Section - Vi Index: Projects & Development India LTD

PC150/E/4004/SEC-VI 0
PROJECTS & DEVELOPMENT INDIA DOCUMENT NO REV

LTD
SHEET 1 OF 5
SECTION – VI
INDEX
PLANT: RAW WATER TREATMENT PLANT- DM WATER-

CONDENSATE POLISHING UNIT- EFFLUENT
TREATMENT PLANT WITH ZLD & SEWAGE TREATMENT
PLANT

PROJECT: INTEGRATED COAL BASED FERTILIZER COMPLEX AT
TALCHER, ANGUL, DISTRICT- ODISHA, INDIA
FORM NO: 02-0000-0021F1 REV4 All rights reserved

TITLE : INDEX (SECTION-VI) PC150/E/4004/SEC-VI 0
PLANT : RWTP-DMW-CPU-ETP WITH ZLD & STP
PROJECT :INTEGRATED COAL BASED FERTILIZER COMPLEX DOCUMENT NO REV
AT TALCHER SHEET 2 of 5
CONTENTS (PART-A_RWTP-DMW-CPU)
SECTION DESCRIPTION
VI-1.0 PROJECT DESCRIPTION
VI-2.0 RAW WATER,CONDENSATE & TREATED WATER QUALITY
VI-3.0 CONTRACTOR’S SCOPE OF WORK
Rotating
Attachment: Sec VI 3.1
Attachment: Sec VI 3.2 Static
Attachment: Sec VI 3.3 Piping
Attachment: Sec VI 3.4 Electrical
Attachment: Sec VI 3.5 Instrumentation
Attachment: Sec VI 3.6 Civil & Structural work
Attachment: Sec VI 3.7 Construction
VI-4.0 DESIGN BASIS
VI-5.0 DESIGN PHILOSOPHY
VI-5.1 DESIGN PHILOSOPHY – PROCESS
VI-5.2 DESIGN PHILOSOPHY – MECHANICAL
VI-5.2.1 DESIGN PHILOSOPHY – STATIC EQUIPMENT
VI-5.2.2 DESIGN PHILOSOPHY – ROTATING EQUIPMENT
VI-5.2.3 DESIGN PHILOSOPHY – PIPING
VI-5.3 DESIGN PHILOSOPHY – ELECTRICAL
VI-5.4 DESIGN PHILOSOPHY – INSTRUMENTATION
VI-5.5 DESIGN PHILOSOPHY – CIVIL & STRUCTURAL WORKS
VI-6.0 PROJECT EXECUTION PLAN

CONSTRUCTION, ERECTION, PRECOMMISSIONING,
VI-7.0
COMMISSIONING AND START-UP
VI-8.0 PERFORMANCE AND GUARANTEE TEST
VI-9.0 DRAWINGS & DOCUMENTS
FORM NO: 02-0000-0021 F2 REV3 All rights reserved

VI-10.0 SPARE PARTS
VI-11.0 VENDOR LIST
VI-12.0 INFORMATION REQUIRED IN THE TECHNICAL PROPOSAL
VI-13.0 SITE WORKING AND SAFETY CONDITIONS


CONTENTS (PART-B_ETP-STP)
SECTION DESCRIPTION
VI-1.0 PROJECT DESCRIPTION
VI-2.0 EFFLUENT –SEWAGE & UTILITY QUALITY
VI-3.0 CONTRACTOR’S SCOPE OF WORK
Rotating
Attachment: Sec VI 3.1
Attachment: Sec VI 3.2 Static:
Attachment: Sec VI 3.3 Piping:
Attachment: Sec VI 3.4 Electrical
Attachment: Sec VI 3.5 Instrumentation
Attachment: Sec VI 3.6 Civil & Structural work
Attachment: Sec VI 3.7 Construction:
VI-4.0 DESIGN BASIS
VI-5.0 DESIGN PHILOSOPHY
VI-5.1 DESIGN PHILOSOPHY – PROCESS
VI-5.2 DESIGN PHILOSOPHY – MECHANICAL
VI-5.2.1 DESIGN PHILOSOPHY – STATIC EQUIPMENT
VI-5.2.2 DESIGN PHILOSOPHY – ROTATING EQUIPMENT
VI-5.2.3 DESIGN PHILOSOPHY – PIPING
VI-5.3 DESIGN PHILOSOPHY – ELECTRICAL
VI-5.4 DESIGN PHILOSOPHY – INSTRUMENTATION

DESIGN PHILOSOPHY – CIVIL & STRUCTURAL
VI-5.5
WORKS
VI-6.0 PROJECT EXECUTION PLAN
CONSTRUCTION, ERECTION, PRECOMMISSIONING,
VI-7.0
COMMISSIONING AND START-UP
VI-8.0 PERFORMANCE AND GUARANTEE TEST
VI-9.0 DRAWINGS & DOCUMENTS

VI-10.0 SPARE PARTS
VI-11.0 VENDOR LIST

INFORMATION REQUIRED IN THE TECHNICAL
VI-12.0
PROPOSAL
VI-13.0 SITE WORKING AND SAFETY CONDITIONS


PART-A
RAW WATER TREATMENT
DMW PLANT
&
CONDENSATE POLISHING UNIT

0
PC0150/E/4004/SEC-VI-1.0A
PROJECTS & DEVELOPMENT INDIA
LTD DOCUMENT NO REV
SHEET 1 OF 7
SECTION – VI 1.0 (PART-A)
PROJECT DESCRIPTION
PLANT: RAW WATER TREATMENT, DMW PLANT &


TALCHER, DISTRICT-ANGUL, ODISHA (INDIA)

TITLE : PROJECT DESCRIPTION PC0150/E/4004/SE 0
PLANT : RWTP,DMW & CPU C-VI-1.0A
PROJECT :INTEGRATED COAL BASED DOCUMENT NO REV
FERTILIZER COMPLEX AT TALCHER SHEET 2 OF 7
LIST OF ANNEXURE
Annexure Number Description Drawing No. Number

of
Sheets
Annexure - I Overall Plot Plan – TFL PC009-0000-0001-REV 6_OP 1
Annexure - II Schematic Process Flow 1. PC150-7318-021 REV 0 5

Diagram 2. PC150-7318-022 REV 0
3. PC150-7318-023 REV 0
4. PC150-7318-024 REV 0
5. PC150-7318-025 REV 0


1.0 INTRODUCTION:
Government of India has formed a joint venture company of major Public Sector Units – M/s
GAIL (India) Limited (GAIL), M/s Rashtriya Chemicals & Fertilisers Ltd. (RCF), Coal India Limited
(CIL) and M/s Fertilizers Corporation of India Ltd. (FCIL) by name M/s Talcher Fertilizers Ltd.
(TFL) hereinafter also referred to as “OWNER”, for setting up a Coal Gasification based
Ammonia Urea Fertilizer Complex along with its associated offsite & utility facilities at Talcher, in
the Angul District of Odisha State.
Projects & Development India Ltd. (PDIL) has been retained by TFL as Project Management
Consultant for selection of a suitable Lump-Sum Turnkey (LSTK) Contractor for execution of the
Raw Water Treatment, De-mineralised (DM) & Condensate Polishing Unit for Coal Gasification
based integrated Ammonia& Urea fertilizer complexes as detailed in subsequent sections of this
NIT with Single point responsibility.
2.0 PLANT LOCATION:
Talcher site is located at Vikrampur in Angul district of Odisha on the Cuttack – Sambalpur
National Highway NH-42. NH-42 is passing at about 8 km from the site. The nearest railway
station is Talcher at about 7 km from the site. Nearest air port Bhubaneswar is 150 km, 3 hours
journey by road/ rail. Nearest sea port is Paradip, 200 km by rail/road from the site. Talcher is
situated at 21o10” N Latitude and 82o5” E Longitude.
3.0 PLANT CAPACITY & CONFIGURATION:

The project would essentially consist of Coal gasification based Ammonia and Urea plants and
related off-site and utility facilities. The proposed plot plan for Talcher has been shown in
Annexure-1.The broad provision of plants and facilities envisaged for the LSTK contractor has
been presented in following Tables:
Sl. No. Plants & Facilities Capacity for Talcher Unit

1.0 RAW WATER TREATMENT PLANT 2X 1200 M3/HR
2.0 DRINKING WATER TREATMENT PLANT 130 M3/HR
3.0 DM PLANT 180 M3/HR Each,(2W+1S)
4.0 CONDENSATE POLISHING UNIT 270 M3/HR Each, (1W+2S)


5.0 CHEMICALS & RESIN STORAGE Two Months
6.0 FILTERED WATER STORAGE TANK 24000 M3 (Effective Capacity)
7.0 DRINKING WATER STORAGE TANK 1100 M3 (Effective Capacity)
8.0 DM / POLISHED WATER STORAGE TANK 2 x 4500 M3 (Effective Capacity)
9.0 CONDENSATE STORAGE TANK 7500 M3 (Effective Capacity)

10.0 ELECTRICAL SUB STATION &
AS REQUIRED
DISTRIBUTION
11.0 PLC & INSTRUMENT CONTROL STATION AS REQUIRED
12.0 CONTROL ROOM FOR RAWWATER
AS REQUIRED
TREATMENT ,DM & CPU
Note: ‘PLANT’ shall mean the following:

PLANT A - Raw Water Treatment Plant
PLANT B - DM Water & Condensate Polishing Unit
PLANT C- Effluent Treatment Plant & Sewage Treatment Plant
3.1 Plants & facilities under LSTK Contractor’s Scope
Brief Description is given below describing the minimum requirement; in addition to this any items
required shall be provided by the bidder for meeting the guaranteed parameters and for safe,
reliable trouble free continuous operation and maintenance requirement of the system.
Process documents enclosed are the basic documents which are to be followed as
minimum requirements for execution of job leading to successful commissioning &
performance guarantee test run of the Plant. During the course of execution,
updating/modification to the process documents that would become necessary is to be
carried out by the Bidder with the approval of PDIL / Owner. The resultant work arising out
of this shall also form the part of contractor’s scope from detailed engineering to handing
over of the Plant with no time and cost implication.
3.1.1 The Raw Water Treatment plant shall have following sections
i. Pre Chlorination with chlorine di-oxide
ii. Cascade Aeration
iii. Flash mixing
iv. Clarification
v. Filtration
vi. Storage and Pumping


vii. Chemical Dosing System
viii. Storage for chemicals & lubricants
ix. Safe disposal of hazardous solid waste
3.1.2 The Drinking water treatment plant shall have following sections
i. Post chlorination with chlorine di-oxide.
ii. Drinking water storage tank
iii. Pumping to plant and colony
3.1.3 DM plant shall have following sections

i. Active Carbon Filtration
ii. Cation & Anion Exchangers
iii. Degasser System
iv. Mixed Bed
v. DM/Polished Water Storage Tank with nitrogen blanketing
vi. DM/Polished Water transfer pump to Coal Gasification, Ammonia–Urea, Steam
generation plant and other users
vii. Neutralisation pit, Pumping & piping facilities for transfer to ETP.
3.1.4 Condensate polishing unit shall have following sections

i. Plate Type Heat Exchanger
ii. Trim Cooler
iii. Condensate Water Storage Tank
iv. Active Carbon Filtration
v. Cation Exchanger
vi. Mixed bed
3.1.5 Interconnecting Piping:

All interconnecting piping, up to Battery Limit shall be provided by the bidder. Bidder shall provide
double block & bleed arrangement along with spectacle blind at the battery limit for complete
isolation. Provision for Hook-ups to be provided for future expansion.
3.1.6 Chemical Laboratory:

Bidder shall provide comprehensive furnished Chemical Lab along with required lab instruments
& equipments to meet the laboratory measurement & analysis requirement of the plants for day to


day operation of the DM Plant, Raw Water Treatment plant & CPU Plant. In addition to DM Plant
and Raw Water Treatment Plant, this comprehensive lab should cater the tests pertaining to
following units also:
a) Effluent Treatment Plant*
b) Steam Generation Plant
c) Cooling Water Systems and
d) Any other water sample.
*- Comprehensive lab shall contain CN-, NH3/NH4+ and Methanol tests in addition to rest of the
tests specifically for ETP Lab. All tests and its monitoring shall be in compliance to Odisha State
Pollution Control Board (OSPCB) and Central Pollution Control Board (CPCB) requirements.
Bidder shall provide but not limited to minimum following equipments in laboratory:
Sno. Instrument name Quantity Make
1 pH meter (Portable) 02 Nos Mettler/Metrohm/Hach/WTW
2 pH meter (Table top) 02 Nos Mettler/Metrohm/Hach/WTW
TDS/Conductivity meter
3 (Portable) 02 Nos Mettler/Metrohm/Hach/WTW
TDS/Conductivity meter
4 (Table top) 02 Nos Mettler/Metrohm/Hach/WTW
5 Jar Test with dosing 01 No YAtherm/Amco india/Electronic india
6 Hot Plate (Rectangular) 03 Nos Ika/Coleparmer/UWR/Thermo
7 Magnetic Stirrer with hot plate 02 Nos Ika/Coleparmer/UWR/Thermo
8 Water bath with 16 holes 02 Nos Remi or equivalent
Perkin Elmer/Shimdzu/Analytica
9 UV visible spectrophotometer 02 Nos Jena/Thermo
10 Oven Approx 110 Lit 02 Nos Memmert/Thermo/Carbolite
11 Oven Approx230 Lit 01 No Memmert/Thermo/Carbolite
Water Purifier System(18.2
12 Megahertz) 01 No Millipore/Elga or equivalent
13 BOD Incubator 01 No Memmet/Hach/WTW
Muffle Furnace (1100 Deg C
14 MLSS VLSS Scale) 01 No CEM/Carbolite or equivalent
15 BOD Apparatus 01 No Merck/WTW/Hach
COD Digester with safety
16 shield & photometer 01 No Merck/WTW/Hach
17 Flame photometer 01 No Systronics or equivalent
Dissolved oxygen Analyser for
18 ETP 01 No Hach/Mettler or equivalent
19 Auto Titrator 02 Nos Mettler/Metrohm or equivalent
Ion Chromatograph for
20 Cations & anions 01 No Metrohm/Thermo or equivalent
21 Turbidity meter 02 Nos WTW/Hach or equivalent
22 Oil in water Analyzer 01 no Horiba or equivalent
23 Dew Point Meter 01 No. Shaw or equivalent
Vensil/AggarawalGlassworks/JainScientific
24 Orsat Apparatus 02 Nos Glassworks


Vensil/AggarawalGlassworks/JainScientific
25 Filtration Assembly 02 Nos Glassworks
26 Vacuum pump 01 No Sigma/Vacuubrand or equivalent
Glasswares: For 06 months operation post commissioning

Chemicals & Reagents: For 06 months operation post commissioning
Certified Reference Material: For 06 months operation post commissioning
Mandatory items/consumables not mentioned above to be provided for 06 months
operation post commissioning.
3.1.5 Temporary Construction Facilities:

The Bidder shall arrange following facilities at his own cost for Construction/Erection purpose:
i. Construction power supply facilities: 1 No. 11 kV Feeder (rated for 2 MVA) at Existing
Substation near 132 KV Switchyard shall be made available. Tapping of Construction Power
(chargeable on actual basis rate at the time of consumption) from this feeder (including
supply & erection of all required materials like structural supports for cable tray, cable trays,
power cables, control cables, protection & metering, cable termination etc. as well as
underground cabling work) and further distribution shall be in LSTK Contractor’s scope.
ii. Construction Water Supply facilities: Construction water shall be supplied at one point at
plant location, bidder to make arrangement for construction water supply from given plant
location to bidder plant battery limit on chargeable on actual basis rate at the time of
consumption. Bidder to install meter for consumption measurement.
iii. Construction sheds
iv. Material storage
v. Construction offices
vi. Temporary Communication facilities
vii. Office furniture
3.1.6 Filter water Storage Tank: There shall be two compartment in Filtered water tank, Lower
compartment & Higher compartment. Lower compartment is dedicated for cooling water make up
wherein RO permeate water from ETP will also be received. Second compartment (i.e. Higher) is
dedicated to ClO2 dilution water, service water, DM plant feed respectively.

ANNEXURE-1
PC150/E/4004/SEC-VI-2.0A 0

DOCUMENT NO REV
LTD
SHEET 1 of 8
RAW WATER, DM WATER, CONDENSATE & TREATED WATER

QUALITY


TALCHER, ANGUL DISTRICT, ODISHA, INDIA

TITLE :RW,DM & CPW & TREATED WATER PC150/E/4004/SEC-VI-
0
QUALITY 2.0A
PLANT :RWTP,DMW & CPU DOCUMENT NO REV
PROJECT :INTEGRATED COAL BASED
1.0 FEED WATER QUALITY:
1.1 Raw Water:
Feed raw water quality available in the Battery Limit of Raw Water Treatment Plant (RWTP) at
Talcher Unit:
Table: Raw Water quality
Sr. Parameters Inlet Raw water

Unit
No. Quality (Design)
1. pH at 27Deg C - 6.8-8.0
2. Temperature Deg C Ambient
3. Turbidity NTU Up to 215
4. Total Suspended Solids (TSS) Mg/l Up to130
5. Total Dissolved Solids (TDS) Mg/l Up to 210
6. Total Hardness ppm Up to 70
7. Ca Hardness (as CaCO3) ppm Up to 64
8. Mg Hardness (as CaCO3) ppm Up to 20
9. Chlorides (as Cl) ppm Up to 32
10. M Alkalinity (as CaCO3) ppm Up to 54
11. Sulphates (as SO4) ppm Up to 20
12. Sodium (as Na) ppm Up to 30
13. Potassium (as K) ppm Up to 8
14. Nitrates (as NO3) ppm Up to 6
15. Total Iron(as Fe) ppm Up to 8
16. Manganese (as Mn) ppm Up to 6
17. Zinc (as Zn) ppm ≤1
18. Oil & grease Mg/l Up to 5
19. Colloidal Silica ppm Up to 3
20. Total Silica (as SiO2) ppm Up to 16
21. Quantity M3/hr 2400
Note:
The water analysis given above is for design purpose. However actual water analysis may vary
from time to time. Both water pre treatment & DM plant shall be designed considering these
variations. However bidder to satisfy himself regarding raw water quality before bidding to
formulate the scheme and meeting the guaranteed parameters.
1.2 Turbine Condensate Quality
Turbine condensate quality received from Coal gasification, Ammonia & Urea ISBL at the Battery
Limit of CPU shall be as follows:

0
QUALITY 2.0A
Table: Turbine Condensate Quality & Quantity (From different units)
Sr. Parameter Value

No.
1 pH 7.0-9.0
2 Conductivity , micro-S/cm Max. 20
3 Total SiO2, ppm wt 0.02
4 Iron as Fe, mg/L 0.2
5 Oil Content , ppm NT
6 Ammonia as NH3 ,ppm wt Max 4
7 Temp., Min/ Normal/ Max/ 0C -/50/-
8 Design Temperature 0C 80
9 Operating Pressure kg/cm2g 2.5
Quantity M3/hr 569
1.3 Process / Steam Condensate Quality & Quantity :
Process / Steam condensate quality received from Coal gasification, Ammonia & Urea ISBL at
the Battery Limit of CPU shall be as follows:
Sr. Parameter Value Value

No. (Coal gasification) ( Ammonia & Urea)
Process / Steam Process Steam

Condensate Condensate Condensate
1. NH3, ppm NIL Max 5 NIL

2. Urea, ppm NIL Max 3 NIL
3. Oil NT NT NT
4. Methanol NT Max 100 NIL
5. pH 8.5 - 9.5 7.5-8.5 6.5-7.0
6. Conductivity, μS/cm MAX 20 NIL Max 20
7. TDS PPM (Max.) 0.5 0.5 0.5
8. Turbidity NTU NIL Nil Nil
9. Total Silica (SiO2), ppm (max) 0.5 NIL 0.5
10. Total Iron (Fe), ppm (max) 1.0 NIL 1.0
11. Copper (Cu), ppm (max) 0.1 NIL 0.1
12. Sulphate (SO4 2-), PPM (Max.) 0.02 NT
13. Chloride (Cl-), ppm (max) 0.1 Nil Nil
14. Temp., Min/ Normal/ Max/ 0C -/50/70 -/45/-
15. Design Temperature 0C 85 115
16. Operating Pressure kg/cm2g 1.5 2.5
17. Quantity M3/hr 45 135 84
*- Non Traceable.
Bidder to design the system considering worst of the case among the above.
0
QUALITY 2.0A
2.0 Treated Water Quality:
Treated water quality required after treatment in RWTP shall be as follows:
Table: Treated Water Quality
Sr.No Parameters unit Treated raw water quality

1. pH - 7.0-8.5
2. Turbidity NTU <1
3. Total Suspended Solids (TSS) Mg/l <1
4. Total Dissolved Solids (TDS) Mg/l <100
5. Total Hardness (as CaCO3) Mg/l <150
6. Ca Hardness (as CaCO3) Mg/l <100
7. Chlorides (as CI-) Mg/l < 20
8. Free Chlorine ppm 0.01-0.05
9. Alkalinity (as CaCO3) Mg/l < 68
10. Cadmium (as Cd) Mg/l <0.003
11. Chromium (as Cr) Mg/l <0.05
12. Copper (as Cu) Mg/l <0.05
13. Lead (as Pb) Mg/l <0.01
14. Total Iron(as Fe) Mg/l <0.1
15. Manganese (as Mn) Mg/l <0.1
16. Reactive Silica as SiO2 Mg/l 4 max. (Bidder to design for
lowest value)
17. Colloidal Silica PPM Nil
18. Total coliforms MPN/100ml BDL
19. Faecal coliforms MPN/100ml BDL
20. Ammonia Nil
21. Oil & Grease Nil
22. Temperature Deg C Amb.
Note:
1. pH value of 7.0-8.5 shall be maintained with pH correction if required by bidder.
2. Treated water pressure at B/L for feeding water to DM Plant shall be decided by bidder & to
other users shall be as specified in technical specification.

0
QUALITY 2.0A
2.1 Drinking Water Quality:
Table: Drinking Water Quality
Sr.No Parameters unit Drinking water quality

1. Color <5.0
2. 2Smell Agreeable
3. 3Taste Unobjectionable
4. 4pH 7.0-7.5
5. 5Turbidity NTU <1
6. 6Total Hardness mg/l <85
7. 7Total Iron as Fe mg/l <0.1
8. Manganese(as Mn) mg/l <0.1
9. 9Chloride as Cl mg/l <20
10. Free Chlorine PPM 0.05 to 0.1
11. Sulphate as SO4 <60
mg/l
0
12. Dissolved Silica mg/l <4
13. TDS mg/l <150
14. Total caliform
Shall not be detectable in any 100 ml sample
3 bacteria
15. Operating 0
C Amb.
4 Temperature
16. Operating Pressure kg/cm2g 8.0
5
17. Mechanical Design
kg/cm2g 12.5
6 Pressure
18. Mechanical Design 0
C 65
7 Temperature
In case of variation in raw water quality, guarantee deviation shall apply on overall
chemical load variation.
Drinking water quality shall conform to latest BIS 10500 (latest)
2.2 Polished Water Quality From DM Plant:
Polished water quality required after treatment from DM plant shall be as follows:
Table: DM water quality at outlet of DM plant
Sr.No. Parameters Value

1. pH 6.8-7.2
2. Total Hardness Nil
3. Conductivity at 20 deg. C, Micro-mho/cm < 0.2
4. Total suspended solids ppm wt (Max) Nil
5. M Alkanity as CaCO3 ppm by wt Nil
6. Turbidity NTU Nil

0
QUALITY 2.0A
7. Total Iron as Fe ppm by wt (Max) < 0.01

8. Sodium as Na ppm by wt (Max) Nil
9. Chlorides ppm by wt Nil
10. Oil & grease mg/kg Nil
11. Dissolved Oxygen saturated mg/l <6.5
12. Colloidal Silica as SiO2 ppm Nil
13. Total Silica as SiO2 ppm by wt (Max) <0.01
14. Total Copper, mg/kg <0.003
15. Total Dissolved Solids < 0.1
16. Operating/Design Temperature in Polished AMB/70
water tank outlet, 0C
17. Operating/Design Pressure kg/cm2g 8/10
2.3 Polished Water Quality From CPU:
Polished water quality required after treatment in CPU plant shall be as follows:
Table: Quality of Polished Condensate at outlet of CPU
Sr.No. Parameters Value

1. pH 6.8-7.2
2. Total Hardness Nil
3. Conductivity at 20 deg. C, Micro-mho/cm < 0.2
4. Total suspended solids ppm wt (Max) Nil
5. M Alkanity as CaCO3 ppm by wt Nil
6. Turbidity NTU Nil
7. . Total Iron as Fe ppm by wt (Max) < 0.01
8. Sodium as Na ppm by wt (Max) Nil
9. Chlorides ppm by wt Nil
10. Oil & grease mg/kg Nil
11. Dissolved Oxygen saturated mg/l <6.5
12. Colloidal Silica as SiO2 ppm NIL
13. Total Silica as SiO2 ppm by wt (Max) <0.01
14. Total Copper, mg/kg <0.003
15. Total Dissolved Solids < 0.1
16. Operating/Design Temperature 0C AMB/70
17. Operating/Design Pressure kg/cm2g 8/10

0
QUALITY 2.0A
2.4 Service Water Quality:
Sr.No Parameters unit Treated raw water

quality
1. Temperature Deg C Amb.
2. Supply Pressure, kg/cm2-g 9/9.5/10
(Min/Nor/Max)
3. Supply Temperature, deg c Ambient
4. Mechanical Design deg c 65
Temperature,
5. Mechanical Design Pressure, kg/cm2-g 11.5

0
QUALITY 2.0A
Utilities:
Nitrogen:
1 Pressure,Kg/cm2g 6.0/8.0/9.0/10.5
(Min/Nor/Max/Design)
2 Temperature 0C Amb.
3 N2+Inerts, Vol%, min 99.99%
4 O2 Vol PPM < 10
Instrument Air:
1 Pressure,Kg/cm2g 6.0/8.0/10.0/10.5
2 Temperature 0C (Nor/Max/Design) Amb./ 50 /65
3 Dew Point (-40 0C) @ 8 kg/cm2g
LP Steam:
1 Pressure,Kg/cm2g 3.0/3.5/4.5/6.0
2 Temperature 0C (Nor /Design) 180 /250
Cooling Water:
1 Pressure, Kg/cm2g (Nor/Design) 3.5/8

2 Temperature 0C (Nor/Design) 33/70
Delta T 0C 10
Delta P Kg/cm2 across battery limit 1 max
Plant air
1 Pressure, Kg/cm2g (Nor/Design) 7/10.5

2 Temperature 0C (Nor/Design) 40/65
Moisture Saturated
Oil Content Nil

PC150/E/4004/SEC-VI-3.0A 0
DOCUMENT NO REV
LTD
SHEET 1 of 10
CONTRACTOR SCOPE OF WORK

PROJECT: INTEGRATED COAL BASED FERTILIZER COMPLEX

AT TALCHER, ANGUL DISTRICT, ODISHA (INDIA)

TITLE: : CONTRACTOR SCOPE OF WORK PC150/E/4004/SEC-VI- 0
PLANT : RWTP,DMW & CPU 3.0A
PROJECT :INTEGRATED COAL BASED DOCUMENT NO REV.
FERTILIZER COMPLEX AT TALCHER
SHEET 2 of 10
1.0 GENERAL:
The LSTK Bidder’s scope of work shall include detailed design & engineering complete with
all equipment & accessories, procurement of complete materials & bought-out items
whatever deemed necessary for process, mechanical, electrical & instrumentation,
analysers fabrication at shop/site as required, loading, transportation, unloading & storage
at site, assembly, erection of mechanical, electrical & instrumentation system, inspection,
testing, painting, statutory approvals, calibration commissioning, trial runs and
demonstration of guarantees, & supply of complete package along with spares &
maintenance tools etc. Training of owners personnel, trial runs, Sustained Load Test after
commissioning and performance guarantee test run for 72 hrs continuous operation,
guaranteeing and handing over to the Client including six months supervisory services, all
on turnkey basis, as per the Design Basis, Job Specifications, Standards, P&IDs, PFDs,
Data Sheets, Equipment List, Drawings, Test Certificates of Equipment, Instruments &
Machineries, Piping Materials, Vessels & others relevant items etc. as required & complete
in all respect.
The scope of supply will include the items but not limited to the items as listed below
including Interconnecting piping, all fittings, mechanical valves, control valves, motors,
cables, field and control room instrumentation etc. as required for completing the systems
as per enquiry specifications. Any work not listed herein but is necessary for
completion and smooth, safe & trouble free continuous operation and maintenance
of the plants as well as those required as part of good engineering practices shall be
deemed to be included.
Raw Water Treatment Plant (RWTP):
The scope of supply for RWTP shall include Two PLC based Raw Water Treatment streams
broadly include the following facilities with interconnecting piping, valves, chemical storage
and handling equipments and other accessories as detailed in data sheets and drawings.
i. 1 no of Cascade Aerator (common for both stream)
ii. 2 nos of Flash Mixer
iii. 2 Nos of Floculator
iv. 2 Nos of Clarifier (HRSCC)
v. 1 No. of Clarified Water Sump
All rights reserved

SHEET 3 of 10
vi. 3 Nos. of Filter Feed Pump (2W+1S)
vii. 2 Nos. of Sludge Discharge Pump (1W+1S)
viii. Dual Media Filters (Vertical) considering minimum 25%extra margin. Vendor to
decide numbers (minimum eight + two standby.).
ix. 2 Nos. of Filter Backwash Pump (1W+1S)
x. 2 Nos. of Backwash Blowers (1W+1S)
xi. One Nos. Filter Water Storage Tank of capacity as specified in Section-4.0 Design
Basis.
xii. One Nos. of Drinking Water Storage Tank of capacity as specified in Section-4.0
Design Basis. Inter connection of drinking water pumps between plant and
township to be provided by bidder.
xiii. 2 Nos. of Drinking water supply pumps (1W+1S) for supplying to township and 2
Nos. of drinking water supply pumps (1W+1S) to Plant for further distribution with
capacity as specified in Section-4.0 Design Basis.
xiv. 3 Nos of Cooling water make up pumps (2W+1S) Capacity as specified in Section-
4.0 Design Basis.
xv. 2 Nos of Service water pump (1W+1S) Capacity as specified in Section-4.0 Design
Basis. Inter connection of service water and cooling water make-up to be provided
by bidder.
xvi. 3 Nos of DM plant Feed Pump (2W+1S).
xvii. All pumps will be in Shed with hoist and all other accessories.
xviii. Chemical storage, dosing tanks, lubricants and unloading facilities including shed,
pumps, agitators, tanks etc with all safety systems, alarms and emergency
handling.
xix. Warehouse facility for any requirement of chemicals.
xx. Safe disposal of hazardous solid waste, bidder to furnish the detail procedure.
xxi. Any other item necessary for safe and trouble free operation of the plant at full
load.
NOTES: Requirement of ACF backwash pumps to be decided by bidder. Bidder may carry
out backwashing by feed pumps.
DM Plant:
The scope of supply for DM Plant shall include three PLC based DM streams each of net
capacity 180 cum/hr. Complete with regeneration (through fare) facilities, chemical storage
and handling equipments, two (2) nos. DM/Polished water storage tanks of capacity 4500
All rights reserved

SHEET 4 of 10
cum each, waste neutralizing facilities with interconnecting pipings, valves and other
accessories as detailed in data sheets and drawings.
The DM Plant shall be supplied complete and shall include, but not limited to the following.
It shall also include the Interconnecting piping, valves & other accessories.
a) Three (3) (2W+1S) nos. Activated Carbon filter with all accessories
b) Three (3) (2W+1S) Degasser Tower with air blowers with all accessories
c) Three (3) (2W+1S) nos. Degassed water transfer pump with all accessories
d) Three (3) (2W+1S)) nos. Weak Acid Cation exchanger (if required by bidder)
and Strong Acid Cation exchanger with all accessories.
e) Three (3) (2W+1S) nos. Weak Base Anion exchanger (if required by bidder)
and Strong Base Anion exchanger with all accessories.
f) Three (3) (2W+1S) nos. Mixed Bed exchanger along with 2 nos. blowers with all
accessories.
g) Complete acid / alkali handling, storage of Chemicals, Storage of fresh Resin,
Charcoal and regeneration system including pumps with drive motors and
interconnecting piping & valves. Acid/alkali pipeline flanges will be provided with
guards storage, PPE to be provided
h) Two (2) nos. DM/Polished Water Storage Tanks 2 X 4500 cum complete with all
accessories with nitrogen blanketing.
i) Three pumps (2W+1S) DM/Polished Water transfer pumps Capacity with all
accessories
j) Two (2) no. safety shower with eye fountain & all accessories.
k) One (1) no. centralized sampling rack for DM stream.
l) All auto valves above 150NB shall be pneumatic operated butterfly valves
(Leakage Class IV) except for drain valves on vessels
m) One (1) no. Neutralization Pit in two compartments complete with integral pipe,
valves & accessories along with proper mixing arrangement common for DM &
CPU regeneration waste.
n) Two (1W+1S) nos. Of Submersible Effluent transfer pumps with electrical drive
motors and other accessories as required.
o) One (1) no. of brine preparation tank with injection Pumps complete with all
accessories.
p) One (1) no. of hot water tank with Electrical heater complete with all
accessories & One (1) no. of alkali filter complete with all accessories.
All rights reserved
SHEET 5 of 10
q) Any other items required for completion and smooth, safe & trouble free
continuous operation at full capacity and maintenance as well as those required
as part of good engineering practices shall be deemed to be included.
Condensate Polishing Plant (CPU):
The scope of supply for CPU shall include Three (3) (1W+ 2S) PLC based, process/
contaminated turbine condensate streams each of capacity 270 cum/hr. complete with
regeneration facilities, chemical storage and handling equipments, unpolished condensate
storage tank of capacity 7500 M3, waste neutralizing facilities with interconnecting pipings,
valves and other accessories as detailed in data sheets and drawings.
The CPU Plant shall be supplied complete and shall include, but not limited to the following:
It shall also include the Interconnecting piping, valves & other accessories.
a) One no. unpolished condensate storage tank 7500 m3 complete with all
accessories
b) 3 nos. (1 W +2S) filter feed pumps with all accessories.
c) 3 nos. (1W+2S) Plate heat exchanger, MOC SS-316.
d) 3 no. Trim cooler, MOC of Tubes: SS-316 with back flushing arrangement for on
line cleaning of deposits on cooling water side.
e) 3 nos. (1 W +2S). Activated Carbon Filter with all accessories.
f) One no. centralized sampling rack for CPU stream.
g) All auto valves above 150NB shall be pneumatic operated butterfly valves
(Leakage Class IV) except for drain valves on vessels.
h) One no. neutralizing pit in two compartments complete with integral pipe, valves
& accessories common for DM & CPU regeneration waste.
i) Any other items required for completion and smooth, safe & trouble free
continuous operation at full capacity and maintenance as well as those required
as part of good engineering practices shall be deemed to be included.
Commons Points for RWTP, DMW & CPU Plant:
i. Detailed process design including preparation of P&ID, mass balance diagram,

control and logic diagram, interlock schemes, etc.
ii. Detailed design of plant and equipment, instrumentation, electrical and control
system.
All rights reserved

SHEET 6 of 10
iii. Detailed equipment layout, piping GAD & isometrics, battery limit hook ups and
other works as required.
iv. The complete civil and structural work, including detailed design, preparation of all
drawings for construction, fabrication, erection, grouting, etc. of all structural works
e.g. platforms, stairs, ladders, hand railing (including insert plates) and wherever
required, pipe and cable racks / supports, underground & above road crossing
(including culvert / trench) for piping and cabling, etc. are to be included.
v. RCC Drains, storm water drainage system and roads within the battery limit.
Approach road and fencing are also included in LSTK Bidder’s scope.
vi. Construction of RCC pavements, foundations and inside kerbs as and where
required, pipe/cable racks and supports. LSTK Bidder shall rectify the road as per
specification, if damaged during construction of road crossing for piping and cabling.
Connection of any storm water, sewage water, drains etc.
vii. All architectural works including plastering, painting, roof treatment, doors, windows,
ventilators / exhausts, flooring, skirting, rain water pipes, sanitary fittings, wash basin
and tiling in laboratory/wash rooms, etc. as per specific requirements, standards,
specifications and drawings etc., all complete.
viii. Complete mechanical works, design, and procurement of materials, supply,
fabrication, erection and testing.
ix. Complete instrumentation work for smooth operation, control and monitoring.
x. Complete design, procurement, supply erection, testing and pre-commissioning &
commissioning of electrical & instrumentation Works, including lighting switch gears,
earthing, power for instrumentation, drives, power and control cabling, cable
trays/trenches all complete as per standards etc..
xi. Complete plant lighting i.e. inside the control room and outside within plant battery
limits for area lighting including fixtures, accessories, cabling, conduiting, earthing
switch gear, welding receptacles, etc. all complete.
xii. Cleaning and external painting of all vessels, tanks equipments, piping, structural
hand railing, platforms, ladder, stairs, inserts, etc. for relevant environment.
xiii. Clear the Battery Limit of all construction aids, debris, etc. and provide a tidy work
plan.
xiv. All documents/drawings shall be submitted by LSTK Bidders as per documentation
schedule & general specification as referred in technical specifications of Civil,
Mechanical, electrical and Instrumentation.
All rights reserved

SHEET 7 of 10
xv. Design calculations sheet shall be furnished for all chemical consumption based on
the inlet feed quality & quantity parameters as per design basis. This may be used for
any corrections required during performance guarantee test run.
xvi. All Chemicals & Consumables required during testing, pre-commissioning,
commissioning & guarantee test. Regents/chemicals for testing/analysis 6 months
storage to be provided by bidder.
xvii. Arrange all necessary instruments, tools/tackles required to aid pre-commissioning,
commissioning and performance guarantee tests.
xviii. Any other item required.
xix. All statutory approval shall be in the scope of LSTK Bidder except consent to
establish & consent to operate.
xx. Design calculations sheet shall be furnished for all chemical consumption based on
the inlet effluent quality parameters as per design basis. This may be used for any
corrections required during performance guarantee test run.
xxi. Piping network to distribute the treated sewage water in the green belt area around
the plant area as shown in overall plot plan attached with NIT. Piping material of
distribution piping shall be of CPVC.
xxii. All necessary hoist/EOT or equivalent of suitable capacity with associated test
certificates from authorities.
In addition to what has been described in above, Bidder scope of services

shall include submission, review, Finalisation and getting approval from PMC/
Owner of following:-
a) Detailed process design including preparation of P&ID,
b) Detailed design of plant and equipment, instrumentation, electrical and
control system, control and logic diagram, interlock schemes, etc., detailed
design of structural work.
c) Detailed equipment layout, piping GAD & isometrics, battery limit hook ups
and other works as required.
d) Documentation & approvals including approvals from statutory authorities
including those required to be taken by client.
e) Procurement of raw materials, bought out components, Fabrication and
assembly at shop & at site.
f) Inspection & testing, including third party inspection at shop and at site
Packing, forwarding & delivery to site.
g) Storage & handing at site.
All rights reserved

SHEET 8 of 10
h) Erection & Installation of all equipments and materials at site including

Mechanical, Electrical & Instrumentation work at site.
i) All piping works as per piping specification.
j) Mechanical Completion.
k) Hydro testing, Pre-commissioning and reliability runs.
l) Arrange all necessary instruments, tools/tackles required to aid pre-
commissioning, commissioning and performance guarantee tests.
m) Commissioning and performance guarantee run and handing over.
n) Clear the Battery Limit of all construction aids, debris, etc. and provide a tidy
work plan.
o) All documents/drawings shall be submitted by Bidders as per documentation
schedule & general specification as referred in technical specifications of
Civil, Mechanical, Electrical and Instrumentation. QAP shall be submitted for
the approval.
p) Design calculation of process and mechanical design, civil & structural
design for all the buildings, structures, equipment and systems. The bidders
shall show, explain and prove the validity of the basis/procedures and
methods used in these calculations.
q) 25 NB stainless steel DM water line from MB header to water analysis room,
instrument rooms, oil and gas analysis room, resin and raw material testing
room and pollution control room of chemical laboratory with Double Block &
Bleed isolation valves shall be provided.
r) 25 NB instrument air pipeline be provided in all the rooms mentioned under
clause (q) above.
s) Submission of O & M Manuals & Material Safety Data Sheet for all
chemicals shall be provided.
Must include following:
1. Detailed operational procedure of testing, pre-commissioning, start-
up, & operation of the sections including valve numbers.
2. Emergency shutdown, planned shutdown detailed procedures.
3. List of all instruments with settings of all process alarms, trip
interlocks, PSVs with settings, logic diagram with interlock narrative
4. Complete analysis procedures with list of all reagents to be used and
other instruments required.
5. Procedure for operation of all laboratory instruments / equipments.
6. Details of safety systems, MSDS of all chemicals
All rights reserved
SHEET 9 of 10
7. Procedures for handling upsets.

8. Design Basis, Equipment list, P&IDs, PFDs, heat & Mass balance
Technical specifications of all instruments and equipment,
9. All chemical consumption quantity related calculations, & utilities
consumptions
10. Individual instruments / equipment operating procedures,
11. List of chemicals and their normal consumption quantities,
12. CPCB / SPCB liquid, gaseous effluents list of parameters with the
limiting values
13. Operation manual must include all DCS pages, all tag numbers with
their process alarms ,the actions required for bringing the process to
normal, all explanation regarding deviation of parameters and their
consequences on process, All isolation of loops, sections for handing
over for any test or maintenance requirements, etc
14. All above also to include vendors documents.
15. Electrical load list
16. Six months operation supervision after PGTR of all plant are in
vendor scope.
17. Any other details as required.
t) Submission of detailed procedure for various performance tests and getting

the owners approval for the same.
u) Reviewing of all the drawings prepared by owner/PMC in connection with
this work like area layout, piping layout, piping terminals and interconnection
drawings of various panels, electrical cabling layout etc.
v) Apart from lab instruments provided in main laboratory, bidder shall provide
lab instruments for day to day operation of RWTP/DM/CPU Plants.
w) HAZOP study at PMC’s office Noida by external agency (charges of same to
be paid by Bidder) shall be considered by bidder. Bidder to implement
HAZOP study recommendations without any price & time implication.
x) Lubricants, Chemicals, Consumable etc. –As per Cl 1.2.9.2 of SCC
y) Submission of engineering drawing & document for Owner/PMC review &
approval. All drawing submitted to Owner/PMC shall be thoroughly
checked and authorised by contractor before submission.
z) N2 filling of equipment with Pressure gauge (PG) indicating the N2 pressure
with protecting cover for PG from getting damaged while transportations.
All rights reserved
SHEET 10 of 10
1) In addition to above, following attachments to be also referred for corresponding

departments:
i. Rotating : Attachment: Sec VI 3.1
ii. Static: Attachment: Sec VI 3.2
iii. Piping: Attachment: Sec VI 3.3
iv. Electrical : Attachment: Sec VI 3.4
v. Instrumentation : Attachment: Sec VI 3.5
vi. Civil & Structural work: Attachment: Sec VI 3.6
vii. Construction: Attachment: Sec VI 3.7
All rights reserved

PC150/E/4004/SEC-
0
VI-3.0 (PART-A)
PROJECTS & DEVELOPMENT INDIA REV
DOCUMENT NO
LTD SHEET 1 OF 2

PROJECT:INTEGRATED COAL BASED FERTILIZER COMPLEX


All rights reserved

PC150/E/4004/SEC-VI-
RWTP ,DMW & CPU PLANT 3.1 (PART-A)
0
TALCHER FERTILIZERS LTD. DOCUMENT NO REV
CONTRACTOR SCOPE OF WORK SHEET 2 of 2
1.1.4.3 Rotating equipment : (For details, refer section 5.2.2 )
Bidder’s scope of work shall include complete basic & detailed engineering,
procurement, supply, manufacturing, fabrication, transportation, loading,
unloading, insurance during transit, storage, construction, erection/ installation of
all Mechanical Rotating Equipment with allied electrical, instrumentation and
civil works, obtaining all necessary statutory approvals from concerned
government authorities as applicable, testing, mechanical completion, pre-
commissioning, commissioning, performance guarantee test runs including total
project management and handing over of RWTP,DMW & CPU Plant of
prescribed capacity for M/s TALCHER FERTILIZERS LIMITED ( TFL),
ODISHA.
Bidder’s scope of Work shall include but not be limited to following:
a) Complete design of rotating equipment.

b) Detailed engineering of equipment including all mountings, accessories &
bought-out items.
c) Procurement of all materials & bought out items.
d) Shop fabrication (as applicable) & assembly.
e) Inspection, testing (including hydro testing)
f) Surface preparation, painting, insulation, pickling and Passivation etc.
g) Packing , forwarding, transportation, loading & unloading, etc.
h) Storage and preservation at site.
i) Statutory approvals.
j) Stage wise and final inspection by appointed TPIA & Owner.
k) Any other requirement for safe and smooth operation.
l) Submission of engineering drawing & document for Owner/PMC review &
approval. All drawing submitted to Owner/PMC shall be thoroughly checked
by contractor before submission.
m) Supply of “As Built documentation and QC dossiers”.
All rights reserved

PC150/E/4004/SEC-VI-3.2 0
(PART-A)
DOCUMENT NO REV
LTD SHEET 1 OF 3
(MECHANICAL STATIC EQUIPMENT)


TALCHER, ANGUL DISTRICT, ODISHA (INDIA)

PC150/E/4004/SEC-VI-3.2 0
SCOPE OF WORK (STATIC EQUIPMENT)
(PART-A)
RWTP ,DMW& CPU PLANT DOCUMENT NO REV

TALCHER FERTILIZERS LTD. SHEET 2 OF 3
1.0 Scope
This specification covers the requirements for the complete design ( Mechanical), procurement,
fabrication, construction/erection , insulation, painting ,Pickling & Passivation (for SS equipments),
inspection and testing of static equipment ( Pressure Vessels, Heat Exchangers, Storage Tanks, and
Vessel Internals e.t.c) for RAW WATER TREATMENT, DMW PLANT & CONDENSATE POLISHING
UNITof the M/s TALCHER FERTILISER LIMITED, ODISHAin accordance with this specification,
standards specification, codes and other attachment etc. listed in bid document.
Bidder scope of Work (For Static Equipment) shall include but shall not be limited tofollowing:
a) Complete mechanical design & thermal design (For heat exchanger).
b) Detailed engineering of equipment including all mountings, accessories & bought-out items.
c) Procurement of all materials & bought out items.
d) Shop/site fabrication ( as applicable) & assembly
e) Route survey, if required
f) Inspection, testing (including hydro testing)
g) Surface preparation, painting , insulation, pickling and Passivation (for SS equipments),
internal and/or external coating, epoxy coating, rubber lining e.t.c
h) Packing (seaworthy when sea transportation)forwarding, transportation to site etc.
i) N2 filling of equipment
j) Storage and preservation at site
k) Statutory approvals
l) Stage wise and final inspection by appointed TPIA/Owner
m) Fire proofing as per requirement of the bid package
n) Any other requirement for safe and smooth operation
o) Submission of engineering drawing & document for Owner/PDIL review. All drawing
submitted to owner/PDIL shall be thoroughly checked by contractor before submission.
p) Supply of “As Built documentation and QC dossiers”.
The above mentioned activities shall be carried out in accordance with applicable code and all
technical requirements covered in the bid package.
1.1 Scope of supply (For Static Equipment)

PC150/E/4004/SEC-VI-3.2 0
SCOPE OF WORK (STATIC EQUIPMENT)
(PART-A)
RWTP ,DMW& CPU PLANT DOCUMENT NO REV

TALCHER FERTILIZERS LTD. SHEET 3 OF 3
Bidder scope of supply shall include but shall not be limited to following:
 Supply of static equipment( Vessels, heat exchanger , Tanks, PHE e.t.c) including their
accessories
 Supply of all fabricated and proprietary internals for all equipment as applicable.
 Supply of mandatory (spare parts for two yearoperation) and commissioning spares attached
elsewhere in bid package.
 Insulating material, primer paints, fire proofing material e.t.c.
 Supply of material & equipment required for blast cleaning, chemical cleaning, pickling
passivation, surface preparation & polishing & coating of internal surface, epoxy coating,
rubber lining,and FRP lining e.t.c. for equipment as applicable.
 Supply of all equipments , tool & tackles including torque wrench, bolt tensioner e.t.c. as per
specification and all material required for inspection and testing ( i.e. NDT, Hydro testing,
performance testing e.t.c) erection & Hydro testing including all site re-hydro tested
equipment.
 Supply of all tools and tackles, template for foundation for heavy lift equipment and for the
erection for all equipment.
 Eye bolts, jack screws, dowel pins and lifting lugs etc. as required
 Lifting lugs / erection lugs
 Cleats for earthing connections
 Name plate with bracket
 Cover flanges for manholes, handholes, inspection openings etc. with bolting and gaskets.
 Supply of all other materials whether specifically mentioned or not but required for
completion of the job in all respect as per bid package.

PNMP‐TS‐6000 0
DOCUMENT NO REV
PROJECTS & DEVELOPMENT INDIA LTD
SHEET 1 OF 6

ENGINEERING SPECIFICATION–PIPING
(FOR PACKAGE UNITS)




PNMP‐TS‐6000 0
ENGINEERING SPECIFICATION – PIPING DOCUMENT NO REV
(FOR PACKAGE UNITS)
SHEET 2 OF 6

CONTENTS
SECTION
DESCRIPTION SHEET NUMBER
NUMBER
1.0 GENERAL PIPING SCOPE OF WORK 3
2.0 DESIGN & DETAILED ENGINEERING 3
3.0 PROCUREMENT & SUPPLY BY BIDDER 4
4.0 INSPECTION 4
5.0 PAINTING 5
6.0 CONSTRUCTION 5
7.0 BIDDER’S RESPONSIBILITY 5
8.0 DRAWING/ DOCUMENTATION SCHEDULE 6
9.0 PACKAGING 6
10.0 DOCUMENTATION WITH BID 6
LIST OF ATTACHMENTS
SL NO.OF
DOC.NO. DESCRIPTION
NO. SHEETS
B20, B22G, B22IS, B24, B24P, B24RL,

1 PIPING MATERIAL CLASSES 29
B24S, B24F, B24FL, B24D, B50, D24, F24
BAV201, BAV202, BAV210,

2 BAV211,BAV222, BAV501, BAV510, DATA SHEETS- BALL VALVES 8
BAV520
3 BUV202, BUV203, BUV204, BUV510 DATA SHEETS- BUTTERFLY VALVES 4
CHV201, CHV201S, CHV207, CHV210,

4 CHV210D, CHV210S, CHV212, CHV211, DATA SHEETS- CHECK VALVES 12
CHV501, CHV510 , CHV511F, CHV520
GAV201, GAV201S, GAV207, GAV210,

5 GAV210S, GAV211,GAV212, GAV501, DATA SHEETS- GATE VALVES 9
GAV510,
GLV201, GLV201S, GLV210, GLV210S,

6 DATA SHEETS- GLOBE VALVES 8
GLV211,GLV212, GLV501, GLV510
7 NEV501 DATA SHEETS- NEEDLE VALVES 1
PLV201, PLV202, PLV205, PLV501,

8 DATA SHEETS- PLUG VALVES 5
PLV510
BAV500C, BAV501C, CHV500C,
9 DATA SHEETS- MISC VALVES 1
GAV500C
TTS210, TTS510, YTS201, YTS210,
10 DATA SHEETS- STRAINERS 7
YTS501, YTS510
11 EM0000-PNMP-TS951 DESIGN PHILOSOPHY – PIPING 34
12 PC-150-PDS-600 OTHER STANDARDS / DATASHEETS 11

PNMP‐TS‐6000 0
(FOR PACKAGE UNITS)
SHEET 3 OF 6

13 PC009-0000-0001 PLOT PLAN 1
1.0 GENERAL PIPING SCOPE OF WORK

1.1 The detail scope of work includes such as but not limited to complete management,
Design, Detailed Engineering, 3D modelling, Stress Analysis, to provide all the
necessary data, drawings, documents required as per the project requirements,
Procurement, Supply, Transportation of materials, shop & site Fabrication, Erection,
Installation, Supporting, Non-Destructive Testing (NDT) & required Inspection , pre-
heating, dye-penetrant test, Magnetic Particle Test, post weld heat treatment,
radiography, Ultrasonic test , Testing, Flushing, Air drying, blowing , cardboard-blasting ,
seal/leak-testing, Pre-Commissioning, Trial run, Commissioning and Guarantee of all the
associated works pertaining to complete piping system and related facilities for Raw
Water Treatment, DMW Plant & Condensate Polishing Unit at TFL, TALCHER.
1.2 Design, material, fabrication and erection shall be in accordance with latest edition of
ASME B31.3 chemical plant and petroleum refinery piping code. The dimensions,
manufacturing tolerances shall conform to applicable standards.
1.3 All works described in this package shall be performed in accordance with the design-
basis, specifications, drawings, and other requirements of NIT and shall be subject to
Owner’s review and approval.
1.4 MATERIAL OF CONSTRUCTION
Materials as per internationally acceptable code shall be used for piping based on service
requirement. All materials for piping Components shall conform to ASTM or API
Specifications as per enclosed piping specifications. All piping materials and valves shall
be procured from the reputed approved suppliers/vendors.
1.5 Cost of piping job shall also include the cost of supervision, Labour, overheads / profits,
materials, consumables, scaffolding and all other associated arrangements required to
execute the related activities of this package.
1.6 PIPING INTER - CONNECTION
Piping lines as per P&ID, shall be provided at battery limit which shall be indicated later
by Owner. Bidder shall provide valve at battery limit for respective piping system of the
package unit.
1.7 SPARES
Two years operation spares shall be quoted as recommended by bidder for this
package unit.
1.8 After completion of erection jobs, all piping system will be suitably hydraulically tested as
per the test pressure indicated in the line list / relevant document approved by owner.
2.0 DESIGN AND DETAILED ENGINEERING BY BIDDER

2.1 Collection of all data/ information furnished in the NIT and additionally collected/
generated by Bidder.
- Finalization of design data/ basis for carrying out design, detailed Engineering for
complete scope of work as per project specifications, contained in the NIT.
2.1.1 Performing design and detailed engineering of the following:
a) Complete piping system for the package unit.
b) Carry Out all necessary calculations in accordance with approved design basis, drawings
/ documents and requirements of the NIT.
c) Finalization of layouts for the unit and preparation of construction drawing, preparation of
piping drawings, equipment layouts, piping general layout drawings (GAD’s) , pipe

PNMP‐TS‐6000 0
(FOR PACKAGE UNITS)
SHEET 4 OF 6

supports, piping isometrics. Typical indicative sketches/drawings included in NIT
document shall be taken as broad basis for developing the layouts. Since the availability
of free space is limited, Bidder shall plan his piping layouts in such a way so as to
minimize the area requirement while giving due importance to ease of access, operation
and maintenance of the facilities installed by the Bidder. The fabrication/erection & all
other piping jobs shall be carried out as per drawings/documents approved by Owner.
d) Carrying out Material Take Off for the entire piping system for the package unit.
e) The detail design shall take into consideration of local Statutory Regulation, if any, for the
package unit.
3.0 PROCUREMENT & SUPPLY BY BIDDER

3.1 Bidder shall procure and supply all materials whatsoever required for
temporary/permanent installation of piping system in sequence and at appropriate time.
All equipments, materials, components etc shall be suitable for the service and the
design life of the system.
3.2 Bidder shall procure all materials, components, equipments, consumables etc required
for successful completion of the piping system. Bidder shall also procure spares required
for pre-commissioning and commissioning/start-up the as recommended for all the items
supplied by him as per specifications provided in the NIT. Where no specifications are
available in the contract, the same shall be prepared by the Bidder, and shall be subject
to Owner’s approval.
3.3 Material take-off with complete description of size, rating, material, thickness and
specifications.
3.4 Preparation and finalization of data sheets for all piping materials e.g. all valves etc. All
data-sheets shall be subject to review and approval by Owner.
3.5 Preparation of Material requisitions, Request for Quotation & its evaluation and
recommend Bidders for Owner’s approval. Preparation of purchase requisitions, review of
Bidder’s drawings and calculations, approval of manufacturing procedures wherever
necessary, and the party inspection at manufacturer’s works of the materials by reputed
agencies as required. Quality control and expediting of all procured items at Bidder’s
shop or at fabrication yard.
3.6 Bidder shall procure materials as per specifications and list of approved
Vendors/Suppliers (for major Items) included in the bid document.
3.7 Carry out proper documentation of inspection and quality assurance programs for all
equipment and bulk materials duly approved by Owner. Bidder shall maintain an accurate
and traceable listing of procurement records for the location, quality and character of all
permanent materials in the Project.
3.8 Bidder shall immediately report to the Owner of all changes which will affect material
quality, and take necessary corrective actions. Purchase requisitions including Purchase
Orders of all major items shall be approved by Owner. For balance items, records shall
be furnished for information only.
3.9 Compliance with Bidders and supplier’s instructions and recommendations for
transportation, handling, installation and commissioning.
4.0 INSPECTION
4.1 Inspection authority means the Third Party Inspection Agencies (TPIA) approved by the
Owner to carryout inspection of materials.
4.2 The inspecting authority shall have the right to select random samples for check test and
reject materials, if samples furnished as above and tested as per the specifications fail to
meet the requirement specified.

PNMP‐TS‐6000 0
(FOR PACKAGE UNITS)
SHEET 5 OF 6

4.3 All the items shall be inspected and tested in the presence of one or more
representatives of the purchaser during various stages of manufacturing. Material shall
be considered acceptable for dispatch only after final certificate of acceptance is issued
by the Inspector.
4.4 Testing performed in the presence of the purchaser’s representatives shall not relieve the
supplier of their own responsibilities and guarantees and any other contractual
obligations.
4.5 Quality Assurance plan (QAP) / Inspection Test Plan (ITP) shall be submitted by bidder
for approval by Third Party Inspection Agency (TPIA).
4.6 Scope of Inspection by TPIA:
Review of MTC (all batches).
Visual check for surfaces, external appearance (10% random witness).
Dimensional check (10% random witness).
Positive Material Identification (PMI) for alloy steels (10% random witness).
Hydrostatic test (10% random witness).
Packing: Report review.
Documentation (MTC, Inspection Release Note): 100% Review
5.0 PAINTING
Painting shall be as per specification attached elsewhere in NIT.
6.0 CONSTRUCTION
All construction works be carried out as per “Approved for Construction” drawings,
procedures, specifications and applicable codes and standards. Any changes at site shall
also need prior approval from the Owner and revision of drawings.
Bidder shall procure and supply all materials whatsoever required for
temporary/permanent installations of piping system in required and at appropriate time.
All equipment, materials, components etc. shall be suitable for the intended service and
the design life of the system. Wherever no specification is available in the contract, the
same shall be prepared by the Bidder and shall be subject to Owner approval.
7.0 BIDDER’S RESPONSIBILITY

All works shall be carried out by Bidder in accordance with the drawings / documents /
specifications indicated in the subsequent paragraphs.
7.1 Specifications
7.2 Standards
7.3 Piping Support Standards
7.4 Drawings
7.5 Design Review
7.6 Bidder shall submit all proposal designs, analysis, drawings, installation and testing
procedure for review & approval by Owner as mentioned in the scope work. Bidder shall
as a minimum, provide above deliverables for Owner’s information / records & review /
approval.
7.7 Typical Plot Plan drawing of package unit is attached in the NIT. This drawing is
INDICATIVE only and is furnished for Bidder’s information. Issued for construction (IFC)
drawings shall be prepared by Bidder after detailed engineering being done by him and
shall be subject to approval by the Owner.

PNMP‐TS‐6000 0
(FOR PACKAGE UNITS)
SHEET 6 OF 6

7.8 The Bidder shall submit separately, the material take off for piping, valves, fittings and all
other accessories as per requirements.
7.9 Bidder shall obtain statutory approval from various authorities having jurisdiction over the
area, as necessary, for construction of the unit package.
8.0 DRAWINGS/ DOCUMENTATION SCHEDULE

Bidder shall furnish all the drawings/ documents to Owner for comments/ approval. He
shall incorporate all comments/ modification suggested by Owner. The
drawings/documents should be properly organised, supplied & submitted as per
documentation schedule of NIT.
9.0 PACKAGING
9.1 Items shall be thoroughly dried, cleaned and shall be free from moisture, dirt & loose
foreign materials, with ends protected from mechanical damage during transportation,
shipment & storage.
9.2 For transportation overseas, protection and packing shall be adequate to prevent
damage from sea atmosphere.
10.0 DOCUMENTATION WITH BID

Following drawings/documents must be submitted along with the bid.
i) Proposed equipment layout drawing.
ii) Proposed piping Layout drg.
iii) Quality control procedure & plan for piping system.
iv) Completion schedule of piping job in Bar-chart format.
v) List of all construction equipments, tool-tackles & man power resources proposed to
be used.
vi) Clause wise list of deviations / exclusions, if any, to bid requirements shall be
furnished. Bidder is cautioned that exclusions and deviations listed elsewhere in bidder’s
offer shall not be considered for evaluation.

