Electrical Design

PART III
SECTION 3
CONTENTS
CHAPTER
DESCRIPTION
1)
Scope of Work for Electrical Engineering
2)
Standard Specification for Electrical Equipment
3)
Engineering Design Basis for Electrical
4)
Electrical Engineering Job specification
5)
Standard Specifications for 415 V Motor Control Center
6)
Standard Specification for Medium Voltage Motor
7)
Standard Specification for Electrical Cabling
8)
Standard Specfication For Electrical Motor Operated Valve Actuators
9)
Standard Specification for Uninterrupted Power Supply System
10)
Standard Specification for High Voltage Motors
11)
Standard Specification for Air Conditioning System
1
TECHNICAL SPECIFICATIONS ELECTRICAL WORKS FOR OFFSITE AUTOMATION PROJECT
PART III
SECTION 3
CHAPTER 1
ELECTRICAL SCOPE OF WORK
FOR
OFFSITE AUTOMATION
2
PART III
SECTION 3
OFFSITE AUTOMATION Electrical Scope of Work

1.
The scope of work of the contractor for the Offsite Automation System comprises of
Design, Detailed Engineering, Supply, Erection/Installation, Testing and
Commissioning of all Electrical equipment and systems required to meet the
functional needs of the Offsite Automation Project.
2.
The list of Electrical equipment and systems covered in the scope shall include, but not
limited to the following:i)
All electrical drive motors
ii)
Local Push Button Stations for each motor
iii)
Transformer as per requirement
iv)
Power cables, cable installation equipments & accessories and

conduits for routing cables required
v)
Motor operated Valves
vi)
415V MCC / power distribution boards / Local control panels required

to feed electrical power loads
vii)
Uninterrupted Power Supply Systems for Control Systems, Analyser

and Motor Operated Valves.
viii)
Earthing system consisting of provision of required earth pits at suitable

location and connection of earth lead from all bidder supplied
equipments
ix)
Lighting System inclusive of lighting fixtures, fitting and switches.
x)
Air conditioning systems for control rooms and other locations where
instrumentation systems that require air conditioning are installed.
xi)
Building electrification works
xii)
Motor Operated Valves
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PART III
SECTION 3
3.
All civil and mechanical works, such as foundations, structural works, false ceiling
works, ducting etc., related to the completion of the electrical scope of work is
included in the scope of the contractor.
4.
All equipment and components shall be procured from the manufacturers listed in the
enclosed approved vendor list.
5.
Bidder shall be provided suitable feeders in the substation nearer to the load center by
CPCL subjected to the availability of spare feeder. PURCHASER reserves the right to
reserve spare feeders for future maintenance purposes. In case, required number of
feeders could not be spared by CPCL, the Bidder shall erect a separate distribution
board for the purpose inside the substation / extend the existing panels if load
conditions permit. In case of extension, extension panels shall be of same standards as
that of existing panels and preferably of same make.
6.
Bidder shall note that his scope of work includes supply of all material and resource.
CPCL will not provide any material or resource.
7.
The bidder shall design, supply, erect , test and commission a centralised air
conditioning and ventilation system for the following
(a) Control Room
(b) Rack room
(c) Shift In-Charge room
(d) Computer room
(e) Operator room
(f) UPS Room
(g) Operator Room
(h) Dining Room
The sizes of the rooms shall be as per the drawings enclosed.
8.
The bidder shall design, supply, erect, test and commission the Uninterrupted power
supply (110 V) system for providing power supply to DCS system and analysers shall
be considered. The UPS shall be parallel redundant with by-pass facility having three
independent incomers. The batteries shall be Ni-Cd type and shall provide a minimum
back up of 30 minutes in event of mains failure. Suitable power distribution board
shall be provided for feeding to various devices. UPS in the control room shall be for
control room instrumentation and other requirements only. UPS requirements of
analyser sheds shall be met through separate UPSs in those locations.
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PART III
SECTION 3
9.
The bidder shall design, supply, erect, test and commission the DC power supply (110
V) system for providing power supply to Critical lighting, etc. The battery charger
shall be of dual float cum boost type and the batteries shall be Ni-Cd type or Plante
lead acid and shall be designed to provide a minimum back up of 2 hours in event of
mains failure. Alternatively, the vendor can source DC from OMS/Ref-I substation by
laying suitable cables. For analyser shelters only portable emergency lights shall be
provided.
10.
Additional outdoor lighting shall be provided wherever operation of equipments are

envisaged.
11.
HT motor feeders will be made available in OMS/REF-I HT substation by CPCL. One

LT (415V) feeder of required capacity will be provided by CPCL in each of the SS4,
SS5, Ref-I substations. Further power distribution, including that for inputs to UPS,
Airconditioning plant MCC, shall be carried out by the contractor through separate
switchboards.
12.
Vacant space with floor opening available in the above mentioned substations can be
used by the contractor for erection of his panels. However, if the space is not sufficient
the contractor has to extend the substations/ floor openings, as required.
13.
Ten number telephones of premier model of tatafone make shall be provided and
installed in the control room. All required cabling from the junction boxes shall be laid
and connected by the contractor.
14.
Bidder shall involve CPCLs Engineers at each and every stage of the project and
shall proceed only after obtaining the necessary approval from CPCL.
15.
The scope includes supply of miscellaneous items as per specifications.
16.
The scope includes supply of Special tools and test equipment, calibration and
maintenance of the system.
17.
The vendor shall supply all final drawings, documents. Operating / maintenance
manuals, test reports, commissioning reports, etc in following form :- 6 nos. of
hardcopies including tracing & prints for drawing. One set in digitized form in floppy
and one set in CD.
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PART III
SECTION 3
18.
Supply of two years Operational, Mandatory & Commissioning Spares as per spare
philosophy Warranty and Post-Warranty Maintenance etc. mentioned in the
specifications of equipment.
19.
BIDDER IS ADVISED TO CAREFULLY SCRUTINIZE THE TENDER

DOCUMENT, SPECIFICATIONS, AND INSTRUCTIONS. ETC AS CONTAINED
HEREIN AND TO UNDER TAKE A SITE VISIT BEFORE SUBMITTING THEIR
OFFER FOR CPCLS REVIEW AND ACCEPTANCE. ANY ADDITIONS, WHICH
SHALL BE REQUIRED DURING THE EXECUTION OF THE PROJECT TO
MEET THE FUNCTIONAL REQUIREMENT, SHALL BE PROVIDED BY
BIDDER AT NO EXTRA COST.
6
PART III
SECTION 3
CHAPTER 2
STANDARD SPECIFICATION
FOR
ELECTRICAL EQUIPMENT
7
PART III
SECTION 3
CONTENTS
1.0
SCOPE
2.0
CODES AND STANDARDS
3.0
SITE CONDITIONS
4.0
AREA CLASSIFICATION AND EQUIPMENT SELECTION
5.0
EQUIPMENT SPECIFICATIONS
7.0
EARTHING SYSTEM
7.0
LIGHTING SYSTEM
8.0
FACILITIES INSIDE CONTROL ROOM
9.0
CONTROL STATION
10.0
INSPECTION, TESTING AND COMMISSIONING
11.0
SPARES
12.0
DRAWINGS AND DOCUMENTS
13.0
OTHERS
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PART III
SECTION 3
1.0
SCOPE
1.1
This specification along with specific job requirements. Standard specifications, etc.
defines the requirements for design, engineering, supply and, where included in job
requirements, installation, testing and commissioning of electrical equipment and
facilities for the OFFSITE AUTOMATION PROJECT.
1.2
For the purpose of this specification, the term `package equipment' or `package'
denotes the all equipment to be supplied or work to be carried out by the vendor.
1.3
It is not intended to cover all aspects of design but to indicate the basic requirements
only. Vendor shall ensure that the design and installation of the equipment is carried
out as per good engineering practice to meet the requirements of safety, reliability,
ease of maintenance and operating, aesthetics, scope of further expansion and
maximum interchangeability of equipment. Vendor shall acquaint himself with
CPCL standards, specification and field testing procedures as deemed necessary for
proper execution of the work.
1.4
Compliance with this specification and /or review of any of the vendor documents
shall not relieve the vendor of his responsibility and his contractual obligations with
regard to the completeness and satisfactory operation of the project.
2.0
CODES AND STANDARDS
2.1
All electrical equipment and the complete package shall meet the requirements of
this specification and enclosed data sheets in addition to the relevant Publications
and Codes and Practice of Bureau of Indian Standards, , statutory regulations and
good engineering practices. Complete system must be also conform to the latest
revisions of the following:
a) Indian Electricity Act and Rules framed thereunder
b) Fire Insurance Regulations
c) Petroleum Rules and any other regulations laid down by Chief Controller of
Explosives
d) The Factory Act and regulations laid down by Factory Inspectorate
e) Regulations laid down by local statutory authorities and Electrical Inspectorate
f) Oil Mines Regulations (For Projects under DGMS jurisdiction).
g) OISD Standards
h) Requirement of other statutory bodies as applicable -eg. CEA, CCE, TAC,
DGFASLI
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PART III
SECTION 3
2.2.
Vendor shall obtain all necessary approvals from statutory authorities (Central
Electricity Authority) for materials, plant design/drawings and complete installation.
The statutory approval from CEA shall be obtained by the vendor prior to energising
the electrical installations.
2.3
Where Indian Standards do not exist, the relevant IEC/British/ German (VDE)
standards shall apply. Any other international standard may also be followed
provides it is equivalent to or more stringent than the standards specified above.
2.4.
In case of any discrepancy/conflict between this specification and the specified codes
and standards, the following order of decreasing precedence shall govern:
i)
Statutory Regulations
ii)
Electrical Design basis and Equipment Data Sheets
iii) Job specifications
iv)
CPCL Standard Specifications and Installation Standards etc.
iv) Codes and Standards
In case of any discrepancy/conflict between the specification of the same level [2.4 i)
to iv) ] mentioned above, the better standard among them shall be adopted.
CPCL's concurrence shall, however, be sought and obtained before taking a decision
in the matter.
3.0
SITE CONDITIONS
Provided in design basis.
4.0
AREA CLASSIFICATION AND EQUIPMENT SELECTION
4.1
In case of storage handling or processing of flammable materials within the battery

limits of the package, area classification shall be carried out in line with IS : 5572,
Petroleum Rules and DGMS guidelines where applicable. Where specified, the
vendor shall furnish an Àrea Classification Drawing' indicating the zones of
hazardous area and the applicable gas groups. A list of flammable materials handled
alongwith their properties like flash point, ignition temperature, explosive limits etc.
shall also be furnished.
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PART III
SECTION 3
4.2.
Selection of the type of all equipment for use in hazardous areas shall be done in
accordance with IS : 5571 and DGMS regulations where applicable. The electrical
equipment shall meet the requirements of relevant IS, IEC or NEC standards.
Increased safety type Ex (e) equipment shall not be permitted for use in Zone -1
areas. For Zone-2 areas, Increased safety type Ex(e) or Non sparking Type Ex(n)
equipment shall be provided as a minimum, subject to the same being acceptable to
statutory authorities. Ordinary safe type electrical equipment shall not be used in
Zone -2 areas (even though this may be permitted by NEC for Div.2 areas).
4.3.
Electrical equipment for hazardous areas shall be certified by CMRI and approved
by CCE/DGMS as applicable (or equivalent recognised testing agency and statutory
approval authority) for installation and use in the specified hazardous area.
Flameproof equipment of indigenous origin shall be `BIS' market. Vendor shall
furnish the necessary certificate indicating such approvals.
4.4.
Unless otherwise specified, electrical equipment for hazardous areas shall generally
be suitable for gas IIA and IIB and Temperature Class - T3 applicable to the selected
type of explosion protection. In case hydrogen is handled, the gas group to be
considered shall be IIC.
4.5.
Unless otherwise agreed, electric motors for agitators/mixers, metering pumps and
oil sump pumps handling flammable materials shall be flameproof Ex(d) type,
irrespective of the area being classified as Zone-2 or Zone-1.
4.6.
In case the Package or part of the package /equipment is to be located in a classified

hazardous area, the same shall be indicated in the data sheet. In such a case, the
offered equipment/ package shall conform to whichever are the more stringent
requirement i.e. either due to materials being handled in the package or hazardous
location in which package is installed.
5.0
EQUIPMENT SPECIFICATION
5.1.
Specifications of each system and equipment shall be furnished by the vendor for
review by CPCL. However, certain minimum requirements for the major equipment
are highlighted in this section.
5.2.
All equipment and components shall be new and supplied by CPCL approved
manufactures. Equipment requiring specialized maintenance or operation shall be
avoided as far as possible and prototype equipment shall not be accepted. All
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PART III
SECTION 3
equipment shall be complete with all necessary weather and anticorrosion protection
including tropicalization to prevent damage due to climate, sline atmosphere, dust
and corrosive vapours.
5.3.
All equipment /material shall be protected for inland / marine transport,. carriage at
site and outdoor storage during transit and at site. Vendor shall be responsible for
any damage to the equipment during transit. All packages shall be clearly, legibly
and durably marked with uniform block letters giving the relevant
equipment/mutable details . Each package shall contain a packing list in a
waterproof envelope.
5.4.
All electrical components and equipment shall be sized to suit the maximum load
under the most severe operating conditions. Rated voltage and frequency for the
equipment shall be as indicated in enclosed date sheet.
5.5.
All spares required for testing and commissioning the package shall be included
alongwith any special tools and tackles required for operation and maintenance.
6.0
STANDARD SPECIFICATIONS
Standard Specifications have been enclosed for Induction motors, Cables, UPS,
MCC, Transformer and MOV. All of the above equipment supplied by the vendor
shall meet the requirements specified therein.
7.0
EARTHING SYSTEM
7.1
Earthing system design and installation shall generally be as per IS:3043. One or
more number of G.I. earth plates shall be provided for the equipment in package
depending upon in size. All metallic non-current carrying parts of electrical
apparatus, control stations, current and potential transformer secondaries, structural
steel, vessels etc. shall be connected by at least two distinct separate earth
conductors to an earth plate. All earth plates shall be bonded together and shall have
the provision for interconnection to owner's main earth grid at two points. Earth
plates shall be of 3060x80x10mm size and shall be provided with adequate number
of tapped holes. Earth continuity bonding shall be provided across all pipe flange
joints.
7.2
The resistance value of earthing system to the general mass of the earth shall
ensure the operation of the protective device and in any case should not exceed 5
ohms. Normally earthing system shall comprise of main earth grid along with
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PART III
SECTION 3
suitably located disconnecting plates to provide multiple earth connections

between earth grid and equipment and for connections between main earth grid
and electrodes. Connections between earth electrodes and the disconnecting plates
shall be done by GI strip. Connection between disconnecting plate and various
equipment shall be done by GI strip, GI wire or GI rope. Earth electrodes and
conductors shall be designed to cope with the conditions imposed. The earth
conductor shall be adequately sized to carry the applicable maximum earth fault
current without undue temperature rise. All joints shall be protected to prevent
corrosion.
7.3
Design calculations and for earthing layout has to be submitted for approval.
7.4
All hardware used for earthing installation shall be hot dip galvanized for zinc
passivated. Thickness of hot dip galvanizing shall be minimum 700gm/m2.
Specifically provided bolts, lugs and spring washers shall be used for all earthing
connections of equipment.
Following sizes of earth conductors shall be used for motors:
Upto 3.7 KW 85WG GI wire
5.5 to 30 KW3/8" GI fine wire rope or 35mm2 AI insulated conductor
37 to 75 KW 5/8" GI fine wire rope or 70mm2 AI insulated conductor
Above 75 KW
40 x 5mm2 GI strip.
Earthing connections to equipment shall be made by means of bolts and lugs
provided specifically for this purpose.
8.0
LIGHTING SYSTEM
8.1
General lighting for areas in which equipment supplied in the package is to be

installed shall be provided by vendor. Normal lighting system shall be fed by 415/240
VAC supply.
8.2
HPMV lamps or MLL lamps shall be used for outdoor plant lighting, however to
overcome the re strike time lag in case of voltage dip/ blackout incandescent lamps
may be judiciously distributed throughout the plant area. All chemical handling
facilities shall be provided with chemical resistant fixtures. Control gear boxes shall be
located at accessible level, which should not exceed 2m above operating level.
8.3
Fluorescent lamps with electronic ballasts shall be provided for indoor lighting for
non process buildings and control rooms.
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PART III
SECTION 3
8.4
All outdoor lighting shall be automatically controlled by synchronous timers with

manual overriding control. Lighting panels shall be used for distribution and these
panels shall be provided with MCB + ELCB as incomer and MCBs for outgoing
feeders control and protection. Only 8 -10 fixtures shall be wired in each circuit.
MCBs shall not be loaded beyond 80% rated capacity. A minimum of 25% of MCB
s shall be left as spares. The lighting distribution shall not combined with power
distribution and separate panels have to be used for power distibution.
8.5
The minimum illumination levels for the following areas shall be:
Process areas - 60 LUX
MCC room - 200LUX
Control room - 500LUX
8.6
Design calculations and for lighting system lighting layout has to be submitted for
approval.
8.7
Lighting fixtures mounted on plat forms, walkways, stairs, High bays etc shall be
installed in such a way that relamping can be done without the use of ladders.
8.8
Any other lighting requirements such as Local panel lighting shall be provided by
vendor. Power for such local lighting shall be obtained from a suitable feeder in
PDB/Local Panel.
8.9
All lighting circuits shall have provision for isolation in both phases and neutral for
packages to be installed in hazardous areas. For packages under DGMS jurisdiction,
power supply voltage shall be limited to 240V between phases by the use a suitable
transformer.
9.
Facilities Inside Control Room Building
9.1
Concealed conduit wiring shall be used below the false ceiling and surface conduit
wiring above the false ceiling.
9.2
Adequate number of combined 5/15 Amps power sockets shall be provided.
10.
CONTROL STATION:
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PART III
SECTION 3
10.1 Each motor shall be provided with a control station in the field. The control station
shall have suitable protection for site conditions (such as flameproof, weatherproof ,
dust proof, corrosion resistant etc.). and minimum acceptable IP class is 55. Canopy
shall be provided to protect outdoor control station against direct rain. The control
station shall include start & stayput type stop pushbuttons and Ammeters (for motors
rated > 18.5 KW)
11.0
INSPECTION, TESTING AND COMMISSIONING

All equipment shall be tested and inspected at vendor's works before dispatch to
ensure compliance with the relevant specifications and agreed quality
assurance/testing plan. Precommissioning and Commissioning tests have to be
carried out by the vendor on all the electrical equipment.
The owner or his authorized representative may visit the works during manufacture
or various electrical equipment/materials to assets the progress of work as well as to
ascertain that only quality raw materials are used for the same. He shall be given full
assistance to carry out the inspection. Owner's representative shall be given
minimum two weeks' advance notice for witnessing the final testing. The minimum
testing/inspection requirements for all components/equipment shall conform to the
requirements stipulated in applicable codes and standards. Test certificates including
test records and performance curves etc. shall be furnished by the vendor.
Vendor shall submit the field testing procedures for CPCL's approval. Field tests as
per the approved procedures shall be performed on the electrical system/ equipment
before its being put into service. All test equipment required for this purpose shall be
arranged by the vendor, in case testing and commissioning at site is included in his
scope, and test reports shall be approved by the size-in-charge before acceptance of
the complete package.
12.0
SPARES
Vendor shall separately quote for 2 years' operation and maintenance spares for all
electrical equipment in the package, including but not limited to the following.
Vendor shall indicate unit rates and recommended quantity for each item in his offer.
All spares required for commissioning the equipment is included in the scope of the
contractor.
M.V.Motors
Terminal block
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PART III
SECTION 3
Terminal cover with screws etc.

Fans for critical motors.
DE, NDE end Shield
Power Distribution Board/Local Panel

Switches and fuses of all ratings
Set of main contacts and coils of all contactors
Bimetal relays
Indicating lamps assemblies/lamps
Push buttons and auxiliary devices.
13.0
DRAWINGS AND DOCUMENTS

All drawings, SLD s design calculations and data sheets has to be approved by CPCL
before issuing for construction. Four copies of As-built documents/vendor drawings shall
be provided by the vendor as per contract. Additionally, one set of all as-built documents/
vendor drawings in bound volumes and/or in the form of electronic files on specified
media shall be submitted to CPCL alongwith certified and updated drawing schedule. The
following shall also be included.
a.
Design and installation instruction manual including design documents,

certificates relating to type/acceptance/special tests, description of procedures
and description of field testing procedures after installation.
b.
Operating instruction including description of start-up procedure and description

of conditions of use.
c.
Maintenance
instructions
including
precautionary
maintenance
instructions/periodic inspection programmes, setting instructions, procedures for
removing and replacing all parts and accessories included in the spare parts list,
and list of spare parts and consumables together with all information required
for ordering them from manufacturers.
Sub-suppliers of individual components shall be clearly identified. Communication

address shall be indicated for each reference.
14. OTHERS :
14.1
Lifting facility for motors have to be provided where ever necessary.
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PART III
SECTION 3
14.2
14.3
All equipments supplied (except fuses and bulbs) shall have warranty for 12 months
from the date of commissioning.
Any deviation from the specifications is not acceptable, unless it is specifically
approved by CPCL. Deviations to Electrical specifications, if any envisaged by the
vendor shall be submitted clause wise, as a separate Annexure to the technical bid, for
consideration of CPCL.
14.4
Any discrepancies between different specifications provided in this document shall be

notified clause wise in a separate Annexure to the technical bid and the specification to
be adopted shall be indicated there in. However CPCL decision on the standard to be
adopted shall be final.
14.5
If some of the Specification specified anywhere in the document is not part of the
document the same shall be provided by CPCL on request.
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PART III
SECTION 3
CHAPTER 3
ENGINEERING DESIGN
BASIS
FOR
ELECTRICAL
18
PART III
SECTION 3
1. SITECONDITIONS
A. Equipment design temperature (IS 9676)
B. Soil Resistively
* ohm m
C. Min. temps. for battery sizing
10 DEGC
D. Min. Temp. For Electric heat tracing
E. Seismic zone(IS 1893)
F. Altitude above mean sea level
G. Design wind velocity

IS 875,
40.0 DEG C
10 DEGC
*
3.5 m
:
150 km/hr. or as per

Which ever is
higher.
2.0 POWER SOURCE DETAILS
2.1 General
Independent system or extension of existing system : Extension of existing system.
2.2.Grid Supply:
A. Name of grid sub station
: To be decided later.
B. Number of feeders
: Later
C. Length of feeder / conductor size
: Later
D. Voltage
: 6.6.KV or 415 V + 10%
E. Frequency
: 50 Hz + - 3%
F. Min / max fault level / BIL
: 40 kA / 60 kV
G. Design fault level / BIL
: 40 kA / 60 kV
H. System neutral earthling
: Resistance Earthed
I. Minimum load p.f. stipulated by

Supply authority
: 0.9
J. Parallel operation of incomers
: No
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PART III
SECTION 3
3.0. POWER SUPPLY DISTRIBUTION SYSTEM

3.1. Voltage and frequency variation
(Refer cl.6.6.for design voltage / frequency variation for motors)
A. AC System
Voltage
Frequency
: 6.6.kv + - 10% (motors rated above 160KW)

415 V + - 10% (motors rated less 161KW)
: 50Hz + - 10%
B. DC System (at system output terminals)

Electrical Control, Lighting etc.
: 110V + - 10%
3.2 Utilisation voltage & operating philosophy
A. Primary HV distribution voltage
: 6.6kv
B. Secondary HV distribution voltage
: 6.6kv
C. Primary HV distribution system neutral
: Resistance earthed
D. Secondary HV distribution system neutral : Resistance earthed
E. HV motor voltage
: 6.6kv (above 160 kW)
F. Auto transfer at 6.6KV Bus
: Not Applicable
G. Auto transfer at MV (At PCC Level)
: Yes
H. Continuous Parallel operation of Incomers
- HV
: No
- MV
: No
I. Load shedding
: Provision for wiring of trip contact
in HV SW. Gr.
J. MV motor voltage (415 VAC)
: :
0.37 kW to 160 kW
K. Power factor improvement capacitors
: NA
L. Battery charges
: 415 V AC
M. UPS System
: 415 V AC
N. AC Lighting / Power Panels and
Auxiliary Boards
: 415 VAC
O. Welding Receptacles
: 415 V AC
P. Bulk loads like Process Heaters etc.
: 415 VAC
Q. Normal Lighting / Emergency Lighting
: 240V AC
R. Motors rated below 0.37 kW
: 240 V AC
S. Convenience outlets
: 240 V AC
T. DC Motor
: DC motors not envisaged in hazardous
areas.
( e.g. emergency lube oil pump motor etc.)
U. MOVs
3.3 Utilisation voltage for critical supplies
A. Normal Instrumentation power supply
B. Critical instrumentation power supply
C. Shut down system power supply
D. Switchegear protection and critical
lighting power supply
: 415V AC
: # V AC
: # V AC/ DC
: V, AC (UPS) /DC
: 110 V, DC
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PART III
SECTION 3
E. DC supply for instrumentation #

Refer Instrument design basis
F. Fire alarm system power supply
: Independent system
: 240 V. AC Normal
4.0 Metering for grid incomers ( If applicable)

A. I) protection relays for 11 or 33kv switch gear : NA
II) Protection relays for 6.6kv switch gear
: On switch gear
B. 11kv or 33KV Switch gear control
i) ON/ OFF for testing purpose
ii) Normal operation
C. 6.6KV Switch gear control
i) ON / OFF for testing purpose
ii) Normal operation for Incomers/
Bus Tie/ Transformers feeders
iii) 6.6KV motors feeders
D. Annunciation panel
i)
For each substation in operation room
ii)
For Power Plant control room
iii)
UPS and DC trouble
: NA
: NA
: NA
: From switch gear
: From switch gear
: Field / DCS control room
: NA
: NA
: shall be provided in control room DCS
E. Numerical Protection / Monitoring system

(MMI/ SMS for each substation)
i) EHV system
ii) HV Switch board
iii) 415V MCC
iv) 415 V MCC
: NA
: Yes
: No
: No
F. MMI / SMS system separate for

EHV / HV system relays
: NA
G. Centralised Lighting control

From operator room.
H.. Microprocessor based system for control
Interlocking and monitoring of electric MR.
switch
Power system.
NA
: interface I/ O requirement etc. shall be

furnished by CPCL for inclusion in
Gear.
I. Limiting Conditions for Motor start up

(e.g. starting current limitation or
method of starting )
i) HV Motors
: Motors starting current as per standard
specification for motor rated upto 2500KW and
Motor starting current limited to 400% of normal
Current for KW more than 2500kw.
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PART III
SECTION 3
ii) MV Motors
: As per standard specification unless other

wise specifically mentioned.
iii) Method of starting

For large HV motors
: Direct on line (DOL)
iv) Method of starting

for large MV Motors
(Above details shall be forwarded by CPCL to CPP Contractor to decide machine
parameters and system design)
G. Isolation for remote transformers
: Push button near transformer bay for

tripping remote Breaker.
4.3 Protection devices for power distribution system shall be as indicated below.
Requirements for switchyard, power generation and D.G (If required) shall be as per cl.
14.0 of this document or as shown on the single line diagram and data sheets
Transformer feeder
Relay number
51 IDMTL over current

relay
51 N IDMTL earth fault
relay
51G back up earth fault
relay (secondary neutral)
Motor protection relay with
locked rotor feature (50,
50N, 46,49, 50L /R)
64 R instantaneous
restricted earth fault relay
(secondary side)
50 instantaneous over
current relay.
50N instantaneous earthfault relay.
87 differential protection
relay
86 tripping relay
95 trip circuit supervision
relay.
63 auxiliary
relay(transformer)
27,2 undervoltage relay
Motor
feeder
(L.V
winding
> 3.3kv )
(L.V
HV&M
winding V above
< 3.3kv) 55 kW)
Yes
Yes
Yes (7)
No
Yes
Out going
Feeder
HV
Incomer
MV
/PCC/
PMCC
HV
MV /
PCC/
PMCC
Yes
Yes (4)
Yes (4)
Yes
No
Yes
No
No
Yes
(12)
Yes(
12)
No
No
No
No
Yes
No
Yes (8)
No
No
Yes
No
No
No
No
No
Yes
Yes
No
No
No
No
Yes (6)
Yes
No
No
No
No
Yes (1)
No
Yes (2)
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
(3)
Yes
Yes
Yes
No
Yes
Yes
Yes
No
Yes
Yes
No
No
No
No
No(13)
Yes
Yes (5)
22
Yes (4)
PART III
SECTION 3
Transformer feeder
Relay number
with timer.
25 check synchronisation
relay.
(L.V
winding
> 3.3kv )
-
Motor
feeder
Out going
Feeder
(L.V
HV&M
winding V above
< 3.3kv) 55 kW)
-
HV
Incomer
MV
/PCC/
PMCC
-
HV
(5)
Yes
(9)
MV /
PCC/
PMCC
Yes (9)
NOTES :
1.
FOR transformers rated 5 MVA and above.
2.
For motors rated 1500 kW and above.
3.
For critical / long feeders and plant feeders connected to main power generation
&distribution bus.
4.
_______.
5.
Where ever auto transfer feature is provided.
6.
Instantaneous earth fault 50 N shall be provided only for transformer with delta
primary.
7.
Directional IDMTL earth fault 67N shall be provided only for transformer with
star primary.
8.
For motor feeders rated 75 kW & above.
9.
For switch gears having bus transformer scheme, where continuous or momentary
Paralleling in envisaged, check synchronising relay shall be integrated with
overall
paralleling scheme.
10.
The bus tie feeders in HV switch boards shall be provided with 51, 51N, 86 and
95 relays.
11.
HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage),
60(Neutral displacement), 86 and 95 relays.
12.
In case of HV switch board with parallel operation if incomers, following

additional relays shall be provided.
i)
One set of 87B (Bus differential) and 95 B( Bus wire supervision) for each
bus section.
ii)
67 and 67N (Directional IDMTL over current & earth fault) relays for the
incomers.
23
PART III
SECTION 3
13. The following feeders shall be provided with timers for delayed tripping on bus under
voltage while the under voltage relay shall be common for the bus:
i)
HV & MV capacitor feeders
ii)
HV and MV breaker controlled motor feeders or contractor feeders with

DC- control supply.
14. One no. DC supply supervision relay (80) shall be provided for each incoming DC
supply to the switchboard.
15. One set of bus differential relays (87B) and bus wire supervision relay (95B) for each
bus section shall be provided for HV switch boards connected directly to generation
buses and those used as extension buses at remote substation.
4.4.The metering devices in HV and MV switchboard shall be as below.
Feeder type
Hz
PF MW
HV Incomer
HV Bus Tie
HV Transformer
HV Bus P.T
HV Plant Feeder
HV Motor
X
X
X
X
X
X
X
-
X
-
X
-
HV Capaciter
PCC/ PMCC
Incomer
PCC/ PMCC Bus
Tie.
PCC Bus Tie
ACB Out going
X
X
X
X
X
-
X
X
X
X
MV Motor(>- 75
kW)
MCC/ ASB
Incomer
MCCB/SFU Out
going (>- 250A)
LDB Incomer
DG Set
MWH Hour
Run
X
X
X
X
X
(kWh)
X(kW h)
-
MVA
R
-
--
X(kW
h)
-
X(kW
h)
X(kW
h)
X
(kWh)
MVAH MVA
5. Substation Design
24
PART III
SECTION 3
5.1. EHV Switchyard (IF applicable)

NA
A. Type
: String bus / Tubular bus
B. Structure
: Galvanised
C. Bus material
: Aluminium / Copper
5.2. HV / MV Substation
HV
Elevated with trays in cable cellar
Raised with internal trenches
All top cable entry with trays below
ceiling
Pressurisation against ingress of dust
Air conditioned room for operator /
Variable speed drives / Annunciator
panel / MMI system/ Exiter panel etc
Final paint shade for switchboard /
Busduct / Pressurisation duct / all elect,
equipment, Panels, JB etc.
Yes
No
No
MV
Yes
Yes(for MCC room)
No
Yes
Yes
Yes
Yes
Shade 631
as per IS -5
Shade 631
as per IS 5
5.3. Specific Equipment Locations

A. Batteries
: Separate room in sub station / control

room for electrical and
instrumentation system respectively.
B. Battery charger
: Air conditioned room
C. Variable speed drive panels/ Thyristor

Controlled panels.
: Air- conditioned room
D. UPS System
: Air- conditioned room in control room
E. Lead- Acid and Nickel- Cadmium

Batteries in separate rooms.
: Yes
F. Annunciation panel
: Operator room in substation.
6. EQUIPMENT DESIGN
6.1. EHV Switchyard (if applicable)*
: NA
A. Bus bar system
: Single
B. Circuit breaker type
: SF6
C. Isolator type
: Center break
6.2. HV Switch board
25
PART III
SECTION 3
A. Execution
B. Bus bar
C. Circuit breaker type
D. Motor Control
E. Separate
: Drawout
: Single
: Vacuum
: Breaker
: No
6.3. Current Transformer (CT)/ potential Transformer (PT)

A. CT Secondary
B. PT Secondary
Protection
: 1A
Metering
: 1A
: 110 V AC
6.4.Transformers (Power / distribution)

Transformer
Main power transformer
Generator unit
transformer
Intermediate power
transformer
Dedicated (eg for VSD)
Distribution transformer
(< - 2000 KVA)
Vector group
Tap changer
Soak pit
Preferred rating
(MVA)
NA
NA
NA
As Reqd
Dyn 11
6.5.MV Switchboard
A. Execution
i).PCC / PMCC Breaker panels
contractor feeders
ii). MCC
iii). ASB
iv). LDB
v) .Motors PMCC
MCC
Off circuit
Off- circuit
No
Later
2MVA Later
: Drawout / Single front

: Drawout, Single / Double front
: Drawout : Single / Double front
: Fixed : Single
: Fixed : Single
: Above 55KW Upto 160 kW
: Upto 55 kW
B. Motor Starter Type

i). Contactor and switch fuse with over load relay : Upto 22 kW
ii). Contactor, switch fuse & CBCT for
: Sw. fuse 250 A & for motor
feeders above 22 KW up to 55 KW
with earth fault protection
iii) Contactor and switch fuse with motor
protection relay
: More than 55 KW and up to 75 KW.
iv) Air circuit breaker with motor protection relay : Above 75 KW upto 160 KW
v). Contactor and MCCB with over load relay
: Not applicable
vi) Contactor, MCCB & over load relay
with CBCT for earth fault protection
: Not applicable
C. Motor Controls
26
PART III
SECTION 3
i). Auto/ Manual switch
: DCS in control room @
ii). Local/ remove switch
: DCS in control Room @
iii). Normal / Standby switch
: DCS in Control Room @
iv). Sequence interlock
: PLC in control room @
v). Process interlock
: PLC in control room @
vi) Reacceleration equipment
: Switch gear in substation
@ To be provided as per process package / operating philosophy.

vii) Control voltage for contractor Starter
viii) Control supply for contractor starter
220 V AC
: Control transformer.
6.6.Motors
Motors
Enclosure : Indoor
Outdoor
Insulation class
Terminal box
Anti- condensation heater
Additional canopy (out door
motors)
Design voltage / frequency
variation
High voltage
F (Temp. Rise limited to B)
415 volts
IP55
IP55
F (Temp. Rise limited to B)
Yes
Yes
Above 30kW
Yes
+ - 10% / + - 3%
+ - 10%/ + - 3%
IP55
IP55
6.7. UPS System

A. Redundancy
B. Type of redundancy
C.
D.
E.
F.
Back up time
Inverter by pass transformer
By pass transfer control
Battery type
G. Battery execution
: 100%
: Parallel redundant for UPS for DCS
power
Non redundant for Analyser shelter
UPSs
: 30 minutes
: Static
: Auto / Manual
: Ni- Cd for capacities above 5 KVA
SMF for lesser capacities
: Single up to 600 Ah. Parallel
bank above 600 Ah.
6.8.Communication System
A. Plant Communication System
: NA
B. Telephone System
:Yes
C. Telephone System & plant communication system: Separate

D. No. of intercom & P&T lines
: Later
E. Battery type
27
PART III
SECTION 3
F. Battery back up time
: 2 Hrs.
6.9. Fire Detection &Alarm System

A. Type
: Analogue addressable
B. Name of buildings to be Provided with detectors
: Substation / Control room

building etc.
C. Battery type
: VRLA
D. Battery back up time

E. Detection System
: 48 hrs. (Normal) + 30 minutes. (Alarm)

: Break Glass/ Smoke and Temp. Detector.
F. Siren for the plant
: Not Attended
6.10. DC System
If DC Supply is required the same shall be sourced from a separate dual float cum
boost charger and DCDB.
A. Battery type
i)
Switch gear Protection ,Control & critical lighting. : Ni -cd
ii)
Instrumentation System
: Ni cd
iii)
Diesel Engine Starting
: NA
iv)
DC Motors
B. Battery back up time

i)
Switch gear Protection & Control
: 2 Hours
ii)
Critical lighting
: 2 Hours
iii)
Instrumentation
: 30minutes
iv)
Diesel Engine Starting
: NA
v)
DC Motors
: NA
6.11. Cables
The power and control cables shall have the following minimum cross sectional areas:
a). Medium voltage power cable
: 25 mm2 (Aluminum) / 2.5. mm2 (Copper)
b). Controls cables
: 2.5 mm2 (Copper)
c). Lighting
: 2.5 mm2 (Copper)
d) Communication system
: 0.9 mm dia (Copper) jelly filled
e). Fire Alarm system
: 1.5. mm2 2.5. mm2 (Copper) twisted pair $
28
PART III
SECTION 3
Note
: 1)
2)
3)
For lighting inside the building, minimum 1.5 mm2 copper conductor, PVC
insulated wire shall be used in conduit system (for circuit and point wiring),
with proper colour coding.
All power cables up to 16mm2 shall be of copper conductor.
Cable size are indicative only and same shall be finalized as per equipment /
Manufacturers recommendation.
7.
Cabling System
7.1. Cable details
Design Criteria
Loads located beyond 1 km
Loads located 200 1000 m
Load located upto 200m
Loads beyond 1 kA ratting
Recommended limiting size of
multi core cable (mm2)
Short circuit with stand time
(seconds)
Insulation voltage grade
Type of cable insulation
7.2.
High Voltage
Cable
3 -core cable
Cable
Bus duct/ Cable
300
415 volts
3 - core cable
Cable / Bus trunking
Bus duct
300
0.2 (Out going ) / 0.06 (Plant)/

1.0 (Incomer)
Unearthed for 6.6KV
XLPE
N.A
Earthed
PVC
Cable laying philosophy
A. Process area
: Above ground in overhead cable tray/ directly buried
B. Off site paved area
: Above Ground cable tray (on sleeper / Overhead rack) or

RCC trench/ directly buried
C. Offsite unpaved area
: Above Ground cable tray (on sleeper / Overhead rack) or

RCC trench or directly buried type.
D. Cables for non hazardous area : Armoured.

E. Type of cable trays
: Galvanized prefabricated
F. Special requirements
: Cables for fire water system shall be taken on exclusive

route through underground trench starting from main substation
G. Road Crossings for under ground cables

H. Road Crossings for above ground cables
: Cable culvert.
: Over head cable bridge / Cable culvert
8.0. Earthing System

A. Earth electrode
: GI Pipe
B. Main earth loop
: GI strip
C. Substation earth loop
: GI strip
D. EHV switch yard earth grid
: GI strip / MS with corosion compensation NA
29
PART III
SECTION 3
E. Lightning conductor
: As per IS: 2309.
9.0. Lighting System

9.1. Supply System
A. Centralised with separate transformer
: No
B. At each substation with separate transformer : Yes

C. Separate metering required
: Yes
9.2. Control Philosophy

A. Out door yard
: Auto / Manual ; Centralised / Local
B. Street lighting
C. Out door process area
D. Process building
: Auto / Manual ; Centralised/ Local
E. Auto control
: Synchronous timer.
F. Lamp type for Outdoor lighting
: HPSV / MLL/ Metal Halide lamp /HPMV
G. Panel execution
H. ELCB at incomer of
lighting & Power Panels
LDB connected to MCB panels.

