:
Fill Pump Location :_Ch__________ Make : ________________
Out Put : ________ M3 /hr Max. Pressure : __________ Bar
Dosing Pump Make : Model : Out Put : Ltrs./ Min.

Max. Pressure :
Flow meter: Make: Model: Output: Calibration Certificate No.& Date
Filling Direction : From To
Pig Sequence :
Pre filling Length ( Mtr.) Volume (m3)
Ist Pig Type
Between Pig 1 & 2 Length ( Mtr.): Volume (m3)
2nd Pig Type:
Time Cumulative Volume

Volume Fill Water
Sl. (24 Fill Pressure Flow meter Filled
Date this Including Temperature Remarks
No. Hour (kg/cm2) Reading Volume after
period prefill Range
format) Sec.Pig
(hrs) (m3) (m3) (m3) (m3) (deg. C)
Filled water temperature to be recorded continuously on Temperature Recorder & readings to be recorded hourly
REMARKS :
Acceptance of WATER FILLING : Yes / No

NAME : NAME : NAME :
Page 2016 of 2065

Page 2017 of 2065

Format No : P-38
INSPECTION REPORT FOR THERMAL STABILISATION OF PIPELINE SECTION DURING HYDROTESTING
OWNER: CONSULTANT:
CONTRACTOR: DATE:
WEATHER:
No of welded joints:
Time Location No. ----> 1 2 3 4 5 6 7 8 9 10 11 12
( Hrs) Difference between Average Pipe Temperature
Date in 24 Average and Average Soil Temperature (0 C)
hour Chainage ( Km) ---->
format
TEMPERATURES ( o C )
Pipe
Soil
Pipe
Soil
Pipe
Soil
Pipe
Soil
READINGS TO BE TAKEN EVERY TWO HOURS
THERMAL STABILIZATION BE CONSIDERED TO HAVE BEEN ACHIEVED, WHEN THE DIFFERENCE BETWEEN THE AVG. PIPE TEMP. AND AVG. SOIL TEMP.IS NOT HIGHER
THAN 1˚C. FOR 2 CONSECUTIVE READINGS.
Remarks:
Acceptance of THERMAL STABILIZATION : Yes / No

Name : Name : Name :

Page 2018 of 2065

Format No : P-39
INSPECTION REPORT FOR AIR VOLUME CALCULATIONS DURING PRESURE TEST OF PIPELINE SECTION
PROJECT NAME: JOB NO: CONSULTANT:
OWNER: CONTRACTOR: DATE:
FROM: TO: REPORT NO.: SECTION:
WEATHER: ALIGN.SHEET NO.: No of welded joints:
Pressurization Cycle: 50% / 75 % / 100%

Test Station Location ___________ Test Pressure ________________ Bar
Avg. Pipe Temp. ( ˚C )
Pressure Pressure Lowering Volume of drained Water
(Bar / Kg/cm2) (Bar / Kg/cm2) (liters)
Initial
After First Pressure Lowering
After Second Pressure Lowering
To Calculate the theoretical volume of water required to achieve a change in pressure, the volume pressure equation is Vp = (0.884 ri/t+A)x 10-6 x Vt X ∆ Px K
Where : Vp = Computed water amount required to raise by
P The Pressure in the section to be tested ( m3 )
Vt = Geometrical Volume of the Section ( M3 ) =
ri = Nominal inner radius of the pipe (mm) =
t = Nominal pipe thickness (mm) =
A = Isothermal compressibility value for water at the pressurization temperature in
the" P" range ( Bar-1 ) x 10.6 Refer graph. =
∆ P = Pressure Rise ( bar ) =
K = A dimensionless coefficient that is equal to a
Value of 1.02 for longitudinally welded pipe. =
Therefore Vp = M3
= litre
Actual Volume of water drained to drop pressure by 0.5 kg/cm2 = Litre ( vi)
Therefore Vi / Vp =
Since the ratio is less than 1.06, the filling is acceptable and the test section may be pressurized to the final test pressure
Note: In case the test section have multiple wall thickness, ri shall be correspond to the wall thickness which have max total length in the test section
Acceptance of The AIR VOLUME : Yes / No

Page 2019 of 2065

Format No : P-40
INSPECTION REPORT FOR PRESSURIZATION OF PIPELINE SECTION DURING HYDROTESTING

Pressurization Cycle: 50% / 75 % / 100% Target Pressure at Test Station (Bar / kg/cm2):
Section Length: Theoretical volume: Material: Wall thickness: Source of water:
Elevation /Pressure at: Highest point: Pressurizing Point:
Lowest point: Pressurizing Point:
STROKE COUNTER/Flow mtr
TIME ( in Pressure/Dead Wt AMBIENT
DATE 24 hour READING VOLUME M3 CUM. VOL. M3 REMARKS
format)
Bar/Kg TEMPERATURE
STROKE COUNTER FLOW METRE
Pressurization Pump : Make ____________ Model ___________ Discharge Pressure ____________________
Dead Weight Tester : Make ____________ Model ___________ Calibration Certificate No: & Date _________
Flow Meter : Make ____________ Model ___________ Calibration Certificate No: & Date _________
Acceptance of PRESSURIZATION : Yes / No

NAME : NAME : NAME :

Page 2020 of 2065

Format No : P-41
INSPECTION REPORT FOR DEAD WT. PR.PIPE TEMP & SOIL TEMP. DURING 24 HR PRESSURE TEST OF PIPELINE
SECTION

Time Press P- S-
P-1 P-2 P-3 P-4 P-5 P-6 P-7 P-8 P-9 S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8 S-9
(Hrs) ure 10 10
Ambient
(Bar Average Pipe Average Soil
Date (in 24 /
Temp REMARK
Temperature Temperature
hour Kg/c KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM ˚C S
format) m2)
DEAD WEIGHT TESTER READINGS TO BE RECORED AT EVERY HOUR, PIPE & SOIL TEMPERATURE READINGS TO BE RECORDED EVERY 2 HOUR.
LINE PRESSURE AND AMBIENT TEMPERATURE TO BE RECORDED CONTINUOUSLY ON RECORDERS.

