PC TSP HP&LP Dos LCP

Bharat Heavy Electricals Limited
Piping Centre Chennai-17
ENGINEERING DEPARTMENT
Rev. No Specification No. Sheet No.

00 PC:TSP:HP & LP DOS - LCP 1 of 16
TECHNICAL SPECIFICATION FOR SUPERVISORY CONTROL PANEL FOR HP & LP

DOSING SYSTEM
APPLICABLE TO UTILITY AND INDUSTRIAL UNITS
05
04
03
02
01
00 15.06.17 Fresh Issue B.Sumith B.Sumith R.Prabha
REV. DATE ALTERATION PREPARED CHECKED APPROVED



DOSING SYSTEM
1 SCOPE OF SUPPLY
1.1 Floor mounted control panel for H.P & LP dosing pumps and agitator drives, in
line with Clause 5 of this specification.
1.2 Cable glands.
1.3 Commissioning spares, if any, along with maintenance spares for 3 years
trouble free operation (to be separately listed).
2 SPECIFIC DATA SHEET
2.1 Designation : H.P & LP Dosing System Control Panel
2.2 Quantity / Boiler : 1
2.3 Location : Outdoor
2.4 Protection : IP 55
2.5 Design Data



DOSING SYSTEM
2.5.1 Ambience : Dusty & Corrosive (Ambient Temp. 50°C)
2.5.2 Mounting : Floor
2.5.3 Cable entry : Bottom
2.5.4 Sheet Steel Thickness : Minimum of 2.5mm
2.5.5 Painting : Outside Shade 692 of IS 5
2.5.6 Internal wiring : PVC, FRLS cable to be used and shall be

grouped as per voltage level & ferruled.
2.5.7 Supply voltage : 1 feeder of 415V, 3 phase, 50 Hz of

10.0 kW will be made available to the
Panel.
2.5.8 Voltage : 24 V DC (to be derived from 415V supply

using redundant power pack)
2.5.9 Purchasers earthing conductors: G.S. of 25 x 3 mm
2.5.10 Status Indicating Lamp : As per requirement
3 GENERAL REQUIREMENTS
3.1 Panel shall conform to general conditions as indicated in spec., to the extent they
are applicable and not contradicted elsewhere.
3.2 No.of D.O.L. starters, selector switches, indicating lamps etc. shall be such that
local supervision are possible to be effected.
3.3 All logics are built in DCS. Hence, this panel shall have adequate D.O.L. starters,
annunciator local / remote selector switch, ON-OFF Push Buttons, Relays and
contactors, status indicating lamps etc. All these devices shall be wired to screwed
TB, which can accept 1.0 mm² conductor.


DOSING SYSTEM
3.4 DCS voltage is 24V DC. All selector switches, PBs shall be miniature type. 24V DC
shall be derived using suitable redundant power pack mounted inside the
panel.
3.5 The front shall be provided with a hinged door with glass for lamp portion so that
viewing is possible without opening the front door.
3.6 The number of D.O.L. starters, status indicating lamps, PBs, Relays and contactors,
status indicating lamps etc shall cater to process all the signals listed in the “Signal
Exchange List” provided. Suitable relays for processing 24V DC signals from DCS to
Local Control Panel shall be provided. Please refer “Signal Exchange List” provided.
3.7 Operators interface PB, SS etc. shall be located between 800 mm and 1600 mm
from bottom of panel.
3.8 Testing, Inspection & Documentation will be as specified elsewhere.
3.9 Cable glands to suit cable sizes (indicated below) specified as applicable, shall be
supplied.
3.9.1 Main Incomer : 3 Core x 16 mm² Al, PVC, armoured
3.9.2 Outgoing Feeder

Upto 3 kW : 3 Core x 2.5 mm² CU, PVC, armoured
> 3 kW and < 7 kW : 3 Core x 6mm² AL, PVC, armoured
4 CONTROL PANELS / DESKS
4.1 General
Following are the general requirements for the control panels.
4.1.1 The selection and design of all the equipment shall ensure reliable and safe
operation of the plant. Makes and types of all components of the panel shall be
subject to the Engineer's approval. Wherever alternative makes are offered, the
Owner shall have the right to choose any particular make of component, and this
discretion shall be binding on the Contractor.