PC150/E/4004/SEC-VI-3.0 (PART-
0
A&PART-B)
PROJECTS & DEVELOPMENT INDIA LTD DOCUMENT NO REV
SHEET 1 OF 5

SECTION – VI 3.4 (PART-A & PART-B)



0
A&PART-B)
SHEET 2 OF 5

Electrical Scope of Work for Raw Water Treatment Plant - DM Water - Condensate Polishing
Unit - Effluent Treatment Plant
Manufacture, testing at works, getting inspected by owner and/ or their consultant/ third party, packing,
transportation and delivery to site in well packed condition, insurance during transit and till commissioning &
handing over, storing at site as per recommendation of manufacturer/ supplier/ direction of supervising
engineer of Owner/ Consultant until required for erection, transportation to work place. Erection, testing &
commissioning, handing over of complete electrical system of ‘Raw Water Treatment Plant - DM Water -
Condensate Polishing Unit - Effluent Treatment Plant’ (hereinafter referred as Plant in short) comprising, but
not limited to :
a. Bus Ducts
b. Transformers viz.
 11/3.45 , 11/0.433 kV, 3.3./0.433 V Transformers, as required
 Lighting Transformers
c. Switchgears:
 11 kV / 3.3 kV ICOG Panel, as required
 11 kV Switchgears/ switchboards, as required
 3.3 kV Switchgears/ switchboards, as required.
 415 Volt Switchgears/ switchboards including PCCs, PMCCs, MCCs, EPMCCs MLDBs,
ASPBs, LSDB, PDB, Junction boxes etc as required.
 Local control Panels, Local Control stations, Switch Sockets.
 Variable Frequency Drive Panels / Soft starters, as required
d. 11kV, 3.3kV, 415V Motors and other special application/ voltage motors as required.
e. All Cables viz
 Power Cables (11kV, 3.3kV and 1.1kV)
 Control Cables,
 Earthing Cable
 Signal cables,
 Optical fibre cables
 Data Cables
 Communication cables
 Special application cables
f. Erection/ installation & all sundry materials for installation, testing & commissioning of equipment/
panels/ fittings/ cables (including jointing & termination of cables) comprising (but not limited to)
following:
 Foundations,

0
A&PART-B)
SHEET 3 OF 5

 Brackets, support structures, erection materials & accessories, as required
 Cable trays, racks, pipes, ducts, cable channels etc as required.
 Testing checking kits/ instruments
g. Illumination system - Normal, Emergency and Panic Lighting
h. Aviation lighting, as required.
i. Neutral Grounding, NER.
j. Earthing of equipment & structures.
k. Protection against lightning.
l. 110V DC Batteries, Battery Charger and DC Distribution Boards.
m. 115V AC UPS Panels with batteries & UPS & UPS Power Distribution Boards for Instrument.
n. 240V AC UPS with batteries & UPS & UPS Power Distribution Boards for Electrical.
o. Complete Electrics for Air Conditioning and Ventilation systems.
p. Complete Electrics for Chemical Dosing System.
q. Complete Electrics for fire fighting system,
r. Complete Electrics for EOT Crane, Hoists,
s. Plant Communication system
t. Cathodic Protection System.
u. Public Address System for Plant and interface & Seamless Integration of same with Owner’s
Public Address System..
v. Fire Detection & Alarm System for Plant and interface & Seamless Integration of same with
Centralised Fire Detection & Alarm System .
w. Cable trench/Cable tray with supporting structure.
x. Substation (for Raw Water Treatment Plant), Substation (for DM Water Plant and Condensate
Polishing Unit) and Substation (for Effluent Treatment Plant), all along with Transformer Rooms.
y. Fire fighting systems for Electrical Equipment/ Panels by gas flooding.
z. The scope shall also include the erection, testing, commissioning of above equipments.
aa. The contractor shall clear the site after commissioning of the equipments / system and obtain the
Site Clearance Certificate from owner’s Engineer-in-charge
bb. Any and all other Materials, Equipment and Services so as to make a totally integrated and
functional system together with all accessories and associated equipment, ensuring safety,
maintainability and reliability in compliance with all applicable codes, standards, guidelines,
statutory regulations and safety requirements in force.
cc. Any other equipment, not specified, but required for safe, proper, trouble free and efficient
operation of the system
dd. LSTK Contractor shall consider any other requirement which is not covered in this NIT, but
required for successful operation of the plant.
ee. Spares & consumables for complete electrics as follows:

0
A&PART-B)
SHEET 4 OF 5

 Commissioning Spares (as per Clause No. 20.0 of Design Philosophy-Electrical) and Spares
for 2 Years operation (Mandatory/Insurance) for all equipments (as per Section 10.0: Spare
Parts) shall be supplied by the Contractor as part of LSTK contract.
 LSTK Contractor shall recommend 2 years Operational Spares (other than mandatory /
Insurance Spares) for all the equipment (item-wise) with recommended quantity & unit price
with validity of 2 Years. The same shall not be part of LSTK price.
 Spares and consumables required and first oil fills including short fall during erection, testing,
cold trials, commissioning, performance evaluation tests, guarantee tests etc and till handing
over of installation.
ff. Tools& Tackles.
gg. Testing Equipments/ instruments
hh. Arranging services of major equipment suppliers during installation and commissioning.
ii. Training of Owner’s Personnel for Operation & maintenance of the Plant.
jj. Any and all other items/ facilities/ services not specifically mentioned but essential/ required for
completeness of the systems/ equipments/ facilities.
kk. Relay Co-ordination & Relay Settings etc.
ll. Obtaining statutory approval from all statutory bodies.
1.1 LSTK Contractor shall consider following additional feeders in their 3.3 kV Switchboard / 415 V
Switchboards / UPS Distribution Board of Raw Water Treatment Plant Substation for Owner’s use
a) 3 Nos. additional feeder of 250 KW (2W + 1S) for Raw Water Pumps motors in their 3.3 kV
Switchboard. These motors shall be located in Water Reservoir Pump House
b) 1 Nos. additional feeder of 250 KW for Fire Water Make-up Pump motor in their 3.3 kV
Switchboard. This motor shall be fed from Emergency Power. Considering the same, 3.3 kV
Switchboard shall have 3 Nos. Incomers 2 Normal, 1 emergency. This motor shall be located in
Water Reservoir Pump House.
c) 1 No. Additional Spare feeder of 250 KW motor in their 3.3 kV Switchboard.
d) 3 Nos. 125A power feeders in their 415 V EPMCC for EOT and other Loads of Water
Reservoir.
e) 2 Nos. 125 A Feeders (Indoor Bus) and 1 No. 125A Feeder (Outdoor Bus) in MLDB for Lighting
Loads of Water Reservoir.
f) 2 Nos. 125A Feeders in ASDB for Switch Sockets of Water Reservoir.
g) 1 No. 32A power feeders in their 115 V AC UPS Distribution Board for UPS Loads of Water
Reservoir .
LSTK Contractor to provide required provision in their transformers, Switchboards and other
associated equipments for feeding these loads.
1.2 Separate PMMCC and separate EPMCC shall be provided for Raw Water Treatment Plant, DM Water
Plant, CPU Plant, and Effluent Treatment Plant.

0
A&PART-B)
SHEET 5 OF 5

1.3 Separate Substations shall be provided for Raw Water Treatment Plant, DM Water Plant, CPU Plant,
and Effluent Treatment Plant.
1.4 Tapping of Normal Power and Emergency Power from dedicated feeders at Offsite & Utilities
Substation shall be in LSTK Contractor’s scope.

0
3.0 (PART-A)-5.4
SHEET 1 OF93

SECTION – VI 3.5 (PART A)

CONTRACTOR SCOPE OF WORK/DESIGN PHILOSPHY -

INSTRUMENTATION



PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
TALCHER FERTILIZERS LTD.
SHEET 2 of 93
CONTENTS
SECTION NUMBER DESCRIPTION
1.0 Instrumentation And Controls PHILOSOPHY

2.0 Documentation
3.0 Control Philosophy (General)
4.0 Instrumentation Code And Practices
5.0 Hazardous Area Classification & Electrical Execution
6.0 Electrical Supply
7.0 Field Instruments
8.0 Control system
9.0 Local Control Panel
10.0 Pneumatic transmission
11.0 Erection , installation & commissioning
12.0 Storage Tank
13.0 CCTV System
14.0 Training
A. List of Annexure:
ANNEXURE DESCRIPTION
NUMBER
ANNEXURE-1 Instrumentation Accuracies
ANNEXURE-2 Instrument process connections
ANNEXURE-3 System Configuration
ANNEXURE-4 OS/ES/SOE specification
ANNEXURE-5 Cable Sizes
B. List General Specification
ATTACHMENT NUMBER DESCRIPTION

GSTD-0100 GENERAL SPECIFICATION FOR INSTRUMENT TUBE FITTING
GSTD-0101 GENERAL SPECIFICATION FOR INSTRUMENT TUBING
GSTD-0102 GENERAL SPECIFICATION FOR INSTRUMENT VALVES AND
MANIFOLD
GSTD-0103 GENERAL SPECIFICATION FOR JUNCTION BOXES AND
CABLE GLAND
GSTD-0201 GENERAL SPECIFICATION FOR DCS & PLC SYSTEM
GSTD-0202 GENERAL SPECIFICATION FOR PLC SYSTEM
GSTD-9998 INSPECTION AND TEST REQUIREMENTS
1.0 INSTRUMENT AND CONTROL PHILOSOPHY

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 3 of 93

SCOPE
The description and requirements contained in this specification are concise by

necessity and cannot include all details. However, it is the responsibility of the
contractor to execute the job on a turnkey basis in accordance with the specifications
and internationally recognized good engineering practices for smooth and successful
operation of various units of the plant.
Any activity specifically not listed in this document, does not absolve the contractor of
their responsibility to include such activities in their scope of work and supply, which
otherwise is necessary, to complete instrumentation work for the WTP/DM plant. All
such activities shall be carried out by the contractor without any implication.
This section outlines the general requirements and specifications for Instrumentation
and Control System for Design, Engineering, and Manufacture, Shop test, third party
Inspection, Supply, erection and commissioning of Water Pre treatment, DM water
treatment plant along with associated facilities. The Instrumentation and Control
System shall consist of but not limited to the following:
 Water pre-treatment package plant shall be provided with DCS/PLC based control
system. This control system will accommodate all control/trip and monitoring
signal/functions for raw water pre-treatment plant (RWPT), DM plan, Condensate
polishing unit and drinking water.
 Common DCS/PLC has been considered for WTP package and bidder to ensure
segregation of individual plant level signals at AI/AO/DI/DO card level so as to
ensure the reliability of the system.
 The Complete DCS/PLC control system i.e. marshalling panels, Cabinets (System,
I/O, PDB, IRP etc.) HMI/Consoles, printers, furniture etc. for the above package
shall be housed in the new air conditioned control room for this package.
Construction of CR with HVAC (Control room) shall be in bidder scope.
o 3 nos. OS, 1 no. ES cum OS with SOE, with dual LED monitors will be used
for controlling Water Pre-treatment package out of which 2 nos. OS will be
placed on the consoles of CR, 1 no. ES cum OS cum SOE will be placed
on the consoles of engineering room.
o Left out one no. OS will be placed in the CCR operator room.
o One no. Aux. Console with Ann. window, push buttons, switches for critical
trip and alarm shall also be provided.
o RIO shall not be considered anywhere in the package.

 The control room shall have console area, engineering room, equipment/rack
room, 2 nos. Manager room, 1 no. supervisor room, UPS, battery, meeting room,
pantry room, ladies and gents toilet as minimum.
 Separate entry & exists with Air lock doors shall be considered for control room.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 4 of 93

 2 Nos. Corrosion monitoring (copper & silver) with temperature and humidity
measurement of M/S PURAFIL make shall be mounted in control room. The
location of the monitors must be near the duct and cable entry. The four different AI
signals corresponding to above measurements from these two monitors shall be
connected to contractor control system with suitable soft alarms.
 Suitable Clean Agent System as per NFPA 2001 shall be provided in control room.
 Packaged Air conditioning (HVAC) of control rooms. It shall be designed

considering the equipment heat loads, solar heat loads, heat gain into the room,
adequate no. of air changes etc. to maintain a uniform temperature and relative
humidity within the air conditioned areas.
 All the required protections & interlocks shall be carried out in DCS/PLC. All the
features such as graphics, alarms, and process parameters display diagnosis for
plant equipment shall be displayed in package’s operator station installed in the
CR.
 For important operating data and indications required for surveillance and
monitoring, a provision shall be made to repeat the signals in Client’s DCS/ ESD
from WTP package control PLC/DCS, wherever applicable. For this bidder to
provide communication redundant port, MODBUS TCP/IP. Bidder to provide
necessary interfacing cards in the CR and CCR. All the hardware & software
required for the same shall be in bidder scope.
 Network securities shall be provided by Vendor in all control rooms as per IEC
62443 for protection of the system from both internal and external threat. The
requirement includes all USB port blocking (including all monitors / CPU), provision
of sufficient firewalls, and antivirus update for one year, patch update;
unauthorized logging recording with events etc. must be addressed by Vendor.
 The Instruments in general shall be Electronic Micro processor based type with
latest revision of software. The field instrumentation i.e. Flowmeters, Transmitters,
Smart Positioner, etc. shall have latest HART protocol latest version as minimum.
 All equipments/instruments/system oriented items (with all its sub-systems) shall

be of field proven quality both with respect to design and materials. Prototype
instruments or instruments of an experimental nature shall not be offered or
supplied. In general, all the supplied items by supplier shall have a well proven
performance record of operating satisfactorily in a Offsite/Acid Plants for minimum
of one year. No instrument requiring special maintenance or operating facilities
shall be offered or supplied as far as possible. PTR for field instruments shall be
considered min for 2 years.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 5 of 93

 Preparation of engineering and construction documents like functional schematics,
I/O list, logic diagrams for interlocks as per ISA 5.2 with functional descriptions,
configuration diagram, electrical load list, cable schedule, cable tray/trench layout,
instrument air requirement, nameplate schedule, JB schedule, instrument location
layout, electrical instrument signal interface, instrument index, layout drawings,
loop diagrams, primary and secondary sketches and bill of materials, any other
drawing or documents which is required for package erection & commissioning and
SAT as well.
 Preparation of all engineering documents for DCS/PLC like graphic schemes,

instrument loop data base, log formats and any other documents necessary to
carry out the system engineering of DCS/PLC.
 Co-ordination with Control system vendor for system engineering, implementation,

software testing, supply and final commissioning and site acceptance tests.
 Co-ordination with all instrumentation vendors for obtaining sufficient information in

the form of documents, drawings for engineering and approval from OWNER.
 Preparation of specification for erection materials like cables (Signal, power,

control, Optical fiber etc), cable trays, pipe & pipe fittings, air tubing, junction
boxes, air distribution pots etc.
 All system cables/fiber optic cables in the field (including communication between
CCR and CR) shall be routed in HDPE Hard pipe. Fillings shall be used for joining
the HDPE pipe. HDPE pipes shall be ORANGE in colour with BLACK fillings. All
system cables/fiber optic cables shall be routed in the middle 150mm portion of the
tray. Wherever it is absolutely necessary to route these cables underground, it
should be routed in the RCC Trenches only.
Separate route should be followed for redundant system cables. Supply of Cable
trays and laying of cables through trenches upto CCR are in bidder scope.
 No copper or copper alloy shall be used for the parts coming either in contact with
process fluid or outside atmosphere.
 Package vendor shall be responsible for local instruments, controls, local panels,
installation & wiring, trays & cable laying & termination to junction boxes within the
battery limit. Bidder’s scope shall also supply, laying, termination of multi-core
cable in the junction boxes within battery limit as well as multi-core cable and other
inst. /power cables in package DCS/PLC located at Control Room.
 On line continuous monitoring analyzers system shall be provided to measure
Sodium, Silica and Chlorine to ensure that water is not contaminated.
 All instruments and equipments shall be suitable for use for specified site climatic
conditions and industrial environment in which corrosive gases and/or chemicals
may be present. As a minimum, all instruments and enclosures in field shall be
dust proof and weatherproof to IP-67 as per IEC-60529 or equivalent NEMA 4X
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 6 of 93

enclosure rating or better and secure against the ingress of fumes, dampness,
insects and vermin. All external surfaces shall be suitably treated to provide
protection against corrosive plant atmosphere.
 All Inst. JB’s shall be of FRP material with minimum 4 mm thickness with proper
support to protect against corrosive environment and cable entry shall be from
bottom only.
 The design of electronic instruments shall be in compliance with the

electromagnetic compatibility requirements as per IEC 61000-4 ''Electromagnetic
compatibility for Industrial Process measurement and Control equipment''.
 Process switches, shall be realized through field transmitters only. If for some
packages, process switches are unavoidable same shall be provided, with
Client/PMC approval, with sealed micro switch contacts rated for the specified
application. Contacts shall be 1 no. DPDT preferably. Otherwise 2 nos. SPDT can
be considered. All switch contacts except those used in intrinsically safe circuits
shall be silver plated. Contacts used in intrinsically safe circuits shall be suitable for
the applications. Switches shall be hermetically sealed type. Switches shall be
connected through interposing relays. The material of its construction shall be
resistant to acid environment.
 All Field transmitter supports should be properly clamped with SS304 accessories
to the pipe for pre-fabricated wherever required and closed couple installation. No
air gap shall be kept between support clamp and pipe.
 All Solenoid valves shall be Intrinsically Safe type (24 V DC), with details inside the
design basis. Solenoid valve body material shall be SS316. All critical loops must
have redundant SOV’s.
 All online/offline process analysers and gas detectors shall be supplied complete
with proper calibration apparatus / calibration gas cylinders, local indication etc.
Auto calibration facility need to be provided for the analysers and gas
chromatographs, if applicable. Wherever auto calibration features are not available
for any analysers from the approved manufacturers, manual calibration shall be
considered.
 Other specification like panel earthing, instrument earthing, MCT material, temp
monitoring inside panels, inside CR the scope of vendor shall still be as per
contract, UPS monitoring alarms in control system, H2 detector in battery room etc.
shall be as specified elsewhere in this tender.
 Fire Detection & Alarm system to be considered and hook up / interface with
redundant configuration with main fire alarm system located in central fire station.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 7 of 93

All engineering, design, erection, commissioning, cable laying etc. Shall be done
by the bidder.
 In the event of any conflict between this specification, related standards and codes,
any other attachment to this package or process packages, the contractor shall
follow the following documents in the order of their priority:
General Standard specification attached
Licensor’s recommendation
Statutory requirements and codes & standards
WTP/DM plant shall be providing as per below mentioned Control System:
OPTION 1
DCS based control system for Control & ESD function also with applicable redundancy
as specified in this tender. This control system will accommodate all control/trip and
monitoring signal/ functions. One redundant controller with I/O cards (redundant cards
to be considered only for closed loops signals) for control & monitoring application and
one separate redundant controller with redundant I/O cards for trip/shutdown functions.
Scan time of the controllers shall not be more than 250 msec.
Control system for WTP/DM plant shall be placed in CR.
(Detail specification of DCS shall be share with the bidder on later stage.
OPTION 2
PLC based control system (TMR/DMR)
Scan time of the controllers shall not be more than 250 msec. (Other requirements for
PLC system shall be per NIT)
o 3 nos. OS, 1 no. ES cum OS with SOE, with dual LED monitors will be used for
controlling Water Pre-treatment package out of which 2 nos. OS will be placed on the
consoles of CR, 1 no. ES cum OS and 1 no. SOE station will be placed on the
consoles of Engineering room.
o One no. Aux. Console with Ann. window, push buttons, switches for critical trip and
alarm shall also be provided.
Dedicated SOE work station is not required. Engineering station shall have feature of
SOE.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 8 of 93

Bidder to consider one no. Additional I/O card (16 channel) of each type i.e AI/AO/DI/DO
for raw water storage pumps package (pumps are not in bidder scope). As the I/O of these
packages are very less, it will be connected to additional I/O card and control system of
DM/RWTP, in the control room. Accordingly, execution of one or two small interlock and
development of 2-3 graphic pages in the bidder control system are in bidder scope.
2.00 DOCUMENTATION
SL Document Description Document to be submitted *

No
With Bid After order Final
for approval
1 List of Instruments (tag wise) Yes Yes Yes
indicating type of Instrument, make,
model no., quantity etc.
2 Instrument mounting and connection Yes Yes
details
3 Instrument layout drawings Yes Yes
4 Catalogue of Instruments & System Yes Yes
5 List of spares (item wise and Yes Yes Yes
quantity) for Commissioning and 2
years of operation
6 Specification of Instruments Yes Yes Yes
7 Detail wiring/ interconnection Yes Yes
diagram
8 P and I Diagram Yes Yes Yes
9 I/O list Yes Yes Yes
10 Loop Diagram Yes Yes
11 Logic Diagram for interlock & safety Yes Yes Yes
(if any)
12 J.B. termination drawings Yes Yes
13 Instrumentation, operating, Yes
maintenance manuals
14 Instrument Test Certificate Yes
15 Vendor to indicate power Yes Yes Yes
requirement (if any) for the control
system
16 Other documents necessary to have Yes Yes Yes
a clear understanding of the system
17 List of alarms Yes Yes Yes
18 Schematic drawings for controls Yes Yes Yes
19 Control Room Layout Yes Yes Yes
20 Field Operator Room layout Yes Yes Yes
21 System Architecture Yes Yes Yes
22 Instrument Air Consumption Yes Yes Yes
Requirement
23 UPS power & Heat Load Yes Yes Yes
Requirement
24 Bill of Material Yes Yes Yes

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 9 of 93
3.0 CONTROL PHILOSOPHY (GENERAL)
3.1 Design and installation of instrumentation shall comply with codes and recommendations
listed in item 4.0.
3.2 The instrumentation shall be designed to provide stable and accurate plant control ensure
safe plant operation and to facilitate plant maintenance, Control and Monitoring. The
operating interface to the process shall be colour dual (stacked monitors) screen 22” LED
TFT Colour (Minimum) display units with touch facility, presenting overview, group and
point displays as well as process graphics with live data. The operator will manipulate all
facilities through dedicated operator’s keyboard and using the touch panel.
3.3 I/O units, marshalling cabinets, power distribution cabinets shall be housed in Rack room
in the control room.
3.4 ES cum OS (dual stacked) with SOE shall be placed on the console of engineering room.
3.5 Package Unit PLCs :
Bidder to provide PLC with redundancy at all levels and with latest model. It shall have
provision to communicate with main DCS system through Modbus protocol and connected
by Serial cable in redundant mode. Main programmable Logic controller based system for
the package including marshalling cabinets, relay cabinets, MCC Interface cabinets,
power supply distribution cabinets, instrument isolator, alarm cards, terminals, relays with
accessories duly mounted, wired & tested to meet specified requirements.
3.6 DIs/DOs from MCC to control system or from control system to MCC shall be with relays
only (no fuse shall be considered). Separate panels for DI/DO and AI/AO. The details
will be discussed during detailed engineering.
3.7 Alarm and Annunciation System (LED type only):
Annunciation system is used to indicate and sound alarm for any process abnormality,
trip/status change of Electric drive. Annunciation system shall be of modular design &
programmable type. Electrical circuit is designed to read the change of state of discrete
signal and generate the output to illuminate the window and give the alarm. The alarm can
be silenced by acknowledge switch. Window light can be reset after acknowledgement
and, when the state of signal returns to the prior alarm state. Annunciation system can be
configured for any of sequences of ISA standard. There shall be a provision in circuit
design to change the state of signal required to generate alarm (from Open to Close or
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 10 of 93

vice versa) simply by changing the jumper position on circuit board. Lamps in window shall
be replaceable from the front.
Hooter in general, shall be solid state type with audibility of the order of 100 dB at the
distance of 3 meters. An interruption of power supply up to 20 msec shall not affect the
functioning of unit.
The minimum instrument accuracy shall be as defined in Annexure-1.
3.8 SIL certification rating for all the instruments shall be minimum as per following list :-
 All Smart Positioners - SIL 2

 All Transmitters - SIL 2
 All Solenoids - SIL 3
 All Gas Detectors - SIL 2
 All switches - SIL-3 or maximum SIL rating available
3.9 Universal HART Protocol with Latest Revision shall be used in all cases.
3.10 Card mounted Relays are acceptable but cards must have redundant power facility, with
its power healthiness indication in diagnostic graphics.
3.11 Cable entry to control room, analyser shelter, substations shall be through MCT blocks
with SS316 MOC only.
3.12 Entry into the Marshalling Panels in the control room shall be through bottom mounted
316SS MCT blocks.
3.13 General Earthing & Instrument Earthing shall be provided separately (Panel and power
earthing, PLC system earth and Instrument signal earth is minimum envisaged).
3.14 All wetted part materials for all instruments (sensing elements) for corrosion prone area
shall be min SS316L.
3.15 The Instrument item like control valve, pressure relief valve, orifice flanges, level
instrument, thermowell etc., coming on pipe and vessel under IBR services shall be
certified by IBR or IBR authorised representative, even for SS metallurgy.
3.16 Turbine Flowmeter shall not be used.
3.17 All Contacts shall be 2 SPDT or 1DPDT.
3.18 No Switches (Pressure / Level/ Flow / Temp.) shall be used.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 11 of 93

3.19 All Field transmitters for pressure, d/p, level and flow shall be microprocessor based (dual
compartment) SMART transmitters with “UNIVERSAL HART” protocol with latest revision.
The transmitter selection shall be such that the operating maximum upper limit shall be
around 70% of the total measurement range of the transmitter.
3.20 All Field transmitters for pressure, d/p, level and flow shall be provided with 10 years
stability (0.1%).
3.21 Package vendor shall provide a common laptop (latest configuration 8th Generation Intel
i7 8550U processor, Windows 10 Pro OS, 8GB RAM, 256 GB SSD+, 1TB HDD, Full HD
display (15"),3 yr warranty with anti-virus and other engineering software) for configuration
of dedicated vendor standard PLC/DCS.
3.22 All equipment/materials supply shall include spares required for 2 years operation and
separate consumable for commissioning.
3.23 Motor / electrical equipment control philosophy
a. Field :
 Ready to START (Lamp)
 START
 STOP
 L/R Switch
b. For Package PLC

 STOP Command
 Discrepancy Alarm
 Running Indication
 Motor Fault Alarm
 Current Indication ( All motor > 5KW)
 L/R Switch Indication
 Ready to START F/B
c. For start / stop of all electrical equipments, local/remote selector switch shall be
located in field, A/M (Auto/ Manual) and stop push buttons on consoles in CR.
d. Local stop push button on LCS (local control station) shall be always effective.
e. In remote mode, motor can be stopped from control system.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 12 of 93

f. In LOCAL mode, both START and STOP shall be possible only from LOCAL. Only in
REMOTE, stopping is possible from control system.
g. Auto / manual selection shall be in PLC/Main Control System.
3.24 For all motors current indication shall be provided in control system for rating more than 5
KW.
3.25 Auto start for pumps must be designed using 1oo2 philosophy.
3.26 All Instruments including volume bottle must be painted with Corrosive resistant epoxy
paint.
3.27 Local indicators, start /stop switches, emergency stop switches shall also be provided near
package units/rotating machines where local start up of the equipment is advisable.
3.28 For instrumentation electrical interface, input and output contacts shall be in separate
multicables (should be signal cables).
3.29 Trip solenoids shall be dual redundant, and configured and hooked up properly in such a
way that failure of one solenoid doesn’t initiate a false trip. Trip solenoids shall be normally
in energised condition and shall be de-energised to initiate trip.
3.30 All trip interlocks must be designed on 2oo3 philosophy.
3.31 Emergency stop and critical stops must have transparent protective cover.
3.32 PB’s , Annunciator , EPB must be available on console placed in CR.
3.33 Air fail to open, Close or Hold of any control valve shall be as per Licensors document, to
take care of process, plant and human safety. For Piston actuators necessary air volume
chambers and lock up relay shall be provided to achieve the fail-safe condition.
3.34 All Analysers shall be Ex.proof irrespective of area of installation.
3.35 All control valves / On–Off Valves / MOVs shall be flanged type.
3.36 Control valve / on-off valve, pneumatic valve shall be designed for minimum 4 Kg/cm2 air
pressure.
3.37 Actuator design shall be of 1.5 times of shut off pressure or design pressure, whichever is
higher.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 13 of 93

3.38 Valve body MOC in steam service shall be of WCC or better irrespective of pipe class.
3.39 Air distribution pots shall be of stainless steel (SS304). Inst. Impulse pipes / tube for
process parameters shall be in accordance with piping specifications.
3.40 Hart Compatible gas-detectors to be provided. Electrochemical type gas detectors shall
not be considered. Bidder to submit suitable gas detectors as per OEM recommendation/
as per ITB as specified elsewhere. Bidder to submit gas detectors quantity calculation
along with layout. Bidder to provided hooters (electric type) & beacon ( rotating type with
light flash).
3.41 All line mounted instruments like in-line SOVs, Magnetic flow meter, Rotameter, Mass flow
meters etc shall be provided with block & bypass arrangement, with their indications in
system as per requirement, which will be discussed in detailed engineering.
3.42 Separate Sample handling system shall be used for each analyzer. Multi Channel with
stream selector can be used, provided the total system including sample handling system
shall be imported. Necessary sequence shall be inbuilt in the analyzer for draining the
condensate.
3.43 For double acting valve, air accumulator (with MOC as SS304) shall be used for achieving
fail safe operation.
3.44 FRP Canopies (UV stabilized 3 mm thick), 2” Pipe mountable, are required for Transmitter,
JBs, LCPs, Control Valve positioner, Temp Elements, Proximity level switch, remote
mounted electronics, mass flowmeter, ultrasonic flowmeter etc. FRP Canopy shall be
Prefabricated type. Canopy for transmitters shall cover top and 3 sides. SS canopy instead
of FRP, if offered by package vendor, shall also be acceptable. No separate canopy shall
be required for instruments located under shed like compressor shed etc.
3.45 System / Marshalling/ Packages cabinet size shall be 2100 (H) X 1200 / 800 (W) X 800 (D)
Rittal make.
3.46 Separate Tapping shall be used for each instrument coming for trip, control & monitoring,
local display. Not more than 3 set of taps are allowed.
3.47 Smart positioner shall be considered for all Control Valves. For high temperature services
(Above 200 Deg C) remote mounting shall be used for the smart positioner.
3.48 Positioner shall be of valve OEM or as per approved vendor list.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 14 of 93

3.49 For all Local panels rain cover to be provided. The gasket of local panels must be acid
resistant preferably Silicone/EPDM or better which will be discussed during detailed
engineering.
3.50 For Analysers separate feeders to be directly taken from UPS. No sub-branching is
allowed at any place.
3.51 No Switches to be used. If in pump seal plan, if level measurement is requirement, GWR
to be used.
3.52 Fibre optic cables shall be armoured, multicore type. All fibre optics cable must be laid
through HDPE conduit. The make of fibre optic cables shall be Belden / Leoni.
3.53 All cables inside package battery limit shall be supplied and laid by Package vendor
through instrument cable trays supplied by Package vendor. All cables inside
skids/modules shall be supplied in pre-wired & pre-tested condition.
3.54 All Instrument Hookups shall be approved by owner/PMC.
3.55 All fittings shall be SS316 and in inch only.
3.56 All tubing shall be SS316 and must be made from hot extrusion process only.
3.57 The manifolds (3 valve/5-valve/2 valve) material shall be SS316L.
3.58 All the soft parts of Local panels/JB/SOVs etc shall be of acid resistance, preferably
silicone, EPDM or better which will be discussed during detailed engineering.
3.59 Level measurement in the acids tanks shall be of Ultrasonic type with Instrument and
sensor material suitable for acid application.
3.60 For all Diaphragm Seal Type DP Transmitters/Gauges on Vessels, min size and rating
shall be 3” 300# RF. Isolation valve shall be BALL type.
3.61 Level measurement in the acids tanks shall be of ultrasonic type.
4.0 INSTRUMENTATION CODE AND PRACTICES

IEC 13 Diagrams, Charts and Tables, Preparation of Logic Diagrams
IEC 534 Industrial - Process Control Valves
IEC 584 Thermocouples

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 15 of 93

IEC 605 Equipment Reliability Testing elements
IEC 611-12 Part 12 Graphical Symbols for Diagrams. Binary Logic
IEC 654 Measurement and Control equipment
IEC 751 Industrial Platinum Resistance Thermometer Sensor
IEC 801 Electromagnetic Compatibility for Industrial Process measurement

and Control Eqpt.
IEC 848 Preparation of Function Charts for Control Systems
IEC 902 Industrial Measurement and Control Terms and Definitions
ISA S-5 .1 Instrumentation Symbols and Identification
ISA S-5.2 Binary Logic Diagrams for Process Operation
ISA S-5 3 Graphic Symbols for Distributed Control/Shared Display

Instrumentation, Logic and Computer Symbols
ISA-S20 Instrumentation specification formats
ANSI/ISA S 5.1 Process Instrumentation Terminology
ANSI/ ISA S71.04 Environmental conditions
ANSI/ ISA S75.01 Control Valve Equations
ANSI/ ISA S75.02 Control Valve Procedure Capacity Test
ANSI/ ISA S75.03 Face-to-Face Dimensions for Flanged Globe Style Control Valve
Bodies
ANSI/ Quality Control Standard for Control Valve Seat
FCI 70.02 Leakage
BS 6020 Instruments for the Detection of Combustible Gases
DIN 43760 Measurement Standard for RTD.
DIN 19243 Measurement and Control Electrical Sensors, Electrical Position

Sensors and Signal Converters used for Intrinsically safe two-wire DC
System.
EN-50-014/020 Electrical Apparatus for Potentially Explosive Atmospheres
EN 54 Part I Components of Automatic Fire Detection System Introduction.
EN 54 Part 5 Heat sensitive Detectors - Point Detectors containing a Static

Element.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 16 of 93

ISO 3511.1 Process Measurement Control Functions and Instrumentation
Representation Part I: Basic requirements.

Representation Part 2: Extension of Basic Requirements.

Representation Part 4: BasicSymbol for Process Computer, Interface
and shared Display/Control Systems.
ISO 4200 Plain End Steel Tubes, Welded and Seamless - General Table of
Dimensions and Masses per Unit Length.
ISO 5167 Measurement of Fluid by Means of Orifice Plates, Nozzles and

Venturi Tubes Inserted in Circular cross-section Conduits Running Full.
API RP 520 Sizing, selection and Installation of Pressure relieving devices in

Refineries
API RP 521 Guide for Pressure Relieving and Depressuring System
API RP 2000 Venting Atmospheric and low-pressure storage tanks
API-RP-550 Manual on Installation of refinery Instruments Part I and Control

System
ANSI - B 16.104 Control Valve seat leakage
ISA-S 75.01 Control Valve sizing
ISA S 18.1 Specifications and guides for the use of general Annunciators.
IEC 529 Environmental Protection of equipment
ANSI B 2.1 Pipe threads
ANSI B 16.5 Steel pipe flanges, flanged valves and fittings
IEC 79.11/ Intrinsic safety code and practice
IEC-79.14 International Boiler Regulation
IS 2148 Flameproof enclosure of electrical apparatus
BS EN 62676 series Video surveillance systems for use in security applications
BS EN 62676-1-1 Video System Requirements
BS EN 62676-1-2 Video Transmission – General Video Transmission –

Requirements
BS EN 62676-2-1 Video Transmission Protocols – General Requirements

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 17 of 93

BS EN 62676-2-2 Video Transmission Protocols – IP Interoperability implementation
based on HTTP and REST services

based on web services
BS EN 62676-3 Analog and Digital Video Interfaces
BS EN 62676-4 Application guidelines
5.0 HAZARDOUUS AREA CLASSIFICATION & ELECTRICAL EXECUTION
5.1 Irrespective of area classification, the execution of instrumentation shall be as per area
Zone 2, group IIC, T6, EExib and Protection.
Electrical / Electronic instruments IP 67
Sensors; RTD, T/C, etc. IP 65
Local Gauges; PG, etc. IP 55
Pneumatic instruments IP 54
Solenoid valves IP 67
Local Panel / Skid Mounted Panels IP 55
EMC compatibility and electrical safety as per latest IEC standard.
5.2 Electrical instrument equipment shall be designed for and supplied as intrinsic safe
certified.
Analysers, solenoid valves and other equipment that cannot be classified intrinsic safe
shall be ex-proof in accordance with the above mentioned electrical specification.
In general, Intrinsic philosophy shall be followed for all the instruments. Where ever
intrinsically safe philosophy is not available, Exproof/Flame proof philosophy shall be
followed.
Certification for installation in hazardous areas in accordance with IEC 60079 series is
shown below:
Transmitters, positioners, Limit Switches, etc.: Ex ib IIA/IIB T6
Field Switches: Ex de IIA/B T6
Analysers and Panels: Ex p IIA/B T6
Solenoid Valves: EEx ib IIA/B T6 (Ex md not allowed)
Junction Boxes and Cable Glands: Exe/Exd

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 18 of 93

6.0 ELECTRICAL SUPPLY
The electrical supply will be as follows:

S.No. Description 110 V 110 V 24V 110 240V AC 415 V Remarks
AC DC DC V AC 50Hz AC-3
50Hz Non (Non UPS phase
UPS UPS )
1 PLC/DCS YES
2 Package Units YES YES Non UPS for

Lighting
3 Alarm YES
Annunciator
5 Solenoid Valves YES
6 Smart YE S
Positioners, I/P,
Transmitters
7 I/P Interrogation YE S
Voltage
8 Gas Detectors YE S
9 Analyzers and YES

Analyzer
System
11 Level Gauge YES
Illumination
12 Cabinets Fan YES
13 Cabinets YES
Lighting
14 Control Room YES
15 Local Panel YES YES YES Non UPS for
Lighting
16 CCTV YES
17 Analyzer YES
Cabinet Air
Conditioning
18 Analyzer YES
Shelter HVAC
19 Normal AC for YES
Field Operator
Room
Where 24V DC is needed, it will be generated by local rectifier units (bulk power supply
with MOSFET O-ring), which are part of the instrumentation supply. The power supply to
these units shall be taken from the UPS.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 19 of 93

Where 24V DC are used for Safety Circuits, the rectifier units shall be duplicated and with
high reliability and form a part of DCS/PLC vendor. The bulk power supply shall be with
MOSFET O-ring.
Two Nos. Of earthing system of each type (total 8 nos.) separate instrument earthing
system (separate for instrument signal and control system) apart from the power supply
and panel protective earthing system is foreseen. Same shall be in bidder scope
UPS supplies shall not be used for utilities supplies cooling fans, panel/cabinet lighting
etc. A separate non-UPS supply shall be used for the same.
A summary of all critical UPS alarms, 24V DC supply, Panel supplies, diode o rings
healthiness shall necessarily provided in control system system and hardwired
annunciation in control room or any manned location
Only copper cables & tin-plated copper lugs shall be considered for instrumentation
power distribution system.
One no of redundant UPS supply feeder will be provided by the client. Further distribution
to the bidder system in the CR, Field operator room and in the field shall be in the bidder
scope.
Protection coordination with respect to fuse/MCB ratings from the supply source
ACDB/DCDB to downstream distribution panels shall be thoroughly studied by the system
designers/OEM and documented as a part of the system documentation and be
implemented accordingly.
MCB’s must have DI contact’s which must be wired to DCS/PLC and available in
diagnostic graphics.
7.0 FIELD INSTRUMENTS
7.1 Analyser
All liquid analysers (pH, conductivity, pH in Effluent) shall be of intrinsic safe design
suitable for execution class specified for the area. Liquid Analyser, sampling conditioning
unit and other accessories shall be mounted on a rack suitable for field mounting. pH,
conductivity shall be installed preferably in a bypass line to facilitate maintenance of the
analyser.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 20 of 93

All Analysers shall be micro-processor based in general and shall be capable of providing
detail diagnostic alarms, messages to help maintenance personnel. Analysers shall have
manual/auto calibration facility.
Self diagnostic routines and calibration functions shall be provided as standard. The
Bidder shall supply details of self diagnostic routines and calibration functions including
calibration intervals. The Analysers shall use tried and field tested analysis technology.
Analysers shall generally be single stream. Multi stream Analyser applications shall be
supplied where process requirements specify.
7.1.1 pH ANALYSER
Design Data and Construction
7.1.1.1 The bidder shall provide a complete pH Analyser with electrodes mounting accessories,
sample handling system & indicating analyser transmitter.
7.1.1.2 The pH of the solution shall be detected by a sensor assembly. This sensor shall provide
an output signal proportional to the concentration of free hydrogen ions. Unless otherwise
specified, measuring system shall be provided with automatic temperature compensation.
Temperature sensing shall be through temp sensor 3-wire platinum RTD.
7.1.1.3 In general, the selection of Analyser shall be based on the type of installation e.g. Flow
thro’, insertion or submersion and the area classification.
7.1.1.4 When installed in electrically hazardous areas, the installation could be either intrinsically
safe. Specific preference, if not indicated, Intrinsic Safety shall be considered. In either
case, certification from statutory bodies such as ATEX, PTB or equivalent shall be
provided. Evidence of such approval shall be affixed to each and a copy of the certification
letter shall be provided.
7.1.1.5 DELETED
Sensor
7.1.1.6 Sensor shall consist of measuring electrode, reference electrode & 3-wire platinum RTD
temp sensor for automatic temperature compensation.
Electrodes

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 21 of 93

7.1.1.7 The type electrode and material of construction shall be decided based on the process
conditions furnished in data sheet. Bidder in his offer shall clearly demonstrate suitability
of selection of sensor.
7.1.1.8 Where required, bidder shall provide appropriate cleaning device for the electrodes.
7.1.1.9 For sanitary applications, provisions for sterilization shall be provided.
Transmitter
7.1.1.10 Transmitter electronics shall be microprocessor based, two-wire transmitter with 4~20mA
DC linear output proportional to the pH with HART protocol. Transmitter electronics shall
be interchangeable with all other pH analysers.
7.1.1.11 Transmitter shall be provided with local LCD display and the range shall be user
configurable.
7.1.1.12 Transmitter housing shall be weatherproof to IP65 and shall have two number ½” NPT(F)
electrical entries for termination of cables.
7.1.1.13 Transmitter shall be suitable for 2” pipe mounting. Bidder shall provide mounting bracket &
other accessories of (SS304) .
7.1.1.14 In the event of transmitters being specified as ‘SMART’, following requirements shall be
met.
• All transmitters shall be high performance type microprocessor based ‘SMART’ type
with ‘HART’ protocol with latest version.
• Configuration shall be possible by locally and/or with handheld communicator. Bidder

shall optionally quote for hand held communicator.
• Multiple level of security shall be provided including elimination of zero and span
adjustments, software lockout of local adjustment and complete write protect
capabilities.
ACCESSORIES
7.1.1.15 Sensor Cable and Junction Box
• Bidder shall supply special cable for connecting sensor to the transmitter along with
SS316 double compression cable glands at both ends.
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 22 of 93

• Cable length shall be as specified. Where specified length is not available, bidder
shall supply junction box for connecting sensor cable and the extension cable.
• If applicable: Junction box shall be of SS316L & IP65. Bidder shall also supply
associated cable glands. Flameproof certification shall be provided if hazardous area
is specified in the specification. Spare entries of junction box shall be plugged (Ex
proof SS316).
Special Consideration
7.1.1.16 High Temperature
The problems of pH measurement at high temperatures are mainly associated with

electrode construction and assembly design. The performance of the glass electrode is
dependent on two factors, the composition of the glass bulb to withstand chemical attack,
and the performance of its inner reference electrode at high temperatures. Bidder shall
consider such application & suggest the electrode type.
7.1.1.17 Low Conductivity Water
The extremely low ionic strength of boiler feed or de-ionized water, demands the use of a
flowing sample, and the careful exclusion of air to prevent any ingress of carbon dioxide.
The glass electrode will tend to read high if the sample is not flowing past it. Some
response lag may occur because the low ionic concentration provides a very poor
diffusion gradient for hydrogen ion activity changes while a very high flow-rate could
evolve streaming potentials. Bidder shall consider & suggest the electrode & sampling
system for such application.
7.1.1.18 Installation
pH analyser shall be installed in field. Bidder shall provide analyser with Hazardous area
suitability, sample take off technique and inline installation drawing, Local LCD display on
analyser front.
7.1.1.19 The sample conditioning system shall be provided as necessary to reduce temperature
and pressure to conditions suitable to the pH electrode. This shall consist of sample
cooler, filter, pressure regulator, relief valve, pressure gauge, thermometer, etc.
7.1.1.20 Flushing: pH analyser with arrangement of flushing sequence with suitable time & SOVs
for slurry application shall be provided by bidders as per the requirement in the datasheet.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 23 of 93

7.1.2 CONDUCTIVITY ANALYSER
7.1.2.1 The analyser shall perform the unattended analysis of the conductivity level of the stream.
7.1.2.2 The bidder shall-provide a complete conductivity analyser system. The system shall
consist of the following:
• Conductivity cell with accessories.
• Sample handling system.
• Indicating analyser transmitter,
7.1.2.3 Sample Conditioning System (If Required)
and pressure to conditions suitable to the conductivity cell. This shall consist of sample
7.1.2.5 Sample conditioning system components with the exception of the conductivity cell shall
be constructed of 316 SS.
7.1.2.6 The conductivity cell and the sample conditioning system shall be mounted on a steel
plate suitable for surface mounting.
7.1.2.7 Conductivity Cell
 Conductivity cells are to be suitable for the individual process streams as listed on the
data sheets.
 Line mounted insertion type conductivity cell, when specified on the Instrument Data
Sheets shall be retractable with suitable packing gland and isolation valve.
 Conductivity cells shall be provided with automatic temperature compensation.
 Electrodes shall be platinized, gold plated nickel or 316 SS with stainless steel
fittings.
 Conductivity cells shall be certified for installation in the electrical area classification
as specified on the data sheet.
Indicating Analyser Transmitter

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 24 of 93

7.1.2.8 Each analyser shall be suitable for pipe or wall mounting and shall be the indicating type.
7.1.2.9 Calibration check switches shall be provided on each analyser.
7.1.2.10 Automatic temperature compensation shall be provided for each analyser.
7.1.2.11 The analyser shall have a weatherproof (IP 65 as minimum) housing and shall be certified
for installation in the electrical area classification specified on the Instrument Data Sheets.
7.1.2.12 Transmitter shall be the two wire type and provide an isolated 4-20 mA linear output wired
in control system and local indication.
7.1.2.13 Transmitter shall be suitable for field installation.
7.1.2.14. Transmitter shall be suitable to Hazardous area classification.
7.1.3 SILICA Analyzer
7.1.3.1 Silica Analyzer shall be HACH make. It shall be an on-line multi channel analyzer,
designed to provide continuous monitoring or programmed sampling of silica
concentration, utilizing a standard colorimetric analysis principle. Silica Analyzer shall be
of 5 nos. of Channels/streams and range shall be 0-0.02ppm (0-20ppb) (freely
configurable) with 0.5ppb resolution for all range. Response time shall be <15 Min per
sample.
7.1.3.2 The bidder shall-provide a complete Silica analyser system. The system shall consist of the
following:
• Silica cell with accessories.
The analyser complete with sample conditioning system shall be housed in a cabinet.
7.1.3.3 Analyser shall be provided with serial output and shall be integrated with Package
vendor’s control system.
7.1.3.4 The control unit shall be microprocessor based smart type with temperature controller, auto
calibration and zeroing facility, self diagnostic facility, with local indication and alarm for

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 25 of 93

operating parameters, Automatic shutoff on sample failure and automatic start up on
revival of sample etc.
7.1.3.5 The control unit shall be weather proof to IP-65 ,intrinsically safe and shall be suitable for
hazardous area mounting.
7.1.3.6 Sample Inlet/Outlet Connections shall be ¼ inch OD .Tubing material shall be

Polypropylene or better.
7.1.3.7 Enclosure shall be constructed of SS.
7.1.3.8 Analyzer shall provide 2 isolated 4/20 mA outputs and 4 programmable alarm relays.
Relays shall be rated for 5 A @ 240 V AC
7.1.3.9 Analyzer shall be capable of auto ranging and auto calibration.
7.1.3.10 Display shall have digital graphics LCD with backlight.
7.1.3.11 Any other reagents/chemicals/specialized tools and tackles required for successful
installation & commissioning and on site calibration (if required) of the system will be in
vendor scope.
7.1.4 Sodium Analyzer
7.1.4.1 Sodium Analyzer shall be multichannel on-line analyzer, providing continuous sodium
measurement using ion selective electrode or vendor to specify. No of Channels/streams
shall be 3 nos. and range shall be 0-5ppm (Range shall be freely configurable)
7.,1.4.2 The control unit shall be microprocessor based smart type with temperature controller,
auto/manual calibration and zeroing facility, self diagnostic facility, with local indication and
alarm for operating parameters, Automatic shutoff on sample failure and automatic start up
on revival of sample etc.
7.1.4.3 The control unit shall be weatherproof to IP-65, intrinsically safe and shall be suitable for
7.1.4.5 There shall be two 4-20 mA outputs, one dedicated to sodium and other one to
temperature.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 26 of 93

7.1.4.6 Temperature compensation shall be provided
7.1.4.7 Sample conditioning system details shall be provided by vendor.
7.1.4.8 The vendor shall maintain sufficient stock for reagents/chemicals.
vendor scope.
7.1.4.10 Display shall be backlit LCD with temperature, concentration, mV, error codes etc.
7.1.5 Chlorine Analyzer

7.1.5.1 Chlorine analyzer shall be an on-line analyzer, designed to provide continuous monitoring
of chlorine, chlorine dioxide based on amperometric / colorometric method. The system
shall monitor and control free/ residual chlorine levels accurately. Range shall be 0-5ppm.
(Range shall be freely configurable)
7.1.5.2 The analyzer shall be complete with sample conditioning system.
7.1.5.4 The control unit shall be microprocessor based smart type with temperature controller,
alarm for operating parameters, Automatic shut off on sample failure and automatic start
up on revival of sample etc.
7.1.5.6 Analyzer shall be capable of automatic temperature compensation.
7.1.5.7 The sample shall drain into a non-metallic pipe due to the corrosive nature of chlorinated
water.
7.1.5.8 Self cleaning sensor assembly shall be considered to prolong sensor life and maintain
accuracy.
7.1.5.9 The sample tubing shall be kept as short as possible to minimize lag time.
7.1.5.10 Ph compensation shall be provided wherever necessary.
7.1.6 ORP Analyser
The bidder shall provide a complete ORP Analyser with electrodes mounting accessories,

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 27 of 93

The principle behind the ORP measurement is the use of an inert metal electrode
(platinum), which, due to its low resistance, will give up electrons to an oxidant or accept
electrons from a reductant. The ORP electrode will continue to accept or give up electrons
until it develops a potential, due to the build up charge, which is equal to the ORP of the
solution.
The analyser shall be stand alone panel mounted and protection class shall be IP67 .
Suitable canopy shall be provided for the enclosure. Analyser shall have 4-20mA for
indication in CR. Local display shall be digital LED type.
Sampling system shall be rugged construction and all tubing/ fittings shall be of SS 316
material (in inches only). Sample Flow Meter on Sampling Handling System shall be
provided. Vendor shall submit the details of sampling system along with offer.
Measurement of ORP shall be in mV. The accuracy shall be less than 1 mV.
Range shall be +/- 2000mV.
7.1.7 Turbidity Analyser

The bidder shall provide a complete Turbidity analyser along with mounting accessories,
sample handling system, calibration unit, and maintenance kit.
Turbidity is a measure of water suspended solids (SS) concentration. Turbidity

measurement shall be done based on 90º light scatter principle (Nephelometry). The
turbidity meter shall have following outputs:
 Analog 4-20mA output
 Self checking relay output
 Alarm Relay output
The sensor material shall be SS316L and shall have IP67 min, protection. The accuracy
shall be +/- 2 % of reading (NTU) and repeatability shall be +/- 1 % of reading (NTU).
Auto calibration shall be required for all analyser. Zero & span calibration gas cylinder to
be provided for the all analyser as applicable.
7.2 Flow Instruments
7.2.1 Flow Transmitters
D/P cells shall have measuring method on the floating capacitance technology. The signal
transmitter shall normally be a 2-wire system and shall be capable of delivering rated
current into external load of at least 600 ohms when powered with 24 V d.c. Protection
against short circuit and reverse voltage shall be provided. Bodies shall normally be in
stainless steel with SS316L internals. Integral 3- valve manifold similar to AGCO make
model 4A shall be used for mounting transmitters on manifold for ease of maintenance.
Material of manifold in general shall be SS316L but may vary depending upon service.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 28 of 93

Digital output indication shall be preferable on the integral output meter with the
transmitter. All flow transmitters shall have sq.root extraction function.
Pressure elements in austenitic stainless steel is a requirement. The transmitter shall be

furnished with an output meter or gauge with a sqrt scale. Smart type transmitters will be
used with Hart V protocol. Overall accuracy for SMART transmitters shall be +/- 0.050% or
better. Process connection size shall be 1/2” NPT.
All field transmitters shall be 2 wire type, 24 Volt DC, SMART with HART protocol, and
shall be equipped with Local LCD type digital indicator. 2” pipe mounting, SS304 MOC
brackets and other accessories, as applicable, Accuracy 0.050% of Span , Rangeability
1:100, Local Display configurable, SS MOC, Double Compression SS 316 cable glands,
Exiab IIA/B/T6, IP67, Wetted MOC SS316L, SS316L MOC Manifold, Housing Die-Cast
Aluminium Epoxy Painted, Universal Hart Protocol with Latest Revision is required.
7.2.2 Rotameter with Transmitters
Rotameters or variable area meters may be used in pipe sizes from 1 1/2” and smaller.
The meter shall be selected for normal flow at 50 to 60% of the span. In applications with
toxic or inflammable fluids, glass tubes must not be used except for low pressure analyser
sample flows. They may be used for severe corrosive services and of fluid of high
viscosity. The metal tube meters shall be of stainless steel, PTFE lined or any other
suitable lining for the service. The Indicator assembly shall be magnetically coupled and
mounted with Rotameter body. Transmitters or Indicators on float extension are not
recommended except for cryogenic services. The switch assembly shall be of proximity
type. All Rotametres shall be metal tube type with transmitter. The rotameter transmitters
shall have 4-20 mA output at 24V d.c. power on two wire system, which must wired to
control system.
7.2.3 PRIMARY DIFFERENTIAL PRODUCERS
7.2.3.1 Orifice Plates
Orifice plates of the square edged concentric type shall be specified except where
unsatisfactory for the application. Materials of orifice plate shall normally be AISI 316
unless special materials are required for the service. The maximum ratio of orifice to inside
pipe diameter of 0.70 and minimum ratio of 0.30.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 29 of 93

Orifice plates dimensions and calculations shall be in accordance with ISO 5167-1980.
Minimum orifice plate thickness shall be 3.16mm.
The flow range shall be selected such that normal flow rates are between 50% and 70% of
the flow upper range value.
Material of construction of orifice plate shall be 316L SS except where this material is
unsuitable for the service because of corrosion or erosion considerations, in which case
an alloy shall be chosen whose corrosion allowance is equal to or better than line material.
Orifice plates dimensions, finishing, flatness, tolerances for dimensions and identification
information shall be in accordance with ISO standard. Orifice plate shall be provided with
tab handle, which is welded on the orifice plate and engraved with following information on
the upstream of the tab handle:
- UPSTREAM or UP
- Instrument tag number
- Orifice diameter
- NPS (Nominal Pipe Size) and ANSI flange class
- Material of the orifice plate
- DP range & Meter ( Flow) range
The tab shall also be in line with the Drain or Vent hole and shall indicate the direction of
flow.
BIDDER shall submit the sizing calculations for orifice plates for review.
Pressure drop for orifice sizing shall generally be selected among the following values:
125, 250, 500, 625, 1250, 2500, 5000 and 10000 mm H2O with standard selection at
2500 mmH2O.
Orifice plates shall be installed on horizontal lines when practical. Vertical meter runs may
be used for down flow of vapour and up flow of liquids.
Differential ranges for all liquid flow meters shall not exceed 5000 mm water. Typical
ranges for gas, steam or vapour meters are as follows:
Static Pressure Diff. Range

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 30 of 93

(in Kg/Cm2g) (in mmwc)
0.35 to 2.5 500-1200
2.6 to 6 1250-2500
Above 6 2500-5000
Orifice bore with diameter less than 0.125” shall be avoided.
a) Flange taps orifice shall generally be used for line sizes 2” to and including 18”. Above
18”line size, D and D/2 taps shall be used. Integral Orifice assembly with transmitter shall
be used for line size 1 1/2 “or below (as per standard BS-1042)
Orifice assembly shall be provided with two sets of “Flange Taps” located in accordance
with latest AGA standards. The orifice assembly shall be provided with jack screw for
removal of orifice plate. In case of 2 out of 3 logic requirement, three different transmitters
shall be used and no two transmitters shall share the common tapping. In such case six
set of taps (independent tapping from Flange Itself , NO TEE / Elbow shall be used ) shall
be provided in orifice assembly. Instrument tapping connections shall be 1/2”NPT
(F).ONE Set of spare flange ts required for 2oo3 configuration i.e. total FOUR Sets ( 8
Nos. ) Of flanges tapping.
b) Orifice flanges shall be in accordance with the ANSI B16.36, ANSI B16.36a and
applicable piping specification and shall generally be of weld-neck type only. The
minimum pressure rating of flanges shall be ANSI 300 lbs.
Flanges larger than 3" shall have a pair of jack-screws. The mating flanged shall be
aligned in such a way that jack-screws will be diametrically opposite.
Orifice flanges used at pressure ratings up to 600 Ib. shall be tapped ½” NPT(F) tap for
900 # above ¾” NPT(F). Orifice connections for Vena contracta taps or pipe taps ½”
socket with schedule/MOC as per piping specs
c) For line size below 2” Integral orifice with corner taps shall be supplied as an integral
assembly consisting of upstream and downstream straight pipes, integral orifice of 316L
SS (as a minimum) installed along with H type manifold and SMART, 2 wire 24 V DC, DP
transmitters with latest HART protocol (refer 7.2.1 for tx details). End flanges shall be as
per piping specifications. Upstream and downstream pipes shall be honed from inside to
achieve smooth surface. Integral orifice meters, when used, shall be installed with block
and bypass valves.
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 31 of 93

d) Upstream and downstream straight length shall be provided based on maximum d/D ratio
of 0.70, in general. Where it is difficult to meet this requirement, the actual d/D can be
considered for reducing the straight length as permitted by ' recommended practice shall
be as per API-MPMS Recommended Practices and AGA Report No.3. The piping layout,
where possible, shall be arranged such that straightening vanes are not required.
e) Orifice plates with RTJ flange connections above 2” shall be supplied with Carrier rings /
Plate holder. Holder MOC shall be same as Plate material as minimum.
f) Meter taps shall be horizontal for liquids, condensable vapors and steam. The tap shall
be on top for gas, non-condensable vapor, or liquids, which boils at maximum design
ambient temperature at operating pressure.
g) The Meter Range flow shall be equal to the 1.5 times of normal flow or 1.3 times of the
maximum flow and it shall be nearest higher multiple of 50/100/1000s of units of measure
(in Engg. Unit) in round figures. This meter max range criteria specified is applicable to all
other type of flow transmitters also.
7.2.3.2 Nozzles
ISA 1932 Nozzles may be used in high and medium pressure steam and BFW piping.
Materials for nozzle element shall normally be AISI 316L steel unless special materials
are required for the service. Dimensions and calculations shall be in accordance with ISO
5167-1980. Generally, branch pipe is required with the nozzle the same shall be
machined from higher schedule pipe than the one used for the service or forged branch
pipe shall be used if higher schedule pipe is not available. The branch pipe bore shall be
same as that of nozzle ID and shall have mirror finish.
7.2.3.3 Venturi Tubes
Venturi Tubes or nozzles as per ISO 5167-1980 or similar type elements may be used to
measure the flow of low pressure gases or liquids where loss of pressure is an important
consideration.
7.2.3.4 Averaging Pitot tube/Annubar (Not to be used)
7.2.3.5 Local Flow Indicator
Motion balance (Barton cell type) type differential pressure indicator shall be used for
local flow indication. Body and internals shall be of 316L SS. Process connection shall be
1/2” NPT(F) . SS316L 5-valve manifold with 1/2” NPT connection shall be used with the
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 32 of 93

meter.
7.2.4 OTHER FLOW METERS
7.2.4.1 Mass Flowmeter
Coriolis type mass flow meter with local digital display of flow shall be used to measure
the process flow where high accuracy is required. Normal accuracy for mass flowmeters
shall be 0.15% of span. The sensing element shall be straight/U-tube, matl. 316L in
general.
7.2.4.2 Vortex Meter
Vortex shedding meters may be used for wide range of flows for gases and liquids. The
measured flow shall be temperature compensated.
Insertion type vortex meter may be used in utility services for line size more than 6”
inplace of Pitot /Annubar/Pitot Venturi tubes.
7.2.4.3 Ultrasonic Flowmeter
Ultrasonic flow meters (non- insertion probes preferred) based on the “time-of-flight”
method shall be used. Meters based on the “Doppler” principle are less accurate and
shall not be used. Ultrasonic flow meters shall be considered for large turn downs and
where pressure drop is not permitted. Upstream and downstream straight lengths shall
be as per standard.
7.2.4.4 Electro-Magnetic Flowmeter
Electromagnetic Flowmeter with ceramic lining shall be used for the measurement of flow
with high accuracy for highly viscous and corrosive services. Instrument shall be suitable
for Acid and alkaline measurement.
7.3 LEVEL INSTRUMENTS
Level Instrument shall be suitable for Acid and alkaline measurement. Guided wave radar
type instruments (SMART) shall normally be used for level measurement up to 2400 mm,
wherever guided wave radar cannot be used then only external displacer type transmitter
to be used.. Differential pressure transmitter (Capillary type) shall be used for level
measurement above 2400 mm and for services requiring purge or where liquid might boil
in external portion. Capillary type DPTs shall not be used in vacuum services. Internal

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 33 of 93

displacer type of level transmitters shall be not be used. Remote Seal PT/DPT shall be
with min 5 mtr Capillary with SS armoured in PVC sheath of Protection with DRIP RING
and with Ball type Isolation Valve. For Vessel/Equipment requiring more than 5 m
capillary electronic remote seal shall be provided. Process connections shall normally be
3” flanged.
7.3.1 External Displacement
Displacer type level instrument shall be avoided and guided wave radar type or remote
diaphragm seal DP shall be used in their place if suitable to process condition.
If unavoidable External displacement type instruments shall generally be used (with

owner/PMC approval) for small spans only (The standard ranges shall be: 350 mm, 810
mm., 1200 mm). The cage material shall normally be forged material conforming to the
service requirements. Where the vessels are of alloy steel construction, the body material
shall be equivalent or of a better material. The displacer shall be in stainless steel
(SS316L) and the torque tube in inconel. If LVDT type transmitter in place of torque tube
is selected then the range spring of such transmitters shall be Inconel and cannot be
used for temp. more than 330 degree C. Process connections shall normally be 2”
flanged with side-side connections.
For high temperature as well as low temperature and cryogenic services, torque tube
heat insulation extension or torque tube extensions shall be applied. Radiation fins or
extensions shall be used for temperature above 200 degree C or below 0 degree C.
7.3.2 LEVEL GAUGE GLASS
Gauge Glasses
Glass gauges shall be avoided and magnetic type level gauges shall be used if suitable
to process condition. If unavoidable Gauge Glasses shall normally be reflex type for all
process services, except for boiler drums bicolour types shall be used, and in corrosive
services. Where transparent gauges with glass protection and illuminators shall be used,
Illuminators shall be explosion-proof in hazardous areas. Gauge glass columns will not
exceed 1500 mm. Multiple level gauges shall be used for visible lengths more than 1500
mm.
Transparent type gauge glasses (double glass) will be used for services in which a level
may not be distinguishable, such as interface services, between different liquids, where
mica shields are required and fluids of high viscosity or high solid content.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 34 of 93

For corrosive services, such as strong acids or alkalies, special devices such as magnetic
followers or plastic ("KelF") coated glasses shall be used.
Level gauges shall be supplied with a pair of off-set shut off valves with ball check with
SS304, or material suitable to process, as its MOC.
For cold services where temperature is below 0 deg C a non-frosting gauge will be used.
Glass tube level gauges shall be avoided.
Gauge glass columns will not exceed 1500 mm. Multiple level gauges shall be used for
visible lengths more than 1500 mm.
7.3.3 Non Contact Radar/Guided Wave Radar
Displacer type level instrument shall be avoided and guided wave radar type shall be
used in their place if suitable to process condition.
Ultrasonic / Radar type Instrument shall be used for large liquid storage tanks. Guided
Wave Radar type level instruments, where used, shall be external type with side / side
connections and rotatable transmitter head. Vent and drain valves shall be provided.
Non-Contact Radar type level shall be used on corrosive, congealing, slurry services
where diaphragm seal type transmitter cannot be used. Dip tube can be used in above
services where radar cannot be used. In case of heavy congealing service (sticky liquid)
rigid single lead type GWR shall be used. All guided wave radar will be coaxial type,
where high accuracy or interface level measurement is required. However single rod
design to be avoided to extent possible).
Guided Wave Radar Level transmitter shall be applicable for liquids or slurries,
hydrocarbons too water- based media. In absence of dielectric constant for the process
fluid, Bidder shall confirm the suitability of Guided Wave radar Level Transmitter for such
applications and Bidder shall suggest the suitable model for the same. Bidder shall
suggest the suitable model for Interface applications like oil on water, Hydrocarbon on
water, etc. Electronics shall be capable of measuring upper liquid and interface level
simultaneously. Selection shall be available for analog output signal from level transmitter
corresponding to upper liquid or Interface. Process connections shall normally be 2”
For sump levels, Guided wave radar for DCS and non- contact type radar level instrument
for interlock shall be used within accuracy ±3mm. For servo gauges where used,
calibration chamber with access for removing the displacer for maintenance purpose shall
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 35 of 93

be provided.
7.3.4 Magnetic Level Gauges
Magnetic type level gauges shall be considered for:
• Cryogenic services
• Fluids that attack glass (e.g., strong acids, alkalies, boiler feed water)
• Light ends services
• Toxic services
• Pressures above 500 psig (3450 kPa) special consideration must be given to the
design of float for high pressure
Magnetic- type level gauges shall consist of a liquid chamber enclosing a float which
is magnetically coupled to a rotary wafer-type indicator. It shall be top or side
mounted type. The liquid chamber shall be one- piece construction with a minimum
internal diameter of 50 mm, provided with a bottom flange for removal of the float,
vent and drain connections. Indicator shall be adjustable around the chamber with
provisions to indicate float failure.
The indication shall consist of bi-colour (red/white, silver/black) magnetic rollers

mounted on outside the magnet chamber. As the float rises or falls with the liquid
level each roller rotates 180 Deg and so presents a contrasting colour.
Floats shall be designed and manufactured for suitable to the process parameters. It
shall be designed to be adequate for hydrostatic test conditions. Floats shall be
hermetically sealed, no vented or pressure equalized construction shall be allowed.
7.4 PRESSURE INSTRUMENTS
7.4.1 Pressure Transmitters
Pressure Transmitters and differential pressure transmitters shall be modern inherent

motion-free type. Bodies shall normally be in stainless steel with pressure elements in
SS316L. Two valve integral manifold of SS316L material in general shall be used with
pressure transmitters.
The signal transmission should normally be a 2-wire system and shall be capable of
delivering rated current into external load of atleast 600 ohms when powered with 24 V.
Protection against short circuit and reverse voltage shall be provided. Pressure
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 36 of 93

transmitters shall normally be electronic type and shall have digital transmitter.. Smart
type transmitters will be used with Hart V protocol. Overall accuracy for SMART
transmitters shall be +/- 0.050% or better. Process connection size shall be 1/2” NPT.
shall be equipped with Local LED type digital indicator. 2” pipe mounting, SS304 MOC
1:100, Local Display configurable, SS MOC, Double Compression SS316 cable glands,
Exib IIA/B/T6, IP67, Wetted MOC SS316L, SS316L MOC Manifold, Housing Die-Cast
Aluminium .Epoxy Painted, Universal Hart Protocol with Latest Revision is required
7.4.2 Pressure Gauges
Gauges for process and utility services shall be industrial SS316L Bourdon
gauge/diaphragm or spring bellows type as per process requirement with the case in
316L stainless steel. The gauge for 60 kg/cm2 above pressure shall preferably be a
safety type with solid front where pointer and glass are partitioned off from the sensor by
a solid disc. Pulsation dampeners shall be installed with the gauges where pulsating
pressure occurs. Process connection shall be 1/2” NPT (M) bottom in general. Bezel
rings shall be screw on pattern. Dial Size minimum 150mm
Blow-out discs are required for all pressure gauges except for instrument air services.
Vibration proof gauges or remote seal type shall be used if the surrounding environment
is subject to vibration.
Minimum accuracy for pressure gauges shall be +/- 1%,
Pressure gauges for vibrating services shall be glycerine filled type or with pulsating
dampener device.
7.4.3 Pressure Switch (Not to be used)
7.4.4 Diaphragm seal
Diaphragms or liquid seals shall be inserted between the instrument and the process for
corrosive or highly viscous fluids. For all services element material shall be minimum
SS316L.
Pulsation dampeners shall be furnished with pressure transmitters on pulsating services.
All catalyst vessel’s dP measurement shall be with ERS (electronic remote seal).