WATER BLEED OFF MEASUREMENT (IF ANY)
Detection of leak(if any) and extension of HT duration : Yes/No

Acceptance of Pressure Test ( 24 HOURS HOLD ) : Yes / No
EIL
CONTRACTOR OWNER

Page 2021 of 2065

Format No : P-42
INSPECTION REPORT FOR CALCULATION AND EVALUATION OF HYDROSTATIC TEST FOR PIPELINE SECTION
DESCRIPTION Highest point Lowest point Start Point End point

ELEVATION IN METRES
PRESSURE IN BAR OR KG/CM2
Date Time (24 hr format) Pressure ( Bar /Kg/cm2) Average Pipe Temp (Deg C)
Start of Test
End of Test
Algebraic Difference (Start - End)
CALCULATIONS :
∆p= ( B x ∆ T) / (0.884x ri / t + A)
Where :∆ =P Pressure change resulting from temperature change
B= Value of the Difference between thermal expansion of water and steel at temperature and pressure as measured from enclosed table at the end of the test ( ˚C -1) X 106
ri = Nominal inner radius of pipe ( mm)
t = Nominal wall thickness of pipe ( mm)
A= Algebraic compressibility factor of water ( Bar-1 ) X 106
∆T = Algebraic difference between pipe temperature at beginning and at end of the test. ( ˚C ) (start - end)
EVALUATION :
( 1 ) Pressure at the end of the test __________________ Bar
( 2 ) Pressure change resulting from temperature change (as calculated above) Bar
( 3 ) Adjusted pressure at the end of the test after adding pressure change resulting from temperature change Bar
( 4 ) Difference between pressure at the start and the adjusted pressure at the end of the test (start - end) Bar
( 5 ) The test shall be accepted if the difference is algebraically less than or equal to 0.3 Bar (0.306 Kg/cm2)
CONCLUSION :
Test is Acceptable / Not Acceptable ( Strike out whichever is not applicable )
Section is released for depressurization : Yes / No
Note - All Calculations & Evaluation to be done considering the Algebraic Signs

Page 2022 of 2065

Format No : P-43
INSPECTION REPORT FOR DEWATERING AFTER HYDROSTATIC TEST FOR PIPELINE SECTION

Compressor Location Ch Make : Model :

Out Put : Max. Pressure : kg/ Cm2
Dewatering Direction From : Ch To : Ch
Discharge point :
Quantity of
Avg Vel
Start End Pressure(kg/cm2) Water /
Run No Type of PIG Km/hr
Remarks
DATE TIME DATE TIME Min Max
Repair of coating at Thermo-couple locations: OK / Not OK

REMARKS
ACCEPTANCE OF DEWATERING : YES / NO


Page 2023 of 2065

Format No : P-44
INSPECTION REPORT FOR SWABBING OF PIPELINE SECTION

O D (mm) Wall Thk. (mm) I.D.(mm) Grade Length :

Min. : Min. :
Max: Max: Volume: CUM
Compressor Location Km ________ Make : Model :
Out Put : ________ Max. Pressure : _________ kg/ sqcm
Pigging Direction From : Ch __________ To : Ch__________
Pressure
Pig Type Start End Avg. Vel. Weight of the PIG
Run No ( Kg/ Cm2) REMARKS
HD/LD Km/HR.
DATE TIME DATE TIME Min Max Initial Final
REMARKS:
Acceptance of Swabbing of section : Yes / No

CONTRACTOR EIL CLIENT
Name: Name : Name :

Page 2024 of 2065

Format No : P-45
INSPECTION REPORT FOR SV INSTALLATION

WEATHER: ALIGN.SHEET NO.: Valve Tag No: Make:
Verified
Sl. No. Description Detail/Report no Remarks
CONTRACTOR EIL
1 Chainage / Location
2 Valve / Insulation Joint No.
3 Valve Assembly Fabrication Report
4 NDT Report Valve Assembly
To be done in partial open condition
5 Hydro test Report of Valve Assembly
of valve
6 Tie-in Valve / Insulation Joint
7 Tie-in NDT Report
8 Field Coating Report
9 Concrete Foundation with insulation sheet on top
10 Padding & Backfilling
11 Civil / Structural work
12 Painting of above ground structures
Progress :
ERECTION PREVIOUS CUMULATIVE
MANPOWER
MACHINERIES
Name: Name : Name :

Page 2025 of 2065

Format No : P-46
INSPECTION REPORT FOR RESTORATION

WEATHER: ALIGN.SHEET NO.:
Chainage Removal of Replaceme

Type of
S No Surplus nt of Top Reinstallation of Boundary stones Remarks
From To Land
Material soil

Name: Name : Name :

Format No : P-47
INSPECTION REPORT FOR CALIBRATION OF
INSTRUMENTS

OWNER: CONSULTANT:
CONTRACTOR: REPORT NO:
SECTION: DATE:
FROM: TO:
MASTER INSTRUMENT DETAILS CALIBRATION DETAILS:
MASTER INSTRUMENT ID VALIDITY:
Instrument I.D: Instrument Detail:

Date of calibration: Valid up to:
Instrument Instrument
Master
S. Readings Readings while Difference in
Instrument Difference Remarks
No. while going coming down %
Reading
up the scale the scale
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2026 of 2065

Format No : P-48
RECORDING OF SITE DATA FOR PREPARATION OF AS
BUILT OF OFC

OWNER: CONSULTANT:
CONTRACTOR: DATE:
SECTION: CABLE ALIGN.SHEET NO.:
DATE OF LAYING OF OFC
S No OFC AS BUILT DETAILS MEASUREMENTS
1 Type of Road/ Canal / River / High way / Joint / Tie-in
2 Starting P/L Chainage and welding joint No of pipe ( m / Km )
3 Starting OFC Reading / Marking ( m )
4 Starting OFC drum No:
5 Ending P/L Chainage and welding joint no of pipe ( m / Km )
6 Ending OFC Marking/Reading ( m )
7 Ending OFC drum No:
8 Length of OFC laid(m/km)
9 Length of conduit used ( m ) ( if any )
10 Type of conduit used ( if any )
11 OFC Loop length ( m ) with start & end marking readings ( if any )
12 Detail of markers used ( if any )
13 Detail of underground markers used ( if any )
14 Detail of the joint closures used ( if any )
15 Physical location in case of OFC joint.
NOTE: Permanent land mark may be used in defining physical location of OFC joint / joint pits.
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2027 of 2065