DOSING SYSTEM
4.1.2 The panels shall be supplied to Site completely assembled and wired. Required
anchoring hardware for fixing the panel to wall shall be supplied, as also all cable
glands and lugs required for terminating the cables being supplied under this
package.
4.1.3 The reference ambient temperature outside the desks and panels shall be taken as
50°C, and relative humidity as 100%.
4.2 Codes & Standards
4.2.1 The design, manufacture and performance of the equipment shall conform to the
requirements of latest revisions of the following standards.
4.2.1.1 IS:4237 General requirements for switch gear and control gear
for voltages for exceeding 1000V AC.
4.2.1.2 IS:8623 Factory built assemblies of switchgear for voltages upto

1000V AC and 1200V DC.
4.2.1.3 IS:3202 Climate proofing of electrical equipment.
4.2.1.4 IS:2147 Degree of protection provided by enclosures for low

voltage switchgear and control gear.
4.2.1.5 IS:4064 Air break switches, air break disconnectors, air break
switch disconnectors and fuse combination units for
voltages not exceeding 1000V AC and 1200V DC.
4.2.1.6 IS:2208 & IS:9224 Low voltage fuse.
4.2.1.7 IS:6875 Control switches (switching devices for control and

auxiliary circuits including contactor relays) for voltages
upto and including 1000V AC and 1200V DC.
4.2.1.8 IS:1248 Direct acting electrical indicating instruments.
4.2.1.9 IS:2419 Panel mounted indicating and recording electrical

instruments.


DOSING SYSTEM
4.2.1.10 IS:2959 Contactors for voltage not exceeding 1000V AC or
1200V DC.
4.2.1.11 IS:694 PVC insulated cables for working voltages upto and
including 1100V AC.
4.2.1.12 IS:375 Switchgear busbars, main connections and auxiliary

wiring, making and arrangement.
4.2.1.13 IS:8828 Miniature circuit breakers for voltages not exceeding

1000V.
4.2.1.14 IS:5 Colour.
4.2.1.15 IS:6005 Code of practice of phosphating iron and steel.
4.2.2 Equipment confirming to other recognised standards shall also be acceptable

provided requirements of such standards are equal or superior to those of the
relevant Indian Standards.
4.2.3 The equipment shall also conform to the provisions of latest versions of the
Indian Electricity Act and Indian Electricity Rules.
4.3 Constructional Details (as applicable)
4.3.1 The panel frames shall be fabricated using suitable mild steel structural sections of
pressed and shaped, cold rolled sheet steel of thickness not less than 2.0mm.
Frames shall be enclosed in cold rolled sheet steel of thickness not less than
1.6mm. Stiffeners shall be provided wherever necessary. Gland plates shall be of
the removable type and at least two separate gland plates shall be provided for
each panel. They shall be of sheet steel of thickness not less than 3.0mm. All
hardware used shall be Ni-Chromium plated.


DOSING SYSTEM
4.3.2 All panel edges and cover / door edges shall be reinforced against distortion by
rolling, bending or by the addition of welded reinforcement members. There shall
be no sharp edges or corners.
4.3.3 The complete structure shall be rigid, self supporting, free from flaws, twists and
dents. All cut-outs shall be true in shape and devoid of sharp edges.
4.3.4 Panels shall be provided with hinged doors of width not exceeding 600 mm (with
in-built locking arrangement and handle). It shall be possible to open the door
through 100 degrees. The doors, cut-outs and covers shall be equipped with
approved type of neoprene / synthetic rubber all round and sufficient latches /
bolts shall be provided.
4.3.5 Each of the local panel shall be provided with a front door having a cut-out duly
covered with glass or equivalent transparent sheet through which status indicating
lamps are clearly visible. Further, all D.O.L. starters, local / remote selector
switches, push button stations, lamps etc. shall be mounted on the panel.
4.4 Control and Selector Switches
4.4.1 Control and selector switches shall be of miniature type with escutcheon clearly
marked to show the function and positions. The switches shall be of sturdy
construction suitable for mounting on panel front. Switches with shrouding of live
parts and sealing of contacts against dust ingress shall be preferred.
4.4.2 Control / selector switches shall be spring return or stay put type as per the
requirements. Lost motion feature shall be provided wherever required. Handles of
control / selector switches shall be black in colour. Shape and type of handles shall
be subject to approval of the Owner.
4.4.3 PB shall be used for ON / OFF applications.
4.4.3.1 Contact of the switches shall be spring assisted and shall be of suitable material
to give a long, trouble free service.
4.4.4 The contact ratings shall be as specified.
4.5 Push Buttons