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 37 of 93

Remote Seal PT/DPT shall be with min 5 mtr Capillary with SS armoured in PVC sheath
of Protection with DRIP RING and with SS304 Ball type Isolation Valve. For
Vessel/Equipment requiring more than 5 m capillary electronic remote seal shall be
provided.
DP transmitters with diaphragm seals are envisaged, where condensing leg required to
be filled in normal DP transmitters, at all those locations, remote seal type DP
transmitters are to be used. Also, wherever there is a control and interlock on level
measurement, one transmitter shall be remote diaphragm seal type and one will be
guided radar type with Material: Minimum Inconel. Guided Wave radar may be used for
non-critical applications. Process connection will be 3” flanged and sealing liquid must be
selected as per process requirement.
7.5 TEMPERATURE INSTRUMENTS (Duplex Type)
7.5.1 Thermocouples
Thermocouples shall normally be the sheathed type with high purity magnesium oxide
insulation. The hot junction shall be isolated from ground. Sheath diameter shall normally
be 6mm (1/4”) Inconel 600 sheath material shall be used for design temperatures above
400 degree C, whereas ordinary SS material can be used below 400 degree C. The
nominal wire diameter shall be approximately 0.19 x sheath OD. The casing material
must be SS316L.
Inputs from thermocouples shall be provided with cold junction compensation and
downscale burns out feature for high temperature shut downs and vice versa for low. A
passive alarms shall warn about the burn-out.
In general type K thermocouples shall be used according to IEC 584, class-1. All
temperature elements shall be duplex type, one connected and the second one shall be
used as spare.
Thermocouple head must be of die cast aluminium with epoxy paint to with stand the
corrosive environment.
Unless otherwise specified, thermocouples cable color coding shall be in accordance with
the latest edition of ANSI-MC 96.1.
The type of thermocouple shall be selected based on the following guidelines as

minimum:

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 38 of 93

Copper-Constantan (ISA-Type-T) (-) 200 to 200°C
Chromel-Constantan (ISA-Type-E) (-) 200 to 600°C
Iron-Constantan (ISA-Type-J) (-) 40 to 750°C
Chromel-Alumel (ISA-Type-K) (-) 180 to 800 °C
NiCrSil - NiSil (ISA-Type-N) 0 to 1200 °C
Platinum Rhodium-Platinum (ISA-Type-S or B) 600 to 1600°C
7.5.2 Resistance Temperature Probes
Resistance Temperature Probes shall be considered for applications where very narrow
spans and high accuracy are required as well as low temperature service. They shall be
6mm (1.4”) stainless steel sheath type similar to the thermocouples and with a Pt 100
ohms (0 degree C) element. The sensors shall be duplex type and shall be spring loaded
for vibration proof. The elements shall conform to DIN 43760 or IEC 751. The casing
material must be SS316L. RTD head must be of die cast aluminium with epoxy paint to
with stand the corrosive environment.
Class 'A' / Class '1’ tolerance as per IEC 751 / 584-2 shall be specified for all RTD and
thermocouple sensors in complete temperature measurements for all open/closed loops
and interlocks/Logic.
7.5.3 Temperature Transmitters
Temperature transmitters shall be Remote mounted type (on 2” Pipe), Smart with latest
HART protocol and integral digital output meter, dual compartment type.
Head mounted transmitters shall not be used.
Conventional transmitter shall have universal input for thermocouple / RTD and output 4-
20 mA DC for 2 wire system.
Transmitter output signal shall be linear and directly proportional to the measured
temperature with overall accuracy of +/- 0.1% FS. TT body must be of die cast aluminium
with epoxy paint to with stand the corrosive environment
Thermocouple transmitters shall have cold junction compensation and thermocouple

linear characterization. Resistance temperature transmitters shall have resistance
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 39 of 93

element linear characterization.
Burnout protection (selectable Up Scale / Down Scale) must be provided for temperature
transmitters.
No temperature switches are to be used. The same is to be achieved through

transmitters which shall be directly connected as analog input to DCS / PLC.
Temperature transmitters are to be provided for all temperature measurement

(closed/open/interlock) loops. All process temperature measurements shall be done
through Temp. Transmitters. No temp. Input shall be connected directly to
ESD/PACKAGE UNITS. MUX is not allowed.
7.5.4 Thermometers
Thermometers shall normally be bi-metallic, heavy duty, weatherproof (IP 65), adjustable
angle connected type with 150 mm dial as a minimum, dials of smaller size may be used
for auxiliary services on machinery. Casing material shall be SS316L.
Liquid filled indicators will be used only where indication is required to be remote Case
and stem shall be in stainless steel. Dials shall be of white, non-rusting metal with black
figures.
For local temperature control upto a maximum scale range of 530 deg C, liquid filled
sensors with capillary extension shall be used.
Filled system instruments when used shall be fully compensated for ambient temperature
variations.
Capillary shall be SS armoured and length of which will not generally exceed 3 mtrs.
Range should be selected so that normal operating temperature is approximately 70% of

full scale, and the maximum expected temperature is approximately 90% of full scale.
7.5.5 Thermowells
Thermowells shall normally be made from bar stock material.
Flanged thermowell shall be used of 1 1/2” size, threaded thermowell shall not be used,
except where accepted by piping specifications, in such case they shall be 1” NPT(M)
and real welded. Flanges rating, facing and material shall be in accordance with the
equipment or piping standard. Thermowell flange rating shall be 11/2” 300# minimum.
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 40 of 93

Thermowell shall be used for thermocouples, bimetallic thermometers, filled system and
for temperature test points (TW).
Thermowells in vapor-liquid applications, inside columns, shall be located in the liquid

phase, unless otherwise dictate by process requirements.
Test wells shall be equipped with threaded plugs and chains.
The preferred mounting position of thermowells, in horizontal pipelines, shall be in the

upper half of the pipe.
For lines up to 3 inch size, the pipe shall be enlarged to 4 inches.
Thermowell material in general shall be of AISI 316L SS.
Immersion length of thermowells for different line sizes shall be as follows:-
Line Size Immersion length (U)
4" to 6" 280 mm
8" and above 320 mm
Vessels 400 mm
Immersion length is based on 200 mm length between flange face and inner well of pipe
and approx. 60% insertion in the pipeline. In vessels, where fouling with vessel internals
is expected, the immersion length shall be suitably modified. Other sizes and immersion
lengths may be considered based on special condition/actual requirements.
The design of the wells shall be verified by means of stress analysis, resulting from
stream velocity condition. The wake frequency shall not exceed 66% of the thermowell
natural frequency. Wake frequency calculation is required for all thermowells. Bidder has
to submit Wake frequency calculations for all thermowells as per latest PTC 19.3.
Velocity collars not to be used.
7.6 CONTROL VALVES
Valve types shall be selected, pneumatic diaphragm/piston operated globe, ball or

butterfly shall be selected taking into account such factors as piping, operating and
design conditions, fluid being handled, tangibility required, allowable leakage, noise and
other special requirements. The valves shall have smart electropneumatic positioners of
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 41 of 93

same OEM make as the valve. All control valves shall be provided with SMART valve
positioner with valve position signal feedback connected to DCS system by 4 to 20 mA
analog signal. It shall be HART compatible. Seat Leakage shall be chosen in accordance
with process demands and safe operation of the plant and in accordance with AISI
B16.104-1976. However, in general, the globe valves used shall be of class IV leakage
minimum as per ANSI B6.104 in general. Metal seated valves shall be preferred instead
of soft seated valves. Soft seat requirement shall be evaluated by PMC/Client on case to
case basis. However, in general, the globe valves used shall be of class IV leakage
minimum as per ANSI B6.104 in general. For vent services the leakage class shall be
class V or VI depending upon process requirement.
Safety shutoff valves must not be used in throttling service during normal operation.
Noise abating devices shall be provided with valves where noise level at the outlet of
valve at a distance of 1 metre all around is more than 85 DBA for valve which have
operating times of 5 minutes or more in general and which are only working during start
up and in upset conditions. For continuous operation the allowable sound level shall be
85 dBA. All noise abating plates, expanders, flanges, gaskets, studs & nuts shall be in
the scope of valve manufacturer. The noise abating plates shall be of wafer design for
easy removal for maintenance. Source treatment for noise shall be preferred over path
treatment and for high noise vent applications “DRAG” type trim shall be specified.
All valve bodies shall be cast or forged. Stainless steel bodies shall be acceptable inplace
of alloy steel bodies, if not available, for low temperature application.
The valve body, positioner and actuator body material shall be suitable to corrosive
environment. Suitable lining shall be provided inside wetted parts as per application.
Flanged bolted type gland packing boxes shall be used, unless other specified. Gland
packing shall normally be self-lubricating type. Packing shall be PTFE type up to 200”C.
For temperature above 200 “C, grafoil is to be used. Usage of asbestos is not allowed in
any part.
Bellows seals shall be used wherever gland leakage is not permissible like toxic /
hazardous product like carbon monoxide gas, etc.
As a minimum, trim MOC shall for all control/on-off valves shall be SS316L. By default, all
Guide MOC shall be hardened stainless steel like 440 C, 17.4 PH. For erosion service,
high pressure drop, cavitating service hard surfacing of plug and seat material, satellite
shall be used for all cases as specified in above point 22.1. Special cases valve may
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 42 of 93

require 17.4PH seat and 440C solid plugs or other material like Hastelloy, Monel,
Zirconia, duplex steel, etc. for severe services like steam, urea grade, carbamate
solution, acid, etc.
Mechanical stopper shall be provided as per process recommendations for Min/Max.

Flow condition.
On line replaceable trims shall be considered for all high pressure valves of butt-weld or
socket weld connections. Trim characteristics shall be equal percentage, unless
otherwise specified. For high erosion service or in steam service where, the delta P is
higher than 5 Kg/Cm2, hardened trim with stelliting shall be used. When this alone is not
sufficient, in such cases, special Anti-cavitating trim or shall be selected. In general, for all
trims, hardened full stelliting shall be used, as a minimum.
All on-off valves shall be ball type on-off valves only. The ball valves of up to 2” size shall
be floating ball design with full bore design, unless otherwise specified. Other ball valves
with higher size can be trunnion supported ball type design type.
For all shutdown valves on fire safe applications, air volume tank shall be supplied for the
storage of air volume for minimum 3 stroke operation.
Oxygen service valves shall be de-greased completely and certified for oxygen service
use. MOC for body shall be Monel and trim shall be Inconel 600 only.
Control / Ball valves bodies used in steam services should be A182 F22/ A217 WC9.
Split body design for ball valves acceptable where top entry ball design has not been
considered for economical reasons. Mufflers shall be provided on ball valve vent air lines
for noise suppression. Spring loaded seat and hard chrome plated ball shall be a
standard feature for ball valves, in general. Wherever springs come into picture, vendor to
ensure corrosion resistant spring steels are provided.
All control valves/ Actuators (pneumatic & Motorised) shall be painted with corrosive
resistant epoxy paint. SS bug screen shall be provided for the exhaust ports.
All valve actuators shall be selected for a minimum operating air pressure of 4.0 kg/cm2g.
The actuators shall be diaphragm or piston actuators in general. Diaphragm actuators
with single or concentric multi-springs shall be used. volume tank with airlock relay ,
booster relays shall be avoided as far as possible.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 43 of 93

Rotary rack and pinion pneumatic actuators may be used with ball and butterfly valves for
on-off services.
In general, if otherwise not specified in the valve data sheet the time for full travel shall
not exceed 10 seconds.
Wherever handwheel is required with a valve the same shall be side mounted type.
All split range functions for valve operations shall be carried out in control system and
split range provision in valve positioners shall not be necessary.
Butterfly valve bodies shall be of wafer design. Lug type body shall be considered for size
above 12”. Face to face dimensions shall conform to ANSI B 16.10 and ANSI B 16.47
wherever applicable. Butterfly valves shall be used for high flow, low pressure drop below
10 kg/cm2g.
All instrumentation butterfly control valves shall be triple offset type only.
Non destructive test like radiography, ultrasonic, die penetration and magnetic particle
shall be carried out for cast and forged bodies conforming to procedures laid down in
ANSI B16.34. Radiography or ultrasonic test, if not specifically mentioned in the data
sheet, shall be carried out for cast or forged bodied of rating 900 lb. or above.
Valve bonnets shall be in general of bolted bonnet design as per ASME B 13.3 par 307.2
with minimum four bolts.
Smart E/P positioners with position transmitter along with valve signature software to be
provided for all control valves. It shall be HART compatible, The software shall be
provided for remote configuration and diagnostic analysis too.
Actuator sizing shall be done at 4 Kg/cm2.
Handwheel (Side-mounted) for All regulating control valves to be provided
By-pass valve provision shall be as per process licensor requirement.
The control valve % opening shall be at minimum flow 10-20%, for normal flow 50 to
70%, for maximum flow 75 to 85%.
All on – off application valve shall be fixed with necessary limit switches.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 44 of 93

Valve Sizing shall be used on a maximum flow rate of approx. 1.5 time normal flow or 1.3
times the max. flow, whichever is greater, and the process conditions that exist at the
increased flow (Pressure and differential pressure). Valve lift shall be approximately 70 %
for equal percentage and 60 % for linear characteristic plug design at normal flow. It shall
be checked that the calculated and the selected valve also covers start-up and stop
conditions. In cases where over sizing shall not apply, it will be specifically mentioned in
the Instrument Data Sheets.
The fluid velocity at outlet flange shall not exceed 6 m/sec for liquids whereas the velocity
of gas or vapor shall not normally exceed 0.3 Mach under operating conditions. To meet
this, valves shall be selected having reduced trim, labyrinth plug or cage trim as
manufacturer standards.
Bidder shall submit the sizing calculations for all control valves.
Face to face dimensions of the control valves shall be as per ANSI/ISA-S75.03.
Direction of flow indication shall be engraved or embossed on the body.
Stroke time of the antisurge valves shall be 2-3 seconds and for critical services shall be
as defined by process licensor or as mentioned in individual data sheet.
7.6.1 Control Valve Test and Inspections
Valves shall be tested in accordance to individual specification which shall cover but not
limited to:
- Visual Inspection and dimensional check
- Liquid Penetrants examination on stellite coating as per ASME B16.34 ann D.
- Radiographic, ultrasonic, magnetic particle as per ASME B16.34
- Hydrostatic Body Test - Duration 3 min. (including all parts in assembled condition
like body, gland, all joints)
- Impact test
- Seat leakage test as per ANSI B16.104/FCI 70.2
- Performance tests and Functional tests

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 45 of 93

- Leakage test from actuators and seals and packings
- Diaphragm head test
- Complete actuator leak test
- Helium leak test for control valve with bellow seals
- Stroke calibration
- Stroke speed test
7.6.2 Limit switches / Position Switches:
7.6.2.1 All type of limit switches shall be 2 wire, proximity type sealed, intrinsically safe certified.
Limit switches shall be provided both for close and open positions for all shutdown
valves. The material of its construction shall be resistant to acid environment.
7.6.2.2 The make shall be P+F only. The sensor shall be generally cylindrical NAMUR sensor
type proximity switch. The diameter and sensing range shall be selected based on
application.
The MOC of sensor shall be SS316 or acid resistant body.
All limit switches sensor shall be adjustable with the threaded length and check nut
arrangement.
Flying lead type loose connections for NAMUR sensors are not acceptable. All these
NAMUR sensors installed on any instruments to sense the position shall be housed in a
closed box certified for weatherproof to IP65. The gland size shall be ½” NPT(F).
7.6.2.3 All ON-OFF type application valves taking in part in interlock/shutdown shall be provided
with Open and Close type NAMUR sensor as limit switches. The sensors along with
enclosure shall be installed in control valve in such a way that it can be removed with
ease for maintenance.
7.6.2.4 Limit switches shall not be used for Control Valves.
7.6.3 Actuators
7.6.3.1 Generally, control valve actuator shall be of the spring and diaphragm, pneumatically
actuated type. Standard air control signal to positioner shall be 0.2 to 1.0 kg/cm2g. For
larger dP shut offs, higher spring range/higher areas shall be considered.
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 46 of 93

7.6.3.2 Actuators shall be single acting type for all valves.
7.6.3.3 All valve actuators shall be designed with 1.5 times factor of safety.
7.6.3.4 Piston type actuators (spring return type) with or without fail-safe capacity tanks (minimum
of 2 strokes to be possible in case of air failure) shall be considered for high-pressure drop
services or if actuator force requirements fall beyond the normal range of diaphragm
actuators. All actuators shall be adequate to fully stroke the valve under the
maximum differential pressure specified by the process requirements.
7.6.3.5 Air filter Regulator filter to be 5 micron. Miniature type, plastic body & drain assembly etc
as parts of air filter regulator are not acceptable.
7.6.3.6 Actuators must be painted with corrosion resistant paints and all its springs must be
corrosion resistant spring steels. SS bug screen shall be provided for the exhaust ports.
7.7 DELETED
7.8 PRESSURE RELIEVING DEVICES
7.8.1 Pressure Relieving Devices

All Pressure Relieving Devices shall be sized in accordance with applicable local and
national code requirements. Formulas shall be in accordance with API RP 520, 1990 and
ASME Codes section I and VIII.
7.8.1.1 Percent Overpressure and Accumulation used in calculation of sizes of relieving devices
shall be :
Overpressure
3% - Steam services where ASME Power Boiler Code applies.

10% - Gas or Vapour service.
15% - For liquids and pump discharge lines with 6% system accumulation
(Power Boiler Code) and with 10% system accumulation (Pressure
Vessel Code)
21% - Fire exposure on unfired pressure vessels.
10% - Liquids for thermal relief of pipelines or vessels Accumulation
10% - Gas , Vapour and liquid where ASME Pressure Vessel Code applies
and the system is protected by means of multiple valves.
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 47 of 93

7.8.1.2 Nomenclature
Nomenclature used shall be in accordance with API RP 520.
7.8.1.3 Safety and Relief Valves
Safety and Relief Valves shall normally be direct spring loaded type. Balanced bellows
valves shall normally be furnished for relief into closed flare and slowdown systems, if the
developed back-pressure exceeds 10% of the set pressure. Bellows shall also be
specified where leakage of gas from the seals are not permitted during normal plant
operation. Steam jacketing may be considered necessary to keep some valves and lines
warm at all the times to avoid the solidification of the lading fluid.
Full nozzle types of valves shall be specified for sizes 1” or above.
Test gags shall be furnished on all safety and relief valves. Test gags shall be removed
and transferred to Owners possession after testing, clearly labelled with the tag number
of the valve.
Lifting levers shall be furnished for exposed spring bonnets on valves on steam and hot
water services, on air valves and hot water service valves with closed bonnets.
Bonnet construction shall be plain closed bonnet for toxic and inflammable gases as well
as vapour and liquids. Exposed bonnet shall be specified for steam service and in Boiler
feed water service above 200°C. Bonnet extension shall be used above 400°C.
Springs shall be of carbon steel for normal process operating temperature of (-) 25°C to
200°C and tungsten alloy or high temp. alloy steel above 200°C. Stainless steel spring
may be used for services below (-) 25°C. Carbon steel is permitted above 200°C for open
bonnets.
Blowdown shall be between 5% to 7%. For steam services under Power Boiler Code as
per ASME the blowdown shall be 3% - 4%
All connections shall be flanged in general with facing and rating in accordance with the
piping specification or API 526 whichever is higher.
Centre to Centre dimensions shall be in accordance with API 526
7.8.2 Rupture Discs

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 48 of 93

Rupture discs may be used in lieu of or in combination with safety and relief valves,
where applicable or required. For disc rupture trip or alarm disc shall be with bursting
sensors.
7.8.3 Pressure and Vacuum Relief Valves
Pressure and Vacuum Relief valves for storage tanks shall normally be of the weight
loaded or pilot operated type, and sized in accordance with API RP-2000 Tank Venting
Code, or Local Codes if they govern.
7.8.4 Thermal Relief Valves
For thermal relief of accumulated liquids in pipelines and vessels 1” x 2” size valves shall
be used in general.
7.8.5 Centre-to-Face
Centre-to-face dimensions shall be in accordance with API 526.
7.9 SWITCHES AND SOLENOID VALVES
7.9.1 Switches
Process switches, shall be realised through field transmitters only. If for some packages,
process switches are unavoidable same shall be provided with sealed micro switch
contacts rated for the specified application. Contacts shall be 1 no. DPDT preferably.
Otherwise 2 nos. SPDT can be considered. All switch contacts except those used in
intrinsically safe circuits shall be silver plated. Contacts used in intrinsically safe circuits
shall be suitable for the applications. Switches shall be hermetically sealed type.
Switches shall be connected through interposing relays.
7.9.2 Solenoid Valves
Solenoid valves shall normally be used to actuate other instruments/valves connected

directly to the process. The SOVs shall be SIL3, direct acting type (3/2 external pilot
operated, universal type, low power intrinsic safe type, with manual override and LED
indication). Protective enclosure shall be IP 67 and the coil insulation H class or better
suitable for continuous operation in 85 degree C ambient temperature (max. surface
temperature in sun) for outdoor service. Body materials shall normally be stainless steel
316. Solenoid valves will be powered by 24V DC or through barrier, insulation class ‘H’
and orifice size 9 mm. The D.C. solenoids shall not have in built rectifier to operate with
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 49 of 93

A.C voltage. The d.c. solenoids shall be used as an alternative to A/C solenoids only for
low current intrinsic safe operations.
All solenoid valves shall be fitted with 1/2” NPT (F) SS 316 double compression cable
gland connection. The cable entry should be from bottom only and solenoid coils must be
hermetically sealed. SS bug screen shall be provided for the exhaust ports. The sealing
medium of the SOV’s will be EPDM or better (will be discussed during the detailed
engineering).
8.0 CONTROL SYSTEM (DCS/PLC)

DESIGN CRITERIA
EXPANDABILITY
Systems shall be designed with 20% installed pre-wired spare capacity for all I/O type
cards of each category for project development. The sparing supplied shall be for
“complete loop”; i.e. corresponding marshalling, power supply, terminals/barriers,
interposing relays, pre-fab cables other accessories, etc. and its space, and panel cut
outs where appropriate, etc.
To allow for future expansion 20% spare capacity shall be allowed & terminated in multi
core cables, junction boxes, marshalling racks, etc,
Communication networks and cables shall have a spare load capacity of 50% as a
minimum.
Plant wide networks shall have a node connection spare allowance of 50 % as a

minimum.
Local networks shall have a node connection spare allowance of 30% as a minimum.
Operators’ Keyboard
This shall be used by plant operators along with each Operator station display unit for
operation of the plant. It will have multiple assignable keys to directly open pre-
programmed display as well as few other system typical templates for selected tags
including controller group display, trend, configuration display, alarm summary pages,
etc. There shall be both numeric and alphabet keys and dedicated function keys on
membrane type operator keyboard each of which must be freely programmable. There
shall be one no. of operator keyboard with each of the operator stations.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 50 of 93

This shall be membrane type fully dust proof and spill proof & corrosion proof.
Key lock switch / password switch shall be provided for operator/supervisor/engineer

security levels.
Dummy Consoles/Filler Panels shall be provided to maintain aesthetic and mounting

instruments like indicators, annunciators etc. as well as for push buttons, lamps, key
switches, paging system hardware.
Entry into the Marshalling Panels shall be through SS316 ET double compression cable
glands only.
PLC CONTROL SYSTEM
8.1 General
The operation and control of WTP/DM Plant shall be through Process PLC based Control
system.. The system shall be microprocessor based programmable logic control (PLC)
with fault tolerant redundant processors based on DMR/TMR/QUAD technology.
The PLC will be used to provide protection and controls for the entire plant.
Following minimum functions are provided on the OS (Operator station):
1. Area wise display of the plant.

2. Operation of the plant from the OS.
3. The schematics will be having dynamic parameters like valve open / close and motor
running/ fault indications
The Control system shall perform any of the following functions for safety of the plant from
control room.
- Total Shut Down
- Unit Shut Down
It will perform the following functions also:
Data Display
Process Control
Process and system alarms
Logging
Real Time trends & Historical trend
Dynamic Graphics
Report Generation (shift, daily, weekly, monthly and on demand)
System diagnostics

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 51 of 93

The following shall be adhered to while selecting the DMR system
a) Redundant CPU’s shall be applied.
b) If a CPU fails, the other(s) shall continue to operate. Single CPU operation system to
be certified to operate without any time limitation of faulty CPU repair.
c) Dual Redundant buses shall be applied.
d) All closed loop shall be Redundant
e) Redundant communication interfaces shall be supplied.
f) Redundant Power supplies (at least three in parallel) shall be supplied.
g) In the event of a failure of a fault tolerant component, power supply or other function, of
the system shall change over to "single mode" operation without causing nuisance trips
and also generate alarm on Operator and Engineering console.
h) In case of failure of complete processor system, i.e., system outputs shall take fail
safe state automatically unless otherwise specified.
Operator interface for critical trips shall be mosaic display with illuminated push button
for trip, reset, inactivation etc. and LED indication for each element of trip & actions.
The operator will be informed about a trip situation by a warning sound (to be different
from the audible signal from the alarm system), and a LED display will clearly inform
about the alarms in trip position. The first up alarm will flash.
Scan time shall be maximum 250 msec. CPU loading shall not exceed 50%, Bus
Communication modules, Power Supply and I/O cards shall have 100% redundancy
and fail safe certification.
System Redundancy
Following system redundancy shall be available as a minimum.
1. Controller 1:1
(CPU for control, I/O communication,
network communication)
2. Communication Bus 1:1
3. I/O communication modules with CPU 1:1

(I/O bus between CPU and I/O
with all necessary hardware)
4. Main data highway 1:1

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 52 of 93
5. Communication Cards 1:1
6. System Device 1:1
7. Power supply 1:3

(Power supply for all CPUs,
I/O power supply modules)
8. History 1:1
9. Modbus/Serial interface 1:1
10. OPC server: OPC server, If applicable shall have RAID-5 configuration with firewall.
11. System server (for server based PLC): Redundant (1:1 redundancy)
However, lamp drive cards, supporting mosaic need not be redundant also. Active
isolator/barriers need not be certified for fail safe operation.
The operator can bypass trip alarm inputs, which may be necessary in abnormal situations.
A lamp shall indicate that the trip alarm is inactivated. The operator will be warned by
sound and fast flash if the inactivated circuit goes in alarm status.
The system shall include an event recording system, and it shall be considered to store
about 500 events. The system should have SOE backup facility for 30days. Sequence
event recorder (SOE) of 1 msec, resolution to be envisaged.
Display colours shall be in accordance with the following:
Alarm and Trip (safety operations) : Red

Pre-alarm for trip (safety operations) : Orange
Indication for by pass of trip (safety operations) : Red
Equipment in operation (alarms and pilot lights) : White
Ready (standby of equipment) : Green
The mosaic panels shall be mounted on auxiliary consoles of PLC operating console.
Consumables like printer paper, cartridges, fuses etc shall be supplied along with the PLC
control system for a minimum period of one year duration.
Loading philosophy ( with 20% installed spares and 20% future expansion).
Control Processor 50%

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 53 of 93

Communication Processor 50%
Communication Bus 50%
8.2 PLC requirements
a) All systems' all cards shall be supplied with ISA G3 level or equivalent coating for
environmental protections.
b) ISOLATIONS
Analog I/Os to Field : Galvanic Isolation through safety barriers
Analog I/Os Module : Channel to Channel Galvanic Isolation
If individual channel to channel isolation is not available with system vendor, then only
Isolation shall be provided in a group of 4 channels as per system vendor design.
Digital Input to Field : barriers + optical isolators on cards
Digital Output to Field : Interposing relays + smart barriers for monitoring purpose
c) PANELS:
All panels shall be either 1200 mm (wide) x 800 mm ( depth) x 2100 mm ( height) or
as a special case 600 mm( wide) x 800 mm ( depth) x 2100 mm ( height), RITTAL
make, with 100 mm black powder coated metal base frame and with colour shedding
of RAL7032 ( Siemens Grey) and removable gland plates at bottom only. This applies
to all types of instrument panels to be used in the whole project like various PDB,
Electrical / Instrument panels, Third party device panels, etc.
d) All A/D converters of system I/O cards shall have resolution of min. 13 bits and all D/A
converters of system I/O cards shall have resolution of min. 10 bits
e) There shall be 20% installed spares minimum 1, installed and wired capacity for I/O
cards of each category in DCS, including all peripheral termination modules, prefab
cables, Relays, Safety barriers, etc
f) All marshalling and system panels shall have minimum 20 % wired spare capacity for
future expansion (should be possible with the same wiring philosophy.)
g) I/O cards’ Channel density shall not exceed the following limits:
Analog Input 16 Channels

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 54 of 93
Analog Output 16 Channels
Digital Input 32 Channels
Digital Output 16 Channels
h) Maintenance override switches (MOS) shall be soft type. One hardkey shall
be provided in Auxiliary console for the Activation of the MOS.
Process override switches (POS) shall be soft type.
i) Auxiliary Hardwired console
Auxiliary consoles shall be provided for high priority discrete hardwired safety
functions, which shall be manually operated. The console shall be installed adjacent
the operator station console, near 22” TFT/LED color monitors in the control room.
The console shall be equipped with, Mushroom top Emergency push buttons for
emergency shut-down action only. All Emergency stop and manual start/stop push
buttons shall drive an interposing relay located at IRC. For all critical electricals
drives (list will be discussed separately during detailed engineering), the spare
contact of final DO command from PLC going to MCC, must be connected as DI into
PLC and configured in SOE for confirmation of command to MCC from PLC.
All trip parameters shall have override switches and their output status lamp on
console.
j) All interlock and control transmitters shall be separate right from field junction box to
marshalling panels
k) Those parameters, which are directly or indirectly tripping the plant or may cause
production loss, shall be wired with 2 out of 3 transmitter trip voting interlock in PLC.
There shall be three separate analog input channels in three different cards. AI cards
shall be used for this purpose in system. Same thing is applicable to Digital inputs
also.
8.3 System Cabinets
8.3.1 Interlock Marshalling Cabinet
Marshalling cabinet(s) are foreseen for both incoming to Interlock system and outgoing
from Inter (‘from’ and ‘to’ field) termination. The interlock marshalling cabinet(s) shall also

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 55 of 93

accommodate the repeater power supplies for the field transmitters, galvanic isolators for
all inputs, trip amplifiers, output relays etc.
The termination strips shall be arranged or grouped for inputs/outputs 24VDC, 115VAC,
etc. both for inputs as well as outputs.
The terminals shall be of the Wago/weidmuller/Phoniex /Klippon make screwless, cage

clamp type, single tier design (double tier design shall be avoided). Terminal stack for each
unit shall be supplied with approx. 20% extra terminal points as spare/future provision in
addition to the existing inputs and outputs.
Physical separation between the terminal stacks/points shall be maintained for the
intrinsically safe and normal termination. Also the termination area shall be physically
separated from the electronics area there by sealing the latter from dust ingress.
8.3.2 Sequence of event (SOE)
Bidder shall provide the Sequence of event recorder function, with a time resolution not
above the machine scanning time. This information shall be available, for archiving, filtering
and visualization operations to the dedicated SOE workstation, located on the consoles of
Engineering room in CR, to aid in diagnosis and recognise the first cause of plant or
equipment shut-down.
Sizing of the system bulk memory capacity shall be done considering for SOE activities a
rate of 5000 events/day (shall be finalised during detail engineering ).
8.3.3 System Clock
The PLC control system clock shall have facility for synchronising with a Main plant DCS
through hardwire DI signal. Bidder shall consider Ethernet port/TCIP for synchronising to
Master GPS clock. Additional hardwired or communication connections / networks between
PLC/DCS control system and Main plant DCS shall be consider by the bidder.
8.3.4 DELETED
8.3.5 Power Supply
All instrumentation shall be fed by an Uninterruptible Power Supply (UPS) system.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 56 of 93

An uninterrupted Supply to PLC system shall be provided to the power distribution cabinet
of PLC system at 115VAC +/- 10%, 50Hz +/- 3%. UPS feeders from ACDB to DCS/PLC
loads shall be redundant whereas UPS feeders for Non-Control system loads shall Non-
redundant, The Contractor shall prepare a list Non-Control system UPS load requirement.
110 VAC UPS Power supply feeder failure alarm before PDB shall be provided in PLC by
using double pole MCB in PDB. One contact of these MCBs shall be wired to PLC for alarm
purpose. Single point Power supply shall be provided at Main Control Room / SS, all cable
supply & laying, termination, any work related execution of this package shall be in bidder
scope.
In case rectification to DC is involved, rectifiers shall be dual redundant and both shall be
‘hot’ (on line) so that failure of one rectifier will not cause a system trip. Provision shall be
included in the system to annunciate the rectifier/DC power supply failure.
24V DC power supply
i) 24 VDC power supply required for interrogation voltage, solenoid valve supply,
lamp, pushbutton, etc and for other packages shall be supplied by contractor using
dual redundant Bulk Power Supply (BPS).
ii) Each redundant bulk power supply shall be sized for maximum50% loading of its
capacity in normal time; the maximum loading is to be 70% of its capacity of BPS.
iii) All bulk power supply (BPS) shall be provided with surge protection capability. BPS
shall also provide with cooling fans and with fan failure alarm indications in
DCS/PLC system.
iv) Each BPS shall be provided with Mosfet based redundancy with auto-current
balancing and equal loading on both PS.
v) Power supply & redundancy module shall be same make .
vi) Current output (4 to 20 mA) shall be available from the power supply unit and the
same shall be wired to DCS/PLC for Power supply health monitoring and indication
from all BPS.
Philosophy of power isolation and over load protection (switch fuse units) or only over load
protection shall be extended upto individual card level, while designing the system, so that,
minor card failures can be localised for easy rectification. Also this will avoid major down
time on the system.
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 57 of 93

Earthing /Grounding bus bars for terminating shields of the cables shall be provided on the
cabinet.
Power supply (For all DCS/PLC and Vendor Packages): All BPS Failures shall be
connected to DCS/PLC as a separate DI signal. All Diode O rings Failures shall be
connected to DCS/PLC as a separate DI signal. All power feed Modules shall be connected
to DCS/PLC as a Separate DI signal. All MCB healthiness feedback shall be connected to
the DCS/PLC as a Separate DI signal. Silver/Cu/humidity/temperature monitoring shall be
with 2 nos. of C/R with indication in DCS/PLC.
Healthiness of BPS/MOSFET O ring must have LED indications for indicating the
healthiness of the module locally. 110 V AC and 24 V DC supplies must have current and
voltage transducer wired to PLC.
8.3.6 Annunciator
The Annunciator display stations will consists of:

- LED Lamps
- Split type architecture with lamps and electronics separate

- All connections with interlock system cabinet and interlock marshalling cabinet shall
be through plug in connectors.
- About 20% spare capacity shall be there
- All switches and status lights indicated below shall be an integral part of Display
Modules.
- Supply shall include mounting accessories and about 20% of unassembled extra LED
lamps
8.3.7 Precision & Accuracy
The isolator, repeater modules/trip amplifiers for analog inputs shall have a total accuracy
of less than 0.2% of full span for the measurement circuit.
The accuracy and stability for thermocouple trip amplifiers, if applicable, shall be +/- 0.5%.
8.3.8 PLC Spare Philosophy:

Installed Spares I/O Level 20%
Marshalling 20%
Spare Space I/O Level 20%

Processor 50%
Marshalling 20%
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 58 of 93

8.3.9 DCS CONTROL SYSTEM
The control system shall be a modern Digital Distributed Control System (DCS) located in
the Control Room. The system shall be reliable, fault tolerant and build up in modules
from the suppliers’ standard components and software. The system shall have facilities
for plant control monitoring, alarm handling, shutdown & trip functions. It shall be self-
diagnostic, self documenting and contain all the functions necessary for advanced
regulatory control and trip functions.

The critical trip shall be displayed on a separate graphics available in control system.
All Emergency stop and manual start/stop push buttons shall drive an interposing relay
located at IRC. For all critical electrical drives (list will be discussed separately during
detailed engineering), the spare contact of final DO command from DCS going to MCC,
must be connected as DI into DCS and configured in SOE for confirmation of command
to MCC from DCS.
The control system shall comprise racks with I/O devices, control cards, CPU cards, hard
disk, system buses, and required number of operator stations with colour video display
units (VDU) with dynamic graphic generation capabilities to ensure complete access to
the process during normal operation, start-up, and upset conditions. The operator shall
use dedicated operator keyboards to manipulate the DCS.
The DCS shall have the following main components. Detailed specifications of each of
them are given in subsequent sections. The system shall be 100% fault tolerant and dual
redundant, except the redundancy at I/O cards levels. This means, all central control
processors, all communication processors and all other central rack and individual node’s
common cards, all the communication cards, networks and cables, etc. shall be 100%
fault tolerant and dual redundant, except individual IO cards of the system. All the system
hardware of DCS shall have ISA G3 level corrosion protection. Since redundancy at I/O
card level is not envisaged, the failure of a single card from complete system shall not

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 59 of 93

affect more than the I/Os supported by that particular I/O card. It means all the hardware
except I/O cards shall be 100% fault tolerant. All the hardware including
control/communication processors, networks, cables, all type of system cards, all type of
I/O cards shall be hot replaceable.
All operating consoles for control system shall be located inside the central control room
but their I/O units, marshalling cabinets, power distribution cabinets and engineering
station shall be housed in the adjacent room.
DCS Functions
The DCS will perform, as a minimum the following functions:
Data Display
Process Control & Trip/Interlock
Logging
Dynamic Graphics
System diagnostics
Trend: All the critical parameters (Temperature, flow, pressure, level, speed, vibration
etc) as well as the Closed loops (PV,LV, MV etc) the trend shall be recorded for every 1
second with the back up of minimum 4 days. Recording shall be on FIFO basis.
8.3.10 Data Storage and Retrieval
Data storage and retrieval will be provided on hard disc and on DVD or DAT. The trend
shall be recorded as follows:
Analogue signals
Last 3 days Every 1 second.
Last 7 days Every 1 minute.
Last 45 days Every 1 hour
Last 1 year Shift averages
Last 2 years Daily averages
Alarms Last 48 hours (Minimum)

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 60 of 93

8.3.11 DCS Operator Interface
For Details of OS/ES please refer Annexure -3 System configuration
One Emergency Stop push button station directly wired to MCC, should be provided for
all critical drives (if applicable). The spare contact of this emergency push button must be
mapped to DCS/PLC as a DI contact for SOE punching. All emergency push buttons and
stop push station must be provided with transparent safety covers.
8.3.12 Process Controller Cabinets
The process controllers will contain the microprocessor based system capable of
combining continuous, sequential and discrete functions in order to the requisition of
analog and discrete signals, sequential and continuous control.
The process controller cabinets shall/may have incoming and outgoing cable marshalling
facility. All field cables shall be terminated in marshalling cabinets in single tier WAGO
make cage clamp type terminals. Isolators shall be provided for all intrinsic safe input and
outputs. All thermocouple signal wiring from terminal to respective isolator/input card shall
be through extension wires corresponding to the type of thermocouple element used.
The signal I/O cards may also be installed in Process Controller Cabinets. Some
marshalling/I/O racks may be installed in remote safe areas by extending the system bus,
especially in MCC rooms where lot of inputs from drives shall directly be terminated in the
marshalling /I/O racks.
8.3.13 DCS Redundancy Philosophy
In order to increase the system availability and then the continuity of plant operation,
redundancy shall be provided as follows:
100% fault tolerance and dual redundancy in DCS shall be for Controller cards, all
communication cards and buses, all control buses, all type of common cards in the
system, all power supply modules, all I/O modules for closed loops and interlock I/Os,
buses, Ethernet modules. The failure of any single I/O module for open loop shall not
affect more than the channels being catered by that particular I/O card. Dual redundant
power supply modules for each dual redundant controller shall be dedicated.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 61 of 93

8.3.14 Multiloop Controllers and Input/Output Cards
All multi loop shared controllers will be redundant with 1:1 redundancy. The control
processors shall be of fault tolerant type and both shall be active with cyclic changeovers.
All I/O cards for close loop applications shall be capable of holding the last value in case
of open condition of input. Input cards for specific open loop inputs used for calculation
functions must also be capable for holding the last value. As otherwise the same function
shall be built up in DCS software.
8.3.15 I/O Segregation:
The I/O card segregation for DCS shall be as per physical units of the plant.
8.3.16 Controller Loading
Each Controller loading shall not exceed more than 50% (hardware and software load of
each controller) in any case, after implementation of complete project and running at
peak load. In case more controllers are required to meet 50% loading criteria,
CONTRACTOR to include additional controllers without any cost implication.
8.3.17 DCS requirements
a) All DCS/ESD systems' all cards shall be supplied with ISA G3 level or equivalent
coating for environmental protections.
b) All digital output from DCS and ESD shall drive interposing relays of OMRON make, 4
Change over (4 NO/NC) with socket mounted relays with LED indicators and built in
surge suppressor. The contact rating shall be minimum 230 V AC/ 5 amps. Any DO
Channel from DCS/ESD shall not be directly connected to any devices without
interposing relays.
c) DCS shall be a large and expandable type system available with the vendor.
d) The system architecture shall be compliant to IEEE 802.XXX with dual redundant and
100% fault tolerant BUS/RING topology. System shall be fully open with
DDE/OPC&ODBC compliant. System availability shall be better than 99.95%.
e) DCS and ESDS I/O cards channel density shall be as per following:
I/O cards’ Channel density shall not exceed the following limits

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 62 of 93

RTD/T/C Inputs 16 channels
Digital Output DCS-32 Channels /ESDS-16 Channels
f) All I/O cards in individual category shall be of same type/model/revision only. No diff
bulk I/O cards or I/O cards with degraded features shall be accepted in any of the
category in a mix mode supply.
g) ISOLATIONS
If individual channel to channel isolation is not available with DCS / ESDS vendor,
then only Isolation shall be provided in a group of 4 channels as per DCS / ESDS
vendor design.
h) PANELS:
Electrical / Instrument panels, Third party device panels like wood word digital
governors, Bentley Nevada system hardware panels, etc.
i) All A/D converters of system I/O cards shall have resolution of min. 13 bits and all D/A
j) There shall be 20% installed spares minimum 1, installed and wired capacity for I/O
k) All marshalling and system panels shall have minimum 20 % wired spare capacity for
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 63 of 93
DCS System Redundancy
a. Controller 1:1
b. Input / output cards redundant

closed loops
c. Communication Bus 1:1
d. I/O communication modules with CPU 1:1

e. Main data highway 1:1
f. Communication Cards 1:1
g. System Device 1:1
h. Power supply 1:1

i. Serial (RS-485) Modbus (For Interlock PLC) 1:1
j. In case of client-server system, 1:1

server shall be redundant (Raid-6 Configuration)

I/O bus and I/O interface card at controller rack shall be redundant
Connectivity from Upstream redundant device to downstream redundant device shall be through
redundant device or cable.
Loading philosophy ( with 20% installed spares and 20% future expansion). Same philiosphy
applicable for PLC also.

8.3.18 Scanning Time
not more than 250 msec.
8.3.19 Other requirements
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 64 of 93

including controller group display, trend, configuration display, alarm summary pages, etc.
There shall be both numeric and alphabet keys and dedicated function keys on membrane
type operator keyboard each of which must be freely programmable. There shall be one no.
of operator keyboard with each of the operator stations.

security levels

Entry into the Marshalling Panels shall be through bottom mounted MCT blocks.
8.3.20 Consumables
One No. Spares like printer cartridges with each printer to be provided.
8.4 System Cabinets


PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 65 of 93

8.5 Sequence of event ,SOE (as feature of ES )
and visualization operations to the SOE which shall be feature of ES station. (I.e this feature
to be provided in Engineering station) located in the Engineering room in CR, to aid in
diagnosis and recognise the first cause of plant or equipment shut-down.
rate of 500 events/day (or shall be discussed during detail engineering).
The SOE package of the offered system must have facility to generate a separate SOE file
for critical event trips that is all important events just before and just after tripping event.
Time stamping of the SOE must be generated directly from the controller and it must be as
latest ISA standard.
8.6 System Clock

The PLC/DCS control system clock shall have facility for synchronising with a Main plant
GPS clock system through hardwire DI signal & Ethernet port/TCIP for synchronising to
PLC/DCS control system and Main plant DCS, if any shall be consider by the bidder.
8.7 Power Supply

An uninterrupted Supply to PLC/DCS system shall be provided to the power distribution
cabinet of PLC system at 115VAC +/- 10%, 50Hz +/- 3%. UPS feeders from ACDB to
DCS/PLC loads shall be redundant whereas UPS feeders for Non-Control system loads
shall Non-redundant, The Contractor shall prepare a list Non-Control system UPS load
requirement.
115 VAC UPS Power supply feeder failure alarm before PDB shall be provided in PLC/DCS
by using double pole MCB in PDB. One contact of these MCBs shall be wired to PLC/DCS
for alarm purpose
24V DC power supply

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 66 of 93

DCS/PLC system.
same shall be wired to DCS for Power supply health monitoring and indication from
all BPS.
time on the system.
cabinet.
connected to DCS/ PLC as a separate DI signal. All Diode O rings Failures shall be
connected to PLC/DCS as a separate DI signal. All power feed Modules shall be connected
to PLC/DCS as a Separate DI signal. All MCB healthiness feedback shall be connected to
the PLC/DCS as a Separate DI signal. Silver/Cu/humidity/temperature monitoring shall be
with 2 nos. of C/R with indication in PLC/DCS.
8.8 Precision & Accuracy

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 67 of 93

8.9 DCS Spare Philosophy:

Marshalling 20%

Processor 50%
Marshalling 20%
Rack
9.0 LOCAL CONTROL PANELS
All local panels under the scope of package vendor shall follow the minimum
specifications listed below:
9.1 Panels shall be suitable for acidic environment. All field mounted panels shall be of FRP
material only. Sealings of the panel will be Silicone/EPDM or better, which will be freezed
during detailed engineering.
9.2 Panel shall be free standing close cabinets, constructed in sections of min. 1000 mm
wide. The panel construction shall be welded or bolted frame construction with upright
and and additional framing in modular construction. The panel front sheet thickness shall
be min. 3 mm. The front of panel shall be stiffened where necessary with profiles tack
welded to the rear. Top, sides and doors can be made out of 1.6 mm thick plate.
9.3 The panels shall have environmental protection conforming to IP 55 min.
9.4 Instrument air shall be provided for purging of local panels.
9.5 Panel face, sides and doors shall be sand blasted and cleaned before primer and two
coats of paints are applied. The colour of paint shall be bright grey. The final surface shall
be semi mat, free from blemishes and paint runs.
9.6 115V A.C. +/- 10%, +/- 3% Hz power at one point to the local panel shall be provided by
the client. Any other voltage level if required preferably 24 V, DC, the same shall be
arranged by the vendor. Redundant rectifier units shall be provided for the generation of
d.c.by the vendor.
9.7 Earthing lugs for both power and system earthing shall be provided by the vendor.
9.8 The wiring shall preferably contained in polymer ducts. Instrument safe wiring shall be
laid separately from others. The colour of IS wiring shall be light blue.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 68 of 93

9.9 Wago/weidmuller/Phoniex /Klippon type cage clamp type terminals shall be used for
cable termination and wiring. 20% terminals shall be kept as spares in each terminal strip
and box. Terminals shall be spring loaded with screws, single tier in general.
9.10 Gland plates shall be provided alongwith cable glands (ex. proof wherever required) in
each panel for cable termination.
9.11 A miniature circuit breaker shall be provided for each power supply with DI contact wired
to system.
9.12 All panels shall be provided with vibration dampening pads.
9.13 Each panel section shall be provided with illumination level of 300 Lux min.
9.14 Each Control panel shall be provided with set of cooling fans to maintain and protect the
installed Control system.
9.15 Name plate/labels shall be provided for each panel mounted instruments, equipments
and accessories mounted in the front or rear of the panel.
9.16 Purged panels shall be provided with purge fail alarm. Purge fail trip shall be provided
with a bypass switch.
9.17 The local panel must have power segregation at all levels. There shall be clear
segregation and isolation of power supplies for all the local panels (115 VAC /240 VAC
/24 VDC ).
10.0 PNEUMATIC TRANSMISSION
10.1 Output Signal
Output signal from all pneumatic transmitters shall be 0.2-1kg/cm2g.
10.2 Pneumatic Receiver Instruments
Pneumatic receiver instruments shall have receiver elements design for 0.2-1 kg/cm2g
input signal.
10.3 Pneumatic Transmission Tubing
Pneumatic transmission tubing for local transmission shall be ½”or ¼” OD stainless steel
tubing with SS316 fittings (inch).
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 69 of 93

10.4 Instrument Air
Instrument air required is available at 6.5 kg/cm2g and max. 70 degree C. However, the
air pressure can be down to 4.5 kg/cm2g for remote consumers. Design pressure is 10
kg/cm2g. Dew point is -40 degree C at line pressure.
Air Distribution Headers shall be as SS 304.
11.0 ERECTION , INSTALLATION & COMMISSIOING
The bidder shall be responsible for the installation, calibration & testing, commissioning of
the complete instrumentation and controls as defined in this specification as minimum. All
the instruments & systems installed by the bidder as per scope subject to inspection,
checking, calibration & testing to prove their operational fitness. Testing & calibration
shall be done by the bidder, if required , all the required tools, tackles, calibration
instruments, qualified skilled manpower for conducting these tests shall be provided by
the bidder.
Testing & calibration may be witnessed by representative Client/PMC and/or

manufacturer's representative.
LETTER WRITING : LETTER WRITING FOR ALPHA-NUMERIC TAGGING ( WITH

SYNTHETIC ENAMEL). :- Letter writing of different sizes on Instrument Panels/misc.
Instruments/ Equipments with synthetic enamel paints (Asian/ Jonson & Nicolson/ Berger
/Nerolac Make) suitable for a temp. of 100 degree Celsius for writing of letters, figures
etc. Job includes cleaning of surface on panels/instruments/misc. instruments etc. All
complete with labour and materials as per drawings, specifications, Name plate schedule
and directions of Engineer-in-Charge. (Supply of paints is in contractor scope).
11.1 INSTRUMENT LOCATION
11.1.1 The location of instruments, control valves. Including junction boxes shall permit easy
access from grade, permanent platforms or stairways for operation, inspection and
maintenance.
11.1.2 The use of portable ladder or mobile platform shall be limited to access root valves,
thermowells and line mounted flowmeters.
11.1.3 Locations shall be decided to minimize the possibility of damage from passing or falling
objects and the possibility of tripping hazard or obstruct on walkway.
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 70 of 93
11.2 INSTRUMENT CABLE
11.2.1 Overhead Runs
Instrument main cable tray from field junction boxes to main control building or local
control room shall generally be laid in aboveground cable tray with protection cover. Tray
protection cover shall be provided only for the tray on top of tray layer.
Instrument branched cable runs from junction box or local panel to each instrument in the
field shall also be routed aboveground and supported with trays, steel angles and
channels.
FRP perforated cable trays/cable ducts shall generally be used for main cable trays.
Single pair cables from instrument to junction box and branch cable tray shall be through
perforated FRP cable trays.
The scope of supply includes FRP perforated type cable trays, FRP accessories such as
Bends, tees, crosses, reducers & connector plates and accessories like bolts, nuts etc.
FRP trays shall be vinyl ester resin based and all tray shall be manufactured using the
PULTRUSION process.
For Signal 900mm/ 600mm tray and for power 600mm/ 300 mm tray to be considered or
shall be discussed during detail Engineering.
Cable tray segregation shall be based on the voltage level. Cable tray shall be supported
at every 3M. 20% spare to be considered in the cable tray filling.
Instrumentation cables that form part of intrinsic safe (IS) circuits, if any, Shall be
segregated from other instrument signal cables.
Instrument power supply (AC) cables shall not run in the same tray of instrument signal
cables. Cable tray shall be dedicated for laying instrument power cables separately from
the signal cable tray.
Alternatively, cable ducts of suitable size shall also be considered for main cables. When
common cable ducts are used for running both power and signal cables, necessary air
gap partition shall be used to segregate the cables.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 71 of 93