Format No : P-49
INSPECTION REPORT FOR OFC LAID IN CROSSINGS
OWNER: CONSULTANT:
CONTRACTOR: DATE:
TYPE OF CROSSING
A) Laying in CS conduit
S.No.
Cable
Chainage
Drum
No. Installation of duct with pulling wire inside CS conduit Remarks
From To Previous Today Cumulative
B) Cable Laid In Separate Trench:

Near Repeater Station Other location
Reason for
S.No. Chainage Chainage laying in Remarks
Length Length separate trench
From To From To
C) Material Used:
Heat
OFC
S. No. Chainage HDPE CS Pipe shrinkable Joint Pit Electronic Marker Remarks
Marker
cap
From To
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2028 of 2065

Format No : P-50
INSPECTION REPORT FOR OFC DRUM TESTING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
Drum Length
Drum No. Date of testing

Testing OTDR Eqpt. Used &
Wavelength SR/CERT NO Supplier
Fibre Identification Optical Average Loss
Fibre NO. Remarks
Length ( dB/km )
Bundle Color
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2029 of 2065

Format No : P-51
INSPECTION REPORT FOR OFC JOINTING & SPLICING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
JOINT No: JOINT KIT DETAILS:
OTDR Details: (Make, Sl No, Calibration Details) Cable No. (+Ve direction) :
Cable No. (-Ve direction) :
Testing Wave Length
Fibre Splice
Positive Direction Negative Direction Remarks
Fibre Identification Loss
No. Fibre Loss Fibre Loss
Bundle Color
Length dB/Km Length dB/Km
Note : Positive Direction is in the direction of Liquid Flow.
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2030 of 2065

Format No : P-52
INSPECTION REPORT FOR OFC LINK TESTING

OWNER: CONSULTANT:
CONTRACTOR: DATE:
DETAILS OF INSTRUMENT USED:
JOINT No:
Fibre
Splice Loss, Joint No. Splice Loss ,Joint No. Splice Loss, Joint No. Remarks
Identification
Fibre
NO. Fibre A' B' Average A' B' Average A' B' Average
Bundle
Color Direction Direction (A+B)/2 Direction Direction (A+B)/2 Direction Direction (A+B)/2
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2031 of 2065

REMARKS
OWNER
RESTORATI
ON DATE
DATE OF PCP

6-82-1900 Rev. 2
OFC FINAL TESTING

Page 92 of 106
EIL
BANK MINOR
C
PROTECTIO
N MAJOR
FINAL TIE-
IN DATE
DATE OF IP
CONTRACTOR
CONTRACTOR
DATE OF SV
OFC PART TESTING
HYDROTES
P/L FINAL T DT
CONC.
OWNER
FOR CROSS COUNTRY PIPELINE
COAT
ANTI-
INSPECTION & TEST PLAN
BUOYANCY SADDLE
CONTROL WT.
BACKFILL DATE
WORKS
EIL
OFC
SPLICING & JOINTING
B
TCP DATE
CONSULTANT
LENGTH
CONTRACTOR
OFC
LOWERING DATE
TIE-IN DATE
LOWERING DATE
JT CTNG. DATE
UT DATE
OWNER
PIPE BOOK FORMAT
X-RAY DATE
WPS No
WELDING DATE
JOINT NO.
__________ mtrs
__________ mtrs
A
To:
BENDING DATE
EIL
P-53
STRINGING DATE

THK (mm)
LENGTH (mtrs)
:
CONTRACTOR
From:
PIPE LENGTH ON
UPTO THIS PAGE

CUMM. LENGTH
COATING
Format No
No.
THIS PAGE
CLIENT
HEAT No
KM
PIPE NO
Page 2032 of 2065
(Sheet 1 of 2)
Format No : P-54
INSPECTION REPORT FOR CATHODIC PROTECTION
SYSTEM
PROJECT NAME: REPORT NO.:
OWNER: DATE:
CONTRACTOR: CONSULTANT:
PIPELINE CHAINAGE: JOB NO:
REF DOC NO.:
THERMIT WELDING / PIN BRAZING Date:

Sr. CABLE SIZE CONTINUITY CONTACT HOLIDAY TEST REMARKS
PIN BRAZING Date:

Sr. CABLE SIZE CONTINUITY CONTACT HOLIDAY TEST REMARKS
BONDING CHECK BETWEEN PIPE AND CABLE BY MANUAL PULLING OK / NOT OK

CONTINUITY CHECK OK / NOT OK
EPOXY AND HARDNER FILLING OK / NOT OK
CABLE LAYING Date:
Sr. CABLE SIZE FROM TO MEGGER REMARKS
DEPTH OF LAYING OK / NOT OK

SAND BRICKS COVER, WARNING MAT & BACK FILLING OK / NOT OK
TAGGING / FERULLING OF CABLE OK / NOT OK
CABLE TERMINATION OK / NOT OK
MAGNESIUM ANODE INSTALLATION:- Date:
Sr. DEPTH OF ANODE SPACE BETWEEN ANODES DISTANCE FROM OPEN CIRCUIT VOLTAGE
No PIPELINE
PSP BEFORE CONNECTION OF ANODE Volt

PSP AFTER CONNECTION OF ANODE Volt
BACKFILLING OF ANODE OK / NOT OK
Page 2033 of 2065

(Sheet 2 of 2)
Format No : P-54
INSPECTION REPORT FOR CATHODIC PROTECTION
SYSTEM
ZINC ANODE INSTALLATION: Date:

SR. SPACING BETWEEN DISTANCE OPEN CIRCUIT
DEPTH OF ANODE
NO. ANODE FROM VOLTAGE
PSP BEFORE CONNECTION OF ANODE Volt

PSP AFTER CONNECTION OF ANODE Volt
BACKFILLING OF ANODE OK / NOT OK
TLP INSTALLATION Date:

TYPE OF CHAINAGE DISTANCE ENTRY MEGGER PIPE TO REMARKS
TLP FROM SEALING VALUE SOIL
PIPELINE POTENTIAL
LETTER WRITING ON TLP (Ch.No. DISTANCE FROM PIPELINE, DIR OF FLOW):- OK/NOT OK
Fixing of Schematic Diagram plate ON TLP :- OK/NOT OK
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2034 of 2065

Format No : P-55
INSPECTION REPORT FOR ANODE CONNECTION & SEALING

OWNER: DATE:
REF DOC NO.:
SR
ANODE NO CABLE LENGTH CONTINUITY TEST ENCAPSULATION
NO
REMARKS
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2035 of 2065