: Yes
9.3. AC Emergency Lighting:

A. Name of process plants
: NA
B. Name of buildings
: Control room to be provided
C. Power supply
: NA
9.4. DC Critical Lighting For Escape

A. Name of process unit
: As per OISD guidelines
B. Name of building
: Substation, control room Buildings, ACplant etc.
C. Power supply
: 110 V DC
9.5.Wiring Type:
A. Process plant / Building / Shed
: Armoured cable
B. Large service building
: Concealed conduit
C. Buildings with false ceilling
: Cables / surface conduit above false ceiling.
D. Substation (Switch gear Room)
: METSEC channel
E. Substation(Cable Cellar)
: Armoured cable
F. Other buildings
: Surface armoured cable / Surface conduit
30
PART III
SECTION 3
9.6 Specific Lighting Requirements

A. Aviation lighting
: NA
B. Navigation lighting
: No
C. Security lighting for peripheral road

Boundary wall
: NA
D. Type of control gear for HPMV/ HPSV lamps for

Process units, Plant / non plant building
E. Control gear box location
: Separate
: Accessible level(Not more than 2 meters above

operating level) for separate control gear.
F. Type of flood light mast
: Telescopic tubular (30m High lighting mast) with

integral power control.
10. Electric Heat Tracing System

A. System Design Basis
11.
: Product Classification approach.
Electrical Equipment for Hazardous Areas
11.1 The electrical equipment for hazardous areas shall be selected as per IS 5571 and
petroleum rules. The minimum requirement is summarised below.
Equipment
Zone-I
Gas Group IIA,IIB
Gas Group IIC
Zone-II
Gas Group IIA,IIB
Gas Group IIC
MV Motors
Ex d
Ex-d
Ex-e
Ex-e
HV Motors
Ex-d / Ex p
Ex d/ Ex-p
Ex-e
Ex-e
Push Button Station
Ex-d
Ex-d
Ex-d
Ex-d
Motors Starters
Ex-d
Ex-d
Ex-d
Ex-d
Plug & Socket
Ex-d
Ex-d
Ex-d
Ex-d
Welding Receptacle
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Div.2 Ltg.
(IS 8224)
Ex-d / Ex-e
Div.2 Ltg.
(IS 8224)
Ex-d/ Ex-e
Ex-d
Ex-e
Ex-e
Lighting Fixtures
i)
Lighting
Ex-d
fitting
Ex-d
ii)
Control Gear
Box
Junction Boxes
Ex-d
31
PART III
SECTION 3
Hand Lamps
i)Light fitting
ii)Transformer
iii)Plug & Socket
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Break Glass Unit
Ex-d
Ex-d
Ex-d
Ex-d
/ Ex-d
Ex-d
Ex-d
Ex-d
(FireAlarm System)
Lighting
Panel
Power Panel
Hermetically sealed with surface temperature not exceeding 200 0C
Transformers
Notes :
1.
The electrical equipment for hazardous areas shall generally be suitable for gas
group IIB and temp classification T3 as applicable to the selected type of
explosion protection. In case of hydrogen of hydrogen or hydrocarbon mixtures
having more than 30% volume hydrogen, the gas group to be considered shall
be IIC.
11.2.As additional safety features, the following requirements for electrical equipment shall
be followed.
A. All electric motors for agitators / mixers and metering pumps handling flammable
material shall be flame proof type irrespective of the area being classified as zone -2
or zone -1.
B. All electric motors for vertical oil sump pump shall be flame proof type.
C. Irrespective of the area classification (whether zone -1 or zone 2 ) all lighting fittings
with in the storage areas shall be flameproof type.
D. Irrespective of the area classification (whether zone 1 or zone-2 ) , all motors and
lighting fittings within the pump house (station) associated within the loading /
unloading gantries shall be of flame proof type.
E. All emergency / critical lighting fixtures and associated junction boxes in hazardous
areas (whether zone -1 & zone 2 ) shall be flameproof type.
F. Even though fired heaters in process units are not considered ammonia as refrigerant,
the room housing air conditioning equipments associated with fired heaters in process
units shall as a minimum be suitable for installation in Zone -2 area.
32
PART III
SECTION 3
G. Where air conditioning system is designed considering ammonia as refrigerant, the

room housing air conditioning equipment shall be adequately ventilated to classify it is
a safe area. For additional safety the following shall be considered:
!
100% standby system for ventilation
Location of MCC / local panels in adjacent separate room.
Instrumentation to be flameproof type or hermatically sealed.
AC plant room motors suitable for zone 2 area.
Lighting in AC plant room suitable for zone -2 area.
H. All electrical equipment installed in Analyser room shall be flameproof type suitable for
gas group IIA, IIB , IIC irrespective of the area being classified as Zone 1 or Zone -2.
12. Statutory Approval
Statutory Authority for
Electrical Installation
: Central Electrical Inspectorate
Statutory approval / License

For hazardous area equipment
: For indigenous equipment

CMRI Test certificates, CCE, DGF
ASLI approval certificates and BIS
License (for flameproof equipment)
13. Cable Sizes for MV Motors

13.1 Direct on line (D.O.L) start motors
Motor Rating
Below 3.7 kW
3.7kW
5.5kW
7.5kW
9.3 kW
11K
15W
22kW
30kW
37kW
45kW
55kW
75kW
90kW
110Kw
125/ 132 kW
160kW
Number
of runs
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
Cable Details
No. of cores
Conductor
per run
material
4
Cu
4
Cu
4
Cu
4
cu
3
Al
3
Al
3
Al
3
Al
3
Al
3
Al
3
Al
3
Al
3
Al
3
Al
3
Al
3
Al
3
Al
Conductor
size mm2
4
6
10
16
25
35
50
70
70
95
120
150
185
120
120
185
185
33
PART III
SECTION 3
180kW
3
3
Al
185
13.2 Cable sizes for motors not conforming to above table (e.g Extended distances, Reduced
voltage starting) shall be as below.
13.3 Cable sizes mentioned above are applicable for a distance of maximum 350 m and for
2/4/6 pole motors. Cables sizes for other distances and low speed motors shall be
worked out by the engineering contractor.
CHAPTER 4
JOB SPECIFICATION
FOR
ELECTRICAL FACILITES
34
PART III
SECTION 3
CONTENTS
1.0
SCOPE
2.0
CODES AND STANDARD
3.0
STATUORY REQUIREMENTS
4.0
SYSTEM DESIGN PHILOSOPHY
5.0
EQUIPMENT DESIGN PHILOSOPHY
6.0
SUBSTATION DESIGN PHILOSOPHY
7.0
INSTALLATION DESIGN PHILOSOPHY
35
PART III
SECTION 3
1.0 SCOPE
This specification along with the applicable project design data shall form the basis for
developing detailed design and engineering for electrical facilities including electrical
power system, electrical equipment, plant communication system, fire alarm system and
electrical installation etc.
2.0 CODES AND STANDARDS
The main codes and standards, considered as minimum requirements, are as follows.
Latest version of these shall be followed:IS 9676
: Reference ambient temperature for electrical equipment
SP- 30
: National Electrical Code(NEC) BIS Publication
IS- 13234
: Guide for short circuit calculation in three phase AC system.
IS- 5572
: Classification of hazardous areas having flammable gases & vapours

for Electrical installations.
IS- 5571
: Guide for selection of electrical equipment for hazardous area.
IS- 4201
: Application guide for C.T.
IS- 4146
: Application guide for V.T.
IS- 6665
: Code of practice for Industrial Lighting.
IS- 3646
: Code of practice for Interior Illumination.
IS- 1944
: Code of practice for lighting of public thoroughfares.
IS- 13346
: General Requirements for electrical apparatus for explosive gas

atmospheres.
IS 13408
: Code of practice for the selection, installation & maintenance of

electrical Apparatus for use in potentially explosive atmospheres.
IS- 3043
: Code of practice for Earthing.
IS- 3716
: Application guide for Insulation Coordination.
IS- 10561
: Application guide for Power Transformer.
IS- 10028
IS- 8478
: Code of practice for selection, installation & maintenance for switch

gear & control gear
: Application guide for on load tap changers.
IS- 10118
: Code of practice for selection, installation & maintenance for switch
36
PART III
SECTION 3
gear & control gear.

IS- 7689
: Guide for Control of undesirable static electricity.
IS- 2309
: Code of practice for the protection of buildings and allied structures

against lighting.
IS 12360 : Voltage bands for electrical installations including preferred voltages

and frequencies.
IS- 3961
: Recommended current ratings for cables.
IS- 7752
: Guide for improvement of power factor- consumers installations.
IS- 1646
: Code of practice for fire safety of buildings Electrical Installations.
IS- 3034
: Code of practice for fire safety of industrial buildings Electrical

generating and distributing stations.
OISD 113 : Classification of areas for electrical installations at hydrocarbon

processing and handling facilities.
OISD 173: Fire prevention and protection system for electrical installations.
OISD- 110: Recommended practices on static electricity.
IEC specifications shall be followed where equivalent Indian Standards are not available in
specific cases.
3.0 STATUTORY REQUIREMENTS:
The latest version of the following statutory regulations shall be followed for design of
electrical system,
- Indian Electricity Act.
-
Indian Electricity Rules.
The Factory Act.
The Petroleum Rules.
Requirements of other statutory bodies as applicable, e.g. CEA, CCE,

DGFASLI, TAC
4.0 SYSTEM DESIGN PHILOSOPHY

4.1 General
The electrical system shall be designed to provide:
-
Safety to personal and equipment both during operation and maintenance .
Reliability of Service.
Minimal fire risk.
Ease of maintenance and convenience of operation.
37
PART III
SECTION 3
4.2
Automatic protection of all electrical equipment through selective relaying system.
Electrical supply to equipment and machinery with in the design operating limites.
Adequate provision for future extension and modification.
Fail safe feature.
Suitability for applicable environmental factors.
Maximum interchangeability of equipment.
Area Classification and Equipment Selection
4.2.1 All the areas with in the battery limits shall be classified for the degree and the extent
of hazard from flammable materials. Classification of hazardous areas shall be done in
accordance with Petroleum Rules, DGMS regulations (where applicable) and IS5572.
4.2.2
Following factors shall be considered for proper selection of electrical equipment for
use in hazardous area.
-
Area classification i.e. Zone.
Gas classification i.e. Group- The characteristic of the gas or vapour involved in
relation to the ignition current or minimum ignition energy and safe gap data.
Temperature classification The ignition temperature of the gas vapour involved

or the lowest value of the ignition temperature if more than one combustible
material is present.
Environmental conditions in which apparatus is to be installed The selected

electrical apparatus shall be adequately protected against corrosive and solvent
agencies, water ingress, thermal and mechanical stresses as determined by the
environmental conditions.
4.2.3
All electrical equipment installed in hazardous areas shall be selected as per IS- 5571
and shall meet the requirements of relevant IS, IEC or NEC Standards. However,
electrical equipments for Zone 2 areas as a minimum shall be ex (e)/ Ex (n) type as
per IS/IEC codes. Increased safety {Type Ex(e)} equipment shall not be used in Zone1 areas. Ordinary industrial electrical equipment (even though permitted for use in
Div.2 area as per NEC) shall not be used in Zone 2 areas. Type of explosion
protection to be used for individual equipment shall be as specified in the job design
data.
38
PART III
SECTION 3
4.2.4
For pressurised electrical equipment {Type Ex(p)}, on failure of pressurisation system

, the following minimum actions shall be provided:
Area classification
Enclosure does not

Contain ignition
Enclosure contains ignition

capable apparatus.
Capable apparatus
4.2.5
4.2.6
Zone 1
Alarm
Alarm and Switch- off.
Zone-2
No action reqd.
Alarm.
All electrical equipments for hazardous areas shall be certified by CMRI, PTB,
BASEEFA, UL or FM or equivalent independent testing agency for the service and the
area in which it could be used and shall be approved by CCE/DGFASLI/DGMS (as
applicable). All indigenous flameproof equipment {Type Ex (d)} shall be under BIS
license.
Motors fed by frequency converters/variable frequency power supplies shall be tested
and certified along with the converter by an a appropriate agency.
4.3
Power System Design

The distribution system shall be designed in accordance with project specification
taking into account all possible factors affecting the choice of the system to be adopted
such as required continuity of supply, flexibility of operation, operational costs,
reliability of supply from available power sources, total load and the concentration of
individual loads.
Special attention is drawn to chapter X of IE rules which includes requirements for
design of electrical system as applicable to oil mine installation under the
jurisdiction of DGMS.
4.4
Capacity of Electrical System

All the components of the electrical system shall be sized to suit the maximum
load, under the most severe operating conditions. Accordingly, the maximum
simultaneous consumption of power, required by continuously operating loads
shall be considered and an additional margin shall be taken into account for
intermittent service loads, if any. System design shall permit direct- on- line
starting of all motors unless specified otherwise.
The amount of electrical power consumed by each process unit shall be calculated
for its operation at the design capacity. As far as practicable, a switchboard for
essential services required for plant maintenance during extended period of shut
down, shall be provided.
39
PART III
SECTION 3
4.5 System Voltages

Voltage selection shall be based upon the following factors:
a) Size and location of loads.
b) Provision of future extension
c) Short circuit level
d) Availability of switch gear with suitable current rating and rupturing capacity
e) Possibility of keeping the number of different voltage levels to a minimum
f) Utilisation voltages for various equipment
g) Economics
The choice of voltages may also be affected by local regulations, standards, as well
as, the voltages of existing installations.
4.6 Voltage Drops
4.6.1 The maximum voltage drops in various sections of the electrical system under
steady state conditions at full load shall be within the limits stated in the
following table:
S.NO
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
MAXIMUM
SYSTEM ELEMENT
PERMISSIBLE
VOLTAGE DROP
Busduct or cable between transformer secondary and 0.5%
HV Switchboard or PCC/PMCC
Cable between PCC/PMCC and MCC or auxillary
switchboard.
i)MCC / Auxillary
Switch board near 0.5%
PCC/PMCC
ii) MCC / Auxillary Switchboard situated remote 2 to 2.5%
from PCC / PMCC.
Cables between HV Switchboard and HV Motor
3%
Cable between PCC/ PMCC and motor.
5.5%
Cable between MCC (situated near PCC/PMCC) and 5%
motors.
Cable between MCC (situated remote from 3%
PCC/PMCC) and motors
Cable between Auxillary Switchboard & Lighting 1 to 1.5%
Panel.
Circuit between lighting panels and lighting points.
4%
DC Supply Circuit (Electrical Controls)
5%
DCDB to Control Room
2% (Note 1)
UPS outgoing circuit
5% ( Note- 1)
Note 1 Minimum voltage available across any instrument in the field shall be as per
Instrumentation design basis. Distribution system for instrumentation supplies shall be
40
PART III
SECTION 3
designed accordingly. In case of any conflict between electrical design basis and
instrumentation design basis, the later shall govern regarding instrumentation power supplies.
4.6.2 The maximum voltage drop at various buses during start up of large motor and / or
motor reacceleration conditions shall be with in the limits stated below:
S.NO
SYSTEM ELEMENT
a)
At the busbars of the worst

affected Switch board.
b)
At the busbars of the worst

affected MV Switchboard.
(PCC/PMCC/MCC)
c)
Cables between HV Switch

board & motor.
Cables
between
MV
switchboard
(PCC/PMCC/MCC)
&
motor.
d)
OPERATING
CONDITION
MAX.
PERMISSABLE
VOLTAGE DROP
Start up of the large HV 15%
motor with other loads on
the bus or reacceleration of
a
group
of
HV
motors(Simultaneous start
up or group reacceleration
of MV motors is not
envisaged)
Start up of large MV 10%
motor with other loads on
the bus, or reacceleration
of a group of MV motors.
Motors
start
up
or 5%
reacceleration.
Motor
startup
or 15%
reacceleration.
NOTES:
a) The voltage available at the motor terminals during start up must be sufficient to ensure
positive starting or reacceleration of the motor (even with the motor fully loaded, if
required), without causing any damage to the motor.
b) For medium voltage motors, the voltage available at the motor terminals must not be less
than 75% of the rated value during start- up or reacceleration.
c) For high voltage motors, the voltage available at the motor terminals must not be less than
80% of the rated value during start up or reacceleration.
4.7
System Earthing
4.7.1 System earthing for incoming supply & primary / secondary / HV distribution system
shall be as per design data. The 415 V system neutral shall be solidly earthed.
4.7.2
For resistance earthed system, the resistance value shall be chosen to limit the earth
fault current to a value which shall be sufficient for selective and reliable operation of
heartfelt protection system, while ensuring minimum equipment damage during an
41
PART III
SECTION 3
earth fault. However, the value of limited earth fault current shall generally not exceed
50% of transformer or generator full load current.
4.8
Short Circuit Capacities

Each short circuit interrupting device shall be designed to have rated servicebreaking capacity (Ics) equal to or higher than the maximum value of short circuit
current calculated, at is location. The related switchgear and busduct shall
withstand the above maximum available fault current for a minimum period of one
second. The sizing of high voltage cables shall be based on the short circuit
withstand capacity for a minimum time period as dictated by the protection system
in addition to the maximum anticipated load current.
4.9. Insulation System

The insulation of electrical facilities shall be designed considering the system voltage,
the system neutral earthling and the over voltages resulting due to system fault,
switching or lighting surges. The insulation coordination between the electrical
equipment and the protective devices shall be done in line with IS: 3716.
Lighting arresters ad surge absorbers shall be provided where necessary.
4.10 Protection and Metering Schemes
4.10.1 The protective system shall be selected and coordinated to ensure the following:
a) Protection of equipment against damage which can occur due to internal or external
short circuits or atmospheric discharges.
b) Uninterrupted operation of those parts of the system which are not affected by the
fault.
c) Personal and plant safety.
4.10.2 In general, quick acting relays (with time delays, if necessary) shall be used and all
fault tripping shall be done through high speed tripping relays. All relays, excepting
auxiliary relays and timers, shall be draw out type.
4.10.3 Metering instrument shall be provided to keep a record of power consumption and
supervision of all instrument shall be flush mounted back connected type.
42
PART III
SECTION 3
4.11.
DC Power Supply
Independent DC Power supply systems shall be provided for the following:
-
Plant shutdown system and DC instrumentation.
Electrical switch gear controls and critical lighting.
PLCC equipment.
Emergency DC motors (if applicable)
Telephone system
Fire alarm system.
Diesel engine starting (for each engine)
Communication system (if applicable)
Telecom & SCADA ( if applicable)
Each DC power supply system shall include charger -cum rectifier, dual float cum
boost type, batteries and DC distribution board.
4.12.
Emergency Power Supply

The emergency power supply system, where ever envisaged, shall feed the following:
- Electrical loads essential for the safe shutdown of the plant.
- Emergency lighting.
- Process plant instrument as required.
- Communication equipment.
- Fire alarm system.
- D.C Supply system.
- UPS Systems.
- Fire fighting equipment excluding main fire water pump.
- Loads critical for process, plant and personnel safety.
- Emergency power supply shall be made available within a time period of 30
seconds, from the instant of failure of normal supply.
- The emergency generator shall, generally, not be required to run continuously
in parallel with the normal power supply system.
4.13 Uninterrupted Power Supply

Uninterrupted power supply system shall be provided, (if required) for meeting critical
loads that cannot withstand a momentary interruption in voltage. A separate battery
shall be provided for UPS system. Following loads shall be connected to the UPS
system.
- Critical instruments and control.
-
Critical communication equipment.
Critical security equipment.
Computers.
Annunciation panel.
43
PART III
SECTION 3
4.15
Plant Communication System
4.15.1 It shall consist of the following:

-
Micro processor based central exchange installed in the control room.
Power supply system.
Master station along with external loudspeaker, microphone etc.
Desk type call stations along with microphone and external loudspeaker for
installation in buildings.
Wall / column mounting type call stations for hazardous / safe areas with
external loudspeaker.
4.15.2. Paging speakers provided in areas having high ambient noise levels shall produce a
paging level at least 6dB above the anticipated ambient level. Field stations shall be
capable of operating in areas of high noise without any interference. Separate battery
and battery charger shall be provided for each exchange.
4.15.3. System shall have provision for addition of10% field call stations/ loud speakers in
future.
4.16
Fire Detection & Alarm System:
4.16.1 The Fire Detection & Alarm System shall be an independent system comprising of
individual break glass type manual call points, automatic sensors e.g. smoke and heat
detectors, main panel, zonal panel, hooter, battery charger & other hardware. The
system shall be designed to provide audio visual indication at the main panel to be
located in fire station and zonal panel, in control room. Repeater panels shall be
provided as applicable.\
4.16.2. The manual call points shall be provided at strategic locations with access of 60mtrs.
Along all exit routes & roads.
4.16.3. Battery and battery charger shall be provided for each panel separately.
4.16.4 Electrical sirens shall be provided at stragegic points to cover entire plant area.
4.16.5 Response indicators, hooters & exit lights shall be provided at required locations.
4.16.6 System shall have provision for addition of 10% detectors, manual call points in future.
4.16.7 The fire detection system shall be interfaced with fire suppression system; wherever
required.
44
PART III
SECTION 3
5.0
EQUIPMENT DESIGN PHILOSOPHY
5.1
General
The equipment shall in generation conform to Standard specifications. Equipments
shall be designed as per philosophy given below.
5.2 Transformers
5.2.1 All Transformers except lighting transformers shall be three phases, oil immersed,
double wound type suitable for outdoor use. Lighting transformers shall be dry type.
5.2.2 The rating of transformers shall be decided based on the following criteria:ONAN transformers:- The rating shall be equal to or higher than 110% of maximum
simulations demand envisaged.
ONAN/ONAF transformers:- The ONAN rating shall be equal to or higher than the
maximum simulations demand envisaged. The ONAF rating shall be equal or higher
than 125% Of ONAN rating.
5.2.3 The percentage impedance of each transformer shall generally be as per Indian
Standards.
5.2.4
100% standby transformers shall be provided in all unit, offsite & utility substations,
unless otherwise specified.
5.3 Switchgear
5.3.1 All switchgear and associated equipment fed from generators and transformers shall
have rating equal to the rating of respective generators and transformers feeding it,
under any circuit configuration. However, generator incomer shall be rated at least
equal to 110% of the continuous rating of generator and transformer incomer shall be
rated atleast equal to forced cooled rating of transformer or 110% of ONAN rating as
applicable.
45
PART III
SECTION 3
5.3.2 Bus tie circuit breakers shall have rating higher of the following:
a)
Largest incoming circuit breaker.
b)
Maximum running load on either side of bus section.
In no case shall the tiebreaker rating be less than the busbar current rating.
5.3.3 All other switchgears not directly fed from generator and transformers shall have
rating atleast equal to the maximum demand under any circuit configuration plus a
provision for 10% future load growth. Incomers of these switchgears shall be designed
to cater to the complete load including 10% margin for future load growth.
5.3.4 Spare outgoing feeders shall be provided in all switchgear. At least one number of
each rating and type or 20% whichever is more, shall be provided as spare.
5.3.5 Circuit breakers/ contactors controlling motor feeders shall have a rating of at least
125% of the maximum continuous rating of the connected motors.
5.3.6 Separate feeders shall be provided in the switch board for each load/ motor. However,
as an exception maximum two numbers welding receptacles may be connected to one
power feeder.
5.3.7 All circuit breakers shall be of single break type having one pole per phase. Circuit
breakers for MV generator incomer shall be with four poles. Alternatively three pole
breaker with adequately rated air break contactor for neutral isolation may be
provided.
5.3.8 In case of HV vacuum circuit breaker, adequate provision shall be made for motor
switching to limit the over voltage to 2.2 per unit of rated peak line to earth voltage.
5.3.9 Service breaking capacities (i.e. Ics) for all breakers & MCCB s shall be equal to or
higher than the maximum value of the short circuit at the point of installation. MCBB
s with back up fuses shall not be acceptable.
46
PART III
SECTION 3
5.3.10 Air circuit breakers (ACB) shall be provided in MV switchboards for all feeders rated
above 400 A and switchfuse units / MCCB s shall be provided for all feeders rated
upto 400A.
5.3.11 Circuit breakers/Switch fuse units for capacitors shall, have a current rating of at least
135% of the capacitor rated current. Circuit breakers capability to interrupt applicable
capacitive current shall be specifically verified.
5.3.12 The switchboard components viz. Circuit breakers, main horizontal and vertical busbars, bus bar joints, busbar supports etc. shall be designed to withstand the maximum
expected short circuit level for a minimum time of 1 sec.
5.3.13 For motors above 5.5 KW, CT shall be provided in the switchgear for ammeter on the
local push button station. Indication lamp on the switchgear shall be LED type.
5.3.14 The maximum rating of bus bars for MCC s / ASB s / LDB s shall preferably be
limited to 800 Amps, Heavy-duty type load break switches / ACB shall be used for
incoming and tiebreakers and these shall have suitable interlocks.
5.3.15 The Auxiliary Service Board (ASB) and / or lighting distribution board containing
mainly switch fuse units shall have horizontal and vertical bus bars like those in PCC
& MCC.
5.4
Bus Duct
The rating of bus ducts connected to breakers shall have same continuous & short
circuit rating as that of breakers. Similarly bus ducts connecting to two bus sections
shall have same continuous & short circuit rating as that of main bus bars.
5.5
Neutral Grounding Resistor

Neutral Grounding Register (NGR) shall be housed in a sheet metal enclosure and
shall be naturally ventilated. The resistor shall be of unbreakable, corrosion proof
jointless stainless steel grids. The grids shall be in punched form. The NGR s shall be
rated to withstands the fault current for 10 seconds.
47
PART III
SECTION 3
5.6
Battery
Batteries shall be of adequate capacity to meet the back up requirements as envisaged
on the duty cycle as well as to take care of future load growth of 10%. While sizing the
battery, temperature correction factor and ageing factor shall be considered in addition
to the maintenance factor. Batteries shall be complete with battery racks and
accessories.
5.7
Battery Charger and Distribution Board
5.7.1 Charger and DB shall be floor mounted, free standing, metal enclosed and vermin
proof type having hinged door for front access and shall be suitable for indoor use.
The battery charger/rectifier shall feed the load and keep the batteries under fully
charged condition. Provision shall also be made for necessary boost charging/initial
charging of battery.
5.7.2 Each battery charger & DCDB shall have at least 10% spare capacity to meet future
requirements.
5.7.3
Each DCDB shall have at least 10% spare feeders for future use of owner.
5.8
Uninterrupted Power Supply System
5.8.1 The panels for UPS system shall be of floor mounted, free standing, metal enclosed
and vermin proof type having hinged door for front access and suitable for indoor use.
5.8.2 UPS system shall be sized to take care of the crest factor of the load current.
5.8.3
UPS system shall include a set of storage batteries, rectifier transformer, rectifiercum charger, inverter, set of filter circuit, static switches, bypass transformer, facility
for manual transfer between inverter supply and bypass line, facility for bypassing
inverter and static switch for maintenance, AC Distribution board and other associated
accessories.
48
PART III
SECTION 3
Under normal conditions, the rectifiercum- charger shall feed the inverter and charge
the battery set. Incase of mains failure, the battery shall supply the necessary power to
the inverter. The inverter in turn shall feed the load through the static switch. If the
inverters malfunction or get overloaded, the load shall be instantaneously transferred
to the bypass line through the static switch. Normally, the inverter shall be operated in
synchronized mode with the bypass line, and manual forward transfer or manual
reverse transfer shall be effected without any break. Automatic forward transfer, in
case of inverter malfunction shall be affected with a break not exceeding 4
milliseconds.
5.8.4 Each branch circuit of the UPS distribution system shall have a fused disconnect
switch. The fuse shall be fast clearing type and the fuse rating shall be coordinated
with the rating of the UPS system. Normally the largest branch circuit load shall not
exceed 25% of the system rating.
5.8.5 Each UPS shall have at least 10% spare capacity to meet future requirements.
5.8.6 Each UPS ACDB s shall have atleast 10% spare feeders for future use by owner.
5.9 Motors
5.9.1 In general, three phase squirrel cage induction motors designed for direct on line
starting shall be used. Motors shall be totally enclosed, fan cooled type and suitable for
continuos outdoor use.
5.9.2 All motors shall be continuous maximum rated with possible exception of crane and
hoist motors and turbine/engine starting motors which may be rated for the envisaged
duty cycle.
5.9.3
Motors with anti- condensation heaters shall have a separate terminal box provided
for the same. All HV motors shall have temperature detectors for bearing & winding
temperature along with the temperature scanner, which shall be interfaced with
instrumentation DCS.
49
PART III
SECTION 3
5.9.4
High voltage motors shall be suitable for starting under specified load conditions with
80% of the rated voltage at the terminals and medium voltage motors shall be suitable
for starting under specified load conditions with 75% of the rated voltage at the
terminals.
5.9.5 For heavy duty drives such as reciprocating compressor/ agitator/ crusher etc.,. high
starting torque motors (minimum 150% of the rated torque) shall be provided, and
starting time shall be limited to ensure adequate protection by motor protection relays.
5.9.6 HV motor terminal box shall be capable of withstanding the specified fault level for
0.25 seconds without damage. Winding ends shall be brought out and star point shall
be made in a separate terminal box. Neutral terminal box shall have necessary space
provision to mount current transformers for differential protection.
5.9.7 Greasing provision shall be provided for all motors > 15 kW
5.10
HV Capacitor banks
5.10.1 The capacitor banks shall be supplied with series reactor & RVT (residual voltage
transformer).
5.10.2 The capacitor banks shall be provided in star configuration with minimum 4Nos. basic
single phase units in parallel per phase.
5.10.3 The capacitors shall be with all polypropylene or mixed dielectric having low watt
loss. The impregnant shall be non toxic, non PCB (poly chlorinated biphenyl)
based and bio degradable.
5.10.4 Capacitors shall be with internal element fuses and external expulsion type fuses.
5.10.5 The series reactors shall be non magnetically shielded design and oil immersed & air
cored construction. They shall be provided with a conservator. The series reactors
shall be designed to limit the inrush current & to suppress harmonics.
50
PART III
SECTION 3
5.10.6 The capacitor banks, RVT s & series reactors shall be interconnected with PVC
sleeved, aluminium/copper bus bars. They shall be mounted on elevated structures
such that the bottom most portion of the bushing is at least 2.75 mtr. above the ground
level. The whole bank shall be suitable for outdoor location.
5.10.7 The capacitor bank in conjunction with series reactor shall provide minimum net
KVAR at rated nominal voltage. However, the insulation system shall be designed to
withstand continuous over voltage of 110%.
5.11
Emergency Generator
5.11.1 The emergency generator set shall be procured as a complete package and shall be
designed to start automatically on power failure and feed the selected loads. It shall be
capable of taking care of the load variations (e.g. the starting of the largest rated
motor). The unit shall be complete with necessary starting equipment, associated
control panel and shall be suitable for remote starting.
5.11.2 The regulation of generator voltage shall be automatic and necessary instruments for
metering viz., Ammeter, Voltmeter, frequency meter, kwh meter, power factor, hour
run counter etc. shall be included in control panel. Warning of abnoraml conditions
shall be incorporated prior to automatic trip to prevent unnecessary shutdown.
5.11.3 Emergency D.G set shall have auto starting arrangement but only with manual
switching off features. Fail to start annunciation shall be provided, in case the engine
fails to start.
5.11.4 The load shall be switched on to the generator only after the requisite voltage buildup. The generator set shall be provided with complete protection against overloads,
short circuits, ground faults, excitation failure, prime mover failure and shall include
other connected instrumentation interlocks.
5.11.5 The generator shall have atleast 10% spare capacity for meeting future requirements.
51
PART III
SECTION 3
5.12
Annunciation Panel
5.12.1 An audio visual annunciation panel shall be provided to monitor the switchgear and
other electrical equipments. The panel shall be free standing or wall mounting type.
5.12.2 Detailed annunciation schedule shall be based on but not limited to the following:
a) HV Switchgear
-
Breaker- wise fault trip alarm
Status of Auto changeover scheme
Trip circuit status for breakers
Differential relay operation alarm.
DC supply failure trouble alarm
PT secondary MCB trip alarm for all line & bus PT s.
b) MV switchgear
- Incomer/Bus coupler fault trip alarm.
- Status of Auto changeover scheme.
-
Bus- wise group fault trip alarm for outgoing feeder breakers.
D.C. supply failure alarm(Bus- wise)
PT secondary MCB trip alarm for all line & bus PT s.
c) Operating status/ fault conditions forUPS system.

d) Operating status/ fault conditions for DC supply system.
e) Operating status / fault condition for DG sets.
5.13
Annunciation panel shall be complete with acknowledge, test and reset pushbuttons.
20% spare windows for future use shall be provided in panel. Generally, annunciation
panel shall be fed from the UPS system.
5.14
Cables And Wires
5.14.1 HV cables shall be dry cured XLPE insulated, PVC sheathed, armoured type with
aluminum/copper conductors. They shall be provided with conductor & insulation
screen.
52
PART III
SECTION 3
5.14.2 MV power
cables shall be PVC insulated, PVC sheathed, armoured type with
aluminum /copper conductor while aluminum conductor shall be used above 16mm2.
5.14.3 The control cables shall be PVC insulated, PVC sheathed, armoured type with copper
conductors. Twisted pair or shielded controls cables shall be used where
electromagnetic / electrostatic interference is expected.
5.14.4 All power and control cables shall have extruded inner and outer sheaths.
5.14.5 The cables shall be sized based on the maximum continuous load current, the voltage
drop, system voltage, system earthing and short circuit withstand criteria. The derating
due to ambient air temperature, ground temperature, grouping and proximity of cables
with each other, thermal resistively of soil, etc,. shall be taken into account.
5.14.6 Cables connected in parallel shall be of the same type, crosssection and terminations.
5.14.7 As an exception within substation areas, unarmoured cables may be used.
5.14.8 All power and control cables shall be in continuous length (except for long feeders)
without any splices or intermediate joints. The cables used for lighting and wires in
conduits shall have approprite junction boxes with adequately sized terminals. Cable
joints on hazardous areas shall not be permitted.
5.14.9 All incoming cables to switch gear/ UPS/DC system/DB s and other equipment shall
be sized for actual rated capacity of the equipment. Cable for capacitor banks shall be
sized for 135% of the rated capacitor current.
5.14.10 The incoming cable for heat tracing power distribution panel shall be with cores with
four neutral conductor being of same size as the phase conductors.
5.14.11All control cables shall have minimum 20% spare cores except that control cables
having up to seven cores may have one core as spare.
53
PART III
SECTION 3
5.15
Control Station
5.15.1 Each motor shall be provided with a control station in the field.
5.15.2 The control station enclosure shall have suitable protection for site conditions (such as
flameproof, weather proof, dust proof, corrosion resistant, etc.).Canopy shall be
provided to protect outdoor control stations against direct rain.
5.15.3 The control station shall include the following equipment as per individual
requirements:
-
Start/ stop push buttons.
Ammeter
Auto/ Manual or Local / Remote selector switch.
Cable glands.
5.15.4 Stop push button shall generally have stayput feature except in the case critical drives
such as lube oil pump etc.
5.15.5
Motor installed at elevated platforms (such as cooling tower fan etc.) shall be
provided with a stop push button at ground level in addition to the one near the motor.
5.16
Convenience Receptacles
5.16.1 These shall have the necessary mechanical and earthing facilities. The enclosure shall
have suitable protection for site conditions specified (flame proof, weather proof, dust
proof, corrosion resistant, etc.)
5.16.2 Adequate number of welding receptacles shall be provided with a stop push button at
ground level in addition to the one near the motors.
5.16.3 Adequate number of three- pin sockets for lamps and portable tools shall be provided
at suitable locations to ensure accessibility with a 15 meters length of cable to all
manholes of process equipment &other important areas in the process units. These
shall be rated for 15A, 240 V single phase with earth connection. Hand lamps and
54
PART III
SECTION 3
portable tools shall be earhted through flexible cords. In hazardous areas, hand lamps
shall be rated for 24V. Accordingly 240/24V transformers shall be provided either in
the plug or in a separate flameproof enclosure.
5.17
Actuators for Motor Operated Valve
5.17.1 Generally MOV s shall be provided with integral starters. The necessary local/remote
selector switch, start / stop control switches or pushbuttons, torque limit switches, ,
etc. shall be provided on actuator for local / remote control depending on the mode of
selection. In case of torque limit switches, the mechanical design shall be adequate to
stall and trip the motor without damage. The control circuit shall be A.C operated for
short distance and D.C. operated for extended distances. The actuator shall be
provided with an anti- condensation heater and status indications.
5.17.2 The motors shall be provided with class F insulation with temperature rise limited to
class B.
5.17.3 The MOV shall be suitable for starting at 75% voltage across the motor terminal.
6.0
SUBSTATION DESIGN PHILOSOPHY
6.1
The substation shall be located in a safe area close to the load center. Consideration
shall be given to cooling tower sprays, vapours contributing to the insulation breakdown, vehicular traffic or any other factor that might affect the operation of the sub
station.
6.2
HV sub-stations floor shall be raised above grade level and the space below the switch
gear room shall be utilized as cable cellar. The cable cellar floor shall be 300mm
above the approach road level and shall be paved and cemented. The cable cellar shall
have a minimum clear height of 2.5 m and shall house all cable trays and their
supports.
55
PART III
SECTION 3
6.3
MV substations & MCC rooms shall be eleveted at least 1M by compacting the soil
so that the bottom of the cable trench within sub-station is above the surrounding
grade level.
6.4
A separate entry of 3 m x 3 m with rolling shutter shall be provided for drawing in all
equipment for erection. The main entry for operating personnel shall be preferably
provided with double door system. The sub-station shall also have an emergency door
opening outwards.
6.5
For attended substations an operators room shall be provided. An annunciation panel
to monitor the switch gear located in the sub station shall be installed in the operators
room.
6.6.
Sub station wall adjacent to the transformer bays shall be 355 mm thick in case of
brick construction or 230 mm thick in case of RCC construction.
6.7
Sub station building shall be without any columns within the switchgear room to
ensure optimum space utilisation.
6.8
Battery banks shall be located in a separate adequately ventilated room in the substation room in the substation buildings, along with the necessary exhaust system and
water connection with sink. Floor of the battery room and walls upto 1.0 m height
shall have acid/ alkaline resistant protective material coating/tilling. Light fittings in
this room shall be chemical resistant type.
The battery rooms shall be provided with aluminum two exhaust fans and louvred
opening on opposite wall/ door.
6.9
UPS system and other power electronics equipment e.g. variable speed drive panels
shall be located in air conditioned room.
6.10
Rooms housing critical power supply equipment and operators room of large sub
stations locatedclose to process units shall be of blast proof design in case main
control room being of blast proof construction.
56
PART III
SECTION 3
6.11
Sub station shall have fire fighting equipment, first aid boxes and other safety
equipment as per statutory requirements. Mats of required voltage rating shall be
provided in front of switch boards.
6.12 Equipment like transformers, neutral grounding resistors, reactors and HV capacitor
banks shall be located in bays adjacent to the substation building. All bays shall have
well drained floor, surfaced with gravel or other suitable material. Each bay shall be
provided with 2.5m high removable chain link fence with a locakble gate at the open
side. Partition walls between transformer bays and the ends of the last by shall be of fire
proof type and shall extend at least 600 mm above the height of the equipment. Height
of the bay shall be decided so as to facilitate maintenance and easy removal of
equipment and requirements of natural ventilation.
6.13 Oil immersed transformers with oil capacity exceeding 2000 liters shall be provided
with a soak pit of sufficient capacity to take the whole of the oil of the equipment.
Where oil capacity of transformers exceeds 9000 liters, provision shall be made to drain
away the oil to a separate waste oil tank/pit located away through suitable drain pipes of
150 mm or 200 mm in diameter. Fixed fire extinguishing system shall be provided for
all oil field transformers having oil content more than 2000 liters.
6.14 One set of accessories consisting of cell testing voltmeter, spanner, face shield, PVC
apron, rubber gloves, etc. shall be provided in each battery room.
6.15 The substation building shall be sized to take care of present and future needs and to
maintain adequate clearances between equipment for case of maintenance.
The following minimum clearances around various equipment shall be maintained:
a) Front clearance for HV switchboard
2500 mm
b) Front clearance for all other switchboards/panels

c) Rear clearance for panels having
Maintenance access from front only.
2000 mm
less than 200 mm or
More than 750 mm
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d) Rear clearance for panels having

maintenance access from front only
e) Side clearance between two switch
1500 mm (HV swbds)

1000 mm (MV swbds)
1500 mm
Boards or from nearst obstruction.(but not less than twice the width of
each panel)
f) All around clearance for transformers/NGR 1000 mm
g) All around clearance for capacitor bank/ 1000 mm
series reactor.
h) Battery rack to wall clearance for

- Single row, single/double tier
100 mm
- Double row, single tier
100 mm
750 mm
Double row, double tier
i) Battery rack to rack clearance
750 mm
j) Head room clearance below busducts or 2000 mm

Any other over head equipment.
k) Front clearance for wall mounted equipment 1000 mm
l) Front clearance for operation station
/ annunciation/ control panel.
2500 mm
Vertical clearance above the top of the highest equipment shall be minimum 1500 mm
measured from bottom of room slab and minimum 500 mm measured from the bottom
of the lowest roof beam. However for the areas with false ceiling, minimum clearance of
750 mm shall be provided between false ceiling & top of any equipment.
6.16 All substations, UPS rooms, battery charger / battery rooms shall be provided with
atleast 25% space for future expansion.
6.17 The DG shall be preferably located in a separate building other than the substation, in a
safe area to reduce noise level in substation. However in case the same is located in the
substation building, the DG set foundation shall be structurally delinked from the slab/
floor of the rest of the substation building. Exhaust of diesel engine shall be kept away
from the process/ hydrocarbon handling areas and diesel day tanks shall be located
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outside the DG room. Suitable ventilation system shall be provided to avoid heat
accumulation in the DG room.
7.1
7.2
INSTALLATION DESIGN PHILOSOPHY

General
The installation work for equipments, cabling system, earthing system and lighting
system shall generally conform to standard specifications & installation standards.
7.2
Cabling System
7.2.1 Cabling system for various areas shall be generally as under, unless otherwise
specified in job design data.
-
For process units overhead cable trays on above ground pipe sleepers/racks
where these exist and separate above ground/overhead cable trays shall be
provided for offsites cables, where pipe sleepers/racks do not exist.
Lighting, fire alarm, communication & other cables laid on road beams
shall be directly buried.
Total cable route connected to FW pump/motors starting from main

receiving substation to FW pump house shall be directly buried
underground.
RCC trenches shall be used at specific requirement of clients.
7.2.2 The cable trenches shall be sized depending upon the number and voltage grade of
cables. The trenches in hazardous areas shall be filled up with sand. Where
underground cables cross road ways, pipe sleepers at grade etc, they shall be protected
by being drawn through sleeves/ducts to provide a permanent crossing. RCC lined
trenches shall have suitable drainage arrangement to avoid water collection.
7.2.3
RCC cable trenches shall be sealed against ingress of liquid and gases wherever the
trenches leave a hazardous area or enter a control room or substation. Pipes laid for
mechanical protection shall be sealed at both ends. Incase of direct burial, cable route
makers shall be installed at every 30 m interval all along the cable routes and also at
cable joints and locations where the direction of cable trench changes.
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7.2.4 Above ground cables shall be well supported on cable trays and suitably protected
against mechanical damage. Routing shall be decided to avoid interference with host
surfaces or places subject to undue fire risk.
7.2.5 Cable trays, racks and trenches shall be sized to allow for 20% future cables. Cables
installation shall provide minimum cable bending radii as recommended by cable
manufacture. Separate trays shall be provided for HV / MV power, control & plant
communication cables. Separate cable provided for AC and DC signal/control circuits.
7.2.6 Cables connected in parallel shall run together so that their length remains the same
and these shall be suitably secured so as to avoided stresses arising due to short
circuits.
7.2.7 All cable trays and accessories shall preferably be prefabricated, hot dip galvanized.
For tray system design, in addition to self load and wind forces, following guidelines
for design shall be considered.
a) Support span
: 3000 mm
b) Cable load
: 75 kg/linear meter
In addition to this, 75 kg concentrated load at center span shall be considered. All

structural steel design shall be as per Indian Standards.
Bends, tees, reducers, crosses, droppers etc. shall have the required bending radii as
required for various cable sizes with a minimum of 300 mm.
7.2.8 All cables shall carry the cable tag numbers for easy identification.
7.2.9 Instrument and communication cables shall not be laid in the same trench along with
electrical cables. The overall cable layouts shall be designed for minimum interference
between signal and power cables.
7.2.10 The armour and semiconductor screen of signal core cables shall be broken at each
joint. The continuity of armour & screen shall be insulated.
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PART III
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13.3
Earthing System
7.3.1 Earthing system in general, shall cover the following:

-
Equipment earthing for personnel safety.
System neutral earthing.
Static and lighting protection.
7.3.2 The earthing system shall include an earthing network with designed number of earth
electrodes attached to meet the required value of earth resistance. The following shall
be earthed:
-
System neutral
-
Current and potential transformers secondaries.
Metallic non current carrying parts of all electrical apparatus such as transformers,
switch gears, bus ducts, UPS, chargers, capacitor banks, NGR s, motors, lighting/
power panels, cable trays, terminal boxes, control stations, lighting fixtures,
receptacles etc.
Steal structures.
Storage tanks, vessels, spheres, columns and all other process equipment.
Cable shields and armour.
Any other equipment required to be earthed/bonded.
Fence / gate for transformer & capacitor banks.
Lighting poles & masts
7.3.3
All utility/process pipelines shall be earthed on entering or leaving the hazardous

areas, except where conflicting with the requirements of cathodic protection. In
addition, steel pipe racks shall be earthed at every 25 meters. Equipment located
remote from main earth network, may be earthed by means of individual earth
conductors and earth electrodes.
7.3.4 As a minimum, lightning protection shall be provided for the equipment, structures
and buildings as per IS- 2309. Self conducting structures may not be provided with
aerial rod and down conductors, they shall however be connected to the earthing
system at minimum two points at the base. An independent earthing network shall be
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provided for lighting protection and this shall be bonded with the main earthing
network only at the buried electrode.
7.3.5 The resistance value of an earthing system to general mass of earth shall be as follows:
7.3.5.1 For the electrical system and equipment a value that ensures the operation of the
protective device in the electrical circuit but not in excess of 5 ohms. However, for
generating stations and large substations this value shall not be more than 1 ohm.
7.3.5.2 For lightning protection, value of 5 ohms as earth resistance shall be desirable but in
no case it shall be more than 10 ohms.
7.3.6 The main earth network shall be used for earthing of equipment to protect against
static electricity.
7.3.7 All the electrical equipment operating above 250 volts shall have two separate and
distinct connections to earth grid. Transformers shall be provided with two dedicated
earth electrodes for earthing of neutral and transformer tank earthing.
7.3.8 Normally earthing system shall comprise of main earth grid along with suitably
located disconnecting plate and equipment and for connections between main earth
grid and electrodes.
All connections shall be adequately locked against loosening.
Connections between earth electrode and the disconnecting plates shall be done by GI
strip. Connection between the disconnecting plate and various equipment shall be done
by GI strip, GI wire or GI wire rope.
Earth electrodes and conductors shall be designed to cope up with the conditions
imposed. The earth conductor shall be adequately sized to carry the applicable
maximum earth fault current without undue temperature rise. All joints shall be
protected to prevent corrosion.
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7.4
Lighting System
7.4.1
Plant lighting system shall comprise:

i) Normal lighting.
ii)
Emergency lighting.
iii) Critical lighting.