11.3 CABLES
The primary insulation material shall be XLPE (cross linked polyethylene) for all types of
multi pair cables as per IEC-60502/60840/IS-7098 Part-1. Inner and outer jacket shall be
made of extruded flame retardant 90 deg C PVC to IS-5831
All cables shall be FRLS zero halogen as per standard IEC 332-3 Part 3 Cat. A. Fire
resistance cables whenever specified shall be as per me 331 Cat. A.
The insulation grade shall be 600 V/1100 V as a minimum arid shall meet insulation
resistance, voltage and spark test requirements as per BS-5308 Part-2
All cables shall be armoured. Armour over inner jacket shall be of galvanised steel
wire/flat as per IS-1554 part I I lEC 502. All the cores of single pair or multi-pair shall be
twisted and numbers of twist shall not be less than 10 per metre.
For signal and control cables, inner jacket colour shall be black. Outer jacket colour shall
be light blue, for intrinsically safe application and black for others. For thermocouple
extension cables the inner and outer jacket colour shall be as per IS-8784.
L/R ratio of adjacent cores shall not exceed 40 H/ohm for cables with 1.5 mm2
conductor Electrical Properties of Cables shall be in line with EN50288-7:2005
Contractor shall ensure a minimum of 20% of quantity of each type of cables supplied as
spare including any special cable and in each multipair cables 20% pairs shall be kept as
spare.
11.3.1 Instrument Signal Cable
a) Single pair shielded signal/alarm cables shall be used between all field instruments
including switches and junction boxes/local control panels.
b) Triad cable shall be used between GDs/RTDs to JB/Transmitter respectively.
b) Multipair individually and overall shielded signal/alarm cables shall be used between
junction boxes/local control panels and control room.
c) The single pair/triad cables shall be 1.5 mm2 conductor size made of annealed
electrolytic copper conductor of 7 strands with each strand of 0.53 mm diameter.
Multipair cables with 1.5 mm2 conductor size shall have 7 strands of annealed
electrolytic grade copper conductor with each strand of 0.3 mm diameter. Multi triad
cable or multi pair cable with 1.5 mm2 conductor shall have 7 strand with each
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 72 of 93

strand of 0.53 mm diameter. Colour of core insulation shall be black blue in pair and
black, blue and brown in a triad.
d) Shield shall be aluminium backed mylar/polyester tape bonded together with the
metallic side down helically applied with either side having 25% overlap and 100%
coverage. The minimum shield thickness shall be 0.05 mm in case of single pair/triad
and 0.075 mm in case of multipair/triad cable.
e) Drain wire shall be provided for individual pair and overall shield which shall be 0.5
mm2 multi stranded bare tinned annealed copper conductor. The drain wire shall be
in continuous contact with aluminium side of the shield.
f) All multi pair cables shall have 6 pair/12 pairs only while multitriad cable shall have 6
triads/8/12 triads only. Size for multipair cable will be 1.5mm2 with drain and overlap
as above.
11.3.2 Cables and Multicore Cables for Solenoids etc.
Cables and multicore cables for such items as solenoid valves and flame detectors shall
normally have a conductor size of 2.5 mm2. However, conductor sizes for power cables
shall be co-ordinated with the Electrical Group to avoid too many different cable types.
Signals (4-20 mA or switch 'contact): 6/12 pair individually and over all shielded
(screened) and armoured, twisted, 1.5 mm2 conductor.
11.3.3 Thermocouple Extension Wires
a) Single pair shielded thermocouple extension cables shall be used between

thermocouple head and junction boxes transmitters/ local control panel mounted
instruments.
b) Multipair individually and overall shielded thermocouple extension cables shall be

used between junction boxes and main control room mounted devices.
c) The type of thermocouple extension cables shall be compatible with thermocouple

used. In addition the colour coding of the primary insulation shall be as per ANSI.
d) The cable shall have 16 AWG and 18 AWG solid conductors for single and multipairs
respectively.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 73 of 93

e) All thermocouple extension cable shall be matched and calibrated in accordance with
MC-96.1.
f) Shield shall be aluminium backed by mylar/polyester tape bonded together helically

applied with the metallic side down with either side having 25% overlap and100 %
surface. Minimum shield thickness shall be 0.05 mm for single pair and0.075 mm for
multipair cable. Drain wire shall be 0.5-mm2 multi-strand bare tinned annealed copper
conductor. The drain wire shall be in continuous contact with the aluminium side of
the shield.
g) Inductance shall not exceed 4mH/Km.
h) All multi-pair cables shall have 6 pairs/12 pairs only.
11.3.4 Power supply Cables
All power supply cables shall be as per IS-1554 Part I and shall have copper conductors.
Minimum conductor size shall be 2.5 mm2. The cables shall be PVC insulated and
armoured. The higher size conductors shall be used incase of long distance power cable
where voltage drops more than 3 volts than required supply.
Any other special cable required for instruments that should also be supplied as per
requirements. CONTRACTOR shall ensure that these cables are armoured type and
shall meet all other requirements.
11.3.5 OPTICAL FIBER CABLE
The Optical Fiber Cable (OFC) used shall conform to the following specification as a
minimum:
a) The OFC shall be CSTA (corrugated steel tape armored, electrolytically chrome
plated low carbon steel) armored cable.
b) The OFC shall have FRP strength member, loose tubes for single mode optical fibers
filled with moisture resistant jelly, moisture barrier of polymer coated Aluminum tape
or water swellable tape, inner sheath of HDPE and outer sheath of PVC.
c) Optical fibers shall be single mode fibers compliant to ITU-TG.652 and fibers colours
shall correspond to IEC 793-2 and 304. Optical fibers shall be coated with UV cured
double acrylic resin. It should not have any reaction with cladding or core material.
The coating should provide maximum resistance to micro-bending & abrasion and
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 74 of 93

ensure mechanical & optical strength. The coating shall be easily stripped with
mechanical tools.
d) The number of fibers in the OFC shall be decided depending upon the requirement
with 8 fibers as a minimum.
e) The cabled fiber attenuation shall be -S 0.37 dB/km for 13] 0 nm wavelength range
and 0.22 dB/km for 1550 nm wavelength range.
f) The tensile performance shall be as per . IEC 60794-1-2 E1 and with tensile load of
9.81 x 2.5 W (Where W= mass of 1 km of cable in Kg)Newton Or 2670 N whichever
is higher.
11.4 JUNCTION BOX
a) JB MOC shall be FRP and 4 mm thick sheet. Junction boxes shall be for IEC Zone 2
& Gas group IIA/IIB EExe. with acid resistant gasket (will be freezed during detailed
engineering).
b) In all JBs, cable entries shall be from Bottom only. Further after commissioning, all
JB’s should be covered with Aluminum tapes at its periphery to prevent water
ingress.
In general a junction box shall contain only signal of same class. The signal class is
categorized as following type:
i) Signal Level
 Analog
 Digital
 T/C
 Solenoid Valve
 Instrument Power
 Gas Detectors
ii) Type of protection

 Non IS, Ex d
 IS
c) All JB extra entries shall be plugged with SS316 plug. Each junction box shall be
provided with 2 multi-cable entries from the bottom of the junction box with one
plugged. All Cable entry shall be at the bottom only, and not from side or top.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 75 of 93

d) All spare cable cores shall be terminated in the Junction box, at the marshalling panel
end and wired through spare barriers / isolators or relays (as the case may be) right
upto the corresponding spare channel of I/O module.
e) All spares hole of JBs, T/C head etc to be plugged with metallic plugs. The metallic
plugs, Junction box hinges, Handle, DIN rail, Allen screws shall be SS 316 material of
construction.
f) For ease of identification shutdown JB’s shall be colored should be marked with RED.
g) Cable glands shall be provided with Cables shrouds. 20% spare terminals shall be
supplied in each junction box.
11.5 CABLE GLANDS
a) Contractor shall supply all cable glands required for glanding the above mentioned
cables both at field instrument and local control panel side, junction boxes side and at
control room side.
b) All cables glands shall be of SS316 ex-proof and they shall be double compression
type suitable for armoured cables. Glands shall be in line with Area classification
c) Flame proof glands wherever required 'shall be supplied with EX'd' certification.
11.6 INSTRUMENT VALVES AND MANIFOLDS
a) Contractor shall supply instrument valves (miniature type) and valve manifolds
wherever required.
b) Body rating shall be as per piping class or better. All valves and manifolds shall be
forged type only.
c) Valve body and trim material shall be SS 316L unless otherwise specified. Superior
trim material shall be selected as requirement by process conditions. Packing material
in general shall be of PTFE
11.7 INSTRUMENT IMPULSE LINES
a) In general ½” OD annealed seamless SS 316 tubing shall be used in preference to

piping.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 76 of 93

b) Tubing standard shall be used upto 600 # only where the same is required as per job
specification. For rating above 600 # and hydrogen/lethal service, only piping
standard shall be used. The tubing shall be 1/2" OD tube with all fittings suitable for
the same. Valves used shall be threaded. At the first isolation / root valve end suitable
pipe tag to tubing conversion fittings shall be used. For remote installation suitable
unions / couplings shall be used.
c) Piping standard shall be used for all installation where specified in job specification.
For rating upto 600#, the connection to the transmitters shall be with a male
connector and tubing 1/2" OD. For rating higher than 600 #, no tubing shall be used.
The connection to the transmitters shall be with 1/2" piping with flanges in between
piping standard, all pipes shall be 1/2" NB unless higher sizes required to meet the
"requirements, with all fittings suitable for the piping. All the joints shall be welded or
flanged as required. For instrument end connection i.e root valve of orifices and other
items, level gauges vent and "drain connection, seal welding shall be provided. For
non diaphragm seal instruments and instruments where provided with threaded
connection, no welding is required at instrument end
d) All instruments shall be provided with isolation, drain and/ or vent valves with
vent/drain end duly capped. This isolation valve shall be SS304 GATE type. It shall be
in addition to the first isolation /root valve provided on the pipe or vessel at instrument
take off.
f) For diaphragm seal type instruments, spacer ring with vent and drain connection
along with vent / drain valve with end capped.
g) Contractor shall supply flareless compression type of tube fitting and of three piece
construction with design similar to Swagelok/Parker Hannifen etc.
h) Socket-weld type forged pipe fittings of suitable material and rating shall be supplied
for pipe fittings. The minimum rating shall be 3000 #. Weld neck fittings shall be used
where socket weld type are not allowed by piping class.
i) All pipe fittings shall be according to piping material specification as per piping class
of the pipe on which instrument is connected. In case of vessel/equipment / reactor,
PMS of equivalent piping class shall be considered.
11.8 INSTRUMENT AIR SUPPLY DISTRIBUTION

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 77 of 93

Instrument air headers, pipes and distributors shall be of S.S 304. Instrument air manifold
shall be used for supplying instrument air to control valves and other instruments. These
shall be with 10 nos. of tappings and be with ½” NPT (F), SS 304 valves. From the
nearby air manifold, instrument air shall be supplied to the control valves. For the
purpose, all tubing shall be used shall be of SS316, ¼”, 1/2” OD, seamless tubes, laid in
perforated aluminium trays. All intermediate fittings shall be double compression, SS316
MOC, Swaglok /Parker make only.
Instrument air shall be provided at one point at battery limit. Package vendor has to
develop air distribution scheme.
11.9 MCT Blocks
Cable entry to main control room shall be through MCT blocks.
Entry into the Panels in the control room shall be through bottom mounted MCT blocks.
Bidder shall provide minimum 8+8x6 MCT frame along with multi-dia blocks with peeling of
arrangement and centre plug, with wedge, lubricant, stay plate. Bidder shall provide at
least 20% installed spares with mult-dia blocks with peeling of arrangement and centre
plug. ( Qty of frame shall be submitted by the bidder during bidding stage with typical
cable arrangement).
11.10 PROTECTION AND PAINTING
All exposed carbon steel parts to be painted shall be thoroughly cleaned from inside and
outside to remove scale rust, dirt and other foreign materials by wire brushing / sand
blasting as applicable. Minimum acceptable standard in case of power tool cleaning shall
be St. 3 and in case of blast cleaning shall be SA 2. as per Swedish standard SIS 055900-
1967.
 Non – ferrous materials. Austenitic stainless steels, plastic or plastic coated materials.
 Insulated surfaces of equipment and pre-painted items shall need not be painted.
 Stainless steel surfaces, both inside and outside. Shall be pickled and passivated.
 Machined and bearing surfaces shall be protected with varnish or thick coat of grease.
Depending on the environment the following primer and finish coats shall be applied:
S. No. Environment Description Minimum Requirements

1 Normal – Industrial Primer 2 coats of Red oxide
Zinc phosphate each 30-35 microns thick

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 78 of 93

Finish Coat 2 coats of synthetic enamel, each 25 microns (min.)
thick.
2 Corrosive – Primer 2 coats of epoxy zinc chromate, Each 35 microns
Industrial (min.) thick.
Finish Coat 2 coats of epoxy high build paint, each 100 microns
(min.) thick.
3 Coastal and Primer 2 coats of high build chlorinated rubber. Zinc
Marine phosphate, each 50 microns (min.) thick.
Finish Coat 2 coats of chlorinated rubber coat paint. Each 35
microns (min.) thick.
(Any values refer to dry film thickness).

Colour Band shall be provided on loading arm as per Product colour code at site.
11.11 THIRD PARTY INSPECTION

Al instrumentation shall be inspected by TPIA as per approved QAP / ITP plan. General
specification for Inspection & Testing is attached herewith further bidder to submit detailed
QAP/ITP for each item for approval /review by Client/PMC. Client reserves the right to
review / inspect / witness the items at any stage of inspection.
The list of approved inspection agency Is:‐
a) Engineering India Limited
b) Lloyds Register of Shipping
c) Project & Development India Limited
d) Mecon Limited
e) SGS India Pvt. Ltd.
f) RITES Limited
g) Det Norske Veritas
h) TUV Rhineland (I) Pvt. Ltd.
i) TUV India Pvt. Ltd
11.12 PACKAGING AND IDENTIFICATION
All packaging shall be done in such a manner as to reduce the volume. The equipment
shall be dismantled into major components suitable for shipment. All assemblies shall be
properly match marked for site erection.
Attachments, spare parts of the equipment and small items shall be packed separately in
wooden cases. Each item shall be appropriately tagged with identification of main
equipment. Item denomination and reference number of the respective assembly drawing.
Detailed packing list in waterproof envelope shall be inserted in the package together with
equipment Each equipment shall have an identification plate giving salient equipment
data, make, year of manufacture. Equipment number, name of manufacturer, etc.
12.0 Storage Tank

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 79 of 93

Instrument design Philosophy shall be same as per section above.
For each storage tank 2 Nos. of Level measurement of two different principles shall be
provided (One ultraonic & one DP Type level measurement.)
13.0 CCTV System
Bidder shall provide 6 nos. (3 for DM and 3 for ETP) of (2MP minimum) PTZ, picture IP
based digital video camera with inbuilt IR to be installed at strategic location of the DM
plant. Provision shall be made in the CCTV system to connect total 10 nos. Of camera.
These camera shall be hooked up with main plant CCTV system, so all the hardware’s
and software’s required for successful implementation of the same shall be in the scope
of the bidder. Client will provide 3 nos of channels to connect with the central CCTV
system. Main plant CCTV system shall be BOSCH / PELCO/ Honeywell or make shall be
discussed during detail engineering. Bidder to offer all the materials accordingly.
Minimum requirement is as below:
a) All cameras shall be ONVIFS with all mounted accessories.
b) Supply and laying of FO & Power cable upto CCR. Armoured FO cable shall be laying
through HDPE pipe.
c) Any additional requirement of splicing for FO cable
d) Media converter card if any or any other hardware to fulfil the above requirement.
e) Any other hardware / software etc. for execution of CCTV System.
14.0 Training
Supplier shall train Clients’ maintenance engineers as well as operations staff in his
works at Vendors Center of Excellence. The training imparted shall be by qualified and
experienced staff available. It shall be exhaustive and aimed at making clients’
maintenance & operations staff self reliant for most of the day to day applications. For
training, supplier shall make available as close a model of the system with all the
representative nodes, as the actual system to be installed. It is envisaged that following
be covered in the training:

Operating Staff Training

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 80 of 93

Operating courses include all aspects involved in operating the Control System from
operator interface. This shall include operation under normal and abnormal conditions as
may result from minor or major system malfunctions such that the trainee can take the
appropriate remedial actions. The training shall include but not be limited to the following:
• Overview of the system
• Control philosophy
• User interfaces
• Messages and alarms
• Operator commands
• Generation of reports
• Predictable events and expected operator action

Engineering staff training
Software Design courses shall be provided which would train the Employer's
Maintenance and Design staff to be able to identify and remedy software faults, upgrade
and implement data and software changes, generate/develop new software for the
purpose of improving the system and production of revised or new displays. The training
shall include but not be limited to the following:
• Overview of the system architecture, hardware and software
• Software design and organisation
• Database structure, generation and modification
• Generation and modification of the VDU screen
• Customization of report/chart/graph format
• Assembly, compilation, linking, editing, debugging, distributing, testing and integration

of program modules

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 81 of 93
ANNEXURE -1
INSTRUMENT ACCURACIES
The instrument reference accuracies shall be as per the table below. Accuracy of the
Instruments shall be minimum as follows. Custody Transfer accuracies shall be as defined in
the ITB in terms of rms.
Type of Instrument Accuracy

Process Gas Analyzer – All type +/- 2% FS
Conductivity , pH meters +/- 0.5 % of Reading
Belt weighers +/- 0.5 % of range
SILICA Analyzer +/-0.5 ppb or better
Sodium Analyzer ±5 % of reading or better
Chlorine Analyzer ± 2 % or better
Differential pressure & Pressure transmitter - SMART ± 0.050% of span within TD ratio of 1:
100 or better
Diaphragm seal transmitter & Pressure transmitter - ± 0.050% of span within TD ratio of 1:
SMART 100 or better
Variable area type flow meter with transmitter ± 2.0% FS Note (1)
Vortex flow meter ± 0.7 % FS
Positive displacement flow meter
- Raw material and Product ± 0.2% FS
- Others ± 0.5% FS
- Turbine meter or Mass flow meter
- Others ± 0.5% FS
- Magnetic type flow meter ± 0.5% FS
- Mass flow meter (Coriolis Type) ± 0.1% FS
- Ultrasonic type flow meter ± 0.5% FS
- Ultrasonic type flow meter( 5 – path) ± 0.1% FS
Orifice plate : Normal Application +/- 2% of flow rate
Orifice plate : Special Application +/- 1.5% of flow rate
Venturi +/- 1 % of flow rate
- Displacement type level indicator ± 1.0% FS
- Displacement type level transmitter ± 0.2% FS (Smart)
- Tank gauge (Custody Transfer) ± 1 mm with +/- 1 mm resolution

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 82 of 93

- Servo type tank gauge ± 2 mm (up to 20 m height)
- Radar type tank gauge ± 1 mm or better for custody transfer
± 5 mm or better for normal application
± 0.2% of span within TD ratio of 1: 100
- Pressure gauge ± 1.0% of span for Bourdon type , 1.5%
for diaphragm
- Temperature Transmitter ± 0.15 % of calibrated span for RTD &
T/C
- Filled system/Bimetallic ± 1.0% FS
- Small size pressure gauge ± 3.0% FS
- Draft gauge ± 3.0% FS
- Receiver gauge ± 1.5% FS
- Thermocouple & Resistance Bulb Applicable Codes/Standards
Note: 1. Vendor's standard accuracy is applied to local indicator type
Remarks: 1. Accuracy of instrument and special articles except for the above mentioned instrument
shall be in accordance with the applicable codes/standards, or Vendor's standards as
approved by Purchaser.
2. FS: Full scale.
3. Overall rangeability of transmitter except for draft range shall be 1: 100. Draft range
transmitter rangeability shall be 1: 30 for the accuracy indicated above.
4. Accuracy for the instruments shall be % of reading and shall be supplied with wet
calibration certification.


PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 83 of 93

ANNEXURE -2
Field instrument connections shall be as follows.
Instrument Type Process / Vessel Instrumentation

Connection Connections
DP Flow Instruments ½” NPT (M) ½” NPT
External Displacer on Vessel 2" Flanged 2" Flanged

( Min. Rating ANSI 300#)
Internal Displacer 4" Flanged 4" Flanged
External Ball Float on Vessel 2" Flanged 2" Flanged
Internal Ball Float 4” Flanged 4” flanged
Magnetic Level Gauge 2” Flanged 2" Flanged
D/P Level ½” NPT (M) ½” NPT
D/P Level with Remote Seal Diaphragm 3” Flanged 3” Flanged
D/P Level Direct Vessel Mounted 3” Flanged 3” Flanged
RADAR – Direct Mount on vessel 3" flanged 3" flanged
GW RADAR – Side/Side Chamber Mounted 2" flanged 2" flanged
on vessel (Min. Rating ANSI 300#)
Internal GWR on Equipment 4” Flanged 4” flanged
Special Level Instrument on Equipment 2" flanged 2" flanged
(Capacitance/ Ultrasonic/R.F.Probe)
Tank Level Instruments (Servo) on 6" flanged 6" flanged
Atmospheric tank/ Pressurized Equipment
Tank Level Instruments (Radar) on 8" flanged 8" flanged
Atmospheric tank clean service / Pressurized
Equipment
Atmospheric tank viscous service /
Pressurized Equipment
Tank Level Instruments (Capacitance/ 2" flanged 2" flanged
Ultrasonic/R.F.Probe) on Atmospheric tank /
Pressure Instruments ½” NPT (M) ½” NPT
Press.Gauge ½” NPT (M) ½” NPT
Pressure with diaphragm seal, 3" Flanged 3" Flanged
(Min. Rating ANSI 300#)
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 84 of 93

Pressure Instruments on Vessel 1 ½” Flanged ½” NPT
Pressure Instruments on Standpipe ¾” SW/BW/Flanged ½” NPT
Chemical Seal pressure Instrument gauge on 1 ½” Flanged ½” NPT

Vessel
Diaphragm Seal pressure Instrument gauge 1.5" Flanged 1.5" Flanged
on Vessel
Thermowell 1 ½” Flanged 1 ½” Flanged
Multipoint Temperature Element for Tanks 2" Flanged / 3" 2" Flanged / 3"
Flanged Flanged
Standpipe 3" Flanged -
Note:-
a. There shall be a separate tapping for each of the instruments on any pipeline/vessel. No
multiple instruments from one tapping is acceptable (for example PG and PT from single pipe
line tapping with single or double mechanical isolation valves are not acceptable). However,
as an exception to this, three transmitters on clean gas services from one orifice (with two
pairs of tapping) is acceptable, where multiple (2 out of 3, etc.) transmitters are to be
installed.
b. All type of instrument tapping flange rating shall be minimum ANSI 300#, irrespective of
minimum design pressure. However for pressure rating of 600# class and above, RTJ flange
shall be used. At few locations, double isolation valves shall be used as per table given
below.
PRESSURE LEVEL FLOW CONTROL

INSTALLATION TAPPINGS TAPPINGS ELEMENTS VALVE
RATING
300 # SINGLE SINGLE SINGLE SINGLE
600 # DOUBLE DOUBLE DOUBLE SINGLE
900 # / 1500 # / 2500
# DOUBLE DOUBLE DOUBLE SINGLE

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 85 of 93

Annexure ‐ 3
SYSTEM CONFIGURATION
PLC/DCS system package
2 Nos Operator Stations with ,22” TFT, COLOR, LED type dual stacked monitors to be place
in CR consoles
in CCR consoles .
1 Nos ES/OS (dual stacked) dual personality, 22” TFT, COLOR, LED type
1 no. of Membrane Operator’s Keyboard and 1 no. of QWERTY engineer’s
keyboards with mouse with each operator station
1 No. Annunciator with LED lamps with split type architecture
1 No Auxiliary Console
All USB ports must be blocked and the system must have latest anti-virus.
Printers
1 Nos A3 Heavy duty Colour HP make Laser printer
1 Nos A4 Black and White HP make Laser printer
(All printers shall have wireless facility)
Required furniture of reputed make shall be considered in the offer.
All the license required for OS,ES shall be in Bidder’s scope.

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 86 of 93
Annexure - 4
OPERATOR STATION SUB-SYSTEM
* Model No. _Note-1___
A. General Requirement
1 Number of Operator Consoles Three
2 Inter-changeability between operator consoles Required
3 On-line system diagnostics on Console Monitor Required at Module level
4 On-line configuration change Required
5 Console configuration Single
B. OPERATOR CONSOLE
1 Console's basic electronics Individual electronics for each monitor
μp Type 64 bit
μp Manufacturer/ model Note-1
Memory size /Cache size 16_GB (Vendor to check the suitability
of memory size)
2 Type of Database Functionally Separate
Database Storage Devices:
Sr. ITEM MODEL No. FUNCTION REDUNDANCY REMARK

No. (Refer Note)
1. HDD Note-1 REQUIRED 1 TB Min
2. Combo drive Note-1 REQUIRED
Vendor Note-1 REQUIRED
3.
recommended
4. REQUIRED
(Note: Full Redundancy is required if Centralized global database is provided)

STORAGE DEVICES ARE APPLICABLE IN EACH OPERATOR STATION.
3 Number of Devices (per console)

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 87 of 93

S. Description OF DEVICES NO. OF
TYPE OF DEVICE REMARKS
No REQUIRED DEVICES
22” TFT, COLOR, LED type dual

1. MONITOR stacked monitors 1 per console
(water package PLC architecture)
1 no. of Membrane Operator’s
2. KEYBOARD SETS Keyboard and 1 no. of QWERTY 1 per console
engineer’s keyboards with mouse.
ALARM & EVENT, 1 Nos A3 Heavy duty Colour –HP 1

3.
LOG A3 PRINTER make
7. DVD DRIVE 1 per console

1 No. Annunciator with LED lamps
ANNUNCIATOR
8. with split type architecture 1
KEYBOARD
4 Inter-changeability between Monitors Required
5 Spare memory requirement Min. 40%

6. Keyboard Set
a) Keyboard Security against unauthorized access Required with Key-lock
Note: Key-lock Password shall be provided for each operator console.
b) Maximum number of keystrokes for accessing views as per standard display

hierarchy:
S.No. TYPE OF VIEW REQUIRED OFFERED REMARKS
1. GROUP VIEW TWO
2. LOOP VIEW THREE
3. LOOP IN ALARM TWO
4. GRAPHICS VIEW TWO
c) Assignable function keys for single keystroke access Required

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 88 of 93

d) Number of Assignable function keys per Monitor 64
7 a) Number of devices for cursor control Two/Monitor
b) Devices for cursor control Keyboard [X] Mouse [X]
8 Monitors and Displays

a) Size of Monitor 22" diagonal
b) Type of Monitor TFT LED
c) Surface Treatment Hard Coating anti Glare
d) Length of tag number (characters) 16 alphanumeric
e) Length of description (characters) 24 alphanumeric
f) Display update rate 2s
g) Dynamic graphics Required
h) Multi Window Capability Required
i) Control through dynamic graphics Required
j) Screen displays and Call-up time
S.No. TYPE OF DISPLAY REQUIRED CALL-UP TIME(S)* REMARKS
1. OVERVIEW YES
2. GROUP DISPLAY YES
3. LOOP DISPLAY YES
DYNAMIC
4. YES
GRAPHICS
5. REAL-TIME TREND YES
6. HISTORIC TREND YES
7. ALARM SUMMARY YES
8. ALARM HISTORY YES
9. CONFIGURATION YES
10. DIAGNOSTIC YES
k) Display Hierarchy

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 89 of 93
S. SYSTEM
DESCRIPTION REQUIREMENT REMARKS
No. CAPABILITY
1. NO. OF OVERVIEW PAGES AS REQD.
2. NO. OF GROUPS/OVERVIEW AS REQD.
3. NO. OF LOOPS / GROUP 8
4. NO. OF GRAPHIC PAGES AS REQD.

NO. OF POINT IN ALARM AS REQD.
5.
SUMMARY
NO. OF POINTS IN ALARM AS REQD.
6.
HISTORY
7. NO. OF TRENDS PER DISPLAYS AS REQD.
8. NO. OF MULTI-TREND DISPLAYS AS REQD.
9. OTHERS AS REQD.
l) Multi Windowing facility Required

Note: Opening of more than four windows on the same Monitor shall be restricted by
the system .
m) Trending functions: Each Operator Console shall be capable of trending all analog
points.
n) Real-time trend
Number of parameters Required for ALL TAGS
o) Historical trend
Time period 30 Days
9) Logging Function
a) Number of tags to be logged Required for ALL TAGS
b) Number of log reports:
Alarm History per shift
Event logging
Hourly logs
Shiftly logs
Daily logs
PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 90 of 93

Weekly logs
Shutdown report
Trip initiated log
Others (Note)
Note: Other log reports as required shall be furnished during execution stage.
c) Log formats User definable
10 System boot-up from Engineer console

11 Auto boot-up on power On Required
12 Storage disks
a) Type of storage disk HDD Optical (DVD)
b) Number of disks and capacity
Sl. NUMBER MEMORY CAPACITY PER

No. TYPE OF DISC (MINIMUM) DISK REMARKS
1 1 TB Min
HDD AS per latest configuration
One Per Monitor
2.
OPTICAL One Per Monitor AS per latest configuration
3. Other
13 Any other feature available as a standard:

a)______________________________________________________
b) ______________________________________________________
14 CPU Loading 60 %
15 Memory Utilization 60 %
16 Operating System Latest must have validation with the system
17 Antivirus/Network Security Required

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 91 of 93

ENGINEERING Cum OPERATOR STATION SUB-SYSTEM
 Model No. _______
1. Number of Engineering cum Operator Station One
2. Number of Monitors per Engg. Station One

3 Type of electronics Individual per Monitor
µP type 64 bit
Memory size NOTE-1
Model No. NOTE-1
4 Number of engineering keyboards One per Monitor
5 Number of Operation keyboards One per Monitor
6 Functional Capability Same as operator station subsystem
7 Basic functions of Engineering Console

a) System configuration and reconfiguration
b) Group & multi-groups alarm inhibiting
c) Plant views with/ without plant operation
d) Graphic page compilation
e) Setting/ resetting real-time clock
f) Loop tuning on selectable basis
g) System maintenance and diagnostics
8 Monitor specification As per operator station subsystem
9 Keyboard specification As per operator station subsystem

10 Data storage Devices and capacity
Sr. NUMBER MEMORY CAPACITY

TYPE OF DISC REMARKS
No. (MINIMUM) PER DISK
As per Latest
1 HDD One 1 TB Min
configuration
2. DVD writer One
As per Latest
3. OPTICAL(DVD) One
configuration
5. OTHER
11. Antivirus/Network Security Required

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 92 of 93
SEQUENCE OF EVENT (SOE)

*Model No.________
Offered System Details
1 Dedicated Sequence of Event Station Required
SPECIFICATIONS
1 Type Integrated with PLC system
2 Scan time Not more than system scan time
3 Resolution Required
Digital 1 msec [ X ] 10 msec [ ]
Analog 250 msec [ X] 100 msec [ ]
4 SOE PC Required
Function of PC:
Event Data Collection
Alarm Data collection

Diagnostics
History Data
SOE Printer Required
Alarm Data Storage Required
Storage Time 30 Days
5 Interfacing with:
PLC Yes

PC150/E/4004/SEC-VI- 0
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 93 of 93
ANNEXURE -5
Type of Inst to JB (1P,1T) JB to CR (6P/12P/6T/8T/12T) CR to MCC/MCC to CR

Signal (Multi‐conductor cable)
Size Type * Size Type Size (mm2) Signal
*(mm2) (mm2)
AI 1.5 Signal 1.5 Signal 1.5 Signal
AO 1.5 Signal 1.5 Signal 1.5 Signal
DI 1.5 Signal 1.5 Signal 1.5 Signal
DO 1.5 Signal 1.5 Signal 1.5 Signal
RTD 1.5 Signal 1.5 Signal 1.5 Signal
TC 1.5 Signal 1.5 Signal 1.5 Signal
GD 1.5 Signal 1.5 Signal ‐ ‐
SOV 2.5 Signal 2.5 Signal ‐ ‐
POWER 2.5 Power 2.5 Power 2.5 Power
TC Special compensation
Extension cable between
cable Element to
transmitter
RTD Triad cable between
Extension Element to
cable transmitter of
1.5mm2
Analysers 1.5 Signal 1.5 Signal or serial
communication
as the case
may be.
*Note : Above size is minimum. Further cable size may be increase based on voltage
drop calculation .

PC150/E/4004/SEC VI-
0
3.0 (PART A)
SHEET 1 of 3
DESIGN PHILOSOPHY FOR CIVIL & STRUCTURAL

WORK



PC150/E/4004/SEC
RWTP ,DMW & CPU PLANT VI- 3.0 (PART A)
0
TALCHER FERTILIZERS LTD. CONTRACTOR
DESIGN PHILOSOPHY FOR CIVIL & DOCUMENT NO
Rev
.
STRUCTURAL WORK SHEET 2 OF 3
GENERAL DESCRIPTION OF SCOPE
This section of the Tender Documents deals mainly with the Scope and Technical
Specifications needed for the Detail design, preparation of detailed Drawings and getting
the design/ drawings approved by Owner/Consultant, execution and construction of
complete Civil, Structural and other Allied Works on turnkey basis.
The scope of Civil Structural and Architectural Works under this Contract shall include
carrying out Basic Design, Detailed Engineering, development of Drawings, Supply of
materials, Procurement of materials, Construction, Demolitions, Supervision of all relevant
Civil and Structural Works including providing all labour, supervision, material, scaffolding,
construction equipment, tools, tackles and plants, supplies, transportation, statutory
approvals, all incidental items though not indicated or specified but reasonably implied or
necessary for successful completion of the project.
Scope consists as listed below but not limited to the followings:-
Type of Structure Materials of Construction

Foundation of all equipments (Static and RCC
Dynamics) , Structures and Tanks
Substation building (common for DM plant and RCC framed with brick cladding
ETP)
Central Control Room (common for DM plant RCC framed with brick cladding
and ETP)
Piperacks,Platforms,sheds Structural Steel
Field operator room (with normal AC facility) RCC framed with brick cladding
Pipe-rack Steel structure
Support structures Structural Steel/ RCC
Intermediate Sumps etc RCC

Plant & Machinery/Technological Building Structural Steel
Dyke wall As required
Paving All around the plant area

PC150/E/4004/SEC
RWTP ,DMW & CPU PLANT VI- 3.0 (PART A)
0
TALCHER FERTILIZERS LTD. CONTRACTOR
DESIGN PHILOSOPHY FOR CIVIL & DOCUMENT NO
Rev
.
STRUCTURAL WORK SHEET 3 OF 3
Roads As per Technical Specifications

Perimeter Compound Wall/Fencing RCC with hollow/solid block work
Drainage System As per Technical Specifications
Sewage System As per Technical Specifications
Soil investigation Within battery limit
DM & CPU are shall be covered with shed and brick wall cladding all-around up to suitable
height. WTP area shall remain open.
Chemical storage, preparation & dosing system shall be housed in a RCC framed building.
Neutralization pit and waste water channel shall be of RCC construction with acid proof
brick lining.
Area around degasser, water storage, DM water storage and acid alkali handling shall be
lined with acid proof bricks.
Remaining area shall be properly paved with provision of suitable storm water drain.

PC-150/E/4004/P-II/SEC-3.0 0
SHEET 1 OF 19

PROJECT:INTEGRATED COAL BASED FERTILIZER COMPLEX

All rights reserved

RWTP ,DMW& CPU PLANT PC-150/E/4004/P-II/SEC-3.0
2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 2 of 20
WORK
CONSTRUCTION ERECTION COMMISSIONING AND PAINTING
(For details refer construction/ erection, pre-commissioning, commissioning and

start-up section 6.0)
1.1 General scope of Work and services - Construction/Erection
LSTK CONTRACTOR shall be responsible for construction and erection of all civil,
mechanical, electrical and instrumentation works, assembly and Installation,
obtaining all necessary statutory approvals, Testing, Mechanical Completion, Pre-
Commissioning, Commissioning, Performance Guarantee Test Run (PGTR)
including Total Project Management and handing over of the plants and facilities
under contractor scope of work duly completed on single point responsibility basis.
Construction shall be carried out by experienced contractor & approval of the same
shall be carried out by OWNER/PMC Consultant.
LSTK CONTRACTOR shall be responsible for construction and erection of the
Plant/ Unit(s), including but not limited to the following:
1.1 Construction and erection of Plant/Units and/or Utilities and Off-site facilities,
and perform all other activities required to be performed for implementation of
the work.
1.2 Provide and supply in due course all construction Equipment and Materials,
tools, and temporary facilities necessary for implementation of the WORK.
1.3 Establish and operate adequate material control system at site for receipt,
unloading, inspection, maintenance, handling, storage and utilization to ensure
all Equipment and Materials are preserved and available as necessary for
completion of the Plant/Unit.
1.4 Provide and supply all staff, tradesmen and labours for implementation of the
WORK.
1.5 Establishment of overall construction policy and procedures for the Plant/Unit.
1.6 Provision of overall management and control of construction phase of the
Plant/Unit.
1.7 Ensuring that all parts of the Plant/Unit are constructed and tested strictly in
accordance with the specifications and applicable codes and standards asked
for in the project documents.
1.8 Ensuring that construction is accomplished in accordance with the schedules.
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 3 of 20
WORK
1.9 Provide transportation of all Equipment and Materials to be provided and
supplied by LSTK CONTRACTOR under the CONTRACT either from inside or
outside to Site.
1.10 Construct, operate and maintain all temporary facilities required for its
personnel involved in the WORK.
1.11 Provide transportation in the area of the Site and between Site and temporary
facilities for all its personnel involved in the implementation of the WORK,
including field labour, administrative staff, etc.
1.12 Recruit and organize, manage and supervise its Sub Contractors and field
labour for the WORK.
1.13 Provide liaison with OWNER, Sub Contractors, Licensors and Vendors to
ensure that the Plant/Unit is constructed in accordance with the respective
standard and specifications, set forth in the CONTRACT.
1.14 Establish with OWNER adequate procedures, control and reporting systems to
provide close control of the progress of the WORK.
1.15 Provision of labour and facilities for loading, unloading and transportation of
the Equipment within the site area.
1.16 Performance and / or provision of all other works and / or services required for
performance of the WORK.
1.17 Execution of the whole civil, structural and building works of the Plant/Unit
and/or utilities and off-site facilities.
1.18 Prefabrication of piping spools in a shop on the Site.
1.19 Erection and installation of EQUIPMENTS and auxiliary facilities associated
with the Plant/Unit.
1.20 Erection and field fabrication of structural steelwork, cladding ladders,
handrails, stairs and platform of the Plant/Unit and/or utilities and off-site
facilities.
1.21 Installation of pipe work including field fabrication of the Plant/Unit.
1.22 Installation and testing of all instrumentation network and equipment of the
Plant/Unit.
1.23 Installation and testing of electrical system and equipment of the Plant/Unit.
1.24 Installation of refractory including brickwork’s of the Plant/Unit.
1.25 Painting of steelworks, piping, Equipment and building of the Plant/Unit.
1.26 Maintenance of construction equipment, vehicles and tackles of the Plant /
Unit, during construction and erection period.
1.27 Pre-commissioning, Commissioning and Start-up of the Plant / Unit.
All rights reserved
2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 4 of 20
WORK
1.28 Carrying out Mechanical Completion as per finally approved P&ID after
HAZOP Study.
1.29 Perform all material identification as per application codes and standards.
1.30 Provide drawings and documents as required.
1.31 Supply to OWNER complete test records within three (3) days after completion
of actual testing.
1.32 Supply to OWNER complete survey report within three (3) working day after
completion of any survey.
1.33 Installation and testing of all underground piping along with cathodic protection.
1.2 General scope of work and services- pre-commissioning:
LSTK CONTRACTOR shall be responsible for the pre-commissioning phase of the

Plant/Unit.Pre-commissioning activities are defined as those activities which are
required to be performed after completion / installation, inspection, hydrotesting,
etc. of the Plant to make it ready for commissioning.
LSTK CONTRACTOR shall provide at SITE an adequate number of qualified pre-
commissioning engineers to direct and control pre-commissioning activities.
LSTK CONTRACTOR shall also ensure that all special tools and test equipment
required for pre-commissioning are available at its own cost.
LSTK CONTRACTOR shall provide adequate construction labour, construction
tools and equipment for pre-commissioning.
Pre-commissioning which shall be performed by LSTK CONTRACTOR shall
include, but not limited to, the following:
 Cleaning, flushing, draining blowing out, steaming out, drying and purging of
Equipment and their linings and piping systems, including the installation and
removal of temporary blinds, strainers, screens etc., and the replacement of all
permanent items removed while the WORK is in progress.
 Chemical cleaning wherever required, including but not limited to
compressor(if any) suction piping and lube and seal oil piping, heaters, supply
of chemical and disposal of wastes.
 Chemical cleaning of feed water systems, and steam systems, Supply of
chemical and disposal of wastes.
 Chemical cleaning of any other parts, which have corroded to an extent, which
will detrimentally affect Plant/Unit performance or run length for such reasons
as increased fouling due to rust, Supply of chemical and disposal of wastes.
All rights reserved
2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 5 of 20
WORK
 Checking, Testing, calibration simulation test and adjustment of instruments,
equipment and systems including control valves and safety devices, and
installation and checking of orifices plates and other sensor devices in so far
as this can be done before actual operation of the item concerns of complete
system and loops.
 Function test and checking out of electrical systems including substations,
transformers, cables and switchgear, checking of all interlocks and setting of
all relays. This shall include drying out operations, filtering of oil if required.
 For motor driven equipment, amperage checking of motors and removal of
temporary safety screens.
 Cleaning of screens and filters replacement and adjustment of packing and
seals and tightening of flanges.
 Introduction of fuels.
 Introduction of lubricants and oil flushing for machinery.
 Introduction of chemical into and initial operation of treatment plant.
 Drying out of stacks and all refractory lined equipment if any.
 Test running of all other compressor if any and drivers for 72 hours
continuously without any problems and adjustment of all protection and safety
devices.
 For all piping systems, installation and removal of temporary blinds as
required, circulation and commissioning of systems including process systems,
services and potable water, effluent and drainage, fire protection, utilities
distribution, relief and blow down and interconnecting lines.
 Setting up of circulators and running in of pumps on water or other medium as
appropriate for 24 hours wherever possible and all possible functional testing
of instruments.
 Test running of all other rotating equipment for 24 hours wherever possible.
 Adjustment of all piping expansion and support devices.
1.3 Mechanical Completion:

Mechanical completion of the Plant shall mean that all installations works of the
Plant have been completed and hydro tested in accordance with approved
construction drawings, approved specifications, applicable codes, accepted
International good engineering practices and all the activities have been
completed in a comprehensive manner by the Contractor.
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 6 of 20
WORK
Mechanical Completion means the time when all construction, erection &
installation work as per finally approved P&ID after HAZOP Study and pre-
commissioning related to the Plant / Unit is completed in accordance with the
Project drawings and specifications, and all mechanical and pressure tests,
including but not limited to hydro testing, non- operating adjustments, cold
alignment checks, final cleanup, hot bolting, refractory drying, field calibration of
safety valves, calibration of all instruments, instrument loop checking and testing,
monitoring / control / safety systems checking and testing, and all pre-
commissioning activities have been completed, all incoming & outgoing services
and utilities have been connected to each unit of the PLANT, interconnections of
process lines and interconnection are completed and the Plant / Unit is ready in
every respect for commissioning and for the first introduction of feed stock.
When OWNER is satisfied that Mechanical Completion of the plant / Units has
been achieved, OWNER shall issue certificate of Mechanical Completion to LSTK
CONTRACTOR in accordance with the CONTRACT.
In order to meet this, LSTK CONTRACTOR shall perform all necessary
mechanical works, tests and checks.
1.4 Commissioning:
 Schedules for Commissioning:
LSTK CONTRACTOR shall prepare a schedule for commissioning, start-up, and
performance testing and initial operation in conjunction with OWNER. This shall
be issued at least three months before pre commissioning of the first facility.
This schedule shall include all activities as detailed herein and any other special
activities, which require to be performed during commissioning.
 Commissioning:
LSTK CONTRACTOR shall be responsible to perform commissioning of the
Plants and to provide necessary facilities during commissioning of the Plant / Unit
including the Performance Tests. LSTK CONTRACTOR shall provide
commissioning engineers and supporting staff and adequate commissioning
labour.
The Plant shall be considered "Ready for Commissioning" when all the facilities
have been completed along with their auxiliaries and support facilities in every
respect including charging of lubes, chemicals, filters & resin media, preparation
of solution, etc. as recommended by Owner / PDIL in standard format with all
exceptions, if any, resolved. Commissioning of the Plant shall mean taking the
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 7 of 20
WORK
feed in the system, passing it through normal route and establishing the process
control parameters. The Plant shall be considered to be commissioned
successfully with instrumentation / control system, process, utilities & support
system have been on uninterrupted stable operation for not less than 72 hours.
Whether the 72 hours operation has been successful or not shall be decided by
Owner based on observations recorded during 72 hours. The countdown for 72
hours operation shall start on after the system has been on stable operation with
all controls and safety systems in normal operation for a period of not less than
48 hours. Contractor shall ensure that all plants i.e. RWTP, DM, CPU can be
commissioned individually and PGTR also individually and all necessary
provisions like valves, interconnection piping etc. shall be kept.
1.5 Start UP:

LSTK CONTRACTOR shall be responsible to perform start-up of the Plant / Unit.
LSTK CONTRACTOR shall provide necessary facilities and for Start Up of the
PLANT.
NOTE:Detailed LSTK CONTRACTOR’S scope of work in relation with the
construction / erection, and pre-commissioning, commissioning and start-up from the
point of scope of execution as well as performing way are described in detail in the
following Sub-Annexure of Section- 6.0.
2.0 STATUTORY CLEARANCES
All the applicable safety codes, national laws and local regulations shall be followed
by the successful bidder for the design, engineering, fabrication, erection,

commissioning & handing over of the Plant / Equipment and necessary approvals
shall be obtained from the concerned statutory authorities by the contractor. Statutory
bodies from which approvals may have to be taken include State Pollution Control
Board, Chief Inspector of Boilers / IBR, Factory Inspectorate, Labour Authorities,
Electrical Inspectorate and Chief Controller of Explosive, Directorate General of Mines
and Safety requirements etc. The contractor shall ascertain requirement of approvals
as applicable in such Plants and initiation of action as required shall be in contractor’s
scope.
3.0 SAFETY
These activities shall be carried out by contractor as specified elsewhere in the tender
document. All safety procedures for different types of work as per the safety rules
from time to time by PDIL/Owner shall be binding and adhered to by the contractor.
All rights reserved
2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 8 of 20
WORK
Safety report generation for different situations as per the rules and required by
PDIL/Owner are to be adhered to. HAZOP shall be arranged by contractor. This shall
be carried out for the system by an Independent agency approved by PDIL/Owner.
Any requirement arising thereof shall be implemented by the contractor without any
time and cost implication to the owner. HAZOP shall be carried out before final
approval of vendor documents.
4.0 SCOPE OF WORK FOR OPERATION AND MAINTENANCE:
The plants covered under this contract would be Complete O&M of water treatment
plant of TFL, consisting of following:
I. O&M of Raw water Treatment Plant

II. O&M of De Mineralization Plant
III. O&M of Condensate Polishing Unit
IV. O&M of Chlorine Di Oxide system.
Operation:
a. The scope of work includes complete operation of all the plants as above round the
clock basis throughout the contract period. However, it may also be mentioned that
operation of RWTP and DM plants during the initial months is expected to be
intermittent. Contractor to plan manpower deployment considering intermittent
operation of RWTP and DM plant during first year as per requirement of LSTK main
plant contractors.
b. Contractor will depute adequate skilled and experienced staff capable for
supervision of operation and maintenance of the plants covered under this contract
till acceptance.
Contractor shall depute minimum manpower during O&M of these facilities on round
the clock basis during three shifts of eight hours each as follows:
1) Plant in charge :1 No (General shift) – chemical engineer (Degree / Diploma) having
minimum 5 /10 years experience respectively in operation of water treatment
facilities
2) Process engineer (Degree / Diploma): 1no.per shift with 5 years of experience.
3) Operators (Diploma/B.Sc) :3 nos per shift with minimum 2 years experience.
4) Maintenance Technician (ITI/ Diploma): 6 Nos(General shift)-Electrical, Mechanical ,
Instrumentation- 2 each with minimum 5 years experience)
5) Labour (Skilled / non-skilled) required for carrying out sundry activities shall be hired
by the contractor on as required and as agreed with Owner. Contractor may
All rights reserved
2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 9 of 20
WORK
augment the above list of manpower as per instructions of owner for carrying out
trouble free operation and maintenance off the plants.
c. It is further clarified that Contractor will mechanically complete and commission each
stream of RWTP and DM individually. O&M charges shall apply after acceptance of
full plant i.e acceptance of all the streams
d. Round the clock continuous monitoring of the plant and equipment covered in the
battery limits of above plants. The battery limits shall be as per the process flow
diagram and would cover all equipment within the same.
e. Contractor shall be responsible for loading, unloading and handling and storage of
chemical required for the operation of the plants from store by arranging his own
vehicle & manpower.
f. Contractor shall be responsible for routine analysis to be carried out for proper
operation and water chemistry of all the plants.
g. Contractor shall depute experienced Chemist to carry out the analysis in the lab
provided byTFL.
h. Contractor shall ensure working in all the three shifts for dosing of chemicals and their
solution preparation.
i. The contractor shall ensure collection and analysis of samples of above plants in all
three shifts. The contractor will also ensure collection of various oil samples from
various locations/equipment of the plant as per the instructions.
j. Contractor will submit records of all analysis in format as per requirement of TFL.
k. Contractor will be responsible for maintaining all necessary documentation and
records such as log sheets, weekly, monthly, performance reports, consumption
reports etc. These documents shall be developed in consultation with TFL. Relevant
important data shall be computerized for easy scrutiny of various parameters as well
as graphical form as desired by TFL. Contractor will facilitate monitoring of the
performance on a monthly basis by the first week of every month whenever possible.
l. Arrangement of transportation facilities for Manpower, etc & for Emergency duty shall
be in contractor’s scope.
m. Contractor shall train TFL personnel for plant operation and maintenance during the
contract period.
MAINTENANCE:
General
(a) Equipment/Items which shall be under Contractor’s guarantee shall be rectified/

replaced by the Contractor as per the relevant guarantee clause of the tender for
All rights reserved
2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 10 of 20
WORK
which TFL shall have no liability.
(b) Contractor shall carryout all running maintenance / repair jobs required to keep the
plant at maximum productivity level. These shall include maintenance of all
equipments and other facilities of the Plant as per the maintenance schedule specified
by TFL.
(c) The Contractor shall maintain adequate stock of consumables like gaskets, gland
packing, O rings, drive belts, indicating lamps, fuses, blades, shims, cleaning agents,
cotton waste, adhesives, etc
(d) ) Contractor shall carry out breakdown maintenance job as and when
problems/defects are noticed.
(e) Dismantling and assembling of equipment items, components and subassemblies like
pumps, motors, agitators, drive heads, centre, mechanism, gearboxes, etc. as
required.
(f) Cleaning, dislodging& flushing of various oil & sludge handling units
(g) Cleaning and flushing of various units, pipelines, tanks and vessels.
(h) Periodic inspection of all installations for checking any deterioration in surface
finish/rubber lining etc.
(i) Cleaning of Filters elements, screens and media & checking for integrity and fouling.
Changing Filters elements and media if they are due for replacement, etc.
Control & Instrumentation Maintenance:
1. The contractor is to maintain all types of controls & instrumentation associated with
all the plants listed in scope of work.
2. Contractor is to carry out day to day Preventive/Breakdown maintenance.
3. Contractor should keep adequate number of manpower so that work does not suffer.
4. A contractor has to carry out regular cleaning of all Panels including HMI station in
control room.
5. Contractor has to maintain PLC system. It has to keep a person having knowledge
of PLC of DM Plant system or has to avail services of OEM for preventive/break
down maintenance at its own cost.
6. Contractor has to maintain all Annunciation/Alarm system in healthy condition.
7. Contractor has to maintain required reagents for Analyzers in spares for smooth
operation of the plant
Calibration of Instruments:
Contractor has to carry out calibration and servicing of all field instruments like
Pressure Gauges, Transmitters etc and all types of Analyzers, Pneumatic Actuators
All rights reserved
2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 11 of 20
WORK
etc. once in six months and a proper record of the same shall be maintained by firm, at
its cost. If officer in-charge feels the need for calibration of instruments earlier than six
months, it will be done by firm at its cost. Thecontractor should maintain dead weight
test bench, HART communicator, Manometer, Portable Power Supply etc.
T&P, Consumables & Safety Appliances:
Contractor has to keep all type of T&P like Tong tester, millimeter, pliers, screw drivers,
megger meter, gravity meters, vibration meter, alignment tools required for maintenance
of the Plant. Consumable like Glass Fuse, HRC fuse etc., Indication Lamp, Cleaning
Agents, Cleaning Brush, Old Dhoti, PVC Insulation Tape & Teflon Tape. Contractor has
to keep all Safety Appliances including personal protection equipments. Any other
special tools & tackles required during maintenance will be in the scope of contractor.
Scope of work w.r.t. Control & Instrumentation Maintenance:
a. The contractor is to maintain all types of controls & instrumentations associated with
PT, DM Plant, CPU etc.
b. Contractor is to carry out day to day routine preventive/breakdown
maintenance/emergency maintenance/predictive maintenance.
c. Contractor has to carry out regular cleaning of all panels including C&I panels,
instruments, analyzers, PLC UPS HMI station in control room and field operator room
DM plant & CPU.
d. Contractor has to keep maintenance all type of analyzers like pH, Silica, Sodium
ClO2, conductivity, PH & Conductivity instruments etc. Contractor has to avail the
services of OEM for preventive /breakdown maintenance of these analyzers.
e. Contractor has to keep adequate skilled number of manpower so that work does not
suffer.
f. Transportation of material within the plant, repair/welding of impulse lines, SS tubing
etc.
g. Dust free &air conditioned storage of Instruments if necessary for some of the items
to be provided.
Note:-
1. Any other work which is not included in above activities but it is required for smooth
operation of DM, RWT plant, shall be carried by the contractor without any extra
charges.
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 12 of 20
WORK
2. For above jobs, the contractor will deploy the adequate skilled manpower. In case of
emergency, the contractor has to be increase the work force as per site
requirement. However the required spare will be arranged by the maintenance
division.
3. In case the contractor fails to do the above works same will be got carried out by
TFL at the risk and cost of contractor
MECHANICAL MAINTENANCE:
The scope of contractor shall be to carry out all running maintenance required for
keeping the plant at maximum productivity level. The Mtc. shall include day to day Mtc.
preventive Mtc. and break down Mtc. of all equipments& system/facilities in DM plant,
Raw Water Treatment Plant, Acid/Alkali dosing system and condensate polishing units.
The mechanical maintaninance shall cover servicing and replacement of damage parts
of various pumps & replacement of new pump of unloading/transfer/dosing of
water/acid/alkali, metering/chemical dosing pumps for alum, lime, polyelectrolyte,
phosphate ,)N-pit pumps, sludge /disposal pumps, along with maintenance of, high
velocity mixed beds, ion exchangers , air blowers , agitators, acid /alkali/ DM water
storage tanks, clariflocculator & other vessels and their piping (all type PP, MS, CS,SS,
MSRL, HDPE, PTFE etc.), valves/actuators and hoists /lifting equipments installed in DM
plant, and condensate polishing system.
Top up/ replacement of resin’s /filters media, & repair of lining of vessels, acid/alkali &
other chemicals shall also be in the scope of contractor. Supply of all chemicals &
consumables required for the operation & maintenance of plant during start up, pre
commissioning, commissioning, trial runs & performance guarantee test runs upto
Preliminary Acceptance Test of complete system + 3 months during O&M shall be in the
scope of supply of bidder. Month wise DM water & treated water requirement schedule
may be referred for consideration of chemical consumption. Chemical consumption after
commissioning of 1 stream till PAC of plant shall be in bidder’s scope. Month wise DM
water & treated water requirement schedule from commissioning of one stream to PAC
is enclosed herewith.
All deficiencies in services as pointed by TFL, shall be made good in respect of

manpower or otherwise within 48 (forty Eight) hrs. of time after being indicated by TFL in
writing, failing which such deficiencies shall be made good by TFL at the sole risk & cost
of the contractor.
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 13 of 20
WORK
The above mechanical Mtc. is inclusive of all above equipments. Any of equipment /
work not mentioned above but is part of above plant equipment or mechanical jobs or
activities arising out of day to day plant operation shall be considered in scope of work.
The contractor shall keep all equipments, piping & structure etc of all plants clean/ tidy.
All leakages of oil / water & chemicals shall be attended on priority. He will carry out
cleaning / flushing of tanks, pipe line, vessels repair of rubber lining,welding and
hydrotests as and when required. Transportation of material from store to site and return
of scrap to store or any other specified area shall be in scope of contractor.
In case any alteration/modification is required during mtc. activities same will be in the
scope of contractor.
The scope of contractor shall include supply / provision of all consumable of reputed
make like gaskets, gland packing, ‘O’ rings, drive belts, blades, streams cleaning agents,
cotton waste & adhesive etc. All tools & tackles, welding electrodes, gases for cutting,
torch, cells, hacksaw blades, lighting lamps & chain pulley block, vibration meters,
alignment tools, hammers, spanners, allen-keys, pliers, pulersetc as shall be arranged
by contractor.
Lifting arrangement of heavy machinery such as pumps, motors, vessels, pipes, tanks
etc. by arranging lifting equipments like hydra, fork lifter, cranes etc. will be in the scope
of contractor.
The contractor will supply the list of tools and tackles to Engineer-in-Charge. In case any
other tools/tackles or special tool is required as per direction of Engineer-in-charge,
same will be arranged by the contractor
Welding:
Repair /Replacement of damaged pipes, Repair of the supports of various pipes

&equipments with welding joints(MS, SS, MSRL, CS. PP, HDPE, PTFE etc.) will also be
in the scope of contractor. The contractor has to be maintain an certified argon/TIG Non
Metallic Piping welder with tools & consumables are also required at site 24X7 for
various welding works at site. Contractor should maintain Portable Welding Set, SS Tube
Bender & Cutter etc.
ELECTRICAL MAINTENANCE:
I. The scope of work shall include Operation and Maintenance of all the electrical
equipment supplied/erected/tested/commissioned by the Contractor for the plants
All rights reserved
2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 14 of 20
WORK
(mentioned elsewhere in the ITB) on round the clock basis throughout the contract
period for electrical facilities.
II. The Operation and Maintenance envisage all the required tasks to ensure:
a) System availability.
b) Most efficient, effective and optimum usage of electrical system.
c) Enhance the life expectancy of equipments.
d) Regular operation and maintenance of equipments.
e) Compliance of safety rules and regulations.
f) Preventive maintenance / scheduled maintenance.
g) Break down maintenance.
h) Maximum service to consumers for maintaining uninterrupted power supply.
i) Maintenance of proper records of operation and maintenance (Log book, Registers,
check list etc., shall be approved by Engineer-in-charge).
III. The Operation and Maintenance of substation shall include the following job:
a) Switching ON and Switching OFF of 0.415kV, 3.3kV and 11kV Circuit Breakers,
Isolators, transformers, HT/LT Panels, battery charger, battery bank, VFD, wall
mounted distribution boards, Substation Lights, etc. as and when required according
to load requirements and instructions from Engineer-in-charge.
b) Maintaining records of all the operations, maintenances and records of loads such as
voltage, current, power factor, frequency, connected load, energy consumption on
hourly/ daily/ weekly/ fortnightly/ monthly/ quarterly/ half yearly and yearly basis and
maintaining records of power failures with reasons.
c) Observing the substation continuously and reporting any problem or faults to the
Engineer-in-charge which require major / minor improvements/repairs.
d) Maintaining system handing over and taking over charge sheets.
e) Format for operation and maintenance shall be prepared and approved by the owner.
f) Current and voltage settings of feeders right from 11kV, 3.3kV and till the user end.
g) With prior intimation to Engineering Site In-charge, changing the taps of transformers
as and when required.
h) Co-ordination with operators in other Substations for efficient, reliable operation of
construction power substation.
i) Attending the faults and restoration of the power supply without delay.
j) Follow permit system (Line clearance) and maintain a permit book to facilitate system
maintenance without accident / mishaps. Attending to all emergencies which may
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 15 of 20
WORK
arise during the contract period such as equipment failures, fire accidents, etc., shall
get acquainted with the operations of all equipments covered under the contract
k) Routine Surveillance of 0.415kV, 3.3kV and 11kV indoor / outdoor equipmentslike
transformer, NER, high Mast, Street Light, plant lighting fixtures, HT & LT Distribution
Boards.
l) Observing all safety precautions and ensure safety to men and material and the
equipment during the contract period.
m) Ensuring routine, preventive and breakdown maintenance works for the Maintenance
of 0.415kV, 3.3kV and 11 kV Indoor/Outdoor Sub Station equipments, HT&LT Switch
Gear, battery charger, battery bank & Distribution Systems etc.
n) Attending to all Telephone calls and issue receipt message promptly.
o) The Operation of 0.415kV, 3.3kV and 11 KV Indoor Sub Station, HT & LT Switch Gear
and Distribution Systems involves deployment of right persons as mentioned
elsewhere in the NIT for operation and these persons would be responsible for the
work contracted for this purpose.
IV. The operation & maintenance shall also include of field equipments like High Mast (if
any), street lighting, area lighting etc.
V. Items of Electrical equipments, headgears, torches, uniforms including rain coats,
jerseys, safety shoes, hand gloves etc. for efficient conduct of duty by the contractor
personnel shall be provided by the contractor and shall be in good working condition.
(a) Routine maintenance of Electrical Motors:
i) Greasing of motors.
ii) Replacement of Bearings as per requirement.
(b) During Capital over hauling.
i) Replacement of Bearings.
ii) Measurement of Winding resistance.
iii) Measurement of IR Values.
VI. Maintenance of PMCC’s/MCC’s
Checking of contractors/kit./fuse, checking of overload relay, control circuit indication
lamp, interlocking, protection system, checking/tightening of connections etc.
VII. LT Cables
Checking/tightening of connection, burnt cable/lugs/socket to be replaced,
replacement of cable (Making joint box), laying of cable, crimping of socket/lugs,
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 16 of 20
WORK
checking of IR value. The scope of work includes day to day preventive & breakdown
maintenance of Electrical Equipments along with accessories associated. Cleaning of
panels will be carried out daily by the contractor
VIII. Important Note