Format No : P-56
INSPECTION REPORT FOR ZINC RIBBON ANODE
INSTALLATION

OWNER: DATE:
REF DOC NO.:
CHAINAGE IN KM
LOCATION
TYPE OF CROSSING
ZINC ANODE AS PER SPECT. OK / NOT OK
LENGTH OF ANODES mm
NO. OF ANODE Nos.
SPACING BETWEEN ANODES Mtrs.
ANODE CORE EXPOSED EITHER SIDE mm
ANODE CORE CONNECTION TO PIPE AS PER OK / NOT OK
APPROVED DESIGN / DRAWING
CORE ENCAPSULATION OK / NOT OK
REMARKS
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2036 of 2065

Format No : P-57
INSPECTION REPORT FOR ANODE JUNCTION BOX
INSTALLATION

OWNER: DATE:
CP STATION NO : JOB NO:
REF DOC NO.:
PIPELINE CHAINAGE IN KM :
PIT DIMENSION AS PER APPROVED DRAWING OK / NOT OK
CONCRETE MIX, CONCRETE FOUNDATION,

REINFORCEMENT & SIZE AS PER APPROVED DRG. OK / NOT OK
& CURING 7 DAYS.
MOUNTING OF JUNCTION BOX OK / NOT OK
CHECK FOUNDATION LEVEL OK / NOT OK
HEIGHT OF FOUNDATION ABOVE GROUND OK / NOT OK

LEVEL
ANODE TAIL CABLE CONNECTION OK / NOT OK
ANODE HEADER CABLE CONNECTION OK / NOT OK
PAINTING OF JUNCTION BOX OK / NOT OK
AVAILABILITY OF DOORS, LOCKS & GASKETS OK / NOT OK
FINAL ACCEPTANCE OK / NOT OK
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2037 of 2065

Format No : P-58
INSPECTION REPORT FOR CPTR AND CPPSM INSTALLATION
OWNER: DATE:
STATION LOCATION: REF DOC NO.:
INSTALLATION OF TRU / CPPSM
1 Installation (Indoor / outdoor) OK / NOT OK
2 Cable connection, termination & tagging OK / NOT OK
3 Earthing of the unit
COMMISSIONIG OF TRU / CPPSM
1 Sr. No. Of the TRU / CPPSM
2 Total anode bed resistance OHMS
3 Test in manual / auto mode
3.1 Operation of switch / breaker Accepted /rejected
3.2 Operation of TRU / CPPSM Accepted /rejected
A) Auto mode Accepted /rejected
B) Manual mode Accepted /rejected
3.3 Meter calibration Accepted /rejected
DESCRIPTION METER READING MEASUREMENT WITH

PORTABLE PANEL
Input voltage
Input current
Output voltage
Output current
PSP
3.4 Operation of auto / manual switch Accepted /rejected
3.5 Operation of meter switches Accepted /rejected
3.6 Operation of current limits Accepted /rejected
3.7 Operation of voltage limits Accepted /rejected
3.8 Operation of failure mode led’s Accepted /rejected
3.9 Operation of other led’s Accepted /rejected
3.10 Operation of reference electrode circuit Accepted /rejected
3.11 Operation of current interrupter Accepted /rejected
3.12 Megger value input to ground OHMS
3.13 Megger value output to ground OHMS
4.1 SETTINGS
Current Limit: A Voltage Limit: V
4.2 Observations
Input side (AC/ DC)
Current: A Voltage: V
Output side (DC)
Current: A Voltage: V
PSP: V Ref 1: V
Ref 2: V Ref 3: V
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2038 of 2065

Format No : P-59
INSPECTION REPORT FOR ER PROBE INSTALLATION

OWNER: DATE:
CP STATION NO: JOB NO:
REF DOC NO.:
1 CHAINAGE IN KM : KM
2 ER PROBE CONDITION OK / NOT OK
3 DEPTH OF ER PROBE INSTALLATION MTRS.
4 DISTANCE FROM PIPELINE MTRS.
5 CABLE TERMINATION IN TEST OK / NOT OK

STATION
6 IDENTIFICATION GIVEN
7 READING TAKEN BY ER PROBE

READER
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2039 of 2065

Format No : P-60
INSPECTION REPORT FOR HORIZONTAL ANODE BED
INSTALLATION

OWNER: DATE:
CP STATION NO: REF DOC NO.:
DIMENSION OF ANODE : TAIL CABLE SIZE :
SPACING BETWEEN ANODES : BACK FILLING MATERIAL

CABLE PE / PVC CABLE CABLE ANODE
ANODE NO LENGTH SLEEVE CONNECTION CRIMPING INSTALLATION CABLE TAG
(DEPTH IN M)
A1
A2
A3
A4
A5
A6
A7
A8
A9
A 10
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2040 of 2065

Format No : P-61
INSPECTION REPORT FOR COMMISSIONING OF ANODE BED

OWNER: DATE:
DIMENSION OF ANODE : TAIL CABLE SIZE :

SPACING BETWEEN ANODES : BACK FILLING MATERIAL:
INDIVIDUAL ANODE
ANODE NO CABLE LENGTH REMARKS
RESISTANCE(IN Ω)
A1
A2
A3
A4
A5
A6
A7
A8
A9
A 10
TOTAL CIRCUIT RESISTANCE :- OHMS
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2041 of 2065

Format No : P-62
INSPECTION REPORT FOR VERTICAL ANODE BED
INSTALLATION
OWNER: DATE:
Dimension of anode Spacing between anode

Tail cable size Backfill material
Casing pipe Dia Thickness Anode bed depth (m)
Vent pipe Dia Length Anode bed chamber / pit Ok/not ok
Pvc shrouding
Dia Length Coke filling & compaction Ok/not ok
pipe
End weight Kg. Connection Cable laying Ok/not ok
Individual
Cable Depth of Anode
Anode no Cable tag number anode
length (m) anode (m) centralizer
resis.(in Ω)
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
TOTAL CIRCUIT RESISTANCE= IN OHMS
Remarks:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2042 of 2065