Normal and emergency lighting shall be fed by AC supply (415/240V, three phase four
wire except in case of oil mines where it shall be 240 V three phase three wire) while
critical lighting shall fed by DC supply.
7.4.2 Normal lighting system shall provide enough illumination so as enable plant operators
to move safely with in the accessible areas of plant to perform routine operation
including reading of field instruments, operation of all valves etc. and to carry out all
the necessary maintenance and adjustment to equipment.
7.4.3 Areas requiring AC emergency lighting shall include, but not to be limited to, the
following.
-
All Areas requiring DC critical lighting.
Strategic locations in process, utility areas where specific safety/shutdown

operation are to be carried out.
Generally 20- 25% of the total lighting fixtures shall be fed from AC emergency
supply.
7.4.4. Areas requiring DC critical lighting shall include, but not be limited to, the following:
-
Control rooms.
Substations.
Adequate number of self contained portable hand lamps and battery operated
emergency lighting units shall be provided for immediate use for buildings where no
DC supply is a avialable.
7.4.5 During normal operation, both emergency and normal lighting shall be fed by normal
power source. On failure of normal supply, emergency lighting load shall be
transferred to emergency source after the start of DG set. Critical (DC) lighting shall
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be normally kept OFF and during failure of AC power, battery shall feed the critical
lighting system.
7.4.6 HPMV lamps shall generally be used for plant lighting. Keeping in view the restrike
time lag and to avoid complete darkness in case of a voltage dip/black out condition
necessary incandescent lamps may be judiciously distributed throughout the plant area.
Fluorescent lamps with electronic ballast shall be used for indoor lighting for non
process buildings and control room. Safe area street and area lighting may employ
sodium vapour lamps. All chemical handling facilities shall be provided with chemical
resistant fixtures. Low-pressure sodium vapour lamps shall not to be installed in
hazardous areas.
DC critical lighting shall employ incandescent lamps. All ballasts shall be with copper
winding and capacitor for power factor improvement (to 0.95) shall be provided with
fixtures as applicable. Tall structures shall have aviation obstruction lighting as per
statutory requirements.
7.4.7
Lighting system shall consist of lighting distribution boards (LDB s ), lighting and
power panels, fixtures, junctions boxes etc.
7.4.8
All outdoor lighting shall be automatically controlled by means of synchronous timers

with manual overriding control.
7.4.9 Telescope tubular high mats shall be provided for illumination of tank farm/general
area. The high mats shall be of continuously tappered polygonal cross section and
fabricated out of steel plates. The masts shall be provided with motorised racking
mechanism for lowering & hoisting lantern carriage.
7.4.10 Lighting and power panels shall be fed from LDB through 433/433 V. Incase of oil
mine installations, secondary side voltage shall be 240 V between phases. These
panels shall be provided with MCB + ELCB as incomer and Miniature Circuits
Breakers (MCB s ) for outgoing feeders control and protection of lighting circuits.
MCB s shall not be loaded beyond 80% of rated capacity. A minimum of 25% of
miniature circuit breakers of each board shall be left as spares. Normally about 8-10
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PART III
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fixtures shall be wired in each circuit. In areas having less lighting load, lighting
transformer can be avoided.
7.4.11 Lighting Lux Levels
Lighting system design shall be based on minimum illumination levels as specified
below:
Area
Lux
- Roads and tank farm
10
- Pump house
100
Main operation platforms and access stairs 60
Ordinary platforms
Process area, pipe racks, heat exchanger
20
Heater, cooling tower, separators etc.

- Switch gear room
- Cable cellar
- Battery room
60
200
70
150
- Control room, Laboratory
500
- Switchyard
20
- Warehouse
100
- Office
300
- Compressor area
150
7.4.12 Lighting design shall conform to relevant International Codes & Standards, IES Hand
Book and shall take into consideration the requirements from point of view of safety
and case in operation and maintenance. A maintenance factor of 0.8 shall be assumed
for lighting illumination level calculations for normal areas. However for dusty areas,
maintenance factor as per relevant codes and standards shall be considered.
7.4.13 Wiring for lighting and convenience outlets in outdoor areas shall be carried out with
PVC armoured cables run along the column / platforms and structures. The armoured
cable shall enter lighting fixture/ JB through double compression gland for safe area,
Ex(e) or Ex (n) equipment and through flame roof glands for Ex (d) equipment. Where
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PART III
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required, suitable mechanical protection shall be provided for lighting fixtures (e.g.
wire guard).
7.4.14 Adequate number of ceiling fan points shall be provided in Administration Building,
Offices, rooms allocated for operating and maintenance personnel etc.
7.4.15 Two pole isolation devices shall be used for controlling fixtures in hazardous areas to
isolate phase as well as neutral. For all oil mine installations all switches shall be two
pole type.
7.4.16 For buildings with false ceiling, concealed conduit wiring shall be used below the false
ceiling and surface conduit wiring above the false ceiling.
7.4.17 Adequate number of pull boxes shall be used to aid wire pulling and inspection. No
joints shall be allowed inside these pull boxes.
7.4.18 Battery room shall have fixtures mounted on wall in order to facilities easy
replacement of fused lamps. Switches controlling the lighting fixtures and exhaust fan
shall be installed outside battery room.
7.4.19 Locally mounted lighting fixtures on platforms, walkways, stairs shall be installed in
such a way that relamping can be done with out the use of ladders.
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PART III
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CHAPTER 5
STANDARD
SPECIFICATIONS
FOR
415 V MOTOR CONTROL CENTRE
67
PART III
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1.
1.1
Scope
The scope of work includes the supply, erection, testing and commissioning of all the
switch boards required for feeding power to the equipment covered in the scope of the
project. The same shall even apply for any extension of MCC/PCCs envisaged.
1.2
The 415 V MCC and its accessories shall conform to the latest editions of national and
international standards, including the following.
IS : 5578
IS : 8623
Guide for marking of insulated conductor.

Factory built assemblies of switchgear and controlgear for voltages
upto and including 1000 V AC and V DC. Part-II particular
requirements for busbar trunking systems (busways).
The individual equipment mounted in the switchgear shall conform to the following
Indian standards.
IS : 772 Part-I
AC Electricity meters : Part-I general requirements and
tests(Second Revision).
IS : 1248
Direct acting electrical indicating instruments(First Revision)
IS : 2705
Current transformers:
IS : 3156
Voltage transformers:
IS : 3231
Electrical relays for power systems protection.
IS : 3618
1.3
Phosphate treatment of iron and steel for protection against

corrosion.
All 415V MCCs shall be procured from the same source in order to ensure inter
changeablity of components. In case of the extension of existing panels, the vendor shall
source the additional panels from the OEM of the existing panels.
1.4
Power Source for 415 V MCC s

The MCCs shall derive power from the 415 V PCC/MCC located in substations. The
vendor shall lay cable from CPCL MCC to new MCCs.
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PART III
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1.5
1.5.1
Feeder Details:
MCC s shall be provided with one incomer and required number of outgoing feeder
modules.
1.5.2
1.6
1.6.1
Atleast one outgoing feeder of each rating shall be provided as spare in the switch board.
Construction:
MCC shall be metal enclosed, fully drawout, indoor, floor mounted modular type, dust
and vermin proof of uniform height of not more then 2450 mm, easily extensible on
both sides having switch board designation indicating labels. The IP degree of
protection shall not be less than IP 42.
1.6.2
The external paint shade shall be -631 of IS 5.
1.6.3
MCC shall be single/double front execution.
1.6.4
The frame of individual panel shall be fabricated using pressed and shaped cold rolled
sheet steel of adequate thickness or by using suitable mild steel structural sections. The
sheet steel used for panels shall be minimum 14 SWG CRCA except that the doors and
covers may be made of 16 SWG CRCA. Stiffeners shall be provided to increase
stiffness of large doors and covers.
1.6.5
Switchboard shall be provided with integral base frame for each vertical panel. The
switchboard integral base frame shall be suitable for directly bolting with the help of
foundation bolts and shall be suitable for track welding to the floor embedded
channels.
1.6.6
All openings, covers and doors shall be provided with neoprene gaskets. Blanking
plates shall be provided for all sizes of modules to covers the openings in the event of
withdrawing the feeder modules.
1.6.7
All hardware shall be corrosion resistant. All joints and connections of the panel
members shall be made by high quality cadmium plated steel bolts, nuts and washers,
secured against loosening. Star washers shall be used to ensure effective continuity.
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PART III
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1.6.8
Suitable removable type lifting hooks shall be provided, and the hooks when removed
shall not leave any opening in the panel.
1.6.9
MCC shall be divided into distinct vertical sections of:

(a)
Uniform height
(b)
Completely enclosed metal busbar compartment running horizontally.
(c)
Individual feeder modules in multitier arrangement.
(d)
Enclosed vertical bus bars serving all modules in vertical section. The
vertical busbar shall be sleeved and provided with anti-tracking barriers
as an integral part of bus bar zone.
(e)
Vertical cable alley covering entire height and minimum 200 mm wide.
(f)
A horizontal separate enclosure for all auxillary power and control bus, if
required.
(g)
Each vertical section shall be equipped with space heater with thermostat.
(h)
Cable alley shall be provided with suitable hinged doors.
(i)
Metal sheet shall be provided between two adjacent vertical panels

running upto full useful heights of switchboard. In the cabling chamber
shrouds shall be provided on the side of vertical busbars.
1.6.10
Panels shall be suitable for bottom entry of cables
1.6.11
Rear of single front switch board shall be provided with removable panels.
1.6.12
All doors shall be with concealed type hinges and captive screws.
1.6.13 Auxiliary busbars each of minimum size 18 sq.mm copper shall be provided for space
heater supply, control supply. Tee-off connectors shall be used for distributing supply
to each vertical panel. Rubber grommets shall be used for all wire entries to make
panel dust and vermin proof.
1.6.14 Busbars shall be of high conductivity aluminum (E91E) supported on insulators made
of non-hygroscopic, non-inflammable materials with tracking index equal to or more
than 600mm as per IEC-112. Such as glass reinforced phynolic material or cast resin.
Bus bar joints shall be shrouded with moulded epoxy shrouds. The main busbar shall
have uniform current ratings throughout their length. The current rating of the neutral
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PART III
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shall be half that of the phase busbars. Removable neutral links shall be provided on
feeders to permit isolation of the neutral busbar.
1.6.15 All busbars, bus joints and supports shall be capable of withstanding dynamic and
thermal stresses of the specified short circuit currents for 1 seconds. Only zinc
passivated or cadmium plated high tensile strength steel bolts, nuts and washers shall
be used for all busbar joints and supports. The short circuit capacity of the neutral
busbars shall be in line with IS 13947.
1.6.16 All busbars shall be insulated with heat shrunk PVC sleeves of 1100V grade. Red,
yellow and blue colour shall be used for phase busbars and black colour for neutral
busbars. Joints shall be shrouded properly.
1.6.17 Minimum clearance between live parts, between live parts/neutral to earth shall be
19mm. However clearances at components shall be as per individual standards.
1.6.18 Interconnections between main busbars and individual units shall be made by vertical
aluminium busbars of adequate rating. These interconnections and the vertical busbars
shall be compartmentalised and fully shrouded. Busbars shall be of uniform crosssection and the vertical size of busbars shall not be less than 50 * 10 mm. Per phase.
All joints surfaces at aluminium to copper joints shall be silver/tin plated, alternatively
bimetal washers may be used. Minimum size of busbars for starter/feeder power
connection above 100 Amp rating shall be 20X6 mm of Aluminium.
1.6.19 Inside the switchboard wiring for power control etc shall be done with BIS approved
660 volts grade PVC insulated copper conductors. All control wiring shall be enclosed
in plastic channels or neatly bunched together. Conductors of cross section 1.5sq.mm
shall be used for control circuits with control fuse rating of 10 amps or less and
2.5sq.mm for other circuits and CT wiring.
1.6.20 Each wire shall be identified at both ends by PVC ferrules.
1.6.21 Interpanel wiring shall be taken through PVC sleeves or rubber grommets.
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PART III
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1.6.22 A minimum of 10% spare terminals shall be provided on each terminal block.
Conductors shall be terminated with adequately sized compression type lugs. Clamp
type terminals for direct conductor termination shall be acceptable for wires upto
10sq.mm size and bolted type terminals with crimping type copper lugs shall be
provided for all outgoing cable connections larger than 10sq.mm.
1.6.23 All vertical panels shall be connected to a tinned copper earth busbar running
throughout the length of the switchboard. The min earth bus size shall be 300sq.mm
tinned copper. All doors and movable parts shall be earthed using flexible copper
connections to the fixed frame of the switchboard. All non-current carrying metallic
parts of the mounted equipment shall be earthed. Minimum 4 nos. of 10-mm dia bolts
with nuts shall be provided on the earth bus for termination of fourth core per vertical
panel.
1.6.24 A nameplate with the switchboard designation shall be fixed. A separate nameplate
giving the details of each compartment of bus section shall be provided.
1.6.25 Nameplate shall be provided for each equipment (lamps, pushbuttons, relays,
contactors etc) mounted on the switchboard. Special warning plates shall be provided
on removable cover or doors giving access to cable terminals and busbars.
Identification tags shall be provided inside the panels matching with those shown on
the circuit diagram.
1.6.26 Engraved nameplates shall be of 3 ply lamicoid sheets or anodised aluminium. And
they should be fastened to the panels by screws and not by adhesives.
1.6.27 The nameplate for feeder compartments shall be in two parts. One part shall have
details pertaining to the
other part shall be removable and shall contain details
regarding the drives/equipments controlled by particular module.

1.6.28 All metal surfaces shall be thoroughly cleaned and degreased to remove millscale,
rust, grease and dirt. Fabricated shall be pickled and then rinsed to remove any trace of
acid. The undersurface shall be prepared by applying a coat of phosphate paint and
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PART III
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coat of yellow zinc chromate primer. The under surface shall be made free from all
imperfections before undertaking the finishing coat.
1.6.29 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. The finished panels shall
be dried in stoving ovens in dust free atmosphere. Panel finish shall be free from
imperfection like pinholes, orange peels, runoff paint etc.
1.6.30 All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust
formation. If these parts are moving elements then they shall be greased.
1.6.31 MCC shall be designed such that all component equipment and bus bars operate
satisfactory with out exceeding their respective maximum permissible temperature
limits of 85 deg C.
1.6.32 The bus bar rating of the 415 V MCC shall be rated for full load current plus 20%
margin rounded off the next standard rating.
1.6.33 All identical equipments and corresponding parts shall be fully interchangeable,
without requiring structural modification.
1.7
Control Supply
Control transformers (2 nos) shall be provided for deriving control supply at 240 V
AC . 1 phase. A selector switch having Control Transformer 1 Control Transformer
2 - Independent selection shall be provided for control transformer selection. Two
numbers 415/ 240V transformer of 100% capacity shall be provided for control
supply of switchboard.
1.8
Specific Requirements
1.8.1
MCC shall comply with specification requirements indicated below:
1.8.2
The cable alleys shall be liberally designed considering the size and number of
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PART III
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cables, future additions of cables, ease and safe maintenance. Cable alleys shall be
provided with suitable hinged doors. Sheet steel barriers shall be provided
between individual compartments of cable alley. This barrier shall be provided
with the opening for power and control connections to any one circuit in the cable
alley with the busbars and the adjacent circuits live.
1.8.3 For each vertical section a separate set of vertical bus bars shall be provided to
Serve the modules.
1.8.4
The design of feeder trolley shall remain same for both single front and double single
front and double front. Separate vertical busbars shall be used for each front. Identical
feeder modules in both the fronts shall be interchangeable.
1.8.5
The outgoing feeder trolleys shall be fully drawout and shall have the following
features: It shall be possible to withdraw the trolley without having to unbolt or
unscrew any power and control connections to the equipments mounted on the
withdrawable trolley. Both power and control connections shall be drawout type.
However incomer feeder may be of fixed execution.
1.8.6
Various compartment sizes in a vertical MCC panel shall be in multiples of a basic

dimension. However the minimum module size shall be 200mm for switchfuse feeder
and 240mm for contactor feeders.
1.8.7
The trolley withdrawal shall be by means of crank and screw arrangement or by

movement on guided rollers. Plug in independent of manual force. Necessary
clamping may be done to ensure all-round positive pressure on the drawout contacts
once the trolley is plugged in. power drawout contacts shall be located towards the
bottom position of each trolley. The trolley shall be lockable in fully plugged in
position and devices shall be provided to ensure positive in. in test position power
contacts shall be totally isolated and a device shall be provided for indication of test
position.
1.8.8
All switch drives other than rotary switches shall be lockable in both ON and OFF
positions. The switches shall be interlocked with the compartment door to prevent
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opening of the door when the switch is in ON position. A defeat mechanism for this
interlock shall also be provided.
1.8.9
The maximum height of the operating handles, etc on the panel shall not exceed
1900mm and shall not be below 300mm from the floor.
1.8.10 Unused modules in the panel shall be fully equipped with hinged door, power and
control terminals for starter modules and cradle for future use.
1.8.11 All bimetal relays shall be separately mounted type with connecting links rated for the
maximum rating of the contract in the Starter module.
1.8.12 Bimetal relays of various current ranges required for motors likely to be connected to a
contactor must be identical in dimensions for interchangeability, else special mounting
plate to mount different relays shall be provided.
1.8.13 Heavy-duty starters with saturable type CT operated relays shall be used for motors
with starting time more than 15 seconds.
1.8.14 The feeders shall meet the requirement of type-II co-ordination as per IS 13947
1.8.15 All identical modules shall be interchangeable.
1.8.16 All switches or fuse switches shall be load break, heavy duty/motor duty 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.
1.8.17 Fuses shall be pressure fitted, non-deteriorating HRC cartridge link types. Diazed
fuses are not acceptable.
1.8.18 It shall be possible to handle the fuses during off load conditions with full voltage
available on the terminals. Wherever required fuse pullers shall be provided. The fuse
base shall be located in the modules to insert fuse pullers and insert or remove the
fuses without any problem.
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1.8.19 The contactors shall be AC3 rated, air-break type, equipped with three main contacts
and minimum 2NO+2NC auxiliary contacts.
1.8.20 The coil of the contactor shall be suitable for operation on 240 V, 1PH AC supply and
shall work satisfactorily between 65 to 110% of the rated value.
1.8.21 Bimetal relays shall be manually reset type with reset button brought out on the front
of the panel. The reset push button shall be capable of being operated without opening
the compartment door.
1.8.22 Bimetal relays shall be positive acting ambient temperature compensated type with
adjustable setting range shall have built-in single phase prevention feature which
operate even with 50% rated current at the time of single phasing.
1.8.23 Current transformers shall conform to IS2705. Protective current transformers shall
have an accuracy class of 5P and an accuracy limit factor greater than 10. Metering
CT shall have an accuracy class of 1 and accuracy limit factor less than 5.
1.8.24 Current transformers shall be capable of withstanding the applicable peak momentary
short circuit for 1 second and shall have a minimum rating of 10VA.
1.8.25 Voltage transformers shall be cast resin type and shall be provided with primary fuses.
Miniature circuit breakers with auxiliary contact shall be provided on the secondary
side.
1.8.26 All indicating instruments shall be of 96X96 mm-square pattern. All AC ammeters and
voltmeters shall be moving iron type with accuracy class of 1.5 as per 1248. Ammeters
for motor feeders shall have a non-linear compressed scale at the end to indicate motor
starting current. Voltmeter shall be suitable for direct on line connection.
1.8.27 Pushbuttons for stop (Red colour stayput type) and reset (White) shall be provided on
the front of the panel.
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PART III
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1.8.28 Cluster Led type indicating lamps shall be provided with translucent covers for ON,
OFF and TRIP indications.
1.8.29 The switches, contactors and other power devices shall consider a margin of about
20% over the name plate current rating of the respective load.
1.8.30 Minimum of one NO and one NC spare contracts of all contactors & relay devices
shall be wired to terminal block.
1.8.31 20% spare terminals shall be provided for each module.
1.8.32 For CT & VT circuits disconnecting type of terminals shall be provided .
1.8.33 Space heater with MCB & thermostat shall be provided for each vertical panel.
1.8.34 Necessary instrumentation for measurements of following parameters shall be
provided for incoming feeders of 415 V MCC.
-
3 phase Current with selector
3 phase Voltage with selector
1.8.35 Module Details

(a) Incomers
(i)
The incomer modules of 415 V MCC shall be of switch fuse controlled.

They shall be provided with
! One set of CT for metering
! Selector switches
! Ammeter
! Voltmeter
! Indication lamps for all three phases
(b)Feeders provided for supplying local control panels, power sockets etc., shall be
provided with suitably rated switch & fuses .
(c) 240V, 1 phase, control transformer modules and space heating module shall be
provided with incoming side switch, fuse, suitably rated 415/240V cast resin type
77
PART III
SECTION 3
transformer (expected loads +30% margin) Secondary fuse, and supply indicating
lamp and connection to the buses.
(d) Motor modules
(i)
The motor modules shall be provided with

! On , Off and fault indicating lamps.
! Necessary auxiliary contactors for fault alarm circuit, 240V space
heating circuit.
! Module on, off PBs for non reverible modules and forward reverse and
Off PBs for reverseible modules.
! Appropriate circuitry for reciving the on , off and forward reverse
commands from remote panels / system , interlocks, On and Off
command from local push buttons, etc.,
! Two pole MCB for space heating circuit.
ii)
The motor modules rated above 22 kW shall be provided with 240V, 1

phase space heating arrangement.
iii)
The modules for motors rated 18.5 kW and above shall have a CT The
CT connection shall be so wired to the terminal block so that provision
for remote current indication is available at the motor local push button
station.
iv)
Ammeters shall be provided on the panels for all motors rated above
18.5 kw.
v)
Depending on the rating of the motors, the motor starter modules shall
be designed as per the enclosed Electrical Design Engineering Basis
data.
1.8.36
APPROVED MAKES OF COMPONENTS :1. Contactors, Bimetal relays,
: - Siemens, L&T , Alstom/GE
SFU , Fuses, timers etc

2. Numerical relays, Motor protection relays :- Alstom
3. Panel wiring and cables (BIS certified)
:- Finolex/ Asian / CCI
78
PART III
SECTION 3
1.9
1.9.1
TESTS AND ACCEPTANCE

During fabrication switchgear is subject to inspection by CPCL, and the vendor shall
furnish all necessary information concerning the supply to CPCL inspectors.
1.9.2
All routine tests and following acceptance tests shall be carried out at manufacturers
works under his care and expense
! General visual check shall be carried out. This shall cover measurement of overall
dimension, location, number and type of devices, terminals etc.
! Manual and electrical operation of contactors, relays shall be checked under the
worst conditions of auxiliary supply voltage.
! Dry insulation test with power frequency voltage shall be conducted for the main
and auxiliary circuits.
! Insulation resistance of the main and auxiliary circuits shall be checked before and
after high voltages withstand test.
! Operation check shall be carried out for every control function
as per the
schematic diagrams by manually simulating fault conditions and operation of

control switches/ relays etc.
! Relays shall be tested with secondary injection test equipment.
! For equipment bought from other sub-suppliers, certified test reports of test carried
out at the manufactures works shall be submitted. Normally all routine tests as
specified in the relevant standards shall be conducted by the sub-supplier at his
works.
! Inter changeability of similar modules shall be checked on a random basis.
1.9.3
Functional tests shall be conducted to check mechanical & electrical operation is as

per specifications.
1.9.4 Stage inspection after pre-treatment and preparation of under surface and before final
painting shall be carried out by CPCL.
1.9.5
Routine and acceptance shop tests will be inspected by CPCL.
1.9.6 Prior notice of minimum 4 weeks shall be given for all inspections mentioned above.
1.9.7
After erection at site, all precommissioning tests have to be carried out, in presence of
CPCL inspectors.
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PART III
SECTION 3
ANNEXURE
(Data To Be Furnished By The Vendor After Award Of The Contract)
1.0 List Of Drawings:
The VENDOR shall furnish after receiving of the order the following drawings for each panel
and switch gear. If a large number of switch gears are involved, the PURCHASAR will
indicate the priorities.
1.1
Over all outline dimensions and general arrangement including plan, front , clearances
required in front and back, details of busduct connections, if any.
1.2
Overall outline dimensions and general arrangement including plan, front elevations,
clearances required in front and back, details of busduct connections, if any.
1.3
Schematic control diagrams to cover controls, protection, interlocks, switch

instruments, space heaters, etc. for each type of module.
1.4
Itemised bill of material for each module, listing all devices mounted and also
otherwise furnished like cable glands, indicating the MANUFACTURES type, rating
quantity & special notes, if any.
(a) Detailed internal wiring diagram of each type of module, including terminal
block number
(b) Ferrule numbers and the PURCHASER s external cable connection
designations.
(c) Interpanel interconnection wiring diagram including terminal numbers and
ferrule numbers
NOTES: The VENDOR shall be entirely responsible for the correctness of the internal
wiring diagrams mentioned against item 1.4 which will not be reviewed by
PURCHASER/ ENGINEER.
1.5
The VENDOR shall plan his manufacturing schedule so as to allow atleast 4 weeks
time for approval of the drawings after their receipt by the PURCHASER.
2.0 TEST CERTIFICATES

Type test certificates of all standard component parts, e.g. breakers, switches, fuses,
relays, CTs , VTs, and for the assembled switchgear with bus bars shall be submitted by
the VENDOR before dispatching the equipment.
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PART III
SECTION 3
3.0 INSTRCUTION MANUALS:

The VENDOR shall furnish specified number of copies of the instruction manual at the
time of dispatch. The manual should contain detailed instructions for all operational and
maintenance requirement and shall fully cover the following aspects:
(a) Outline dimension drawings showing relevant cross sectional views, earthing
details and constructional features.
(b) Rated voltages, current, duty- cycle and all other technical information which
may be necessary for correction operation of the breakers.
(c) Catalogue numbers of all components liable to be replaced during the life of
the switch gear / breakers.
(d) Storage for prolonged duration.
(e) Unpacking.
(f) Handling at site.
(g) Erection.
(h) Precommissioning tests.
(i) Operating procedures.
(j) Maintenance procedures.
(k) Precautions to be taken during operation and maintenance work.
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PART III
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CHAPTER 6
STANDARD
SPECIFICATION
FOR
MEDIUM
VOLTAGE MOTOR
82
PART III
SECTION 3
CONTENTS
01
SCOPE
02
STANDARDS
03
OPERATING CONDITIONS
04
PERFORMANCE
05
GENERAL REQUIREMENTS AND CONSTRUCTION DETAILS
06
MISCELLANEOUS ACCESSORIES
07
NOISE LEVEL
08
MOTOR VIBRATION
09
CRITICAL SPEEDS
10
PAINTING
11
INSPECTION AND TESTING
12
DRAWINGS AND DATA
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PART III
SECTION 3
SCOPE
This specification covers the design, manufacture and testing of three phase
medium voltage squirrel cage induction motors.
STANDARDS
Unless they are at variance with the clauses of this specification, the squirrel
cage induction motors and their components shall comply with the latest
applicable Indian standards listed below. Where Indian standards do not exist,
the relevant IEC, British or German (VDE) standards shall apply.
IS 325
Three phase induction motors.
IS 1076
Preferred numbers.
IS 1231
Dimensions of three phase, foot mounted induction motors.
IS 1271
Insulating materials for electric machinery and apparatus in

relation to their therminal stability in service, classification of
IS 2148
Flame proof enclosures of electrical apparatus.
IS 2223
Dimensions of flange mounted AC Induction motors.
IS 2253
Types of construction and mounting of motors
IS 2254
Dimensions of vertical shaft motors for pumps
IS 2968
Slide rails for electric motors, dimensions of
IS 4029
Guide for testing three phase induction motors.
IS 4691
Degrees of protection provided by enclosures for rotating

electrical machinery.
IS 4722
Specification for rotating electrical machines.
IS 4728
Terminal marking for rotating electrical machinery.
IS 4889
Methods of determination of efficiency of rotting electrical

machines.
IS 6362
Methods of cooling for rotating electrical machines.
IS 6381
Construction and testing of electric apparatus with type of

protection è.
IS 7389
Pressurized enclosure of electrical equipment for use in

hazardous area.
IS 7816
Guide for testing insulation resistance of rotating machine.
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PART III
SECTION 3
IS 8223
Dimensions and output ratings for foot mounted rotating

electrical machines with frame number 355 to 1000.
IS 8289
Specifications for electrical equipment with type of protection `n.
IS 8789
Values of performance characteristics for three phase induction

motors.
IS 9283
Motors for submersible pump sets.
IS 9628
Specification for three phase induction motors with type of

protection `n.
IS 12075
Mechanical vibration of rotting Electrical Machine.
IS 12065
Permissible limits of noise level for rotating Electrical Machines.
IS 12802
Temperature rise measurement of rotating electrical machines.
IS 13529
Guide on effects of unbalanced voltages on the performance of

three phase cage induction motors.
IS 13555
Guide for selection and application of three phase induction

motors for different type of driven equipment.
3.1
Ambient Conditions
Motor shall be suitable for operating satisfactorily in humid and corrosive
atmosphere found in Refineries, Petrochemical complex, fertilizer and
metallurgical plants.
Service conditions shall be as specified in the data
sheets. If not specifically mentioned therein, a maximum ambient temperature

of 40o C and an altitude not exceeding 1000 meters above mean sea level,
shall be taken into consideration.
3.2
Frequency and Voltage Variations

Unless otherwise agreed motors shall be designed for continuous, satisfactory
operation at rated output under the following conditions:
a)
The terminal voltage differing from its rated value by not more than +/- 6
%, or
3.3
b)
The frequency differing from its rated value by not more the + / - 3% or
c)
Any combination of (a) and (b).
Starting
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PART III
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Unless otherwise specified motors shall be designed for direct on line

starting. Motors shall be designed for re-acceleration under full load after a
momentary loss of voltage with the residual voltage being 100% out phase.
Minimum locked rotor thermal withstand time at rated voltage shall be 10

seconds under cold conditions and 8 seconds under hot conditions.
The
starting time of the motor shall be less than the hot thermal withstand time
(time tE in case of increased safety motors) to permit application of
conventional bimetal relays or thermal release against locked rotor and
overload conditions.
Unless otherwise specified, all motors shall be suitable for starting under
specified load conditions with 75 per cent of the rated voltage at the terminals.
Motors shall be designed to allow the minimum number of consecutive starts

indicated below:
TABLE I
Starts
Minimum No. of consecutive starts
No. of consecutive start-ups with initial temp.

Of the motor at ambient level (Cold)
No. of consecutive start-ups with initial temp. of the

Motor at full load operating level (Hot).
3.4
Directions of Rotations
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. A painted arrow shall
86
PART III
SECTION 3
not be acceptable. Directional arrow should be manufactured from corrosion

resistant material. When a motor is provided with bi-directional fans, a double
headed arrow should be provided.
Normally, clockwise rotation is desired as observed at (facing) the driving

(coupling) end when the terminals marked as per IS : 4728 are connected to a
supply giving a terminal phase sequence corresponding to the alphabetical
sequence of the terminal letters. Counter clock - wise 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
any two external leads for obtaining the reverse phase sequence.
PERFORMANCE
4.1
Motors shall be rated for continuous duty (S1) unless otherwise specified.
4.2
The starting current (as % rated current) shall not exceed 600% for motors up
to and including 75 KW and 550% for motors above 75 KW subject to
tolerance.
4.3
Starting torque and minimum torque of the motor shall be compatible with the
speed torque curve of the driven equipment under specified operating
conditions. For heavy-duty drives such as blowers, crushers etc. high starting
torque motors shall be provided. In case where 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.
4.4
The pull out torque at the rated voltage shall be not less than 175 per cent of
the rated load torque with no negative tolerance. Unless otherwise agreed,
the pull out torque shall not exceed 300 per cent for the rated load torque.
In case of motors driving equipment with pulsating loads (e.g. reciprocating

compressors) the minimum value of pull out torque at 75 per cent of the rated
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PART III
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voltage shall be more than the peak value for pulsating torque and the current
pulsation shall be limited to 40%.
4.5
The minimum value for product of efficiency and power factors for motors
rated up to and including 37 KW shall be as per IS : 8789.
The minimum value for product of efficiency and power factors of 2 pole, 4 pole, and 6 - pole motors rated above 37 kw shall be as given below.
TABLE III
Rated output Product of efficiency and power factor at rated load (minimum)
2 POLE
4 POLE
6 POLE
45 KW
0.82
0.80
0.79
55 KW
0.82
0.80
0.79
75 KW
0.82
0.80
0.80
90 KW
0.82
0.80
0.80
110 KW
0.86
0.80
0.80
125 KW
0.86
0.80
0.80
160 KW
0.86
0.81
0.80
180 KW
0.86
0.83
0.80
200 KW
0.86
0.83
0.80
Efficiency and power factor figures for motors having synchronous speeds of
750 r.p.m and below, shall be as agreed between the purchaser and
manufacturer.
GENERAL REQUIREMENTS AND CONSTRUCTIONAL DETAILS
5.1
Windings
a)
Insulation and bracing

Unless other wise specified in the data sheet motors shall be provided
with class `B insulation as a minimum. In case of motors with class `F
insulation the permissible temperature rise as measured by resistance
method above the specified ambient temperature shall be limited to
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PART III
SECTION 3
those specified in the applicable Indian standards for class `B

insulation.
The winding shall be tropicalized. The windings shall preferably be

vacuum impregnated.
Alternately the windings shall be suitable
varnished, baked and treated with epoxy gel for operating satisfactorily
in humid and corrosive atmospheres.
Windings shall be adequately braced to prevent any relative movement

during operation and in this respect, particular 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. Core laminations must be capable of withstanding burnout for
rewind at 400o C without damage or loosening.
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.
b)
Phase Connections
The windings shall be connected in delta. However, for motors rated
2.2 KW and below, star connection may be accepted.
If star - delta starting is required, this will be specified in the data sheet
and the motor windings shall be fully insulated for delta connection.
c)
Winding Terminations
The ends of the windings shall be brought out into a terminal box. They
shall be terminated by means of terminals mounted on an insulating
base made of non hygroscopic and non flammable material.
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.
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PART III
SECTION 3
All terminals shall be adequately designed.
Line terminals shall be
thoroughly insulated from the frame with material resistant to tracking.
Anti loosening, anti vibration type of terminals shall be provided in

case of increased safety (Type è) and non sparking (Type `n) type
of motors.
d)
Terminal Box and Cable Entries

Unless otherwise specified, the terminal box shall be located on the
right hand side as viewed from the driving (coupling) end. It shall be
rotatable in steps of 90o to allow cable entry from any direction.
The terminal box shall be of sturdy construction and large enough to

facilitate easy connection of the cables. Terminal box cover shall be
provided with handles to facilitate easy removal.
An adequately sized earth terminal shall be provided in the motor

terminal box for termination of the fourth core of specified cables.
The terminal box shall be provided with cables lugs and entries for
suitable cable glands corresponding to the number and size of specified
cable. Nickel plated brass (or aluminium if specifically required), double
compression type cable glands shall be supplied along with the motor
for mentioned cable sizes.
Equipment and accessories provided shall conform to the hazardous

area classification and the environmental conditions wherever required
as specified in the motor data sheet.
Unless otherwise specified the terminals, cable lugs, terminal box, cable
entries and cable glands shall be suitable for the cables sizes as
specified below for 2 pole, 4 pole or 6 pole motors:
90
PART III
SECTION 3
Motor rating up to and including
NOTE :
Size of phase conductor (mm2)
2.2 KW and below
4 AI./2.5 cu
3.7 KW
6 AI./4.0 cu
5.5 KW
10 AI./6.0 cu
7.5 KW
10 AI./6.0 cu
9.3 KW
16 AI./10.0 cu
11.0 KW
16 AI./10 cu
15.0 KW
25 AI./16 cu
18.5 KW
35 AI
22.0 KW
35 AI
30.0 KW
50 AI
37.0 KW
70 AI
45.0 KW
95 AI
55.0 KW
120 AI
75.0 KW
185 AI
90.0 KW
2 x 95 AI
110.0 KW
2 x 120 AI
125 KW / 132 KW
2 x 150 AI
160.0 KW
2 x 185 AI
180.0 KW
2 x 240 AI
200.0 KW
2 x 300 AI
Cable sizes for motors having synchronous speeds 750 rpm and below
shall be as agreed between the purchase and manufacturer.
Cable Type
Cables used are of 650 / 1100 V grade Aluminium conductor, PVC
insulated, PVC Extruded inner sheath, armoured with overall PVC
sheath for conductor cross sections of 35 mm2 & above. However for
cables up to & including 16 mm2 cross section cables used may be with
copper or aluminium conductor as indicated in the data sheet.
The terminal box shall be capable of withstanding internal short circuit

conditions without danger to personnel or plant from the emission of hot
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PART III
SECTION 3
gases or flame or due to excessive distortion or damage to the terminal

enclosure.
e)
Phase Marking
Appropriate phase markings as per IS : 4728 shall be provided inside
the terminal box. The marking shall be non-removable and indelible.
5.2
Motor Casing and Type of Enclosure