All routine and breakdown maintenance replacement of components shall be covered
under the scope of contractor. Spares shall be under the scope of respective
maintenance divisions. Lighting shall also be under the scope of respective
maintenance division. All required spares will be supplied by the respective
maintenance divisions. All tools and tackles shall be under the scope of contractor,
however available hoist, special tool of the plant may be used by the contractor with
written permission of respective division and it will be responsibility of the contractor
for its proper use.
IX. OEM Services:-

The contractor shall avail services of OEM, for all type of specialized
equipments related to DM plant covering UPS, PLC & their MMI computers,
Analyzer of DM Plant & CPU Various pumps/Motors, battery charger, VFD,
various analyzers of CPU, DM Plant, etc., for carrying out preventive as well as
breakdown maintenance is in scope of contractor.
X. Spares:
All Spares, Consumables, Lube Oil to be in Bidder Scope. They have to maintain
minimum spares as per list provided in Annexure-Iof this sectionand to replenish the
same after use. The minimum items specified in the Annexure to be handed over to
TFL at the end O&M contract.
XI. Preventive Maintenance:-
Preventive maintenance of all equipments as directed by Engineer-in-charge will be
carried out by the contractor and records of same will be maintained by the contractor.
Same will be got checked from engineer-in-charge and submitted to Engineer-in-
charge every month.
XII. TOOLS & TACKLES:

All tools and tackles required for the safe and satisfactory operation and maintenance
including preventive and break down maintenance of the substation and related
equipment shall be provided by the contractor. The careful maintenance and
management of these tools will be the responsibility of the contractor.
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 17 of 20
WORK
The tools and tackles, apart from other things, must comprise of :
a) Discharge rods suitable for 11, 3.3kV (minimum Three No’s)

b) Tubular & Box Spanners - 2 sets each.
c) Complete set of all sizes of screw drivers - 2 sets
d) Complete Tool Box - 2 nos.
e) 2 Nos. Blower & Vacuum Cleaner.
f) Minimum three sets of hand gloves of each HT & LT of different voltage ratings, 5
Nos. Helmets, 5 nos. safety belts.
g) 2 Nos. of heavy duty dry cell or rechargeable (without acid) torches.
h) Rain coats and gum boots as required.
i) First aid box.
j) 1 No. Insulation tester 5 kV capacity.
k) 1 No. Insulation tester 1 kV capacity.
l) 2 nos. Multi meter Analog & Digital.
m) 2 nos. Tong tester.
n) Cable crimping tools of adequate capacity etc.
o) Extension Power supply boards (single phase).
p) Phase Sequence meters.
This Maintenance scope (includes both preventive and breakdown maintenance) is

indicative only and shall include other maintenance activities required for satisfactory
operation.
SPECIAL TERMS AND CONDITION FOR OPERATION AND MAINTENANCE

CONTRACT:
Guaranteed parameters:
Contractor shall treat and supply water of the required specification for the TFL
requirements throughout the year. Maintenance scheduled shall be worked out stream
wise so to ensure availability of water requirements. Contractor shall guarantee to
achieve the following:
Quality and quantity: Contractor shall be responsible towards operation and

maintenance of the system to achieve the desired quality as per the designed
standards or as per the takings over the protocol and the quantity as per the
requirement for the water treatment plant.Contractor shall identify the process variables
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 18 of 20
WORK
that need to be adjusted on a day to day basis for optimum plant operation based on
inlet water quality in consultation with Owner.
Compliance to maintenance schedule: Contractor shall offer service to achieve the

overall maintenance schedule.
Contractor has to ensure daily the suggestive staff posted at site in all three shifts and
general shift to complete the operation and maintenance work to theentire satisfaction
of Engineer in-charge. During leave / absence of any staff, contractor has to arrange the
necessary manpower to ensure smooth O&M. Also the above mentioned manpower is
the suggestive manpower; however the contractor has to depute extra manpower as
and when required at site for smooth O&M as per advice of Engineer in-charge.
EXCLUSIONS:
Power (free of cost) at motor control centre
Utilities (free of cost)
Necessary work permits as required for the staff and visiting expertsInsurance of all the
facilities owned byTFL.
Suitable Cranes required for maintenance of the Plant at site.
Gate pass and other permissions required for working in the Owner nominated premises.
Office (space only), maintenance-cum-store room in chemical house building (space
only), and intercom phone facility shall be provided by TFL to the contractor free of cost.
5.0 SUPPLY OF CONSUMABLES & CHEMICALS
Supply of all chemicals, spares and consumables required for the Operation and
Maintenance of the plant during start-up, pre-commissioning, commissioning, trial runs
and performance guarantee test runs shall be in the scope of supply of the LSTK
contractor. Special chemicals required, if any, shall be clearly defined by the bidders
during bid stage with respect to quality & quantity and the supply of the same shall be in
contractor's scope. Unloading, handling and storage of all chemicals and consumables
(including provision of necessary facilities) shall be done by the contractor.
6.0 SPARES:
 Mandatory spares:
Requirement of mandatory spares as mentioned elsewhere shall be provided by the

bidder. Mandatory spares are to be provided by the bidder within the quoted lump sum
price. Refer Document no. PC161-E001-P-II/9.0 for mandatory spares.
All rights reserved

2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 19 of 20
WORK
 Special tools and tackles:
Contractor to ensure supply of all special tools and tackles for operation and maintenance
of the entire plant. The lump sum price, for the Package, quoted shall be deemed to be
inclusive of cost of such tools.
 Two years recommended spares:
Two years normal operation spares required are to be identified by the bidder. The
bidder shall separately furnish the itemized list of two years recommended spares along
with the cost. The cost of spares to be valid for two years after successful commissioning
of plant.
Please note that cost of two years normal operation spares shall not be included in the
quoted lump sum price. Owner may award the 2 years spares order separately within
contractual completion period and the quoted prices should hold good accordingly. All
spare parts supplied by the bidder shall be wrapped and packaged so that they will be
preserved in original and new condition under the normal conditions of storage to be
anticipated in India and shall be properly tagged and coded so that later identification as
to intended equipment usage will be facilitated. They shall be packed separately clearly
marked as 'spare parts'. Packing lists shall be furnished so that the parts can be handled
without uncrating if desired.
7.0 In addition to what has been described in above, Bidder scope of services shall include
submission, review, Finalization and getting approval from owner of :-
a) Detailed process design including preparation of P&ID,

b) Detailed design of plant and equipment, instrumentation, electrical and
control system, control and logic diagram, interlock schemes, etc.,
detailed design of structural work.
c) Detailed equipment layout, piping GAD & isometrics, battery limit hook
ups and other works as required.
d) Documentation & approvals including approvals from statutory authorities
including those required to be taken by client.
e) Procurement of raw materials, bought out components, Fabrication and
assembly at shop & at site.
f) Inspection & testing, including third party inspection at shop and at site
Packing, forwarding & delivery to site.
g) Storage & handing at site.
h) Erection & Installation of all equipments and materials at site including
Mechanical, Electrical & Instrumentation work at site.
i) All piping works as per piping specification.
All rights reserved
2
TFL TALCHER ODISHA
DOCUMENT NO REV.
CONTRACTOR SCOPE OF
SHEET 20 of 20
WORK
j) Mechanical Completion.
k) Hydro testing, Pre-commissioning and reliability runs.
l) Arrange all necessary instruments, tools/tackles required to aid pre-
commissioning, commissioning and performance guarantee tests.
m) Commissioning and performance guarantee run and handing over.
n) Clear the Battery Limit of all construction aids, debris, etc. and provide a
tidy work plan.
o) All documents/drawings shall be submitted by Bidders as per
documentation schedule & general specification as referred in technical
specifications of Civil, Mechanical, Electrical and Instrumentation. QAP
shall be submitted for the approval.
p) Design calculation of process and mechanical design, civil & structural
design for all the buildings, structures, equipment and systems. The
bidders shall show, explain and prove the validity of the basis/procedures
and methods used in these calculations.
q) 25 NB stainless steel DM water line from MB header to water analysis
room, instrument rooms, oil and gas analysis room, resin and raw material
testing room and pollution control room of chemical laboratory with
isolation valves shall be provided.
r) 25 NB instrument air pipeline be provided in all the rooms mentioned
under clause (q) above.
s) Submission of O &M Manuals.
t) Submission of detailed procedure for various performance tests and
getting the owners approval for the same.
u) Reviewing of all the drawings prepared by owner in connection with this
work like area layout, piping layout, piping terminals and interconnection
drawings of various panels, electrical cabling layout etc.
v) Apart from lab instruments provided in main laboratory, bidder shall
provide lab instruments for day to day operation of WTP/DM/CPU Plants.
w) HAZOP study by external agency shall be considered by bidder.
All rights reserved

PC150/E/4004/SEC-VI-4.0 A 0
LTD
SHEET 1 OF 29
SECTION – VI 4.0 (Part A)
DESIGN BASIS



TITLE : DESIGN BASIS PC150/E/4004/SEC
-VI-4.0A 0
PLANT : RWTP,DMW & CPU
FERTILIZER COMPLEX AT TALCHER SHEET 2 of 31
CONTENTS
Section Number Description
1. Design Capacity
2. Process Description
3. Technical Specification
4. Control Philosophy
5. Selection Of Material Of Construction
6. Site meteorological data
7. Utility System
All rights reserved

-VI-4.0A 0
1.0 DESIGN CAPACITY
A- Raw Water Treatment Plant (RWTP)

Design Capacity :- 2400 M3/hr
No of streams :- Two (2+0); Each of capacity 1200 M3/hr
Drinking Water Treatment Plant

Design Capacity :- 130 M3/hr. ( Net output )
No of streams :- One
Service Water
Design Capacity :- 100 M3/hr
B- DM Water Plant:
Design capacity: - 360 M3/hr. (Net output)
No of streams : - 3 (2W+1S) Each of capacity 180 M3/hr DM plant (net output)
C- Condensate Polishing Unit

Process/Turbine condensate treatment
Design capacity: - 270 M3/hr.
No of streams: - 3(1W+2S) Each of capacity 270 M3/hr. (Net output)
2.0 PROCESS DESCRIPTION:
2.1 Raw Water Treatment Plant :
The Raw water from raw water storage shall be received at RWTP battery limit through a
dedicated pipe line @ 2.0 kg/cm2g. The raw water shall be initially chlorinated using ClO2
and thereafter taken to Cascade Aerator common for both streams. After aerator raw water
will be directly fed to flash mixer where it will be mixed with Poly aluminium chloride
(PAC)/FeCl3, lime solution & polyelectrolyte solution etc. The mixed water shall flow to High
Rate Solid Contact Clarifier (HRSCC) where, water will be clarified. It is preferable to remove
all colloidal silica in the Clarifier itself. Bidder to make necessary arrangement for the same.
The clarified water shall be stored in clarified water storage from where it will be pumped to
All rights reserved

-VI-4.0A 0
Dual media filter for final removal of suspended matter. It may be noted that, Bidder to keep
25% capacity as spare of Dual media filters for each media. The filtered water will be stored
in filtered water storage tank from where it will be pumped to cooling towers & DM water
plant as make-up.
A part of filtered water shall flow directly from outlet of DMF to drinking water storage of RCC
where dosing of chlorine dioxide shall take place.
The backwash water from filters shall be stored and recycle back to inlet of clarifier. The
sludge from clarifier shall be collected and pumped to ETP. All, chemical waste water
generated in Raw Water Treatment Plant, DM and CPU shall be routed to neutralised pit in
DM plant area.
ClO2 dosing system shall be provided for both pre & post chlorination.
Chlorine Dioxide system shall be used for organics/ microbiological growth control in feed
raw water stream. Chlorine dioxide (ClO2) shall be generated at site from the reaction of
Hydrochloric acid and the Sodium chlorite solution.
Complete chlorine dioxide generation system, dosing facilities, storage facilities of chemicals
including bulk tanks and unloading/ transfer facilities shall be in scope of package vendor.
Chlorine Dioxide Generators, bulk chemical storage tanks & unloading facilities for sodium
chlorite and hydrochloric acid, dosing tanks and pumps for Sodium Chlorite and Hydrochloric
acid, its associated piping for unloading/ transfer facilities as well as to the Chlorine Dioxide
generator /dosing location, along with safety equipments, all instrumentation and interlocks
including local PLC panel (for ClO2 generation and dosing skids), Level instrumentation in
tanks, pH sensors in chlorine dioxide line, flow & pressure transmitters on all chemical feed
lines, dilution water lines, and chlorine dioxide solution lines, pressure regulators, chlorine
dioxide rate controller, low vacuum switch, solenoid valves, chlorine di oxide leak detector,
chlorine gas detector in curb wall pit etc. All items required for continuous, reliable & safe
operation & maintenance of complete system shall be provided. Package Vendor shall also
consider ClO2 analyser at the each ClO2 generator outlet to know the exact concentration of
ClO2 is being generated. Air contact with chlorine dioxide solutions should be controlled to
limit the potential for explosive concentrations possibly building up within the generator.
Package vendor shall submit the complete details and track record of the chlorine dioxide
system supplier for Owner/ consultant approval before order/installation.
The system shall confirm to the recommendations of the Chlorine Institute and relevant
International standards/ codes. The same shall be substantiated by relevant documents.
All rights reserved

-VI-4.0A 0
Inclusions
The package vendor's scope of supply shall be in general but not limited the following:
a. Automatic Chlorine-dioxide generator of required capacity shall be provided. One number
of standby ClO2 generator shall also be provided of equivalent capacity.
b. Each Chlorine Dioxide generator capacity shall be minimum 10 kg/hr or pre-chlorination.
This is a minimum requirement and if vendor recommends for high dose rate/ capacity to
ensure trouble free operation of RWTP and to meet treated raw water guarantees, the same
shall be provided.
Capacity of ClO2 generator for post chlorination (for drinking water) shall be Minimum
1Kg/hr, more if required by Bidder.
c. 1 (One) No. Residual Chlorine Dioxide Analyzer Kit shall also be provided.
The chlorine dioxide dosage rate shall be controlled through a control valve through
feedback from the Residual Chlorine Dioxide value in the raw water.
d. Acid and NaClO2 storage, distribution and handling facility. Package vendor shall also
provide fume absorption system for HCl and NaClO2 storage tanks.
e. ClO2 dosing system (ClO2 dosing tank and pumps) shall be skid mounted and housed in a
room provided near chemical handling area. The room shall also house control system for
ClO2 system and the control system area shall be isolated from dosing room area and
provided with separate entry/ exit.
f. The ClO2 dosing area shall be provided with ventilation and exhaust fans located at ground
level (since ClO2 is heavier than air) and be provided with two separate entry/ exits. The
room shall also house all the safety equipment in a separate enclosure isolated from ClO2
dosing area.
g. ClO2 generators type shall be as per recommendations of system supplier. Downstream
piping from generator to dosing point including diffuser assembly shall be provided by the
package vendor.
h. In case of water supply to the generator stops, the chemical dosing pumps shall also stop
automatically.
i. Generators must be equipped with systems of dosing and/ or measurement for reagents
and diluting water. These systems must be able to shut down the operation of the generator
in case any of the supplies is cut off.
All rights reserved

-VI-4.0A 0
j. ClO2 leak sensor (ClO2 in air detector) shall be installed at ClO2 dosing section. The least
count of sensor shall be 0.1 ppm and generator shall stop automatically if ClO2 in air is
detected. This shall also generate alarm in the local panel provided for ClO2 system.
k. One (1) No. of Safety shower and eye wash facility (located just outside the Chlorine-
dioxide dosing system room) shall be provided.
l. Trial runs, commissioning of the system, training of operator’s personnel and handing over
the plant to the owner.
m. Approvals, if any, from any local regulatory/ statutory body shall be in the scope of
package vendor. The plant shall comply with all safety regulations as applicable as per local
codes & international standards.
n. Safety equipments: - Chlorine institute approved safety equipments shall have 2 (Two)
nos. respiratory equipment (pressure demand type air masks-full face for working in leak
area), 2 (Two) nos. canister type gas mask, 2 (Two) nos. of Ammonia torches, 2 (Two) Nos.
of emergency repair kit, One No. Weather sock provided at a suitable location on the
building, 2 (Two) no. each of Safety helmets, goggles, rubber boots, gloves and coloured
vests (aprons), Display charts of PFD, Safety checks, maintenance procedure, Emergency
Action Plan, etc.
o. All piping i.e. pipes, valves, fittings, etc. in the HCl, NaClO2 and Chlorine Dioxide system
shall be of CPVC material or equivalent and as per tender piping specifications.
Minimum 2 Nos. (1W+1S) dosing pump shall be considered for both pre & post chlorination
separately.
In case of off specs, automatic by passing to be provided at various units.
Note:
Space for processing approx. 600 m3/hr of raw water to be provided in the layout
considering future provision.
2.2 DM Plant:
To meet the DM water requirement for the fertilizer complex, Resin based Demineralized
(DM) Water Plant with Storage and Pumping facilities are envisaged. The feed to DM plant
shall be filtered water.
DM plant will comprise of Activated Carbon Filter, Cation Exchangers, Degasser Towers,
Degassed water Tank, Anion Exchangers, Mixed Bed, Polished (DM) water storage &
pumping, chemicals handling & regeneration facilities, neutralization & Effluent pumping
facilities, etc. To meet the DM water requirement of the complex three (2W+1S) chains of
All rights reserved
-VI-4.0A 0
DM plant of 180 m3/hr (net DM water) each shall be provided. To meet the net normal DM
water requirement normally two chains shall be in operation. In case of non availability of
condensates, third chain shall also be in operation & accordingly total system to be
designed. The DM plant shall be capable to operate on turndown capacity as per the normal
DM water demand and on Design capacity on continuous basis.
Suitability of strong or combination of strong & weak Cation & Anion Exchanger can be
considered.
Space for additional one chain of DM plant to be provided in the layout considering future
provision.
2.3 Condensate Polishing Unit :
The process condensate and steam condensate generated from the complex shall be
collected in Process/Steam condensate storage tank. The Process/Steam condensate shall
be pumped by condensate pumps to active carbon filter. The treated water from ACF shall
flow directly to Cation Exchanger & then to Mixed Bed Exchanger for final polishing. Outlet
from Mixed Bed Exchanger shall be sent to DM / Polished water storage tank. Suitability of
strong or combination of strong & weak Cation Exchanger can be considered.
In normal condition, turbine condensate shall be sent directly to respective ISBL Plant for
their use. However, if need arises, turbine condensate shall be treated in above chains &
system to be designed accordingly.
Separate cooler to be provided for cooling Process /steam condensate & turbine
condensate.
3.0 TECHNICAL SPECIFICATION

3.1 Raw Water Treatment Plant:
1 Flash Mixer
Number of Flash Mixer Nos 2
Flow rate each M3/hr 1200
Retention Time Min. 1
MOC RCC
All rights reserved

-VI-4.0A 0
Agitator SS 316
Cascade Aerator Nos. 1(Common for both stream)

No of step 6 steps (min)
Surface flow rate 0.015 – 0.040 m2/m3/hr
Capacity 120% of design capacity
MOC RCC
2 Clarifier along with

Flocculator
Type HRSCC
Number of Clarifier No. Two (2)
Capacity of each Clarifier M3/hr 1200
Type & Construction Circular, RCC Epoxy Painted
Flocculator Paddle Sludge MOC:CSEP
mechanism
Inlet turbidity NTU 500 max
Outlet turbidity NTU <10
Sludge blow-off: Intermittent
Sludge Consistency 2%
Hydraulic Loading margin in 20%
civil work
3 Clarified Water Storage

Tank
Number No. One with Dual Chambers of equal
capacity
Effective capacity m³ 30 minutes hold up volume
MOC RCC, above ground, covered

Free board mm 300 (min)
4 Filter feed pump

Numbers Nos. Three (3) (2W+1S)
Type Horizontal
Pump Capacity each CMH As per system req.
Head MWC As per system req.
Material of Construction
Casing 2.0% Ni-Cast iron
Impeller SS-CF 8M
All rights reserved

-VI-4.0A 0
Shaft SS-410
Shaft sleeves SS-316
5 Chemical House/storage
Number No One (1)
Type Two (2) storied building RCC sufficient
to hold 60 days chemical storage
Ground Floor Chemical storage for Water -treatment
Plant
First Floor Location of Chemical Tanks EL
Approx. 5.0m.
Handling Facility Electrically operated hoist of suitable
capacity (By Bidder)
6 Dosing System Nos. Alum Lime Poly
Dosing Tanks Alum Tank Lime Polyelectrolyte
Tank Tank
Numbers required Minimum 1W+1S 1W+1S 1W+1S
Construction RCC RCC SS-316
Minimum total effective m³ Adequate to hold 12 hours requirement
Capacity of each tank on design flow (i.e. 2400 m3/hr) &
dosing with 20% margin
Solution strength % 10 5 0.5
(Indicative)
Agitator – type Vertical Vertical Vertical
- MOC SS-316 SS-316 SS-316
Dissolving basket In SS Construction with 10 mm dia
holes on 50mm triangular pitch.
M.O.C. for piping valves, & CPVC schedule 40
fittings
Dosing Pumps 2W+1S 2W+1S 2W+1S
Positive Screw Positive
Type of pump Displacement Displacement
Diaphram Diaphram
SS-316 SS with SS-316
MOC Nitrile
Stator
Minimum Capacity LPH 650 1000 1000
Dosing shall be capable of auto operation
using Pneumatic /EM actuator. Range
0%- 120%.
7 Filter Water OH Tank For No. One(1)

chemical Dosing
Capacity By bidder (min 10 m3)
MOC By Bidder
All rights reserved

-VI-4.0A 0
8 Sludge Sump
No. of sludge sump No. One (1/Single compartment) Cap. 800 m³
(Min)
Construction RCC;
type Vertical cylindrical
9 Sludge discharge pumps
a) Number No. 2(1W+1S)
b) Type Horizontal
c) Capacity (Vendor to Indicate)
d) discharge head (Vendor to Indicate)
10 Dual Media Filters with .

Auto-backwash filter
arrangement
Nos (NW+2S) / Vertical (N:No of working to
be specified by bidder) However,
Vendor to consider minimum 25%
extra margin and decide numbers
(minimum eight nos.).
Design Flow per unit (net) m3 / hr Vendor to confirm
Design Surface Flow Rate m3/m2/hr not more than 15
Free Board Space % 75 min.

Fill Material Quartz sand free from Carbonate &
impurities & anthracite as per BSEN:
12909.
Media Trap No. Two (2) per unit. At service & rinse
outlet of filter.
Design code for Shell & ASME Section 1 Div 1, SA 516 Gr. 70
Dish or equivalent for Shell and SA 516 Gr.
70 or equivalent for Dish.
Material of Construction for Epoxy coated carbon steel
Vessel Internals
Manhole /Handhole No. mm One (1) No. Dia 500 mm/100 mm
Sight windows. No. One (1)

Guaranteed Effluent
a. Turbidity(NTU) <1
3 2
Back wash flow rate m /m / hr Bidder to decide (considering minimum
24 m3/m2/hr)
Filter Material depth min mm 1000
Under Drain System Strainers on plate
Pressure drop 0.3 / 0.8 kg/cm2
clean/clogged
All rights reserved
-VI-4.0A 0
11 DMF Filter Backwash

pumps
Numbers Nos. Two (2) (1W+1S)
Type Horizontal
Pump Capacity each CMH By bidder (considering minimum 24
minimum m3/m2/hr)
Type of lubrication Self-lubrication
a) Casing 2.0% Ni-Cast iron IS210 FG260, ASTM

A48 No 35
b) Impeller SS-CF 8M
c) Shaft SS-410
d) Shaft sleeves SS-316
12 DMF Backwash Blowers

Type ROTATRY LOBE
Capacity each CMH By bidder (considering minimum 40
m3/m2/hr)
a) Casing & lobe 2.0% Ni-Cast iron IS210 FG260, ASTM
A48 No 35
b) Shaft SS-410
c) Shaft sleeves SS-316
13 Backwash Waste Underground RCC

Collection Sump for DMF
Capacity 200 m3 minimum (Vendor to Confirm
as per requirement of their offered
system.)
Compartment One
14 Backwash Waste transfer

pumps
Type Vertical
Pump Capacity each CMH 100 m3/hr minimum
minimum (Vendor to Confirm as per
requirement of their offered
system.)
All rights reserved
-VI-4.0A 0

d) Casing 2.0% Ni-Cast iron IS210 FG260, ASTM
A48 No 35
e) Impeller SS-CF 8M
f) Shaft SS-410
g) Shaft sleeves SS-316
16 Thickener Nos. 2(1W+1S)
Capacity By Bidder
Surface loading rate 60 Kg/m2/day
Residence time 8 Hrs

17 Sludge Discharge Pump
b) Type Horizontal screw type (non-clog)
c) Capacity (by bidder) m3/hr
d)discharge head By bidder
18 Centrifuge
b) Type Centrifugal
c) centrifuge Capacity By bidder
calculated
d)MOC SS316
e)Running Time 16Hr/day
f) Thickener consistency By Bidder
g)centrifuge Capacity By bidder
selected
h) Type & quantity chemical By bidder
dosing
i) Installation In Shed
Disposal through Trolley are in vendor scope.
2 no of hydraulic type trolley (standard size) for each centrifuge.
19 Filter water storage tank

Number No. One tank with Dual Chambers of equal
capacity
Effective capacity m³ Min.24000
All rights reserved
-VI-4.0A 0
20 Drinking water storage

tank
Effective capacity m³ Min.1100
Pump Capacity Each 50 m3/hr for township 2 nos (
1W+1S)
Each 80 m3/hr for plant supply 2 nos (
1W+1S)
Battery Limit Pressure (min) Kg/cm2g 8 for township
8 for plant
21 Chlorine dioxide dosing
system
A) No 2 (1W+1S) Each for pre chlorination and post
chlorination
B) NaClO2 & HCL Dosing
Pump
Capacity As per system requirement
Number 2 (1W+1S) Each for pre chlorination and post
chlorination
MOC PP for NaClO2,
Alloy 20 for HCL or higher
C) NaClO2 & HCL Unloading/Transfer Pump
Number 2 (1W+1S)
MOC PP for NaclO2, Alloy 20 for HCL or
higher
D) NaClO2 storage tank Capacity Minimum For 15 days requirement with
additional capacity of 20 %
Or
Each Tank should have minimum
capacity for unloading of 1 Tanker with
additional capacity of 20 % (Minimum
for Unloading of 15 MT tanker
unloading)
Whichever is higher.
No. 2 Common for Pre and Post Chlorination
MOC FRP
E) HCL storage tank Capacity Minimum For 15 days requirement with

additional capacity of 20 %.
Or
Each Tank should have minimum
capacity for unloading of 1 Tanker with
additional capacity of 20 % (Minimum
for Unloading of 15 MT tanker
unloading)
All rights reserved
-VI-4.0A 0
No. 2 Common for Pre and Post Chlorination
MOC FRP
F) NaClO2 Dosing tank Capacity 12 Hours of storage (hr.) / Min. 1 m3

whichever is higher.
No. 2 Each for Pre and Post Chlorination
MOC FRP
G) HCL Dosing tank Capacity 12 Hours of storage (hr.) / Min. 1 m3

whichever is higher.
No. 2 Each for Pre and Post Chlorination
MOC FRP
H) Fume chamber, By Bidder
I) Lime tank By Bidder
J) Any other item for safe, By Bidder

reliable operation
22 Chlorination System 2(1W+1S)

Ventilation Fan
Capacity By Bidder
MOC SS-316
23 ClO2 Dilution Pump

Capacity M3/hr By Bidder
Nos. 2 (1W+1S) Each for pre chlorination and post
chlorination
Head MWC By bidder
Casing 2.0% Ni-Cast iron IS210 FG260, ASTM

A48 No 35
Impeller SS-CF 8M
Shaft SS-410
24 Service water pump

Numbers 2(1W+1S)
Type Horizontal
Pump Capacity each CMH 100 m3/HR
All rights reserved

-VI-4.0A 0
Battery Limit Pressure Kg/cm2g 9.5

Casing 2.0% Ni-Cast iron IS210 FG260, ASTM

A48 No 35
Impeller SS-CF 8M
Shaft SS-410
25 DM plant feed pump

Numbers 3(2W+1S)
Type Horizontal
Pump Capacity each m3/hr By Bidder
Head MWC By Bidder
Casing 2.0% Ni-Cast iron
Impeller SS-CF 8M
Shaft SS-410
26 Cooling water make –up

pump
Numbers 3(2W+1S)
Type Horizontal
Pump Capacity each CMH 925 m3/hr
Safety showers As per NIT/requirement
3.2 DM plant:
1 Activated Carbon Filters Nos. Three (3) (2W+1S) Vertical

Design Flow per unit (net) m3 / hr Bidder to indicate
3 2
Design Surface Flow Rate m /m /hr 15
Free Board Space % 75 min.
All rights reserved

-VI-4.0A 0
Fill Material Activated Carbon, De-oiling Grade

Media Trap No. Two (2) per unit. At service & rinse outlet
of filter.
Material of Construction for Epoxy Lined carbon steel
Vessel Internals
Manhole /Handhole No. mm One (1) No. dia 500 mm/100 mm
Sight windows. No. One (1)
Guaranteed Effluent
a.Free Chlorine Non-detectable
b.Organic Matter Traces
c. Turbidity NTU <0.5
Back wash flow rate m3 / m2/ hr 15
Filter Material depth mm 1200 min
Under Drain System Strainers on plate
Characteristics of Activated
Carbon
Bulk Density: Kg/m3 >400
Particle Density wetted in gm/cc 1.3-1.4
water:
Uniformity Coefficient 1.5-1.6
Mean Particle Diameter mm 1.2-1.4
Total Surface Area m2/gm >850
Iodine No. Min. 850
Moisture Content 5%( Max.)
Ash Content 8 %( Max.)
Chemical Measuring / Chemical

2 Solution Preparation Acid NaOH Cleaning Skid
Tanks (if applicable)
1no. For MB-DM 1no. For MB-DM
1no. for MB-CPU 1no. for MB –CPU
Number (min) No. 1 no. for SAC-CPU 1 no. for SBA CPU As per bidder
1no. for N-pit 1no. for N-pit
1 no for SAC/WAC-DM 1 no for SBA/WBA-DM
Type Vertical cylindrical with dished end bottom

Effective capacity M³ Minimum 1
Tank – M.O.C. FRP CSRL FRP
All rights reserved
-VI-4.0A 0
Agitator – Type Slow speed

Agitator - M.O.C. SS-316 / Alloy 20
M.O.C. for piping valves, & CPVC schedule 40
fittings
3 Metering Pumps
Number 2 (1W + 1S) for each tank
- Positive displacement, constant speed,
Type variable stroke, diaphragm operated
reciprocating type
Duty – Continuous Intermittent
Suction condition – Flooded
Head MWC As per Process requirement
Pump speed rpm 1450
Pump - M.O.C. - All Wetted parts in SS-316 /Alloy20
4 Degasser System
3(2W+1S)
Number
Tower
Type - Forced draft type (Vertical Cylindrical)
Packing Rings (Fill) Material - Polypropylene
Shell material - CSRL
Rubber lining mm 4.5 thick in three layers
Internal Distributors - None clogging, Non corrosive type.
All internal fittings, water -
distribution tray and hand-
To be provided
holes for loading and
removal of packing rings etc
Surface Loading Rate (SLR) m³/m²/h Not more than 60

Degassed Water Storage
5
Tank
Number 1
Effective Capacity , M³ 600
Minimum
Type & Material of - CSEP
construction
6 Degasser Air Blowers
All rights reserved

-VI-4.0A 0
Numbers required 2(1W + 1S)

Type - Centrifugal
Capacity M³/Hr By Bidder
Location - Outdoor on degasser tank
h) Casing & lobe 2.0% Ni-Cast iron IS210 FG260, ASTM

A48 No 35
i) Shaft SS-410
j) Shaft sleeves SS-316
7 Degassed water Transfer pump

Number 3 (2W+1S )
capacity By bidder
Type Horizontal Centrifugal
Operation Continuous
Suction condition Flooded
Discharge pressure As per system requirement
- Casing Stainless Steel CF 8M
- Base plate Carbon steel
- Impeller Stainless Steel CF 8M
- Shaft Stainless steel SS 316
- Shaft coupling Stainless Steel SS 304
- Shaft sleeve SS 316
8 Exchanger Vessels
A Cation- Exchanger
i) Number of streams 3(2W+1S)
ii) Service Down flow
iii) Design flow per stream M3 / hr 180 (min)
(net)
iv) Output per stream
between two consecutive
regenerations
- Nett M3 3600
- Gross M3 3600 +regeneration requirement
downstream
v) Cycle time Hrs. 20
All rights reserved
-VI-4.0A 0
vi) Regeneration time Hrs. 4

vii) Design surface flow rate m3/m2/hr Not more than 35
viii) Free board At least 100% above resin bed
ix) Material of Construction CS
x) Shell lining (internal) Natural Rubber, 4.5 (minimum) in 3
layers, 65 ± 5 shore A to IS:4682 Part-I
xii) Manhole and hand Hole mm Two (2) each dia 500 and hand hole 150
xiii) Sight windows. Nos. Two (2) in each vessel minimum
xiv) Resin
a. Type SAC polystyrene resin
b. Minimum Resin mm 1000
Bed Depth
xv) Regeneration by Hydrochloric Acid
xvi) Resin Trap Two (2) per unit at service & rinse outlet
xvii) Material of Construction As per manufacturer standard
of Internals
b Anion- Exchanger
i) Number of streams 3(2W+1S
)
iii) Design flow per stream m3 / hr 180 (min)
(net)
between two consecutive
regenerations
- Nett
- Gross M3 3600
M3 3600 +regeneration requirement
downstream
xiv) Resin
a. Type SBA polystyrene resin.
b. Minimum Resin mm 1000
Bed Depth
xv) Regeneration by Sodium Hydroxide
of Internals
c Mixed Bed
i) Number of streams Three (3)(2W+1S)
All rights reserved
-VI-4.0A 0
iii)
Design flow per stream M3 / hr 180 (min)
(net)
between two consecutive 25200
regenerations m3 25200 +regeneration requirement
- Nett m3 downstream
- Gross
xiv) Resin
a. Type Mixed ions polystyrene resin in uniform
bead form.
b. Minimum Resin mm 500 for each type of resin
Bed Depth
xv) Regeneration By HCI and NaOH
of Internals
9 Polished/DM Water Tank
Number 2
MOC CSRL
Capacity (Effective) 2X4500 m3
Polished/ DM water
10
Transfer pump
Numbers Nos. 3(2W+1S)
Type Horizontal
Capacity, Each m³/hr 600 m3/hr
i. Casing SS-316
ii. Impeller SS-316
iii. Shaft SS-316
Neutralisation Pit &
11
System
All rights reserved

-VI-4.0A 0
Nos. One with 2 compartments

Type Vertical underground
MOC RCC with acid/alkali resistant brick lining
Capacity of each compartment shall be
capacity sufficient to collect regeneration waste of
one stream of RWTP+DM+CPU
Acid dosing tank 1 no, Capacity-1.0 m3
Alkali dosing tank 1 no, Capacity-1.0 m3
Air Blower For 2(1W+1S)

12
Neutralization Pit/MB
Capacity By Bidder
k) Casing & lobe 2.0% Ni-Cast iron IS210 FG260, ASTM

A48 No 35
l) Shaft SS-410
m) Shaft sleeves SS-316

13 Acid storage tanks for DM & CPU plant
Nos Two (2) nos.
MOC FRP
Minimum For 15 days requirement with
Or
Capacity for each tank Each Tank should have minimum capacity
for unloading of 1 Tanker with additional
capacity of 20 % (Minimum for Unloading of
15 MT tanker unloading)
14 Alkali storage tanks for DM & CPU plant
Nos Two (2) nos.
MOC SS316
Minimum For 15 days requirement with
Capacity for each tank Or

Each Tank should have minimum capacity
for unloading of 1 Tanker with additional
capacity of 20 % (Minimum for Unloading of
All rights reserved

-VI-4.0A 0
15 MT tanker unloading)
15 Alkali & Acid Unloading /Transfer Pump
Number 2 (1W+1S)
MOC PP or higher for Acid & Alkali
16 Hot water tank for regeneration with Electrical heater.
No One (1) no.
MOC CS FRP lined
Capacity Bidder to decide
17 Effluent discharge pumps

Nos 2 (1W+1S)
M³/hr / Min.100 M3/hr @ 3.0kg/cm2g ( Decided
Capacity / Head
Kg/cm2g By Bidder)
i. Casing SS-316
ii. Impeller SS-316
iii. Shaft SS-316
ACF Air Blower (if 2(1W+1S)

17
required)
Capacity By Bidder
n) Casing & lobe 2.0% Ni-Cast iron IS210 FG260, ASTM

A48 No 35
o) Shaft SS-410
p) Shaft sleeves SS-316
All rights reserved

-VI-4.0A 0
3.3 Condensate Polishing Unit (CPU):
1 Condensate Storage Tank Unit

Number . One (1)
MOC CSRL
Effective Capacity m3 7500
2 Filter feed Pumps
Numbers Nos. 3(1 W + 2 S )
Type Horizontal
Capacity m³/hr By Bidder
Head MWC By bidder
i. Casing SS-316
ii. Impeller SS-316
iii. Shaft SS-316
3 Activated Carbon Filters Nos. Three (1W+2S)

i) Design Flow per unit (net) m3 / hr By bidder
ii) Design Surface Flow Rate m3/m2/h 15
iii) Free Board Space % 75 min.
iv) Fill Material Activated Carbon.
v) Media Trap No. Two (2) per unit. At service & rinse
outlet of filter.
vi) MOC CS
vii) Material of Construction for Vessel Internals Epoxy coated carbon steel
viii) Manhole /Handhole No. mm One (1) No. dia 500 mm/100 mm
ix) Sight windows. No. One (1)
x) Guaranteed Effluent
a. Free Chlorine Non-detectable
b. Organic Matte Traces
c. Turbidity <0.5
xi) Back wash flow rate m3 / m2/ 15
hr
xii) Filter Material depth mm 1200
xiii) Under Drain System Strainers on plate
xiv) Characteristics of Activated Carbon
a. Grade: Dechlorination Grade
b. Bulk Density: Kg/m3 >400
c. Particle Density wetted in water: gm/cc 1.3-1.4
d. Uniformity Coefficient 1.5-1.6
e. Mean Particle Diameter mm 1.2-1.4
f. Total Surface Area m2/gm >850
g. Iodine No. Min. 850
h. Moisture Content 5% ( Max.)
i. Ash Content 8% ( Max.)
Cation Bed
All rights reserved
-VI-4.0A 0
Cation- Exchanger
iii) Design flow per stream (net) m3 / hr 270
iv) Output per stream between two
consecutive regenerations
- Nett
- Gross m3 5400
m3 5400 +regeneration requirement
downstream
xiv) Resin
a. Type SAC polystyrene resin
b. Minimum Resin Bed Depth mm 1000
xv) Regeneration by Hydrochloric Acid
xvii) Material of Construction of As per manufacturer standard
Internals
NOTE: 1. Activated Carbon Filter shall be of de-oiling grade for Process & Turbine Condensate
MIXED BED
Mixed Bed
iii) Design flow per stream (net) m3 / hr 270
iv) Output per stream between two
consecutive regenerations
- Nett m3 19440
- Gross m3 19440 +regeneration requirement
downstream
xiv) Resin
a. Type Mixed ions polystyrene resin in uniform
bead form.
All rights reserved

-VI-4.0A 0
b. Minimum Resin Bed Depth mm 500 for each type of resin

Regeneration By HCI and NaOH
xvii) Material of Construction of As per manufacturer standard
Internals
d Plate Heat Exchanger

Nos. 3(1W+2S)
Type Plate Heat Exchanger
0
Condensate from Plant C Bidder to consider mixed inlet temp of
Temperature/Flow Max/Normal Turbine / Process / Steam Condensates
mentioned in section-VI-2.0 of part A of
NIT.
0
Temperature Approach C Min 10 for design
0
DM water/Polished water C AMB
Temperature
MOC SS-316
e Trim Cooler
Nos. 3(1W+2S)
Type Shell & Tube
Cooling water Pr. Kg/cm2g 3.5
0
Cooling water I/L Temperature C 33
0
Cooling water O/L Temperature C Max.- 43
Pressure Drop Kg/cm2 0.5
Condensate Flow Max. 270 M3/hr each
0
Condensate I/L Temp. C Max/Min -70/50
Temp mentioned considering bypass of
Plate Heat Exchanger mentioned above.
(Bidder to design trim cooler accordingly)
0
Condensate O/L Temp. C 45
MOC SS-316
3.5 Resins for Cation, Anion & Mixed Bed

Resins shall be of reputed make and must have been in use in demineralising plants capable
of producing water as specified or better for a period of not less than five (5) years.
a. The strong/ weak cation resins shall be high capacity premium grade sulphonated
strong acidic cation resin in hydrogen form, micro porous polystyrene bead Gel type
suitable for counter current regeneration. The attrition loss of the cation resins shall be
guaranteed not to exceed five (5) percent per year for the five (5) years of operation.
Resin quantity for cation exchanger shall be supplied to ensure minimum cation leak
and regeneration level shall be selected so as keep sodium slip is Nil as Na in the
treated water.
All rights reserved
-VI-4.0A 0
b. The strong/ weak anion resin shall be high capacity strong base, quaternary
ammonium type-1 anion resin in chloride form, microporous polystyrene bead Gel type
resistant to organic fouling suitable for counter – current regeneration. Anion resin
should be able to with stand a temperature of 600 C. The attrition loss of the anion
resins shall be guaranteed not to exceed five (5) percent per year for the first five (5)
years of operation. Resin quantity for anion exchanger shall be supplied to ensure
minimum anion leak and regeneration level shall be selected so as to keep silica slip
less than 0.01 ppm as SiO2 in the treated water.
c. The mixed bed cation & anion resins shall be strong acid cation & strong base anion
resin as described above suitable for simultaneous counter current regeneration.
d. Effective bed depth for each exchanger shall be 1.0m minimum.
e. Quantity of 150 mm bed depth inert resin provided in cation & anion exchanger shall be
indicated separately.
f. Quantity of resins in each exchanger shall be adequate so as to require not more than
one (1) regeneration per day at design capacity.
g. At least 100% free-board shall be provided over resin bed for expansion during
backwashing or addition of some extra resins if required.
h. Regeneration effluent generated from cation and anion exchangers and also acidic and
alkaline effluents from mixed bed shall be self neutralizing.
i. Complete performance characteristics of the selected offered resins along with
regenerant / neutralizing chemical consumption calculations shall be furnished.
j. The resin shall be unaffected by acids, alkalis or common solvents. The resin shall be
able to withstand a temperature of 600 C. (minimum) continuously.
k. All Resins shall be supplied in manufacture’s own sealed containers. No broken
drum/containers or loose packing for resins will be accepted.
l. The bidder should consider 10% (minimum) deration over the corrected exchange
capacity, obtained from the manufacturer’s published resin literature.
m. The uniformity co-efficient of resins shall be less than 1.2.
4.0 CONTROL PHILOSOPHY:

4.1 RWTP, DM plant and CPU:
RWTP, DM plant and CPU shall be operated and controlled through a PLC based control
system. The control system shall be provided in line with the engineering specifications /
standards / drawings attached elsewhere in the tender document. Backwash sequence for the
DMF, ACF and Regeneration sequence of ion exchangers shall be automatic while regeneration
sequence of ion exchangers shall be initiated manually by push button. The plant will also have a
All rights reserved
-VI-4.0A 0
provision for manual operation. The Instrumentation and Control Philosophy for the Plant shall be
as applicable to the smooth, safe & trouble free operation of Unit and shall be defined in detail in
Process specifications. Following on line analyzers shall be installed for smooth, safe & trouble
free operation of RWTP, DM plant and CPU:
1. Turbidity analyser & pH analyzer at the out let of each dual media filters.
2. Residual chlorine analyser at downstream of Pre-chlorination & out let of drinking water
pump.
3. pH, conductivity & Sodium analyser at the out let of Cation exchangers.
4. pH, conductivity & silica analysers at the out let of Anion exchangers.
5. pH & conductivity & silica analysers at the out let of Mixed Bed exchangers.
6. pH meter at out let of neutralization pit effluent transfer pump.
Following Flow Transmitter shall be installed for smooth, safe & trouble free operation of RWTP,
DM plant and CPU:
1. Electro-Magnetic type Flow Transmitter with totalizer at common Raw Water Inlet along
with individual FT at each Flash mixer inlet.
2. DPT across each Dual media filters (DMF)/ACF/SAC/SBA/MB. FT at outlet of each
DMF/ACF/SAC/SBA/MB/Heat Exchanger.
3. FT with totalizer at common header outlet of Drinking water (Plant & township), DM water,
Service Water, Cooling water make-up.
4. All Pumps shall be equipped with Pressure Transmitters.
5. All tanks shall be equipped with Level Transmitters.
In addition to above mentioned instruments/analyzers, bidder to provide all necessary

Instruments during detail engineering for smooth, safe & trouble free operation without any cost &
time implication.
5.0 SELECTION OF MATERIAL OF CONSTRUCTION:

Minimum requirements of materials of construction for some major equipment and piping are as
follows. However, Vendor shall provide any superior material than as specified as required by the
process.
5.1 Plant equipment metallurgy:

Sr. Equipment Material
No
All rights reserved

-VI-4.0A 0
Neutralization Pit
1Neutralization Pit ( 2 compartments ) RCC – acid/alkali proof brick lining

2Priming Chamber SS-316
3Effluent Transfer pump SS-316
Chemical Handling & Storage
Bulk Acid Storage Tank FRP

Acid Measuring Tank (Cation) FRP
Acid Measuring Tank (MB) FRP
Caustic Solution Storage Tank CSRL
Caustic Measuring Tank (Anion) CSRL
Caustic Measuring Tank (MB) CSRL
Anion Hot Water Tank CS FRP lined
Acid Dilution Tank (Cation) FRP

Acid Dilution Tank (Mixed Bed) FRP
NaClO2 Dosing Tanks FRP
NaClO2 Dosing pumps PP/PVDF & Teflon
Acid Tank For neutralisation pit FRP
Caustic Tank for neutralisation pit CSRL
Agitator for Alkali measuring Tanks for SS 316 L
(MB)
5.2 Critical Piping:

Material of construction for pipes carrying fluids shall be as below
1. Raw Water Carbon Steel
2. Filtered Water Carbon Steel
3. Acidic Water Carbon Steel Rubber Line (CSRL)
4. DM water SS 304
5. Acid (Hydrochloric) CPVC
Alkali (Sodium Hydroxide) Dilute

6. CPVC
Strong
7. Lime solution CPVC
All rights reserved

-VI-4.0A 0
8. Coagulant aid solution CPVC
9. Chlorine dioxide CPVC
10. Chlorinated Water CPVC
11. Process/Turbine condensate SS304 / CS
12. Process Air Galvanised CS
13. Instrument air SS 304
14. LP Steam CS ( IBR )
Waste effluent from DM Plant

15. CSRL
vessel & Chemical solution tank
All rights reserved

-VI-4.0A 0
6.0 SITE METEOROLOGICAL DATA:

Site conditions
Air Temperature:
Parameters Temperature, °C Remarks
Dry bulb (Summer) 46.3
Dry bulb (Winter) 1.0
Average Temperature 31.9
wet bulb 29.0
Max for Mechanical / Civil / Structural 35.0
Minimum for winterization (Average) 18.7
Relative Humidity:
Relative Humidity RH%
Relative Humidity 100
Wind:
Wind Load Design: as defined in IS: 875 Part 3
Prevailing Wind Direction : W & NW

Rainfall:
Rainfall Value
Annual (Average) 1329 mm
Design rainfall (per hour) 116 mm
Barometric Pressure:
Barometric Pressure Value n
Average 1008 mbar
Seismic Design Code:

Refer Section-5.5 (Design Philosophy – Civil &
Structural Works) Part II-Technical.
The final plant elevation shall be established in consultation with owner / consultant
based on overall project requirement.
7.0 Utility System

 Instrument Air shall be provided at the plant battery limit by client. Further distribution
of instrument air to various distribution points shall be done by Contractor.
 Plant Air shall be provided at the plant battery limit by client. Further distribution of
plant air to various distribution points shall be done by Contractor.
 Cooling water shall be provided at the ISBL battery limit by client. Further distribution
of CW to various distribution points shall be done by Contractor.
All rights reserved

-VI-4.0A 0
 Supply of drinking water for safety shower & Process water for miscellaneous job to be
considered.
 Nitrogen shall be provided at the ISBL battery limit by client. Further distribution of
Nitrogen to various distribution points shall be done by LSTK Contractor.
All rights reserved

PC150/E/4004/SEC-VI-5.0 0
LTD
SHEET 1 OF 2
PART –II: TECHNICAL
SECTION – 5.0
ENGINEERING DESIGN SPECIFICATION



TITLE : DESIGN SPECIFICATION PC150/E/4004/E/SEC-
0
PLANT : RWTP,DMW & CPU VI-5.0
PROJECT :INTEGRATED COAL BASED DOCUMENT REV
SHEET 2 OF 2
CONTENTS
5.1 DESIGN PHILOSOPHY – PROCESS
5.2 DESIGN PHILOSOPHY – MECHANICAL
5.2.1 DESIGN PHILOSOPHY – STATIC EQUIPMENT
5.2.2 DESIGN PHILOSOPHY – ROTATING EQUIPMENT
5.2.3 DESIGN PHILOSOPHY – PIPING
5.3 DESIGN PHILOSOPHY – ELECTRICAL
5.4 DESIGN PHILOSOPHY – INSTRUMENTATION
5.5 DESIGN PHILOSOPHY – CIVIL & STRUCTURAL WORKS

PC150/E/4004/SEC-VI-5.1A 0
LTD
SHEET 1 OF 9
PART –VI: TECHNICAL
SECTION – 5.1
DESIGN SPECIFICATION – PROCESS

PLANT: RAW WATER TREATMENT, DMW PLANT & CONDENSATE

POLISHING UNIT


TITL : DESIGN SPECIFICATION - PROCESS PC150/E/4004/SEC-VI-
0
FERTILIZER COMPLEX AT TALCHER DOCUMENT NO REV
SHEET 2 of 9
CONTENTS
1.0 General
2.0 Design Pressure
3.0 Design Temperature
4.0 Corrosion Allowance
5.0 Hydraulic Retention Time
6.0 Heat Exchangers
7.0 Pumps
8.0 Compressors
9.0 Pressure Relief Valves
10.0 Columns & Vessels

0
SHEET 3 of 9
1.0 GENERAL:
The plants shall be designed to operate safely and satisfactorily at a capacity of 50 to 110% of
Design Capacity. Equipment and machinery shall be provided so that the plants can operate for
at least two years without major overhaul or inspection. All design shall conform with the latest
edition of the applicable sections of ASME, ASTM, IEEE, NFC, TEMA, AISI, NEMA, AISC, ACI,
OSHA, UBE and other governing codes or standard practices. Any other equivalent and
acceptable Code of Standard practice may be adopted with the approval of the PMC/Owner. In
addition, the following state/local Codes/laws shall supplement:
Pressure Vessels/
a) ASME, Section VIII, DIV.I
Formed ends
Buildings &
b) Relevant Indian Standard (BIS)
Structural
c) Electricity Indian Electricity Rules.
d) Sanitary Relevant Indian Standard (BIS)
a) Manual of Chief Inspector of Explosives, Govt. of India.

e) Safety
Relevant Indian Standard (BIS) / ODISHA Pollution Control Board

f) Water Pollution
limits
1.1 System of Measurements

The system of measurement shall be Metric as follows:
Parameter Preferred Units Alternative Units

Temperature °C
Pressure - absolute kg/cm² abs
Pressure - gauge kg/cm² g
Flow (liquid) m³/hr kg/hr
Flow (gas) Nm³/hr kg/hr
Flow (steam) kg/hr
Length, Level mm M
Time hr sec, min
Heat kcal Gcal

0
SHEET 4 of 9
Power kW
Fouling resistance m² hr °C / kcal
Pipe size / diameter Inches (in) mm
Mass kg
Liquid relative density sp gr T°C/15.6°C
Liquid density kg/m3
Vapor flowing density kg/m3
Furnace draft mm of WC
Storage tank pressure mm of WC
Vacuum mm of Hg, mm WC
Nm3/hr at 0°C & 1.033
Standard vapor
kg/cm2a
Standard liquid m3/hr at 15.6°C
Thermal conductivity kcal/hr-m-°C
Heat Transfer coefficient kcal/hr-m2-°C
Enthalpy, Entropy kcal/kg
Heat rate 106kcal/hr or MM kcal/hr Gcal
Viscosity cP
Kinematic Viscosity cSt
Sound Pressure dB(A)
Sound Power dB(A)
2.0 DESIGN PRESSURE:
2.1 General Rule:
Design pressure of Process Static Equipment shall be based on the maximum Operating
Pressure. Malfunction and Equipment failure shall be taken into consideration by safety devices.
Design pressure shall be for process equipment shall be whichever is higher. Alternatively LSTK
Contractor shall select the design pressure as standard design.
a) For max operating pressure below 2 kg/cm2 g use 3.5 kg/cm2 g

b) For max operating pressure between 2 kg/cm2g and 15 kg/cm2g use Max. Operating
Pressure + 1.5 kg/cm2

0
SHEET 5 of 9
c) For Max. Operating Pressure between 15 kg/cm2 g and 100 kg/cm2 g use Max. Operating
pressure x 110 %
d) For Max. Operating Pressure equal and above 100 kg/cm2 g use the Maximum Operating
Pressure + 10 kg/cm2 g.
2.2 Equipment under Vacuum:
Equipment normally operated under vacuum is designed for full vacuum and for the highest
pressure it can experience in case of vacuum failure. Equipment containing a fluid with a vapour
pressure at ambient temperature lower than atmospheric pressure which can be isolated shall be
equipped with vacuum breaking device or else be designed for full vacuum. Equipment subject to
vacuum due to mal-operation or failure shall be equipped with vacuum breaking devices or else
be designed for full vacuum.
2.3 Complete Systems:
Several pieces of Equipment protected by the same relief valve shall have a design pressure of
at least the set pressure of the relief valve.
2.4 Equipment on the Discharge of a Pump:
Equipment which may have to bear the shut-off pressure of a pump shall have a design pressure
equal to or higher than the shut-off pressure. Pump shut-off pressure shall be estimated
according to Clause 7.0.
2.5 Thin Walled Tanks And Vessels:

Atmospheric thin walled tanks and vessels shall have a design pressure equal to the highest
pressure imposed upon discharge of the pressure relief device. The design pressure for vacuum
shall be equal to the lowest pressure imposed upon suction of the vacuum relief device.
3.0 DESIGN TEMPERATURE:
Design temperature for process equipment shall be whichever is higher:
a) Maximum operating temperature + 15 °C (+25ºC for Feed/Effluent exchanger)

b) Boiling temperature at design pressure of process medium inside, if applicable.
c) Design temperature shall be rounded up to full 5°C steps.

0
SHEET 6 of 9
d) Design minimum temperature shall be specified only if the minimum operating

temperature is below 0 °C. Design minimum temperature shall be 5 °C less than the
minimum operating temperature. Special attention shall be given to low boiling liquids.
e) For piping, design temperature shall be determined according to ASME B 31.3.
Alternatively LSTK Contractor shall select the design temperature as standard design.
4.0 VELOCITY IN PIPES
Acceptable range velocity to be followed is as follows:
 Pump Suction & Gravity Flow lines : 0.5-0.8m/s
 Liquid Pressure Lines : 1.2-1.8m/s
 Air Velocity : Not more than 20m/s
 Steam lines less than 20 m/sec.
5.0 CORROSION ALLOWANCE:
Materials of construction and corrosion allowance for all Equipment and machinery shall be for a
design life of minimum 20 years (except for heat exchanger tubes). However, minimum corrosion
allowance for carbon steel (including 0.5 Mo alloy steels) shall be if bidder requires higher
corrosion allowance then same to be provided:
Pressure Vessels and other applicable Equipment 3 mm

Storage Tanks 1.5 mm
Piping 1.5 mm
Removable parts or internals (on each side in Contract with operating fluid) 0.75 mm
For stainless steel/titanium 0 mm
Carbon steel with epoxy resin coating 3 mm
6.0 HYDRAULIC RETENTION TIME:
Hydraulic retention time (Hold-up Requirements) is defined between low level (LL) and high level
(LH).

0
SHEET 7 of 9
Type of Service Retention Time

Storage tanks As per requirement of NIT
Measuring tanks By vendor
Acid storage tanks Minimum For 15 days requirement with
Or
Each Tank should have minimum capacity for
unloading of 1 Tanker with additional capacity of
20 % (Minimum for Unloading of 15 MT tanker
unloading)
Alkali storage tank Minimum For 15 days requirement with
Or
unloading)
Naclo2 storage tank Minimum For 15 days requirement with
Or
unloading)
Flash mixer 1 min
Clarifier 2 hrs. min
Filtered water storage 24000 M3
Neutralisation pit Capacity of each compartment shall be
sufficient to collect regeneration waste of one
stream of RWTP+DM+CPU
7.0 HEAT EXCHANGERS:

In general heat exchangers shall be designed to 110 % of their operating duty/flow.
Columns overhead coolers shall be designed to 120 % of their operating duty/flow.

0
SHEET 8 of 9
Large heat exchangers shall be split into two or more shells for easy operation and maintenance.
8.0 PUMPS:
Pumps shall be designed to 110 % of their maximum required flow rate in worst case of
operation.
The shut-off pressure for piping design upto the last isolation valve shall be estimated according
to the following criteria:
a) Differential head at rated flow x 125 % (*) + Max suction static head + design pressure of
pressure suction side.
(*) Shall be corrected as per pump vendor data
Shut off pressure of pump shall not be more than 120% of rated head of the pumps
9.0 COMPRESSORS:
In general, compressors shall be designed to a minimum of 110 % of their maximum required
flow. However, they are subject to special considerations according to the process.
10.0 PRESSURE RELIEF VALVES:

Pressure relief valves shall be supplied with locked open isolating valves. Pressure relief valves
for operational failure shall have installed spares. Also PRV on fire case with Hydrocarbon
service shall have installed spare. LSTK Contractor shall take care of any additional requirement
as per guidelines. The set pressure of pressure relief valves shall be equal to the design pressure
of the equipment. All safety valves will have bypass with exception of safety valves which are
only for fire cases and if there is more than one safety valve.
All solenoid operated on-off valve 4” and above shall be butterfly valve.
11.0 COLUMNS AND VESSELS:
11.1 Nozzle:
a) Minimum size 3/4" (for S.S shall be 1 inch).

b) Nozzle rating according to once of connected piping for instrument min. Class 150 ANSI
rating.

0
SHEET 9 of 9
11.2 Manhole:
Manhole size 24” (*)
11.3 Hand hole or Inspection hole:
a) Preferable Size 8 inches

b) Minimum Size 6 inches
11.4 Vent and Drain:
Vent and drain for vessels will normally be provided at the minimum length on overhead or
bottom line in accordance with the following table:
Volume or diameter of vessel (m3 or mm) Vent diameter Drain diameter

(inches) (inches)
V < 75 or D <= 4,500 2 2
75 < V <= 220 3 3
4,500 < D <= 6,000
220 < V <= 420 or 4 4
D > 6,000
V > 420 6 4
Note: Vent and drain connections are not necessarily located on vessels.
11.5 Storage (Resin/Chemicals):
LSTK Contractor shall consider all facilities necessary for safe loading, unloading, storage,
transportation of Resin/ chemicals within the plant Battery limit during Construction stage.
Notes:
All pumps shall be with 10% margin over normal capacities of pumps and motor rating shall
be suitable for end of curve operation of pump.
All strainers, filters, Cation-Anion-MB vessels, shall have Differential Pressure Transfer (DPT)
with local and DCS indication –Alarms to be provided.
Motor (5KW and above) current status in DCS and all motors shall have running status in the
DCS.
All chemical dosing discharge lines shall have minimum Rotameter flow meter.