DOSING SYSTEM
4.5.1.1 Push buttons shall be spring return, miniature, push to actuate type and rated
to make, continuously carry and break and 0.5A (inductive) at 24V DC. The
push buttons shall have at least 1 NO & 1 NC contact, all contact faces shall be
of silver or silver alloy.
4.5.1 All push buttons shall be provided with integral escutcheon plates marked with
its function. The colour of push buttons shall be as follows.
4.5.1.2 Green : For motor START, breaker CLOSE, valve / damper OPEN.
4.5.1.3 Red : For motor TRIP, breaker OPEN, valve / damper CLOSE.
Red push buttons shall always be located to the left of green push buttons.
Designation indicating tag plates to be provided.
4.6 Indicating Lamps
4.6.1 Indicating lamps shall be of the panel mounting, filament type low wattage and
Capable of clear status indication to operator under the normal room
illumination. Lamps shall be provided with non-hydroscopic series
resistors, preferably built in the lamp assembly. The lamps shall have
escutcheon plates marked with its function, wherever necessary.
4.6.2 Lamps shall have translucent covers of the following colours.
4.6.2.1 Red : Alarm indications.
4.6.2.2 Green : For motor OFF, valve / damper CLOSED, breaker OPEN.
4.6.2.3 White : For motor AUTO-TRIP.
4.6.2.4 Amber : Drive faults.
4.6.3 Bulbs and lamp covers shall be easily replaceable from the front of the panel.
4.6.3.1 Indicating lamps should be located directly above the associated push button /
selector switches. Red lamps shall invariably be located to right of green lamps.
The fault lamp coloured amber shall be placed between red and green lamps of
status indication.


DOSING SYSTEM
4.6.3.2 All indicating lamps shall be suitable for continuous operation at 90% to 100%
of their respective nominal control supply voltage, i.e. 24V DC.
4.7 Name Plates and Labels
4.7.1 Each panel shall be provided with prominent, engraved identification plates for
all front mounted equipment. Panel identification name plates shall be provided
a front and rear.
4.7.1.1 All name plates shall be of non-rusting metal or 3-ply Lamicoid, with white
engraved lettering on black background. Inscription and lettering sizes shall be
subject to the Owner's approval.
4.7.1.2 For easy identification of all equipment from inside the panel. they shall be
marked with suitable, clear, indelible paint markings. use of stickers for
identification is not preferred. Labels for fuses shall be also clearly indicate
current ratings of the respective fuses.
4.7.1.3 These labels shall be positioned so as to be clearly visible and shall give the
device number, as mentioned in the wiring drawings.
4.8 Terminal Blocks
4.8.1 Terminal blocks shall be of 100V grade, rated for 2 Amps and in one piece
moulding. They shall be complete with insulating barriers, clip-on type
terminals and identification strips. Marking or labels on terminal block shall
correspond to their identification on wiring diagrams. They shall be KLIPPON
type (RSFI) with insulating material of melamine or equivalent.
4.8.2 All terminal blocks shall be suitable for terminating on each side,two(2) 0.5mm2
size stranded copper conductors. Not more than two (2) wires shall be
connected to any terminal.
4.8.3 All terminals shall be numbered for identification and grouped according to the
function.