Motors for use in safe areas shall be normal industrial types meeting the
specified ambient conditions and operating requirements.
The minimum
degree of motor enclosures including terminal boxes and bearing housing shall
be IP 55 as per IS : 4691.
Motors for use in hazardous areas (Zone 1 or Zone 2) shall have type of
protection Ex (d), or Ex (e) or Ex (n) as specified in the data sheet and shall
meet the requirements of applicable Indian standards. Ex (d) type of motors
shall have a BIS making on the nameplate.
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.
Vertical motors with downward shaft shall be provided with fully covering rain
canopies. Vertical motors with upward shaft e.g. on fin fan coolers, shall be
adequately protected, (such as cowls / canopies) against ingress of water into
the enclosure or the bearing housing even when standing still for long periods
of time. Motors designed to handle external thrust from the pump shall be
supplied with a thrust bearing at the non-driving end.
All internal and external metallic parts, which may come into contact with
cooling air, shall be of corrosion resistant material or appropriately treated to
resist the corrosive against, which may be present in the atmosphere. Screws
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PART III
SECTION 3
and bolts shall be hot dip galvanized or zinc personated to protect against
corrosion.
Unless otherwise agreed, motors shall have standard frame size for various
output ratings as stipulated in IS : 1231.
5.3
Bearing and Lubrication
Motors shall have grease-lubricated ball or roller bearings. In all cases, the
bearings shall be chosen to provide a minimum L 10 rating life of 5 years,
(40,000 hours) at rated operating conditions (The L 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). Unless otherwise
specified the bearing shall be adequate to absorb axial thrust produced by the
motor itself or due to shaft expansion. Vertical motors shall be provided with
thrust bearings suitable for the load imposed by the driven equipment. In
cases such as pumps for hot liquids where the driven machine 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 object by condition or convection.
For motors
operating in hazardous areas fans shall be of an anti-static non sparking

material.
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 or
moisture e.g. labyrinth seal. Where grease nipples are provided, these shall
be associated, where necessary, with appropriately located relief devices,
which ensure passage of grease through the bearings.
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.
5.4
Cooling System
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PART III
SECTION 3
All motors shall be self-ventilated, fan cooled.
Fans shall be corrosion
resistant or appropriately protected. They shall be suitable for motor rotation

in either direction without affecting the performance of the motor. If this is not
possible for large outputs, it shall be possible to reverse the fan without
affecting the balancing of the motor.
5.5
Rotor
The rotor shall be of squirrel cage type, dynamically balanced to provide a low
vibration level and long service life for the bearings. The accepted values of
peak to peak vibration amplitudes for a motor at rated voltage and speed on a
machined surface bedplate with the motor levelled and with a half key or
coupling fitted shall not exceed those given in IS 12075. Die cast aluminium
rotors for motors in hazardous areas may be accepted provided the same are
type tested and approved by competent authorities.
5.6
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.
5.7
Lifting Hook
All motors except for fractional horse power motors shall be provided with
lifting hooks of adequate capacity.
5.8
Earth Terminals
Two earth terminals located preferably on diametrically opposite points shall
be provided for each motor. Unless otherwise specified, the size of each earth
stud shall be as given below :
Motor Rating
Stud Size
Upto and including 3.7 KW
6 mm
5.5 KW to 30 KW
10 mm
Above 37 KW
12 mm
Necessary nuts and spring washers shall be provided for earth connection.
94
PART III
SECTION 3
An additional earth terminal shall be provided inside the terminal box as stated
in 5.1
6.1
Anti Condensation Heaters

All motors rated above 30 KW shall be provided with 240 V anti
condensation heaters, size and located so as to prevent condensation of
moisture during shut down periods. Motors rated 30 KW and below shall be
provided with anti condensation heaters if specified in the requisition.
Motors meant for humid location such as cooling tower fans, sump pump
motors etc. shall be provided with space heaters irrespective of the motor
rating in the motor data sheet.
The heaters shall permanently remain ÒN
when the motor is not in service and as such shall not cause damage to the
windings.
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 excepting
that the cable glands provided shall be suitable for two core 4 sq. mm
aluminium conductor, armoured cable or 3 x 2.5 sq. mm copper conductor
armoured cable.
A warning label with indelible red inscription shall be provided on the motor to
indicate that the power line and the heater supply shall be isolated before
carrying out any work on the motor.
6.2
A stainless steel nameplate manufactured from series 300 stainless steel and
as required under specification IS 325 shall be provided on each motor. In
addition to the motor rating plate a separate motor plant equipment
numberplate shall be fixed in a readily visible position. This number shall be
indicated in the data sheets attached with purchase requisition.
Additional information as stipulated in applicable Indian standards shall be

included in the name plate for motors meant for use in hazardous
atmospheres as per IS : 13408.
95
PART III
SECTION 3
NOISE LEVEL
The permissible noise level shall not exceed the stipulations laid down in IS :
12065.
MOTOR VIBRATIONS
Motor vibrations shall be within the limits of IS : 12075 unless otherwise
specified for the driven equipment.
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 critical speed shall be above 125
% of the synchronous speed.
10
PAINTING
Internal and external parts of the casing and all metal parts likely to come in
contact with the surrounding air shall be protected with anti acid paint that
will resist the particular ambient condition.
All external surfaces shall be given a coat of epoxy based painted.
11

The vendor shall allow purchaser or his authorized representative to visit the
works during manufacture of motors to assess the progress of work as well as
to ascertain that only quality raw material is used for the same. He shall be
given all assistance to carry out the inspection.
The vendor shall give at least 4 weeks advance notice to the purchaser,
regarding the date of testing to enable him or his representative to witness the
tests.
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PART III
SECTION 3
The motors shall be tested in accordance with IS : 325 and IS : 4029. Routine
tests shall be carried out on all motors. In addition measurement of vibration
and noise level (if desired) shall form a part of route tests. Type test certificate
of testing motor of similar design shall be submitted.
Tests on completely assembled motor shall be carried out in the presence of

purchaser or his representative. The results shall be tabulated and signed by
both vendor and purchaser or their representatives. Though the motors shall
be accepted on the basis of the satisfactory result of the tests at the works, it
shall not absolve the vendor from liability regarding the proper functioning of
motor coupled to the driven equipment at site.
12
DRAWINGS AND DATA
12.1
Following minimum information shall be furnished along with the Bid :

a)
KW rating, make, frame size, full load speed, mounting, enclosure type
and specific type of construction { Ex (d), Ex (n) etc.}.
b)
For heavy duty drives starting torque, starting time and lock rotor
withstand time of the motor shall also be furnished.
12.2
After placement of order, vendor shall furnish all necessary data / drawings /
documents including but not limited to the following :
a)
Completed motor data sheet.
b)
GA, Dimension and mounting details.
c)
Details of terminal box and auxiliaries.
d)
Performance characteristics viz. speed v/s current and speed v/s

torque.
e)
Thermal withstands curves under hot and cold conditions.
Subsequent to completion of satisfactory inspection and testing, duly signed

test certificates, insulation, operation and maintenance manual shall be
furnished by the vendor to complete the contractual obligations.
97
PART III
SECTION 3
DATA SHEET FOR MEDIUM VOLTAGE SQUIRREL CAGE INDUCTION MOTOR

ELECTRICAL DESIGN DATA
1. Motor Tag No.
2. Voltage/Phase/Frequency
415 volts / 3 phase / 50 Hz
3. Fault level KA
50 KA (Fuse Protected)
4. Method of starting
DOL
5. Phase connection / No. of terminals

6. Ambient temp oC / Temp. rise 0C
7. Cable size / type
IP55 / TEFC
9. Insulation class
Area
45 deg c / 75 deg c
Later
8. Enclosure type / cooling
10. Haz.
3 / Delta / six
F with temp rise limited to class B
classification
Gas
Later
11. Type of explosion protection Ex(n) /
Later
Group
Ex (e) / Ex (d) / and applicable

standards
TECHNICAL PARTICULARS FROM EQUIPMENT MANUFACTURER
12. Recommended Driver Rating in KW
13. Shaft KW / KW at end of curve
14. Speed / rotation of equipment from
NDE
15. Starting / max. Torque required
(Mkg)
16. WK
of
equipment
including/excluding flywheel kgm 2

17. Thrust up / down (kg)
18. Equipment / coupling type
19. Manufacturer
TECHNICAL PARTICULARS FROM MOTOR MANUFACTURER
20. Manufacturer
21. KW Rating /No.of poles
98
PART III
SECTION 3
22. Frame designation / mounting
23. Full load speed / torque Mkg.
24. Starting / torque as % of full load
torque
25. Full load current (A)
26. Locked rotor current (A) (including
tolerance )
27. Breakdown or pull out torque %
28. Rotation viewed from non-driving
end
29. Starting time at 80%V/100 %V
(Sec)
30. Locked rotor with stand time cold /
hot (sec) *
31. WK 2 of motor Kg M 2
32. Power factor at 100/75 load
33. Efficiency at 10 /75% load
34. Space heater watts / volts
35. Bearing type / No DE/NDE
36. Type of Lubrication

37. Weight of motor (kg)
38. Canopy required / Not required
Required
* Locked rotor withstand time under hot conditions at rated voltage shall be min 2 sec
more than the starting time at 80% rated voltage and minimum hot withstand time
shall be 8 sec.
99
PART III
SECTION 3
CHAPTER 7
FOR
MEDIUM AND HIGH VOLTAGE CABLES
& ACCESSORIES
100
PART III
SECTION 3
1.0 SCOPE
This specification along with data sheets covers requirements for design,
manufacture and supply of PVC/XLPE cables and cable jointing / terminating
accessories for high voltage systems.
2.0 STANDARDS
The cables shall comply with latest edition of the following standards as
applicable.
2.1
IS :1554 PVC insulated (heavy duty ) electric cables.
2.2
IS: 7098 Cross- linked polyethylene insulated PVC sheathed cables.
2.3
IS: 8130 Conductors for insulated electric cables and flexible cords.
2.4
IS: 5831 PVC insulation and sheath of electric cables.
2.5
IS : 3975 Mild steel wires, strips and tapes for armoring of cables.
2.6
2.7
10810 (part 41) Methods of test for cables: Mass of zinc coating on steel
armour.
IS : 209 Specification for zinc.
2.8
IS : 3961(Pt 2) Recommended current ratings for cables: Part -2 PVC

insulated and PVC sheathed heavy duty cables.
2.9
IS: 10418 Drums for electric cables.
2.10
IS: 10462 (Pt 58) Fictitious calculation method for determination of

dimensions of protective coverings of a cables : Part 1
Elastomeric and thermoplastic insulated cables.
2.11
IS: 10810(Pt 58) Method of test cables: Part 58 Oxygen Index test.
2.12
IS: 10810 (Pt- 61) Method of test cables: Part 61 Flame-Retardant test.
2.13
IS: 10810 ( Pt- 62) Method of test cables: Part 62 Fire retardant test
for brunched cables.
2.14
IS: 13573 Joints and terminations for polymeric cables for working
voltages from 6.6KV upto and including 33KV Performance
requirements and type tests.
2.15
IEC: 332- 3 Tests on electric cables under fire conditions.
2.16
IEC: 502 Extruded solid dielectric insulated power cables for rated
voltages from 1 kV upto 30 kV.
IEC : 540& 540A Test methods for insulation and sheaths of electric
2.17
cables and cords.

2.18
ASTM : D2863 Standard method of test for Flammability of plastics .
101
PART III
SECTION 3
using oxygen index method.
The cables and accessories shall also conform to the provisions of Indian
Electricity Rules and other statutory regulations, as applicable.
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 PVC and XLPE cables shall be black in colour and the
minimum value of oxygen index shall be 29 at 27 + - 2 deg. C. In addition
suitable chemicals shall be added into the PVC compound of the outer shealth
to protect the cable against rodent and termite attack.
3.3
All cables covered in this specification shall be flame retardant (FR) unless
specified otherwise in the data sheet. The outer sheath of PVC and XLPE
cables shall possess flame propagation properties meeting as per IS 10810
(Part 62) category AF.
3.4
Sequential marking of length of the cable in meters shall be provided on the

outer sheath at every one meter. The embossing / engraving shall be legible
and indelible.
3.5
The overall diameter of the cables shall be strictly as per the values declared
in the technical information furnished along with the bids subject to a maximum
tolerance of +/- 2 mm up to overall diameter of 60 mm and + - 3mm for beyond
60 mm.
3.6 PVC / Rubber end caps shall be supplied free of cost for each drum with a
minimum of eight per thousand meter 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 cables used in installations under the jurisdication of Director General of
Mines and Safety shall be of copper conductor only.
3.8 The vendors shall specifically note that any one of the make of cable accessories
listed in data sheet will be used for termination of jointing of the cables offered.
102
PART III
SECTION 3
3.9 PVC cables

3.9.1 All power / control cables for use on medium voltage systems shall be heavy
duty type, 650/1100 V grade with aluminum / copper conductor. PVC
insulated, inner sheathed, armoured and overall PVC sheathed. Cables used
in mines shall be of copper conductor only.
3.9.2 The conductors shall be solid for conductor of nominal area upto and including
6mm2 and stranded beyond 6mm2. Conductors of nominal area less than
25sq. mm shall be circular or shaped. Cables with reduced neutral conductor
shall have sizes as per Table 1 of 1554 (part 1)
3.9.3 The core insulation shall be with PVC compound applied over the conductor
by extrusion and shall conform to the requirements of type A compound as
per IS 5831. The thickness of insulation and tolerance on thickness of
insulation shall be as per Table 2 of IS: 1554 Part 1. Controls 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 upto 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 Type ST- 1 PVC compound as per IS: 5831.
The thickness of inner sheath shall be as per IS: 1554 Part 1. Single core
cables shall have no inner sheath.
3.9.5 Of armouring is specified multicore cables in the data sheet, the same shall be
by single round galvanised steel wires where the calculated diameter below
armouring does not exceed 13 mm and by galvanised steel strips where this
diemension is greater than 13mm. Requirement and methods of tests for
armour material and uniformly of galvanisation shall be as per IS 3975 and
IS 1554 (Part -41). The dimensions of armour shall be as per method (b) of
IS -1554 (Part 1). If armouring is specified for single core cables in the data
sheet, the same shall be with H4 grade hard drawn aluminum round wire of
2.5 mm diameter.
The combined conductance of armour for mining cables shall be equivalent of
75 % of the conductance of the largest conductor of the cable.
103
PART III
SECTION 3
3.9.6 The outer sheath for the cables shall be applied by extrusion and shall be of
PVC compound conforming to the requirements of type ST 1 compound as
per IS: 5831. The thickness of outer sheath shall be as per IS: 1554 (Part 1)
for unarmoured and armoured cables.
3.9.7 If heat resisting PVC cables are specified in the MR, the following shall be the
requirements. It shall be possible to continuously operate the cable at a
maximum conductor temperature of 85 deg. C. PVC compounds used for HR
PVC cables shall be as follows:
a) Conductor insulation
3.10
- Type C
b) Inner sheath
- Type ST 2
c) Outer sheath
- Type ST 2
XLPE Cables
3.10.1 Power cables for 3.3 KV up to and including 33 KV system shall be Aluminum /
copper conductor. XLPE insulated, sheathed, armoured 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 / 6.6 kv and above shall be provided with both conductor
screening and insulation screening. The conductors shall be provided with non
metallic extruded semiconducting 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 stress under steady state and transient
operating conditions. It shall conform to the properties given in Table -1 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 magentic metallic copper screen.
Unless specified otherwise, the copper the single line to ground fault current
value and the duration specified in the data sheet. Vendor shall furnish
calculation in support of selection of the size of copper screen along with bids.
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.
104
PART III
SECTION 3
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 uniform thickness. In case of single core
cables, there shall be extruded inner sheath between insulation metallic
screen and armouring.
3.10.8 For multicore cables, the armouring shall be by galvanised steel strips as per
method (b) of IS 7098 (part 2). If armouring is specified for single core
cables in the data sheet, the same shall be with H4 grade hard drawn
aluminum round wire of 2.5mm diameter.
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 ST2 compound of IS: 5831. The thickness of outer sheath shall be as per
IS: 7098- part2 for both unarmoured and armoured cables.
3.10.10 The dimensions of the insulation, inner sheath shall be governed by values
given in I
S: 7098 Part 2.
3.10.11Where specified, 1100V grade power cables may also be XLPE insulated and
shall meet the requirement specified in IS 7098(part 1).
4.0 CABLE ACCESSORIES

4.1
The termination and stright through jointing kits for use on the systems shall be
suitable for the type of cables offered as per this specification.
4.2.
The accessories shall be supplied in kit form. Each component of the kit shall
carry the manufacturer/s mark of orgin.
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 450C, 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 weather - proof cable box of an outdoor
mounted transformer / motor. For outdoor terminations, wether shields /
sealing ends and any other accessories required shall also form part of the kit.
105
PART III
SECTION 3
The terminating kits shall be from one of the makes / types mentioned in the
data sheet.
4.6
Jointing Kits: The straight thro jointing kits shall be suitable for insulation 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.
5.0 TESTING AND INSPECTION

The cables shall be tested and inspected at the manufactures works. All the
materials employed in the manufacture of the cable shall be subjected, both
before and after manufacture, to examination, testing and approval by owner.
Manufacture shall furnish all necessary information concerning the supply to
owners/ inspectors. The inspector shall have free access to the manufacture in
all its stages and he will have the power to reject any material which appears
to him to be of unsuitable description or of unsatisfactory quality. The vendor
shall give at least 4 weeks advance notice to the purchaser, regarding the date
testing to enable him or his representative to witness the tests.
5.1 PVC & XLPE 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. Owner reserves the right to witness all tests with sufficient advance
notice from vendor. 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 on cables as listed in IS: 1554
Part 1, and IS: 7098 part 2.
106
PART III
SECTION 3
5.1.3. The inner and outer sheath of XLPE cables shall be subjected to all the tests
applicable for PVC cables. The test requirements for insulation and sheath of
PVC cables shall be as per latest revision of IS: 5831.
5.1.4. 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.
These tests are required to be witnessed by owner before despatch of cables.
a)
Accelerated water adsorption test for insulation as per NEMA

WC- 5. (For PVC insulated cables) and as per NEMA WC 7.
(For XLPE insulated cables) . sampling for this test to be done
randomly and once for each size per order wise provided outer
sheath remains same.
b.
Dielectric Retention Test: The dielectric strentght of the cable

insulation tested in accordance with NEMA WC 5 at 75 +- deg.
C. Shall not be less than 50% of the original dielectirc
strength.(For PVC cables). Test certificates with respect to this
test (not older than one year ) from recoginsed testing laboratory
to be furnished for review by owner before despatch clearance of
cables. In case test certificates are not available, test to be
conducted by vendor at his own cost in a recognized test
laboratory before despatch clearance of cables.
c.
Oxygen Index Test: The test shall be carried out as per ASTMD
2863 or applicable Indian Standard specifications. 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 to be
done randomly once for each size per sampling paln.
e.
Test for rodent and termite repulsion property: The vendors shall
furnish the test details to analys e the property by chemical
method. Sampling to be done for every offered lot/size as per
sampling.
5.2 Cable Accessories
Type tests should have been carried out to provide the general qualities and
design of a given type of . termination / jointing system as per IS: 13573. The
107
PART III
SECTION 3
type test certificates shall be submitted along with the offer. Incase type test
certificates are older than 5 years. Vendor shall be carry out the type test at his
own cost.
6.0 PACKING AND MAKING
6.1
Cables shall be despatched in non returnable wooden or steel drums of

suitable barrel diameter, securely battened, with the take off end fully
protected against mechanical damage. The wood used for construction of the
drum shall be properly seasoned, sound and free from ducts. Woods
preservatives shall be applied to the entire drum. 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.

Manufacture name, type size, voltage grade of cable length of cable in meter
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
Unless otherwise specified. Cables shall be supplied in drum length
as
follows:
Medium voltage power cables up to and including 6 sq. mm 1000 m
Medium voltage power cables from 10 sq. mm up to and including 300 sq.mm -500 m
Control cables up to and including 27 cores
- 1000 m
HV power cablesUpto 11kv (E) grade. 3x400 mm2
- 500 m
Upto 11kv (E) grade. 1x630 mm2
- 1000 m
33kv (E) grade, upto 3x400 mm2
- 250m
33kv (E) grade, upto 1x400 mm2
- 1000m
A tolerance of plus or minus 3% shall be permissible for each drum. However

overall tolerance on each size of cable shall be limited to 27 + -. Offers with
snort / non-standard lengths are liable for rejection. If non standard drum
lengths are specified in the data sheet, the same shall be supplied.
108
PART III
SECTION 3
CHAPTER 8
STANDARD SPECFICATION
FOR
ELECTRICAL MOTOR OPERATED
VALVE ACTUATORS
109
PART III
SECTION 3
CONTENTS
1.
SCOPE
2.
CODES AND STANDARDS
3.
SERVICE AND SITE CONDITIONS
4.
POWER SUPPLY
5.
TECHNICAL SPECIFICATIONS
6.
EQUIPMENT FOR CLASSIFIED AREAS
7.
TESTING AND INSPECTION
8.
PACKING AND DESPATCH
110
PART III
SECTION 3
1.
SCOPE
The scope of work of the vendor includes design, supply, installation, testing and
commissioning of all electrical motor operated valve actuators intended for
fully/partially opening/closing valve duty, required for completion of the scope of
the project. This specification does not cover the actuators for flow regulating duty.
2.
CODES AND STANDARDS

This design, manufacture and performance of equipment covered by this
specification shall conform to the relevant Indian/International standards and Codes.
In particular the equipment offered shall conform to the latest revision of the
following standards:
IS
IS
IS
IS
:
:
:
:
IS :
IS :
3.
325
13947
2148
4691
4722
9334
Three-phase Induction Motors

Low Voltage Switchgear and controlgear.
Flame proof enclosure for electrical apparatus.
Degree of protection provided by enclosure for rotating
Rotating electrical machines.
Electric Motor Operated Actuators.
SERVICE AND SITE CONDITIONS

The electrical motor operated valve actuator shall be suitable for operating under
seric conditions and system conditions as specified in the data sheet. If not
specifically mentioned therein a design ambient temperature of 40C and altitude not
exceeding 1000 meters above mean sea level shall be considered.
4.
POWER SUPPLY
The electrical motor operated valve actuator shall be suitable for power supply at
415 V 10%, 50 Hz 3%, 3 phase, unless otherwise specified in the data sheet.
5.
TECHNICAL SPECIFICATIONS
5.1
Motor
5.1.1
Motor shall be 3-phase squirrel cage induction type unless otherwise specified in the
data sheet.
111
PART III
SECTION 3
5.1.2
The motor shall be rated for S2-15 minute duty and shall conform to IS:325, or
equivalent international standard.
5.1.3
The motor shall be provided with thermostat(s)/thermistor(s) embedded in hot spot

of motor windings.
5.1.4
The motor shall be able to operated the actuator at 75% of rated voltage.
5.1.5
Motor shall have class `F' insulation with temperature rise limited to class `B' limits.
Winding shall be treated to resist corrosive agents and moisture.
5.1.6
Motor rotor shall preferably be of die cast aluminium and if braze shall be free from
phosphorous.
5.2
Integral Starter and Control Transformer

The reversing starter, control transformer and local controls shall be integral with the
valve actuator, unless as specified otherwise in the data sheet. Solid state control of
valve actuator and upto-isolated interface fore remote control requirement maybe
provided, wherever these features exist in manufacture's design.
The integral started shall be supplied with following devices:
(a) Electrically and mechanically interlocked reversing contractors for opening and
closing operations.
(b) Control transformer with necessary tapping and protected with easily
replaceable type HRC fuses.
(c) Terminal block for external cable connection fully premiered of internal devices
of value actuator.
5.3
Integral Push Button, selector switches, indication and control devices

Following local control devices shall be provided, integral with MOV actuator:
(a) Push buttons for "Opening/closing/stop" or alteratively òpen/close' selector
switch.
(b) `Local/Off/Remote' selector switch pad lockable in each position.
112
PART III
SECTION 3
(c) Indication lamps/LED's or mechanical indication for valve fully open fully
closed.
(d) Local continuous position indications from fully open to fully closed status,
which may be mechanical analogue or electronic digital type.
5.4
Torque & Travel Limit Switches

Torque limit switches shall be provided to protect the motor from over loading by
cutting off the supply to motor during opening and closing operations. The switch
shall be provided with potential free contacts of requisite number for valve actuator
operation and of specified number for indication on remove panels, as per data sheet.
It shall be possible to set the value of torque during closing from 50% to 100% of
rated torque of actuators. Travel limit switch shall be provided to cut-off the supply
to the motor at the end of present limit of valve travel and shall be provided with
potential free contacts of requisite number for vale actuator operation and of
specified number for indication on remote panels, as per data sheet. Instead of
mechanical torque limit switches, magnetic pulse counter to measure and control the
stroke of actuator may be provided, wherever this feature exists in manufacture's
design
5.5
Control Facilities
The internal controls and monitoring circuits shall be incorporated within integral
starter with transformer and control unit of valve actuator.
The remove control facility, if specified in the data sheet shall be provided. The
remove control may be powered from internally derived control supply voltage
unless specified in data sheet for using external supply for removal control. In order
to cater to remove control and indication requirement for valve open, valve closed,
remove/local/off position of selector switch, etc., as specified in the data sheet, the
additional monitoring relay/auxiliary relay, if required shall form part of valve
actuator supply.
One number hand-held infra-red remove programming device (where applicable)
required for site commissioning and reconfiguring without the need of removal of
the MoV cover, shall be supplied for each group of 5 valve actuator (or minimum on
infra-red remove setting device, even if number of value actuators are less than five).
113
PART III
SECTION 3
As an alternative common status contract for availability of the MOV actuator for
remote control may be provided by monitoring the following:
-
Loss of one or more phrase of power supply

Loss of control circuit supply
Selector switch in local mode
Local stop such button set to off
Motor thermostat tripod
Any other local fault/abnormal condition
5.6
Hand Operation
A hand with hand/auto lockable level shall be provided for emergency operation, of
the MOV. The energisation of the motor shall automatically re-engage power
operation.
5.7
Two Wire control system

Where specified on the data sheet the MOVs shall be suitable for 2 wire control
system. These MOVs shall have individual field units connectable to a master station
through a single 2 core cable loop for control and monitoring of MOVs. The
maximum number of field units that can be connection to a master station and
maximum number of control input and control/status output from each field unit that
can be handled the 2 wire control system shall be indicted by the vendor.
Each field unit/MOV shall be addressable from the master station through a unique
address code. Unless otherwise specified in the data sheet, all the field
settable/adjustable parameters of the MoV shall be settable from the master station.
Similarly all the indications available on the MOV shall be available at the master
union. Full diagnostic feature for the MOV shall be available from the master station
as well.
In case of a fault at any location in the cable loop the field units shall still have the
accessibility to/from the master station through the other side of the cable loop. The
master station shall be suitable for hook-up with the plant DSC system.
5.8
Position Indicator
The position indicator shall continuously indicate the position of travel of the valve.
If specified in the data sheet a 4-20m. A remote position transmitter shall be
provided in the valve actuator and one number continuous position indicator for
mounting in Purchaser's remote panel shall be supplied as a loose item.
114
PART III
SECTION 3
5.9
Name Plate
Each motorized valve actuator shall be provided with a stainless steel name plate
attached firmly to it a place convenient for reading, furnishing the following details.
A separate name plate shall be provided for hazardous area application.
i) Actuators tag number as per data sheet.
ii) Motor KW rating, motor time rating, motor supply voltage, phase nominal
motor current, auxiliary switch rating.
iii) Max, Torque setting
iv) Actuator enclosure type, lubricant type
v) Actuator type, wiring diagram number/catalogue number, actuator serial
number.
5.10
The enclosure of complete MOV actuator, including motor, integral starter and
control transformer unit and all control devices shall have minimum IP-65 ingress
protection.
5.11
Wiring and Terminals

All devices provided in the actuator shall be wired upto the terminal bloicim. The
contacts for the remote operation and indication shall be wired upto the terminal
block. 20% spare terminals shall be provided for future interlocks. Internal wiring
for power and controls circuits shall be appropriately sized for MOV actuator rating.
Each wire shall be identified at both ends using PVC ferrules. The terminal
compartment shall be separated from the inner electrical components of the actuator
by means of water tight seal so that the actuator electrical components are protected
from the ingress of moisture and foreign materials when the terminal cover is
removed during installation and maintenance.
5.12
Vendor shall be solely responsible for selection and sizing of various electrical
devices.
6.
EQUIPMENT FOR CLASSIFIED AREAS

Actuators meant for hazardous area shall meet the requirements of IS:2148, IEC 79
or equivalent international standard and shall be suitable for as group IB, Temp.
class T3 (200C). Indigenous equipment shall be certified by CMRI and approved
by CCE and shall carry the BIS license marking. Imported equivalent shall be tested
and certified by an independent certifying agency of country of equipment origin.
115
PART III
SECTION 3
7.
TESTING AND INSPECTION
7.1
The equipment shall be subject to inspection by CPCL or by an agency authorized

by CPCL. All necessary information concerning the supply shall be furnished to
CPCL for witnessing the final testing of the complete assembly to ensure satisfactory
operation of the MOV.
7.2
Routine tests shall be carried out at the manufactures works under his supervision
and at his own cost. Type test certificates shall be furnished with bids. Final
acceptance of MOV at site shall be subject to successful testing of the MOV actuator
with valve.
8.
PACKING AND DESPATCH
The electrical motor operated valve actuator shall be shipped to site packed in wooden crates.
They shall be wrapped in polyethylene sheets before having placed into the crates to prevent
damage to the finish. Crates shall have skid bottom for handling.
116
PART III
SECTION 3
CHAPTER 9
FOR
UNINTERRUPTED
POWER SUPPLY SYSTEM
117
PART III
SECTION 3
CONTENTS
1.0
SCOPE
2.0
CODES & STANDARDS
3.0
SITE CONDITIONS
4.0
GENERAL REQUIREMENTS
5.0
TECHNICAL REQUIREMENTS
6.0
7.0
PACKING AND TRANSPORT
118
PART III
SECTION 3
1.0
SCOPE
The scope of work of the vendor includes design, supply, installation, testing and
commissioning of all static Uninterrupted Power Supply (UPS) systems required for
the completion of the scope of work of the project.
2.0
CODES AND STANDARDS
2.1
The equipment shall comply with the requirements of latest issue of relevant Indian
standard specifications/equivalent specifications of the country of origin/IEC
specifications. Some of the applicable IS/IEC specifications are listed below:
IEC:146
IS:3700
:
:
IS:3715
IS:4411
IS:5001
:
:
:
IS:5469
IS:10918
IS:2959
IS:13314
IS:1651
:
:
:
:
IS:8320
IS:7204
(Part 1-4)
IS:2147
IS:13703
(Part 1-4)
IS:1248
:
:
:
Semi-conductor converters.
Essential rating and characteristics of semi-conductor
devices.
Letter symbols for semi-conducting devices.
Code of designation of semi-conducting devices.
Guide for preparation of drawings for semi-conductor
devices.
Code of practice for the use of semi-conductor junction
devices.
Vented type Nickel Cadmium batteries.
Contractors for voltage not exceeding 1000V AC or 1200V DC.
Solid state inverters run from storage batteries
Stationary cells and batteries, lead acid type (with tubular
positive plates)
General requirement and method of tests for Lead Acid
storage batteries.
Stabilised power supplies D.C. output.
Degree of protection provided by enclosure for lower
voltage switchgear and control gear.
L.V. fuses
Direct acting indicating analogue electrical measuring
instruments and their accessories.
(Part 1, 2 and 9)
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PART III
SECTION 3
IS:13947 :
L.V. Switchgear and control gear
(Part 1, 3, 4 and 5)
IS:12021 :
Specifications for control transformers for switchgear and control
gear for voltages not exceeding 1000 V AC
IS:5
:
Painting
2.2
The equipment shall also conform to the provisions of Indian Electricity rules and
other statutory regulations currently in force.
2.3
In case of any contradiction between the standards listed in 2.1 and this
specifications, the requirements laid down in this specification shall prevail.
3.0
SITE CONDITIONS
The UPS system shall be suitable for installation and satisfactory operation in a
closed substation with restricted natural air ventilation in tropical humid and
corrosive atmosphere. The UPS system shall be designed to operate under site
conditions as specified in the data sheet. If not specifically mentioned therein design
ambient temperature of 40oC and altitude not exceeding 1000M above MSL shall be
considered.
4.0
4.1
The UPS system shall be an integrated system comprising static rectifiers, battery,
static inverters, static switches, manual by pass switch, AC distribution board,
voltage stabilizer in by pass, isolating and protection devices and all other
equipment/accessories required for completeness of the system whether specifically
mentioned herein or not, but necessary for completeness and satisfactory
performance of the system.
4.2
The UPS system shall be suitable to feed all loads connected to output which are
primarily instruments, DIDC (DCS) computers, disc drives and other SMPS
equipment leading to high crest factor of the load.
4.3
The UPS system shall be based on latest generation technology having proven
performance of satisfactory operation for similar applications. The inverter shall be
transistorised type. All components shall be of a quality and reliability that satisfies
the requirements of a secure AC power to vital equipment performance, controlling,
monitoring and safe guarding function in continuously operating petrochemical
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process units, petroleum refineries, gas processing facilities and utility installation.
Components shall be capable of withstanding the thermal and dynamic stresses
resulting from internal and external short circuits and circuit switching operations
etc.
4.4
The design of the UPS shall be such as to minimise the risk of short circuits and shall
ensure personal and operational safety.
4.5
The vendor shall be responsible for design, engineering and manufacturing of the
complete system to fully meet the intent and requirements of this specification.
4.6
The UPS shall be single phase or three phase system as per requirement.
5.0
TECHNICAL REQUIREMENTS
5.1
Input Power Supply
5.1.1
The UPS shall be suitable for input power supply as defined in the data sheet. If not
specified therein the UPS shall be suitable for the following input power supply.
Voltage
:
415 10%
Frequency
:
50 Hz 5%
In addition to above variations, the input voltage may be subject to transient
comprising voltage dip to 20% of normal voltage during motor start-up and voltage
interruption during short circuit. UPS system shall be designed to operate
satisfactorily while deriving input power from an emergency diesel generator set.
5.1.2
The incoming power supply to UPS will be provided by 2 Nos. feeders. One feeder
shall feed the rectifier(s) while other shall supply power to stabilised bypass supply.
5.2
UPS configuration & operational requirements.

The UPS system shall have one of the following basic configurations as specified in
Electrical system design data sheet.:
5.2.1
Single UPS with Bypass (Non-redundant)
In UPS system having this-configuration a single rectifier and inverter shall be

provided. Under normal conditions when AC mains power is available the rectifier
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shall simultaneously feed DC power to inverter as well as for float/rapid charging of

the battery. The AC supply to loads shall be fed from inverter output.
In case of any fault in the inverter, the load shall be automatically transferred to
stabilised bypass supply and retransfer of load from stabilised bypass supply to the
inverter shall only be in manual mode.
In case of AC input power failure or battery charger failure, the battery shall supply
power to inverter without any interruption. The charger shall be designed for
simultaneously feeding complete inverter load and for float/rapid charging the
battery to its rated capacity within 10 hrs. Charger shall be equipped with automatic
Òn Line' as well as manual charging facility.
5.2.2
Parallel Redundant UPS with bypass

In UPS system having this configuration two sets of rectifiers and inverters shall be
provided. Under normal conditions, when AC mains power is available, both the
rectifiers shall operate in parallel and supply DC power for float/rapid charging the
battery and simultaneously to inverters. In case of failure in one rectifier, the other
rectifier shall feed the complete load and the battery without any interruption. In case
of incoming supply failure or failure of both rectifiers the battery shall feed the
inverters without any interruption. Each rectifier shall be designed for
simultaneously feeding complete inverter load and float/rapid charging of the battery
to its rated capacity within 10 hrs. Each rectifier shall be equipped with automatic
Òn Line' as well as manual charging facility.
Normally both inverters will be synchronised with each other and with stabilized
bypass supply. The two inverters shall operate in parallel and share the load equally.
When a disturbance/fault occurs in any one of the inverters, the faulty unit shall
automatically get disconnected and the entire load shall be fed from the other
inverter. In case both the inverters develop a fault, the complete load shall be
transferred to stabilized bypass supply through the static switches and retransfer of
load from stabilized bypass supply to the inverter shall only be in manual mode.
5.2.4
In all UPS configurations, the facility for uninterrupted manual transfer in either
direction through static switches shall also be provided.
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5.2.5
For ease of maintenance, it shall be possible to isolate inverters and static switches
from load through manually operated make before break switches. In case of larger
rating UPS, where it is not possible to provide one power switch with make before
break feature, combination of breakers with the control scheme having make before
break logic may be provided which ensures momentary paralleling before tripping of
selected breaker.
5.3
UPS design & performance requirements
5.3.1
Incoming AC supply shall be converted to DC through phase controlled rectifiers.