0
SHEET 10 of 9
All dosing / bulk chemical storage tank shall have separate vent / overflow line with fume
mitigation system.
RO permeate shall be diverted to UF permeate tank automatically in case of off spec.
All centrifugal pumps shall be provided with automatic minimum circulation line.
All reciprocating / diaphragm pump shall have pressure safety valve & diaphragm rupture
alarm.
Sample points to be provided at various locations.
All lines at B/L shall be provided with lockable isolation valve along with drain and vent valve.
Tanks shall be provided with local level gauge, transmitters with indication & alarms in CCR,
auto trip & auto start as applicable.
Pumps shall be provided with local pressure l gauge at suction & discharge, transmitters with
indication & alarms in CCR, auto trip & auto start as applicable.
Flow transmitters with pressure & temperature compensation shall be provide at inlets lines,
All DMF inlet & individual outlets Cation, Anion, MB Exchangers, Final DM Water outlet,
All trips shall be 2 out of 3 logic & auto start shall be 1 out of 2 logic.
All utilities & other places as required for guarantees.
All media & Resin traps shall be provided with PDG.
Basket Type Strainers (1W + 1S) to be provided at UF inlets.
Telescopic devices.
All required safety interlocks
These are the minimum instrumentation however, bidder to provide any other instrument
required for trouble free, smooth, safe, continuous operation and maintenance of the plant


0
PROJECTS & DEVELOPMENT INDIA 5.2.1 (PART-A)
REV
LTD DOCUMENT NO
SHEET 1 OF 24
SECTION – VI 5.2.1 (PART-A)
DESIGN PHILOSOPHY-STATIC EQUIPMENT



RWTP ,DMW& CPU PLANT PC150/E/4004/SEC-VI-
5.2.1 (PART-A) 0
DOCUMENT NO REV
DESIGN PHILOSOPHY-STATIC EQUIPMENT SHEET 2 OF 24
CONTENTS
SL. NO. DESCRIPTION

1.0 DESIGN CRITERIA
2.0 MATERIAL OF CONSTRUCTION
3.0 TECHNICAL REQUIREMENT
4.0 FABRICATION
5.0 INSPECTION & TESTING
6.0 PICKLING AND PASSIVATION
7.0 PAINTING
8.0 INSULATION
9.0 SPARE PARTS
10.0 DOCUMENTATION
11.0 VENDOR LIST
LIST OF ATTACHMENTS
SL. NO. DESCRIPTION DOCUMENT NO.
1. VESSEL TOLERANCE PDS:PV-001

2. PROJECTION OF NOZZLES PDS:PV-002
3. NAME PLATE FOR VESSEL & TOWER PDS:PV-003
4. SKIRT SUPPORT FOR VERTICAL VESSEL PDS:PV-301
5. LIFTING LUG PDS:PV-302
6. PIPE DAVIT PDS:PV-303
7. DAVIT WITH MAHOLE WITH ASME FLANGE FOR PDS:PV-304
HOERIZONTAL NOZZZLE
8. NAME PLATE FOR STORAGE TANK PDS:SR-003
9. STORAGE TANK WITH FLAT COVER (CS/SS) PDS:SR-005
10. LUG SUPPORT FOR VERTICAL VESSEL PDS:SR-300
11. SUPPORT SADDLE FOR HORIZONTAL VESSEL PDS:SR-302

12. BRACKET SUPPORT FOR VERTICAL VESSEL PDS:SR-304

5.2.1 (PART-A) 0
DOCUMENT NO REV
1. 0 Design Criteria
1.1 This specification covers the requirements for the complete design (Mechanical), procurement,
fabrication, construction/erection, insulation, painting ,Pickling & Passivation(for SS
equipments),inspection and testing of static equipment ( Pressure Vessels, Heat Exchangers, Storage
Tanks, and Vessel Internals etc.) for RAW WATER TREATMENT, DMW PLANT & CONDENSATE
POLISHING UNIT of the M/s Talcher Fertilisers Limited (TFL) in accordance with this specification,
standards specification, codes and other attachment etc. listed in bid document.
1.2 The equipment shall be designed & constructed as per the latest edition of the following codes
and standards:
Code Description
ASME Section VIII Div 1 & 2 Rules for construction of Unfired Pressure Vessels
Standards of Tubular Exchangers Manufacturer's
TEMA ‘R’ / API 660
Association / For Shell & Tube Heat Exchanger
Heat Exchanger Institute standards for steam surface
HEI
condensers and steam jet ejectors
API 661 Air Cooled Heat Exchangers
API 662 Plate type Heat Exchangers
IBR Indian Boiler regulations
API 650 Welded Steel Tanks for Oil Storage
Reinforced Thermo set Plastic Corrosion Resistant
ASME RTP-1
Equipment
API RP 2000 Venting Atmospheric and Low pressure storage Tanks
ASME Section II A&B/ ASTM Materials Specifications
ASME Section II PART C Specification for welding rod, electrode & filler metal
ASME SEC II PART D Properties
ASME Section V Non-destructive Examination
ASME Section IX Welding Qualification
ASME SEC X Fiber-Reinforced Plastic Pressure Vessels
EN-13121 For Fiber-Reinforced Plastic Pressure Vessels
ASME B 16.5 For Flanges
ASME B 16.47 For large diameter flanges
For Metallic Gaskets for Pipe Flanges: Ring-Joint, Spiral
ASME B 16.20
Wound, and Jacketed
ANSI Pipes, Flanges, Fittings and Valves
IS: 875/SITE DATA For wind load consideration

5.2.1 (PART-A) 0
DOCUMENT NO REV
IS: 1893 (Part 4)& IS: 1893 (Part For seismic design consideration
1)/ SITE DATA
IS:4682 (Part-1) with Amendment Code of Practice for Rubber Lining of Vessels &
No. 3 Equipment for Chemical Process
Factory Act, 1948 BS CP 3003 Factory Act & State Govt factory rules Code of Practice on
(Part 1) lining of Vessels and equipment for Chemical Process.
1.3 Complete mechanical design of Equipment as per latest code /standard of construction shall be
the responsibility of the LSTK Contractor. Strict compliance with the requirement of
codes/equipment specification & any other referred document shall be ensured. In addition, all
statutory rules & regulations shall also be complied with.
1.4 Design conditions for all equipment shall be as per technical Specification and Material
specification. Minimum required thickness is calculated based on design parameters considering
different types of loadings including effect of static head of liquid column. Equipment shall also be
designed for hydrostatic condition. Final thickness is decided giving due consideration for
corrosion allowance.
1.5 Design pressure shall be at the top of vertical vessel or at the highest point of horizontal vessel.
The design pressure at any lower point shall be determined by adding the maximum operating
liquid head and any pressure gradient within the vessel.
1.6 Wind analysis shall be performed as per IS-875 (Latest Edition).Wind forces shall be increased
by 20% (over & above design code requirement) to cater the effect of piping system, platforms
and ladders etc.
1.7 Seismic analysis shall be performed by Response spectrum method (RSM) considering seismic
zone-IV as per IS-1893 part-1& IS-1893 Part 4 (Latest edition).
1.8 All carbon steel (CS) & low alloy steel (LAS) pressure parts shall have 3 mm corrosion allowance
unless specified otherwise.
1.9 All internals CS/ LAS parts including low temperature materials shall have at least 1.5 mm
corrosion allowance on either side unless otherwise specified.
1.10 Design of supports and anchor bolts shall be performed for compressive and tensile loading. In
no case shall diameter of anchor bolts be less than M24 for skirt support and M16 for other type
of support.
1.11 Each Lifting lug shall be designed with shock factor 2.
1.12 Hydro testing of equipment shall be as per UG-99b of ASME Sec VIII Div-1. In order to safeguard
against the risk of brittle fracture during hydrostatic test metal temperature during hydrostatic test
be maintained at least 30°F (17°C) above the minimum design metal temperature, but need not
exceed120°F (48°C).Design pressure for each nozzle shall be sum of maximum allowable
working pressure and static head of corresponding nozzles.

5.2.1 (PART-A) 0
DOCUMENT NO REV
1.13 Bolt of size M 48 and above shall be designed and spaced so as to permit tightening with a
hydraulic stud-tensioner. The bolts shall have an extra threaded length at one end of
approximately 1 bolt diameter, and shall be provided with threaded protection caps. Hex nuts
shall have suitable holes for manual tightening. The requisite no. of hydraulic stud-tensioner
device with necessary adopters/insertions based on varying sizes of studs shall be supplied by
bidder as per mechanical design of the equipment.
1.14 Orientation of longitudinal seams and position of circumferential seams shall be clearly marked in
the fabrication drawing. Nozzles, support and other attachments shall be located clear of welded
joints.
1.15 All process equipments shall be supplied with Nitrogen filled. In case of equipment assembled
and welded at site, it shall be filled with N2 after testing at site. Dry Nitrogen shall be filled at a
pressure of 0.5 Kg/cm2g and equipment shall be fitted with a pressure gauge and valve.
1.16 Bidder shall guarantee the equipment & their components against faulty design with regard to
their mechanical adequacy, improper material of construction & poor workmanship for the period
specified in contract.
1.17 Bidder shall stand Performance Guarantee of equipment as per respective technical
specifications/Process Data sheets.
1.18Design conditions for all equipment shall be in accordance with the process data
Sheets/specification .However, in any case design pressure shall not be lower than 10%over the
maximum anticipated operating pressure and design temperature should be 25°C higher than the
maximum anticipated operating temperature for all equipment unless otherwise specified.
1.19 Basic allowable stresses for shell, heads and other components etc.of vessels and shell, roof,
etc. of tanks shall be the values specified in the design code.
Maximum allowable “tensile stress” and “compressive stress” shall be as per UG-23 of ASME
Sec VIII Div -1. These stresses may be increased by 20% for earthquake & wind combination
case in line with UG-23 (d).
1.20 All blind flanges and man way covers weighing 35 kgs or more shall be fitted with handling
Facilities such as davits.
1.21 As a General rule all nozzle attachment to shell/head shall be set in type.
1.22 In case of conflict between this specification and other specification, codes and data sheets. It
shall be referred to PDIL/ Owner for clarification and the decision of PDIL/Owner shall be final &
binding on contractor without any cost & delivery implications. However, it shall be resolved
considering the most stringent in the following order
▪ Statutory requirement
▪ Requirement specified in this specification
▪ Process data sheet/ P&ID
▪ Applicable codes & standards
1.23 REGULATIONS

5.2.1 (PART-A) 0
DOCUMENT NO REV
Besides codes & standards, LSTK Contractor shall follow National Laws and Regulations such as
Indian Boiler Regulation and Department of Explosives, Nagpur, India together with Local by
Laws for the state including statutory requirements as applicable. Static and Mobile Pressure
Vessel (SMPV) rules as applicable shall also be complied with.
PUBLICATIONS:
WRC Bulletin # 107 Local Stresses in Spherical & Cylindrical Shells due to External
Loadings.
WRC Bulletin # 297 Local Stresses in Cylindrical Shells due to External Loadings on
Nozzles
1.24 DESIGN DOCUMENTATION
1.24.1 Detailed design calculations considering different loadings shall be made as per code/standards
and the additional requirements as mentioned below:-
1.24.2 Design of equipment inside the offsite plant complex shall be in accordance with the process
licensor’s data sheets and specifications.
1.24.3 LSTK Contractor shall consider the interfaces with other engineering disciplines w.r.t.
- Piping Layout/Location Drawings

- Civil / Structural Drawings
- P & ID’s
- Materials
- 3D PDS Model for Piping and Equipment Layout
- Hazardous Area Classification
1.24.4 Design philosophy of other disciplines shall be observed and shall be relevant to the extent
applicable.
- Civil/Structural Design Criteria
- Piping Design Criteria

- Process Design Criteria
- Electrical and Instrumentation Design Criteria
1.25.1 CONSTRUCTION & ERECTION
LSTK Contractor shall follow standard established procedures for handling storage, construction
& erection. LSTK Contractor shall strictly follow Manufacturer’s/Principal’s instructions, approved
drawings and procedures for construction & erection and satisfy Principal in all respects of
storage, handling, construction & erection of Package. All erection work shall conform to the
working/erection drawings (to be prepared by LSTK Contractor) and shall be in conformity with
codes & standards as applicable. The LSTK Contractor shall supply & arrange all necessary
construction & erection tools and tackles, machinery, scaffolding etc.
1.25.2 LSTK Contractor shall perform the following:

5.2.1 (PART-A) 0
DOCUMENT NO REV
i) Before installing the equipment, the foundations shall be checked and wherever Necessary,
chipping shall be done by the LSTK Contractor. All grouting materials, packing
plates/wedges required for the levelling and alignment of equipment, structures & pipelines
etc shall be provided.
ii) Top of the foundations shall be thoroughly cleaned to the satisfaction of Principal / LSTK
Contractor before placing base plates.
iii) All equipment & structure etc. shall be checked and inspected for its proper levelling and
granting (grouting) shall be done with suitable grouting material as required.
iv) After tightening the foundation bolts, the final level / alignment shall be rechecked and
redone, if required.
v) Installation of all supports and hangers, including concreting or welding as necessary.
vi) To check correctness of the piping, instruments and other connecting points in the equipment
and piping installed.
vii) The welding joints shall be stress relieved wherever necessary as per applicable codes,
Standards & specification.
1.25.3 The following shall be arranged and supplied by LSTK Contractor for completion of job. Any other
item whatsoever required shall also be included by LSTK Contractor in their scope.
i) All construction & erection materials, equipment & machinery, scaffolding, consumable, and
test equipment etc.
ii) Cranes/Hydra, temporary lifting beams and spreaders etc.
iii) Procedures for site assembly, construction & erection including lifting methodology for
Owner/Third party approval
.
1.25.4 As a minimum contractor shall comply the requirements indicated below:
i) Fabricate, erect and align the equipment & internals as per applicable codes, standards
& specifications. All internals shall be inspected before and after installation.
ii) Carry out all NDT’s required. The Personnel performing NDT’s should have a minimum
qualification as “NDT LEVEL-II” in the relevant Technique, certified by American Society
for Non-destructive Testing.
iii) Perform non-operating field pressure tests and leak tests on field fabricated equipment in
accordance with the applicable codes, standards and specifications, ensuring disposal
of test media in accordance with instruction/recommendations
.
iv) Notify Owner / Third party of the test schedules for witness the tests by concerned inspector.
1.26 QUALITY ASSURANCE & CONTROL
1.26 1 The quality assurance shall be as per the approved procedures, test methods &facilities to be
developed by the LSTK Contractor to ensure that the supplied equipment shall be of highest
quality. The quality control shall mean that all the tests , measurements, checks & calibration

5.2.1 (PART-A) 0
DOCUMENT NO REV
which are to be carried out may be compared with the actual specified characteristics of the
equipments/unit /system.
1.26.2 Quality Assurance (QA) shall mean the organizational set up, procedures as well as test methods
and facilities developed by LSTK Contractor in order to assure that Equipment leaving LSTK
Contractor’s shop are of the highest possible quality i.e. either equal to or better than the
requirement specified.
1.26.3 Quality Control (QC), shall mean all the tests, measurement, checks and calibration which are to
be carried out in LSTK Contractor’s shop in order to compare the actual characteristics of the
equipment/unit/system with the specified ones, along with furnishing of the relevant
documentation (certificates/records) containing the data or result of these activities.
1.26.4 LSTK Contractor shall submit a comprehensive description (manual) of QA/QC measures
contemplated by him for implementation with regard to this specification. It is contractual
obligation of the LSTK Contractor to develop and implement adequate QA/QC systems.
QA/QC system shall cover all products and services required for the equipment as per scope of work
including job sub contracted by the LSTK Contractor.
2.0 Material of Construction
2.1 Material of construction for various equipment shall be as selected as follows for general
Condition/service unless specified otherwise in respective process data sheet.
a) Pressure Vessel (KCS/CS)

Shell /Head plates : SA 516 Gr. 60/70 (Epoxy /rubber Lined as
applicable)& SA 516 Gr 60 for caustic, amine ,
hydrogen, sour ( Wet H2S) or lethal service tanks,
vessel and heat exchangers (Epoxy /rubber Lined as
applicable)
Nozzle Flange : SA 105 (Epoxy /rubber Line as applicable )
Nozzle Neck (Pipe/Plate) : SA 106 Gr. B (Nozzle size < 10”); SA 516 Gr. 60/70
((Epoxy /rubber Lined as applicable) (Nozzle size > 10”)
Non standard forging SA 266 Gr 2 (Epoxy /rubber Line as applicable )
b) Pressure Vessel (SS)

Shell /Head plates : SA240 Gr*
Nozzle Flange : SA 182 Gr*
Nozzle Neck (Pipe/Plate) : SA 312 Gr*(Nozzle size < 10”); SA
240 Gr *(Nozzle size > 10”)
*SS grade as specified in datasheet
c) Heat exchangers (KCS/CS)
Shell /Channel plates : SA 516 Gr. 60/70 (Epoxy /rubber Lined as
applicable)& SA 516 Gr 60 for caustic, amine ,
hydrogen, sour ( Wet H2S) or lethal service tanks,
vessel and heat exchangers
:Tube sheet : SA266 Cl2 (Forged)
:Tubes : SA179 (Seamless)
Nozzle Flange : SA 105 (Epoxy /rubber Lined as applicable)
Nozzle Neck (Pipe/Plate) : SA 106 Gr. B (Nozzle size < 10”); SA 516 Gr. 60/70
(Epoxy /rubber Lined as applicable) (Nozzle size > 10”)

5.2.1 (PART-A) 0
DOCUMENT NO REV
d) Heat exchangers (SS)

Shell /Channel plates : SA240 Gr*
Tube sheet : SA336 Gr*(Forged)
Tubes : SA213 Gr*(Seamless)
Nozzle Neck (Pipe/Plate) : SA 312 Gr* (Nozzle size < 10”); SA 240 Gr * (Nozzle
size > 10”)
Non standard forging : SA336 Gr */ SA 965 Gr *
e) CS Tanks/ Non- Coded Vessel
Shell/ Roof /Bottom Plates : IS2062 GR B/SA36 with Epoxy /rubber lining as
applicable)
Nozzle Flange : SA 105 (Epoxy /rubber Lined as applicable))
Nozzle Neck (Pipe/Plate) : SA 106 Gr. B (Nozzle size < 10”); IS 2062 GR
B/SA36(Epoxy /rubber Lined as applicable) (Nozzle
size > 10”)
Stud/ bolts and nuts for nozzles fitted SA193 Gr B7/ SA 194 Gr. 2H
with blind flange
f) SS Tanks/ Non- Coded Vessel
Shell/ Roof /Bottom Plates : SA240 Gr*
Nozzle Neck (Pipe/Plate) : SA 312 Gr* (Nozzle size < 10”); SA
240 Gr * (Nozzle size > 10”)
Non standard forging : SA336 Gr *

2.2 The Additional material requirements as indicated below shall be considered by Bidder.
2.2.1 All raw materials including bought -out items, whatsoever required, to complete the supplies shall
be procured and supplied with due identifiable mill material test certificates & inspection reports
duly certified by third party inspection agency
2.2.2 For coarse grained and high tensile materials in carbon steel (UTS > 45 Kg/mm2) and low alloy
steel, guaranteed impact strength shall be ensured at a temperature 15 degree C below
envisaged hydraulic test temperature as a precaution against brittle fracture during hydraulic test.
2.2.3 Carbon steel plates shall be procured in fully killed condition. CS plates shall be fully killed
&normalized. All plates above 50mm thickness shall be vacuum-degassed and examined by
Ultrasonic Testing (UT) as per applicable material specification code/standard.
2.2.4 All Stainless Steel (SS) plates shall be hot rolled & solution annealed and pickled as per SA-480.
2.2.5 All forgings except for flanges as per ANSI shall be UT tested as per ASTM A 388 for the
thickness greater than 50mm and shall be procured in normalized / annealed condition
acceptance standards shall be as per AM 203.2 of ASME Section VIII Div. 2. In case any defect
is found, no repair by welding shall be allowed.
2.2.6 All forgings including nozzle flanges shall be examined for surface defects by MP/PT testing after
matching as per applicable material specification code & standard.

5.2.1 (PART-A) 0
DOCUMENT NO REV
2.2.7 All external / internal attachments, pads/cleats for support directly welded to the equipment shall
be of same materials as that of equipment, unless specified otherwise.
2.2.8 All nozzles up to DN 10” size shall be made of seamless pipe. For sizes above DN 10” nozzle
connection shall be rolled from plates with full radiography of plates.
2.2.9 Unless otherwise specified girth flanges shall be of forged quality and ultrasonically tested.
2.2.10 Unless more restrictive prescription given by material specification the max. Content for carbon
steel used for fabrication as shown by ladle analysis shall be 0.23% for plates, pipes & tubes
0.25% for forging.
2.2.11 In order to minimise the effect of temper embrittlement for material to 2¼ Cr 1 Mo specifications
in the temperature range of 375-575oC, the embrittlement factors 'X' & 'J' shall be limited to:
X = (10P + 5Sb + 4Sn + AS) / 100 ≤ 15

The elements above are expressed as ppm
J = (Si + Mn) (P + Sn) x 104<160

The elements above are expressed as percentages
A stimulated PWHT followed by step cooling shall be performed on a sample of material.

Acceptable toughness shall be demonstrated by means of a Charpy V Impact Test.
2.2.12 Top portion of skirt (min. 500 mm height) welded to the bottom dished head shall be of same
material as that of shell /head for LAS & SS materials.
2.2.13 Heat treatment of formed parts shall be carried out as per following:
For Carbon Steel:
a. Cold formed dished ends or knuckles up to 16 mm nominal thickness shall be stress

relieved.
b. Cold formed dished ends or knuckles above 16 mm nominal thickness shall be normalised.
c. For Low alloy Steel: - Cold Formed Dish ends or Knuckles shall be stress relieved.
d. Hot formed dished ends or similar parts, which have not been uniformly heated in the
normalising range in the final stages of manufacture shall be normalised.
e. When the completed vessel involves post weld heat treatment, heat treatment recommended
in (a) above shall not be applicable.
f. Vessels in caustic service, Amine or Sour gas service shall be stress relieved.
g. All internal and external attachments, clips, insulation studs, name plate bracket, and the like
Shall be welded to the vessel before post weld heat treatment.
2.2.14 PWHT of complete vessel shall be carried out in one go in a furnace. Local stress relieving of
Weld joint in piece meal shall be avoided as far as possible.

5.2.1 (PART-A) 0
DOCUMENT NO REV
2.2.15 All Nozzle Flanges & Gaskets size, rating & type etc.shall be as per applicable piping
Specifications& instrument specification as applicable enclosed with the enquiry and Selected
bolting shall match with corresponding companion flanges.
2.2.16 Equipment under Caustic service shall essentially be PWHT with 100 % radiography. The
hardness of the parent weld, weld & HAZ shall be Limited to 200 BHN.
2.2.17 Pressure part plates having thickness 16 mm to 50 mm (both inclusive) shall be ultrasonically
Tested (UST) as per ASTM A-435. Pressure part plates having thickness above 50 mm and all
Plates to be used shall be UST as per ASTM A-578 Level B. No laminations or inclusions shall
be permitted.
2.2.18 Steel for Hydrogen service at elevated Temperature & pressure shall be selected as per API
941& API 934 .The following special requirements shall be met with for Hydrogen/Sour gas as
perNACE standard.
a) All pressure parts shall be post weld heat treated

b) All pressure retaining welds shall be 100% radiographed after final weld. HoweverRoot run
shall be liquid Penetrant tested.
c) Hardness of base metals, weld and HAZ shall not exceed 22 HRC
2.2.19 Cladded plates shall be supplied as per ASTM A264 material specification. All clad plate shallbe
UT examined at the steel works in accordance with ASTM A578 level S8.
2.2.20 The minimum thickness of weld overlay material shall be 1/8 inch (3 mm) except clad or
weldOverlay tube sheets and gasket surfaces.
2.2.21 Tube sheets shall have a nominal clad or weld overlay thickness of 3/8 inch (10 mm) but not Less
than 5/16 inches (8 mm) regardless of shell side or tube side face. The minimum thickness of
clad or weld overlay at a pass partition groove shall be 1/8 inch (3 mm) minimum
2.2.22 Unless otherwise specified Copper & Copper alloys shall not be used. Copper content up to 0.4%
are acceptable in carbon steel & 0.6% in stainless steel.
2.2.23 In case of equipment fabricated of materials of SS316L for urea service, low ferrite filler material
shall be so selected that ferrite content in two subsequent pass in contact with process fuel shall
be max. 2% and for equipment fabricated of material SS316L urea grade, the limitation of ferrite
content shall be 1%. The welding not in contact with process fluid may have ferrite content limited
to 6%.
.
3.0 Technical Requirements
3.1 Storage Tanks
3.1.1 The following design codes shall be adopted for tank design as applicable:
i) API 650 Welded Steel Storage Tanks for Oil Storage

ii) PDIL standard PDS: SR 005 Storage Tanks with Flat Cover (CS/SS)wherever Applicable

5.2.1 (PART-A) 0
DOCUMENT NO REV
3.1.1.1 For fixing the nominal capacity of the cone roof tank, allowance for free board (minimum 500
mm),vapour space and dead liquid space at the bottom shall be taken in to account. Tank
diameter and height shall be firmed up based on nominal capacity (Cylinder volume)
3.1.2 For Carbon Steel storage tanks the minimum thickness shall be based on stability considerations.
Minimum thickness for roof & shell shall be 5 mm, and bottom plate 6 mm, excluding corrosion
allowance
.
3.1.3 Storage tanks up to 4meter in diameter shall be shop fabricated items. Tanks with diameters
greater than 4 meter shall be field erected.
3.1.4 Tanks constructed of stainless steel shall comply with API 650, Appendix S.
3.1.5 Shell seams shall be located to clear openings to the maximum extent possible in accordance
with API 650.
3.1.6 Bottom plates may be lap-welded with the lap toward the direction of drainage. Butt welded
bottom plates shall be furnished when specified on the tank drawings or data sheets or when
tanks are specified to have rubber lining.
3.1.7 For each surface in contact with product/vapour, the specified corrosion allowance shall be added
to the required thickness of all load-carrying components including shell, roof, bottom and roof
supports. & One-half the specified corrosion allowance shall be added to each surface of no-load-
carrying internal components.
3.1.8 All walkways, stairways, and platforms shall be furnished with handrails on open or exposed
sides.
3.1.9 Tanks having design temperature more than 100 ºC shall have thermal isolation barrier(Suitable
fire bricks) between tank bottom and foundation.
3.1.10 Anchor bolts shall be provided based on design considering wind/seismic loads, uplift due to
internal pressure etc. However, tanks having diameter ≤10 meter shall be provided with anchor
Bolts and shall be spaced at approximately 1.8M of circumference.
3.1.11 Maximum height of unstiffened shell shall be calculated based on the corroded thickness of shell
courses. Section modulus of wind girders shall also based on corroded thickness of shell
courses.
3.1.12 All storage tanks shall be designed considering liquid height up to top curb angle of shell
Usingone foot method for tanks less than and equal to 60 meter. However for seismic design,
operating liquid level may be considered. All design calculation shall be carried out in corroded
condition.
3.1.13 Unless otherwise specified bottom plate slope shall be 1:100 from the centre of the tank towards
shell.
3.1.14 Butt welded annular ring below shell (minimum 8 mm thick excluding corrosion allowance)shall
be provided for all tanks of diameter12 m and above.

5.2.1 (PART-A) 0
DOCUMENT NO REV
3.1.15Fabrication tolerance on shell, bottom, and foundation e.t.c. shall be as per applicable code.
3.1.16 Anchor bolt shall be provided if required by calculation for uplift or stability for wind and Seismic
load. Minimum anchor bolt size shall be M24 excluding any corrosion allowance on bolt diameter.
Tanks with diameter ≤10 m shall be provided with anchor bolt at spacing of maximum 1.8 m,
however minimum 4 nos of M24 shall be provided for all tanks with diameter ≤10 m.
3.1.17 All tanks shall be provided with under tank leak detection and sub grade protection system as per
appendix-I of API-650 for applicable foundation Type.
3.1.18 Thickness of tank bottom shall be determined as per API-650 Appendix –I for tank bottom
Supported bypiers/grillage. Maximum deflection of Corroded bottom plate shall not be morethan
half of the thickness.
3.1.19 The roof plates shall be self supported of supported by structure. Column supported roof
shallnotbe acceptable. The roof and its supporting structure shall be designed to carry the dead
Load, internal and external pressure as specified in process data sheet and live load as per
design code.
3.1.20 Inside/outside painting of tanks shall be carried out based on product stored and as per Process
data sheet enclosed elsewhere in bid package.
3.1.21 For the Rubber Lined Equipments, Equipment corners shall be grounded & corners on rubber
lined surface shall be grounded to 6mm radius & all interior welds surfaces shall be grounded
flush, the internal surface finishes to be suitable for rubber lining with no curves dents or surface
imperfections for air entrapment.

3.2 Shell and Tube Heat Exchangers
3.2.1 Process Shell and Tube Exchangers will comply with the requirements TEMA (Latest) Class ‘R’.
The tube sheet shall be analysis by Appendix “UHX” of ASME Section VIII, Div. 1& TEMA
whichever is more stringent.
(TEMA Class ‘C’ may be used for auxiliary heat exchangers for rotating and packaged equipment
exchangers.)
3.2.2 ASME Section VIII, Div. 1, Appendix “S” shall be considered mandatory for bolted flange
connections. All mandatory requirements are covered under Appendix 2 for different loading
condition.
3.2.3 Mean metal temperature of tube & shell be considered in the design of fixed tube sheet
exchangers.
3.2.4 Parts such as tubes, tube sheets, floating heads etc. which simultaneously come in contact with
both shell side and tube side fluids, shall be designed considering pressure acting on one side
only or the combination of pressures, whichever results in higher thickness of parts.
3.2.5 Exchanger saddle and foundation design shall include additional loadings generated from bundle
pulling. The saddle and foundation design for all exchanger for which tube bundle pulling is
foreseen during maintenance, shall be designed for longitudinal force acting at the exchanger
axis. Pulling force shall be 1.5 times the bundle weights:

5.2.1 (PART-A) 0
DOCUMENT NO REV
Further wind load and piping load shall also considered on the exchanger supports and
foundation.
3.2.6 Tube sheets in vertical exchangers shall be provided with drain and vent arrangement with
threaded plug seal welded.
3.2.7 Shell side “hot” nozzles shall be located at the top of the shell at the channel end whenever
possible.
3.2.8 Lifting lug for heads or bonnets shall be provided wherever frequent dismantling is required.
3.2.9 Bundle weights shall be limited to 10 tonnes. In case the bundle weight increases by 10 Tones,
Bidder shall take care necessary precaution in the design and fabrication of exchanger e.g. by
Providing rollers arrangement, support plates etc. to avoid excessive loading on shell while
Pulling of tube bundle, proper reinforcement in equipment support etc.
3.2.10 Saddle wear plate material shall be the same as the shell material.
3.2.11 Tube sheets and Girth Flanges shall be shall be of Forged Quality & Ultrasonically tested. It shall
not have any segmental joint.
3.2.12 All heat exchanger tubes shall be seamless, cold drawn and formed from single length. CS tubes
shall be normalized. LAS tubes shall be normalized and tempered.
3.2.13 The minimum radius of U tubes shall be not less than 2xOD of tube. Thickness of 2 inner most
rows will be higher than other rows with minimum difference of 2 gauges.
3.2.14 For U tube bundle, the following requirements shall also be met:
i) Each U tube shall be formed from a single straight length

ii) All U tubes shall be cold bent
iii) All C.S, C-Mo, Cr-Mo tubes shall be heat treated after bending
iv) Bent portion of all U tubes shall be examined by PT and hardness check on four opposite
points of bent portion shall be carried out
v) Unless otherwise specified, after bending each tube shall be tested hydraulically
3.2.15 Where fixed tube sheet heat exchangers are specified, thermal stress shall be checked in
accordance with the TEMA standard to determine if an expansion joint is necessary.
3.2.16 Tube to tube sheets joints shall be leak tested with air & soap solution at pressure of 2.0 kg/cm2
g wherever specified leak testing with halogen shall be carried out.
3.2.17 Pass partitions shall be provided with a weep hole of about 6 to 12 mm in diameter at low points
of pass partitions.
3.2.18 Minimum SS 304 as MOC for tubes shall be used for Heat Exchangers having Cooling Water. All
tubes shall be seamless only.
3.2.19 After testing, all exchangers shall be completely dried.

5.2.1 (PART-A) 0
DOCUMENT NO REV
3.2.20 Gaskets used during testing shall be same as specified for operating conditions. Howeverall Joint
gaskets shall be replaced by new gasket which will be opened after Hydro testing.
3.2.21 Bidder shall check adequacy of tube bundle against flow induced vibration.
3.2.22 While deciding the location of heat exchanger in the equipment layout it should be ensured that
there is no restriction in complete opening of the channel, shell and floating head cover, bundle
removal e.t.c. sufficient unobstructed space shall be provided in between two exchangers so as
to allow a man to pass through for maintenance.
3.2.23 Unless otherwise stated inlet nozzles on shell side shall be provided with impingement platein
Compliance with TEMA requirement. The flow area around solid impingement plate shallbe at
least equal to the inlet nozzle cross-section. In case of two phase flow impingementbaffle shall be
perforated. Impingement baffle plate shall extent at least 25 mm beyond theprojection of the
nozzle bore. The clear distance from the nozzle (at the inner surface) to theimpingement plate
shall be at least 0.25 x nozzle diameters. The nominal thickness of theimpingement baffle shall
be at least 6 mm.
3.2.24 Where heat treatment of U-bends is required, the heat treated portion shall extend atleast 150
mm beyond the point of tangency.
3.2.25 All heat exchanger tubes shall be 100% eddy current tested in supplement to hydro test.
3.3 Vessel
3.3.1 Design, materials, fabrication and inspection of welded pressure vessels shall comply with
ASME Code Section VIII, Division 1 & Div 2 (latest edition) and Technical Specifications.
3.3.2 For vessels the minimum thickness of shell & heads, including corrosion allowance shall be as
indicated below:
Sr. No Shell Diameter( mm ) Thickness (Min.) mm
CS / LAS HAS
1. ID < 500 5 3
2. 501 < ID < 1200 5 4
3. 1201 < ID <2000 6 5
4. 2001 < ID < 2600 8 6
5. ID > 2600 10 8
CS = Carbon Steel, LAS = Low-Alloy Steel, HAS = High-Alloy Steel

5.2.1 (PART-A) 0
DOCUMENT NO REV
3.3.3. All nozzles above 24” NB shall comply with ASME B16.47 Series B (API 605).
3.3.4. Minimum branch nozzle thicknesses shall be Schedule Extra Strong above 2” NPS, and
Schedule 160 for 2” NPS and below.
3.3.5 Stress calculations due to Local loads on vessel for external structural attachments, such as
platform clips, pipe support clips and lifting lugs shall be performed.
3.3.6 Design of vessel skirt shall be based on seismic/wind/thermal considerations and fire
proofing/insulation requirements.
3.3.7 Vessel skirts for carbon steel vessels shall be designed from the same material as the shell or the
head. Vessel skirts for other than carbon steel vessels shall be the same material as the shell or
the head for the top 500 mm.
3.3.8 Vessels with skirt support having eight or more anchor bolts shall be required to be supplied with
an anchor bolt template. The template shall be an annulus 10 mm (minimum) thickness and 150
mm (minimum) wide, with boltholes equal to bolt diameter plus 3 mm, stacked drilled with skirt
base plate.
3.3.9 Maximum permissible deflection for columns when subjected to design wind loadings shall not
exceed 0.005 x Vessel height.
3.3.10 Minimum man way size shall be equal to 24” nominal pipe size.
3.3.11 Manhole/hand hole/blind holes covers shall be equipped with davits or hinges to facilitate
handling.
3.3.12 Horizontal vessels of large size and thin wall shell on saddle supports shall be investigated for
buckling, local circumferential bending and shear stress. The method of L. P. Zick (Supplement to
Welding Research, 1971) may be used for this investigation.
3.3.13 Use of structural steel shall be limited to non-pressure parts only.
3.3.14 Local vessel stress calculations for external structural attachments, such as platform clips, pipe
support clips and lifting lugs shall be performed.
3.3.15 Dimensional tolerances shall be in accordance with the design codes or standards, whichever is
more stringent.
3.3.16 For vessel with diameter less than 900 mm and having removal internals, shell flange shall be
provided.
3.4 PLATE TYPE HEAT EXCHANGER
3.4.1 The plate type exchanger shall be designed in accordance with“API 662"
3.4.2 All plates shall be pressed from a homogeneous single metal sheet in one placing and normal
thickness of plate being pressed shall not be less than 0.5 mm
3.4.3 Nozzle neck attachments shall be with full penetration weld. Set on nozzles are not permitted.

5.2.1 (PART-A) 0
DOCUMENT NO REV
3.4.4 Lock washers shall be provided for all rotated nuts.
3.4.5 SS plate shall be of SA 240 specification.
3.4.6 For gasket type PHE, vendor shall be responsible for the compatibility of gasket material & Glue,
selected for specified fluids and design conditions.
3.4.7 All components in contact with process fluids shall be as per Process data sheets (PDS).
3.4.8 Equipment shall be hydro tested at test pressure limits(as differential pressure) for 30 Minutes
minimum. Also mechanical strength of the frame shall be tested by raising the Pressure onboth
side equivalents to test pressure (i.e. 1.3 times design pressure) for 90 Minutesminimum.
3.4.9 All nozzles of Heat exchanger shall be of extended type. Studs connections are not acceptable.
3.4.10 The plate shall be fully supported by carrying bar and only guided by the guide bar.
3.4.11 The carrying bar shall be designed to support at least 1.5 times the total weight of movable cover
and plate pack filled with water or process fluid whichever is having greater density.
3.4.12Bidder shall furnish the complete details of the offered system like features, properties of the
Descalant, system description, operating details etc.
3.4.13 Vendor to develop methodology or device to get the entrapped gases escaped during welding
andalso to ensure that no processed fluid should get entrapped during operation in such area
otherwise it may lead to crevice Corrosion.
3.5 FRP/GRP TANKS
Codes
Construction
• ASME X Rule for Construction
Materials and material testing
• ASTM C-581 Chemical resistance of Resins
• ASTM D-2150 Woven roving Laminated FRP
• ASTM D-2583 FRP hardness test
• ASTM D-2584 Ignition loss of cured FRP
• ASTM D-2990 Flexural creep and Creep-rupture
• ASTM D-2997 Machine made FRP pipe
• ASTM D-3299 Filament-wound reinforcing
• ASTM D-3892 Resin and FRP packaging
• ASTM D-4024 Machine made FRP flanges
• ASTM D-4097 Contact-molded FRP tanks
• ASTM D-5421 Contact-molded FRP flanges
• ASTM D-618 Plastics testing conditions
• ASTM D-638 Plastics tensile properties testing.
• ASTM D-695 Plastics compressive testing
• ASTM D-883 Plastics terminology
• ASTM F-412 Plastics piping terminology
Equipment testing

5.2.1 (PART-A) 0
DOCUMENT NO REV
• ASME V Non-destructive examination
Flange Drilling and bolting

• ASME/ ANSI B 16.5 Flanges and flange fittings
• ASME/ANSI B 16.47 Large diameter steel flanges
3.5.1 Graphite powder/ Resin paste shall be applied behind all welds to provide a permanent earth
Path for spark testing. Permanent metal foil strips shall not be permitted.
3.5.2 Flange face (Front & back) shall be smooth & flat. If the flange faces aremachined, the full
Chemical liner shall be reinstated.
3.5.3 The Barcol Hardness of FRP/GRP wall shall be tested according to ASTM D2583.
3.5.4 The difference in the glass content of FRP/GRP between the samples shall not be more then 5%
wt.
3.5.5 All items shall be cured in accordance with the resin supplier’s instruction s. wherever possible
curing shall be done at Manufacturers works.
3.5.6 High frequency spark testing
All production thermoplastic welds shall be examined visually & by high frequency spark
testEquipment at the following stages:
• Completion of first weld run
• Completion of external run
• After pressure or static head test
• After any boil out test
3.5.7 Reinforcing materials used on the inner surface shall be in compliance with the latest edition of
ASTM D3299.
3.5.8 For FRP/GRP tanks, thickness of Corrosion barrier of the thermoplastic lining shall not be
included in the thickness calculation, to withstand design condition.
3.6 RUBBER LINING
3.6.1 The type of rubber (i.e. Natural, Butyl, Nitrile, Ebonite, and Hypalon etc.), its minimum Thickness
shall be 4.5 mm & hardness shall be decided as per design code/specification.
3.6.2 For vacuum service, the Triplex lining shall be adopted. It shall consist of 3 layers:
1st layer : 60 ±5 shore A

2nd layer : 35 ±5 shore B
3rd layer : 60 ±5 shore
3.6.3 In general for all other services the preferred hardness of rubber shall be 65 ±5 shore A.
3.6.4 Lining up to 6 mm may be applied in single layer. Above this thickness it shall be applied in 2 or
more layers. Except when the sheets shall be prepared by calendaring as follows:

5.2.1 (PART-A) 0
DOCUMENT NO REV
Thickness of Lining (mm) Minimum no. of Plies

Up to 3 2
3 to 5 3
6 4
3.6.5 The surfaces which are to be covered with rubber shall be easily accessible & free from pitting or
other physical imperfection.
3.6.6 Spark testing shall be done for Lining.
3.6.7 The internal surfaces requiring rubber lining shall be prepared by Tank Fabricator to suit rubber
lining. All welds shall be ground smooth and radiused to min. rubber lining thickness. All welds
shall be free from pin holes, pits, pockets and nipples. Porous welds are to be peened until tight.
Since the internal surface preparation of the tank including roof (like grinding of the weld ments
etc.) is to be done by the tank contractor, the same surfaces will also be inspected and approved
by the rubber lining contractor during tank fabrication and/or on handing over of the tank to him
for rubber lining.
In the event of any surfaces found unsuitable, the tank contractor shall carry out necessary
rectifications and make all surfaces suitable as per instructions of the rubber lining contractor or
his authorised representative.
3.6.8 Rubber Lining shall be designed as per IS 4682 (Part 1) Latest Edition (Code of Practice for
Lining of Vessels and Equipment for Chemical Processes).
3.6.9 For critical service or when required the supplier shall furnish rubber sheets to be used for
checking up its suitability by concerned inspector/ owner for the service conditions specified.
3.7 Safety
3.7.1 Safety standards and features which are inherent in the specific mechanical equipment design
codes, standards and regulations are applicable.
3.7.2 Safety features to be incorporated into the design include, but are not limited to, the following
features for equipment:
i) Ladder cages
ii) Safety chain across platform access
iii) Step-off platforms where necessary
iv) Platform grating
v) Toe plates
4.0 Fabrication
4.1 The Bidder shall comply in all respects with the provision of the applicable codes, standards and
specification during fabrication with respect to tolerances, welding, fabrication, forming of heads,

5.2.1 (PART-A) 0
DOCUMENT NO REV
radiography, heat treatment, inspection, testing and quality control etc. unless & otherwise
specified.
4.2 Plates of different thicknesses shall be made flush with the inner surfaces of equipment unless
otherwise stated.
4.3 Larger heads which cannot be formed in one piece shall be fabricated as follows with prior
approval from Principle.
a) In two pieces, with the welding seam included in the middle third and preferably on the centre
line
b) In petal construction, with meridianal seams and a central cap of diameter not larger than
0.75 times the vessel outside diameter
4.4 Due provisions must be kept for venting out entrapped gases during welding of pads, flanges and
liner plates etc.
4.5 All welding shall be carried out by qualified welders using approved procedures in compliance
with the requirements of codes, standards & specifications and shall be duly certified by the
concerned inspecting authority. All welding procedures must be got approved from authorised
inspecting authority before starting any fabrication job. Welding of all parts must be completed
before heat treatment.
4.6 All welds shall be full penetration welds with back chipping and re-welding from the second side.
For those joints which are inaccessible for back chipping the root run shall be carried out with TIG
process. Single side welding with backing strips shall are not permitted.
4.7 All parts shall be fabricated in accordance with good shop practice and in uniformity so that all
corresponding parts will be inter-changeable.
4.8 All sharp corners shall be rounded off with smooth radius. Inside edge of manhole and hand hole
at the internal surface shall be rounded to minimum radius 5 mm.
4.9 All flange bolts & skirt-bolts shall straddle centre line unless otherwise stated.
4.10 In case of nozzle with butt-end construction, extra length shall be provided to facilitate hydraulic
testing and subsequently cutting and edge preparation to suit piping welding at site.
4.11 All nozzles less than or equal to NB 65 mm shall be stiffened with three equispaced plate ribs of
the same material as that of shell.
4.12 Flange facing and thread connection shall be protected against oxidation during HT.
4.13 Longitudinal and circumferential welded seams shall not interfere with nozzle openings,
reinforcement plates, saddle pads, and other attachments as far as possible.
4.14 Welding wherever specified, is to be done by qualified and approved welders using the suitable
fillers and fluxes recommended for the materials in the fabrication drawings.

5.2.1 (PART-A) 0
DOCUMENT NO REV
5.0 Inspection & Testing
5..1 Equipment shall be inspected and tested in accordance with the relevant codes, standards and
specifications by TPIA. All equipment shall be inspected during various stages of manufacturing
starting from identification of raw materials to final completion as per agreed Quality Assurance
Plan (QAP) which shall be prepared by Successful Bidder after award of contract. In case of site
fabricated/assembled equipment same inspection agency shall be responsible for inspection and
testing at site. However all the bought-out items must be supplied with test certificate and
inspection reports.
5.2.2 The equipment shall be inspected by Third party inspection agency (TPIA) as defined
elsewhereas inspection agency. It shall be the responsibility of the Bidder to make available to
the inspector all the drawings, calculations and other documents. However the Principal shall
have free access for inspection at vendor’s/sub-vendor’s shop and at site during project
execution.
5.2.3 The equipment shall be considered acceptable for despatch only after final certification for
acceptance is issued by concerned inspector.
5.2.4 All parent material (Primary& Secondary Components), welds and HAZ shall be impact tested at
Minimum Design Metal Temperature (i.e. minimum service temperature or the temperature to be
computed as per applicable codes, standards &specifications) by Bidder and shall have impact
energy values as per the applicable codes, standards & specifications.
5.2.5 Production control coupons, when required as per codes & standards shall be subjected to
impact test, corrosion test etc. in addition to mechanical tests as required. In case of heat treated
equipment test coupons shall be given similar heat treatment as for the equipment.
5.2.6 Formed heads when fabricated in pieces shall be normalised and weld seams fully radiographed
after forming.
5.2.7 Vessel containing lethal, toxic and highly inflammable substance shall be fully radiographed and
stress relieved.
5.2.8 Tube to tube sheet joints in heat exchanger shall be leak tested with air & soap solution at2
kg/cm2 g. Helium testing shall be carried out wherever required.
5.2.9 All nozzle reinforcing pads shall be tested pneumatically at 0.5 Kg/cm2g pressure with soap
solution on attachment welds. Vent holes shall be plugged with non hardening mastic to prevent
ingress of water.
5.2.10 All completed equipment shall be tested hydraulically as per the requirements of codes,
standards & specifications in presence of the inspecting authority. Pneumatic test of completed
equipment shall be carried out only when specially mentioned in the specification sheets.
Chloride content in water used for testing shall not exceed 30 ppm for SS equipment and 40 ppm
for CS and low alloy steel equipment. Duration of test shall be as per applicable codes&
standards.
5.2.11 The temperature of test water shall comply with requirement of Fabrication code.

5.2.1 (PART-A) 0
DOCUMENT NO REV
5.2.12 Unless otherwise stated gaskets used during testing shall be same as specified for operating
conditions. However all joint gaskets shall be replaced by new gasket which will be opened after
Hydro testing.
5.3 The following NDT requirements are mandatory in addition to codes, standards & specification
requirements:
A) UT examination
i) All butt - welds in thickness greater than 50mm as supplement to radiograph

ii) FPW of nozzle attachments of thickness above 50mm as supplement to radiography
iii) Clad Plates and formed heads from clad plates in all thicknesses
iv) All forgings
B) MP / PT examination
i) All edges of plates and opening in shell of CS having thickness equal to & above 40mm and
LAS / SS having thickness more than 25mm
ii) Root and final layer of all butt welds
iii) Fillet welds of SS
iv) All werld surfaces after PWHT
v) Each layer of weld deposit in SS overlay
vi) Knuckle surfaces of dished ends, expansion bellows and pipe bends
vii) All forgings after machining
viii) Skirt to head joint
ix) Each pass of tube to tube sheet joint
x) Bent portion of all U-tubes
C) Radiography:
i) All weld seams of formed head, if made in more than one segment shall be full radiographed
after forming
ii) When spot radiography is specified, all T – Joints & minimum 5% of total weld length
excluding T joints shall be radiographed
iii) All nozzles fabricated from plates shall be 100% radiographed
iv) Radiography of welds in C - 1/2 Mo & Cr - Mo - Steel preferably be carried out after
Note : If a vessel is not 100% radiographed and/or UT tested, then a minimum examination of butt,
corner & T-joints shall be made.
D) Rubber lining Inspection & Testing as per IS: 4682 (part 1)
6.0 Pickling and Passivation
6.1 All SS material shall be Pickled & Passivated as per following procedures:
6.1.1 Pickling
Aqueous pickling solution shall be as follows:

5.2.1 (PART-A) 0
DOCUMENT NO REV
Nitric acid (Tech. grade) 10 to 25% plus Hydrofluoric acid 1 to 8% (to be used only for stabilised
SS grades). Temperature 50 to 60° C for 10% Nitric acid and 20° C for 25% Nitric acid. When
size and shape of product permit, total immersion in the pickling solution is preferred. Where
immersion is impractical, pickling may be accomplished by wetting the surface by
i) Swabbing or spraying
ii) Partial filling the item with pickling solution and rotating or rocking so that all the surface
receives the required chemical treatment.
The maximum period for which the pickling solution shall be allowed to remain on the surface is
30 minute. During pickling removal of oxides may be hastened by brushing with a hard fibre or
SS wire brush. Over pickling shall be avoided.
The pickling agent shall be washed off with plenty of water so as to leave no trace behind.
6.1.2 Passivation
After pickling and water rinsing, an aqueous caustic permanganate solution containing NaOH 10
weight % and KMnO4 4 weight % shall be used for neutralising pickling solution. This shall be
followed by thorough water rinsing.
Water used for pickling and washing shall not have chloride contents exceeding 30 ppm.
7.0 Painting
7.1 All CS external surfaces of shop fabricated equipment shall be primer and final painted as per
TS-2001as defined in Section-VI-14 of Bid.
8.0 Insulation
8.1 The equipment shall be insulated as defined elsewhere Listed in bid document.
9.0 Spares (Erection & commissioning, 2 years operation & Special Spares etc.)
9.1 COMMISSIONING SPARES
9.1.1 All commissioning spares shall be included by LSTK Contractor in their scope of supply and shall
be part of the main equipment.
9.2 SPARES FOR 2 YEARS OPERATION
9.2.1 2 years operation spares shall be supplied by the contractor as per Section-10 of Bid.
10.0 Documentation
Documents shall be submitted as per “Documentation schedule” in Section-9 of Bid.
11.0 Vendor List

5.2.1 (PART-A) 0
DOCUMENT NO REV
All equipment shall be procured/fabricated as per approved vendor list(Section-11). Any

equipment for which vendor list is not enclosed, the LSTK Contractor may furnish a list of their
proposed vendors along with their references for supply of similar type of equipment along with
bid. However all the additional proposed vendors shall have well proven track record and shall be
subjected to consultant/owner’s approval.

PC150/E/4004/SEC-VI-5.2.2
0
(PART-A)
PROJECTS & DEVELOPMENT INDIA LTD.
Document No. Rev
Sheet 1 OF 12

DESIGN PHILOSOPHY – ROTATING EQUIPMENTS



PC150/E/4004/SEC-VI-5.2.2
RWTP, DMW & CPU PLANT (PART-A)
0
TALCHER FERTILIZERS LTD. Document No. Rev

Sheet 2 OF 12

TABLE OF CONTENTS
SL. NO. DESCRPTION

1.0 SCOPE
2.0 DESIGN PHILOSOPHY FOR MACHINERY
3.0 DESIGN REQUIREMENTS
4.0 INSPECTION AND TESTING
5.0 PAINTING
6.0 VENDOR LIST
7.0 LSTK CONTRACTOR/ VENDOR DOCUMENTATION
All rights reserved

PC150/E/4004/SEC-VI-5.2.2
0

Sheet 3 OF 12

1.0 SCOPE
1.1 General
This Philosophy states that contractor’s scope of work shall include basic & detailed
engineering, procurement, supply, manufacturing, fabrication, transportation, loading,
unloading, insurance during transit, storage, construction, erection/ installation of all
Mechanical Rotating Equipment with allied electrical, instrumentation and civil
works, obtaining all necessary statutory approvals from concerned government
authorities as applicable, testing, mechanical completion, pre-commissioning,
commissioning, performance guarantee test runs including total project management
and handing over of RWTP, DMW & CPU Plant of prescribed capacity for M/s
TALCHER FERTILIZERS LIMITED ( TFL), ODISHA.
In addition, all statutory rules & regulations shall also be complied with.
2.0 DESIGN PHILOSOPHY FOR MACHINERY
2.1 Codes and Standards
Latest Edition of National / international codes and standards shall be followed for
design and manufacturing of different machinery items. Applicable standards are
prescribed in the respective description of the equipment philosophy.
2.2 Design Life
All equipment shall be designed for a minimum service life of 25 years and at least 2
years of uninterrupted operation under normal operating conditions. This requirement
excludes specialised components requiring periodic maintenance and replacement.
2.3 Essential Project Reference Documents

The following documents shall be observed, and relevant aspects incorporated into
specifications and datasheets:
 Process Description, Specifications and Data Sheets .
 Hazardous Area Classification
 Electrical and Instrumentation Design Criteria
2.4 Regulations
Besides codes & standards, LSTK Contractor shall follow National Laws and
Regulations together with Local by Laws for the state including statutory
requirements as applicable.
All rights reserved

PC150/E/4004/SEC-VI-5.2.2
0

Sheet 4 OF 12

2.5 Site Conditions
Site conditions shall be as defined elsewhere.
2.6 Material of Construction
Generally Materials of construction shall be as per the NIT.

Use of equivalent & superior material may be selected & shall be furnished with the
offer along with chemical composition.
2.7 Quality Assurance & Control
2.7.1 The quality assurance shall be as per the approved procedures, test methods &
facilities to be developed by the LSTK Contractor to ensure that the supplied
equipment shall be of highest quality. The quality control shall mean that all the tests
, measurements, checks & calibration which are to be carried out may be compared
with the actual specified characteristics of the equipments/unit /system.
2.7.2 Quality Assurance (QA) shall mean the organizational set up, procedures as well as
test methods and facilities developed by LSTK Contractor in order to assure that the
machines & associated auxiliaries leaving LSTK Contractor’s shop are of the highest
possible quality i.e. either equal to or better than the requirement specified.
2.7.3 Quality Control (QC), shall mean all the tests, measurement, checks and calibration
which are to be carried out in LSTK Contractor’s shop in order to compare the actual
characteristics of the equipment/unit/system with the specified ones, along with
furnishing of the relevant documentation (certificates/records) containing the data or
result of these activities.
2.7.4 LSTK Contractor shall submit a comprehensive description (manual) of QA/QC

measures contemplated by him for implementation with regard to this specification. It
is contractual obligation of the LSTK Contractor to develop and implement adequate
QA/QC systems.
2.7.5 QA/QC system shall cover all products and services required for the complete
machine unit as per scope of work including job sub contracted by the LSTK
Contractor.
3.0 DESIGN REQUIREMENTS
3.1 General
All machines shall be directly coupled to their prime movers. V-Belt drives shall be
avoided. If not, specifically mentioned, the drivers shall have rated output at least
10% greater than the power requirement of the driven equipment and also compliant
to respective API codes / standards whichever is more stringent.
Copper (Cu) or Cu-alloy shall not be used for any components.
All rights reserved

PC150/E/4004/SEC-VI-5.2.2
0

Sheet 5 OF 12

All pumps shall have Mechanical Seals. Single seals will be used in most cases,.
Special tools and wrenches required for installation and maintenance shall be
provided.
Noise level for all rotating equipment shall be limited to 85 dBA measured at 1meter
distance from the equipment.
All equipment shall have a stand-by .
Rotary equipment base frame is to be grouted by epoxy grout.
Pump alignment to be done by Laser and alignment machine to be handed over to
client after completion of project
3.2 CENTRIFUGAL PUMPS
3.2.1 Requirement
This standard shall be followed in establishing the minimum engineering
requirements for centrifugal pumps for non-critical services / water handling
services.
The pumps shall be designed, manufactured and supplied as per Hydraulic
Institute Standard / DIN 24256 / ISO-2858 /IS-1520/ IS-13518/ IS-5120
Standard/ API 610 latest edition for Centrifugal Pumps
The pump shall be designed to develop the specified differential head at rated
capacity, suction pressure and specific gravity while running at the rated
speed. Rated speed of pump shall be full load speed of the drive motor. In
case the driver is not in pump vendor's scope, full load speed of the driver
shall be furnished to the pump vendor along with other details after order. The
pump characteristics shall be guaranteed / tested with reference to the full
load speed of motor.
Guarantee point shall refer to the differential head, rated capacity, specific
gravity, and full load speed of the driver.
The pump and accessories shall be suitable for outdoor, unsheltered
installation and continuous duty unless otherwise specified in the respective
specification sheets.
The pumps shall be supplied complete with all the accessories as specified in
the respective specification sheets inclusive of necessary appurtenances,
auxiliary piping, special tools, spares etc.
Accessories required / recommended by pump vendor other than those specified
in the pump specification sheet for safe and efficient operation of the pump unit
shall be included in the pump vendor’s scope of supply and the same shall be
identified in the bid separately with adequate justification.
All rights reserved

PC150/E/4004/SEC-VI-5.2.2
0

Sheet 6 OF 12

Pumps shall have SI dimensions, comply with applicable ISO standards except
for piping connections which shall be as per ANSI/ASME standard.
Reference list of pumps which are in operation for similar service conditions shall be
furnished with the offer indicating broad specifications, purchase order number, date
and name & address of user.
All pumps shall have a stand-by pump.
3.2.2 BASIC DESIGN

The shut off head of the pump shall be 105% to 120% of the head at rated
capacity.
It should be possible to increase the head minimum by 5% by installing higher
size impeller .
In addition to static balancing, impellers shall be dynamically balanced as per
G6.3 of ISO-21940.
Pump inlet, outlet and auxiliary connections shall be flanged. All connections
shall be provided with slip-on type companion flanges, nuts, bolts and gaskets.
Connections of 11/4, 21/2, 31/2, 5, 7 nominal pipe sizes shall not be used.
When specified, pump shall be provided with drip tray under the stuffing box and
leak-off line with flange, companion flange, nuts, bolts and gaskets. Material
composition shall be same as that of pump casing. Leak - off piping shall be
arranged upto the edge of the base plate and shall be suitably terminated by
bidder to hook-up point.
Pump inlet, outlet and auxiliary flanged connections shall confirm to the facing
and drilling requirements of ANSI / ASME B 16.1 or ANSI / ASME B16.5.
All equipment shall be designed to permit rapid and economical maintenance.
Major parts such as casing components and bearing housings shall be designed
(shouldered or doweled) to ensure accurate alignment on reassembly.
Impeller shall be keyed to the pump shaft. Impeller nut shall be used to secure
the impeller and a positive mechanical locking method shall be adopted.
The pump shaft shall be one piece for horizontal pumps. For vertical pumps
number of shafts shall be minimum.
Shafts for horizontal pumps shall be fitted with deflectors. Deflectors shall be
made of non-sparking material (corrosion resistant material for corrosive
service).
Renewable wear ring surfaces shall be furnished on impeller and casing
Mating wear surfaces of hardenable materials shall have a difference in Brinell
hardness number of at least 50.
Radial and thrust bearings shall be rolling element type. These shall be designed
for minimum 24,000 hours bearing life.
All rights reserved

PC150/E/4004/SEC-VI-5.2.2
0

Sheet 7 OF 12

For between bearing pumps arrangement, bearing housing shall be cast integral
with the lower half of the pump casing or bolted to it. Bearing housing should be
provided with stiffening brackets and be sufficiently rigid to resist the dynamic
loads during operation.
Castings shall be sound and free from shrink holes, blow holes, cracks, scale,
blisters and other similar injurious defects. Ferrous pressure casting shall not be
repaired by peening, plugging, burning in or impregnating. When weld repairs to
castings are authorized by ASTM specification for the material, repair welding
shall be carried out in accordance with that specification. Unless otherwise
specified, weld repairs shall be inspected according to the same quality standards
used to inspect the casting.
Material of construction of various pump parts shall be as per pump specification

sheet, if any. If the vendor considers other materials better, same shall be offered
as an alternative only. Materials not specified in the specification sheet shall be
selected by the vendor in accordance with the service conditions and based on
relevant codes & standards. Chemical composition and physical properties of the
materials (MOC), wherever used by bidder, must be proven ones and furnished
along with the offer.
Copper and copper alloys shall not be used for pump parts .
A name plate of 18 Cr - 8 Ni Stainless Steel or Monel, securely attached by

stainless steel pins at an easily accessible point on the pump body shall be
furnished. The name plate shall be stamped with following information:
- Purchaser’s item number
- Pump serial number
- Capacity in m3/h
- Differential head in meters
- Revolution per minute
- Casing hydrostatic test pressure in kg / cm2g
- Absorbed power in kW
Motor shall have power ratings including service factor at least equal to following
percentage of pump rated absorbed power. :
Pump absorbed Motor rating percentage of

< 22 125
22 - 55 115
> 55 110
All rights reserved

PC150/E/4004/SEC-VI-5.2.2
0

Sheet 8 OF 12

Vendor shall indicate for vertical pumps, minimum liquid level for pump operation
/ startup in the offer.
For vertical pumps, a hole shall be provided in the column pipe above the
maximum liquid level to relieve pressure on stuffing box.
For vertical pumps, the specified head shall be measured at the discharge
flange, at pump mounting level. Pumps shall be suitable to develop specified
discharge head in addition to column losses and vertical distance, between
minimum level in the sump tank and center line of the discharge flange. Pump
vendor shall indicate total head to be developed by the pump in the offer.
Vertical pumps taking suction from sump / vessel shall be furnished with
corrosion resistant suction strainer. Perforation / mesh size shall be suitable for
proper operation of pump. Sufficient free flow area of the strainer shall be
provided.
Pumps shall be provided with shaft sleeve under mechanical seal.