Format No : P-63
INSPECTION REPORT FOR POLARIZATION CELL
INSTALLATION

OWNER: CONSULTANT:
CONTRACTOR: DATE:
PIPELINE CHAINAGE: REPORT NO.:
LOCATION DESCRIPTION
TEST STATION TYPE
RATING TYPE
ELECTROLYTE LEVEL IN POLARIZATION CELL OK / NOT OK
STAND BY CURRENT & VOLTAGE ACROSS AMPS VOLT

POLARIZATION CELL
INSTALLATION OF POLARIZATION CELL OK / NOT OK
Ensure connection to pipeline & Galvanic earthing of OK / NOT OK

Polarisation cell
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2043 of 2065

Format No : P-64
INSPECTION REPORT FOR SURGE DIVERTER
INSTALLATION

OWNER: CONSULTANT:
CONTRACTOR: DATE:
PIPELINE CHAINAGE: REPORT NO.:
IJ LOCATION
SURGE DIVERTER INSTALLATION OK / NOT OK
ENCAPSULATION OF CABLE TO IJ CONNECTION OK / NOT OK
HOLIDAY TEST AFTER ENCAPSULATION OK / NOT OK

.
POLARITY / CONTINUTY CHECK OK / NOT OK
Earthing of unprotected side of the Surge diverter OK / NOT OK

.
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2044 of 2065

Format No : P-65
INSPECTION REPORT FOR PERMANENT REFERENCE CELL
INSTALLATION
OWNER: DATE:
CP STATION NO: JOB NO:
REF DOC NO.:
CHAINAGE (IN KMS)
REFERENCE CELL INSPECTION AS PER SPEC

OK / NOT OK
REQUIREMENTS
DEPTH OF REFERENCE CELL INSTALLATION MTRS.
DISTANCE FROM PIPELINE MTRS.
SPACING BETWEEN REFERENCE CELLS : MTRS.
CABLE TERMINATION IN TEST STATION. OK / NOT OK
PSP REFERENCE CELL NO. 1 VOLT
PSP REFERENCE CELL NO. 2 VOLT
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2045 of 2065

Format No P-66
INSPECTION REPORT FOR POLARIZATION COUPON
INSTALLATION

OWNER: DATE:
POLARIZATION COUPON INSPECTION ON SPEC

OK / NOT OK
REQUIREMENTS
DEPTH OF POLARIZATION COUPON INSTALLATION MTRS.
DISTANCE FROM PIPELINE MTRS.
SPACING BETWEEN POLARIZATION COUPON MTRS.
CABLE LAYING AND TERMINATION IN TEST STATION. OK / NOT OK
PSP W.R.T. REFERENCE CELL VOLT
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Page 2046 of 2065

ATTACHMENT – II
Page 2047 of 2065

k31 ENQNEERS FOR COLOUR CODING OF 6-82-0003 Rev.2
f&fMeg~ INDIA LIMITED PIPING MATERIAL
1.11W,212ZIWA513PCMI/ I A Govt ot Incha Undertaking) Page 1 of 12
trrferrr ~,11 -trr

t'q rafgkii
STANDARD SPECIFICATION
FOR
COLOUR CODING
OF
PIPING MATERIAL
2 25/06/2014 Revised and updated

SM RKD SC
1 10/07/2009 Revised and updated ND

SM SM RKD
0 30/05/2003 Issued as Standard Specification RKN MPJ RSG SKG

Standards Standards
Checked Comm ittee Bureau
Rev. Prepared
Date Purpose by Convenor Chairman
No by
Approved by
Page 2048 of 2065

■
71 "ENGINEERS
-
OfjesW INDIA LIMITED FOR COLOUR CODING OF 6-82-0003 Rev.2
1.1,M CWW17,2513~1 IA Govt ol InOia Undettalong)
PIPING MATERIAL Page 2 of 12
Abbreviations:
API American Petroleum Institute
ASTM American Society for Testing & Materials
IBR Indian Boiler Regulatory
IS Indian Standard
Convenor: Sh. RK Das, ED (Construction)
Members : Sh. M Deshpande, GM (Construction)

Sh. M Natarajan, GM (C&P)
Sh. Rakesh Nanda, GM (Piping)
Sh. S Mukherjee, DGM (Construction)
Sh. Janak Kishore, DGM (Projects)
Page 2049 of 2065

‘31 ENGINEERS
FOR COLOUR CODING OF
$'guri8ffileg
Iff271
INDIA LIMITED
IA Govt of Inda Unclertak.9) PIPING MATERIAL
6-82-0003 Rev.2
Page 3 of 12
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
3.0 GENERAL GUIDELINES FOR IDENTIFICATION BY COLOUR CODING 4
4.0 IDENTIFICATION COLOURS 4
5.0 METHOD OF COLOUR CODING 4
6.0 TABLE: THE FOLLOWING TABLES SHALL FORM AN INTEGRAL PART OF

THIS SPECIFICATION 5
TABLE - 1 BASIC COLOURS FOR IDENTIFICATION 6
TABLE - 2 COLOUR CODES FOR PIPES, FITTINGS & FORGINGS 7
TABLE - 3 COLOUR CODE- STUDS/BOLTS AND

NUTS 9
TABLE - 4 COLOUR CODE FOR GASKETS 10
ANNEXURE-1 SCHEMATIC REPRESENTATION OF COLOUR

IDENTIFICATION 11
Page 2050 of 2065

ENGINEERS
$igz-1~" 2r51- g
Jr,, eizawan~) INDIA LIMITED FOR COLOUR CODING OF 6-82-0003 Rev.2
IA Govt ol Inda UnderlaNing)
1.0 SCOPE
This standard covers the method of identification of the piping materials by coloring using
paints in order to avoid mix-up between materials of different metallurgy but similar in
physical appearance.
2.0 REFERENCES
The following Code shall be referred to as and when required for resolution of colour shades.
IS: 5-2007: Colours for ready Mixed Paints and Enamels
RAL K5 Classic Edition 2006
3.0 GENERAL GUIDELINES FOR IDENTIFICATION BY COLOUR CODING
i. Materials shall be painted with one colour or combination of colours as set out in this
specification.
ii. Paints used for colour coding shall be of quality so as to last for at least 5 years.
iii. Studs/Bolts and Nuts shall be painted.
iv. Colour Identification is not required on Austenitic Steel.
v. Colour identification is not required on galvanized-materials and non-ferrous metals

such as copper, lead, aluminum because they are easily distinguished by their specific
color and character.
vi. Special items like bellows, strainer, steam traps, valves do not require colour
identification as these items are tagged with their identification.
vii. Discrimination colour shall be marked on the inner and outer surface of pipes &
fittings.
4.0 IDENTIFICATION COLOURS
i. Paint colours to be used for identification shall be in accordance with Table-1.