The rectifiers shall operate according to the constant voltage current limiting
principle and shall incorporate a "Soft Start" feature to gradually accept load on
initial energising.
5.3.2
The rectifier section of the UPS system shall be capable of precise regulation to
prevent damage to the battery. The output voltage of rectifier's DC bus without the
battery shall be stabilized to within 1% of set value during load variation between 0
to 100% of the rectifiers and specified mains input supply voltage variation.
5.3.3
Suitable protection shall be provided in the control circuits to guard against

instability of phase controlled rectifiers due to electrical oscillations that may be
present in the input supply as caused by emergency DG set.
5.3.4
UPS 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.
5.3.5
The UPS system including the stabilised by-pass shall be galvanically isolated from
input power supply system by providing double wound transformers. All
transformers shall be natural air cooled, dry type suitable for location inside panel.
All rectifiers shall also have a double wound transformer at its input.
5.3.6
An R.F. filter shall be provided at the input and output of UPS to suppress the radio
frequency interference to permissible limits as specified in IEC.
5.3.7
Transient/surge protection circuit shall be provided in the input circuit to rectifiers to

protect the UPS from surges & voltage spikes.
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PART III
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5.3.8
The UPS system shall be designed to draw power from mains supply at a minimum
power factor of 0.85 while working at rated load in normal operating UPS
configuration. Vendor shall furnish variation of power factor when load varies from
no load to full load.
5.3.9
The UPS shall be provided with automatic sequence and power walk in circuit(s)
with adjustable time delay upto 15 sec. such that the rectifiers and inverters can start
operating automatically when incoming AC power is restored allowing the UPS to
be loaded automatically.
5.3.10
Facility shall be provided to enable testing to rectifier independently without

disconnection of inverter.
5.3.11
Facility for initial charging of batteries shall also be provided. The inverters shall be
disconnected during initial charging of the battery.
5.3.12
Batteries shall be indoor, stationary type, Lead-acid or Ni-Cd type as specified in

data sheets. Unless specified otherwise in the data sheet, Lead acid battery shall be
tubular plate type (positive plate) and Nickel Cadmium battery of pocket plate type
(positive plate).
5.3.13
For battery sizing, the following factors shall be considered unless specified
otherwise in the data sheet :
a. Load Power Factor of 0.8.
b. Minimum ambient temperature specified in Data sheet or 15 C if not specified.
c. Battery Current
= Inverter rated kVA

Inverter efficiency x End cell voltage x No of cells
d. Aging factor of 0.8

e. Back up time of half an hour in case of mains power failure unless specified
otherwise in data sheet.
f. Minimum end cell voltage for lead acid battery 1.75 v per cell and Ni-Cd battery
1.0 v per cell.
g. Battery state of charge factor.
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PART III
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5.3.14
The rectifiers/chargers shall be designed to completely charge the battery in a

minimum time of 10 hours after complete discharge. Facilities shall be provided to
initiate battery rapid charge operation by Manual & Automatic means. An auto
charging sequence should be provided for the rapid and float charging based on
current sensing. In addition to above, the charging shall be transferred from rapid to
float mode after a preset time adjustable through 0-16 hours timer.
5.3.15
The rectifiers shall be sized based on the maximum inverter input load when inverter
is delivering its rated output at 0.8 p.f. lagging and recharge the battery to nominal
rated capacity of the battery. The DC load imposed by the inverters shall be
considered under the worst case where only one rectifier is operating but the UPS
load is equally shared by all, the inverters. The rating of each rectifier shall be not
less than the value calculated as follows:
For Lead Acid Batteries = Max. Inverter inputcurrent - 0.14AH
For Nickel Cadmium Batteries = Max. Inverterinput current - 0.2AH
5.3.16
The DC rectifiers shall sense the battery charging current and adjust the DC bus
voltage to maintain the charging current to preset level. A separate current limit
circuit shall also be provided or adjustment of battery current. The rectifiers shall be
provided for adjustment of battery current. The rectifiers shall be protected against
reverse battery connection at DC link voltage bus. Subsequent to a discharge cycle
when battery is connected to rectifier, the battery current shall be monitored,
controlled and limited to set value automatically irrespective of the inverter input
current.
5.3.17
The battery may be taken out of service for maintenance, during which period it
shall be possible for the inverter to continue operation by drawing power from the
rectifier. Ripple content at the DC link shall not exceed 5% even with battery
disconnected.
5.3.18
Battery shall be provided with a sensitive earth leakage protection.
5.3.19
The intervers shall operate satisfactorily for variation of DC bus voltage from fully
discharged condition of the battery to rapid charge voltage of the battery and Invertor
output load current waveform having a relative harmonic content varying between 0
and 50%, the latter waveform having a crest factor not exceeding 2.5 and individual
harmonics not exceeding the following values:
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PART III
SECTION 3
5.3.20
5.3.21
- 3rd harmonic 44% of fundamental

- 5th harmonic 33% of fundamental
It shall be possible to vary the inverter output voltage steplessly within 5% of the
specified output voltage. This adjustment shall be possible to be made when the
inverter is in operation.
The steady state output voltage and frequency (free running) variation of inverters
shall not exceed 1% from the set value for specified input power supply conditions
from no load to full load condition and load power factor variation from 0.6 lag to
1.0
5.3.22
The UPS output voltage waveform shall be sinusoidal. The Total Harmonic
distortion of voltage waveform at inverter output shall not exceed 4% of the RMS
value of the fundamental considering any linear load upto maximum rated output of
UPS system at rated power factor and not exceeding 15% under non-linear load.
Vendor shall submit with offer empirical data indicating the increase in THD with
rising crest factor of load.
5.3.23
The UPS system shall be able to operate satisfactorily on rated loads (in kVA) with
power factors in the range of 0.7 lag to 1.0, if not specified otherwise in the data
sheet. Vendor shall furnish a graph showing the effect of variation in load power
factor in this range on UPS output parameters. The overall efficiency of the UPS
system shall not be less than 80% at rated load and 0.8 p.f.
5.3.24
The UPS shall have capacity to deliver a minimum overload of 125% for 10 minutes
and 150% for 10 sec., if not specified otherwise in the data sheet. UPS shall be
provided with current limit circuit to avoid excessive loading beyond its permissible
overload withstand capability.
5.3.25
The inverters shall be `phase locked' to the stabilized bypass power supply as long as
stabilized bypass supply frequency remain within 4% of nominal. When bypass
supply frequency variation exceeds the above limits, the inverters shall be delinked
from mains. Free running frequency tolerance limit shall not exceed 1%. Facility
shall also be provided for adjustment of synchronishing frequency from 1% to 4%.
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PART III
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5.3.26
Unless otherwise specified, the voltage variation shall not exceed 10% and complete
recovery to normal steady state shall be within 0.1 Sec. The phase angle disturbance
shall be less than 120 3% in case of 3 phase inverter. The above requirement shall
be complied for following transient disturbances.
a)
b)
c)
d)
e)
100% step load and unload (for hot stand by only)

50% step load
Momentary interruption in power supply
Load transfer to stabilized bypass supply
Complete load transfer to other healthy inverter when one of the two parallel
inverters develop a fault.
5.3.27
For 3 phase UPS system, the maximum output voltage and angle variation between
the phases should not exceed 6% and 3 degrees respectively even under the
condition of 100% unbalanced loading of the 3 phase output.
5.3.28
UPS system shall be suitable both for floating output or earthing of star point in case
of single phase/three phase system respectively.
5.3.29
The stabilized bypass supply shall be designed to regulate the output voltage within
2% of the rated voltage over complete range of load from no load to full load and for
specified input supply voltage variation. Voltage stabilizer in stabilized bypass
supply shall be of static type and not servo controlled type.
5.3.30
The stabilized bypass supply shall have a continuous current rating equivalent to the
rated output of the UPS unit and be capable of conducting a current ten times the
rated output for the duration more than the fault clearing time of the type of fuse
provided. The load transfer devices may comprise either continuous rated static
elements in both inverter and stabilized bypass supply or continuous rated
electromechanical switching devices with short time rated static elements.
5.3.31
Suitable number & configuration of adequately rated static switches must be

provided in the inverter(s) output and stabilized bypass supply to ensure positive
isolation of faulty inverter section such that the other inverter and bypass circuits do
not feed into the fault leading to undervoltage/trip. The short time rating of all the
static switches shall be atleast 10 times the rated output for the duration more than
the fault clearing time of the type of fuse provided.
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PART III
SECTION 3
5.3.32
Facility shall be provided to manually and automatically initiate transfer of the load
from inverters to the stabilized bypass supply and manually from stabilized bypass
supply to the inverters. Undervoltage and overvoltage sensing levels to initiate
transfer shall be adjustable. The maximum transfer time between inverters and
bypass supply shall not exceed 4 msec and 20 msec in synchronous and
asynchronous mode respectively.
5.3.33
The criteria for automatic load transfer from inverter to the stabilized bypass supply
shall be as follows:
(a)
The load transfer shall only by possible when -
(b)
the stabilized bypass output voltage is within 5% of rated UPS output

voltage and
- the mains bypass frequency is within 4%
Auto-transfer of the load from inverter to stabilized bypass supply shall be
initiated when - the inverter output voltage drops below 95% of nominal output voltage
under steady state condition. The transfer shall be accomplished before
the inverter voltage falls below 90% of the nominal value under transient
conditions.
OR
-
The inverter output voltage exceeds 105% of the nominal output voltage
under steady state condition. The transfer shall be accomplished before
the inverter voltage reaches 110% of the nominal value under transient
conditions.
OR
the inverter output current exceeds its tolerable limits.
5.3.34
All breakers shall be adequately rated for continuous rating as well as breaking
capacity as applicable. Paralleling of breaker/ switch/contractor poles to achieve the
required current rating is not acceptable. All output isolating device shall be double
pole type.
5.3.35
All electronic power devices including thyristors, diodes etc. shall be rated under
operating conditions for approximately 200% of the maximum current carried by the
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PART III
SECTION 3
device. All other electrical components such as transformers, reactors, breakers,

contractors, switches, busbars etc. shall be rated for atleast 125% of the maximum
required rating. No electronic device shall be subjected to PIV greater than 50% of
its rated value.
5.3.36
All the thyristors, diodes and other electronic devices of UPS shall be protected with
high speed semiconductor fuses. I2/t co-ordination characteristics between fuse and
semi-conducting power devices shall be furnished.
5.3.37
5.3.38
The outgoing circuits of ACDB shall be protected by semiconductor fuses. Each

inverter shall be designed to clear a fault in any of the branch circuits upto a
maximum rating of 25% of the system capacity without the assistance of the
stabilized bypass supply. In case of any fault in branch circuits, the load connected to
the healthy circuits shall not get affected. The fault clearing time shall be less than 4
msec.
All PCBs shall be provided with a transparent epoxy coating for environmental
protection and tropicalisation. They shall be suitably located away from heat sources.
5.3.39
All electronic control and monitoring printed circuit cards shall be suitable for easy
replacement. Monitoring points shall be provided on each of the PCBs and the PCB
shall be placed in a manner to avoid replacement of a PCB by a wrong spare PCB.
Failure of each PCB shall be indicated by visual alarms. Visual fault diagnostics
shall preferably identify faults upto various sections in the card.
5.3.40
Forced ventilation of panel, if provided, shall be supplemented by 100% redundant

fans. In normal operation, normal & redundant fans shall run together. The power
supply for the fans shall be tapped from the inverter output. However, the rating of
the UPS shall be the net output of UPS after deducting power consumption for fans
etc. However in case of non-operation of 50% of running fans the UPS output shall
not be affected. The fans shall be arranged to facilitate removal of faulty fan for
maintenance without taking system shutdown.
5.3.41
Maximum noise level from UPS system at 1 metre distance, under rated load with all
normal cooling fans shall not exceed 75 dBA.
5.4
Construction
5.4.1
Rectifier/charger and inverter, stabilized bypass supply and static switch sections
shall be suitably housed in sheet steel panels complete with all interconnections. The
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PART III
SECTION 3
panels shall be fabricated with 1.6mm / 2mm. thick cold rolled sheet steel and
structural steel.
The panels shall be free standing, fitted with suitable louvers for ventilation and
cooling fans as required. Hinged doors shall be provided at the front and back with
tight gaskets. Interpanels sheet steel barriers shall be used. The enclosure shall
provide minimum IP-31 degree of protection, if not specified otherwise in the data
sheet. The maximum and minimum operating height of the switches shall be
1800mm and 300mm respectively.
5.4.2
Power cables shall be with aluminum conductors and control cables shall be with
copper conductors. All the cable connections shall be from bottom and front of the
panel, if not specified otherwise in the data sheet. A removable bolted gland plate
shall be provided along with double compression type nickel plated brass cable
glands for external cable connections. Clamp type terminals shall be used for
connection of all wires upto 10mm2. Bolted type terminals suitable for cable lugs
shall be provided for wire size above this. Copper lugs for all external connections
shall be provided with the panels.
5.4.3
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 name plate and
device tag numbers as per the schematic diagram. All wires shall be ferruled and
terminals shall be numbered.
5.4.4
All power and control switches shall be rotary type, mounted on the door and shall
be externally operable. Space heater and 100W incandescent lamps shall be provided
in each panel. All instruments shall be switchboard type, back connected,
72x72 mm. square of reputed make & analogue/digital type. Analogue instruments
scale shall have red mark indicating maximum permissible operating rating. Separate
test terminals shall be provided for measuring and testing of the equipment to check
the performance.
5.4.5
A suitably sized earth bus shall be provided at the bottom of the panels including
ACDB running through the panels line up with provision for earth connection at
both ends to purchaser's main earth grid. The minimum size of earth bus shall be 25
x 3mm2 copper (or equivalent aluminum). All potential free metallic parts of various
equipments shall be earthed suitably to ensure safety.
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PART III
SECTION 3
5.4.6
All panels shall be of same height so as to form a panel lineup which shall have good
aesthetic appearance.
5.4.7
Inside the panels, the controls connections shall be done with 660V grade PVC
insulated wires having stranded copper conductors. 1.5 mm2 size wire shall normally
be used for circuits with control fuse rating of 10 Amps. or less. For circuit control
fuse of 16 Amps., 2.5 mm2 size wire shall be used. Wire size of 0.75 mm2 may be
used for wiring to electronic components.
5.4.8
All control wiring shall preferably be enclosed in plastic channels or otherwise

neatly bunched together. Each wire shall be identified at both ends by PVC ferrules.
Ferruling of wires shall be as per relevant IS.
5.4.9
All metal surfaces shall be thoroughly cleaned and de-greased 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 undertaking the finished coat.
After preparation of the under-surface, the panels shall be spray painted with two
coats of epoxy-based final paint or shall be powder-coated. The colour shade of the
final paint shall be shade 631 (light grey) as per IS:5 unless otherwise specified.
Spray-painted finished panels shall be dried in stoving ovens in a dust-free
atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels,
runoff paint, etc. The vendor shall furnish the painting procedure along with the bids.
5.5
Battery Accessories
5.5.1
The battery shall be complete with all accessories and devices including, but not
limited to, the following (for each battery):
1 Lot Battery stand in double row, double tier formation made of treated
first class teakwood assembled without the use of any metal fastenings for
lead acid battery or PVC coated steel stand for Ni-Cd battery.
1 Lot Inter cell, inter row and inter bank connectors and end take offs.
These shall be of lead plated/PVC sleeved copper.
1 Lot Porcelain cell insulators
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PART III
SECTION 3
1 Lot Stand insulators

2 Nos Hydrometers suitable for specific gravity readings along with wall
mounting teakwood stand
1 Lot Cell number plates and fixing pins as required
2 Nos. Thermometers with specific gravity correction scale along with
wall mounting teakwood stand.
1 No. Cell testing voltmeter (3V-O-3V) complete with 1M long leads.
4 Nos. Level testers
2 Pairs Rubber gloves, eye protection goggles.
2 Nos. Rubber aprons.
1 Set
Acid/Alkali resistant jugs and funnels
1 Set
Spanner set
1 Lot Catalytic caps (for lead acid batteries)

Required quantity of electrolyte for initial filling of the battery set
plus 10% extra in non returnable containers.
1 No. Cell booster shall be provided for each AH capacity of battery
cells supplied with following specification:
Cell booster for charging one to five cells within a duration of 10 hours
shall be supplied. It shall be suitable for charging not only new cells
before being introduced to the battery bank but also any treatment to be
give to the individual weak cells. Quantity of such boosters shall be as
defined in data sheet. Cell booster shall be suitable for 240V 10%, 50 Hz
3% input power supply.
Cell booster shall have heavy duty switch fuse on AC incomer and DC
output, AC voltmeter, DC ammeter and voltmeter, indicating lamp for
AC power ON. The output voltage and current of cell booster shall be
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PART III
SECTION 3
under manual control. Cell booster shall be portable type with wheels.
Each cell booster shall be supplied with 5 m long flexible copper
conductor PVC insulated cable for AC incomer power supply and DC
output connection to the battery.
5.6
A.C. DISTRIBUTION BOARD

Sheet steel enclosed AC distribution board shall be provided as part of the compete
UPS package. They shall accommodate all AC feeders required for the loads. The
distribution board shall be floor mounted, fixed type with compartmentalised
construction, having horizontal and vertical bus-bars. All bus bars shall be PVC
sleeved. It shall be possible to operate the switches without opening the doors.
Switches shall be provided with door interlock. Vertical cable alley shall be provided
for the termination of outgoing cables. Suitable supports shall be provided for
supporting incoming and outgoing cables. All outgoing switches shall be air
insulated load break type. Fuses on outgoing feeders shall be fast acting
semiconductor type and cable entry shall be from bottom. The gland plate of the
distribution board shall be non-magnetic type.
5.7
Alarm, Control, Indication and Metering Requirements

If not specified otherwise in the data sheets, following schedule shall be followed for
alarm, control, indication and annunciation. Any additional devices/features
considered necessary for reliable operation and maintenance shall also be included in
various panels and same shall be highlighted separately. An illuminated one line
diagram indicating operational status shall be provided on the front of the panel.
5.7.1
Metering
5.7.1.1
Rectifier
a.
Incoming line voltages.
b.
Input line currents
c.
D.C. voltage at each rectifier output.
d.
D.C. current at each rectifier output.
e.
Battery current for rapid and float charging/discharging.
5.7.1.2
Inverters
a.
DC input current at each inverter.
b.
AC voltage at each inverter output. (AC voltage for 3 phase inverter.)
c.
AC current at each inverter output. (AC currents for 3 phase inverter.)
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PART III
SECTION 3
d.
Frequency meter at each inverter output.
5.7.1.3
Stabilized Bypass supply

a.
Frequency meter for incoming supply.
b.
Voltmeter with selector switch for incoming supply.
c.
Ammeter with selector switch for incoming supply.
5.7.1.4
ACDB
Following shall be provided for each of the ACDB incomers:
a.
Voltmeter (voltmeter selector switch shall also be provided for a phase
b.
c.
inverter).
Ammeter (ammeter selector switch shall also be provided for 3 phase
inverter).
Power factor meter.
5.7.2
Indications
5.7.2.1
a.
b.
5.7.2.2
Rectifiers (for each rectifier)

a.
Rectifier output ÒN'
b.
Battery on float charge
c.
Battery on rapid charge
5.7.2.3
Inserters (for each inserter)

a.
DC input ÒN'
b.
Load on inverter.
c.
Inverter synchronised with bypass mains
5.7.2.4
Static switch inhibited (on a/c of poor quality of bypass line).
5.7.3
Audio-Visual Alarm (Complete with Accept/Reset/Test Facilities) separately for

each circuit
5.7.3.1
a.
AC mains ÒN' - Rectifier.

AC main ÒN' - Bypass.
Mains failure
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PART III
SECTION 3
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Battery charges failure

Battery fault
Inverter high temperature
Low voltage from inverter
Inverter by-passed
Inverter overloaded
Static switch faulty
All power Fuse failures
Load on bypass.
Fans failure
5.7.3.2
2 nos changeover contacts shall be wired to the terminal strip, 1 no for common
remote alarm of ÙPS fault' in owner's panel and 1 no for `load on stabilized bypass
supply' annunciation.
5.7.4
Controls
a.
All the switches for starting, shut down and testing sequence.
b.
Primary input circuit breakers for feeding chargers, bypass line and dc bus
from battery including backup protection.
c.
Inverter ON/OFF switch (to initiate inverter operation)
d.
Static switch transfer test Push Button.
5.8
Reliability
All necessary care shall be taken in selection, design, manufactures, testing and
commissioning of the equipment for ensuring high system reliability. Vendor shall
furnish the value of `MTBF' `MTTR' and Àvailability Factor'. The above figures
shall be substantiated by tests and field results. Following design consideration shall
be taken into account to ensure maximum availability of the system.
5.8.1
There shall be no common device, between main and redundant units (e.g. master
oscillators etc.) in order to ensure that the failure of the same does not cause
shutdown of more than one unit.
5.8.2
It shall be possible to bring out any individual power circuit for maintenance without
affecting the total UPS supply.
Series-parallel combination of smaller devices to achieve specified rating shall not
be acceptable.
5.8.3
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5.8.4.
All the components used shall be time tested and standardized. Vendor shall state the
safety factors used in selecting such items as semi-conductors, electrolytic
capacitors, transformers etc.
5.8.5.
Vendors shall quote their nearest higher size that will meet the requirement of the
specified UPS rating.
5.9.
Fault Diagnostic Unit

Each UPS set of capacity larger than 15 KVA shall have provision for adding
microprocessor based ÒN line' diagnostic unit. This shall supervise the UPS
operation continuously. It shall identify and locate faults immediately so that
corrective action can be taken. Fault Diagnostic unit shall be compatible to hook up
with PC through RS 232/RS485 interface. The software shall be provided on 3.5.
inch floppy. The PC to be supplied as part of diagnostic unit shall have the
minimum configuration of PENTIUM 4, 20 GB hard disk, CD R/W drive,
WINDOWS 2000 & OFFICE TOOLS, etc for system diagnosis and a DOT
MATRIX PRINTER (not less than 120 COLUMN) for taking out report .
The fault diagnostic unit have provision for following minimum facilities:
Automatic print out facilities for time, input/output voltages, currents,
frequency under the following conditions.
UPS power source changeover from mains to battery.
UPS power source changeover from battery to mains.
Changeover from inverter to stabilized bypass supply and vice versa.
Changeover from one inverter to other inverter.
Prints-out in case of UPS failure.
Output voltage wave form of UPS.
Output current wave form of UPS.
Type of failure incident alongwith diagnostic report.
In addition to the above, any other feature which vendor feels may be useful shall be
provided and highlighted separately.
If any additional equipment (e.g. bin connector, adaptor cards etc.) are required for
connecting this unit with UPS system as well with the PC, the same are also to be
included in the vendor's scope.
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6.0

Tests shall be carried out to prove compliance with the requirements of the
specification and international standards, UPS tests shall be conducted to verify the
performance of the rectifiers, inverters, static switch and all control circuits. Unless
otherwise specified testing of UPS system at UPS manufacturer's works may not
include the battery that also form part of UPS system. Battery capacity and other
tests may be conducted at battery manufacturer's works.
Prior to start of the tests, the manufacturer shall make all relevant adjustments in the
protection and control circuit components of the rectifiers, inverters as necessary to
fulfil the requirements of this specification. The rectifiers output voltage and current
limit hall be set to the appropriate value for the type and no. of battery cells to be
supplied with UPS.
Following system acceptance tests shall be conducted on each UPS system.
6.1
Insulation tests
The voltages specified in the following table shall be applied for one minute to the
circuit indicated:
Table of withstand
Voltage
Control electronics
< 60V
Power electronics
Un1
Auxiliary circuits
Un2
To earth
700 V D.C
2 x Un1 1000V
2 x Un2 + 1000V
To control
electronics
2 x Un1 + 1000 V
2 x Un2 + 1000V
To power
electronics
2 x Un1 + 1000V
2 x Un2 + 1000V
To auxiliary
2 x Un2 + 1000V
2 x Un1 + 1000V
circuits
(Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits respectively)
D.C. test voltage may be applied instead of A.C The magnitude of D.C. test voltages to be
applied shall be 2 times the above mentioned A.C. (r.m.s.) values.
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Insulation resistance test is required to be conducted before and after insulation test and
continuous burn-in test for 100 hours at full load with temperature rise measurement.
6.2
Interconnection cable check

The interconnection cable are to be checked for correct wiring, insulation and quality
of the terminations
6.3
A.C. input failure test

The test is performed with the test battery and carried out by tripping a.c. incoming
circuit breakers or by switching off rectifiers and bypass supply at the same time.
Output voltage and frequency variations are to checked for specified limits.
6.4.
A.C. input return test

The test is performed by closing a.c. incoming circuit breakers or is simulated by
energizing rectifiers and bypass supply. Power operation of rectifiers starting and
voltage and frequency variations of output are to be checked.
6.5
Simulation of parallel redundant UPS fault

The test is applicable for UPS with parallel redundant configuration. Fault of
rectifier or inverter are to be simulated and output transients are to be recorded.
6.6
Transfer test
Transients shall be measured during load transfer from inverter to bypass supply
caused by simulated fault and load manually retransfer after clearing the fault.
6.7
Regulation test
This test shall be carried out by measuring input voltage, input current, output
voltage, output current, DC link voltage, output distortion, input active power, output
active power and frequency at no load, 50% load and 100% load at 0.6 and 0.8. p.f.
Following parameters of rectifiers and inverters are to measured :
Measurement shall be carried out in the rectifier float charge mode and in rapid
charge mode. Measurement shall be at nominal a.c. voltage and at no load, 50% load
and 100% of rectifier full load. Rectifier measurement shall comprise of :Input voltage, frequency, phase current and input power
D.C. output voltage and current
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Ripple current at the D.C. link bus shall be recorded after isolating the test
battery
Inverter measurement shall also be at no load, 50% load and 100% load of inverter
rated output current and shall be repeated for inverter D.C. input voltages
corresponding to battery float charge operation as well as rated inverter maximum
and minimum input D.C. voltage. Measurement shall comprise of :
Input voltage, input current
Output voltage, frequency and waveform distortion, output power and current
6.8
UPS efficiency
This shall be determined by the measurement of the active power input and output at
rated p.f. for 50%, 75% and 100% load.
6.9
Current division in parallel UPS

Load sharing between UPS units shall be measured with a dummy load under
parallel redundant UPS configuration.
6.10
Light Load test

The test is to verify that UPS is correctly connected and all functions operate
properly. The load applied is limited for economic reasons to some percentage of
rated load. The following points are to be checked.
(a) Output voltage and frequency and correct operation of meters.
(b) Operation of all control switches and other means to put UPS system into
operation
(c) Functioning of protective and warning devices
6.11
Continuous Burn-in test for 100 hours at full load and 0.8 power factor with
temperature rise measurement
The test is required to be performed by connecting resistive load or resistive and
inductive load to the UPS system output. The load shall be placed outside the test
room to avoid influences of its heat upon UPS ventilation.
UPS system in this test is required to work continuously for 100 hours at full load
and steady state temperature of rectifier transformer, rectifier set, D.C. choke,
inverter set, static switch etc. shall be recorded. The temperature of all UPS panels
are also to be recorded.
6.12
Auxiliary equipment and control circuit tests
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The correct functioning of all measuring instruments, alarms, indications, protection

devices and controls are to be verified. The functioning of auxiliary devices such as
lighting, cooling fans, annunciation etc. should be checked.
6.13
Synchronization test
Frequency variation limits of inverter is to be tested by feeding bypass supply
incoming line by variable frequency generator and inverter synchronization limit is
to be checked as specified.
6.14
Unbalanced load test (For 3 phase UPS only)

Unbalanced load at specified limits is applied to the UPS system. The specified
voltage and phase angle variation may be checked for compliance with specified
values.
6.15
Output voltage unbalance (For 3 phase UPS only)

Output voltage unbalance shall be checked under symmetrical load conditions and
unbalance load conditions. Phase to phase and phase to neutral output voltage are to
be observed. The voltage unbalance is the ratio of highest phase voltage minus
lowest phase voltage to the average value. Phase angle variation may be measured
for phase to phase and phase to neutral voltages.
6.16
Overload capability test

Specified values of short time overload are to be applied for specified time interval.
Values of output voltage and output current are to be recorded.
6.17
Short circuit current capability test

Specified short circuit current capability is to be tested by application of a short
circuit to UPS output if necessary via a suitable fuse. Short circuit current is to be
recorded.
6.18
Short circuit fuse test

Fuse tripping capability of the UPS system is to be tested by short circuiting the UPS
system output via a specified rating of fuse.
The test shall be repeated to ensure against fuse non uniformity. The test is carried
out at an appropriate UPS load under normal operation.
6.19
Restart
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Manual restart to be tested after complete shut down of UPS system.

6.20
Output over voltage

Operation of output overvoltage protection is to be checked.
6.21
Periodic output voltage modulation

Output recording at different loads and operating condition to be done.
6.22
Harmonic components
Harmonic components of output voltage are to be recorded at no load, 50% load and
100% load conditions. Harmonic currents caused by UPs system components in the
A.C. incomer side shall also be recorded.
6.23
Earth fault test

An earth fault is to be applied to the output terminal of UPS system. UPS output
transients are to be measured. An earth fault is also to be applied to the battery
terminal and UPS system output transient shall be measured.
6.24
Audible noise test

The audible noise is required to be measured at 1 meter distance from UPS system in
at least 4 to 5 locations and its value shall be within permissible limit.
6.25
In addition to above UPS tests, the battery shall be tested as per applicable standards
including duty cycle tests at battery manufacturer works. Following battery tests
shall also be conducted at site :
(a) Rated storage energy time battery test
(b) Battery ripple current
6.26
The test schedule and test procedure shall be formulated in line with above.
Before giving call for the witness of the tests, vendor shall get CPCL's approval
on the test procedures. Vendor shall also indicate the max, allowable tolerance for
each test result, along with the test procedures. If tests show that certain
requirements of the specifications are not met, `vendor' shall make necessary
corrections to the equipment so that it satisfies all the requirements before
acceptance is made.
6.27
Routine and acceptance shop tests will be inspected by CPCL.
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6.28
Prior notice of minimum 4 weeks shall be given for all inspections mentioned
above.
6.29
After erection at site, all precommissioning tests have to be carried out, in

presence of CPCL inspectors.
7.0
PACKING AND TRANSPORT

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 panels shall be wrapped in polytene sheets
before being placed in crates to prevent damage to finish. Crates shall have skid
bottom for handling. special notations such as `Fragile', `This side up', `Center of
gravity', `Weight' etc., shall be clearly marked on the package together with Tag
nos., P.O. Nos. etc.
The equipment may be stored outdoors for long periods before erection. The packing
should the completely suitable for outdoor storage in areas with heavy rains/high
ambient temperature.
8.0
TRAINING
Training shall be provided at free of cost, in two batches, for a minimum of
6 persons per batch at vendors works.
********************
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CHAPTER 10
FOR
HIGH VOLTAGE INDUCTION MOTOR
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PART III
SECTION 3
CONTENTS
1
SCOPE
CODES AND STANDARDS
PERFORMANCE
GENERAL REQUIREMENTS AND CONSTRUCTION DETAILS
CONTROL, ALARM AND TRIP DEVICES
NOISE LEVEL
MOTOR VIBRATIONS
10
CRITICAL SPEEDS
11
PAINTING
12
TESTS AND INSPECTION
13
DRAWINGS & DATA
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PART III
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1.
SCOPE
This specification covers the design and manufacture of high voltage squirrel cage
induction motors.
CODES AND STANDARDS

Unless they are at variance with the clauses of this specification, the squirrel cage
induction motors and their components shall comply with the latest editions of the
applicable Indian Standards listed below. Where Indian Standards do not exist the
relevant IEC British or German (VDE) standards shall apply.
2.1
IS 325
Three phase induction motors
2.2
IS 1076
Preferred numbers
2.3
IS 1271
Insulating materials for electrical machinery and apparatus in

relation to their thermal stability in service, classification.
2.4
IS 2148
Flameproof enclosures of electrical apparatus
2.5
IS 2253
Types of construction and mounting of motors
2.6
IS 2968
Slide rails for electrical motors, dimensions
2.7
IS 4029
Guide for testing of three phase induction motors
2.8
IS 4691
Degree of protection provided by enclosures for rotating

2.9
IS 4722
Specification for rotating electrical machines
2.10
IS 4728
Terminal marking for rotating electrical machinery
2.11
IS 4889
Methods of determination of efficiency of rotating electrical

machines.
2.12
IS 6362
Designation of methods of cooling for rotating electrical

machines.
2.13
IS 6381
Construction and testing for electrical apparatus with type of

protection è .
2.14
IS 7389
Specification for pressurization of equipment for use in

hazardous areas.
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PART III
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2.15
IS 7816
Guide for testing insulation resistance of rotating machines.
2.16
IS 8223
Dimensions and output ratings for foot mounted rotating

electrical machines with frame sizes 355 1000.
2.17
IS 8289
Specifications for electrical equipment with type of protection `n.
2.18
IS 8789
Values of performance characteristics for three phase induction

motors.
2.19
IS 9628
Specification for three phase induction motors with type of

protection `n.
2.20
IS 12065
Permissible limits of noise level for rotating Electrical Machines
2.21
IS 12075
Mechanical Vibration of Rotating Electrical Machines.
2.22
IS 120802
Temperature rise measurement of Rotating Electrical Machines.
2.23
IS 13529
Guide on effects of unbalanced voltages on the performance of

three phase cage induction motors.
2.24
IS 13555
Guide for selection and application of three phase induction

motors for different types of driven equipments.
3.
3.1
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 data sheets.
If not specifically
mentioned therein, a design ambient temperature of 400 C and an altitude not

exceeding 1000 meters above mean seal level, shall be taken into consideration.
3.2
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 % or
c)
Any combination of (a) and (b).
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3.3
Starting
Unless otherwise specified, motors shall be designed for direct on line starting.
Motors shall be designed for re-start with full load after a momentary loss of voltage
with the possibility of application of 100 per cent of the rated voltage when the
residual voltage has dropped down to 50 % and is in phase opposition to the applied
voltage. Motors shall be designed to allow the minimum number of starts on full load
indicated in Table I below:
TABLE I
Min. Number of starts
Upto
500 to1000
Above
500 KW
KW
1000KW
No. of consecutive start-ups with

initial Temperature of the motor at
ambient Level (cold).
No. Of consecutive start-ups with
initial Temperature of the motor at
full load Operating level (hot)
Unless otherwise agreed, the locked rotor withstand time under hot condition at 100 %
voltage shall be minimum 2 seconds more than the starting time at 80 % voltage (time
et for Ex (e) motor) under specified load.
3.4
Unless otherwise stated in the data sheet, motors shall be suitable for starting at 80%
of the rated voltage against the torque speed characteristics of the driven equipment.
This shall be checked against the speed torque characteristics of the load and the
thermal withstand characteristics of the motors.
3.5
Starting torque and minimum torque of the motor shall be compatible with the speed
torque curve of the driven equipment under specified conditions. For heavy-duty
drives such as blowers, crushers, compressors etc. high starting torque motors shall be
provided. In case where characteristics of driven equipment are not available while
selecting the motor, minimum starting torque shall be 90 % of rated value.
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PART III
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3.6
The pull out torque at rated voltage shall be not less than 175 per cent 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 for 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.
3.7
Direction of rotation
Motor 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 bidirectional rotation shall be provided with a double headed arrow. Directional arrow
should be manufactured from corrosion resistant material.
Painted arrow is not
acceptable.
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.
4
PERFORMANCE
4.1
Motors shall be rated for continuous duty (S1) unless otherwise specified.
4.2
Motors shall have adequate torque to accelerate the load from zero to full speed
under starting conditions specified in the data sheets.
Unless otherwise
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PART III
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specified the starting current shall not exceed 550 % (including + ve tolerance)
of rated current.
4.3
In particular cases when the starting current must be limited, care should be
taken that the design values of torque meets the load requirement while at the
same time complying to cl. 3.3 above of this specification.
CONSTRUCTION DETAILS
5.1
Winding
a)
Insulation and Bracing

HT motors shall be provided with class F insulation, unless other wise
specified in data sheet. The permissible temperature rise, as measured
by the resistance method, above the specified ambient temperature shall
be limited to those specified in the applicable Indian Standards for class
`B insulation. The windings shall be tropicalised. The winding shall
be vacuum impregnated or suitably varnished, baked and treated with
epoxy gel for operating satisfactorily in humid and corrosive
atmospheres.
Winding shall be adequately braced to prevent any relative movement
during operating conditions.
In this respect particular attention is
drawn to the stator windings of direct on line starting squirrel cage

motors. Insulation shall be provided between coils of different phases,
which lie together.
Winding laminations must be capable of
withstanding burnout for rewind at 4000 C without damage or

loosening. 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. Windings
shall be designed to withstand a coil surge voltage of 2.4 P.U rated peak
to line voltage.
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PART III
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Motor shall be designed to withstand impulse voltages as per Table II

with 175 micro second wave front and 2500 microseconds wave tail.
TABLE II
Motor Voltage Rating
b)
Impulse Voltage (peak) phase to earth
3.3 KV
18 KV
6.6 KV
31 KV
11 KV
49 KV
Phase connections
Windings of motors shall be star connected.
5.2
Terminals, terminal boxes and cables entries

The ends of the winding shall be brought out into a terminal box. The terminations
shall be by means of bushings with adequately sized bolted terminals. Line terminals
shall be properly insulated from the frame with material resistant to tracking.
The terminal box shall be located on the right hand side viewed from the 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.
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 housed on the opposite side of main terminal box.
The main terminal box shall be of fabricated sheet steel and shall be type unless
otherwise agreed. It shall have the same fixing dimension as Neutral Terminal box so
that their positions can be interchanged if required at site.
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
150
PART III
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and without any compound filling. The terminal box shall be provided with pressure
relief flaps / devices for type è / `n / safe area motor and shall be capable of
withstanding the specified fault current for a period of 0.25 seconds.
Appropriate phase markings as per IS 325 shall be provided inside the terminal box.
The markings shall be non-removable and indelible.
An adequately sized earth terminal shall be provided for cable armor 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 to be provided across
joints on non-active parts. Separate terminal boxes shall be provided for space heaters
and resistance temperature detectors.
Terminal box covers must be provided with handles to facilitate easy removal.
5.3
Motor casing and type of enclosure

All Motors shall be suitable for installation directly outdoors and must have degree of
protection corresponding to IP 55 as per IS 4691.
Motors for use in hazardous areas (Zone 1 or zone 2) shall have type of protection Ex
(d) or Ex (e) Ex (p) or Ex (n) as specified in the data sheet and shall meet the
requirments of applicable standards.
All internal and external metallic parts that 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 avoid
corrosion by gases present in the atmosphere. Screws and bolts shall be of rust proof
material or protected against corrosion.
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PART III
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5.4
Bearing and Lubrication

Motors shall have bearings of grease lubricated ball or roller type, of the
manufacturers standard type. The bearings shall be chosen to give a minimum L 10
rating life of 5 years. (40000 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). Sleeve bearings shall be
of proven design and necessary track record shall be furnished along with the offer.
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. Motor bearings exposed to high temperatures
(e.g. motors for hot oil / boiler feed pumps) shall have adequate provisions for cooling
of bearings. Vertical motors shall be provided with thrust bearings suitable for the
load imposed by the driven equipment. Motors shall be designed to permit removing /
replacement of bearings.
5.4.1
Grease lubricated bearings

These 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.
5.4.2
Sleeve bearings with oilier rings

Sleeve type bearings shall be fitted with oilier 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. Provenness of the design of sleeve bearing along with
necessary PTR is to be furnished along with the offer.
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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.
5.4.3
Forced Lubrication bearings

In this case the oil lubrication circuit may be common with or independent of the
driven machine. In the latter case, oil supply shall be guaranteed by one of the
following systems.
a)
With a mechanical pump co-axial with the motor. When possible, this design
shall be preferred. In this case the bearings shall also be supplied with oil
wiper rings to provide adequate lubrication during the time necessary for the
motor to come to rest even when the forced lubrication is interrupted.
b)
With a mechanical pump co-axial with the motor and supplemented by a

separate motor pump for initial lubrication during start up and stopping
operations.
c)
With a separate motor driven pump. In this case the lubricating system shall
consist of two identical motor driven pumps, one acting as standby.
The lubricating system with separate motor driven pumps under (b) & (c) shall have a
proven track record and shall be supplied complete with the following:
Oil reservoir with resistance heater, if required by the type of oil or ambient
conditions.
Motor driven pumps with check valves and by-pass valves.
Heat exchanger complete with accessories. If required.
Oil filters with filtration efficiency of 10 microns.
Control devices, alarm and trips as stated under paragraph 6.4 and all other items
necessary for the correct functioning of the lubricating system.
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Control panel with accessories for operation and control of the lubricating system.
The control panel shall include fuses, electrical contractors 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 external
electrical connections between the control panel and the lubrication system.
5.4.4
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 drawing showing insulation arrangement.
5.5
Cooling System
All motors shall preferably be self ventilated. Those with higher outputs having
manufacturers standard designs using forced ventilation cooling or closed circuit
cooling employing external coolants may also be considered. For the motors the type
of cooling as per IEC 34 6 shall be furnished.
5.5.1
Self Ventilated Motors

All 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 nonsparking type.
Motor for installation in dusty atmospheres or in the presence of sand, fuels or other
solid particles in suspension in the air shall be fitted with filters for the cooling air.
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The filters shall be easily accessible for inspection and removable for cleaning and reuse. The material of the filter and supports trays shall be rust proof or protected
against oxidation or corrosion.
5.5.2
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.
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 6.3 (a)
shall also be provided.
5.5.3
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 / cm2.
The heat exchangers shall be arranged by the side(s) of the motor, if possible. Screens
shall be provided to protect the motor windings form water leaks or leakage in the
tubes. Suitable drains shall be fitted for draining water in case of leakage. The
cooling system shall include the trip and alarm devices mentioned in paragraph 6.3 (b).
Heat exchangers for identical motors shall be interchangeable.
5.5.4
Motors with closed circuit cooling with air to air heat exchangers
The heat exchanger tubes shall be of steel or extruded aluminum.
All exposed
surfaces of the heat exchanger and of the motors shall be safeguarded against
corrosion by immersion in varnish followed by banking.
Joints between the heat exchanger and the main body of the motor shall be sealed by
weatherproof gaskets.
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Filters shall be provided to prevent the ingress of dust and foreign particles. These
shall be easily accessible for cleaning and replacement.
5.6
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 value of vibration
for a motor at rated voltage and speed shall not exceed those given in IS 12075. The
shaft ends shall be provided with suitably threaded hole or holes to facilitate the
assembly or removal of couplings and bearing races.
5.7
Shaft extension
Motors shall be provided with a single, bare shaft extension with keyway and key.
Motor shaft shall be sized to withstand 10 times the rated design torque.
5.8
Lifting hook
All motors shall be provided with lifting facility (i.e. hooks etc) of adequate capacity.
5.9
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 12mm. 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 earthling of the armour.
CONTROL ALARM AND TRIP DEVICES

All electrical contacts for the devices described below shall have a current carrying
capacity not lower than 5 A and a minimum interrupting capacity of 1 A at 110 V, DC
inductive load or 5 A at 240 V AC.
Adequate number of RTDs for winding
temperatures and BTDs shall be provided. Dial type thermometer for Bearing
temperature shall be provided.
156
PART III
SECTION 3
All 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 one or more
terminal boxes, which shall be explosion, proof or completely sealed. Individual cable
boxes shall be provided for each power cable. Any external connections between the
housing containing the relay contacts and the terminal box shall be carried out in steel
conduits or effected by PVC insulated armoured cables with cable entries through
double compression type cable glands.
6.4
Lubrication Control
Motors with forced lubrication shall be provided with the following:
a)
An indicating pressure gauge fitted on the oil supply line to each bearing, for
local control or checking of the lubricating oil pressure.
b)
One or more pressure switches with make break contracts for the interlocks
required at start up and for tripping the motor.
c)
A thermostat with two electrical contacts for alarm and tripping in case of high
oil temperature.
d)
A local flow indicator on the oil discharge line.
e)
A thermostat for control of the electrical resistance heater provided for the oil.
f)
An indicating thermometer for the temperature of the oil in the tank.
7.1
Current Transformers
Unless otherwise specified motors rated 1500 KW and above shall have differential
protection and shall be equipped with current transformers suitably designed and
installation in the terminal box.
The CTs shall be supplied along with the motor and mounted in the terminal box
which shall and providing the necessary connections. CT terminals shall be brought
out to a separate auxiliary terminal box.
157
PART III
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These transformers shall have a secondary current of 1 A, unless other wise specified.
7.2
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 ÒN when the motor is not in service, and shall not cause damage to the
windings.
For motors installed in hazardous atmospheres (Zone 1 or Zone 2) such heaters shall
conform to the provisions of applicable Indian standards and temp. classification
specified in the 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 excepting that
the nickel-plated brass glands provided shall be suitable for two core 4 sq. mm.
Aluminum conductor, armoured cable.
A warning able with indelible red inscription shall be provided on the motor to
Indicate that isolation of the power line alone is not sufficient and that the heater
supply should also be isolated before carrying out any work on the motor.
7.3
Special tools and spanners

Each motor shall be provided with a set of spanners and special tools, required for
dismantling and maintenance of the motor. Triangular spanners required for explosion
proof or increased safety motors are considered as special tools.
7.4
Motor supplied shall be complete with all double compression cable glands, crimp
type cable lugs and first filling of lube oil for forced lubricated bearings.
7.5
Auxiliary motors, if any shall be as per relevant Indian / International standards and
shall be suitable for the hazardous classification as applicable.
158
PART III
SECTION 3
7.6
A nameplate as required under specification IS 325 shall be provided on each motor.