DOSING SYSTEM
4.8.4 Terminal blocks shall be properly arranged to facilitate easy termination of

cables. They shall have minimum clearance of 200mm to cable gland plates, an
of 150mm to adjacent terminal rows, panel sides and other equipment.
4.8.5 Twenty (20) per cent spare terminals shall be provided distributed over all
terminal blocks.
4.8.6 All switches, PB and status indicating lamps are to be directly wired to JB.
4.9 Wiring
4.9.1 All internal wiring shall be carried out with 650V grade, single core, 0.5mm2
larger stranded copper wires having colour coded, PVC insulation. Space heater
circuits shall have wires having adequate current carrying capacity.
4.9.2 Extra flexible wires shall be used for wiring to devices mounted on moving
parts such as doors. Suitable guards and grommets shall be provided for the
wiring wherever it could get damaged in their absence.
4.9.3 All wiring shall be properly supported, neatly arranged, readily accessible and
securely connected to equipment terminals and terminal blocks. Grouping of
AC/DC circuit shall be made separately.
4.9.4 Internal terminations of stranded conductors shall be made with solderless

crimping type tinned copper lugs which shall firmly grip the conductor.
Insulating sleeves shall be provided over the exposed part of the lugs.
4.9.5 Engraved core identification ferrules marked to correspond with panel wiring
diagrams, shall be fitted to both ends of each wire. Jumper wires between two
terminal blocks shall also be ferruled at both ends.
4.9.6 The ferrule numbers may identify the equipment terminals to which a wire is
connected or may be based on the standard practice of the panel manufacturer.
The exact ferruling arrangement shall be the Engineer's approval during detailed
engineering.
4.9.7 The panels shall have separate wire ways for internal wiring of the panels,
distinct and physically separate from wire ways for external cablings.


DOSING SYSTEM
4.9.8 Internal wiring of the panels shall preferably be done so as to facilitate

termination of the external multicore control cables of the adjacent terminals of
the same terminal block.
4.9.9 Suitable clamping facility for external cables shall be provided in the panels.
4.10 Grounding
4.10.1 A continuous copper grounding bus of 25 x 3 mm size shall be provided along

the bottom of the panel structure. It shall run continuously throughout the
length of the panel and shall have provision at both ends for connection to the
station grounding grid (10x4 mm MS flat). Wherever termination of shield cables
are envisaged, provision for termination of cable shields shall be made.
4.10.2 Metallic parts of all components shall be effectively earthed using green coloured
insulated copper wire or other approved means. However, earthing through
effective connection with the metallic control panel surface by approved type of
washers shall also be acceptable. Electrical continuity of the whole enclosure /
frame work shall be maintained even after painting. All hinged doors shall be
earthed through flexible earthing braids of copper.
4.11 Space Heater and Lighting (if required)
4.11.1 Space heaters shall be provided in the panels wherever the manufacturer
considers
them necessary and recommends their provision for preventing harmful moisture
condensation.
4.11.2 The space heaters shall be suitable for continuous operation on 240V AC 50 Hz,
single phase supply and shall be automatically controlled by thermostat. Each free
standing control panel section shall have a 240V AC, plug point and a compact
fluorescent light operated by a door switch.
4.11.3 Necessary isolating switches and fuses shall also be provided
5 PAINTING
All sheet steel work shall be pre-treated in tanks in accordance with IS:6005.
The phosphated surfaces shall be rinsed and passivated, given a stoved lead


DOSING SYSTEM
oxide primer coating, following by two coats of finishing synthetic enamel paint.
Each coat of primary and finishing paint shall be of slightly different shade to
enable inspection of painting. Finishing paint on panels exterior shall be shade
692 (smoke grey) of IS:5 unless required otherwise by the Owner. The inside of
the panels shall be glossy white. Each coat of finishing shall be properly stoved.
The paint thickness shall not be less than 50 microns. Finished parts shall be
coated by peelable compound by spraying method to protect the finished
surface from scratches, grease, dirt and oily spots during testing,
transportation, handling and erection. Electrostatic painting shall also be
acceptable, in which case the same shade for inside and outside could be
offered.
6 INSPECTION & TESTING
The following tests / inspection shall be carried out by the Contractor in the
presence of the Owner's representative.
6.11 Factory Tests
6.11.1 Compliance with approved drawings, data and specification.
6.11.2 Visual check for workmanship.
6.11.3 Wiring continuity and functional check.
6.11.4 HV test, insulation resistance measurement before and after HV test using a
1000V megger. Insulation resistance shall not be less than 25 mega ohms.
6.11.5 Testing to observe compliance to a degree of protection shall only be as under:
6.11.5.1 It shall not be possible to insert a 1 mm diameter steel wire into the enclosure
from any direction without using force.
6.11.5.2 It shall not be possible to insert a thin sheet of paper under gaskets and
through enclosure joints.