Shaft sleeves shall be hard chrome oxide coated under flexible member of
mechanical seal.
Gland Packed pumps shall not be offered.
When pumps are specified with mechanical seals: Make of mechanical seal shall
be Flowserve, Eagle Burgmann, John Crane make.
Mechanical seal shall be inside mounted, balanced type with Carbon versus
Tungsten Carbide faces or Carbon versus Silicon Carbide faces. Suitable
flushing plan shall be provided.
 Coupling make shall be as follows:
Driver rating up to 25 kW : Lovejoy (RRL), Pinbush type

Unique, Flender
Driver rating more than 25 kW : Pinbush type/All metallic type
Rathi-Discoflex type M,
Euroflex,Triveni-Flexibox
3.3 RECIPROCATING PUMP / METERING PUMPS/ ROTARY PUMPS
Reciprocating pump / metering pump / Rotary type positive displacement pumps

shall be designed as relevant API -675 and API-676 codes & standards, latest edition
.The metering pumps shall be suitable for continuous capacity variation preferably
from 0 to 100%. The capacity variation should be possible while the pumps are
working. All pumps shall have a stand-by pump.
All rights reserved

PC150/E/4004/SEC-VI-5.2.2
0

Sheet 9 OF 12

3.4 CENTRIFUGAL FANS / LOBE BLOWERS
Centrifugal fans/ blower shall be designed as per AMCA standard or equivalent

relevant national/ international codes, latest edition .
Forced and induced draught fans shall be coupled to drivers through shim pack dry
flexible coupling, and the complete assembly shall be mounted on a substantial
bedplate.
First critical speed of the rotor shall be higher than 120% of rated speed. Rotor
assembly shall be dynamically balanced.
Capacity control shall be achieved by means of dampers (Preferably on suction side)

specially for constant speed fans, as applicable.
The fan casing shall be suitably split such that impeller assembly can be removed for
maintenance without disturbing inlet and outlet ducting.
SS bolts and nuts shall be provided for the split casing joints of fans for corrosive
service.
The drive motors of the fans/ blower should be designed with additional capacity to
take care of surge loading. However Motor rating shall be minimum 125 % of shaft
power for shaft power up to 22 KW, 115 % of shaft power for shaft power between 22
– 55 KW and 110 % of shaft power for shaft power above 55 KW.
Bearing shall be preferably oil lubricated.
3.5 AGITATOR
Agitators shall be manufacturer as per relevant national / international codes &

standards. Assembly shall be such as to enable replacement of bearings, shaft
sealing devices, gear unit and driver without dismantling other major parts of unit and
without emptying or depressurising the vessel.
First critical speed of the rotor shall not be less than 140% of rated speed.
Adequate space shall be provided for packing replacement without removing or

dismantling of any part other than the gland and the seal cage.
Motor rating shall be minimum 125% of shaft power.
Flexible coupling shall be provided between the power drives and agitator shaft or
gear, and shall have minimum service factor of 2.
All rights reserved

PC150/E/4004/SEC-VI-5.2.2
0

Sheet 10 OF 12

Spacer type coupling shall be provided for units provided with Mechanical Seals. The
spacer shall be of sufficient length to permit replacement of the seal assembly
without removing the driver / gear.
Gear unit shall be provided in accordance with AGMA standard. Gear box rating shall
be selected based on minimum service factor of 1.5.
3.5 HVAC System
Air conditioning system & air flow ventilation rate should be sufficient to satisfy not
only air removal specification, but also to maintain over pressure and temperature
specification. It should be also capable to avoid wind penetration in order to meet the
requirements of a conditioned space, simultaneous control of temperature, humidity,
cleanliness, contamination and air distribution should be considered in design &
selection of HVAC equipment. Eco-friendly refrigerant to be used in HVAC
equipment. All civil buildings / facility, Control room, substation, labs etc to be
equipped with suitable HVAC system with 100 % redundancy. Site related
temperature, humidity shall be considered for adequate design & selection of HVAC
system along with compliance to National / international codes and standards viz.
ISHRAE/ ASHRAE.
4.0 INSPECTION & TESTING
Machines shall be inspected by Third Party Inspection Agency . The Inspection and
testing shall be in accordance with the all relevant codes, standards, specifications,
including the minimum guide line given in NIT.
4.1 All testing accessories, measuring instruments including NDT testing equipment, etc.
shall be arranged by LSTK Contractor. DM water shall be used for hydro testing of
the equipment.
4.2 Job driver / Motor shall preferably be used for MRT and performance test . However,
any limitation regarding use of Job driver / motor shall be submitted to owner with
due justification for owner’s approval during detail engg on case to case basis.
4.3 String test to be performed at Vendor’s shop. String test if not possible at Vendor’s
Works then LSTK Contractor may perform the same at Owner’s site. However,
Contractor shall submit to owner due justification for owner’s approval during detail
engg on case to case basis.
4.4 Witness test (by TPI) for all rotary equipment including stand-by to be done. LSTK
contractor shall furnish project specific QAP/ ITP for all equipment during detail engg
for owner’s approval.
4.5 In general, following tests shall be conducted for all rotating equipments:
 Material test
All rights reserved

PC150/E/4004/SEC-VI-5.2.2
0

Sheet 11 OF 12

 Non-destructive test
 Hydrostatic test for all the pressure containing parts
 Dynamic balancing of rotor
 Over speed test of impeller / Rotor
 Helium leak test of compressor casing (if required as per API Code)
 Mechanical running test
 Barring over check for reciprocating compressor
 NPSHR test for pumps
 Performance Test
 String Test
 Disassembly Test
The tests required to be conducted and witnessed shall be specified in the
equipment data sheet by contractor . Disassembly test for Fans, Blowers & small
Pumps can be waived –off in case no problem occurs during mechanical /
performance Test.
5.0 PAINTING
All exterior non-stainless steel surfaces subject to atmospheric corrosion with the
exception of machined surfaces shall be epoxy painted. All exterior machined
surfaces shall be coated with suitable rust preventives.
6.0 VENDORS LIST

All equipment shall be procured / fabricated as per approved vendor list as per NIT.
However, LSTK contractor may have to furnish Proven track record / reference
record of any vendor opted for specified services / equipment, if, owner desires.
LSTK Contractor to also note that any other vendor or items which are not mentioned
in NIT, successful LSTK bidder may furnish list of proven sub-suppliers with PTR
subject to owner’s approval during detail engg. Document (PTR) shall be in English
language only.
7.0 LSTK CONTRACTOR / VENDOR DOCUMENTATION:
Drawings & Documents of machinery items/ rotating equipment shall be as

mentioned elsewhere in the ITB.
Contractor to furnish Complete List of all rotating equipment with their quantity, tag
numbers and Power consumption along with the bid. Material Requisition (MR) for all
machinery/ equipment to submitted by contractor for Owner’s review & approval.
Owner’s/ PMC comments are to be duly incorporated by contractor and afterwards
contractor shall proceed with procurement activity with respective OEMs. Technical
Bid Evaluation (TBE) documents are to be furnished by bidder to Owner for
information.
All rights reserved

PC150/E/4004/SEC-VI-5.2.3
(PART-A)
0

SHEET 1 OF 44

DESIGN PHILOSOPHY – PIPING



PC150/E/4004/SEC-VI-5.2.3
0
DESIGN PHILOSOPHY-PIPING
SHEET 2 OF 44

CONTENTS
1.0 Scope
2.0 Design Philosophy
3.0 Codes, standards and supplementary specifications
4.0 General Design
5.0 Design Philosophy / Criteria General
5.1 Equipment Layout
5.2 Unit Piping
5.3 Offsite & Yard Piping
5.4 Flare Piping
5.5 Underground Piping
5.6 Air Systems
5.7 In-Line Instruments
5.8 Sample Connections
5.9 Vents and Drains
5.10 Line Strainers
5.11 Spectacle Blinds
5.12 Flexibility Analysis and Supporting
5.13 Personnel Protection
5.14 Mechanical Handling
6.0 Materials
7.0 Painting
8.0 Welding

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 3 OF 44

LIST OF ATTACHMENTS
DOCUMENT/ANNEXURE
NUMBER DESCRIPTION
1 Table Of Basic Span
2 Accessibility For Valves & Instruments
3 Vertical And Horizontal Guides Spacing
4 Clearances
5 Design Philosophy For Stress Analysis
PNMP-TS-6000 Engineering Specification–Piping (For Package Units)

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 4 OF 44

1.0 SCOPE
The scope of this document is pertaining to the design philosophy, norms .and specific
requirements which shall be adhered to by contractor or his associates and representatives
during the course of the project in designing, procurement & construction of piping material.
1.1 APPLICABLE STANDARD & CODES
Standard No. Title
ASME/ANSI B16.5 Steel Pipe Flanges and Flanged Fittings
ASME/ANSI B16.9 Steel Butt-Welding Fittings
ASME/ANSI B16.10 Face to Face and End to End Dimensions of Valves
ASME/ANSI B16.11 Forged Fittings Socket Welded and Threaded -
ASME/ANSI B16.20 Metallic Gaskets for Pipe Flanges – Ring Joint, Spiral
Wound, and Jacketed.
ASME/ANSI B16.21 Non-Metallic Flat Gaskets for Pipe Flanges
ASME/ANSI B16.25 Butt-Welding Ends
ASME/ANSI B16.34 Valves – Flanged, Threaded Welding End.
ASME/ANSI B16.47 Large Diameter Steel Flanges
ASME/ANSI B31.1 Power Piping
ASME/ANSI B31.3 Process Piping.
ASME/ANSI B31.5 Refrigeration Piping
ASME/ANSI B36.10M Welded and Seamless Wrought Steel Pipe.
ASME/ANSI B36.19M Stainless Steel Pipe
API 6D Specification for Pipe Line Valves (Gate, Plug, Ball and
Check Valves).
API 6FA Fire Test for Valves.
API 501 Specifications for Metallic Gaskets for Refinery Piping.
API 594 Check Valves:, Wafer-Lug and double flanged type
API 598 Valve Inspections and Testing.
API 599 Steel Plug Valves Flanged and Butt-weld ends
API 600 Steel Gate Valves Flanged and Butt-welding ends, Bolted Bonnets
API 602 Gate, Globe, and Check Valves for Sizes DN 100
(NPS 4) and Smaller for the Petroleum and Natural Gas Industries
API 603 Class 150 – Corrosion Resistant Flanged End gate valves.
API 604 Ductile Iron gate valves – flanged ends.
API 606 Compact C.S. Gate Valve extended body.
API 607 Fire Test for soft seated Ball Valve.
API-608 Metal Ball Valves, Flanged, Threaded & BW Ends.
API 609 Butterfly Valves, Lug type & Wafer type.
API 623 Steel Globe Valves—Flanged and Butt-welding Ends, Bolted
Bonnets
IBR Indian Boiler Regulations
AWWA C207-D Large Dia. Steel Flanges (Ring Type).
EJMA Expansion Joints Manufacture Association.
MSS SP 6 Standard Finishes for Contact Faces of Pipe Flanges and
Connecting End Flanges of Valves and Fittings.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 5 OF 44

MSS SP 25 Standard Marking System for Valves, Fittings, Flanges & Unions
MSS SP 43 Wrought Stainless Steel Butt-weld Fitting
MSS SP 45 By-pass and Drain Connection.
NACE MR0175-94 Sulphide Stress Cracking resistant Metallic Material
NFPA National Fire Protection Association.
EN 10204 Metallic Products - Types of Inspection documents
ASTM D3035 Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR)
Based on Controlled Outside Diameter
ASTM D3261 Standard Specification for Butt Heat Fusion Polyethylene (PE)
Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing
2.0 DESIGN PHILOSOPHY
2.1 Piping systems shall be in accordance with Clause 1.1, which permits the use of the
following specifications:
ASME B31.1 Power Piping
ASME B31.3 Process Piping
Materials, design, construction, testing and inspection shall be fully in accordance with the
selected specification.
2.2 The dimensions, manufacturing tolerances and marking of ferrous and non ferrous piping
components shall conform to the applicable standards .The design shall comply with all
applicable codes, laws and statutory regulations. The Contractor shall optimize the layout
with the approval of the owner and include any changes resulting from HAZOP studies
and taking into consideration the following :
i) General site layout taking into account the topographical geo-technical aspect of the
site.
ii) Access for maintenance and fire appliances.
iii) The interdependency of units and buildings with each other within the complex.
iv) Safety escape routes for personnel based on emergency or disaster management
plans in the event of environmental upset or fire.
v) Suitable drainage system of Project site.
2.3 Material of construction shall be suitable for specified process duty (both normal and
abnormal operations) and have a projected life and corrosion/ erosion allowance in
excess of minimum life of the project. Piping materials specified in piping materials
specification shall be used for selection of material of construction of major services.
All materials under steam service shall be supplied with proper certificates in prescribed
forms.
3.0 CODES, STANDARDS AND SUPPLEMENTARY SPECIFICATIONS:

3.1 The latest edition of codes shall be applicable for piping system design, materials,
fabrication, manufacture, erection, construction and inspection etc. For any item not
covered in the list of codes and standards / International Standards / proven design
may be finalized based on discussion with OWNER/Consultant.
3.2 Where conflict occurs, the order of precedence shall be:
a) Statutory Regulations
b) National, International and Industry Standards and Codes of Practice.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 6 OF 44

c) Technical Specifications
3.3 Standards, Codes and Supplementary Specifications for piping design shall be applied as
follows:
i) Process and utility piping to ASME B31.3 Process Piping
ii) Power Plant piping to ASME B 31.1
Fire protection system shall be designed and installed in accordance with applicable
NFPA (National Fire Protections Associations) Codes.
4.0 GENERAL DESIGN
4.1 Flanges for process and utility piping shall be in accordance with ANSI B16.5 and ANSI
B16.47.
4.2 Wherever possible all purchased equipment shall be supplied with flanges that comply with
ANSI B16.5/B16.47.
4.3 The minimum size of piping to be used in pipe-racks shall be 2” NB.
4.4 With the exception of equipment connections the minimum size of piping shall be ½” NPS.
4.5 Pipe sizes 1 ¼”, 2 ½”, 3 ½” 5” and 22” NPS shall not be used except as connections to
purchased equipment.
4.6 Threaded pipe nipples between headers and vent, drain and instrument isolation valves shall
be Schedule 160 for CS and Schedule 80S for SS in the size range ½” to 2” NPS.
4.7 Piping 2” NPS and above shall be butt-welded. All weld joints in piping 1½” NPS and below
shall be socket welded using socket weld fittings.
4.8 In Class 600 and higher pressure rating double block valves shall be used for systems open
to atmosphere, such as vents and drains. Piping in hazardous service shall have vents,
drains and bleeds routed to a safe location. Category ‘M’ substances shall be vented to the
flare system.
4.9 When a line of one material specification is connected to a line of higher material
specification, the connecting line shall be constructed of the higher material specification or
pressure rating up to & including the first block valve.
4.10 As a minimum, piping systems shall have isolation facilities as follows:
ASME B31.3 Category ‘M’ service and Normal service (Class 900 and above) shall have
double block isolation valves with a downstream drop-out spool.
ASME B31.3 Normal service (Class 150 and 600) shall have a valve and downstream
spectacle blind.
ASME B31.3 Category ‘D’ service shall have a valve and downstream spectacle blind.
Generally, equipment shall have provision for isolation of piping to each equipment
connection by means of valving and /or blinds as determined by service conditions.
5.0 DESIGN PHILOSOPHY / GENERAL CRITERIA
5.1 Equipment Layout
5.1.1 Basis of Equipment Layout

Equipment Layout shall be finalised based on the following data:

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 7 OF 44

a) Overall Plot Plan
b) P&I Ds
c) Equipment Data Sheets
d) Wind Direction
e) Safety Distance and Specific Distance mentioned in Piping Design Basis and as
per statutory requirements.
5.1.2 Development of Equipment Layout
The following aspects shall be considered during development of equipment layout.
a) Process Requirement -Proper interconnection between equipment as per P&I Ds
to achieve the intended process parameters.
b) Economy of piping material- Minimize the quantity of costly piping.
c) Erection & Construction requirements:
Erection scheme and schedule of all equipment must be considered during
equipment layout to have smooth erection mainly in case of tall columns, heavy
equipments like thick walled reactors, space for laying tall columns, approach roads
for cranes / derricks for lifting the column or reactors and requirement of special
foundation / pile etc.
d) Operation and Maintenance Requirement
- Overhead and side clearances for exchangers and pumps
- Horizontal & overhead clearances for easy movement of working personnel.
- Crane approaches for air coolers/fired heaters.
- Provision of monorail for pumps and exchangers
e) Similar equipment grouping - All columns, exchangers, pumps etc. should be
grouped together for convenience of maintenance and safety wherever feasible.
f) The technological structures should be interconnected for easy movement of
operational personnel.
g) U/G piping corridors for main headers should be marked in equipment layout for all
under ground piping.
5.1.3 Plant Layout & Design guidelines
5.1.3.1 General
The plant layout shall be based on ensuring adequate access, to allow construction,
inspection, maintenance and operation to be performed in a safe and efficient manner. The
alignment of equipment and pipe shall offer an organised appearance. The layout shall be in
accordance with, but not limited to the design practices described in this criteria.
Where dynamic loading, limited pressure drop or other severe service condition applies,
particular care shall be taken in routing pipe lines.
Flushing connections shall be provided on all lines containing flammable or toxic material,
slurries, and materials which solidify when the line is dead. Sufficient Nitrogen purging

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 8 OF 44

points shall also be provided. Supply piping of fuel gas shall be arranged for equal flow
distribution.
Trolley beams, pipe davits, shall be provided with appropriate removable hoists mechanism
for charging and discharging catalysts, chemicals, packing rings etc.
Piping and all other services shall be arranged so as to permit ready access of Cranes for
removal of Equipment for inspection and servicing.
All utility and process piping shall be located above ground, and major lines shall be located
in overhead pipe ways.
Lines that must be run below grade, and must be periodically inspected or replaced, shall be
identified on the P & ID’s; these lines must be placed in covered concrete trenches. Sleeper-
ways shall not be used in process areas where they may block access for personnel and
equipment.
Drip legs and dead ends shall be avoided, especially for piping where solids or fluids may
congeal from corrosive condensate.
Where sleeper ways are used the elevations shall be staggered to permit ease of crossing or
change of direction at intersections. Flat turns may be used when entire sleeper ways
change direction. Flat turns must not be used within pipe racks.
Spacing and routing of piping shall be such that expanding/contracting lines (including
insulation) will not clash with adjacent lines, structures, instruments and electrical equipment
during warm up and cool down.
Piping to be sloped shall be indicated on the P&I D’s.
5.1.3.2 Pipe-Rack/T-Post/Small Portals

In general, equipment layout shall be prepared considering straight pipe rack, however other
shapes like L / T / U / H / Z etc can also be considered based on area available.
The width of the rack shall be 4M, 6M, 8M, 10M or 12M for single bay having four (4) tiers
maximum. In general, the spacing between pipe rack portals (span) shall be taken as 8 M for
main rack. However it can be decreased to 6 M depending on the size/number of the pumps
to be housed below pipe rack. Intermediate Beams between two portals shall be provided to
support smaller pipes <= 2". 20% extra space shall be provided on the pipe rack and portals
on each tier for future expansion/modifications.
-Clearance beneath pipe rack shall be 3.8 M minimum.

-Height between two pipe rack tiers shall be 2.0M minimum.
-Road clearance shall be 9 M minimum wherever heavy duty crane movement is required
during construction and future maintenance.
-Road clearance shall be 7.5 M minimum for main roads.
-Road clearance shall be 5 M minimum for secondary roads.
-T-Portal's width shall not be more than 2.5 M and height shall not be less than.3.0 M
5.1.3.3 Pumps
Wherever practicable pumps shall be arranged in rows with the centre line of the discharge
on a common line. In general, pumps shall be kept inside the pipe rack. However in case of

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 9 OF 44

smaller racks, pumps shall be kept on one side or outside the pipe rack to provide clear
access under the rack as per clause applicable.
Pump foundation height shall be 300 mm above H.P.P.
Gap between each pump foundation / and foundation of technical structure should be
sufficient for easy removal of equipment after piping. Clearance between two adjacent pumps
shall be such that clear 900 mm aisle is available.
All pumps not open to sky with motor rating >= 45 KW shall be provided with monorail. No
monorail should normally be provided for pumps outside rack and sufficient space below rack
shall be available for pump maintenance.
5.1.3.4 Clearance and Accessibility
5.1.3.4.1 Access to Pumps

Clear access of 3.8M vertically and 4.5M horizontally shall be provided centrally under main
pipe rack for small mobile equipment to service pumps, wherever these are put under pipe
ways with prior specific approval. Pumps outside rack shall be approachable by small cranes
etc. from under the pipe rack.
5.1.3.4.2 Access to lower items to grade (Lowering Area)
Clear access shall be provided at grade on the access side for lowering external and internal
fittings from tall elevated equipment by providing pipe davits.
5.1.3.4.3 Layout & Access Requirements for Platforms ladders and Stairs
For providing platform ladder & staircase following guidelines shall be followed.
- Two means of access (i.e. two ladders or one ladder and one stair case) shall be
provided at any elevated platform which serves three or more vessels & for B/L valves
operating platform.
- Platforms, ladders and stairways shall be the minimum, consistent with access and
safety requirements.
- Stairway for tanks to be provided on upstream of predominant wind direction.
i) Platform at elevated structure
a) Dual access (i.e. one staircase and one ladder) shall be provided at large elevated
structure if any part of platform has more than 22.65M (75 ft) of travel.
ii) Platforms with stair access shall be provided for:
a) Location at which normal monitoring (once a day or more) is required or where
samples are taken.
b) Locations where vessels or equipment items need operator attention "such as
compressors, heaters, boilers etc.
iii) Platforms with ladder access shall be provided for:
a) Points which require occasional operating access including valves, spectacle blind
and motor operated valves, heater stack sampling points.
b) Man ways above grade on equipment.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 10 OF 44

iv) Ladder location
a) Wherever practicable, ladder shall be so arranged that users face equipment or
platform rather than facing open space.
b) Landings shall be staggered. No ladder shall be more than 6 M in one flight.
5.1.3.5 Clearances
Minimum clearances shall be as indicated in Annexure.
5.2 Unit Piping
5.2.1 Basis of Unit Piping

- Piping & Instrument Diagram
- Equipment layout
- Equipment Data sheet & Setting plan
- Line list
- Instrument Data sheet
- Structural & building drawings
- Topography of the plant
- Piping material specification
- Overall plot plan
- Tie in point drawing.
The following objective shall be ascertained during piping layout.
- Proper access to all operating points including valves, and for all orifice tapping points
and instruments in particular.
- Proper access to interrelated operating points for specific purpose and for maintenance.
5.2.2 Pipe Ways/Rack piping
5.2.2.1 Racks shall be designed to give the piping shortest possible run and to provide clear head
rooms over main walkways, secondary walkways and platforms.
5.2.2.2 Predominantly process lines are to be kept at lower tier and, utility & hot process lines on
upper tier.
5.2.2.3 Generally the top tier is to' be kept for Electrical (if not provided in underground trench as per
electrical design basis) and Instrument cable trays. Cable tray laying to take care of
necessary clearances for the fire proofing of structure.
5.2.2.4 Generally the hot lines and cold lines shall be kept apart in different groups on a tier. .
5.2.2.5 Generally the bigger size lines shall be kept nearer to the column.
5.2.2.6 Minimum spacing between adjacent lines shall be decided based on O.D of bigger size
flange'(minimum rating 300# to be considered), O.D of the smaller pipe, individual insulation
thickness and additional 25 mm clearance, preferably. Wherever even if flange is not
appearing the minimum spacing shall be based on above basis only. '
5.2.2.7 Actual line spacing, especially at 'L' bend and loop locations, shall take care of thermal
expansion / thermal contraction / non expansion of adjacent line. Non expansion / thermal
contraction may stop the free expansion of the adjacent line at "L' bend location.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 11 OF 44

5.2.2.8 Anchors on the racks are to be provided on the anchor bay, if the concept of anchor bay is
adopted. Otherwise anchors shall be distributed over two to three consecutive bays.
5.2.2.9 Anchors shall be provided within unit on all hot lines leaving the unit.
5.2.2.10 Process lines crossing units (within units or from unit to main pipe way) are normally provided
with a block valve, spectacle blind and drain valve. Block valves are to be grouped and
locations of block valves in vertical run of pipe are preferred. If the block valves have to be
located in an overhead pipe way, staircase access to platform above the lines shall have to
be provided.
5.2.2.11 Provision of block valves, blinds etc. shall be as per Process Design Basis and P & IDs.
5.2.2.12 All small bore piping shall be designed in a way so as to ensure adequate space for
maintenance and operation. For small bore piping intermediate support shall be provided in
between portals.
5.2.2.13 Stubs on saline water (if applicable) service shall be from top of main header.
Minimum branch size for tapping including for instruments e.g PG/ PTI TE etc. shall be of 3"
NPD and 150 mm height on internal cement lined pipes.
5.2.2.14 Aboveground lines shall be grouped to run on pipe racks or sleepers in so far as practicable.
5.2.2.15 Hot lines on pipe racks or sleepers shall be grouped and expansion loops shall be nested
together. The number of expansion loops shall be kept to a minimum.
5.2.2.16 Piping handling corrosive fluids shall be run under piping handling non corrosive fluids, and
shall not, where possible, be run overhead across walkways or normal passages for
personnel.
5.2.2.17 All process and utility piping will be located aboveground within the plant battery limit, except
water mains.
5.2.2.18 All piping shall be arranged in horizontal banks, where possible, to facilitate supporting.
Banks running north-south shall be at different elevations from banks running east-west.
Exceptions are permitted to avoid unnecessary change in elevation at change of
direction or where essential to avoid pockets.
5.2.2.19 All piping shall be routed for the shortest possible run and have the minimum number of
fittings consistent with provision for expansion and flexibility. All piping shall be arranged in a
neat manner, providing free access around all operating equipment.
5.2.2.20 Vertical lines at vessels shall run close to the vessel shell to facilitate supporting. The line
shall be arranged and grouped to allow the use of single support.
5.2.2.21 Lines carrying molten solids, slurries or highly viscous liquids shall have a sufficient
slope for each gravity flow.
5.2.2.22 The shortest and most direct layout possible shall be provided for gravity flow lines,
especially when the fluid is subject to solidification and when the differential pressure is
small.
5.2.2.23 Piping shall be arranged to facilitate handling of equipment for inspection or
maintenance.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 12 OF 44

5.2.2.24 Vapor collecting system shall be routed so that the vapor rises continuously from the vessel
being vented to a higher point without pocketing.
5.2.2.25 Pockets shall be avoided in lines, particularly those carrying corrosive chemicals, slurries,
vents, blow down lines, etc.
5.2.3 Column / Vessel Piping Control Valves

5.2.3.1 Piping shall be supported from cleats welded on the vessel as far as possible.
5.2.3.2 Proper guides at intervals shall be provided for long vertical lines.
5.2.3.3 Access platforms/ladders shall be provided along the column for valves and instruments.
5.2.3.4 For ease of operation and maintenance, column and vessels which are grouped together,
shall have their platforms at the same elevation interconnected by walkways wherever
feasible. However each column \ vessel shall have an independent access also. Column
vessel platforms should be designed in such a way so that all the nozzles should be
approachable from platforms.
5.2.3.5 Unless specifically indicated in P&ID’s control valves shall preferably be kept at grade
instead of platform.
5.2.3.6 Piping intended for vacuum services shall be routed as short as possible, with minimum
bends and flanged joints.
5.2.3.7 Piping support cleats shall be designed for safety valves considering impact loading during
popping off.
5.2.4 Pump Piping

5.2.4.1 Pump drives shall have clear access.
5.2.4.2 Pump suction piping shall be as short as possible and shall be arranged with particular care
to avoid vapor pockets.
5.2.4.3 Reducers immediately connected to the pump suction shall be eccentric type flat side up to
avoid the accumulation of gas pocket. For end suction pumps, elbows shall not be directly
connected to the suction flange. A straight piece minimum 3 times the line size shall have to
be provided at the suction nozzle.
5.2.4.4 Pump discharge check valve if installed in vertical lines shall be fitted with a drain connection
as close as possible downstream of the valve.
When a suction vessel operates under vacuum, the vent connection of the pump has to be
permanently connected to vapour space of the suction vessel to allow possible filling of the
pump with liquid before it is started.
5.2.4.5 Unless otherwise specified T -type strainers shall be used on pump suction piping for sizes 2"
and above.
5.2.4.6 Y-type strainers to be used for all sizes in steam services and for pump suction lines 1½ and
below.
5.2.4.7 All small bore piping connected to pump (drain to OWS & CBD, seat and gland leak drain)
shall have provision for break up flanges for removal of pumps.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 13 OF 44

5.2.4.8 Piping shall be so arranged that forces and moments imposed on the pump nozzle do not
exceed the allowable values as per API 610.
5.2.4.9 Pump discharge should preferably be routed away from the pump rather than towards the
motor side.
5.2.4.10 Pump cooling water connection shall be taken from the top of circulating cooling water
header.
5.2.5 Steam Header & Supply Lines / Steam and Condensate Systems
5.2.5.1 Steam piping shall be designed to have complete condensate removal. Drip legs shall be
provided with steam traps at low points in the system.
5.2.5.2 All steam branch connections shall be taken from the top of the header.
5.2.5.3 Return exhaust steam / condensate lines shall connect to the top of the exhaust steam
Condensate header.
5.2.5.4 Where block valves have been installed in the main steam header such that condensate can
collect either side of the valve when closed, a safe means of draining the condensate prior to
opening the valve shall be provided.
- Steam header shall be located generally on the upper tier and at one end of the rack
adjacent to columns.
- Branch lines from horizontal steam header, except condensate collection points, shall
be connected to the top of the pipe header.
- Isolation valves (if provided) on the branch line shall preferably be provided on the
horizontal run and outside the pipe rack.
- All branch lines shall be drainable.
- Drip legs & steam traps shall be provided at all low points and dead ends of steam
header. Drip legs at low points shall be closer to downstream riser and shall be
provided to suit bidirectional flows, if applicable.
- All turbines on automatic control for startup shall be provided with a steam trap in the
steam inlet line.
- All traps shall be provided with strainers if integral strainers are not provided.
- Steam traps discharging to atmosphere shall be connected to storm water drain/storm
sewer, in case of open system. In case of condensate recovery, traps shall discharge
into condensate header.
- Expansion loops are to be provided to take care of the expansions within units.
- Wherever condensate is to be drained, proper condensate draining facility shall be
provided.
5.2.6. Water Piping

5.2.6.1 Water piping shall be designed to minimize the possibility of water hammer.
5.2.6.2 Water main headers may run underground to prevent freezing.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 14 OF 44

5.2.6.3 Unless local code or regulation prohibits, firewater lines shall be underground to prevent
freezing. Firewater piping system shall conform to egulations of the competent governmental
authorities.
5.2.7 Instrument Air Piping

5.2.7.1 Instrument air lines shall not be connected to process lines, service lines, and other
equipment.
5.2.7.2 Instrument air shall not be used as plant air or service air.
5.2.7.3 Branch lines form the instrument air header shall be taken from the top of the header and
shall be provided with a block valve close to the header. Also in the upstream of Instrument
manifold, Gate valve has to be provided.
5.2.8 Supports and Anchors

5.2.8 1 Supports and/or anchors shall be provided close to changes in direction of lines, branch lines
and, particularly, close to valves to prevent excessive sagging, vibration and strain.
5.2.8 2 Allowable spans between pipe supports shall be determined to keep the maximum deflection
within 16 mm.
5.2.8 3 In cases where periodic maintenance requires removal of equipment, such as pumps and
relief valves, and where lines must be dismantled for cleaning, piping shall be supported to
minimize the necessity of temporary supports.
5.2.8.4 Spring-loaded hangers may be used on piping subject to thermal expansion or
contraction. In cases where the movement is very large, or the limitation of reaction and
stress are very severe, constant support spring hangers shall be used.
5.2.8.5 Suction and discharge lines of rotating equipment shall be supported as close as possible to
equipment nozzles, and shall be relieved of excessive strains by using proper pipe supports.
5.2.8.6 Supports shall not be directly welded to pipes. Where welding is unavoidable, supports
having the same chemical composition as pipe shall be carefully welded.
5.2.8.7 All piping shall be properly supported to minimize vibration.
5.2.8.8 Outlet piping of safety and relief valves shall be supported so that the inlet piping is capable
of withstanding the reaction caused by operation of safety and relief valves. Furthermore, the
supports shall be designed to minimize the stresses due to thermal expansion and the
stresses in the valve body due to the weight of piping.
5.2.8.9 Expansion joints shall be guided and anchored to the extent necessary for their proper
operation and alignment.
5.2.8.10 Anchors shall provide sufficient fixation to substantially transmit all load effects into the
foundations.
5.2.8.11 Underground piping shall be given special anchoring consideration for differential settlement.
5.2.9 Utility Stations

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 15 OF 44

Requisite number of utility stations shall be provided throughout the unit to cater for the utility
requirement. Utility stations shall have four connections one for LP steam (SL), one for Plant
Air (AP), one for Service Water (WS) and one for nitrogen each of 1.0" with isolation valves
unless otherwise specified in P&ID.
Utility connection with nitrogen shall be provided with NRV along with isolation valve kept at a
separate location other than this cluster @ 15 M
Air and water lines shall have quick type hose connection and steam line shall have flanged
type hose connection. All connections shall be directed downward. All connections shall have
globe valve for isolation purpose. An inter connection with valve shall be provided between
steam and service water lines shall be provided. Inert gas hose, when required, shall have
built in non return valve in quick connection coupling of piping end.
Number of utility stations shall be such that all equipments shall be approachable from at
least one utility station. The approach of utility station shall be considered 15 M all around the
station location.
The Utility stations shall generally be located adjacent to pipe-rack column.
The utility stations shall also be provided on elevated structures like - technological structure,
operating platforms of vertical equipments etc.
Operating platforms having manholes must have a utility station. Utility station locations shall
be limited to a height of 35 M from H.P.P.
5.3 Offsite & Yard Piping

In general, offsite piping (except tank ages area), electrical cable and instrumentation cable
shall also be laid either on pipe rack or pipe sleepers.
Wherever piping is laid on pipe sleepers, it shall have hard surfacing below it keeping a gap
of 300 mm from the bottom of the pipes. Hard surfacing should be completed before start of
pipe laying. Width of hard surfacing shall be about 1.0 meter more than the piping corridor.
This extra hard surfacing shall be for movement of operating personnel along the piping
corridor.
Pipes at road crossing shall be under culverts in general. Overhead pipe bridges may be
used for areas where pipe racks are provided. Where culverts are not provided, pipe sleeves
shall be used for underground road crossing. Culverts / overhead pipe bridges shall be
adequately designed to take care of future requirements. Minimum 20% extra width shall be
provided in all such structures.
Clearances between lines shall be minimum "C" as given below:
C=(Do+Df)/2 + 25 mm + Insulation thickness(es) where,
Do - outside diameter of smaller pipe (mm)
Df - outside diameter of flange of bigger pipe (mm)
However this 'C' spacing between the offsite piping on the rack/sleeper can be suitably
increased so that the lines should not touch each other after insulation / lateral thermal
expansion.
Adequate clearance shall be provided for every long & high temperature lines to avoid
clashing at the bends. See 5.2.2 also for line spacing at 'L' bends and loops.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 16 OF 44

Expansion loops for all lines shall generally be kept at the same location.
Vents shall be provided on all high points & drains shall be provided at all low points. Drain
valves at sleeper piping shall be kept outside the sleeper way if the same is not accessible
and valves shall be put in horizontal only.
Places where piping is extended to make drain valves accessible - 2 nos. of stiffeners,
irrespective of pipe rating, shall be provided as per 5.13.1. Spacing of guides on each line on
a pipe bay shall not exceed the value given in clause 5.13.1
5.4 Flare Piping

Flare header shall be sloped towards flare knock-out drum. Only horizontal loop shall be
provided as per requirement to accommodate thermal expansion. The desired slope shall be
ensured throughout including flat loop. Flare header shall be supported on shoe of height
ranging from 100mm to 300mm.
Proper thermal analysis temperature shall be established including the possibility of

temperature gradient along the line before providing expansion loops. Efforts shall be made
to minimize the number of loops. Flare line between knock out drum and water seal drum
shall be designed for pressure fluctuations and adequately supported to avoid vibrations.
5.5 Underground Piping
5.5.1 Underground steel piping shall be protected from electric corrosion.
5.5.2 Underground piping passing under loaded areas, such as main roads in the plant, shall
be protected from heavy traffic by casing pipes or covers extending at least 1 m on either
side of the area or having the wall thickness sufficient to bear earth pressure.
5.5.3 Underground piping shall be sloped to all drain points with a downward slope of not less than
1 m in 150 m.
5.5.4 Expansion elbows or joints of underground piping for hot fluids, such as steam or heated
heavy oil, shall be enclosed in a conduit from which they are separated to allow free
longitudinal expansion.
5.5.5 Where it is impossible to run pipe aboveground or underground, trenches may be used.
5.5.6 Trenches for piping close to process equipment should be avoided, whenever possible.
5.5.7 All underground pipe work shall be provided with following protection:
a) At location where Underground Piping becomes above ground, INSULATING GASKET
with material Glass Filled Teflon or equivalent shall be provided.
b) CATHODIC PROTECTION (CP) shall be provided to all underground piping.
Specification shall be submitted by the CONTRACTOR & shall be approved by the
OWNER.
c) Underground piping shall be wrapped & coated by “PYP KOTE” or equivalent tapes /
sheets, 4.00 mm thick & shall be “HOLIDAY TESTED” before Hydro Test.
d) All underground pipes shall have Sand Bed, at least 150 MM all around the pipe.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 17 OF 44

e) All road crossings by Underground piping shall be through Hume Pipe Sleeves.
5.5.8 Buried Pipes

The following points to be considered in designing of buried pipes
i) All underground metallic piping shall be coated and wrapped and provided with
cathodic protection system. If sacrificial metal is used, permanent testing
arrangement shall be provided.
ii) All cooling water distribution headers 18" and higher shall be laid underground.
iii) All Sewage lines (oily and chemical) from catch basin to mains and manholes shall be
laid underground.
iv) Underground pipe crossing roads, access ways and rails shall have casing pipe
(R.C.C or C.S).
v) Valve chamber wherever required shall be made of brick or concrete. Valve chamber
should be spacious to attend valves during operation/Maintenance.
vi) All U.G. headers shall clear equipment foundations as far as possible. Under special
cases, the C.W. header may be laid over the footing of foundations.
vii) Provide break flange at + 500 MM from floor level connection with cathodic protection
to isolate underground pipe from above ground piping with insulating gasket KIT.
viii) Pipes shall be laid below electrical cables if any.
ix) Top of underground piping shall be below grade level at least 1 meter deep in case of
open areas and 1.5 meter deep for roads.
5.5.9 Piping in Trenches
The following points to be considered in designing of trench pipes
i) Piping located below grade, requiring inspection, servicing or provided with
protective heating.
ii) Fire water lines/Process lines.
iii) Drain lines requiring gravity flow trenches.
iv) Sump for valves and trenches shall be provided.
v) Suitable draining scheme for trenches shall be provided.
5.6 Air Systems

5.6.1 Branch connections shall be taken from the top of the header.
5.6.2 Low points shall be fitted with drains.
5.7 In-Line Instruments

5.7.1 Liquid level controllers and level glasses shall be located so as to be accessible from grade,
platform or permanent ladder. The level glass shall be readable from grade wherever
possible.
5.7.2 Relief valves shall be accessible. Relief valves with a centre line elevation over 4.5 M above
grade (expect in pipe racks) shall be accessible from a platform or permanent ladder.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 18 OF 44

5.7.3 Relief valves that discharge to a closed system shall be installed higher than the collection
header, with no pockets in the discharge line.
5.7.4 Relief valves that discharge to atmosphere shall have tail-pipes extended to a minimum of
3.0 M above the nearest operating platform that is within a radius of 8 M.
5.7.5 Provide steam traps at pocketed low points and at dead ends of steam headers. Provide
steam traps on excessively long runs of steam piping to ensure dry quality steam at
destination. Steam traps located more than 4.5 M above grade, except in pipe racks, shall be
accessible from a platform.
5.7.6 Control valves shall be accessible from grade or platforms. In general, the instruments or
indicators showing the process variables shall be visible from the control valve.
5.7.7 Orifice runs shall be located in the horizontal. Orifice flanges with a centre line elevation over
4.5m above grade, except in pipe racks, shall be accessible from a platform or permanent
ladder.
5.7.8 Orifice taps shall be located as follows:
i) Air, Gas and steam
Top vertical centreline (preferred)
45 degrees above horizontal centreline (alternate)
ii) Liquid
Horizontal centreline (preferred)
45 degrees below horizontal centreline (alternate)
iii) Tap orientation shall be shown on piping isometrics.
5.8 Sample Connections
Sample connections shall be accessible from grade or platforms. In general, where liquid
samples are taken in a bottle, locate the sample outlet above a drain funnel to permit free
running of the liquid before sampling.
5.9 Vents and Drains

5.9.1 The minimum size of vent and drain connections shall be as follows:
For process & utilities lines :
4” & Below NPS ¾”
6” & 10” NPS 1”
12” & above NPS 11/2”
Vent & Drain shall be provided with the valve & blind flange. For all vents / drains of process
lines / utilities lines, double valves shall be required for 600 # & more rating.
Process vents and drains shall be indicated on the P&ID’s
5.9.2 Vent, drain and sampling valves on process lines, not connected to a piping system, shall be
provided with appropriate end closures.
5.9.3 Vents shall be located at high points of pipelines when necessary.
5.9.4 Drains shall be located at low points to empty pipelines or equipment after testing or during
maintenance (i.e for every loop).

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 19 OF 44

5.9.5 All drains and vents shall be provided with valve, except that vents for test purpose for flare
liens (header), may be plugged. Exposed threads shall generally be seal welded.
Low-point hydrostatic drains and high-point hydrostatic vents shall be added as required;
locations to be determined during the design review.
5.9.6 Vent valves shall be the globe or gate type and drain valves the gate type.
5.9.7 Valved bleeds shall be provided at control valve stations, level switches, level controllers,
and gauge glasses.
5.10 Line Strainers
5.10.1 Provide temporary conical type strainers in 2” NB and above butt weld pump suction lines for
use during start-up. Arrange piping to facilitate removal.
5.10.2 Provide permanent Y-type strainers for pump suction piping below 2” NB Thd or SW.
5.10.3 Provide temporary basket type strainers located at the suction pulsation device inlet for start-
up of reciprocating compressors. Arrange piping to facilitate removal of the filter.
5.10.4 Provide temporary basket type strainers and locate them as close as possible to the
compressor inlet flange for start-up of centrifugal compressors. Arrange piping to facilitate
removal of the filter.
5.10.5 Allowable pressure drop when specified shall be certified by vendor along with the offer. If
asked specifically, vendor shall furnish pressure drop calculations
5.10.6 All 2" & higher sized Y type strainers shall be provided with 3/4" threaded, tap and solid
threaded plug as drain connection. For less than 2", this shall be ½ " size.
5.10.7 Bottom flange of Y-type strainer shall not have tapped hole. Full length standard size studs
shall be used for joining blind flange.
5.10.8 For fabricated strainers, all BW joints shall be fully radiographed and fillet welds shall be
100% DP/MP checked.
5.10.9 All the strainers shall be hydrostatically tested at twice the design pressure.
5.11 Spectacle Blinds

5.11.1 Spectacle blinds shall be provided to isolate equipment. In hazardous service flanged drop-
out spools shall be provided for safety purposes. Both shall be shown on the P&ID’s.
5.11.2 Spectacle blinds shall be accessible from grade or platforms. Blinds located in a pipe-rack
are considered to be accessible. Blinds that weigh over 40kg shall be accessible by mobile
equipment. Where this is not possible davits or hitching points shall be provided.
5.12 Flexibility Analysis and Supporting
5.12.1 Pipe Supporting Criteria & General Guidelines.

Piping system shall be properly supported taking into account the following points:
1. Load of bare pipe + fluid + insulation (if any).
2. Load of bare pipe + water fill.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 20 OF 44

3. Load of valves and online equipment and instrument.
4. Thermal loads during operation.
5. Steam-out condition, if applicable.
6. Wind loads for piping at higher elevation, e.g. transfer lines, column over head lines,
flare headers, etc.
7. Forced vibration due to pulsating flow.
8. Vibration due to two phase flow.
9. Loads due to internal pressure.
10. Any external loads/concentrated loads and cold load of springs.
Pipe supporting shall preferably follow the minimum basic span as given in Annexure-1
except for flare line in off site on trestles in which case the maximum basic span shall be
restricted to 18.0 meters, irrespective of line size.
For sizes not covered in Annexure-1, basic span shall be established based on project
requirement. For piping on rack or sleeper, as a minimum, providing resting support on every
grid of pipe rack / sleeper is mandatory. Depending on the pipe size, as a rule, guides shall
be provided on straight run of pipes at intervals as specified in Annexure-3 unless specifically
becomes non-viable due to flexibility problems.
Additional supports, guides, anchors, special supports like spring supports and sway braces
shall be provided after detailed analysis of piping system to restrict the forces experienced on
nozzles of critical items like pumps, compressors, turbines, exchangers, air fin coolers etc.
For lines which do not need any support otherwise but become unsupported by opening of
flange, etc, during maintenance and thereby may transfer the total load on a small branch off,
a permanent support shall be suitably provided which may be a spring support also. Bare
pipes of size 14" and above on elevated structures shall be supported with pad or shoe.
While bare pipes of size 6" and' above, on sleepers, corrosion pads shall be provided.
Pads shall be provided for insulated pipes before welding the shoes for sizes 8" & above.
Adequate stiffening shall be provided for the following:
a) Lines in above 600#,
b) Lines having two phase flow,
c) Lines having Pulsating flow such as discharge of reciprocating compressors &
reciprocating pumps,
For pulsating flow lines detailed thermal and vibration analysis by analog study shall be done
to decide location of anchor supports and guides etc. Pulsating flow lines shall be as
identified by licensor/owner.
Wherever two phase flow in piping is expected, piping design shall be checked by dynamic
analysis to prevent vibrations.
Pipe support design shall be such that deflection in piping systems due to sustained loads
shall not exceed 15mm, in any case, between two adjacent supports.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 21 OF 44

As far as possible long trunnion types of supports (more than 0.5 metre) are to be avoided. In
case long trunnion support is unavoidable in straight length of pipe, trunnion height to be
restricted to 0.5 M and balance height to be made up by providing extended structure.
In the heaters where steam air decoking provision is there, the main lines and decoking lines
should be supported in a way so that either of the lines should not be in the hanging position
while connected to other one. Same philosophy shall be adopted for similar type of switch
over arrangement.
Piping passing through the technology structure or passing near the concrete column etc.
should have adequate annular space to avoid restriction of line movement during thermal
expansion. The gap should take care the thermal expansion along with insulation thickness.
High density PUF blocks shall be considered for cold piping supports. Use of wood blocks
shall be avoided.
All pipes supports shall be so designed that there is no undue tension on equipment flanges.
Flange joints should not move away from each other in case of unbolting of the joint.
5.12.2 Flexibility Analysis Criteria & General Guidelines

5.12.2.1 Formal flexibility analysis by computer program of piping system shall be performed on
latest version of CAESAR-II software as per Annexure 5, 5A & 5B.
5.12.2.2 The directions of forces and moments shall be in accordance with Welding Research Council
Bulletin 107 (WRC 107), with the exception that the radial force (P) shall be away from the
vessel. All forces and moments shall be assumed to act simultaneously and apply at the
nozzle/vessel interface.
5.12.2.3 Air coolers to API 661 shall be specified with Fx forces and Mz moments increased to 1.2
times the value shown in Figure 8 of API 661 for nozzle sizes 6”NPS and larger to simplify
piping flexibility analysis and facilitate piping layout.
5.12.2.4 Piping stress analysis and equipment nozzle loading analysis shall be in accordance with
ASME B31.3 and the relevant API, ANSI/ISO and NEMA Codes.
5.12.2.5 API 610 Pumps
The allowable nozzle loads on centrifugal pumps shall meet the load criteria of API 610.
Heavy duty base plate shall be specified where the pump design temperature is in excess of
150C.
ASME or Manufacturer’s Standard Pumps
The allowable nozzle loads on horizontal centrifugal pumps design to ASME B73.1 shall be
specified by the manufacturer. For preliminary layout and analysis NEMA SM 23 criteria shall
be used for individual nozzles.
Other Horizontal Centrifugal Pumps
The allowable nozzle loads shall meet the load criteria specified by the manufacturer.
Vertical Turbine, Can-Types Pumps
The combined bending and tensional thermal stress in the piping attached to the nozzle shall
be limited to 25 percent of the allowable stress range shown in ASME B31.3. The combined
stress due to dead load and other sustained loads shall be limited to 25 percent of the
allowable hot stress.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 22 OF 44

5.12.2.6 For piping design purposes, differential settlement between items of major equipment on
separate foundations shall be taken as 10 mm.
5.12.2.7 Cold springing in piping shall not be permitted without written permission from the Owner.
Cold springing of piping directly connected to rotating equipment is not permitted under any
circumstances.
Piping shall be analyzed for expansion, contraction, differential settlement, relief, valve
reaction and effects mentioned at CI. 5.12.1.
The design of piping systems shall take into account the different conditions expected during
operation, start-up, shut-down, cold branch in case of standby pump, tracing, etc.
Hydrocarbon lines shall be designed for steam-out conditions, if specified in line schedule.
The use of expansion joints shall be considered only when space oar pressure drop
limitation does not permit pipe bends. Expansion joint of axial type shall be avoided.
Forces and moments due to weight, thermal loads and other imposed loads on the
equipment nozzle must not exceed the allowed loads for the equipment.
Minimum analysis temperature shall be the design temperature of the line as per line list.
5.12.3 Method of Analysis

Formal computer analysis shall be performed on piping systems as per design philosophy for
stress analysis
The package used shall be latest version of CEASER / AUTO PIPE / SIMPLEX / CAEPIPE.
Only one of these packages shall be used for the project & not a combination of the above
packages.
All lines shall be analyzed at design I analysis temperature. In the absence of analysis
temperature lines shall be analyzed at design temperature.
However in case of wide difference in design and operating temperature, temperature for
analysis shall be established in process documents. (e.g. flare line)
All non-critical lines may be analyzed using other methods.
Special analysis methods shall be followed for lines involving pulsating flow such as those
connected to reciprocating pumps & compressors which require acoustical plus analog study
by approved agencies and shall require entire system analysis along with piping I
equipments.
Seismic analysis shall be done for line sizes 12” and above.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 23 OF 44

5.13 Personnel Protection
5.13.1 Eyewash and emergency safety showers shall be provided in areas where operating
personnel are subject to hazardous sprays, emissions or spills.
5.13.2 Personnel protection shall be provided on un-insulated lines and equipment operating above
70 deg C when they constitute a hazard to the operators during normal operation of the
facility.
5.13.3 Leakage indicating tape and spray impingement shrouds shall be provided at flanged joints
in hazardous service.
5.14 Mechanical Handling
5.14.1 Handling facilities such as davits and monorails shall be provided on vessels over 10m in
height where the weight of removable internal and/or external equipment is greater than 35
Kg.
6.0 MATERIALS
6.1 General
6.1.1 Basic material selection of particular line depending on its service, temperature and
corrosivity shall be spelt out in process package. Material specification shall follow the
requirements as per process parameters & attached PMS / VMS.
6.1.2 Only piping materials listed in ASME B31.3 shall be used for Category ‘M’ and Normal
Service piping. Unless otherwise specified in PMS, For Category ‘D’ utility piping, where
scaling and impurities are to be avoided (such as instrument air, potable water and deluge
water) hot dipped galvanised and threaded fittings may be used in sizes up to and including
4” NB. Galvanised piping shall not be used in environments containing acids or other
corrosive commodities. In corrosive environments stainless steel piping material shall be
used for such utility systems.
6.1.2 All items/parts of Austenitic Stainless Steel shall be supplied in solution annealed condition.
For all Austenitic Stainless steels, Inter granular Corrosion' (IGC) Test shall be conducted.
6.1.3 In absence of specific requirement, Natural Rubber shall be used for lining in rubber lined
piping items, wherever applicable. The Vendor shall confirm the suitability of Rubber Material
for specified service. Unless otherwise specified, rubber lining shall be in accordance with
IS4682 Part-I.
6.1.4 Unless otherwise specified, HDPE pipes & fittings shall be in accordance to ASTM D3035/
ASTM D3261/ASTM D3350 or equivalent.
6.1.5 Specification for FRP material
6.1.5.1 Anticorrosion Barrier of Polymer veil having minimum thickness 2.5 mm shall be provided for
chemical resistance. Mechanical resistance to be sustained by FRP.
6.1.5.2 The selected nominal pipe wall thickness will include manufacturers full under tolerance, and

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 24 OF 44

the specified corrosion and/or erosion allowance. The pipe thickness will be adequate to
resist all external loads from thermal, mechanical and other sources in addition to the
process pressure-temperature requirements. However the pipe thickness will be according to
vendor’s norms and standard calculations but not be lower than indicated in DIN 16965 Part
4. External FRP layer shall be protected against ultra-violet light.
6.2 Pipe
6.2.1 Calculation of pipe thickness and branch reinforcement shall be based on requirements of
ASME B31.3. Proper corrosion allowance and mill tolerance shall be considered to achieve
the selected thickness.
6.2.2 Unless specifically exempted, welded pipes shall be acceptable only with longitudinal weld
made employing automatic welding. 100% radiography for all welds except for pipes for
category D service.
6.2.3 Double seam 180˚ apart is allowed for sizes 36" and larger only.
6.2.4 Galvanized Pipes shall be only Hot Dip galv. to ASTM A53.
6.2.5 Hydrostatic tests shall be applied to each length of pipe and be in accordance with the
requirements of ASTM A530/A530M, unless otherwise specified.
6.2.6 Check analysis shall be carried out as per ASTM-A-530 for pipes as per ASTM-A-312 and
pipe size > 8” and thickness > Sch.120, Check analysis shall also be carried out as per
supplementary requirement S1 of ASTM-A-312.
6.3 Fittings
6.3.1 Type of fittings shall be equivalent to pipe type. All fittings shall be seamless similar to pipe
specification in construction unless otherwise specified.
6.3.2 Thickness of fittings at ends to match pipe thickness for BW fittings. For reducing BW fittings
having different wall thicknesses at each end, the greater one shall be employed and the
ends shall be matched to suit respective thickness.
6.3.3 Unless and otherwise specified in the requisition all socket weld and screwed fittings shall be
in accordance with ANSI B16.11 to the extent covered in the specification except for unions
which shall be in accordance with MSS-SP-83.
6.3.4 Special fittings like Weldolet, Sockolet, Sweepolet etc. which are not covered in ANSI , MSS-
SP shall be as per Manufacturer’s Std. Contours of these fittings shall meet the requirements
of ANSI 31.3. Manufacturer shall submit drawings/catalogues of these items along with the
offer & also shall be submitted for approval before manufacturing.
6.3.5 All pipes employed for manufacturing of fittings shall be required to have undergone Hydro
test to ASTM A530 to the extent so as to produce wall stress of 75% of SMYS of the material.
6.3.6 All welded fittings shall be 100% Radio-graphed by X-Ray on all welds.
6.4 Flanges
6.4.1 All flanges shall be of forged one piece material (seamless), and plate may not be
substituted without written approval from the Purchaser.
6.4.2 All flange joints on piping system including flanges on the equipment, manholes, etc shall be
tightened using Torque wrench I hydraulic bolt tensioner depending upon service criticality.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 25 OF 44

6.5 Gaskets
Gaskets shall be as per piping material specification/ applicable standard.
6.6 Stud, Bolts, Nuts and Jack Screws

6.6.1 All bolting shall be as per ASME/ANSI 818.2.1 for Studs, M/C Bolts and Jack screws, and
ASME/ANSI B18.2.2 for nuts. Machine Bolts shall not be used in piping flange joint, except
for Butterfly Valves, which shall be lug type, having UNC Threads in lugs facilitating opening
of flanges from both sides.
6.6.2 Screw threads of bolting shall be unified coarse threads in accordance with ANSI / ASME
B1.1 having Class 2A for bolts and Class2B for nuts. Screw threads in sizel-1/8 and larger
shall be 8 threads per inch.
6.7 Valves
6.7.1 General
All flanged valves (except forged) shall have flanges integral with the valve body.
Valve Castings/Forgings purchased shall be from Local approved foundries/forging shop.
Yoke material shall be at least equal to body material.
Forgings are acceptable in place of Castings but not vice-versa.
No cast iron material valves to be used in any service.
Valves in saline water (if applicable) service shall be with non ferrous trims and all wetted
parts other than trims shall be epoxy coated.
Generic material of valves body, required as per process/service conditions but not
specifically mentioned, shall not be lower in chemical composition than the connecting pipe
material.
6.7.2 Ball/Plug/Butterfly Valves
Use of soft seated ball/plug/butterfly valves shall be suitably selected based on temperatures
handled.
Butterfly valves shall be suitable for throttling application.
As a rule, they shall be limited to water services only. Lug type Butterfly valves shall be with
threaded lugs only. Each butterfly valve shall be provided with the Bolts to be installed from
both sides separately.
PN equivalent rating for Class150# valves shall be minimum PN16.

Ball valves may be used in place of gate or plug valves with the following limitations:
i) Operating conditions are within the permissible pressure - temperature range of seat
materials.
ii) Fire safe type to be used for hydrocarbon services.
6.7.3 Valve Dimensions
Face-to-Face/End-to-End dimension shall be as per ANSI B16.10. In case the same is not
covered under B16.10, the dimension shall be as per BS 2080/manufacturer standard.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 26 OF 44

Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500 mm on
each side. Effort to operate shall not exceed 35 kgf at hand wheel periphery. However, failing
to meet the above requirement, vendor shall offer gear operation.
Quarter-turn valves shall have "open" position indicators with limit stops.
6.7.4 Non Destructive Testing of Valves

6.7.4.1 Radiography procedure, areas of casting to be radiographed, and the acceptance criteria
shall be as per ASME/ANSI B16.34.
All valve castings shall be of radiographic quality.
The minimum requirement of radiography shall be as under:
Class Size Qty
150 Up to 24” 5%
150 26” & above 100%
300 Up to 16” 10%
300 18” & above 100%
600 & above All 100%
6.7.4.2 The welds of body-to-bonnet and body-to-end flange shall be subjected to 100% NDT; both
radiographic and magnetic or liquid penetrant examinations.
6.7.4.3 Beveled ends on each butt welding end valve shall be subjected 100% magnetic particle or
liquid penetrant examination.
6.7.4.4 Each valve shall be pressure tested in accordance with API 598.
6.7.5 Criteria for Isolation Valves
Process Drain/ Pressure Level Flow Safety Control

Installation
Isolation Vent Taping Taping Element Valve Valve
150 / 300# Single Single Single Single Single Single Single
600 # Single Double Double Single Double Single Single
Above 600# Double Double Double Double Double Double Single
Note: For S/D & at battery limit, it will be as per process requirements.
6.8 Traps
Vendor shall also furnish the performance curve indicating the capacity in mass/hour at
various differential pressures across the trap.
Parts subject to wear and tear shall be suitably hardened. Traps shall have integral strainers.
All traps shall be hydrostatically tested to twice the design pressure.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 27 OF 44

6.9 Hoses
Manufacturer shall guarantee suitability of hoses for the service and working conditions
specified in the requisition, if the material is not specified in the Material Requisition for any
particular service.
All hoses shall be marked with service and working pressure at minimum two ends clearly.
Hoses shall be resistant to ageing, abrasion and suitable for outdoor installations.
Complete Hose assembly shall be tested at two times the design pressure
Steam hoses shall be subject to steam resistance test.
6.10 Expansion Joints(Metallic)
The applicable codes are ASME B31.3 and EJMA (Expansion Joint Manufacturer's
Association).
Bellows shall be formed from solution annealed sheet conforming to the latest ASTM Spec.
Any longitudinal weld shall be 100% radiographed. The finished longitudinal weld must be of
the same thickness and same surface finish as the parent material.
Circumferential welds are not permitted. Bellows are to be hydraulically or expansion
(punched) formed. Rolled formed bellows are not acceptable. Noticeable punch or die marks
resulting from expansion operation are not acceptable.
No repairs of any kind are allowed on the bellows after forming. Deep scratches and dents
are not acceptable.
The out of roundness shall be limited to ± 3mm. This is the max deviation between the max &
min diameter.
The actual circumference of the welding end shall be maintained to ± 3mm of the theoretical
circumference.
Apart from the usual requirements, the vendor shall also furnish
a) Design calculations to justify stiffness and fatigue life.
b) Axial, lateral stiffness, angular stiffness, effective pressure thrust area.
c) Installation/maintenance manual.
6.11 Supports & Spring Assemblies
The Material, Design, Manufacture and Fabrication shall be generally as per MSS-SP-58/
MSS-SP-89 and/or BS 3974.
Testing of springs shall be as per BS1726.