ii. Application of various colours for identification shall be as per clause 5.0 of this
standard.
5.0 METHOD OF COLOUR CODING
i. Colours and locations of colour identification on pipes, fittings, flanges, gaskets,

studs/bolts, nuts shall be in accordance with Table-2 to 4 and Annexure-1.
ü. The identification colour on gaskets shall be painted on the peripheral face of each
gasket (refer Annexure-1).
iii. Ends of the materials to be welded shall not be painted.
iv. Width of colour band shall be a minimum of 12 mm for less than 3 inch size
components and 25mm for 3 inch and larger sizes, unless otherwise specified.
The length of inner surface painting
Page 2051 of 2065

ENGINEERS
INDIA LIMITED FOR COLOUR CODING OF 6-82-0003 Rev.2
(A Govt of inda undertak,N) PIPING MATERIAL Page 5 of 12
Shall be not less than 4 inch (100 mm) at both ends of pipes and shall start 2
inch (50mm) from pipe ends.
Shall be about 2 inch (50 mm) at any one end of fittings.
v. Wherever combination of two or more colours is specified, materials shall be painted

in parallel colour bands as close to each other as possible (Refer Annexure-1).
vi. Paints containing chlorine, chlorides, sulphur, lead, zinc or any contents detrimental to
materials are not acceptable. The contractor shall satisfy and produce documents/carry
out tests as required by the owner/EIL.
vii. A query shall be raised with EIL for materials not covered by this specification.
viii. If continuous stenciling of material specification is available then colour coding on

stainless steel material may be avoided.
6.0 TABLE: THE FOLLOWING TABLES SHALL FORM AN INTEGRAL PART OF

THIS SPECIFICATION
Table No. Tittle
1. Basic colour of identification
2. Colour identification on pipes, fitting and flanges
3. Colour identification on Bolts/Nuts/studs
4. Colour identification on Gaskets
Annexure-1 Schematic representation of colour identification
Page 2052 of 2065

k31 ENGINEERS
Of5leg INDIA LIMITED FOR COLOUR CODING OF 6-82-0003 Rev.2
ewasre‘lx~1) (A Govt of )ndo Uneertakm9) PIPING MATERIAL Page 6 of 12
TABLE - 1
BASIC COLOURS FOR IDENTIFICATION

(REF. IS: 5 (2007) APPROXIMATE MUNSELL VALDE REFERENCE)
Equivalent RAL Codes

Indian
standard `Munsell' Value (*)
Name of
SI. No.
Colour shade colour
(ISC) No. Hue Value/Chroma NAME RAL Code
Dove gray 100 694 2.3 G 5.53/0.48 Mouse Grey RAL7005
Salmon Pink 68 443 2.5 YR 6.31/4.7 Beige Red RAL3012

Mahogany
India Brown 65 415 2.7 YR 3.76/3.02 RAL 8016
brown
Canary yellow 39 309 4.8 Y 7.89/11.02 Zinc Yellow RAL1018

Deep orange 87 591 8.9 R 5.04/10.38 Red Orange RAL2001
Lincoln Green
27 276 0.3 G 3.53/2.81 Fir Green RAL6009
Yellow
Sea Green 14 217 6.2 GY 6.12/6.15 RAL6018
Green
Sky Blue 1 101 8.3G 6.09/2.86 Water Blue RAL5021
Navy Blue 6 106 6.2 PB 2.61/0.95 Cobalt Blue RAL5013
Light Purple 73
449 3.2 R 3.07/2.14 Pale brown RAL8025
Brown
Dark Violet 104 796 6.1 P 3.5/4.27 Traffic purple RAL4006
Chocolate
Chocolate 74 451 3.5 YR 2.82/0.67 RAL8017
Brown
Maroon 83 541 1.3 R 2.9/1.36 Wine Red RAL3005
Post Office RAL3002
81 538 4.2 R 3.55/8.39 Carmine Red
Red
NOTE: * The Colours are based on RAL K5 Classic Edition 2006 by RAL, Deutsches institut,
incorporated for international jobs.
Page 2053 of 2065

TABLE — 2
STANDARDSPECIFICATION No.

6-82-0003 Rev.1
11
Salmon Pink
Salmon Pink
"c3
r-.
Deep Orange &Sea Green

Deep Orange &Sea Green
Navy Blue &India Brown
Dove Grey &Navy Blue

Colour
a)
t>.1)
Dove Grey
cz)
c),
No Paint
541Maroon
Maroon
None
(1)
0 0 0 0 (1.)
Z Z Z Z (21
1
1.,
0
0 0
az .LD
591/217
591/217
106/415
r..) C)
.--,
-1- ,--,
591
.d- c+1 cr)

1 1i i
1 1i 1 0•■ C■ .1-
kr)
•:t- •zt
d• •1- o
cn
cO
,—,• 0
87/14
87/14
kr) ....... O
O C) c.)
1I i i 11
87
I ----- O O rel en
i 1 ■C) ,--, ,--, 00 00
A182 Fl o
Flange/Blind
Flan e
O
czt O
o . Q •2
in (--) (1) •
C) oo s-,
,—, ---., 0 0 0 -0
1I
e
11
1 1il 1I
1 1,I •
- (.1-i •-4•-■ czt
czt v) • •-•
"C:3 o ^c, .
A-234 Gr WPB/WPBW-NONIBR1
•■•-,
A-234 Gr WPBW-NONIBR
c‘:3 0 cz; "I:73

•
Elbows, Reducers, Tee's Caps
C • ,C1).
A-234Gr WPB/WPBW-IBR
c
i "C,g - Cv3 5
cc cl T=1, cu
,u +A
,SZ>
A-420WPL6
,•C+
A-234Gr WPB(N)
A-234 WPBW (N)
• ci)
&NORMALISED
1A-420WPL6W
c?,,4
IA-234WP1W
1.) Ov) 0
L.> "10 ,c)
A-234WP 1
(1)
cc)
czt O eD
ci)
'/) . 1") "è.,
0 .•c)
I I I I °
c.) cll P-4
I I I I
I I I I cll c„)
•^. r+-■•' bo
,c,
c/D
(1)
Stainless steel
t/i O
API 5LGr B — Seamless
IS1239/IS3589Gr 410
C.) 0 C,-) el;