DOSING SYSTEM
6.11.5.3 Test on gaskets as approved quality plan.
6.12 Inspection / Testing at Site
6.12.1 IR test before and after HV test.
6.12.2 HV test.
6.12.3 Functional testing.
6.13 Vendor Q.P. to be furnished.
7 DOCUMENTS
7.11 With the bid:
7.11.1 General Arrangement drawing, make of components, foundation details and

Quality Plan.
7.11.2 Compliance to specification.
7.12 On award of Purchase Order:
7.12.1 General Arrangement drawing, foundation drawings and interconnection cable

schedule.
7.12.2 Test Certificates.
7.12.3 Operation & Maintenance manual and catalogue of all components used.
8 2 Numbers Auto Stroke Controllers (ASCs) shall be mounted on each panel.

ASCs will be made available at supplier’s works by purchaser.
9 GENERAL


DOSING SYSTEM
It is not the intent to specify completely herein all aspects of design and
construction of equipment. Nevertheless the equipment shall conform in all
respects to high standards of engineering, design and workmanship and shall
be capable of performing in continuous commercial operation in a manner
acceptable to the owner who will interpret the meaning of specification for the
purpose of which the owner reserves the right to alter the specification even
during the contract execution stage (for which commercial implications will not
be entertained).
10 Annunciator to be provided as per ANNEXURE (enclosed)
11 TENTATIVE MOTOR DETAILS
Quantity Power Supply kW FLC (A)

415V, 3
Phosphate Pump Motor 2 0.37 1.07
phase, 50 Hz
Phosphate Tank Agitator 2 -do- 0.37 1.07
415V, 3
Hydrazine Pump Motor 2 0.37 1.07
phase, 50 Hz
Hydrazine Tank Agitator 2 -do- 0.37 1.07
All motors shall be Energy Efficient Type: High Efficiency (IE2) as per IEC 60034-30
or
Premium Efficiency (IE3) as per IEC 60034-30.
Refer Project specific “C&I Check List” made available as part of Enquiry Documents.


DOSING SYSTEM
ANNEXURE
ANNUNCIATOR
1 The annunciation system for the panel shall be suitable for operation on 240V
AC.
2 The annunciation system shall be suitable for the environmental conditions in

the respective operating areas.
3 Hooters shall be clearly audible even with the ambient noise level in the area
installed.
4 Contact multiplying circuits shall be provided to give necessary numbers of

contacts as required by the system.
5 The annunciation system shall have visual and audible alarms with ‘Accept’,
’Reset’ and ‘Lamp Test’ push bottoms.
6 The lamp cabinet shall consist of an array of 40 translucent windows with

appropriate engravings as indicated elsewhere. Two 3.0 watt lamps in parallel
shall be used. Each lamp shall have a resistor in series which shall be
adequately rated even under lamp shorting condition. The lamps shall be
replaceable from the front of the window.
7 The annunciation system shall withstand 1.2/50 micro second surges.
8 Special precautions shall be taken by the vendor to ensure that spurious alarm
conditions do not appear on the annunciation system wiring due to the
influence of external magnetic fields and also due to the switching disturbances
from neighbouring circuits within the panel.
9 The inscriptions on the facia shall be visible only when the respective facia
lamps are lighted.
10 Any new annunciation appearing after accepting the previous annunciation shall
provide a fresh audible / visual alarm even if the processing of the previous
alarm is going on or is yet to be carried out.


DOSING SYSTEM
11 Each annunciator shall be provided with a flasher with a flashing frequency of

about 90 cycles/min.
12 The annunciation system shall be so designed as to accept field inputs from

either NO or NC contacts.
13 The sequence of operation of the annunciation system shall be as follows and

as per ISA – RP21.
Alarm Conditions Audible Alarm Visual Alarm
13.1 Normal OFF OFF
13.2 Abnormal ON Flashing ON

13.3 Accept OFF Steady ON
13.4 Back to Normal OFF Steady ON
13.5 Reset OFF OFF
13.6 Reset before normal OFF Steady ON
13.7 Lamp Test ON Steady ON (All

lamps shall glow)
14 Earthing with 2.5 mm2 Cu conductor cable for annunciator shall be done
inside panel upto panel earth.