Additional name plates required for hazardous area motors shall be provided as
required by the relevant applicable standards.
NOISE LEVEL
The permissible noise level shall not exceed the stipulations laid down in IS : 12065.
MOTOR VIBRATION
Motor vibrations shall be within the limits of IS : 12075 unless otherwise specified for
the driven equipment. Motors with sleeve bearings shall be provided with proximity
probes to measure the shaft vibration adjacent and relative to the bearings.
10
CRITICAL SPEEDS
The first actual critical speed of still rotors shall not be lower than 1251 for 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.
11
PAINTING
Internal and external parts of the casing and all metal parts likely to come in contact
with the surrounding air shall be protected with anti acid paint that shall resist the
particular ambient condition. All external surfaces shall be given a coat of epoxy
based paint.
12

The vendor shall allow purchaser or his authorized representative to visit the works
during the manufacture of motors to asses the progress of the work as well as to
ascertain that only quality raw material is used for the same. He shall be given all
assistance to carry out the inspection.
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PART III
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The vendor shall give at least 4 weeks advance notice to the purchaser, regarding the
date of testing to enable him or his representative to witness the tests.
The motors shall be tested in accordance with national / international standards. Type
tests shall be carried out on one motor of each rating and frame size, unless other wise
agreed. Routine tests shall be conducted on all motors. Test reports shall be submitted
as per `Vendor Data Requirements.
12.1
Type tests
a)
General check (overall and mounting dimensions, terminal boxes, cable

entries, lubrication, free rotation of shaft and cooling system).
b)
Resistance of stator winding.
c)
No load running measurement of voltages, currents, power input and speed.
d)
Locked rotor measurement of voltages, currents, power input and torque (this
may be made at reduced voltage).
e)
Insulation resistance test before and after high voltage test.
f)
Full load measurement of voltages, currents, power inputs and slip.
g)
Efficiency at , and full load.
h)
Power factor at , and full load.
i)
Hydraulic test for coolers, if provided.
j)
Measurement of radial air gap.
k)
Measurement of radial and axial clearances between fan and stationary parts.
l)
Measurement of surface temperature of frame and space heater.
m)
Noise measurement.
n)
Vibration measurement (with half key)
o)
Temperature rise test.
p)
Over speed test
q)
Tan delta test and polarisation index test.
r)
Shaft voltage measurement.
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PART III
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12.2
Routine Test
a)
Insulation resistance test
b)
High Voltage test
c)
No load running of the motor and measurement of currents and voltages on all
three phases.
d)
Locked rotor test at suitable voltage
e)
Testing of accessories / auxiliaries for correct functioning.
f)
Vibration test
Through the motors shall be accepted on the basis of the satisfactory results of the tests
at the works, if shall not absolve the vendor from liability regarding the proper
functioning of the motor coupled to the driven equipment at site.
13
DRAWINGS AND DATA
13.1
Following minimum information shall be furnished along with the bid.

a)
KW rating make, full load speed, full load current, efficiency, power factor,
mounting, enclosure type, frame size and specific type of construction (Ex (d),
Ex (p), Ex (e), Ex (n),.
b)
Starting current, starting time, starting torque, thermal withstand times (cold
and hot) both at 80 % and 100 % rated voltage.
13.2
c)
Type test certificate with respect to area classification.
d)
Experience list for similar type of installation.
After placement of order, vendor shall furnish all data / drawings / documents
including but not limited to the following:
a)
Completed motor data sheet
b)
GA, dimension and mounting details
c)
Details of terminal box and auxiliaries
d)
Performance characteristics viz. speed v/s current and speed v/s torque.
e)
Thermal with stand curves under hot and cold conditions.
161
PART III
SECTION 3
DATA SHEET FOR HIGH VOLTAGE SQUIRREL CAGE INDUCTION MOTOR

ELECTRICAL DESIGN DATA
1. Motor Tag No.

2. Voltage/Phase/Frequency
6.6 KV, 3 Phase, 50 Hz
3. Fault level KA & Duration
40 KA for 0.25 secs
4. Type of Motor / Duty

5. Ambient temp0C/temp rise 0C
6. Cable size / type
7. Enclosure type / cooling
8. Special execution
9. Haz. Area classification Gas group / location
SCIM / Continous
40 deg C / 75 deg C
LATER
* / IP 55 / CACA/TETV/TEFC
CANOPIES TO BE PROVIDED
*
10. Reacceleration/differential protection C.Ts

11. Type of H.V TERMINAL BOX
12. Method of starting
Phase segregated
DOL
TECHNICAL PARTICULARS FROM EQUIPMENT MANUFACTURER

13. Type of driver mounting / suggested KW
14. Shaft KW/KW at max load
15. Speed / rotation of equip from coupling end
16. Starting / max. Torque required Mkg.
17. WK2 of equipment including/excluding fly whel-kgm2
18. Maximum trust/pulsation rate
19. Equipment / coupling type
20. Manufacturer
TECHNICAL PARTICULARS FROM MOTOR MANUFACTURER
21. Manufacturer
22. KW Rating / pole
23. Frame designation / mounting
FOOT
24. Full load current (A)

25. Full load speed/torque Mkg
26. Type of enclosure/cooling
27. Insulation Class
F with temp rise limited to class B
28. Starting / Pull out torque as % of full load torque

29. Full load starting current
30. Rotation viewed from non-driving end
31. Starting time at 80% and 100% voltage (sec)
162
PART III
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32. Locked rotor with stand time (cold/hot) sec

33. WK2 of motor Kg M2
34. Power factor at 100/75% load
35. Efficiency at 100/75% load
36. Space heater watts/volts
37. Terminal box type / No. of terminals
38. Type/No. of RTD, BTD and dial type thermometer
Phase segregated / six

To be provided
39. Heating / cooling time constant (min)

40. Bearing type/No. DE/NDE
41. Lubrication type
42. Weight of motor (Kg) (Motor /stator/rotor)
43. Design of fan rotation
44. Canopy required / Not required
Required
163
PART III
SECTION 3
CHAPTER 11
FOR
AIR CONDITIONING SYSTEM
164
PART III
SECTION 3
CONTENTS
A.
GENERAL
B.
REFRIGERANT COMPRESSOR
C.
REFRIGERANT CONDENSER
D.
AIR HANDLING UNITS
E.
REFRIGERATION PIPING
F.
FILTERS
G.
AIR DISTRIBUTION SYSTEMS
H.
THERMAL INSULATION FOR COLD SURFACES
I.
LOUVERS
J.
SHOP INSPECTION AND TESTS
K.
DATA SHEETS
165
PART III
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A. GENERAL
1.0 SYSTEM DESCRIPTION
1.1
Air- Conditioning System
1.1.1
Central (DX plant ) / Packaged air - conditioning system for air - conditioning the
following areas is considered.
(i)
Control Room
(j)
Rack room
(k)
Shift In-Charge room
(l)
Computer room
(m) Operator room

(n)
UPS Room
(o)
Dining Room
1.1.2 In this system, the warm air is sucked in by air handling unit blowers through return air
grilles located in false ceiling and is drawn through filters and over the direct expansion
coils where filtered air distribution ducting, diffusers and grills and the cycle is
repeated. Fresh air is supplied to the AHU rooms by provision of fans, filters and
associated accessories.
The system essentially consists of the following:
a) Two (2) nos. condensing units (1 working and 1 standby), each unit
comprising compressor, condenser, refrigerant -R-22, R - 134 a and oil,
refrigerant piping, controls, insulation and accessories and One (1) nos. air
handling units, in case of centralised AC plant. (or)
b) Three numbers of packaged units ( 2 running + 1 standby), each of 50%
capacity of the total load, each packaged unit comprising two compressors
(50% capacity), condenser, refrigerant -R-22, R - 134 a and oil, refrigerant
piping, controls, insulation and accessories. For packaged units.
c) AC drive motors for all the above equipment and isolating switches for
AHU s located near the respective AHU s in AHU room and local push
button stations for all motors.
166
PART III
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d) Electrical strip heaters with controls.

e) Humidification package with controls.
f) Air distribution system including ducting, thermal and acoustic insulation,
volume control and fire dampers, filters, grilles, diffusers and accessories.
g) Fresh air units consisting of wall cowl, bird screen, fan, fan motors,
chemical filters, pre & fine filters, ducting and damper for AHU rooms.
h) Condenser cooling water piping and AHU drain piping with insulation,
valves and specialties.
i)
Condenser cooling water shall be taken by the vendor from the nearest take
off point shown by CPCL. All related piping from the take off point to the
AC plant shall be carried out by the vendor.
j) MCC
2.0
DESIGN REQUIREMENTS
2.1
The design requirements for the air - conditioning and ventilation system shall be in
accordance with the Data Sheet of this specification.
2.2
The air conditioning and ventilation equipment and accessories shall be designed for
operation of 24 hours per day continuously. Heat load shall be calculated and
submitted for approval. The design shall include 15% additional heat load to take care
of future expansions.
2.3
The system has to maintain the specified inside design conditions.
2.4
The underside of roof of air - conditioned areas and AHU rooms to be insulated by 50mm thick fiberglass or equivalent.
2.5
Tables and forms are part of this document to indicate the desired values. However, if
the bidder desires to have different values for better design, the same shall be
submitted for approval along with design calaculations during detailed engineering
and the work has to be commenced only after the approval.
167
PART III
SECTION 3
2.5
Chemical filters to be provided for fresh air units and also outlet of all air handling
units, packaged air conditions and split air conditioners. The air quality shall be
maintained for all air-conditioned areas as follows.
H2S - < 0.01 ppm
SO2 - < 0.05 ppm
Cl2
- < 0.001 ppm
NOX - < 0.05 PPM

SPM -< 200 micro gm/m3
For the above chemical filters outside pollutants shall be considered as follows.
So2
22- 89 ugm / m3
Nox
56 133 ugm /m3
HC
4.4 5.4 PPMV
Co
H25
SPM
2.6
1-2 89 mgm/m3
21.93 ppb mgm Volume.
211to 442 mgm/m3
Air conditioning equipment shall be interlocked with gas / smoke detectors and fire
fighting system.
3.0
SHOP INSPECTION AND TEST REQUIREMENTS

Minimum shop inspection requirements for different AC and Ventilation equipment
shall be as per enclosed specifications.
4.0
GUARANTEES AND ACCEPTANCE TESTS
4. 1 Guarantee Requirements
The specified inside design conditions shall be guaranteed by the BIDDER.
All equipments supplied shall have capacities / performance not less than those
specified in different sections and Data Sheets. If BIDDER feels that a higher capacity
equipments is required to meet the specified conditions, the same has to be
substantiated by the BIDDER with supporting calculations.
4.2 Acceptance Tests at Site:
168
PART III
SECTION 3
4.2.1
After completion of the installation, VENDOR shall balance the system and make
necessary adjustments for all equipment until all guaranteed performance requirements
are satisfied. After completing the adjustments , VENDOR shall conduct acceptance
tests of the installation in the presence of PURCHASER / ENGINEERS during which
the installation shall meet the guaranteed performance requirements to the satisfaction
of PURCHASER / ENGINEER and all inside design conditions specified shall be
maintained , within the specified tolerances.
4.2.2
If the performance is not achived by the VENDOR, VENDOR shall be given the
option of making adjustments after which the tests shall be repeated at the VENDOR
s expense. The repeat test shall be carried out within the stipulated time.
4.2.3
All instrument and services required for the above tests shall be provided by
VENDOR. The test reports shall be submitted for PURCHASER s approval before
handing over the plant.
4.2.4
VENDOR shall ensure that the all instruments installed in the airconditioning and
ventilation systems as well as all instruments required for conducting acceptance tests
shall be only calibrated instruments.
4.2.5
VENDOR shall ensure that calibration of all instruments shall be carried out by any
certified laboratory having traceablitiy to national standards. VENDOR shall submit
such calibration certificates meeting the above requirements to PURCHASER /
ENGINEER for approval prior to installations / conducting of acceptance tests.
4.3
Noise and Vibrations
4.3.1
The design of air conditioning and ventilation system shall ensure maintaining of noise
levels with in 85 dBA at 1.0 m from the equipment to the other neighboring
equipments and structure.
4.3.2
Vibration isolators of proven design shall be furnished by the BIDDER for preventing
transmission of vibrations from the equipment and structure.
169
PART III
SECTION 3
5.0
EQUIPMENT TO BE SUPPLIED
Equipment to be supplied shall include, but not limited to the following :The equipment to be supplied and created under this specification are listed hereunder
and which should be in accordance with standard specifications and relevant data
sheets shall be included in the scope of BIDDER. Also, items which are not
specifically mentioned herein but which are needed to make the system / equipment
complete shall also be treated as included and the same shall also be furnished and
created, unless otherwise specifically excluded.
5. 1.1
For central AC plant :- Two (2) nos. condensing units of 100% capacity (1 working
+1 standby ) each with reciprocating refrigerant compressor working on R-22 / R134
a, AC electric motor drive, V belt drive package with belt-guard , muffler, flywheel,
shell and tube water cooled condenser, refrigerant piping with liquid line solenoid
operated valve, thermostatic expansion valve, isolating bypass arrangement, liquid
suction interchanger, pressure switches, structural steel frame work for mounting the
condensing unit with vibration isolators, first charge of refrigerant, oil and all
accessories. One (1) no. air handling unit (AHU s) of 100% capacity with AC electric
motor drive, V- belt guard drive package with belt guard, filters face and work for
mounting diffusers and grilles.
5. 1.1.1 For Packaged AC plant :- Three numbers of packaged units ( 2 running + 1 standby),
each of 50% capacity of the total load, each packaged unit comprising two
compressors (50% capacity), condenser, refrigerant -R-22, R - 134 a, AC electric
motor drive, V belt drive package with belt-guard, shell and tube water cooled
condenser, refrigerant piping, thermostatic expansion valves, pressure switches,
structural steel frame work for mounting the condensing unit with vibration isolators,
first charge of refrigerant, oil and all accessories.
5.1.2
Air Distribution system consisting of galvanized steel sheet ducting, supply air
diffusers, return air grilles, return air boxing with steel frame, acoustic insulation for
ducting and complete support and steel frame work for installing, ducting and
mounting diffusers and grilles.
170
PART III
SECTION 3
5.1.3
Fresh air filters (HDPE clearable and microvee) , chemical filters, fans, dampers,
louvers , bird screen, ducting, fixing frame and necessary supports.
5.1.4
Piping, pipe fittings, valves, strainers, specialties, necessary supports for piping and
instruments for condenser water systems.
5.1.5
Thermal insulation and acoustic lining for supply air ducting, for return air boxing,
drain line from drain pan of air handling units to floor drain refrigerant piping etc.
5.1.6
Necessary electric strip heaters with controls such as thermostat humidistat and safety
thermostats in order to maintain inside design conditions.
5.1.7
Humidification package with controls in order to maintain inside design conditions.
5.1.8
Fusible link operated fire dampers to be provided in the supply air duct and return air
wall / slab opening in order to isolate the respective AHU room from the a/c area in
the event fire.
5.1.9
Complete associated electrical equipment and electrical facilities such as MCC,

motors, local control stations, cables, earthing, lighting, etc. shall be provided as per
relevant standard specifications.
5.1.10 Start up and commissioning spares as required during startup and commissioning till
handing over the plant to the PURCHASER shall be supplied by the BIDDER and
included in the basic quoted price.
5.1.11
Recommended spares for 2 years trouble free operation shall be furnished by

BIDDER along with unit price. The price indicated by the BIDDER for recommended
spares shall not be included in the quoted price. Same shall be furnished separately.
5.1.12 Grouting of all equipment base plate / foundation bolts shall be included in VENDOR
s scope
6.
Training of Purchasers Personnel
171
PART III
SECTION 3
6.1
The VENDOR s supervisory personnel at Site shall continuously and intensively

instruct and train adequate number of PURCHASER s operating and maintenance
personal at site during erection and commissioning of the plant to enable them to take
over the proper operation and maintenance of the plant after commissioning.
6.2
Vendor shall include minimum 5 man weeks class room training for purchasers
operational and maintenance personal at site before handing over of plant.
7.
PERFORMANCE TESTS
7.1
Performance test shall be carried out in the presence of PURCHASER/

CONSULTING ENGINEER to prove the guarantee indicated by the VENDOR /
CONTRACTOR. Satisfactory operation of control interlock and sequential operation
of the control scheme shall be demonstrated at site.
7.2
All instruments and services required for the above tests shall be provided by
VENDOR. The test reports shall be submitted for PURCHASER S / CONSULTING
ENGINEER s approval before handling over the plant.
8.
PAINTING
For painting specification refer the standard specification for shop and field painting.
9.
ERECTION, TESTING AND COMMISSIONING

The VENDOR s scope of work shall include complete erection, testing and
commissioning of the airconditioning and ventilation and trail operation of the both
system. The VENDOR s supervisory personnel shall be stationed at the plant for
supervision of operation till commissioning and handling over of the air conditioning
and ventilation plants. It is responsibility of VENDOR to meet the guaranteed
performance requirements to the satisfaction of PURCHASER/ENGINEER and all
inside design conditions specified shall be maintained, with in the specified tolerances.
10.
INSTRUMENTATION & CONTROL EQUIPMENT REQUIREMENTS
172
PART III
SECTION 3
10.1
BIDDERS scope of supply of instruments shall be in line with the general flow
diagram of AC plants. The BIDDER shall prepare the flow diagram of the plant and
submit the diagram along with the technical bid. The specification of the instruments
is given in the relevant clauses.
BIDDER shall supply a hardwired, relay based control panel to perform the operation,
monitoring and annunciation of the total A/C and ventilation system. All the interlocks
shall be realised in the control panel through relays. Operator interface such as ILPB s,
annunciation windows etc,. shall be provided on the control panel.
BIDDER shall supply all instrumentation and Control cables related to the complete
system under BIDDERS scope.
(a) 1.1kV grade C&I cable from field devices upto junction box / control panel.
These cables shall include all cables required for interconnection between
BIDDER s supplied equipment.
(b) 1.1 kV grade control cable from control panel to MCC and any other control
cable application within BIDDER s package and also for signal exchange to
Purchasers DCS and also to other systems.
(c) Any special cable shall be supplied as required.
10.2
BIDDER s scope of supply shall also include the following:

i)
Erection, field calibration, testing and commissioning of all I&C equipment

included in the scope of VENDOR as per standard methods and to
PURCHASER s satisfaction.
ii) Cable schedule for all cables in VENDOR s scope.

iii) Preparation of interconnection schedule, laying and termination of all
instrument and control cables.
iv) Complete power supply distribution system.
v)
Instrument air distribution system.
vi) Any other I&C equipment not specifically indicated, but required to make the
system functionally complete, shall be supplied as required.
173
PART III
SECTION 3
10.3
The scope of services under instruments supply along with the specific requirements
are listed hereunder.
i)
BIDDER shall include all erection hardwares including impulse piping,

fittings, instrument isolation valves etc,. as required for the proper installation
of instruments.
ii) BIDDER shall supply one (1)no. 15NB size root valve for all pressure
measurement. Also ,a needle valve shall be provided near the instruments after
root valve for all pressure measurements. All instrument root valves shall be
gate valves.
iii) BIDDER shall supply impulse lines after the root valves for all pressure test
connections up to an accessible location with end connections suitable for
connecting the test instrument.
iv) BIDDER shall supply field mounted junction boxes for connecting the cables
from instruments and initiating devices., limit switches, etc., included in the
scope of the BIDDER. The junction boxes shall be suitable for outdoor
mounting and shall be weather proof. All junction boxes shall be provided with
20% spare terminals.
The incoming terminals into the junction boxes shall be from the bottom and
outgoing terminals shall be from the sides. No openings will b provided on the
top of the junction boxes. All cable connections shall be provided with glands
and all terminals shall be provided with lugs.
v)
BIDDER shall supply all local instruments within the terminal points of ACV
scope.
vi) All binary field devices viz., switches included in the scope of BIDDER shall
have two SPDT switches.
vii) All instruments to be supplied shall be tagged as per PURCHASER/
Engineers tagging procedure, as defined elsewhere in the specification.
viii) The scale graduations for all instrumentation and control equipment shall be in
SI units.
ix) The instrument tap point isolating valves (root valves) shall be located such
that they are accessible from platforms /walkways.
x)
All signaling contacts shall be of SPDT type.
xi) All local gauges dial size shall be 150mm.
174
PART III
SECTION 3
xii) Tap point/instrument isolation valves shall be of gate type and drain/vent
valves shall be provided, wherever required. Material and pressure rating of
valves, impulse piping and fittings shall be so selected to meet the design
requirements. All instruments shall be rigidly supported to provide for
vibration- free mounting. Impulse piping shall be routed and supported in a
manner to provide main line/duct/equipment movements. The tap point
isolating valves shall be mounted with stem horizontal length wise and the
impulse line gradient shall be at least 1:9.
xiii) All accessories shall be supplied, on as required basis.
10.4
Technical features of all instruments, local panel, cables, junction boxes etc., shall be
as given in the relevant clauses. BIDDER shall meet all the specified requirements.
10.5
CONTROL PANEL (CONTROL- CUM- ANNUNCIATION PANEL)
10.5.1 Power supplies, of different voltages, required for the satisfactory operation of the
system offered by the BIDDER shall be derived in the control panel using necessary
equipment. The main power supply to the control panel shall be derived from the AC
MCC.
10.5.2 The make of all the equipment used in the control panel and also the make of the panel
shall be reputed and reliable. These shall be subject to PURCHASER s approval
without commercial implications.
10.5.3 The panel shall include all the equipment required to start, stop, auto and manual
control, ON- OFF indications, interlock and annunciation of the complete A/C and
ventilation system.
10.6 CABLE SCOPE
All instrumentation and control cabling between any two equipment in BIDDERS
scope shall be supplied by BIDDER. Material of these cables shall meet the standard
specifications.
10.7 DATA / DRAWINGS TO BE ENCLOSED WITH THE BID
Deviation list for each item,
175
PART III
SECTION 3
This list shall indicate, deviations if any, from the technical details indicted in
specification data sheet.
Deviations, if any, shall be specifically listed under Scheduled of Deviations. If

no deviation is listed, it will be presumed that the BIDDER has complied with all
the clauses in specification.
P&I diagrams clearly indicating the following:

a)
All instruments with tag nos.
b)
Actuation levels for all switches Eg:- High, Low etc.
c)
Signal destination for each signal Eg: - to control panel, to MCC etc.
d)
Functionality for each signal Eg:- To Pump start interlock, to trip pumpetc.
10.8 VENDOR shall furnish the following documents for Purchasers review and approval.
i) P&I diagram as called for in the above clause.
ii) Duly filled manufacturers data sheets along with deviation lists and catalogues.
iii) PLC configuration diagram with details of PLC system.
iv) Process write up with interlocks and logic diagrams.
v) GA drawing for control panel, with Bill of Material.
vi) Panel internal wiring diagram and wiring diagrams showing interconnection details
between control panels & MCC and between control panel & field instruments /
junction boxes.
vii) Schedule of Instruments with settings. The format will be given to the VENDOR
during detailed engineering.
viii)
Instrument/Control cable schedule and interconnection schedule.
10.9 LAYOUT REQUIREMENTS

The exact routing of impulse pipes will be decided at site during erection depending
upon the location of tap points, PURCHASER reserves the right to approve the suitable
location and grouping of instruments in junction boxes.
10.10 INSTALLATION REQUIREMENTS
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The installation shall be done as per the standards. The exact routing impulse
pipes/tubes will be decided at site during erection by the VENDOR depending upon the
location of tap points.
10.11 ERECTION, TESTING & COMMISSIONNG
Erection, testing and commissioning of all the instrument specified is in VENDOR s
scope. 10% of total quantity or minimum one no. shall be supplied as essential spares.
10.12 GUARANTEES
All instruments supplied by BIDDER shall be guaranteed for proper functioning
within an accuracy called for
10.13 SPARES
The BIDDER shall include in his scope of supply the quantum of startup spares
(commissioning spares) as required and essential spares as specified. For the type of
instruments not covered in the specifications, VENDOR shall supply minimum 1 no. or
10% of total quantity whichever is higher of each type & range.
10.14 VENDOR shall furnish set points for all instruments mounted on his pipes/equipment.
10.15 Signal Exchange Between Bidders System And Purchasers System
The BIDDER shall make available the following outputs for connection to
PURCHASER s system. AC& Ventilation Plant System Trouble . Grouped contact
(NO) shall be provided for the control panel, for annunciation in PURCHASER s
system. Cabling upto Purchasers panel shall form part of vendors scope.
10.16 Power Supply And Instrument Air Supply
In case any instrument / equipment needs the same shall be arranged by the
CONTRACTOR by providing suitable power pack. PURCHASER will provide
instrument air at one point nearer to the AC plant and and further instrument air
distribution is in BIDDER s scope.
10.17 Impulse Pipes & Fittings
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Impulse pipes, fittings and signal piping shall be supplied for all the instruments under
the scope of this specification.
10.18 Selection Of Ranges For Instruments
10.19.1 The ranges of the instruments shall be selected based on the following philosophy:
a) For pressure measurement, the maximum operating pressure will be within 70 to
80% of the maximum scale range.
b) For temperature measurements, the maximum operating temperature will be
within 80 to 90% of the maximum scale range.
10.19.1The make & model of all instruments, local panel and all equipments mounted in local
panel, JB, cables , etc shall be from approved vendors list enclosed. The instruments
shall be field proven i.e. installed, commissioning and successfully operating for a
minimum period of 3 years. VENDOR shall furnish the users certificate to prove the
same during detailed engineering required by PURCHASER.
10.19.2 Any other type of I&C equipment not specified but required for the functioning of the
system, shall be included in the offer. The technical features & make of such
instruments are subject to PURCHASER s approval.
10.19.3 All the system/instruments in the BIDDER s scope shall work satisfactory taking into
account all the required interconnections.
10.20
Instruments For Performance Testing

All instruments required for performance testing to prove the guaranteed performance
of the instrumentation and Control Equipment as specified in the Section, shall be
loaned to the PURCHASER by the BIDDER, at no extra cost duration of the
Performance Test. These test instruments shall have test certificates, from reputed test
house, valid for the duration of the performance test.
10.21 The extent of supply under this contract includes all items shown in the drawings, not
withstanding the fact that such items may have been omitted from the specifications or
schedules. Similarly, the extent of supply also includes all items mentioned in the
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specifications or schedule, not withstanding the fact that such items may have been
omitted in the drawings.
10.22 SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEM
10.22.1 Specification For Field Instruments
(a) Pressure Indicators
Direct reading, pipe mounted Pressure gauges of aluminum casing (epoxy coated) with 4
and inch phenolic dial (white dial with black numerals), 316 SS Bourbon tube, AISI
304 movements and micrometer type adjustable aluminum pointer an accuracy of +0.5%
of span including accessories like, snubbers for pump discharge applications and name
plate, etc., Material of accessories will be SS. IP65 or equivalent degree of protection for
enclosure. Over range protection will be 50% above maximum pressure. Armoured
capillary of 15M shall be provided as required.
(b) Pressure Switches
Non indicating type, field mounted Pressure Switches of aluminum casing (epoxy
coated), and 316 SS element and accuracy of +1 % of span, including accessories like
syphons for steam services., snubbers for pump disscharge applications and chemical
diaphragm for corrosive and oil services, name plate& mounting brackets. Material of
accessories will be SS. Auto reset micro switch with internal adjustment for set values
with 2 SPDT contacts rated for 0.02 A at 220 V DC. IP 65 or equivalent degree of
protection for enclosure. Over range protection 50% above maximum pressure. Scale for
setting shall be provided.
(c) Thermometers
Indicating type, field system with ten (10) meters SS capillary with SS armour and six
(6) inch dial (white dial with black numerals with micrometer pointer) housed in
aluminum casing (epoxy coated) with an accuracy of +1% of span, response time for 2-4
seconds, auto temperature calibration, liner calibration over the range and SS bulb with
316 SS thermowell having a process connection of M33 x 2 thread or 150 RF flanged.
Material of accessories (name plates, mounting brackets, etc.) will be SS. IP 65 or
equivalent degree protection for enclosure. The Thermowell shall bewith Hex head bar
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stock assembly. The thermowell construction shall meet the ANSI 19.3 1994 (latest )
requirements.
(d) Thermowells
Pipe /equipment mounted temperature thermowells shall be 316 SS with a process
connection of M33x 2 thread or 150 RF flanged. Accessories like name plate, plug with
chain, etc. shall be provided. Material of accessories will be SS. Thermowell shall be
hex head of bar stock assembly. In case flanged wells are required for any specific
application, the same shall be supplied as required. The thermowell construction shall
meet the ANSI 19.3 1994 (latest) requirements.
(e) Flow indicating switch
Vane / paddle type water detector, with switched output with time delay. Pneumatically
controlled mechanical delay mechanism . 2 nos. switch contacts rated for 10A , 240
VAC, 2.5 A, 24 VDC.
(f) Junction Boxes
Wall / column mounted MS junction boxes having screwed terminal and bottom cable
entry single lockable door removable gland plated IP 54 or equivalent degree of
protection for enclosure. Separate terminal blocks shall be used for analog and digital
signals and also signals with different voltage. Shield bus, terminal size suitable for 0.5
sq. mm to 2.5 sq.mm wire, accessories like SS metal tag, clamps, bolts, nuts gaskets,
lock and key, fire proof compound for sealing.
(g) Interposing Relay (IPR)
Electro magnetic type IPR s with plug in type connections, suitable for channel / rail
mounting in cabinets : coil rating 24V DC or 110 V AC 2 set of change over contacts
rated for 0.2A 220V DC. Free wheeling diode across relay coil and self reset type status
indicator flag (electronic) shall be provided.
(h) Local Panels
Indoor / located, free standing vertical type panels with 3mm thick sheet material of
cold rold steel: antivibration pads of 15 mm thick ; fluorescent lighting; Double doors at
every 1.5 m; blower in each section with brass mesh; fire proof compound for sealing
cable entry ; fire detector for each section; space heater for each section (strip type). IP
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65 degree of protection for enclosure. Adequate support and mounting arrangement for
instruments, adequate support & clamping for wires and cables , adequate maintenance
space, annunciation windows to be located centrally.
(i) Solenoid valves
Direct operated solenoid valves with shut of class (leakage) , body rating ANSI 150
material of SS 304 plunger material of 316 SS, rated for continuous duty. IP 65
equivalent protection class for enclosure insulation class of F for the solenoid,
moulded type of coil, single/ dual coil.
(j) Wiring, Termination and Accessories
i.
Instrument wires : wires carrying 4-20 mA DC or any other low voltage or

current signals. Used for panel internal wiring, tinned copper conductor of 0.5
sq.mm. cross section with seven strand and twisted pair with 20 twists/meter.
Insulation material shall be PVC, heat resistant with flame retarding properties
with thickness not more than 0.5 mm and voltage grade will be 1100 V.
ii.
Control wires used for power supply like 110V AC , 240V AC 220V DC, +
24Vetc. Used for panel internal wiring, tinned copper conductor of 1.5 sq.mm
cross section with seven strands. Insulation material shall be PVC , heat resistant
with flame retarding properties, voltage grade will be 1100 V.
iii.
Terminal block(TB) : Screwed type, 600 grade, vertically mounted, size of 0.5
sq.mm to 1.5 sq. mm for instrument wires and 1.5 s. mm to 2.5 sq. mm for
control wires. Clearance between TBs will be 150mm and between TB and
bottom plate be 250mm, flame resistant, non- hygroscopic, de-carbonised.
Insulation between adjacent terminals or between terminals & frame work will
be 2kV RMS for 1 minute Power supply and signal TB shall be separate.
Signals shall be grouped in TBs in the same order as that in junction box so as
to provide neat cable layout and wiring. High voltage and low voltage signals
shall be provided on separate TBs which are mounted separately.
iv.
Termination details: Maximum of 2 wires shall be terminated per terminal

Wiring raceways, straps shall be flame retardant. All wiring shall be ferruled.
Wires carrying power and signals wires shall be routed in separate raceways.
Accessories like MCB, cable support, fuses, etc., shall be supplied. Cable entries
shall be cemented with fire proof compound.
(k) Annunciation System:

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Integral architecture, solid state electronics, ISA sequence ring back R-2 response time
of less than 50 milliseconds, adjustable time delay for each point. In rush current
limiter for driving circuits, plug in type PCB with gold plated contacts, LED s in
input/output modules, logic cards and power supply cards for fault indication. Design
for maximum ambient temperature of 50deg. C and relative humidity 95% system can
accept potential free NO or NC contacts, with conversion from normally open to
normally closed contacts possible at site. Contact interrogation voltage 24V DC contact
bounce protection, fuse protection, fuse failure fuse detection, power supply failure and
module failure monitoring for input modules. Translucent back it annunciation
windows mounted on control desk. Two lamps in parallel for each window. Hotter for
main supply failure, buzzer for alarm occurrence and chime for return back to normal.
Test and earth test. Replacement of cards on power on condition.
(l) Illuminated push buttons (lLBP)
i.
Rectangular, twin block per assembly, One block for START/OPEN and second
block for STOP/CLOSE operation; 2 lamps/block, one additional lamp for
discrepancy indication per assembly, 2 NO + 2NC contacts with 5A 230V AC rating ,
110 V AC/24V DC lamp rating, 3watts, series resistance for lamps, colour red/green
amber.
ii. Same single block with one lamp for forward /reverse/stop operation.
(m) Push button (PB)
Rectangler, single block, Momentary contact type with engraved inscription plates, 2
NO+ 2NC contacts with 5A , 230V AC rating, colour red/green /amber.
9.23. Spares
9.23.1 Startup spares shall be as required.
9.23.2 Essential spares shall be supplied as detailed below:
(a) For field instruments, air filter regulators, E/P converter and junction box and drive
modules a minimum of one (1) no. or 10% of the quantity each type and range, whichever
is higher . shall be provided.
(b) Control panel
10% of each type, or minimum one(1) no., whichever is higher shall be supplied for the
following
i)
Fuses of each type and rating.
ii)
MCB of each type.
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iii)
Terminals of each type.
iv)
Male & female parts of pre-fabricates Cables 6 nos. , of each type.
(c) Wiring, Termination & Accessories.

10% of each type, or minimum one(1) no., whichever is higher shall be supplied for the
following
10.0
i)
Fuses of each type and rating
ii)
Miniature circuit breaker of each type & rating.
iii)
Terminals of each type.
iv)
Space heater with thermostatic controls.
v)
Fire detectors.
vi)
Blower.
vii)
Cable clamps each type.
viii)
Male & female prefabricated cables 6 nos. each type.
ix)
Spare terminal in each terminal block in all cabinets.
x)
Spare space for counting additional terminal blocks in all cabinets.
xi)
Wiring raceways to accommodate additional 30% space of total quantity.
TERMINAL POINTS
10.1
All drain piping upto nearest drain in A/C plant room, AHU rooms, shall be
supplied and erected by VENDOR.
10.2
Condenser cooling water supply and return terminal point will be provided at
the point available nearer to the AC plant. Further piping shall be by AC
Vendor.
10.3
Purchasers MCC in the substation will be the terminal points for electrical
supply and vendor shall lay cable and take power to AC MCC and other
utilities.
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B.
REFRIGERANT COMPRESSOR
1.0 SCOPE
This specification covers the design, manufacture and testing of performance at
manufacturers works of Reciprocating Refrigerant Compressor.
2.1 The design, manufacture and performance of Reciprocating Refrigerant Compressor shall
comply with all currently applicable statutes, regulations and safety codes in the locality
where the equipment will be installed. The equipment shall also conform to the latest
applicable IS/ARI/ASHRAE standards. Nothing in this specification shall be construed to
relive Vendor of his responsibility. In particular, the equipment shall conform to the latest
editions of the following standards:
ASHRAE 15 - Safety Code for Mechanical Refrigeration.
ASHRAE 23 - Methods of Testing for Rating Positive
Displacement Refrigeration Compressors and
Condensing Units.
ANSI B 31.5 - Code for Refrigeration Piping.
ARI 575
- Standard for Method of Measuring Machinery

Sound within an Equipment Space.
ISO 1940
- Mechanical Vibration Balance Quality

requirements of Rigid Motors
3.0 DESIGN REQIREMENTS

The compressor shall be in accordance with the specification prescribed in the attached
Data Sheet. The type of accessories, controls and instrumentation shall be as indicated in
the data sheets.
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4.0
TESTS
Hydrostatic, volumetric and refrigerant leak tests shall be carried out at the
manufacturers works before the despatch of the compressor in accordance with the
applicable codes mentioned under clause 2.1.
5.0
MOTOR
The motor, included in Vendor s scope of supply, shall comply with the motor
Specification enclosed along with.
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C.
REFRIGERANT CONDENSER
1.0
SCOPE
This specification covers the design, manufacture and testing of performance at
manufacturers works of Reciprocating Refrigerant Condenser.
2.0
CODES AND STANDARDS
2.1
The design, manufacuture and performance of water cooled Refrigerant Condensers

shall comply with all currently applicable status, regulations and safety codes in the
locality where the equipment will be installed. The equipment shall also conform to
the latest applicable. IS/ARI/ASHRAE standards. Nothing in the specification shall be
construed to relive Vendor of his responsibility. In particular, the equipment shall
conform to the latest editions of the following standards:
ASME SECTION VII Boiler and Pressure Vessel Code.
ISO 10816-1
- Mechanical Vibration- Evaluation of
Machine Vibration by Measurements
on Non rotating Parts. General
Guidelines.
ASHRAE15
- Safety Code for Mechanical
Refrigeration
ASHRAE 23
- Methods of Testing for Rating
Positive Displacement Refrigerant
Compressor and Condensing Units
TEMA
Standards
of
the
Tubular
Exchanger
Manufactures Association.
3.0
DESIGN REQUIREMENTS
The condenser and accessories shall be in accordance with the specification prescribed
in the attached Data Sheet A.
4.0 TESTS
Hydrostatic tests on shell side and tube side shall be carried out at the manufacture s
works before the despatch of the condenser in accordance with the applicable codes
mentioned under Clause 2.1.
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D.
AIR HANDLING UNITS
1.0
SCOPE
This specification covers the general design, materials, construction features,
manufacture, shop inspection and testing at manufacturers works, delivery at site,
handling at site, installation, testing, commissioning and carrying out performance test
at site of Air Handling Units(AHUs)
2.0
CODES AND STANDARDS

The design, materials, manufactures, inspection, testing and performance of AHU
shall comply with all currently applicable status, regulations, codes and standards in
the locality where the equipment is to be installed. Nothing in this specification shall
be construted to relive the CONTRACTOR of this responsibility. In particular, the
AHU s shall conform to the latest edition of following standards:
IS 7613
Methods of Testing Panel Type Air Filters for AirConditioning and Ventilation Purpose.
ASHRAE 33
Methods of Testing Forced Circulation Air Cooling

and Air Heating Coils.
ARI 410
Forced Circulation Air Handling Units.
ARI 430
Central- Station Air Handling Units.
AMCA 210
Laboratory Methods of Testing Fans for Rating.
FED STD 209E
Clean Room and Work Station Requirements,

Controlled Environment
NFPA 90A
Installation of Air- conditioning and Ventilating

System.
3.0
CONSTRUCTION FEATURES
3.1
TYPE
The AHU shall be draw or below through type as specified in data sheet. The unit shall
comprise of various sections such as mixing box, pre-filters, fine filters, cooling coil,
heating coil, humidifier, fan, High Efficiency Particulate Air (HEPA) filters , etc.
3.2 CASING
Casing shall be of single skin or double skin construction as specified in data sheet A.
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3.2.1 Single Skin Construction

AHU shall be of sectional construction fabricated out of 16G Galvanised Steel Sheet
(GSS) or Cold Rolled Cold Annealed (CRCA) sheet.
3.2.2 Double Skin Construction
Double skin wall panels shall be 25 mm thick made of GSS, pressure injected with
polyurethane foam insulation of density 48 Kg/M3 and K factor not exceeding
0.02W/M0C. Double skin wall panels shall be fixed to 2.5 mm thick aluminum alloy twin
box section structural framework with stainless steel screws. Outer sheet of the panels
shall be made of 0.8 mm thick GSS pre- plasticised or powder coated. Inner sheet shall be
0.8 mm thick plain GSS.
The entire frame work shall be mounted on a 100 mm (minimum) aluminum alloy channel
base. The panels shall be sealed to the frame work by heavy duty O ring neoprene
gaskets held respective in the framed extrusion. All panels be detachable or hinged.
Hinges shall be made of die cast aluminum with stainless steel pivots. Handles shall be
made of hard nylon and be operational from both inside and outside of the unit. Units
supplied with various sections shall be suitable for on-site assembly match drilled, with
bolts, nuts and continuous neoprene rubber gaskets. All fixing and gaskets shall be
concealed.
Floor and roof panels shall be double skin type and shall be of same construction as the
wall panels shall be made of same constructions as the wall panels.
AHU s shall have hinged quick- opening insulated access door on fan and filter sections.
Access doors shall be double skin type and shall be of same construction as the wall
panels.
Four (4) fittings lugs shall be bolted to each base section for lifting or pacing the AHU in
place.
All connecting fasteners and related hardware and its accessories shall be in stainless steel.
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3.2.3 Sloping condensate drain pan shall be fabricated from 18G GSS. It shall be isolated from
bottom floor panel through 25 mm thick heavy duty Treated for Fire (TF) quality
expanded polystyrene or polystyrene foam. Drain pan shall extend beyond the coil.
3.2.4 Casing shall be of air-tight construction and sufficiently rigid to exclude vibrations,
throughout the working capacity range of the AHU.
3.3. FILTERS
3.3.1 Pre- Filter
Each unit shall be provided with a factory assembled filter section containing washable
synthetic type air filters having GSS frame. The media shall be supported with High
Density Polyethylene (HDPE) mesh on one side and aluminum on the other side. Filter
banks shall be easily accessible and designed for easy withdrawal and replacement of filter
cells. Filter bank framework shall be fully sealed and constructed from GSS. The
efficiency of the filters shall be 90% down to particle size of 20 microns as per IS 7613.
3.3.2 Fine- filter
Flanged microvee filters with HDPE filter media shall be provided. The filter frame and
filter bank frame work shall be of GSS construction with neoprene rubber gasket. The
efficiency of the filters shall be 99% down to particle size of 5 microns as per IS 7613.
Preferably, fine filters shall be located at the downstream side of fan section inside of fan
section inside the AHU.
3.3.3 HEPA filter
Flanged HEPA filters having Di- Octy1-Phthalate (DOP) test efficiency of 99.97% down
to particle size of 0.03 microns, shall be located at the downstream side of fan section
inside the AHU , HEPA filters made of sub-micron glass fibre paper shall be designed for
velocities of 1.25 meters per second. The filter frame work shall be of a aluminum and
filter shall be of GSS construction. Three (3) mm thick neoprene rubber gaskets shall be
provided to prevent any air leakage.
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3.4 COOLING COILS AND HEATING COILS