API5LGr B — ERW
Cr) ci) " •E •E

T-1
0.) (1) Ci)
a.,
IS3589Gr 330
)
.
(Normalized)
0:1 ,-ti
A106 Gr B
A106Gr B
o.
1A333Gr 6
:5 r,4 czs
FormatNo. 8-00-0001-F7 Rev. 0
Z
„
kr, kr, OO
. en
en c) 0 u.4
.d .< •-
•- •-
12
coH
—• c'., ,__, ,. . „1, ,,, .1- C) ,-,
..... cf-)
-..
kn \ C) li."--- 00 01 —,
1
Page 2054 of 2065

STANDARD SPECIFICATIONNo.
6-82-0003Rev.1
Paae 8 of12
Page 2055 of 2065

TABLE - 2
COLOUR CODESFOR PIPES, FITTINGS& FORGINGS (.... Contd.)
Olc;,
©
1.0
1:::ii
;«I
0
a.>
0
0
L)
U
Elbows, Reducers, Tee's Flange/Blind Flange
ts..
C3
0
z
c:;
m 31 z
7)•. z
Caps
.d-
A335Gr P 11 A-234WP11 A 182 F11 27 276 Lincoln Green II
(^4
\ ,0
C X.1
S
C"--
A691Gr 1.25 Cr CL.42 A-234WP11W Lincoln Green
(EFW)
1•••••4
.--.1
(;)
el
15 A335Gr P12 A-234WP12 A182 F 12 Sky Blue
7
,
e
1
i
C)
.-1
A-234WP12W Sky Blue
;
91
Ln
C•11
<
en
Cs1
(.5
rn
A-234 WP22 A182F22 14 217 Sea Green
e
e
r."..
C•1
d-
,,
A691Gr 2.25Cr CL.42 A234WP22W Sea Green
(EFW)
‘••0
•—■
'4D
C, Navy Blue
S
A335Gr P5 A-234WP5 A 182 F5
e
e
e
1/4.0
,--,
'4:)
C)
A-234 WP5W Navy Blue

l"---
'.0
CT
Lr)
01
en
en
<
c5
II 18 A-234WP9 A182F9 104 DarkViolet
e
e
r---
CT
'4:›
A-234WP9W 104 DarkViolet
<3.■
ii>
d•
r.....
d'
,'
A335Gr P91 A-234WP9 1 A182F91 Chocolate
e
I
d-
ir....
li-1
,.,
.'t
A-234WP91W Chocolate
E-1
Format No. 8-00-0001-F7Rev. 0 Copyright EIL — All rights reserved
u_
O
z
z
o u-
o
po
•< o
<o
z
6-82-0003Rev.1
c) o o_
•w oo<
LT. (3. 1.2
z
G.
-
!".
Page 2056 of 2065

INDIANSTD.
c5
c.)
z
ASTM DESIGNATION COLOURSHADES
COLOUR (ISC) NO.
cT
.±::
C0
0
r4
rn
rn
c,
A 193 GR B7 Canary Yellow
CT
rn
z
,_,
CD
cf-)
0,
A194GR2 H Canary Yellow
■
,--
r2a)
0
0
d-
kr)
,=,,
v-,
A307GRB India Brown
L.,-
\.0
z
,...,
kr)
d-
-1
A 307 GR B India Brown
C\I
•■-■
0
0
rit
r--
r-
C\1
A193 GRB 16 Lincoln Green
C■1
z
0
I--
+,
r-
c\1
A194GR4 Lincoln Green
,C--,r
d-
--1
kr)
--,
0:1
A320GRL7 Chocolate
GC)
;_4-4
CT
d-
s
d-
rn
A 320GRB8 Light Purple Brown
,_,
Z
CT
d-
d-
s
rn
A194GR8 Light Purple Brown
cu
;-T-4
(4-4
r=4
cct
c>
•
cl
0
ao)
0
•
▪
cz$
ftS
czt
c/)
czt
cC
c.)
c.)
4c-4
cu 0
• a)
cu (I)
a)
a)
a)
a)
O
O
o
0
0
0
H
O cr,
6-82-0003Rev.1
CL
o
Page 2057 of 2065

TABLE - 4
INDIAN STD.
z•
:,.,
C/)
C4
E--,
d
P.
<
[-.
›.
ASTMDESIGNATION/DESCRIPTION COLOURSHADES
COLOUR (ISC) NO.
C'
C■
,r
■D
,--.
c>
,--,
7
0
CompressedFibre BS7531GR.X (FULLFACE) Dove Gray
(Ring &FullFace)
1
BS7531GR.X (RING) None
"c
c, ,,
Z
o
4
CD
-■-■
,z)
■D
,--1
c0
(.7
SS304SPRWND+Grafoil Filler
.
•a., o
v, 3
7, d
-_
■
•:1-
.1-
v)
o
O
en
00
W SS 304 H +GrafoilFiller
r=1.
r:Z
o
o
.1-
.1"
,--1
C---
4".
c,
M
SS304+Grafoil Filler
'
r:Ej
.5,
9
kr■
,—,
•ci-
-
■D
v-,
SS304+Teflon Filler
`
—
In
.:I-
m
00
g
SS304LSPRWND+Grafoil Filler
c.5
,f)
CN
—
00
Ir--
P-)'
SS3 16SPRWND + Grafoil Filler

i...
C7
o
,-)
,.5
C sl
a
o
.,5
■0
C■1
r"--
C--
SS316 LSPR. WND+Grafoil Filler

..,,
2ed
o
c..)
CN
<0
C7■
Cn
en
SS316HSPR. WND+ Grafoil Filler

t:
....,
- ed,..
o
•
>.
Teflon Jacketed SPR. WND ,—. rsl

CN C---
■D ■0
C-- r■1
O S
OCT. Ring Gasket 5Cr,1/2Mo (Max. 120 BHN) Lincoln Green

Gasket
CN
•z1"
VD
C;)
•—.
o
Soft Iron (Max. 90BHN) Dove Gray
FormatNo. 8-00-0001-F7Rev. 0 CopyrightEIL — All rights res rved