PC TSP HP&LP Dos LCP

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Bharat Heavy Electricals Limited

Piping Centre Chennai-17

Rev. No Specification No. Sheet No.

TECHNICAL SPECIFICATION FOR SUPERVISORY CONTROL PANEL FOR HP & LP

APPLICABLE TO UTILITY AND INDUSTRIAL UNITS

00 15.06.17 Fresh Issue B.Sumith B.Sumith R.Prabha

REV. DATE ALTERATION PREPARED CHECKED APPROVED

Rev. No Specification No. Sheet No.

TECHNICAL SPECIFICATION FOR SUPERVISORY CONTROL PANEL FOR HP & LP

1.2 Cable glands.

2 SPECIFIC DATA SHEET

2.1 Designation : H.P & LP Dosing System Control Panel

2.2 Quantity / Boiler : 1

2.3 Location : Outdoor

2.5 Design Data

Rev. No Specification No. Sheet No.

TECHNICAL SPECIFICATION FOR SUPERVISORY CONTROL PANEL FOR HP & LP

2.5.2 Mounting : Floor

2.5.3 Cable entry : Bottom

2.5.4 Sheet Steel Thickness : Minimum of 2.5mm

2.5.5 Painting : Outside Shade 692 of IS 5

2.5.6 Internal wiring : PVC, FRLS cable to be used and shall be

2.5.7 Supply voltage : 1 feeder of 415V, 3 phase, 50 Hz of

2.5.8 Voltage : 24 V DC (to be derived from 415V supply

2.5.9 Purchasers earthing conductors: G.S. of 25 x 3 mm

2.5.10 Status Indicating Lamp : As per requirement

Rev. No Specification No. Sheet No.

TECHNICAL SPECIFICATION FOR SUPERVISORY CONTROL PANEL FOR HP & LP

3.8 Testing, Inspection & Documentation will be as specified elsewhere.

3.9.1 Main Incomer : 3 Core x 16 mm² Al, PVC, armoured

3.9.2 Outgoing Feeder

4 CONTROL PANELS / DESKS

Following are the general requirements for the control panels.

Rev. No Specification No. Sheet No.

TECHNICAL SPECIFICATION FOR SUPERVISORY CONTROL PANEL FOR HP & LP

4.2 Codes & Standards

4.2.1.2 IS:8623 Factory built assemblies of switchgear for voltages upto

4.2.1.3 IS:3202 Climate proofing of electrical equipment.

4.2.1.4 IS:2147 Degree of protection provided by enclosures for low

4.2.1.6 IS:2208 & IS:9224 Low voltage fuse.

4.2.1.7 IS:6875 Control switches (switching devices for control and

4.2.1.8 IS:1248 Direct acting electrical indicating instruments.

4.2.1.9 IS:2419 Panel mounted indicating and recording electrical

Rev. No Specification No. Sheet No.

TECHNICAL SPECIFICATION FOR SUPERVISORY CONTROL PANEL FOR HP & LP

4.2.1.12 IS:375 Switchgear busbars, main connections and auxiliary

4.2.1.13 IS:8828 Miniature circuit breakers for voltages not exceeding

4.2.1.14 IS:5 Colour.

4.2.1.15 IS:6005 Code of practice of phosphating iron and steel.

4.2.2 Equipment confirming to other recognised standards shall also be acceptable

4.3 Constructional Details (as applicable)

Rev. No Specification No. Sheet No.

TECHNICAL SPECIFICATION FOR SUPERVISORY CONTROL PANEL FOR HP & LP

4.4 Control and Selector Switches

4.4.3 PB shall be used for ON / OFF applications.

4.4.4 The contact ratings shall be as specified.

4.5 Push Buttons

Rev. No Specification No. Sheet No.

TECHNICAL SPECIFICATION FOR SUPERVISORY CONTROL PANEL FOR HP & LP

4.6 Indicating Lamps

4.6.2 Lamps shall have translucent covers of the following colours.

4.6.2.1 Red : Alarm indications.

4.6.2.3 White : For motor AUTO-TRIP.