3.4.1 Cooling and heating coils shall have 12.5 to 15 mm diameter tubes of minimum 24G
thickness with sine wave aluminium fins firmly bonded to copper tubes assembled in zinc
coated steel frame or 1.5 mm thick. Face and surface areas shall be such as to ensure rated
capacity from each AHU. The coil face air velocity across the coil shall not exceed 2.54
meters per second for cooling coil and 4 meters per second for heating coil. The coil shall
be pitched in the AHU casing to ensure proper drainage. Each coil shall be factory tested
to 21 kg/cm2 (g) air pressure under water. Tube shall be mechanically expanded for
minimum thermal contact resistance with fins. Fin spacing shall be 4 to 5 fins per cm. Coil
piping shall be extended through the casing wall aproximately 150 mm and provided with
1034 kpa raised face flange connection. Incase, multiple coil sections are provided, the
coils outside the AHU. The companian flanges with gaskets, nuts and bolts shall be
provided piping connections. Pipe extenssion shall be IS 1239 heavy class. A packing
gland is required at the casing wall to provide an air tight seal around the opening. Coil
piping connection side shall be determined by final layout and arrangement.
3.4.2 Coils shall be sealed in polythene bags and packed in creates properly. Coil with damaged
fins shall not be accepted.
3. 5
HUMIDIFIER SECTION
3.5.1 Pan Humidifier

Pan humidifier shall be made of 22 gauge SS 304 tank, duly insulated with 25 mm thick
resin bonded fibre glass insulation (32 kg/m3 density) with 0.5 mm GSS cladding. The
humidifier shall be complete with stainless steel immersion heaters, safety thermostat,
float valve with stainless steel ball, sight glass, overflow and drain connections, steam
outlet nozzle and float switch. The humidifier shall be duly wired with bus bar
connections to terminate main power supply from the AHU panel. Step controller shall be
provided switching on/off heater banks in three (3) steps.
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3.5.2 Steam Humidifier

Steam humidifier shall be made of SS 304 stainless steel sparager manold a pneumatic
control valve with pilot positioner, or electricity operated motorised control valve with
humidistat , solenoid valve, steam trap, strainer and temperature switch.
All required piping shall be of carbon steel heavy class as per IS 1239. The piping shall be
extended 150mm outside the unit. The companion flanges with gaskets, nuts and bolts
shall be provided for piping connections. Packing glands shall be provided for piping
penetrating the wall panel.
3.6
FAN SECTION
3.6.1
Fans shall be double With Double Inlet (DWDI) centrifugal type. Fans shall have forward
curved or backward curved blades as specified in data sheet A. the fan speed shall not
exceed 1000 RPM and fan outlet air velocity shall not be more than 11 meters per second.
Fan casing and impeller shall be made of Galvanised steel. Fan shaft shall be made from
EN8 steel and supported in self aligning plumber block, operating at less than 75% of first
critical speed with grease lubricated bearings. Impellers and pulleys shall be individaully
tested and precision balanced statically and dynamically. Fans shall be tested for
performance at manugacturers works as per AMCA 210 and at site.
3.6.2 Motors shall drive heavy duty V- belt, constant speed, fixed pitch drive sheaves, selected
at 1.5 service factor with a minimum of two (2) grooves to prevent start-up slippage and
pre-mature belt failure. Motors shall be specifically designed for quiet operation and
motor speed shall not excced 1440 rpm. Belts shall be of oil resistant type. Belt guard
shall be provided with enough space on motor side to fit in the largest pulley for
maximum speed. Also provision shall be made for adjusting the motor side of the belt
guard in relation with the motor adjustment.
3.6.3
In case of single skin AHU, motor shall be mounted outside the casing on slide rails for
easy belt tensioning. Fan and motor shall be mounted on aluminum alloy of galvanisied
steel base frames. Isolation shall be provided from the AHU casing by combination spring
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and rubber anti-vibration mounts having a 70 to 80% vibration dampening efficiency and
flame retardant, water proof neoprene impregnated flexible connection on fan discharge.
3.6.4 In case of double skin AHU, motors shall be mounted inside the casing on slide rails for
easy belt tensioning. The entire fan and motor assembly shall be mounted on a common
deep section aluminium alloy or galavanisied steel base frame. Isolation shall be provided
from the AHU casing by combination spring and rubber antivibration mounts having a
70 to 80% vibration dampening efficiency and flame retardant, water proof neoprene
impregnated flexible connection on fan discharge.
3.7
MIXING BOX
Mixing box shall be complete with fresh and return air dampers. Mixing box shall be provided
whenever the return air is ducted back to the AHU.
3.8
DAMPERS
Dampers shall be opposed blade type. Blades shall be made of double skin airfoil extruded
aluminum sections with integral gasket and assembled within a rigid extruded aluminum alloy
frame. All linkages and supporting spindles shall be made of aluminum or nylon, turning in
Teflon bushes. In case of automatic dampers, sealed ball bearings shall be provided, in place
Teflon bushes. Manual dampers shall be provided with a bakelite knob for locking the damper
blades in position. Linkages shall be extended for motorised operation if specified in data
sheet A. damper frames shall be sectionalised to minimise blade warping. Air leakage through
dampers when in the closed position shall not exceed 1.5% of the maximum design air
volume flow rate at the maximum design air total pressure.
4.0
GENERAL
4.1
Each AHU shall be provided with manual air vent at high point in cooling and heating
coil and drain plug in bottom of the coil. Vent and drain shall be provided with 15 mm
NB gate valves. Condensate drain line size shall be 40 mm NB.
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4.2
Shop coats of paint that have become marred during shipment or erection shall be
cleaned off with mineral spirits, wire brushed and spot primed over the affected areas,
than coated with paint to match the finish over the adjoining shop painted surface.
4.3
Eliminator plates, is specified in data sheet A, shall be of aluminium alloy or PVC fill
with three (3) bends.
4.4
Blow through AHU shall have diffuser section at the downstream of fan. The diffuser
provided shall be of 18G perforated aluminum sheet having minimum 50% free area.
4.5
Ribbed neoprene rubber pads as vibration isolators shall be provided for AHU s.
4.6
Power and control cabling for fan motors and any other electric consumers inside the
AHU shall be provided and the same shall be brought outside the AHU and terminated in
junction boxes. ockable on/off push button for each motor shall be provided outside the
AHU.
4.7
Marine lights shall be provided in AHU sections for maintenance, if specified in a sheet
A. One (1) light switch shall be provided on the exterior of the AHU to control all the
fixtures. The lighting switch shall be completely pre-wired to a junction box on the top of
the AHU. Lighting wire shall be carried out with PVC insulated, 600 volts grade, 2.5
mm2 stranded copper conductor wires.
5,0
Data To Be Furnished By The Contractor After The Award Of Contract
5.1 Schedule of drawings and documents to be submitted for review, approval and information
with submission dates.
5.2 Quality Assurance Plan(QAP)
5.3 Detailed P&I diagram showing clearly the scope of supply of equipment, piping with line
sizes and material specifications, valves, specialities, instrumentation and control and all
accessories. This drawing or documents mentioned under following clauses shall include
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PART III
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all design data and information furnished in data sheets. The makes of all major
components and controls shall be indicated.
5.4 Dimensioned general arrangement drawing showing all equipment with accessories,
mounting details, nozzle locations etc.
5.5 Overall space and head room requirement with details of handling during erection,
operation and maintenance.
5.6 Foundation drawing with static and dynamic loading data, pocket details, foundation
outline, etc. for all items.
5.7 Cross- sectional drawings of all items with part list and materials of construction.
5.8 Performance curves and selection charts for fan, filters, etc. Selection charts and
calculation for cooling and heating coil.
5.9 Operation and maintenance manual with lubrication.
5.10
Catalogues furnishing detailed technical data for fan, coils, filters , etc.
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E.
REFRIGERATION PIPING
1.0 SCOPE
This specification covers the general design, materials, supply, fabrication, inspection
and testing at manufacturers works, delivery at site, handling at site, erection, testing
and commissioning of refrigeration piping system.
2.1
The design, manufacture and performance of refrigeration piping system shall comply
with all currently applicable statutes, regulations and safety codes in the locality where
the system is to be installed. The systems shall also conform to the currently applicable
Indian and international codes and standards. Nothing in this specification shall be
constructed to relieve the CONTRACTOR of this responsibility.
2.2
Following are some of the applicable codes and standards:

ANSI B 31-5
Refrigeration Piping.
ASHRAE 15
Safety Code for Mechanical Refrigeration.
ASTM A- 106
Seamless Carbon Steel Pipe for Low

Temperature Service.
ASTM A- 333
Seamless and Welded Steel Pipe for Low

Temperature Service.
IS 10773
Wrought Copper Tubes for Refrigeration

and air-conditioning
3.0
3.1
DESIGN REQUIREMENTS
SIZING OF LINES
3.1.1
Suction Lines
Suction line sizing shall be such that the total loss in pressure is
approximately equivalent to 10C drop in saturation temperature for
halogenated hydrocarbon refrigerants and not over the 0.5 0C for
ammonia. Low temperature for halogenated installations shall allow
lower pressure drop than these figures. Suction lines shall be checked
for minimum tonnage capacity of the piping for oil return to the
compressor.
195
PART III
SECTION 3
3.1.2
Discharge Lines
Discharge lines shall be sized so that the total loss in pressure is
approximately equivalent to 0.5 to 10C drop in saturation temperature.
3.1.3
Liquid Lines
Liquid lines shall be on the bases of a velocity of 0.5 m/s. Lower
velocities may be used in smaller sizes of liquid lines. Vapour
equalising lines shall be provided from top of receiver to the top of the
condenser , if 0.5 m/s is used as the design velocity for liquid line from
condenser to receiver.
3.2
DESIGN PRESSURE
3.2.1
Internal Design Pressure

a) The piping shall be designed for an internal pressure representing the most service
condition of coincident pressure and temperature expected in normal operation
including fluid head.
b) Piping shall be designed for not less than the internal pressure given in Table -1
except for limited charge system. For refrigerants not listed in Table-1 the design
pressure for higher pressure side shall not be less than the saturated vapour
pressure of refrigerant at 60 0 C and 50 0 C for air cooled and water cooled system
respectively. For low pressure side, the design pressure shall not be less than
saturated vapour pressure of the refrigerant at 32.5 0 C. For refrigerants not listed
in the Table-1 and having a critical temperature below 55 0 C, the design pressure
for the high pressure side shall not be less than 1.2 times the critical pressure and
design pressure for low pressure side shall not be less than 2kg/cm 2 (g).
Group
Number
Refrigerant
Minimum Internal Design Pressure

HP
Side HP Side LP
kg/cm2 g
kg/cm2 g
Water cooled
Air cooled
kg/cm2 g
B2
R-717
Ammonia
21
27
13
B1
R-123
Dichlro trifluoro ethane
2.5
A1
R-134a
Tetrafluro ethane
13.5
17.5
8.55
A1
R-22
Monochloro difluro methane
20
25
13
196
Side
PART III
SECTION 3
3.3
3.3.1
MATERIALS FOR PIPING

For refrigerants R-22, R-123, and R-134a seamless steel pipes to ASTM- A106 Gr. B
upto (-) 29 0 C and SA 333 of suitable grade below (-) 29 0C or copper tubes to IS
10773 shall be used. For R-717, seamless pipes to ASTM- A106 Gr. B upto (-) 29 0C
and SA 333 of suitable grade below (-) 29 0 C shall be used.
3.3.2
Fittings, flanges and pipe joints shall conform to the requirements of ANSI B31.5 Code for Refrigeration Piping.
4.0 TESTS
4.1
Test pressure for piping shall be 1.1 times of design pressure.
4.2
The pressure shall be gradually increased until a gauge pressure which is the lesser of
one-half of the test pressure or 1.75 kg/cm2 (g) is attained and preliminary leak checks
shall be carried out. Thereafter, the pressure shall gradually increased in steps until the
test pressure is reached. The pressure shall then be reduced to the design pressure and
leakage examination shall be made. The design pressure shall be maintained for 48
hours to 72 hours.
4.3
A pressure relief valve /device shall be provided on test pressure line having a set
pressure slightly above the test pressure.
4.4
Nitrogen shall be used as test medium.
4.5
Oxygen or any combustible mixture of gases shall not be used within the piping for
testing.
4.6
Water or water solutions shall not be used as test medium.
197
PART III
SECTION 3
F.
FILTERS
1.0
SCOPE
at site of Filters.
2.0
CODES AND STANDARDS

The design, materials, manufacture, inspection , testing and performance of filters
shall comply with all currently applicable statues, regulations, codes and standards in
the locality where the filters are to be installed. Nothing in this specification shall be
construed to relieve the CONTRACTOR of this responsibility. In particular, the filters
shall conform to the latest edition of following standards:
ASHRAE 52.1
Gravimetric and Dust - Spot Procedures for Testing

Air -Cleaning Devices Used in General Ventilation for
Removing Particulate Matter.
IS 7613
Methods of Testing Panel Type Air Filters for AirConditioning and Ventilation Purpose.
FED-STD-209
Clean Room and Work Station Requirements,

Controlled Environment.
3.0GENERAL REQUIREMENTS
3.1
PRE-FILTER
Pre-filter shall contain washable synthetic fiber or High Density Polyethylene (HDPE)
media having 18G Galvanised Steel Sheet(GSS) frame. The filter media shall be
supported with HDPE mesh on one side and aluminum on the other side. Filter frame
shall be provided with suitable handles. The gravimetric efficiency of the pre- filter as
per IS-7613 with test dust G3 shall be 90% down to particle size of 20 microns or as
specified in data sheet A.
3.2
FINE FILTER
198
PART III
SECTION 3
Fine filter shall contain HDPE filter media having 18G GSS frame. The filter medial
shall be supported with HDPE mesh on either side. Filter frame shall be provided with
suitable handles. The gravimetric efficiency of the fine filter as per IS 7613 with test
dust G2 shall be 99% down to particle size of 5 microns or as specified in data sheet
A.
3.3.
HIGH EFFICIENCY PARTICULATE AIR (HEPA) FILTER

HEPA filter shall contain sub-micron glass fibre paper with or without aluminum
separators having 18G aluminum frame. Filter media shall be designed for velocities
not exceeding 1.25 meters per second. Filter frame shall be provided with suitable
handles. HEPA filter shall have cold Di-Octyl- Phthalate (DOP) test efficiency of
99.97% down to particle size of 0.3 microns as per FED-STD-209.
4.0
Data To Be Furnished By The Contractor After The Award Of Contract
4.1
Schedule of drawings and documents to be submitted for review, approval and

information with submission dates.
4.2
Quality Assurance Plan(QAP)
4.3
Dimensioned general arrangement drawing showing all equipment with accessories,

mounting details, nozzle locations etc.
4.4
Selection charts with duty point marked for clean and clogged conditions.
4.5
Detailed write up and catalogues on mechanical cleaning, manual cleaning indicating

recommended frequency of cleaning.
199
PART III
SECTION 3
G.
AIR DISTRIBUTION SYSTEMS
1.0
SCOPE
at site of Air Distribution System.
2.0
CODES AND STANDARDS

The design, materials, construction feature, manufacture, inspection, testing and
performance of air distribution system shall comply with all currently applicable
statues, regulations, codes and standards in the locality where the system is to be
installed. Nothing in this specification shall be construed to relieve the
CONTRACTOR of this responsibility. In particular, the air distribution system shall
conform to the latest edition of following standards.
IS 277
Galvanisied Steel Sheet (Plain and Corrugated)
IS 655
Metal Air Ducts
IS 737
Wrought Aluminum and Aluminum Alloy Sheet and Strip

for General Engineering Purpose.
SMACNA
HVAC Duct Construction Standards - Metal and

Flexible
SMACNA
HVAC Air Duct Leakage Test Manual
SMACNA
HVAC System - Testing, Adjusting and Balancing
UL 181
Factory - Made Air Ducts and Connections.
UL 555
Fire Dampers
ASHRAEE 70
Method of Testing for Rating the Performance of Air

Outlets and Inlets.
3.0
MATERIAL REQUIREMENT
Ducting shall be fabricated from Galvanised Steel Sheet (GSS) or Aluminum (AL)
sheet or Stainless Steel(SS) sheet as specified in data sheet.
3.1
GSS duct shall be of lock forming grade, zinc coated conforming to IS 277 coating
grade 200 or better.
200
PART III
SECTION 3
3.2
AL sheets shall be of grade 31000 as per IS 737.
3.3
SS duct shall be of SS 304 as per ASTM A167.
4.0
Fabrication details shall be generally in accordance with the details given herunder.
4.1
RECTANGULAR DUCT
4.1.1 For Low Pressure System (upto static pressure of +- 75 mm WC)

LARGER
SIDE
THICKNESS
OF SHEET mm/G
DUCT mm GSS/SS
Up to 250
0.63/24
AL
0.80/22
OF TYPE OF
TRANSVERSE
TYPE
OF
RENFORCEMENT
JOINT
25x25x3mmCS
angled flanged joint
251 to 750
0.63/24
751 to 1000
1001
to
0.80/22
0.80/22
0.80/22
1.00/20
1.00/20
1500
1501
to
1.00/20
1.25/18
2100
2101
to
1.25/18
1.50/16
2400
Greater than
2401
1.25/18
1.50/16
25x25x3mmCS angled
25x25x 3mm CS angled @
flanged joint
1250 mm c/c
25x25x3mm CS angled
flanged joint
1250 mm c/c
40x40x3mm CS angle
flanged joint
750 mm c/c to 800 mm c/c
40x40x3mm CS angle
flanged joint
65x65x3mm CS angle
flanged joint
50x50x3mm CS angle
50x50x3 mm CS angle @
flanged joint
750to 800mm c/c
With tie rods of 10 mm
with tie rod(s)of 10mm
dia
diameter, evenly
spaced along reinforcing
angle, not
exceeding 1500 mm.
201
PART III
SECTION 3
4.1.2 For High Pressure System (static pressure of + 76 to + 250 mm WC)

LARGER
THICKNESS OF
SIDE OF
SHEET mm/G
DUCT mm
Upto 600
GSS/SS
0.82/22
TYPE OF
TRANSVARESE
REINFORCEMENT
40X40X3
mm
CS
flanged joint
601 to 1200
1.00/20
1.25/18
50X50X3
1.25/18
1.50/ 16
50X50X3
mm
CS
1.50/16
Greater than 1.50/16

2001
1.80/14
1.80/14
65X65X6
50x50x3 mm CS angle
@ 600 mm c/c
mm
CS
flanged joint
1501 to 2000
40x40x3 mm CS angle
@ 750 to 800 mm c/c
flanged joint
1201 to 1500
OF
JOINT
AL
1.00/20
TYPE
50x50x3 mm CS angle
@ 600 mm c/c.
mm
CS
65x65x3 mm CS angle
angle flanged joint
@ 600 mm c/c
50x50x3-mm CS angle
50x50x3 mm CS angle
flanged joint with
@600 mm c/c with tie
rod(s)
of
10
diameter.
tie
mm
rod(s) of 10-mm
diameter evenly
spaced along
reinforcing angle,
spacing not exceeding
1500 mm
4.1.3
Longitudinal seams shall be Pittsburgh lock type at corners as shown on sheet 14to 18.
Longitudinal joints shall not be provided for rectangular ducting at locations other than
corners, except where larger side larger side of duct exceeds 2500 mm. Longitudinal
joints of ducting having side larger than 2500 mm other than corner shall be grooved
or standing seam as shown on sheet 14 to 18.
If specified in data sheet , sealing of the longitudinal seams shall be accomplished
using Dow corning RTV 732 Silastic or equivalent.
4.1.4
Flanges used for transverse joints shall be joined with each other with Galvanised
Steel (GS) bolts, washer and nuts. The bolts shall be of minimum M8 size and the
202
PART III
SECTION 3
spacing between bolts shall be maximum 150mm for low pressure system and 100 mm
for high pressure system.
4.1.5
For transverse angle flanged joints, neoprene gasket (3 mm uncompressed thickness

and width equal to flange face) adhered to the flange face shall be used. The bolts
holes in gasket shall be the same as bolt diameter and shall be punched prior to
insertion of gaskets.
4.1.6
Angles shall have welded corners and shall be riveted to the ducts at 300 mm centres
(maximum).
4.1.7
For SS ducts all related appurtences such as transverse joint angles, reinforcement
angles, fasteners, turning vanes, access doors, etc., shall be of the same material as of
duct.
4.1.8
Ducts shall be fabricated using lock-forming machine.
4.2
ROUND DUCT
4.2.1 Round duct thickness in mm/G for GSS/SS shall be given below:
Upto 50 mm WC static
51 - 250 mm WC static
50 mm WC static
Duct
Pressure positive
Pressure positive
Pressure negative
Dia in mm
Spiral
Longitudinal
Spiral
Longitudinal
Spiral
Longitudinal
Seam
Seam
Seam
Seam
Seam
Seam
Upto 200
201 to 350
351 to 650
0.42/28
0.42/28
0.51/26
0.42/28
0.51/26
0.63/24
0.51/26
0.51/26
0.63/24
651 to 900
901 to 1250
0.63/24
0.80/22
0.80/22
1.00/20
0.80/22
1.00/20
0.63/24
0.63/24
0.80/22
0.42/28
0.51/26
0.63/24
0.63/24
0.63/24
0.80/22
1.00/20
1.00/20
0.80/22
1.00/20
1.00/20
1.25/18
1251 to 1500
1.00/20 1.25/18
1.25/18
1.25/18
1.25/18
1.50/16
1501 to 2100
1.25/18
1.25/18
1.50/16
1.50/16
1.80/14
1.50/16
203
PART III
SECTION 3
4.2.2 Round duct thickness in mm/G for aluminium shall be given below:
Maximum 50 mm WC static Maximum 50 mm WC static
Duct
Pressure positive
Pressure negative
Dia in mm
Spiral
Longitudinal
Spiral
Longitudinal
Seam
Seam
Seam
Seam
0.63/24
0.80/22
0.63/24
1.00/20
201 to 350
0.63/24
0.80/22
0.80/22
1.00/20
351 to 650
0.80/22
1.00/20
1.00/20
1.25/18
651 to 900
1.00/20
1.25/18
1.25/18
1.50/16
901 to 1250
1.25/18
1.50/16
1.50/16
1.80/14
1251 to 1500
1.50/16
1.50/16
2.25/12
1501 to 2100
2.25/12
Upto 200
4.2.3
Round duct shall have longitudinal or spiral seam, as specified data sheet .
Longitudinal and spiral seam shall be as shown on sheet 13 of 17.
4.2.4
If specified in data sheet , sealing of the longitudinal and spiral seams shall be
accomplished using Dow corning RTV 732 Silastic or equivalent.
4.2.5
Angle flanges shall be used for transverse joints and shall be joined shall be with each
other with GS nuts and bolts. Angle shall be minimum 25x25x3 mm for ducts size
upto 350 mm and minimum 40x40x3 mm for ducts size greater than 350 mm.
4.2.6
For transverse angle flanged joints, neoprene gasket (3 mm uncompressed thickness

and width equal to flange face) adhered to the flange face shall be used. The bolt holes
in gasket shall be the same as bolt diameter and shall be punched prior to insertion of
gaskets.
204
PART III
SECTION 3
4.2.7
For SS ducts all related appurtenances such as transverse joint angles, reniforcement
angles, fasteners, turning vans, access doors, etc., shall be of the same material as of
duct.
4.2.8
Ducts shall be fabricated using lock-forming machine.
4.3
DUCTS SUPPORTS
4.3.1
Rectangular duct shall be supported from ceiling using trapeze hangers. Ducts shall
rest on supporting angle or channel and this supporting angle or channel shall be
supported by CS rods or angles or channels on both sides of ducts with weld or bolts.
Supporting details for low pressure system shall be as given below:
LARGER SIDE OF
SUPPORTING
VERTICLA ROD
MAXIMUM
DUCT mm
ANGLE mm
DIAMETER mm
SPACING BET.
SUPPORT mm
Upto 900
40x40x6
10
3000
901to 1500
50x50x6
10
3000
1501 to 2400
50x50x6
10
2400
2401 and above
65x65x6
12
2400
Supporting details for high pressure system shall be as given below:

LARGER SIDE OF
SUPPORTING VERTICLA ROD
MAXIMUM
DUCT mm
ANGLE mm
SPACING BET.
DIAMETER mm
SUPPORT mm
Upto 1250
50x50x6
15
2400
1251 to 2100
65x65x6
15
2400
2101 and above
MC 75x6
15
2400
4.3.2 Round duct shall be supported using single or two hanger straps or rode Straps and
rods shall be of GSS.
205
PART III
SECTION 3
Supporting details for round duct shall be as given below:

STRAP
DUCT
Diameter
NOS WIDTH
ROD
THICKNESS G
NOS
Diameter mm
mm
Up to 600
25
20
601 to 900
25
20
10
901 to 1250
25
20
10
1251 to 1500
25
18
10
1501 to 2100
25
16
10
4.3.3
4.3.4
4.3.5
Zinc coated anchor fasteners or embedded plates shall be provided for upper
attachment to the building. . Anchor fasteners shall be loaded to maximum rated
capacity specified by the manufacturer. SITE ENGINEER shall approve all anchor
fasteners used for supporting duct.
In case of insulated duct, anchor fasteners shall be selected based on actual total load.
Duct supports shall be qualified and sized for seismic forces, if specified in data sheet
A.
4.4. FLEXIBLE CONNECTIONS

Where sheet metal duct connects to the intake or discharge of fan units, a flexible
connection of fire retarding double layer heavy duty canvas of at least 150 mm width
shall be provided. The material shall be attached to angle frames by means of a steel
band over the end of the flexible connection. The material shall be secured between
the band and the angle frame by bolting. Sleeve shall be made smooth and the
connecting duct work rigidly held by independent supports on both ends. The flexible
connection shall be suitable for fan intake and outlet pressures.
4.5
TRANSFORMATION
Duct transformation shall be used to change the shape of duct and shall be made for
easy and noiseless flow of air. Maximum slope of transformation shall be 1:4.
4.6
BENDS, OFFSETS AND BRANCH CONNECTIONS

All bends offsets and branch connections shall be made for smooth and noiseless flow
of air and minimum pressure drop. In case of full radius elbow optimum ratio of center
206
PART III
SECTION 3
line radius of elbow to duct dimension of 1.25 shall be considered. However, due to
space constraint shorter radius elbow or square elbow with guide vanes may be
provided. CONTRACTOR shall furnish details of guide vanes i.e. number of vanes,
location, etc., in the drawing. The flow of air to the branch duct shall be regulated by a
splitter damper or volume control damper.
4.7 SPLITTER DAMPERS AND VOLUME CONTROL DAMPERS (VCD s)

4.7.1
Splitter dampers shall be fabricated of minimum 18G GSS and shall be of robust
construction. The position of splitter damper shall be adjusted by use of the splitter
rod.
4.7.2
VCD shall be fabricated of minimum 18 G GSS and shall be of robust construction.

VCD shall be of single blade type for round duct and opposed blade type for
rectungaler duct. VCD shall have a locking device mounted outside the duct to the
hold the VCD in a fixed position without vibration. Fully open and fully closed
position shall be marked for easier operation of VCD.
4.7.3
Motor operated VCD shall be provided, if specified in data sheet A. Actuator for
dampers shall develop sufficient torque for easy operation of VCD.
4.7.4
VCD shall be provided with Teflon or brass bushing for blade shaft as specified in
data sheet A. motor operated VCD shall be provided with teflon bushing or brass
bushing or sealed ball baring for blade shaft as specified in data sheet A.
4.7.5
4.8
4.8.1
For SS duct, all splitter dampers and VCD s shall be fabricated from SS 304 sheet.
FIRE DAMPERS
All supply and return air ducts at plant room crossings and at all floor crossings shall
be provided with fire dampers of at least 90 minute fire rating, if specified in data
sheet A. These shall be multi leaf dampers.
4.8.2
Fire damper blades and outer frames shall be of 16 G GSS construction. The damber
blades shall be pivoted on both ends using chrome-plated spindles in self lubricated
bronze bushes. Stop shall be provided on top and bottom of damper housing made if
207
PART III
SECTION 3
16 G GSS. For preventing smoke leakage, side metallic compression seals shall be
provided.
4.8.3
Fire damper shall be proivided with factory fitted sleeves. Access doors shall be
provided within the duct in accordance with the manufacturers recommendation.
4.8.4 For SS duct, all fire dampers shall be fabricated from SS 304 sheet.
4.9
CAULKING AND DRAIN

Wherever duct passes through wall or slab, all the openings between masonary and
duct work shall be netaly caluked or sealed by the CONTRACTOR to prevent
movement of air from one space to the adjoining space. Where duct press through the
floor, a drain trap of 100 mm width of the duct and 50 mm depth shall be provided
with a suitable plug at the lowest point in the elbow.
4.10
ACCESS DOOR
Access door shall be provided in duct before and after equipment installed in duct and
at all fire damper locations. All access doors shall be fabricated of the same material as
the duct work and shall be zinc plated and pins shall be of brass. Access doors shall be
of minimum of 305 mm x 305 mm size. At least two heavy soild brass fasteners d
brass handle are required for each door. A continuous neoprene rubber gaskets shall be
adheard to the opening frame with adhesive.
4.11
DIFFUSERS AND GRILLES
4.11.1 The type and quantity of diffusers and grilles shall be provided, as specified in data
sheet A. CONTRACTOR shall ensure that the diffusers and grilles offered are of
reuistate capacity, throw and terminal velocity. Diffusers and grilles shall be fabricated
from CS, factory coated with rust resisitent primer or extruded aluminum section with
powder coating or SS 304, as specified in data sheet A.
Whenever VCD is provided with diffusers or grilles it shall be located within the duct
collar. Diffusers and grilles shall be of flush or stepped pattern, as specified in data
sheet A.
208
PART III
SECTION 3
4.11.2 Ceiling diffusers shall be equipped with fixed air distribution grids, removable key
operated volume control dampers and anti- smudge rings. The extruded aluminum or
SS 304 diffusers shall be provided with removable central core and concealed key
operation for volume control damper.
4.11.3 Liner diffusers shall be of extruded aluminum or SS 304 construction.
4.11.4 Slot diffuser shall be of extruded aluminum or SS 304 construction multi- slot type
with air pattern controller provided in each slot. Supply air slot diffusers shall be
provided with hit and miss VCD s in each slot.
4.11.5 Grilles with VCD shall be single acting or double acting, as specified in data sheet A.
Grilles without VCD shall have fixed blades or adjustable blades, as specified in data
sheet A.
4.12
PLENUMS
Plenums shall be fabricated of 18 G GSS for low pressure system and 16G GSS for
high pressure system. Type of reinforcement and supporting details shall be as per
cluse 4.1 and 4.3. Plenums shall be constructed to withstand 133% of rated plenum
pressure shall not exceed 10 mm per meter of width.
For SS duct, plenum shall be fabricated of the same material as the duct work.
5.0 INSULATION
5.1
ACOUSTIC INSULATION
Ducts shall be acoustically lined from inside , if specified in data sheet A. The
insulation shall be fixed to the sheet metal with cold setting adhesive compund. The
surface of insulation expossed to air flow shall be covered with fibre glass tissue and
26G perforated AL sheet having at least performation with 40% free area and
performation diameter not more than 3 mm. The AL sheet shall be neatly finished to
give a true inside surface. AL sheet shall be secured by GS bolts and nuts. The ducts
dimension shall be incresed as necessary to compensate for liner thickness to provide
net free area.
5.2
THERMAL INSULATION
Ducts shall be thermally insulated from outside, if specified in data sheet A.
209
PART III
SECTION 3
6.0 MEASUREMENTS
6.1
Measurements for ducting shall be on the basis of centre line measurements

described in following paras.
Duct work shall be measured on basis of external surface area of ducts. Duct
measurements shall be taken before the application of insulation. The external surface
area shall be calculated by measuring the perimeter comprisioning of overall width
and depth, including corner joints, in the center of each duct section, multiplying with
overall length from flange face to flange face to flange face of each duct section and
adding up areas of all duct sections.
For tapered rectangular ducts, the average width and depth shall be used to measure
permiter, whereas for tapered circular ducts, the diameter of section midway between
large and small diameters shall be adopted. The length of tapered duct section shall be
the center line distance between the flanges of the duct section.
For special pieces like bends, tees, reducers, branches and colers, mode of
measurement shall be identical to that described above using the length along the
centre line. End cover or closure shall be measured as per end duct cross sectional
area.
The quoted units rate for ducts shall include all wastage allowances, duct supports,
flanges and gaskets for joints, nuts and bolts, anchor fastensers angles, channels,
access door, spliter damper, turning vans, strightening vans, flexible connections at
equipment inlet and outlet and all other accessories shall neither be separtlly measured
nor paid for.
6.2
Special items shall be measured as given below:

6.2.1
Areas shall be calculated by measuring cross- sectional area for air flow
at discharge or caputure area excluding flanges. In case of supply air
diffusers, VCD s shall form part of unit rates quoted and shall not be
separately accounted. Frame work for diffusers shall be included in unit
rates quoted.\
6.2.2
Linear Diffusers
210
PART III
SECTION 3
Linear diffusers shall be measured by liner measurements only, not by

cross sectoinal areas and shall exclude flanges for mounting liner
diffuser. The supply air plenum for liner diffusrs shall be measured
identifical to ducting as described earlier. Frame work for slot diffusers
shall be included in unit rates quoted.
6.2.4 Fire Dampers
Fire dampers shall be measured by their cross-sectional area flanges. In
air flow. Quoted rates shall include necessary accssories and flanges for
mounting, access door etc,. No special allowance shall be payable for
extenssion of crosssection outside the air stream.
6.2.5 Grilles
Area shall be calculated by measuring width by height, excluding
flanges. Incase of supply air grilles, VCD s shall form part of unit rates
quoted and shall not be separatlly accounted. Frame work for grilles
shall be included in unit rates quoted.
6.2.6 VCD in Duct
VCD (manual or motorized) shall be measured by their cross-sectional
area perpendicular to airflow. Quoted rates shall include necessary
collars and flanges for mounting etc., No special allowance shall be
payable for extension of cross-section outside the air stream.
6.2.7 Flexible connection
Flexible Connections other than at equipment inlet and outlet shall be
measured by their cross-sectional area perpendicular to airflow. Quoted
rates shall include necessary mounting arrangement, flanges, nuts and
bolts and treated for fire requisite length of canvas cloth.
6.2.8 Kitchen Hoods
Kitchen hoods shall be measured by their cross- sectional area at the
capture point of fusems, parallel to the surface of kitchen equipment.
Quoted rates shall include grease filters, hood light, suspension
arrangement for hood, profile to direct air to ventilation ducts and
removable drip tray.
7.0 INSPECTION AND TESTING
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The ducts, branches, elbows etc. shall be inspected and the joints and connection shall be
checked before these are assembled in position. After assembly the system shall be
checked for tightness, vibration and noise.
8.0 BALANCING
8.1
The air distribution system shall be tested and balanced so that the requisite
temperature and air flow are maintained throughout the space to be air conditioned
or ventilated.
8.2 During start-up phase, CONTRACTOR shall make all arrangement for drilling or
plugging of all test opening or holes, adjustment of VCD s adjusting of fan speed
to obtain specified flows, obtaining actual motor amopere readings, and all related
functions to ensure the propre operation of all system.
8.3 Test holes for system commissioning shall be minimum 20 mm diameter to accept
a standard pitot tube of 8 mm diameter and each hole shall be fitted with in
effective removable type seal. Location of test holes shall be decided by
CONTRACTOR in consultation with PURCHASER /CONSULTANT.
8.4 All instruments required for testing and balancing of air distribution system shall
be provided by the CONTRACTOR.
8.5 Complete air balance report shall be submitted for scrutiny and approval. Four
copies of the approved balance report shall be provided with completion
documents.
8.6 Splitter damper and VCD adjustments shall be permanently marked after air
balancing is complete so that these can be restored to their correct position if
distributed at any time.
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SECTION 3
H. THERMAL INSULATION FOR COLD SURFACES

1.0
SCOPE
This specification covers the technical requirements and essential particulars for the
supply, application and finishing of the complete thermal insulation and its protective
covering for piping systems, air conditioning ducts and also equipment for fluid
temperatures between ambient and (-) 80 0C and also for dual temperatures above
ambient up to 230 0 C. unless specified otherwise in section - C and /or data sheet A,
the scope of supply of the CONTRACTOR shall include, but not be limited, to the
following items:
1.1
Insulation materials of all types as specified and required.
1.2
Finishing materials of all types including cement, protective coating, sheathing, as

specified and required.
1.3
Angle irons, clamps, lugs, etc. for supporting insulation on pipes and equipment.
1.4
Wire mesh, lacing and binding wires, bands, straps, pop rivets, screws, etc, As
required.
1.5
2.0
Any other material as may be required for making the insulation complete.
CODES AND STANDARDS
The supply and application of thermal insulation to piping system, air
conditioning ducts and equipment covered under this specification shall comply
with all currently applicable statutes, regulations and safety codes in the locality
where the thermal insulation is to be applied. The insulation materials shall also
conform to the latest editions of the codes and standards listed in data sheet A.
nothing in this specification shall be construed to relive the CONTRACTOR. Of
this responsibility.
3.0
3.1
The CONTRACTOR shall furnish all the required details of insulation materials and
also furnish curves of thermal conductivity plotted against mean temperature.
3.2
The specified insulation thickness shall not include the thickness of wire netting,
finishing cement or any other finishing or weatherproofing application.
3.3
The CONTRACTOR shall provide same insulation thickness as specified in data

sheet- A.
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3.4
The insulation material shall be kept dry at all times during transport, storage and
installation. Decking and covering tarpaulins alone are not adequate for any length of
time and shall not be allowed except in extreme emergencies and only for short period.
Stacking of insulation materials directly on ground shall not be done. No wet
insulation shall be installed. If wet insulation is present, it shall be removed and
replaced with new dry insulation. The insulation may be protected with plastic film but
shall be vented to prevent sweating.
3.5
Insulation shall be applied on piping and vessels only after successful completion of
leak test. In case insulation works starts before leak test, all mechanical and welded
joints shall be exposed till the successful completion of leak tests and shall be
insulated subsequently.
3.6
All actions shall be taken to complete the application of finishing material on exposed
surfaces covered with insulation before closing the days work. If this not practicable,
adequate precautions shall be taken to protect the insulation from weather, for example
by wrapping it with polythene sheet, roofing belt or other approved material.
3.7
In order to protect the workers from the hazards of insulation materials, suitable
protective gadgets shall be provided. Required safety precautions shall be taken during
handling and application of insulation.
3.8
Insulation shall not be applied until specific release is given by the PURCHESER /
ENGINEER.
4.0
MATERIALS
4.1
Insulation material
The insulation materials and protective coverings shall be new and fresh,
incombustible, rot proof , non - hygroscope, vermin proof, fungus proof, non
injurious to health, chemically inert, non corrosive to steel and aluminum and shall
be guaranteed to withstand continuously and without deterioration the minimum
temperature to which these shall be subjected under the specified applications. The
insulation materials and any component of the finished job shall not react chemically
singly or in combination, with water or moisture to form substances that are more
activity corrosive to applied surface than water or moisture alone.
The insulation material shall be one of the following types as indicated in data sheet A.
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TABLE 1
Sl.No
Insulation Material
Standard
Density Fluid
Thermal
kg/cm2
Temperature
Conductivity of
Range, C.
Insulation at 10 C
W/m C.
Fire retardant quality IS 4671
20
(-) 80 to 80
0.035
/ BS 5608
32
(-) 80 to 140
0.0302
BS 3927
32
(-) 80 to 130
0.0302
32
(-) 80 to 230
0.0372
85
(-) 80 to 230
0.0372
expanded polystyrene
2
Rigid
polyurethane
polysiocyanurate foam
3
Phenolic foam
4a
Lightly Resin bonded IS 8183

glass wool mattresses
4b
Resin bonded glass IS 9842

wool pipe sections.
4.2
Insulation Adhesive
The insulation adhesive shall be one of the following types:
4.2.1 Hot bitumen of grade 85/25 or 85/40 conforming to IS 702 shall be
uniformly applied at 1.5 kg/cm2 on the surface to be insulated. A
similar layer shall also be applied on the inside surface of the
insulation.
4.2.2
As an alternative to the above, CPRX compound shall be uniformly

applied at 1.5 kg/cm2 on the surface to be insulated. A similar layer
shall also be applied on the inside surface of the insulation.
4.3
Vapour Barrier
The vapor barrier shall be one of the following types
4.3.1
Hot bitumen of grade 85/25 or 85/40 conforming or CPRX compound shall be applied
at 1.5 kg/cm2 on the surface to be insulation and allowed to dry.
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4.3.2
As an alternative, 0.1-mm thick factory laminated aluminum foil with craft paper
shall be provided. All joints shall be provided with 50 mm overlap and all joints shall
be sealed with aluminum tape.
4.4
Insulation Finish
The insulation finish shall be one of the following type:
4.4.1
Sand cement plaster

a)
The finishing cement coating shall have the following properties:

(i)
A light shower of rain, failing immediately after application shall not

wash off the cement.
(ii)
At any time, one week or more after application, it shall not shatter if
struck a sharp blow with a 0.7 kg hammer. Such a blow may damage
the insulation locally but shall not cause large pieces to break away.
(iii)
When set, it shall withstand prolonged exposure to the weather without

additional protection.
(b) Indoor application

After the application of hot bitumen of CPRX compound vapor barrier, the
surface shall be wrapped with 19mm mesh 24 SWG galvanized steel wire,
batting all the joints and laced wire. The ends of all wire loops shall be firmly
twisted together with pliers, bent over and carefully pressed into the surface of
insulation.
12.5 mm-thick sand cement plaster (1:4) in two layers with water - proofing
compound shall be applied.
(c ) Outdoor application
After the application of the sand cement plaster as per procedure for indoor
application, an additional 6-mm thick water proofing compound Shailkote 30
or equivalent shall be applied in two layers.
4.4.2
Aluminium or Galvanised Steel

After the application of hot bitumen or CPRX compound barrier, reinforced plastic
(RP) tissue paper as reinforcement shall be provided.
Unless specified otherwise in data sheet A, the thickness of aluminum or galvanized
steel shall be as follows:
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PART III
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(a)
Pipes, of 450 mm and above over outside diameter of insulation.
(b)
1.219 mm (18 SWG) for aluminum
0.914 mm (20 SWG) for galvanized steel.
Pipes 150 mm and above over outside diameter of insulation but less than 450
mm.
-
0.914 mm (20 SWG) for aluminum.
(c) Pipes, less than 150 mm over outside diameter of insulation.