STANDARDS SPECIFICATION STANDARD SPECIFICATION No.
k31 ENG1NEERS FOR COLOUR CODING OF 6-82-0003 Rev.2
Og-af la5le;g INDIA LIMITED PIPING MATERIAL
IA Govl of lnOo Undertaking) Page 11 of 12
ANNEXURE-1
SCHEMATIC REPRESENTATION OF COLOUR IDENTIFICATION
A. COLOUR IDENTIFICATION OF PIPES
X77-7.-M-71777-77-777777777-777714
ONE COLOUR IWO COLOUR
B. COLOUR IDENTIFICATION OF FITTINGS
EIBOW TEE
ONE COIOUR TWO COLOURS ONE OR IWO COLDURiS)
REOUCER STUES ENO

4' •
ONE COLOUR TWO COLOURS ONE OR TWO COLOUR1S)
CAP COUPL1NG
ONE OR TWO COLOUR(S)

ONE OR 1W3 COLOUR1S)
Page 2058 of 2065

ENGINEERS
INDIA LIMITED FOR COLOUR CODING OF 6-82-0003 Rev.2
+~.rreaxr aaJaael (A Govt of lnOa Unde(taking)
SCHEMATIC REPRESENTATION OF COLOUR IDENTIFICATION (Contd...)
C. COLOUR IDENTIFICATION OF FLANGES
ONE COLOUR TWO COLOURS
D. COLOUR IDENTIFICATION OF GASKET
10 BE COLOUREO AS SkCIFIE0
E. COLOUR IDENTIFICATION OF STUDS/BOLTS & NUTS
MACHINE BOIT SiU0 BOIT NUT
Page 2059 of 2065

ATTACHMENT – III
Page 2060 of 2065

OBSERVATION ON QUALITY ASPECTS
2nd RAW WATER INTAKE PUMP HOUSE Format No: B001-00-000-
AND PIPELINE PROJECT AT 19-41-0001-F1 Rev 0
DAMANJODI, NALCO
OBSERVATION ON QUALITY ASPECTS
Job No: Name of Work: No:

FOI/LOA No:
Issued To : M/s Date of Issue:
Location Of Work:
Item Of Work:
Details Of Observation( Deficiency) Recommended Course Of Action
Time Allowed For Correction
Issued By: Received by:

Name : Name:
Designation: Signature:
Signature: Date and Time:
Corrective Action Report By Contractor/Vendor:
Name
Date: Signature:
Distribution Before Resolution:

RCM/ Area Coordinator /QA Mgr:
Verification Of Resolution By Issuer/Area Coordinator/RCM(EIL):
Name:
Date: Signature:
Distribution After Resolution:
RCM/ Area Coordinator /QA Mgr:
Format No. EIL -1641-1924 Rev1 Copyrights EIL – All rights reserved
Page 2061 of 2065

ATTACHMENT – IV
Page 2062 of 2065

OBSERVATION ON SAFETY ASPECTS
2nd RAW WATER INTAKE PUMP Format No: B001-00-000-
HOUSE AND PIPELINE PROJECT AT 19-41-0001-F2 Rev 0
DAMANJODI, NALCO
OBSERVATION ON SAFETY ASPECTS
Job No: Name of Work: No:

FOI/LOA No:
Issued To : M/s Date of issue:
Location Of Work:
Item Of Work:
Details Of Lapses/Shortfalls/Hazards Identified Recommended Course Of Action
Suspension of work required till resolution.

(Yes/No)
Time Allowed For Correction:
Issued By: Received by:

Name : Name:
Designation: Signature:
Signature: Date and Time:
Corrective Action Report By Contractor/Vendor:
Date: Name And Signature:
Distribution Before Resolution:

RCM/ Area Coordinator/QA Mgr :
Verification Of Resolution By Issuer/Area Coordinator/RCM (EIL):
Name:
Date: Signature:
Distribution After Resolution:
: RCM/ Area Coordinator /QA Mgr:
Format No. EIL -1641-1924 Rev1 Copyrights EIL – All rights reserved
Page 2063 of 2065

TECHNICAL COMPLIANCE FORMAT Document No.
CONSTRUCTION DIVISION
B001-00-000-19-41-TC01
2nd RAW WATER INTAKE PUMP HOUSE
AND PIPELINE PROJECT AT DAMANJODI, Rev 0
NALCO Page 1 of 2
PROJECT : 2nd RAW WATER INTAKE PUMP

HOUSE & PIPELINE PROJECT
OWNER : M/s NALCO, DAMANJODI
PMC : ENGINEERS INDIA LIMITED
JOB NO. : B001
0 19.12.2016 ISSUED FOR BIDS PKR RK GM(C)

Rev.
No
Page 2064 of 2065

TECHNICAL COMPLIANCE FORMAT Document No.
B001-00-000-19-41-TC01
2nd RAW WATER INTAKE PUMP HOUSE
AND PIPELINE PROJECT AT DAMANJODI, Rev 0
NALCO Page 2 of 2
Bidder must furnish answers/clarifications/confirmations of all the following queries and submit
along with offer.
SL. BIDDER'S
COMMENT/QUERY
NO. CONFIRMATION/ANSWER
1. Bidder to confirm that requirement of Health, Safety and
Environment (HSE) as per specification 6-82-0001 are
taken into consideration.
2. Bidder to confirm that Construction Management of this

job shall be done by him and shall not be sub-contracted
to any other agency.
3. Bidder to confirm that required construction personnel for

supervision to meet the contract schedule shall be
deployed by him meeting the requirement of qualification
and experience (refer Doc. No 7-82-0003 in this regard)
without any time & cost implications.
4. Bidder to confirm that required construction equipments

to meet the contract schedule shall be mobilized by him
without any time & cost implications.
Bidder’s Signature and Stamp
Signature Not Verified

Digitally signed by VIVEK DIXIT
Date: 2017.10.21 12:43:23 IST
Location: eProcure
Page 2065 of 2065

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AN NEXURE-2

ENGINEERS FORMAT FOR COMMENTS

Document No. : Rev. No.:

Date of Submission: Date of Review:

Sl. Contractor's Response

Review Code Legend:

Code 2 Proceed with manufacture/ fabrication as per commented document.

Code 3 Document does not confirm to basic requirement as marked.

R Retained for Records.

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Date: Name & Signature

✓ : Check carried out and found OK

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24 Internal co-ordination with all concerned departments.

Date: Name & Signature

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