-
0.559 mm ( 24 SWG) for galvanized steel.
d) Air Conditioning Ducts

-
1.219 mm (18 SWG) for aluminum.
E) Equipment
- 0.914 mm (20 SWG) for galvanized steel.
4.5
Miscellaneous Materials
4.5.1 Binding and Lacing Wire

Binding or lacing wire shall be 24 SWG galvanized steel wire.
4.5.2
Straps and Bands

All straps and bands shall be of galvanized steel. For searing aluminum sheathing
material, stainless steel or anodized aluminum bands shall be used. Bands shall be
20mm wide x 0.6 mm (24SWG) thick.
4.5.3 Screws
Screws shall be of self trapping type and shall be of galvanized materials.
4.5.4 Pop Rivets
Pop rivets shall be of aluminum / galvanised steel.
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5.0 APPLICATION
5.1
5.1.1
General
The application of the insulation materials shall be made in a professional manner. The
insulation shall be applied to all surfaces when these are at ambient temperature.
Ample provision shall be made for the maximum possible thermal movement and the
insulation shall be applied in a manner that will avoid breaking or telescoping due to
alternate periods of expansion and contraction.
5.1.2
All surfaces to be insulated shall be clean and dry before the insulation is applied. The
surfaces shall be cleaned of all foreign material such as scale, dirt, rust and paint, by
the use of steel wire burchess and steel scrapers, where necessary. One coat of primary
paint shall be applied and allowed to dry before application of insulation.
5.1.3
After cleaning and application of one coat of primary paint on the surface to be
insulated, the insulation adhesive shall be applied for fluid temperatures between 20
0C. Insulation material of required thickness shall be stuck to the surface with joints
staggered. The adjoining sections shall be tightly pressed together. All the joints shall
be sealed with adhesive material. Voids, if any, shall be sealed with adhesive material.
Vapour barrier and insulation finish shall be applied as per clause nos. 4.3. And 4.4
respectively.
5.1.4
For fluid temperatures below (-) 21 0C insulation shall be applied directly over the
surface to be insulated without applying the insulation adhesive. Vapor barrier shall be
applied over the insulation material. Vapor barrier and insulation finish shall be
applied as per clause nos. 4.3 and 4.4 respectively.
5.1.5
Where multilayer insulation is provided, insulation adhesive shall be used between

two layers.
5.1.6
If aluminum or galvanized steel sheathing is specified, all joints shall be sealed with
bitumastic paint and made effectively weather and water proof. All fat surfaces shall
be adequately sloped to prevent pools of water collecting. The sheathing shall be
protected internally with 2 coats of bitumastic paint.
5.2
Pipes, Pipe fittings, Valves and specialties
5.2.1
All pipe fittings, valves and specialties shall be covered with the same type and
thickness of insulation as specified for the adjoining pipe. In case of aluminum or
galvanised steel finish for pipes, all valves and flanges shall be completely insulated
with removable type of boxes fabricated from aluminum or galvanised steel sheets of
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PART III
SECTION 3
same thickness as used on adjoining pipes. Pipe insulation on adjoining flanges shall
be stopped at one bolt length plus 25 mm before flange to permit removal of the bolts
and nuts. The insulation shall be applied after the finish has been applied over
insulation on the adjacent piping.
5.2.2
The aluminum or galvanised steel sheathing shall be installed with the longitudinal lap
joints at 45 0 C below the horizontal for horizontal pipes.
5.2.3
All vertical pipes shall be provided with suitable insulation supports to prevent the
insulation form collapsing due to its weight.. Any welding required shall be carried out
by the CONTRACTOR with the prior permission of the PURCHASER/ENGINEER
and only under his direct supervision. Where welding is not permitted, suitable
clamped supports shall be used. The insulation shall be applied starting from bottom to
top. Flexible insulation shall be clamped from top.
5.2.4
On vertical pipes the aluminum or galvanzied steel sheathing shall be applied working
from bottom to top. Each section of sheathing shall have a minimum overlap of 50 mm
longitudinally and circumferentially. Each aluminum or galvanised steel strap and
sealing with bitumastic paint. Longitudinal lap joints shall be fixed with galvanised
steel screws or poprivets on approximately
150-mm centers.
5.2.5
Nozzles and other connections on tanks and other equipment shall be insulated in the
same manner as the pipes.
5.2.6
Valves shall be insulated up to and including their bonnet flange.
5.2.7
On fittings insulation outside diameter of adjecent pipe insulation.
5.2.8
Insulation of pipe outside diameter clamps shall be as per good engineering practice.
5.2.9
Pipe hoods shall be provided for insulated piping passing through floors and walls.
5.3
Equipment
5.3.1
If aluminum or galvanised steel sheathing is specified it shall be applied in a manner

similar to that specified for piping. All vertical and horizontal sheets shall be
overlapped a minimum of 75 mm. The longitudinal lapped joints of adjoining sections
of sheets shall be secured with galvanised steel screws. On all vessels over 2.5 meter
diameter, the shealthing
shall be further secured by circumferential bends at
approximately one meter centres. Each sheet joint shall be sealed with bitumastic
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PART III
SECTION 3
paint. The roof sections shall overlap the side walls to prevent water seepage between
insulation and the
vessel wall. Side wall sheets shall be securely banded at
intersections of the side wall and roof sections.

5.3.2
All equipment and vessel manholes, hatches, bolted or screwed cover plates, flanged
ends, etc. shall have removable box type insulation, with same thickness of insulation
as for adjacent surfaces. Insulation adjoining such equipment or vessel openings shall
be tapered towards these openings to permit removal of bolts, screws, heads, covers or
plates with no damage to adjacent surface insulation or cover.
5.3.3
Name plates on vessels and equipment shall not be insulated.
5.4 Pumps
Pump casing shall be completely insulated with removable type of boxes fabricated
from aluminum or galvanised steel sheets and specified thickness of insulation. Proper
care shall be taken to maintain continually of vapour barrier between static and
removable portion of insulation.
5.5Contraction joints in insulation
Depending on the type of insulation material used and the operating temperature,
contraction joints shall be provided for vessels or pipes to prevent rupturing or bucking
when the cold surface contracts.
6.0
DUAL TEMPERATUERE INSULATION

For dual temperature application, the resin bonded glass wool thermal insulation shall
be provided. The higher of the hot or cold insulation thickness shall be used. The
insulation application procedure shall be same as that for cold surfaces.
7.0
MEASUREMENTS
7.1
Measurements of insulation over tanks, columns, vessels, equipment and piping,

shall be as per IS 14164
7.2
Measurement over airconditioning ducts shall be taken over finished insulation
surface and 5% additional area shall be considered to account for reinforcement
and flanged angle joints.
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PART III
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8.0
MISCELLANEOUS
Approval of the PURCHASER/ENGINEER shall be obtained of samples of all
insulating and shealthing materials and necessary test certificates of approved national
laboratories, before despatching these materials to site. Insulation shall not be applied
until specific release is given by the PURCHASER/ENGINEER.
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PART III
SECTION 3
H.
LOUVERS
1.0
SCOPE
at site of louvers required for fresh air intake and exhaust air outlets for air
conditioning and ventilation systems.
2.0.
CODES AND STANDARDS

The design, materials, manufacture, inspection, testing and performance of louvers
shall comply with all currently applicable statuses, regulations, codes and standards in
the locality where the louvers are to be installed. Nothing in this specification shall be
construed to relieve the CONTRACTOR of this responsibility. In particular, the
louvers shall conform to the latest edition of following standards:
AMCA 500 Test Methods for Louvers, Dampers and Shutters
3.0
3.1
The louvers shall consists of parallel metallic blades. The louvers shall be provided
with fixed type blades or adjustable opening type blades as specified in data sheet A.
3.2
The width and angle of blades shall be such as to minimize the entry of water and
snow inside. The minimum projected width of blades in horizontal plane shall be 150
mm with blades inclined at minimum 35 degrees. The blades shall be overlapping each
other with maximum 30-mm height in vertical plane between two blades. Blades shall
be bent back at edges and ridged to provide stiffness and prevent water from travelling
up. In case width is more, mullions shall be provided to restrict width to less than 1000
mm.
3.3.
For adjustable type louvers, mechanism of blade angle adjustment shall be designed in
such a manner that maximum effort required shall not exceed 20 Kgf.
3.4
The blade linkage rod shall be of cold rolled steel and minimum 8-mm diameter. The
number of blade linkage rod shall be one (1) for every 1000-mm width of louvers or
part there of.
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PART III
SECTION 3
3.5
The louvers shall be located at a minimum 350 mm height above the ground or roof
level to minimize the pick up of dust and the probability of snow piling up and
subsequently entering the louvers during winter operation. The louvers shall be located
in such a manner that cross contamination from other exhaust does not occur.
3.6
Bird screen of 10mm2 and minimum 16 G wire mesh shall be provided on outer face
of louvers, wherever the louvers are exposed to atmosphere.
3.7
The frame of louver shall have a sill extension of 50mm to provide drip ledge so that
rain water drains outside.
3.8 The frame of louver shall have suitable framework for installation of filter and damper, if
specified in data sheet A.
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PART III
SECTION 3
I.
SHOP INSPECTION AND TESTS
1.0
GENERAL
1.1
The following terms used in this specification shall also mean to cover other terms as
shown below:
OWNER OWNER / PURCHESER / USER
CONSULTANT CONSTULTANT / ENGINEER / INSPECTION AGENCY
VENDOR- VENDOR / CONTRACTOR / FABRICATOR / SUPPLIER
SUB VENDOR SUB- VENDOR / SUB SUPPLIER and all such agencies
1.2
The plant and Equipment covered by this Contract shall be subjected to inspection and
testing. The VENDOR shall provide all services to establish and maintain quality of
workmanship in his Works and that of his SUB- VENDORS to ensure the mechanical
accuracy of components, compliance with drawings, identification and acceptability of
all materials, parts and Equipment.
1.3
For supply of systems, VENDOR shall, at the start of the Contract, furnish a total list
of items in their scope of work. This list, giving a brief description of the item,
quantity, names of probable SUB VENDORS, and a blank column for agency for
final approval by drawings/ data sheets, shall be submitted for approval by OWNER
/CONSULTANT. (The blank column shall be filled by CONSULTANT.) The list
shall be submitted within two weeks from the date of LOI.
1.4
For systems and major items such as pressure/load bearings items, machineries etc.,
the VENDOR shall furnish quality plan giving details of checks/ tests to be conducted
by them on material, process, sub- assembly. These shall include requirements as
prescribed in the applicable specifications, codes and statutory requirements. The
quality plan shall be reviewed by the OWNER / CONSULTANT and the stages to be
witnessed and verified shall be indicated by the OWNER/ CONSULTANT in the
quality plan and approved.
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PART III
SECTION 3
1.5
The VENDOR shall give the CONSULTANT written notice of any material being
ready for testing as per format enclosed. The clear notice period shall be seven (7)
days for local inspection. Such tests shall be to the (15) days for outstation inspection.
Such tests shall be to the VENDORS account except for the expenses of the
CONSULTANT. The CONSULTANT, unless the inspection of the tests virtually
waived, shall fix a date for inspection with the VENDOR and attend such tests within
fifteen (15) days of the data on which the Equipment is notified as being ready for
tests / inspection failing which, the VENDOR may proceed with the tests and shall
forthwith forward to the CONSULTANT duly certified copies of tests in triplicate. If
the VENDOR fails to offer the Equipment for inspection as per the agreed date, he is
liable to pay for the time and expenses for the anfractuous visit of the
CONSULTANT.
1.6
In all cases where inspection and tests are required whether at the premises or Works
of the VENDOR or of any SUB- VENDOR or at laboratory, the VENDOR, except
where otherwise specified, shall provide free of charge all facilities such as labor,
materials, electricity, fuel, water, stores, test bed, apparatus and instruments,
laboratory tests etc. as may be required by the CONSULTANT or his authorized
representative to carry out effectively such tests of the Equipment in accordance with
the Contract and shall give facilities to the CONSULTANT or to his authorized
representative to accomplish testing.
1.7
The OWNER or the CONSULTANT shall at all working hours have access to all
parts of the items of the Plant are being prepared, for carrying out inspection activities
as deemed necessary. A set of the relevant latest approved drawings with approval
,making of the CONSULTANT and drawings for proprietary items shall be made
available by the VENDOR to the OWNER or the CONSULTANT, for reference
during inspection.
1.8
In the case of stage inspection hold points, the VENDOR shall proceed from one stage
to another only after the component is inspected by the OWNER or his representative
and written permission given to proceed further. The same procedure shall be adopted
for any rectifications / repairs suggested by the OWNER or the CONSULTANT.
1.9
The OWNER or the CONSULTANT shall have the right to inspect any machinery,
material, structures, Equipment or workmanship furnished or used by the VENDOR
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PART III
SECTION 3
and may reject any which is defective or unsuitable for the use and purpose intended,
or which is not in accordance with the intent of the Contract. The VENDOR, upon
demand by the OWNER or the CONSULTANT, shall remedy or replace at the
VENDORS expense such defective or unsuitable items of the Plant, or the OWNER or
the CONSULTANT may, at the expense of the VENDOR, remedy or replace such
defective or unsuitable items of the plant.
1.10
All principle mill test reports, vendor inspection/tests reports, test certificates and test
curves shall be supplied for all inspection / tests carried out including other records
such as stress relieving charts, radiographic charts and other non destructive testing
records in accordance with the provisions of the Contract, duly certified by the main
VENDOR. The OWNER or the CONSULTANT shall reserve the right to call for
certificates of origin and test certificate for all raw material and Equipment at any
stage of manufacture.
1.11
The CONSULTANT shall within fifteen (15) days from the date of inspection as
defined herein give notice in writing to the VENDOR of any non- conformance
pertaining to all or any Equipment and workmanship which in his opinion accordance
with the Contract. The VENDOR shall give due consideration to such objections and
shall either make the modifications that may be necessary to meet the said objections
or shall confirm in writing to the CONSULTANT giving reasons therein that no
modifications are necessary to comply with the Contract
1.12
When the factory tests and documentation have been satisfactorily completed at the
VENDORS or SUB- VENDORS Works, the CONSULTANT shall issue acceptance
note/certificate to this effect within fifteen (15) days after completion, but if the tests
are not witnessed by the CONSULTANT, the certificate or comments thereof shall be
issued within fifteen (15) days of the receipt of the VENDORS test certificate by the
CONSULTANT to take such an action shall not prevent the VENDOR from
proceeding with the work. The completion of these tests or the issue of the certificates
shall not bind the OWNER to accept the Equipment should it, on further tests after
erection, be found not to comply with the Contract.
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PART III
SECTION 3
1.13
None of the plant and the Equipment to be furnished or used in connection with the
Contract shall be dispatched until shop inspection, satisfactory to the OWNER or the
CONSULTANT has been made. However, such shop inspection and /or certification
shall not relive the VENDOR of his responsibility for furnishing the Plant and the
Equipment conforming to the requirements of the Contract nor prejudice any claim,
right or privilege which the OWNER or the CONSULTANT may have because of the
use of defective or unsatisfactory items. Should the OWNER or the CONSULTANT
waive the right to inspect any item, such waiver shall not relive the VENDOR in any
way from his obligation under the Contract. In the event of the OWNER or the
CONSULTANTS inspection revealing poor quality of goods, the OWNER or the
CONSULTANT shall be at liberty to specify additional inspection procedures, it
required, ascertaining the VENDORS compliance with the Equipment Specifications.
2.0
SUB ORDERS
2.1
In order to facilitate the inspection of bought- out materials and Plant, the VENDOR
shall submit for approval, three (3) copies of all sub orders placed by him as soon as
they are issued. Copies of any drawings referred to in the sub order shall also be
submitted, unless otherwise agreed by the OWNER or the CONSULTANT.
2.2
The sub orders and drawings referred to above shall include all components which
are subjected to electrical and mechanical pressure or stress when the Plant is in
operation, and also auxiliaries and spares which are to be directly despatched to Site
from the SUB VENDORS Works.
2.3
All sub orders of the main VENDOR and SUB- VENDORS shall clearly be marked
with the main VENDORS name and the OWNERS name and Contract reference.
They shall include the following statement:
The Plant or the Equipment which is the subject of this order shall comply in every respect
with the requirements of the CONSULTANTS technical specifications and shall be
subject to inspection and tests to the satisfaction of the CONSULTANT and
ourselves.
2.4
For the purpose of this clause, inter works orders shall also be treated as sub orders.
It is obligatory on the VENDOR that he advise his SUB VENDOR of the pertinent
clauses in this specifications when ordering bought out Plant , Equipment of
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PART III
SECTION 3
materials. In particular, the VENDOR shall advise every SUB VENDOR that he is
required to supply design calculations, drawings, inspection reports and test certificate
strictly in accordance with this Specification and technical information for inclusion in
the Instrumentation Manual as specified in Section E. The SUB VENDOR should
also be reminded that they shall include with their offer all tools and appliances
necessary for proper maintenance and all spare parts in accordance With Selection E
of the Specification. Itemized prices of the recommended spare parts shall be
submitted together with the appropriate spare parts shall be submitted together with
the appropriate part numbers and drawings.
2.5
Sub- ordering / sub contracting for major items such as pressure / load bearing items,
machineries etc. can be done only with approval of the
OWNER.
3.0 MATERIAL TESTS

3.1
In the event of the OWNER or the CONSULTANT being supplied with the certified
particulars of tests which have been carried out for the VENDOR by the supplier of
material, the OWNER or the CONSULTANT may, at his own discretion, accept the
same as proper evidence of compliance with the requirements of appropriate
specifications for the materials.
3.2
The VENDOR is to provide test pieces as required by the CONSULTANT to enable

him to determine the quality of material supplied under the Contract. If any test piece
fails to comply with requirements, the CONSULTANT may reject the entire lot of
material represented by the test piece.
3.3
Critical materials used in manufacture of the Equipment and construction of the Plant
covered by the Contract may also be subjected to one or more of the non
destructive tests (NDT) as called for in the Specification or as mutually agreed.
Salvaging of material due to unacceptable defect is to be attempted by the VENDOR
only after getting specific concurrence from the OWNER or the CONSULTANT and
according to the approved procedures.
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PART III
SECTION 3
4.0
WELDING
4.1
All welding involved in construction and fabrication of the Plant and items covered
under the Contract shall be carried out in accordance with procurement specifications
and applicable codes.
4.2
Welding procedures and welders qualifications shall be approved by the

CONSULTANT. Where applicable, welders shall be tested as detailed in codes
specified for pipe welding and appropriate parent metal to be used on the job. The
CONSULTANT shall have the right to any time during the Contract.
4.3
Recommendation of applicable codes shall be followed for non- destructive tests,

wherever applicable.
4.4
Copies of all welding procedures, procedure qualification records, welders

performance qualification certificates, post heating / stress relieving records, NDT
records and other test results shall be made available upon the CONSULTANT.
5.0 FABRICATION/INSPECTION
Fabrication / Inspection procedures for vessels, heat exchangers, pipes, tubes, valves,
etc. shall be in accordance with procurement specifications, applicable codes or any
other approved equal.
6.0 TESTS AT MANUFACTURERS WORKS
6.1 General
The tests at works shall include electrical, mechanical and hydraulic tests in
accordance with the appropriate clauses of Statutory Regulation, relevant codes and
standards and approved drawings/specifications and in addition any test called for by
the OWNER or the CONSULTANT to ensure that the Plant being supplied fulfils the
requirements of the Specifications. The VENDOR shall carry out all the shop tests and
inspections specified under individual items of the Equipment in Section -D, in
addition to those normally required as per codes / standards. For items not covered by
any code or specifically mentioned in the Specifications, the tests are to be agreed with
by the CONSULTANT. If considered necessary by the OWNER or the
CONSULTANT, multiparty assembles shall be fully erected and tested in the works
prior to packing and dispatch to the Site.
229
PART III
SECTION 3
6.2 Test Certificates

Test certificates including test records, performance curves and balancing certificates
shall be supplied according to the Distribution Schedule. All the tests shall be carried
out in accordance with the provisions of the Contract.
All test certificates must be endorsed with sufficient information to identify the
material or the Equipment to which the certificates refer, and must carry at the top
right hand corner the identification of the OWNER and the Contract.
6.3 Calibration
All instruments used for critical measurement such as pressure gauges for leak tests,
instruments for measuring performance parameters, instrument for precision
dimension measurements shall have valid calibration certificates traceable to national
standards. This means that the calibrating agency engaged by the VENDOR shall use
instruments which are in turn calibrated by Government approved agencies and such
an information shall be recorded in the calibration certificates number, date and date of
validity of the certificate given by the Government approved agency.
230
PART III
SECTION 3
K. DATA SHEETS
231
PART III
SECTION 3
A .1 GENERAL
SYSTEM DESIGN DATA :OUTSIDE DESIGN CONDITIONS
DBT
WBT
SUMMER
42 deg C
29.7 deg C
MONSOON
28.3 deg C
26.7 deg C
WINTER
18.3 deg C
13.9 deg C
INSIDE DESIGN CONDITION

DBT
23 +/- 1 deg C
RH
50 +/- 5%
TYPE OF FALSE CEILING
GYPSUM BOARD
DURATION OF OPERATION
CONTINUOUS
FRESH AIR
ONE AIR CHANGE PER HOUR
REMARKS
1. INSIDE CONDITIONS TO BE GUARANTEED BY THE BIDDER.
2. ALL A/C ROOF AREAS INSULATED ON UNDER SIDE BY 50MM THICK
INSULATION BY PURCHASER AND ALSO ROOF OF AHU / PAC ROOM
INSULATED ON UNDERSIDE BY PURCHASER.
2. BIDDER TO FURNISH SUMMER, MONSOON AND WINTER LOAD.
232
PART III
SECTION 3
A.2 DATA TO BE FURNISHED ALONG WITH THE BID :BIDDER Shall furnish the complete information called for in the Data Sheets, failing which
the Bid will be considered as incomplete and the Purchases reserves the right to reject the bid.
BIDDER shall submit complete cooling load calculations for summer, monsoon and winter
for all the air-conditioned areas in support of the equipment capacities offered by him.
Drawings indicating overall dimensions and weights of condensing unit, AHU, etc and their
mounting arrangements.
Schedule of submission of major drawings by the Vendor after the contract. If any additional
drawings are demanded by Purchaser other than envisaged by the vendor, the same shall be
provided by the vendor within stipulated time.
233
PART III
SECTION 3
B.1
REFRIGERANT RECIPROCATING COMPRESSOR

DATA SHEET A
GENERAL DATA
Service
: Air Conditioning of control

Room Area.
Number
Required : *
Refrigerant
Used
: R22/R134a
Drive
: V- Belt / Direct
Capacity
Control : Auto
Start
: All Cylinders Unloaded
Type
: Open
Stand By
: One Number
Minimum
Capacity
Lubrication
Auto Capacity
Control
Restart (After
Tripping
Restart On
LP Trip
: *
:
: Built In
: Manual
: Auto
ACCESSORIES REQUIRED
High & Low
Oil Failure
Pressure Cut Outs
: Yes
Switch
Relief Valve
: Yes
High Side Pressure

Gauge
Low Side Pressure
Yes
: Yes
Lube Oil Pressure
Gauge
: Yes
Control oil Pressure
Gauge
: Yes
Suction & Discharge
Gauge
: Yes
Stop Valves
Muffler
: Yes
Crank Case Heaters :
Yes
Oil Level Indicator
Yes
Oil Separator
Oil Filter
:
:
Yes
Yes
: Yes
:
Safety Guard For

V- Belt Drive
: Yes
The accessories mentioned above, not applicable to packaged units may be omitted in case
packaged AC unit is provided.
234
PART III
SECTION 3
MOUNTING DETAILS
Gauges And Cut outs
On / In wall mounted sheet metal panel / On compressor panel

Mounted on each unit.
Vibration Isolators
: Steel Springs / Neoprene pads
Motor On Slide Base
: Yes
Compressor Motor
On A Steel Frame
: Yes
1. Each condensing unit assembly ( consisting of compressor and condensor ) to be

mounted on steel frame work and mounted on neoprene rubber pads or springs.
2. The Capacity of compressor shall correspond to saturated suction and discharge
temperature of 2 C & 42 C ( Approx.)
3. Compressor is a part of the condensing unit.
235
PART III
SECTION 3
B.2
REFRIGERANT RECIPROCATING COMPRESSORS
GENERAL
Overall space requirement of compressor and motor
(including space required for servicing)
Total weight of compressor alone
Kg
Total weight of compressor and motor
Kg
Vendor shall furnish performance curve / rating charts of

The compressor offered
mm x
mm
DRAWINGS & INSTRUCTION MANUALS

Equipment drawing complete with accessories and
mounting details including electrical terminal location
Foundation details with static and dynamic loads
Instruction manual for installation, operation, service

and maintenance.
CONSTRUCTION
Number of Cylinders
Bore x stroke of cylinder
Arrangement of Cylinders
Swept volume at operating speed
cm3
Piston speed at operating speed
m/sec.
Clearance
mm
Volumetric efficiency
Details of capacity control furnished
Yes / No
Details of Lubrication furnished
Overall size of Muffler / Oil separator
mm x
mm
Yes / No
mm
236
PART III
SECTION 3
No. of crank case heaters
Capacity of each crank case Heaters
Cooling of Cylinder head / side covers
Cooling water quantity
LPM
Cooling water entering and leaving temperature
Cooling water pressure drop
Kg / Cm2
Cooling water connection size

Type of valves
mm
Make & type of bearings used
MATERIALS
Compressor body
Cylinder
Cylinder liners
Pistons
Piston rings
Piston rods
Crank Shaft
Valve plates
Valve seats
Valve springs
Gaskets
REFRIGERANT AND OIL

First charge of refrigerant provided
(for the whole system)
Make and grade of oil used
:
:
237
PART III
SECTION 3
First charge of oil
DRIVE
Pitch circle diameter of motor pulley
Pitch circle diameter of compressor pulley
Make, section and size of V Belts used
Is safety guard furnished
Yes / No
INSTRUMENTS
Make & range of pressure guages for
Suction
Discharge
Oil
Pressure setting of relief valve

(g)
Kg / Cm2
TEST PRESSURES
Test pressure of compressor body
Kg / Cm2 (g)
Field test pressure ( of system )
Kg / Cm2 (g)
High side
Kg / Cm2 (g)
Low side
Kg / Cm2 (g)
Test certificate for hydrostatic volumetric and refrigerant

Leak tests
238
PART III
SECTION 3
C.1
WATER COOLED REFRIGERANT CONDENSERS

DATA SHEET A.
GENERAL DATA
SERVICE
: AIR CONDITIONING OF CONTROL ROOM AREA.
TYPE
: SHELL & TUBE
NUMBER REQUIRED
:*
REFRIGERANT USED
: R22 / R134 a
CAPACITY (EACH)
: *
DESIGN DATA
SHELL SIDE DESIGN PRESSURE
21 Kg / Cm2 (g)
TUBE SIDE DESIGN PRESSURE
7 Kg / Cm2 (g)
MAX. PRESSURE DROP WATER SIDE
0.5 Kg / Cm2 (g)
FOULING FACTOR
0.0004 HR M2 C/K CAL
MAX. VELOCITY THROUGH TUBES
2.1 m/sec.
MATERIAL
SHELL
: STEEL
TUBES
REPLACEABLE SEAMLESS Cu.
FINS
COPPER (INTEGRAL)FINS
ACCESSORIES
239
PART III
SECTION 3
PURGE AND DRAIN CONNECTIONS
LIQUID LINE SHUT OFF VALVE
RELIEF VALVE/FUSIBLE PLUG
MS SUPPORTING FRAME WORK
YES
YES
YES
YES
Condenser shall have capacity to store full charge of refrigerant.

Test pressure shall be 1.5 times (hydraulic testing) / 1.25 times (pneumatic) the design
pressure
Condenser is part of Condensing unit.
Refrigerant shall be on shell side and water on tube side.
240
PART III
SECTION 3
C.1
WATER COOLED REFRIGERANT CONDENSERS

DATA SHEET C.
(Data To Be Furnished By Vendor After The Award Of Contract Weight)

When empty
With refrigerant fully charged
Kg
:
Kg
Refrigerant Storage capacity (When 80% full )
M3
Thickness of shell
mm
Thickness of tube
mm
Test Pressure
Shell side
Kg / Cm2 (g)
Tube Side
Kg / Cm2 (g)
No. of Passes
CONNECTIONS (Specify size and also type
Weather screwed, welded, etc., )
Gas inlet
Liquid Outlet
Water Inlet / Outlet
Water Drain
Purge
Relief Valve / fusible plug
Total number of tubes
Diameter and length of each Tube
Number of Tubes in each pass
Gasket Material
Maximum permissible water flow
M3 / Hr
Pressure drop and velocity
Kg / Cm2 @ M / sec
mm x
mm
241
PART III
SECTION 3
Heat rejection at the inlet / outlet water

Temperature specified by bidder
Inlet water temperature
Outlet water temperature
Operation & maintenance manuals
kCal / hr
242
PART III
SECTION 3
D.1
AIR HANDLING UNITS

DATA SHEET A
GENERAL
DESIGNATION
AIR HANDLING UNITS FOR A/C SYSTEM OF

CONTROL ROOM.
NUMBER
ONE for centralised AC / * for packaged units
TYPE
BLOW THROUGH
CASING
SINGLE SKIN
LOCATION
INDOOR
DUTY
CONTINUOUS (24 hrs / day)
VIBRATION ISOLATORS :
YES
COMPANION FLANGES
AS PER ANSI B 16.5 CLASS
WITH NUTS, BOLTS
AND GASKETS
:
YES
NOISE LEVEL AT A
DISTANCE OF 1.0 M
70Db (A)
PAINTING OF FAN AND

MS STRUCTURAL
FRAME WORK
MANUFACTURERS STD
FILTERS
PRE-FILTER REQUIIRED :
YES
MAXIMUM FACE VELOCITY:
1.75 M/Sec
MAXIMUM PRESSURE DROP

AT RATED CAPACITY
:
CLEAN CONDITION
CLOGGED CONDITION
MM WC
:
CHEMICAAL FILTER REQUIRED :

MAXIMUM FACE VELOCITY
6 MM WC
YES
M/Sec
243
PART III
SECTION 3
MAXIMUM PRESSURE DROP

AT RATED CAPACITY
CLEAN CONDITION
CLOGGED CONDITION
6 mm WC
HEPA FILTER REQUIRED
NO
MAXIMUM FACE VELOCITY
mm WC
m/sEC
MAXIMUM PRESSUREE DROP AT RATED CAPACITY

CLEAN CONDITION
CLOGGED CONDITION
mm WC
mm WC
COOLING COIL
COOLING CAPACITY
* TR
APPARATUS DEW POINT

TEMPERATURE
* C
ENTERING AIR TEMPERATRUE :

DRY BULB
* C
WET BULB
* C
LEAVING
AIR TREMPERZATURE
DRY BULB
* C
WET BULB
* C
NUMBER OF ROWS DEEP
TYPE OF COIL
DX
BRINE FLOW RATE
*M3/HR
BRINE ENTERING
TEMPERATURE
* C
BRINE LEAVING
TEMPERATURE
* C
BRINE PRESSURE AT
244
PART III
SECTION 3
COIL INLET
* Kg/Cm2 g
MAXIMUM PERMISSIBLE
BRINE PRESSURE DROP
0.7 Kg/Cm2 g
ELIMINATOR PLATES REQUIRED

AFTER COOLING COIL
:
NO
HEATING COIL
HEATING CAPACITY
25 kW
TYPE
STRIP HEATER
NUMBER OF ROWS DEEP
FLOW RATE
*M3/HR
STEAM/HOT WATER
EBNTERING TEMPERATURE
* Kg/Cm2 g
MAXIMUM PERMISSIBLLE HOT

WATER PRESSURE DROP :
0.7 Kg/Cm2 g
HUMIDIFIER
TYPE
PAN HUMIDIFIER / STEAM

HUMIDIFIER
CAPACITY
* Kg / Hr
STEAM PRESSURE AT INLET OF

CONTROL VALVE
:
* Kg/Cm2 g
FAN
CAPACITY
STATIC PRESSURE
50 mm WC
TYPE
FORWARD / BACKWARD CURVED
DISCHARGE DIRIECTION
VERTCAL
MOTOR
BY VENDOR
STARTER
BY VENDOR
245
PART III
SECTION 3
MOTOR TO CONFORM TO
STANDAR SPECIFICATION ENCLOSED
NO
MIXING BOX AND DAMPER

MIXING BOX REQUIRED
FRESSH AIR DAMPER REQUIRED:
YES / NO
SIZE
mm x
TYPE OF SUPPLY AIR DAMPER :
mm
MANUAL / PNEUMATIC / ELECTRIC

AS PER RLEVANT INDIAN STANDARDS
NOTES :
1. ADDITIONAL TESTS IF ANY DEMANDED, SHALL ALSO BE CONDUCTED.
2. STRIP HEATERS WITH BANKS AND CONTROLS TO BE PROVIDED IN THE
DUCT PLENUM (AFTER AHU OUTLET)
246
PART III
SECTION 3
D.2
AIR HANDLING UNITS

DATA SHEET C
DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF

CONTRACT
1.
Schedule of drawing and documents to be submitted for review, approval and

Information with submission dates.
2.
Quality Assurance Plan (QAP).
3.
Detailed P & I diagram showing clearly the scope of supply of equipment, piping with
Line sizes and material specifications, valves, specialties, instrumentation and control and
all accessories. This drawing or documents mentioned under following clauses shall
include all design data and information furnished in data sheets A and B. The makes of
all major components and controls shall be indicated.
4.
Dimensioned general arrangement drawing showing all equipment with accessories,

Mounting details, nozzle locations, etc.
5.
Overall space and head room requirement with details of handling during erection,
Operation and maintenance.
6.
Foundation drawing with static and dynamic loading data, pocket details, foundation
Outline, etc. for all items.
7.
Cross-sectional drawings of all items with part list and materials of construction.
8.
Performance curves and selection charts for fan, filters, etc. Selection charts and
calculation for cooling coil and heating coil.
9.
Operation and maintenance manual with lubrication schedule.
10. Catalogues furnishing detailed technical data for fan, coils, filters, etc.
247
PART III
SECTION 3
F.1
FILTERS
DATA SHEET A
GENERAL
DESIGNATION
SERVICE
AMBIENT AIR VENTILATION SYSTEM
APPLICATION
PRE-FILTER
TYPE
PANEL (CASSETTE / FLANGE)
CLEANING METHOD
CELANABLE/
DESIGN DATA
TOTAL AIR FLOW RATE
* M3/Hr
TEMPERATURE OF AIR
AMBIENT C
RELATIVE HUMIDITY
AMBIENT %
DUST LOADING
EFFICIENCY
gms/M3
:
90% DOWN TO 10 MICRONS
TYPE OF CONTAMINATION :
RADIO ACTIVE / CORROSIVE
MAXIMUM FILTER FACE

VELOCITY
11.75 M/Sec
TOTAL FACE AREA OF

FILTERS REQUIRED
** M2
PREFERRED SIZE OF EACH

FILTER PANEL
:
500mm X 500 mm X 50mm THK
NUMBER OF FILTER PANLES:
MAXIMUM ALLOWABLE PRESSURE DROP FOR DESIGN FLOW RATE IN

CLEAN CONDITION
mm WC
248
PART III
SECTION 3
CLOGGED CONDITIONS
6 mm WC
MOUNTING FRAME / SUPPORTING

FRAME WORK FOR FILTER
ASSEMBLY
:
GSS AND CHANNELS
GASKETS FOR FILTER ASSEMBLY :
NEOPRENE RUBBER
FASTENERS
GS / SS

AS PER RLEVANT INDIAN STANDARDS
TESTING AT WORKS
EFFICIENCY, PRESSURE DROP
TESTING AT SITE
EFFICIENCY, PRESSURE DROP,

LEAKAGE AND FILTRER BANK
LEAKAGE
NOTES :
1. ADDITIONAL TESTS
CONDUCTED.
*
IF
ANY
DEMANDED
SHALL
BE
ALSO
SHALL DEPEND ON ASSOCIATED FAN CAPACITIIES
249
BE
PART III
SECTION 3
F.2
FILTERS
DATA SHEET C
DATA TO BE FURNISHD BY THE CONTRACTOR AFTER THE AWARD OF

CONTRACT
1.
Schedule of drawings and documents to bee submitted for review, approval and
Information with submission dates.
2.
Quality assurance Plan (QAP).
3.
Dimensioned general arrangement drawing showing filter assembly, mounting details,

Materials and construction details etc.
4.
Selection charts with duty point marked for clean clogged conditions.
5.
Detailed write up and catalogues on mechanical cleaning, manual cleaning indicating

Recommended frequency of cleaning.
250

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PART III

Scope of Work for Electrical Engineering

Standard Specification for Electrical Equipment

Engineering Design Basis for Electrical

Electrical Engineering Job specification

Standard Specifications for 415 V Motor Control Center

Standard Specification for Medium Voltage Motor

Standard Specification for Electrical Cabling

Standard Specfication For Electrical Motor Operated Valve Actuators

Standard Specification for Uninterrupted Power Supply System

Standard Specification for High Voltage Motors

Standard Specification for Air Conditioning System

ELECTRICAL SCOPE OF WORK

OFFSITE AUTOMATION Electrical Scope of Work

All electrical drive motors

Local Push Button Stations for each motor

Transformer as per requirement

Power cables, cable installation equipments & accessories and

Motor operated Valves

415V MCC / power distribution boards / Local control panels required

Uninterrupted Power Supply Systems for Control Systems, Analyser

Earthing system consisting of provision of required earth pits at suitable

Lighting System inclusive of lighting fixtures, fitting and switches.

Building electrification works

Motor Operated Valves

Additional outdoor lighting shall be provided wherever operation of equipments are

HT motor feeders will be made available in OMS/REF-I HT substation by CPCL. One

The scope includes supply of miscellaneous items as per specifications.

BIDDER IS ADVISED TO CAREFULLY SCRUTINIZE THE TENDER

CODES AND STANDARDS

AREA CLASSIFICATION AND EQUIPMENT SELECTION

FACILITIES INSIDE CONTROL ROOM

INSPECTION, TESTING AND COMMISSIONING

DRAWINGS AND DOCUMENTS

CODES AND STANDARDS

AREA CLASSIFICATION AND EQUIPMENT SELECTION

In case of storage handling or processing of flammable materials within the battery

In case the Package or part of the package /equipment is to be located in a classified

suitably located disconnecting plates to provide multiple earth connections

General lighting for areas in which equipment supplied in the package is to be

All outdoor lighting shall be automatically controlled by synchronous timers with

Facilities Inside Control Room Building

Adequate number of combined 5/15 Amps power sockets shall be provided.

INSPECTION, TESTING AND COMMISSIONING

Terminal cover with screws etc.

Power Distribution Board/Local Panel

DRAWINGS AND DOCUMENTS

Design and installation instruction manual including design documents,

Operating instruction including description of start-up procedure and description

Sub-suppliers of individual components shall be clearly identified. Communication

Lifting facility for motors have to be provided where ever necessary.

Any discrepancies between different specifications provided in this document shall be

C. Min. temps. for battery sizing

D. Min. Temp. For Electric heat tracing

E. Seismic zone(IS 1893)

F. Altitude above mean sea level

G. Design wind velocity

150 km/hr. or as per

C. Length of feeder / conductor size