6.12 Non Destructive Examination
10% radiography of butt welds and 10%DP/ MP test of fillet welds shall be done for pipe
Classes in 150# & 300#.
100% radiography on butt weld joints and 100% DP/MP for fillet welds test shall be
done for

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 28 OF 44

Pipe Classes in 600# & above.
7.0 PAINTING
Painting shall be as per attachment provided elsewhere in NIT.
8.0 WELDING
Welding shall be as per ASME BPV- Sec. IX

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 29 OF 44

ANNEXURE – 1
TABLE OF BASIC SPAN
PIPE- VAPOR PIPE- LIQUID BARE PIPE BARE PIPE
INSULATION INSULATION EMPTY WATER FILLED Pipe size in.
Pipe SCH/Th
BASIC SPAN (L)M BASIC SPAN (L)M
Size k
0 0 0 0
176 C 316 C 176 C 316 C
In. (in) UPTO UPTO SPAN(L) WEIGHT SPAN(L) WEIGHT
0
TO TO 0
TO TO
175 C 0 0
175 C 0 0
M KG/M M KG/M
315 C 400 C 315 C 400 C
3/4" SCH 40 3.5 3.5 2.5 3.5 3.0 2.0 4.5 1.68 4.0 2.04 3/4"
1” SCH 40 4.5 4.0 3.0 4.5 3.5 3.0 5.0 2.52 4.5 '3.07 1"
1-
SCH 40 5.0 5.0 4.5 5.0 4.5 3.5 6.0 4.08 5.0 .5.4 1-1/2"
1/2"
2" SCH 40 5.5 5.0 4.5 5.0 4.5 3.5 8.5 5.47 5.5 7.65 2"
2-
SCH 40 6.5 6.0 5.0 6.0 5.5 4.5 7.5 8.7 6.5 11.79 2-112"
112"
3" SCH 40 7.5 6.5 5.5 6.5 6.0 5.0 8.0 11.35 6.5 16.15 3"
4" SCH 40 8.0 7.5 6.5 7.5 7.0 6.0 9.0 16.2 7.5 24.45 4"
6" SCH 40 10.0 9.5 8.5 9.0 8.0 7.5 10.5 28.3 9.0 46.7 6"
8" SCH 40 12.0 11.0 10.0 10.0 10.0 9.0 12.0 42.84 10.0 75.22 8"
10" SCH 40 13.5 13.0 12.0 11.5 10.5 10.5 14.0 60.74 11.5 111.9 10"
12" 3/8" w 14.5 13.5 13.0 12.0 11.5 11.0 15.0 74.40 12.0 147.5 12"
14" 318"w 15.0- 14.5 13.5 12.0 12.0 11.5 16.0 82.5 12.5 172.05 14"
16" 318"w 16.0 15.5 14.5 13.0 12.5 12.0 17.0 94.5 13.0 213.15 16"
18" 3/8" w 17.0 16.5 15.0 13..5 13.0 12.0 18.0 106.5 13.5 258.3 18"
20" 318" w 18.0 17.5 16.0 14.0 13.5 12.5 19.0 118.5 14.0 307.5 20"
24" 3/8"w 20.0 19.0 17.5 14.5 14.5 13.0 21.0 1425 15.0 418.2 24"
3/4" SCH 80 3.5 3.5 2.5 3.5 3.0 2.0 4..5 2.20 4.0 2.49 3/4"
1" SCH 80 4.5 4.0 3.0 4.5 3.5 3.0 5.0 3.25 4.5 3.72 1"
1-
SCH 80 5.0 5.0 4.5 5.0 4.5 4.0 6.0 5.45 5.0 6.60 1-112"
112"
2" SCH 80 6.0 5.0 4.5 5.5 5.0 4.0 6.5 7.53 6.0 9.45 2"
2-
SCH 80 6.5 6.0 5.5 6.0 6.0 5.0 7.5 11.49 6.5 14.25 2-1/2"
112"
3" SCH 80 7.5 6.5 6.0 6.5 6.5 6.0 8.0 15.37 7.0 19.66 3"
4" SCH 80 8.0 8.0 7.0 7.5 7.5 6.5 9.0 22.47 8.0 29.94 4"
6" SCH 80 10.5 10.0 9.0 9.5 9.0 8.5 10.5 42.90 9.5 59.85 6"
8" ½” w 12.0 11.5 10.5 10.5 10.0 10.0 12.0 65.10 11.0 94.8 8"
10" ½” w 13.5 13.0 12.0 11.5 11.5 10.5 14.0 82.20 12.0 130.69 10"
12" ½” w 14.5 13.5 ./, 3.0 12.5 12.0 11.5 15.0 98.13 13.0 168.64 12"
14" ½” w 15.0 14.5 13.5 13.0 12.5 12.0 16.0 108.15 13.5 194.4 14"
16" ½” w 16.0 15.5 15.0 13.5 13.0 13.0 17.0 124.2 14.0 240.0 16"

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 30 OF 44

PIPE- VAPOR PIPE- LIQUID BARE PIPE BARE PIPE
INSULATION INSULATION EMPTY WATER FILLED Pipe size in.
Pipe SCH/Th
BASIC SPAN (L)M BASIC SPAN (L)M
Size k
0 0 0 0
176 C 316 C 176 C 316 C
In. (in) UPTO UPTO SPAN(L) WEIGHT SPAN(L) WEIGHT
0
TO TO 0
TO TO
175 C 0 0
175 C 0 0
M KG/M M KG/M
315 C 400 C 315 C 400 C
18" ½” w 17.5 17.0 .16.0 14.5 14.0 13.5 18.0 140.25 14.5 286.64 18"
½” w ..:.17.
20" 18.0 17.5 15.0 14.5 14.0 19.0. 157.5 15.0 341.8 20"
0.
24" ½” w 20.0 19.0 . 18.5 16.0 15.0 15.0 21.0 188.25 16.0 458.44 24"
1" 10S 4.0 3.5 3.0 4.0 3.0 2.5 4.5 2.08 4.0 2.7 1"
1- 10S
5.0 4.5 3.5 4.5 4.0 3.0 5.5 3.12 5.0 4.57 1-112"
112"
2" 10S 5.0 4.5 3.5 4.5 4.0 3.0 6.0 3.94 5.5 6.33 2"
2- 10S
6.5 5.5 4.5 5.5 5.0 4.5 7.0 5.26 6.0 8.85 2-1/2"
112"
3" 10S 7.0 6.0 5.0 6.0 5.5 5.0 7.5 6.45 6.0 11.91 3"
4" 10S 7.5 7.0 6.0 6.p 6.0 6.0 8.0 8.34 7.0 17.87 4"
6" 10S 9.5 9.0 8.0 8.0 7.5 7.5 10.0 13.82 8.5 34.54 6"
8” 10S 11.0 10.5 10.0 9.5 9.5 8.5 11.5 19.94 10.0 55.5 8"
10" 10S 12.5 12.0 11.0 10.5 10.0 9.5 13.0 27.S3 11.0 83.4 10"
12" 10S 14.0 13.0 12.0 11.0 11.0 10.0 14.5 36.00 11.5 114.6 12"
14" 105 14.5 14.0 13.0 11.5 11.0 11.0 15.5 41.18 11.5 132.6 14"
16" 10S 16.5 14.5 14.0 12.0 11.5 11.5 16.5 47.33 12.5 172.2 16"
IS" 10 S 16.5 15.5 14.5 12.5 12.5 11.5 17.5 53.18 13.0 212.1 18"
20" 10 S 17.5 16.5 15.5 13.0 13.0 12.0 18.5 68.50 13.0 264.5
20"
24” 10 S 19.0 18.0 17.0 14.0 13.5 12.5 20.5 94.37 14.0 376.8 24”

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 31 OF 44

ANNEXURE – 2
ACCESSIBILITY FOR VALVES AND INSTRUMENTS
VALVES, INSTRUMENTS, CENTRELINE OF ITEM TO BE CENTRELINE OF ITEM TO BE

EQUIPMENT TO BE OPERATED OPERATED, LOCATED LESS THAN OPERATED, LOCATED MORE
3.6m ABOVE GRADE, 2.75 m ABOVE THAN 3.6m ABOVE GRADE,
FLOOR OR PLATFORM OR 1.8m 2.75m ABOVE FLOOR OR
ABOVE WING PLATFORM PLATFORM OR 1.8m ABOVE
WING PLATFORM
EXCHANGER HEADS NIL PLATFORM
OPER.VALVES 2" & SMALLER FIXED LADDER FIXED LADDER
OPER. VALVES 3" & ABOVE PLATFORM PLATFORM

MOTOR OPERATED VALVES PLATFORM PLATFORM
CONTROL VALVES PLATFORM PLATFORM
RELIEF VALVES 2" & SMALLER FIXED LADDER FIXED LADDER
RELIEF VALVES 3" & ABOVE PLATFORM PLATFORM
BLOCK VALVES 2" & SMALLER PORTABLE LADDER PLATFORM
BLOCK VALVES 3" & ABOVE PLATFORM (NOTE-1) PLATFORM (NOTE-1 )
BATTERY LIMIT VALVES PLATFORM PLATFORM
PRESSURE INSTRUMENT FIXED LADDER IF ABOVE 2.2m FIXED LADDER
HEIGHT
TEMPERATURE INSTRUMENT FIXED LADDER IF ABOVE 2.2 M Ht FIXED LADDER
SAMPLE POINTS PLATFORM PLATFORM
GAUGE GLASSES FIXED LADDER FIXED LADDER
LEVEL CONTROLLERS PLATFORM PLATFORM
PROCESS BLINDS AND SPACERS PORTABLE LADDER I PLATFORM PLATFORM
2" & SMALLER
PROCESS BLINDS AND PLATFORM PLATFORM
SPACERS 3" & ABOVE
MANWAYS/MANHOLES PLATFORM PLATFORM
HANDHOLES/INSPECTION HOLES PLATFORM PLATFORM
NOZZLES (process} PLATFORM PLATFORM

VESSEL VENTS PORTABLE LADDER FIXED LADDER
LINE DRAINS & VENTS PORTABLE LADDER PORTABLE LADDER

ORIFICE FLANGES PLATFORM (NOTE-1) PLATFORM (NOTE-1)
NOTE -1:-BLOCK VALVES / ORIFICE FLANGES, IF LOCATED, WITH CENTRE LINES GREATER
THAN 2 METER FROM THE OPERATING FLOOR / OPERATING PLATFORM, SHALL BE
PROVIDED WITH PORTABLE PLATFORM OR CHAIN FOR OPERATION.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 32 OF 44

NOTE -2 : PLATFORM SHALL BE PROVIDED FOR THE ORIFICE FLANGES ON PIPE RACK.
ANNEXURE-3
MAXIMUM SPACING OF GUIDES FOR VERTICAL & HORIZONTAL PIPES
NOM PIPE SIZE VERTICALSPACING HORIZONTAL SPACING

IN INCHES METRES METRES
1 6.0 6.0
1½ 6.0 6.0
2 6.0 6.0
3 8.0 12.0
4 8.0 12.0
6 8.0 12.0
8 8.0 12.0
10 12.0 18.0
12 12.0 18.0
14 12.0 18.0
16 12.0 18.0
18 12.0 18.0
20 16.0 18.0
24 16.0 18.0
26 & ABOVE 16.0 18.0
NOTES:-
1. These spacings may be varied to suit column spacing of rack. The above spacing is for straight
runs of pipe & does not include guides which are used for control of thermal movements, as
decided by stress group.
2. The guide spacings given in the above table are indicative only.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 33 OF 44

ANNEXURE – 4
CLEARANCES
Minimum clearances for piping, equipment, structures, platforms, and supports shall be in accordance
with the following table:
Item Description
Headroom for primary access roads wherever heavy duty

Roads 9M
crane movement is required.
Headroom for primary access roads 7.5 M
Width of primary access roads excluding shoulders. Refer Civil
Headroom for secondary roads 5M
Width of secondary roads excluding shoulders. Refer Civil
Clearance from edge of road shoulders to platforms,

equipment, pipe associated with equipment, or similar 1.5 M**
features.
Maintenance Aisles at Horizontal clearances for equipment maintenance by
3M
Grade hydraulic crane (12t capacity)
Vertical clearance for equipment maintenance by hydraulic
3.6 M
crane (12t capacity)
Horizontal clearance for fork lift and similar equipment (2500
2.4 M
kgs capacity)
Vertical clearance for fork lift and similar equipment (2500
2.4 M
kgs capacity)
Horizontal clearances for equipment maintenance by
portable manual equipment (A-frames, hand trucks, dollies 1 M
or similar equipment)
Vertical clearances for equipment maintenance by portable
manual equipment (A-frames, hand trucks, dollies or similar 2.4 M
equipment)
Walkways Horizontal clearance (not necessarily in a straight line) 750 mm
Headroom (except for hand wheels) 2.2 M
Platforms Minimum width 1200mm

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 34 OF 44

Item Description
Headroom from stairwell treads. 2.2 M
Minimum clearance around any obstruction on the platform. 500 mm
Platforms Headroom 2.2 M
Maximum vertical distance between platforms 6M
Minimum toe clearance behind a ladder. 210 mm
Minimum handrail clearance. 100 mm
Minimum maintenance space required between flanges of

Equipment 500 mm
exchangers or other equipment arranged in pairs.
Minimum maintenance space required for structural
300 mm
members or pipe.
Clearance from edge of road shoulder (the extreme
1.5 M
projection)
Horizontal clearance from hydrocarbon equipment (shell to
Fired Equipment 15 M
shell)
Exception: Reactors or equipment in alloy systems shall be
located for the most economical piping arrangement.
Clearance from edge of road to heater shell. 3M
Clearance between the outside of the hand wheel and any

Valve Hand wheels 25 mm*
obstruction.
Clearance between the outside diameter of the flange and
Pipe (aboveground) 25 mm*
the outside diameter of pipe insulation.
Clearance between the outside diameter of the pipe, flange
50 mm*
or insulation and a structural member.
Clearance between the outside diameter of the flange and
25 mm*
the outside diameter of bare pipe.
Minimum distance from underside of pipe to grade or
300 mm
platform.
Control Valve Arrangement Centreline of control valve above grade or platform. 450 mm
Minimum centreline of control valve from face of column or 600 mm

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 35 OF 44

Item Description
wall.
Where process conditions require steam or hydrocarbon

vapours to be discharged to atmosphere at a safe location,
the tail pipe shall terminate as below:
Distance above nearest operating platform. 3M
Within radius of nearest operating platform. 7.5 M
** Verify conformance with local regulations.

* With full consideration of thermal movements

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 36 OF 44

ANNEXURE – 5
DESIGN PHILOSOPHY FOR STRESS ANALYSIS
1.0 PURPOSE
This design basis deals with the subject of Identification of Stress Critical pipelines and
preparation of Critical line list. This procedure also defines the minimum requirements for
performing stress analysis, design and location of spring, support and level of system
Analysis with the extent of documentation required for flexibility analysis.
Purpose of piping stress analysis is to ensure:
Safety of piping and piping components
Safety of connected equipment and supporting structure
Piping deflections are within the limits

2.0 SCOPE
This specification covers the supply of engineering services to perform a complete piping and
pipe support analysis for piping systems.
3.0 DEFINITIONS
3.1 Critical Lines / Critical Line List
Critical lines or Critical Line List as referred to in this procedure relates to Piping Stress Critical
Lines and does not include or refer to process critical lines.
3.2 Stress Analysis Temperature
Stress Analysis Temperature refers to either “Maximum Operating Temperature” or “Steam-out
temperature / hot nitrogen purging temperature” of the lines under review whichever is higher.
In absence of the above values, it refers to the Design Temperature of the line under review.
The Line List should be strictly followed in obtaining the above temperature values.
3.3 Design Pressure
Design Pressure refers to the “Design Pressure” of the line under review as indicated on the
Line List. Design Pressure is as defined in clause 301.2 of ASME B 31.3.
3.4 Temperature For Flexibility Analysis
The temperature to be used for the flexibility analysis shall be taken as the maximum /
minimum temperature which the pipe will see under any combination of different normal /
abnormal operating conditions, as defined in clause 301.3 of ASME B 31.3. Where piping is
exposed to direct sunlight, solar radiation temperature of 70 0C is considered in establishing the
maximum temperature of piping. Even, for non-critical piping exposed to direct sunlight on pipe
rack or elsewhere, expansion loops, wherever essential, are provided to take care of pipe
movements resulting from piping skin temperature due to solar radiation.
In general, unless there is a difference of more than 50 0C between working Temperature and
the design temperature, the design temperature should be taken as Flexibility temperature.
Ambient Temperature shall be considered as 21ºC the assumed piping installation
temperature. The displacement stress range from this installation temperature to the minimum
recorded ambient temperature of 00 C being less than the same from installation temperature
to the maximum operating temperature of hot piping in most cases, the later governs as per
clause 319.2.3 of ASME B 31.3

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 37 OF 44

The temperature under fire condition is normally not considered for flexibility analysis.
4.0 SELECTION
A line is selected and listed as a Critical Line provided it falls under any one of the categories
defined below and is intended to include the special requirements of Piping Stress Engineer. It
is hence defined as any line for which a flexibility review is required or where pipe supporting is
deemed to be critical and needs review by a Stress Engineer. Line DN 50 and smaller is
inherently flexible and is not normally considered critical unless built from non-metallic or non-
ferrous materials. In case of more than one applicable line size, larger line size governs. Lines
are classified as Level I, Level II & Level III according to the criteria listed below.
4.1 Level I [Extensive Analysis]
Piping systems or lines that meet Annexure 5A criteria are deemed to be extremely critical.
These lines are categorized as Level I and require careful study to ensure that the code
compliance is met and the accurate determination of nozzle and support loads have been
made. The routing of these lines is very important. They must be analyzed in the early stages
of the project during routing studies so that the impact on the location of less critical lines is
minimized. Normally, these systems require computer analysis. The general intent of the Level
I analysis criteria is to study lines size DN 80 & larger that are affected by thermal expansion
and / or a dynamic response, and that can’t be evaluated by a weight-only analysis (as per the
general intent of Level II analysis). Consideration has to be given to other special situations
that augment the Level I general intent guidelines such as for lines that are excessively large
and stiff.
4.2 Level II [Normal Analysis]
Piping systems or lines that meet Annexure 5B criteria are moderately critical lines and often
do not require such rigorous study to ensure code compliance or accurate determination of
nozzle and support loads. These lines are smaller in size and operate at lower temperatures (in
general) than the lines to be analyzed using Level I Criteria. Normally, only manual
calculations, by use of appropriate monographs are required for analysis of these systems.
4.3 Level III [Minimum Analysis]
All lines that are outside the purview of Level I or Level II criteria will be classified as level III
and shall be reviewed by the Piping Engineer during the squad check of the piping drawings
and or fabrication Iso’s. If more detailed analysis is required, the Piping Engineer may change
the level of analysis during the squad check as applicable. Normally, only visual analysis is
required for these systems.
4.4 Lines Deemed To Be Support Critical
Lines subjected to two-phase flow.
Cross country pipelines.
Lines with pipe thickness Sch 160 or greater.
Lines DN 400 and above with pipe thickness less than 8 mm.
Lines DN 250 and above with corrosion allowance 3 mm and above.
Lines with high concentrated loads such as heavy valves or fittings etc.
Lines downstream of Relief Valve / letdown Control Valves / bursting (rupture) discs.
Connecting to vent or flare systems or discharging to atmosphere
Liquid Blow down Lines.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 38 OF 44

Lined pipes
Non-metallic pipes
4.5 Lines Needing Dynamic Analysis
There are instances where in the frequency of the applied load is comparable to the natural
frequency of the piping system. Such systems tend to store the energy and release it according
to certain scientific laws. Such a system is dynamic in nature and the study of the response of
such a system is referred to as “Dynamic Analysis”. Examples of such kind of systems are
Relief Valve discharge lines, water hammer and surge in pipe lines, two phase flow in
pipelines, reciprocating pumps and compressor piping, submarine piping etc.
4.6 Special Piping
Special piping forming part of reformer tubes, heater internal piping, etc. are treated as
proprietary piping and nozzle loading at the Interface connections are to be co-ordinate with
vendor.
5.0 RELATED DOCUMENTATION
5.1 Critical Line List Format.
The critical line list shall be prepared from the project line list document by inserting following
relevant fields such as Stress level, stress package no., stress analysis temperature, support
critical nature of the line, dynamic loadings, steam out / purge temperature etc.
The list shall reflect analysis status of line that includes its input received date from design &
output handover date to design and specific remark if any.
5.2 Lines Affecting the Flexibility of Critical Lines
Non-critical Lines found to affect the flexibility of critical lines which have not been included
during the initial review are subsequently added to the Critical Line List.
Non-critical Lines on which advice may be sought by the Lead Piping Engineer are not
normally entered into the Critical Line List but covered verbally, or by a memorandum if a
record is required.
6.0 PIPE STRESS ANALYSIS AND SUPPORTING
6.1 Piping system shall be properly supported taking in to account of the following points:
Piping stress analysis shall follow ASME B 31.3 and shall be complete to prevent overstressing
of the pipe during operating conditions with wind and seismic loadings. During sustained,
occasional (wind and seismic) & thermal expansion loading on piping,
The material allowable stresses shall be as per ASME B 31.3 for ASTM materials. For DIN
material specifications the allowable stress values shall be calculated as per ASME
B 31.3 clause 302.3.2(d), wherein yield strength and ultimate strength values at temperature
shall be taken from DIN material standards. For DIN material specifications, the other material
properties viz. elastic modulus, density, coefficient of thermal expansion shall be taken from the
respective DIN material standards.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 39 OF 44

6.2 Analysis shall include, but not be limited to the following; thermal, dead weight, internal
pressure, wind and seismic, and a combination of these based on ASME B 31.3.
6.3 Piping shall be designed in accordance with the Indian Standard criteria for earthquake
resistance design for structures IS: 1893 for seismic zone-IV (refer project design basis). As a
minimum, two (2) orthogonal horizontal components and a vertical component of ground
motion will be considered in the seismic analysis. For American standard, loading applied to
piping would be in accordance with uniform building code (UBC).
The equivalent horizontal static force method shall apply in general .The contractor shall also
carry out special designs and provisions as necessary for piping which is considered to be
dynamically sensitive to earthquake.
Seismic analysis to be performed for lines equal to and above 12”.Seismic load case shall
ALGEBRIC combination with operating cases.
Heavy rigid masses like valves shall be restrained in their vicinity to avoid large seismic
movements. Guides or snubbers as the case may be used for this purpose.
Horizontal seismic coefficient (Ah) to be considered as 0.26 and Vertical (Av) to be considered
as 0.173.
6.4 Wind loads shall be calculated in accordance with IS-875 code of practice for structural safety
of building – Loading Standards for Indian code requirement using basic wind speed as
mentioned in project design basis. For American standard, wind load in accordance to ASCE
07 shall be calculated. Reduction in velocity pressure due to apparent shielding afforded by
buildings and structure or terrain shall not be permitted.
Wind loading shall only be considered for lines larger than 20” OD at elevation higher than 10m
above grade. Displacements due to wind and earthquake should be limited to 50 mm.
Both the horizontal directions shall be analyzed independently in two cases
+X, -X, +Z, -Z
Wind and seismic loading will not occur simultaneously.
6.5 Analysis of all nozzles loading on vessels within the piping boundaries is covered in this
specification. Nozzle analysis shall follow the guidelines of ASME Section VIII, Division 1, and
WRC 297 & 107 (latest editions). Nozzle stresses shall fall within the allowable per ASME.
6.6 Piping system shall have sufficient flexibility to avoid leakage at joints. Flanged joints imposed
by external moments may be analyzed and the stresses evaluated by using the methods of
equivalent pressure given in the ASME boiler and pressure code section III. Flange leakage
shall be assessed as per “Pressure Equivalent Method”. In case of Failure in Pressure
Equivalent Method, the Flanges shall be checked for leakage using Caesar Flange leakage

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 40 OF 44

Module. Flange leakage shall be assessed for all PSV flanges, Control valve flanges, High
Pressure lines, and all steam lines. Also for equipment flanges where loads are high.
6.7 All forces on connections to equipment shall not exceed maximum allowable as specified by
equipment vendor.
6.8 Pipe supports loads shall be based on the maximum loads determined by the piping analysis.
Adjustments shall be made to the piping system and model such that the pipe supports loads
are within a reasonable uniformity throughout the piping system.
6.9 Various Load cases built in Caesar II to check stress in piping system are listed below.
1 WW+HP HYD
2 W+T1+P1 OPE
3 W+T2+P1 OPE
4 W+T1+P1+U1 OPE
5 W+T1+P1+U2 OPE
6 W+T1+P1+U3 OPE
7 W+T1+P1-U1 OPE
8 W+T1+P1-U2 OPE
9 W+T1+P1-U3 OPE
10 W+T1+P1+WIN1 OPE
11 W+T1+P1+WIN2 OPE
12 W+P1 SUS
13 W+P2 SUS
14 L2-L12 EXP
15 L3-L12 EXP
16 L4-L2 OCC
17 L5-L2 OCC
18 L6-L2 OCC
19 L7-L2 OCC
20 L8-L2 OCC
21 L9-L2 OCC
22 L10-L2 OCC
23 L11-L2 OCC
24 L12+L16 OCC
25 L12+L17 OCC
26 L12+L18 OCC
27 L12+L19 OCC
28 L12+L20 OCC
29 L12+21 OCC
30 L12+L22 OCC
31 L12+L23 OCC
P1- Maximum Operating Pressure W- Dead Weight

T1- Maximum Operating Temperature WW- Water Weight

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 41 OF 44

P2- Design Pressure WIN- Wind Load
T2- Design Temperature U- Uniform Load
HP- Hydro test Pressure L2- Load case
SUS, EXP, OCC, HYD, OPE- Various load types, viz., sustained, occasional, hydro test,
operating etc.
7.0 CODES AND STANDARDS
The following codes and standards shall apply in the design and analysis of the piping systems
covered under this specification:
Allowable Stress ASME B 31.3
Piping ASME B 31.3
Nozzle Loadings PMC’s Standard, WRC297/107(Welding Research Council) /
Allowable Vendor
Wind Analysis ASCE 7 – 98
8.0 SOFTWARE USED
The package used shall be latest version of CEASER-II 5.2. Only one of these packages shall
be used for the project & not a combination of the above packages.
9.0 DOCUMENT REQUIREMENT
9.1 A written report shall be submitted on the piping and equipment analysis. The report shall
include all pertinent information that shall include but not be limited to the following.
Location and type of pipe supports with loads and movements.
Location of expansion joints and movements.
Vertical and horizontal loads including moments at all support points.
Vertical and horizontal loads including moments on all equipment and
Vessel connections.
Caesar II analysis report, which shall include as a minimum, restraint forces, movements and
stresses for all load cases. For flange connection, loaded with high bending moments and/or
tensile forces in piping or at equipment connections, Caesar II flange leakage report will be
provided. For piping analyzed, if subjected to hydro test, hydro test load case will be made in
Caesar II to check for loading under hydro test & the requirement of any additional temporary
supports for hydro test.
Detailed nodal model used for the stress analysis
All assumptions and limitations applied to the analysis
9.2 All dimensions and analysis shall be performed using metric and SI units.
9.3 The final report / stress package folder shall be submitted as follows:
1. Front sheet with Approval status
2. Isometrics with following information
- Node numbers
- Type of supports selected by stress engineer

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 42 OF 44

- Springs / Bellows data required for procurement like spring rate, loads, tide/untied
information and SM (special material) identification.
- Maximum Expansion and sustain stress values with node number
- Nozzle/Anchors initial movements and piping imposed forces and moments on the
same
- Support loads (anchors, guides or rest) only they are above limit (The limit is defined in
the beginning of the project in consultation with civil)
- Design and maximum operating conditions
- Coordinate axis system considered for inputs
- Dimensional details for piping designer to locate supports in piping model/layout.
3. Checklist as per Work instructions.
4. Following outputs
- Load Cases
- Restraint summary
- Spring hanger report, if any
5. Stress critical line list extract for the lines analysed
6. Piping material specifications
7. Equipment drawings with allowable loads, if available
8. PID

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 43 OF 44

ANNEXURE-5A
CRITERIA FOR IDENTIFING EXTREMELY CRITICAL LINES (LEVEL I)
Temperature T, Pipe Diameter Piping Service and Description

Degree C DN (mm) Material
All All All Piping which will undergo hydraulic
shock, auto-ignition or is in service.
All DN≥80 All Category M (Lethal) fluid service per
ASME B31.3 (No cyclic service).
All DN≥80 All Piping which is openly exposed to
winds> 75 mph.
T<-29 DN≥80 Carbon Steel All Services.
T<-45 DN≥80 All All Services
T≥65 DN≥80 Non-Metallic All Services
T≥65 DN≥80 All Lines with pressure≥900 psig.
T≥150 DN≥80 All All Services
ALL DN≥400 All All Services.
T≥260 ALL ALL ALL Services.
-29≥T≥65 OR DN≥80 All Piping connected to nozzle load
-7≥T≥50 DN≥100 sensitive equipment, air-cooled
exchangers and rotating equipment
(see note 1).
ALL ALL All Lines requiring expansion joints or
flexible connectors.
DELTA T≥27 DN≥80 All Jacketed piping.
(NOTE 2)
-29≥T≥65 DN≥100 All Internally lined pipe (except glass).
All ALL All Glass lined piping.
All DN≥80 All Differential Tank Settlement (Upto 3
supports from nozzle).
-40≥T≥80 DN≥100 Metallic Underground Piping
-29≥T≥70 DN≥200 Metallic
NOTES:
1) Load sensitive equipment include fired heaters, reformers, lined vessels with lining of brittle
material, non-ferrous equipments, graphite heat exchangers, plate & frame heat exchangers, etc.
2) This criterion is not to be applied to auxiliary piping such as seal flush; bearing cooling, etc. delta
T refers to the differential temperature between the process piping and jacket.

PC150/E/4004/SEC-VI-5.2.3
0
SHEET 44 OF 44

ANNEXURE-5B
CRITERIA FOR IDENTIFING MODERATELY CRITICAL LINES (LEVEL II)
Temperature T, Pipe Diameter Piping Service and Description

Degree C DN (mm) Material
All DN<80 All Lethal fluid service.
T<-29 DN<80 Carbon Steel All Services.
T<-46 DN<80 All All Services
95<T<150 80<DN<200 All All Services
T≥65 DN<80 Non-Metallic All Services
T≥65 DN<80 All All Services
T≥65 DN<80 All Lines with pressure≥900 psig.
T≥150 DN<80 All All Services
ALL 200<DN<400 All All Services.
T≥260 ALL ALL ALL Services.
ALL ALL ALL Piping connected to nozzle load
sensitive equipment, air-cooled
exchangers and rotating equipment
(see note 1 of Table-1).
DELTA≥27(NOTE DN<80 All Jacketed piping.
2 of Table-1)
All ALL All Internally lined pipe (except glass).
All DN<80 All Differential Tank Settlement (Upto 3
supports from nozzle).
All ALL All Underground Piping
All ALL All Piping connected to pressure relief
All ALL All Close coupled interconnecting piping
between equipment with differential
movement greater than 6.0mm.

TFL-PDS-600 0
PIPING MATERIAL SPECIFICATION

AMMONIA UREA COAL BASED FERTILIZER PROJECT.
TALCHER FERTILIZER LTD., ODISHA.
0 09.03.2020 09.03.2020 ISSUED VINEETA NS/RK GL/HOD

REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD
TFL-PDS-600 0
CONTENTS
• Service Index
• Piping Element Data Sheets
• Branch Tables
• Valve Data Sheets
• Strainer Data sheets
• Other Standards
Service Index (SI) TFL-PDS-600 0
of
DOCUMENT NO. REV. NO.
Piping Material Classes
CORROSION ALLOW.
SL.NO. PMC SERVICE RATING, FACE BASIC MATERIAL REV. NO.
(MIN.)
1 B20 CW (UG) CLASS 150, RF CS 1.5MM 0
2 B22G DW , AIR CLASS 150, RF CS (GALV) 1.5MM 0
3 B22IS CONST.W , RW CLASS 150, FF CS 1.5 MM 0
BF, CW, ES, FG, FN, NG, PN, PV, SA, SW, VS,
4 B24 CLASS 150, RF CS 1.5 MM 0
PA,TC, LIME SOL.
5 B24D WASTE EFFLUENT,HCL CLASS 150, FF HDPE 0.0 MM 0
6 B24S SL,SC (IBR) CLASS 150, RF CS 1.5 MM 0
7 B24FL EFFLUENT,ACIDIC H2O ETC. CLASS 150, FF CS FRP LINED 1.5 MM 0
8 B24P ETP,STRONG CAUSTIC ACID CLASS 150, FF, CPVC 1.5 MM 0
EFFLUENT, WASTE H2O, CHLORINATED

9 B24RL CLASS 150, FF CSRL 1.5 MM 0
H2O,DILUTE CAUSTIC ACID
10 B50 AF, AW, CD, DM, HZ, IA, MDA, PC, PH, VS CLASS 150, RF 304 SS 0.0 MM 0
11 B52 UL, RO PREMEABLE CLASS 150, RF 316 SS 0.0 MM 0
12 D24 AG,AL,AW,FG,FN,HG,IAH,IAW, PA CLASS 300, RF CS 1.5 MM 0
13 D50 AF, AW, CD, DM, HZ, IA, MDA, PC, PH, VS CLASS 300, RF 304 SS 0.0 MM 0
14 F24 AW,HG,NG,PA,PC CLASS 600, RF CS 1.5 MM 0
Abbrev. Service Abbrev. Service

CW Cooling water AG Ammonia Gaseous
BF Boiler feed water AL Ammonia Liquid
ES Exhaust steam IAH Instrument air(High pressure)
FG Fuel gas IAW Instrument air(Wet)
NG Natural gas HG Hydrogen Gas
PV Vent gas TC Turbine Condensate
SA service air
SW Service water
SC Steam condensate
SL LP Steam
AF Antifoam solution
CD CO2/Steam mixture
DM DM water
HZ Hydrazine
IA Instrument air
PC Process condensate
AW Ammonia water
PA Process Air
PIPING MATERIAL SPECIFICATION CLIENT : M/S..TFL Project .:TFL
PROJECT : AMMONIA/UREA COAL BASED FERTILIZER PROJECT. DOC. No.TFL-PDS-600
LOCATION : TALCHER ,ODISHA.
Rev.:0.
Class: B20 PROJECTS AND DEVELOPMENT INDIA LIMITED
SERVICE TEMPERATURE LIMITS (Deg.C) INSPECTION CLASS
CW(UG)
Ref.SI Ref.SI
RATING ASME CORROSION ALLOWANCE MATERIAL VALVE TRIM STRESS RELIEF

150# RF 1.5 MM(MIN.) CS
ITEM NOTES SIZE (NPS) SCH/ RAT END DESCRIPTION COMM CODE SPCL REV
PIPE
PIPE 2 - 6 SCH 40 BE SMLS,API 5L GR.B,C&W,ASME B36.10, PPX111300
PIPE 40 - 42 10.00 MM BE ERW,IS 3589 GR.FE410 C&W.,ASME B36.10, PP6511300
PIPE 8 - 10 SCH 10 BE ERW,API 5L GR.B,C&W,ASME B36.10, PPX411300
PIPE 1/2 - 3/4 SCH 80 PE SMLS,API 5L GR.B,C&W,ASME B36.10, PPX121300
PIPE 1 - 11/4 SCH 80 PE SMLS,API 5L GR.B,C&W,ASME B36.10, PPX121300
PIPE 11/2 - 11/2 SCH 80 PE SMLS,API 5L GR.B,C&W,ASME B36.10, PPX121300
FLANGE
FLANGE 1/2 - 24 150# SO-RF 125 AARH CS ASTM A105,ASME B16.5,SLIP ON FL0260801
FLANGE 26 - 72 150# SO-FF IS2062 GR.B,AWWA C207-D,RING TYPE,SLIP ON FLA452701
SPACER AND BLIND 14 - 24 150# RF 125 AARH CS ASTM A105,ASME B16.48, RS022PO01
SPECL BLIND 1/2 - 12 150# RF 125 AARH CS ASTM A105,ASME B16.48, SP022PO01
BLIND FLANGE
BLIND FLANGE 1/2 - 24 150# RF 125 AARH CS ASTM A105,ASME B16.5, BF0220801
BLIND FLANGE 26 - 72 150# FF IS2062 GR.B,AWWA C207-D, BFA412701
GASKET
GASKET 1/2 - 24 150# SPRL-WND RF TP304 SS WDG;GPH FLR;TP304 SS INR RNG;CS OTR RNG,ASME B16.20, GSQN30301
GASKET 26 - 72 150# 3.0 MM THK FF GSKT FLAT RNG,GARLOCK 3000(SYN FBR W/NBR BDR),ASME GSTO8QS01
B16.21/AWWA C207-D,RING TYPE
STUD & NUTS

STUD & 2NUTS HVY - ASTM A193 GR.B7/ASTM A194 GR.2H,, SNDE00000
HEX
FITTING (BW)
BRANCH WELD 2 - 48 BW CARBON STEEL,ASME B31.3, RWOJ11200
BRANCH WELD WITH 2 - 48 BW CARBON STEEL,ASME B31.3, WBOJ11200

RP
CAP 2 - 24 BW ASTM A234 WPB-SMLS,ASME B16.9, CP7310900
ELBOW 8 - 24 BW ASTM A234 WPB-WLDD,ASME B16.9, ELOY10900
ELBOW 2 - 6 BW ASTM A234 WPB-SMLS,ASME B16.9, EL7310900
ELBOW 26 - 48 BW IS2062 GR.B,ASME B16.9, ELA410900
REDUCER CONC. 2 - 6 BW ASTM A234 WPB-SMLS,ASME B16.9, RC7310900
REDUCER CONC. 8 - 24 BW ASTM A234 WPB-WLDD,ASME B16.9, RCOY10900
REDUCER CONC. 26 - 48 BW IS2062 GR.B,ASME B16.9, RCA410900
REDUCER ECC. 2 - 6 BW ASTM A234 WPB-SMLS,ASME B16.9, RE7310900
REDUCER ECC. 8 - 24 BW ASTM A234 WPB-WLDD,ASME B16.9, REOY10900
REDUCER ECC. 26 - 48 BW IS2062 GR.B,ASME B16.9, REA410900

Rev.:0.
CW(UG)
Ref.SI Ref.SI

150# RF 1.5 MM(MIN.) CS
TEE 2 - 6 BW ASTM A234 WPB-SMLS,ASME B16.9, TE7310900
TEE 8 - 24 BW ASTM A234 WPB-WLDD,ASME B16.9, TEOY10900
TEE 26 - 48 BW IS2062 GR.B,ASME B16.9, TEA410900
WELDOLET 2 - 48 BW CS ASTM A105,MSS SP 97, WL0213300
FITTING (SW)
CAP 1/2 - 11/2 3000# SOCW CS ASTM A105,ASME B16.11, CP0230207 W
COUPLING 1/2 - 11/2 3000# SOCW CS ASTM A105,ASME B16.11, CN0230207
ELBOW 1/2 - 11/2 3000# SOCW CS ASTM A105,ASME B16.11, EL0230207
SOCKOLET 1/2 - 48 3000# SOCW CS ASTM A105,MSS SP 97, SL0233307
TEE 1/2 - 11/2 3000# SOCW CS ASTM A105,ASME B16.11, TE0230207
FITTING (THD)
CAP 1/2 - 11/2 3000# THD CS ASTM A105,ASME B16.11, CP0240207 T
PLUG 1/2 - 11/2 THD CS ASTM A105,ASME B16.11,ROUND HEAD PG0240200
THREDOLET 1/2 - 48 3000# THD CS ASTM A105,MSS SP 97, TL0243307
NIPPLE
NIPPLE 1/2 - 11/2 SCH160 PLN-PLN SMLS,API 5L GR.B,ASME B36.10, NPA151312 1
NIPPLE 1/2 - 11/2 SCH160 PLN-THD SMLS,API 5L GR.B,ASME B36.10,NPT NPA161312 2
NIPPLE 1/2 - 11/2 SCH160 THD SMLS,API 5L GR.B,ASME B36.10,NPT NPA141312 3
SWAGE NIPPLE
SWAGE (CONC) 1/2 - 11/2 PE ASTM A234 WPB-SMLS,MSS SP 95, NC73J4500
SWAGE (ECC) 1/2 - 11/2 PE ASTM A234 WPB-SMLS,MSS SP 95, NE73J4500
VALVES
GATE VALVE 1/2 - 11/2 800# SOCW CS BODY ASTM A105,GAV201, GAV201
GATE VALVE 2 - 48 150# FLG CS BODY ASTM A216 GR WCB,GAV210, GAV210
GLOBE VALVE 1/2 - 11/2 800# SOCW CS BODY ASTM A105,GLV201, GLV201
GLOBE VALVE 2 - 10 150# FLG CS BODY ASTM A216 GR WCB,GLV210, GLV210
BUTTERFLY VALVE 2 - 24 150# RF CS BODY ASTM A216 GR WCB,BUV203,LUG TYPE BUV203
:
Rev.:0.
Class: B22G PROJECTS AND DEVELOPMENT INDIA LIMITED
DW,AIR
Ref.SI Ref.SI

150# THD 1.5 MM(MIN.) CS(GALVANIZED)
PIPE
PIPE 1/2 - 3/4 SCH XS THD SMLS,ASTM A106 GR.B,HOT DIP GALV.,ASME B36.10, PPAC31300
PIPE 1 - 11/4 SCH XS THD SMLS,ASTM A106 GR.B,HOT DIP GALV.,ASME B36.10, PPAC31300
PIPE 11/2 - 2 SCH XS THD SMLS,ASTM A106 GR.B,HOT DIP GALV.,ASME B36.10, PPAC31300
PIPE 21/2 - 3 SCHSTD THD SMLS,ASTM A106 GR.B,HOT DIP GALV.,ASME B36.10, PPAC31300
PIPE 4 - 4 SCHSTD THD SMLS,ASTM A106 GR.B,HOT DIP GALV.,ASME B36.10, PPAC31300
PIPE 6 - 8 SCHSTD BE SMLS,ASTM A106 GR.B,HOT DIP GALV.,ASME B36.10, PPAC11300
PIPE 10 - 12 SCHSTD BE SMLS,ASTM A106 GR.B,HOT DIP GALV.,ASME B36.10, PPAC11300
FLANGE
FLANGE 1/2 - 4 150# THD-RF 125 AARH ASTM A105 HOT DIP GALV.,ASME B16.5, FLFDK0801
W.N.FLANGE 6 - 12 150# WN-RF 125 AARH ASTM A105 HOT DIP GALV.,ASME B16.5, WNFD70801
SPECL BLIND 1/2 - 12 150# RF 125 AARH ASTM A105 HOT DIP GALV.,ASME B16.48, SPFD2PO01
BLIND FLANGE
BLIND FLANGE 1/2 - 4 150# RF 125 AARH ASTM A105 HOT DIP GALV.,ASME B16.5, BFFD20801
GASKET
STUD & NUTS

STUD & 2NUTS HVY - ASTM A193GR.B7/A194GR.2H,HOT DIP GALV.,, SNZC00000
HEX
FITTING (BW)
CAP 6 - 12 BW ASTM A234 WPB-SMLS,HOT DIP GALV.,ASME B16.9, CPPD10900
ELBOW 6 - 12 BW ASTM A234 WPB-SMLS,HOT DIP GALV.,ASME B16.9, ELPD10900
REDUCER CONC. 6 - 12 BW ASTM A234 WPB-SMLS,HOT DIP GALV.,ASME B16.9, RCPD10900
REDUCER ECC. 6 - 12 BW ASTM A234 WPB-SMLS,HOT DIP GALV.,ASME B16.9, REPD10900
TEE 6 - 12 BW ASTM A234 WPB-SMLS,HOT DIP GALV.,ASME B16.9, TEPD10900
FITTING (THD)
CAP 1/2 - 4 3000# THD ASTM A105 HOT DIP GALV.,ASME B16.11, CPFD40207
COUPLING 1/2 - 4 3000# THD ASTM A105 HOT DIP GALV.,ASME B16.11, CNFD40207
ELBOW 1/2 - 4 3000# THD ASTM A105 HOT DIP GALV.,ASME B16.11, ELFD40207
HALF COUPLING 1/2 - 4 3000# THD ASTM A105 HOT DIP GALV.,ASME B16.11, HFFD40207
PLUG 1/2 - 11/2 THD ASTM A105 HOT DIP GALV.,ASME B16.11,ROUND HEAD PGFD40200
REDUCER CONC. 2 - 4 THD ASTM A105 HOT DIP GALV.,ASME B16.11, RCFD40200
REDUCER ECC. 2 - 4 THD ASTM A105 HOT DIP GALV.,ASME B16.11, REFD40200
TEE 1/2 - 4 3000# THD ASTM A105 HOT DIP GALV.,ASME B16.11, TEFD40207
THREDOLET 1/2 - 11/2 3000# THD ASTM A105 HOT DIP GALV.,MSS SP 97, TLFD43307
NIPPLE
NIPPLE 1/2 - 11/2 THD SMLS,ASTM A106 GR.B,HOT DIP GALV.,ASME B36.10,NPT NPAC41344
SWAGE NIPPLE
SWAGE (CONC) 1/2 - 11/2 THD ASTM A105 HOT DIP GALV.,MSS SP 95, NCFD44500
SWAGE (ECC) 1/2 - 11/2 THD ASTM A105 HOT DIP GALV.,MSS SP 95, NEFD44500
VALVES
GATE VALVE 1/2 - 11/2 800# THRD CS BODY ASTM A105,GAV207, GAV207
CHECK VALVE 1/2 - 11/2 800# THRD CS BODY ASTM A105,CHV207, CHV207
CHECK VALVE 2 - 12 150# FLG CS BODY ASTM A216 GR WCB,CHV210, CHV210
PLUG VALVE 2 - 12 150# FLG CS BODY ASTM A216 GR WCB,PLV202, PLV202

Rev.:0.
Class: B22IS PROJECTS AND DEVELOPMENT INDIA LIMITED
CONST.WATER,FW
-22 427

150# RF 1.5 MM CARBON STEEL
PIPE
PIPE 2 - 21/2 04.50 MM BE SMLS,IS1239 BLACK,IS 1239 PART I,HVY PPD512600
PIPE 3 - 3 4.80 MM BE SMLS,IS1239 BLACK,IS 1239 PART I,HVY PPD512600
PIPE 1/2 - 3/4 3.20 MM PE SMLS,IS1239 BLACK,IS 1239 PART I,HVY PPD522600
PIPE 1 - 11/4 04.00 MM PE SMLS,IS1239 BLACK,IS 1239 PART I,HVY PPD522600
PIPE 11/2 - 11/2 04.00 MM PE SMLS,IS1239 BLACK,IS 1239 PART I,HVY PPD522600
PIPE 8 - 10 6.30 MM BE ERW,IS 3589 GR.FE410,IS 3589, PP521PK00
FLANGE
FLANGE 1/2 - 11/2 150# SW-RF 125 AARH CS ASTM A105,ASME B16.5, FL02L0801
FLANGE 2 - 24 150# SO-RF 125 AARH CS ASTM A105,ASME B16.5,SLIP ON FL0260801 1
LONG W.N.FLANGE 11/2 - 11/2 300# WN-RF 125 AARH CS ASTM A105,ASME B16.5,38mmBORE,200mmLONG LN0270802
W.N.FLANGE 2 - 24 150# WN-RF 125 AARH CS ASTM A105,ASME B16.5,WELD NECK WN0270801 2
BLIND FLANGE
GASKET
STUD & NUTS

HEX
FITTING (BW)

RP
ELBOW 8 - 24 BW ASTM A234 WPB-WLDD,ASME B16.9, ELOY10900
FITTING (SW)
FITTING (THD)
NIPPLE
Rev.:0.
Class: B22IS PROJECTS AND DEVELOPMENT INDIA LIMITED
CONST.WATER,FW
-22 427

150# RF 1.5 MM CARBON STEEL
NIPPLE 1/2 - 11/2 SCH 80 PLN-PLN SMLS,IS1239 BLACK,IS 1239 PART I, NPD552611 1
NIPPLE 1/2 - 11/2 SCH 80 PLN-THD SMLS,IS1239 BLACK,IS 1239 PART I,NPT NPD562611 2
NIPPLE 1/2 - 11/2 SCH 80 THD SMLS,IS1239 BLACK,IS 1239 PART I,NPT NPD542611 3
SWAGE NIPPLE
SWAGE (CONC) 1/2 - 11/2 PE ASTM A234 WPB-SMLS,MSS SP 95, NC73J4500 P
SWAGE (CONC) 1/2 - 11/2 PLN-THD ASTM A234 WPB-SMLS,MSS SP 95, NC7364500 T
SWAGE (ECC) 1/2 - 11/2 PE ASTM A234 WPB-SMLS,MSS SP 95, NE73J4500 P
SWAGE (ECC) 1/2 - 11/2 PLN-THD ASTM A234 WPB-SMLS,MSS SP 95, NE7364500 T
VALVES
GATE VALVE 1/2 - 11/2 800# SOCW CS BODY ASTM A105,GAV201, GAV201 W
GATE VALVE 1/2 - 11/2 150# FLG CS BODY ASTM A216 GR WCB,GAV210, GAV210 F
CHECK VALVE 1/2 - 11/2 800# SOCW CS BODY ASTM A105,CHV201, CHV201
BALL VALVE 1/2 - 1 800# SOCW CS BODY ASTM A105,BAV201, BAV201
BALL VALVE 11/2 - 11/2 800# SOCW CS BODY ASTM A105,BAV201, BAV201 W
BALL VALVE 11/2 - 11/2 150# FLG CS BODY ASTM A216 GR WCB,BAV210, BAV210 F
BALL VALVE 2 - 16 150# FLG CS BODY ASTM A216 GR WCB,BAV210, BAV210
PLUG VALVE 1/2 - 1 600# THRD CS BODY ASTM A105,PLV201, PLV201
PLUG VALVE 11/2 - 24 150# FLG CS BODY ASTM A216 GR WCB,PLV202, PLV202
:
Rev.:0.
BF,CW,RW,FG,FN,NG,PN,PV,SA,SW,VS,PA ETC.
Ref.SI Ref.SI

150# RF 1.5 MM(MIN.) CS
PIPE
PIPE 2 - 6 SCH 40 BE SMLS,API 5L GR.B,ASME B36.10, PPA111300
PIPE 8 - 10 SCH 20 BE ERW,API 5L GR.B,ASME B36.10, PPA211300
PIPE 1/2 - 3/4 SCH 80 PE SMLS,API 5L GR.B,ASME B36.10, PPA121300
PIPE 1 - 11/4 SCH 80 PE SMLS,API 5L GR.B,ASME B36.10, PPA121300
PIPE 22 - 24 SCHSTD BE ERW,API 5L GR.B,ASME B36.10, PPA211300
PIPE 26 - 28 SCHSTD BE ERW/SAW, API 5L GR.B,ASME B36.10, PPTM11300
PIPE 36 - 36 SCH XS BE ERW/SAW, API 5L GR.B,ASME B36.10, PPTM11300
FLANGE
FLANGE 1/2 - 24 150# SO-RF 125 AARH CS ASTM A105,ASME B16.5,SLIP ON FL0260801
LONG W.N.FLANGE 11/2 - 11/2 300# WN-RF 125 AARH CS ASTM A105,ASME B16.5,24mm Bore,200mm Long LN0270802
W.N.FLANGE 26 - 36 150# WN-RF 125 AARH CS ASTM A105,ASME B16.47 SR.B,WELD NECK WN0270701
BLIND FLANGE
BLIND FLANGE 26 - 36 150# RF 125 AARH CS ASTM A105,ASME B16.47 SR.B, BF0220701
GASKET
GASKET 26 - 36 150# SPRL-WND RF TP304 SS WDG;GPH FLR;TP304 SS INR RNG;CS OTR RNG,ASME GSQN3QJ01
B16.20/B16.47 SR.B,
STUD & NUTS

HEX
DRIP RING
DRIP RING 3 - 3 150# RF 125 AARH CS ASTM A105,PDIL-PDS-600, DR022QK01
FITTING (BW)

RP
ELBOW 8 - 36 BW ASTM A234 WPB-WLDD,ASME B16.9, ELOY10900 L
ELBOW 8 - 36 BW ASTM A234 WPB-WLDD,PDIL-PDS-600,R=3D ELOY1QK00 3
FITTING (SW)
COUPLING 1/2 - 11/2 3000# SOCW CS ASTM A105,ASME B16.11, CN0230207 W

Rev.:0.
BF,CW,RW,FG,FN,NG,PN,PV,SA,SW,VS,PA ETC.
Ref.SI Ref.SI

150# RF 1.5 MM(MIN.) CS
HALF COUPLING 1/2 - 11/2 3000# SOCW CS ASTM A105,ASME B16.11, HF0230207
FITTING (THD)
COUPLING 1/2 - 11/2 3000# THD CS ASTM A105,ASME B16.11, CN0240207 T
NIPPLE
SWAGE NIPPLE
STRAINER
T-TYPE STRAINER 2 - 24 150# FLGD CS ASTM A216 GR WCB,TTS210, TTS210
Y-TYPE STRAINER 1/2 - 11/2 600# SOCW CS ASTM A105,YTS201, YTS201
Y-TYPE STRAINER 2 - 24 150# FLGD CS ASTM A216 GR WCB,YTS210, YTS210
VALVES
BALL VALVE 1/2 - 11/2 800# SOCW CS BODY ASTM A105,BAV201, BAV201
BUTTERFLY VALVE 26 - 36 150# FLG CS BODY ASTM A216 GR WCB,BUV204, BUV204
:
Rev.:0.
Class: B24D PROJECTS AND DEVELOPMENT INDIA LIMITED
WASTE EFFLUENT,HCL
Ref.SI Ref.SI

150# FF NONE HDPE
PIPE
PIPE 1 - 11/4 CALC PE HDPE ASTM D3350 CELL 345464C(PE 3608),D-3035,SDR7 PP5922A00
PIPE 11/2 - 2 CALC PE HDPE ASTM D3350 CELL 345464C(PE 3608),D-3035,SDR7 PP5922A00
PIPE 3 - 4 CALC PE HDPE ASTM D3350 CELL 345464C(PE 3608),D-3035,SDR7 PP5922A00
FLANGE
FLANGE 1 - 12 150# LJ-FF DI ASTM A536 GR.65-45-12,MF.STD/ASME B16.5, FL5193501
BLIND FLANGE
BLIND FLANGE 1 - 12 150# FF CS ASTM A105,ASME B16.5, BF0210801
GASKET
GASKET 1 - 12 150# 3.0 MM THK FF EPDM,ASME B16.21, GS7880401
STUD & NUTS

STUD & 2NUTS HVY - A307 GR.B/A563 GR.B,, SN3B00000
HEX
FITTING
ELBOW 1 - 12 PE HDPE ASTM D3350 CELL 345464C(PE 3608),D-3035/MF.STD,SDR7 EL59J2B00
REDUCER CONC. 1 - 12 PE HDPE ASTM D3350 CELL 345464C(PE 3608),D-3035/MF.STD,SDR7 RC59J2B00
REDUCER ECC. 1 - 12 PE HDPE ASTM D3350 CELL 345464C(PE 3608),D-3035/MF.STD,SDR7 RE59J2B00
STUB END 1 - 12 PE HDPE ASTM D3350 CELL 345464C(PE 3608),MF.STD/ASME B16.5,SDR7 SE59J3500
TEE 1 - 12 PE HDPE ASTM D3350 CELL 345464C(PE 3608),D-3035/MF.STD,SDR7 TE59J2B00
VALVES
CHECK VALVE 1 - 12 150# FLG CS BODY ASTM A216 GR.WCB RUBBER LINED,CHV210D, CHV210D
BALL VALVE 1 - 12 150# FLG SS BODY ASTM A351 GR CF8M,BAV510, BAV510
BUTTERFLY VALVE 1 - 12 150# FF CS BODY ASTM A216 GR.WCB RUBBER LINED,BUV203F,LUG TYPE BUV203F
:
Rev.:0.
Class: B24S PROJECTS AND DEVELOPMENT INDIA LIMITED
SL,SC (IBR)
Ref.SI Ref.SI

150# RF 1.5 MM(MIN.) CS
PIPE
PIPE 2 - 6 SCH 40 BE IBR SMLS,ASTM A106 GR.B,ASME B36.10, PP03A1300
PIPE 1/2 - 3/4 SCH 80 PE IBR SMLS,ASTM A106 GR.B,ASME B36.10, PP03B1300
PIPE 1 - 11/4 SCH 80 PE IBR SMLS,ASTM A106 GR.B,ASME B36.10, PP03B1300
PIPE 11/2 - 11/2 SCH 80 PE IBR SMLS,ASTM A106 GR.B,ASME B36.10, PP03B1300
PIPE 24 - 24 SCHSTD BE IBR SMLS,ASTM A106 GR.B,ASME B36.10, PP03A1300
PIPE 26 - 28 SCHSTD BE IBR EFW,ASTM A671 GR.CC60 CL.22,ASME B36.10, PPRXA1300
PIPE 36 - 38 SCH XS BE IBR EFW,ASTM A671 GR.CC60 CL.22,ASME B36.10, PPRXA1300
PIPE 48 - 48 14.27 MM BE IBR EFW,ASTM A671 GR.CC60 CL.22,ASME B36.10, PPRXA1300
FLANGE
FLANGE 1/2 - 24 150# SO-RF 125 AARH CS ASTM A105,ASME B16.5,SLIP ON FL02F0801
IBR
W.N.FLANGE 26 - 48 150# WN-RF 125 AARH CS ASTM A105,ASME B16.47 SR.B,WELD NECK WN02G0701
IBR
SPACER AND BLIND 14 - 24 150# RF 125 AARH IBR CS ASTM A105,ASME B16.48, RS02BPO01
SPECL BLIND 1/2 - 12 150# RF 125 AARH IBR CS ASTM A105,ASME B16.48, SP02BPO01
BLIND FLANGE
BLIND FLANGE 26 - 48 150# RF 125 AARH IBR CS ASTM A105,ASME B16.47 SR.B, BF02B0701
BLIND FLANGE 1/2 - 24 150# RF 125 AARH IBR CS ASTM A105,ASME B16.5, BF02B0801
GASKET
B16.20/B16.47 SR.B,
STUD & NUTS

HEX
FITTING (BW)
BRANCH WELD 2 - 48 BW IBR CARBON STEEL,ASME B31.3, RWOJA1200
BRANCH WELD WITH 2 - 48 BW IBR CARBON STEEL,ASME B31.3, WBOJA1200

RP
CAP 2 - 48 BW IBR ASTM A234 WPB-SMLS,ASME B16.9, CP73A0900
ELBOW 2 - 24 BW IBR ASTM A234 WPB-SMLS,ASME B16.9, EL73A0900
ELBOW 26 - 48 BW IBR ASTM A234 WPB-WLDD,ASME B16.9, ELOYA0900
REDUCER CONC. 2 - 24 BW IBR ASTM A234 WPB-SMLS,ASME B16.9, RC73A0900
REDUCER CONC. 26 - 48 BW IBR ASTM A234 WPB-WLDD,ASME B16.9, RCOYA0900
REDUCER ECC. 2 - 24 BW IBR ASTM A234 WPB-SMLS,ASME B16.9, RE73A0900
REDUCER ECC. 26 - 48 BW IBR ASTM A234 WPB-WLDD,ASME B16.9, REOYA0900
TEE 2 - 24 BW IBR ASTM A234 WPB-SMLS,ASME B16.9, TE73A0900
TEE 26 - 48 BW IBR ASTM A234 WPB-WLDD,ASME B16.9, TEOYA0900
WELDOLET 2 - 48 BW IBR CS ASTM A105,MSS SP 97, WL02A3300
FITTING (SW)
CAP 1/2 - 11/2 3000# SOCW IBR CS ASTM A105,ASME B16.11, CP02C0207 W
COUPLING 1/2 - 11/2 3000# SOCW IBR CS ASTM A105,ASME B16.11, CN02C0207
Rev.:0.
Class: B24S PROJECTS AND DEVELOPMENT INDIA LIMITED
SL,SC (IBR)
Ref.SI Ref.SI

150# RF 1.5 MM(MIN.) CS
ELBOW 1/2 - 11/2 3000# SOCW IBR CS ASTM A105,ASME B16.11, EL02C0207
HALF COUPLING 1/2 - 11/2 3000# SOCW IBR CS ASTM A105,ASME B16.11, HF02C0207
SOCKOLET 1/2 - 48 3000# SOCW IBR CS ASTM A105,MSS SP 97, SL02C3307
TEE 1/2 - 11/2 3000# SOCW IBR CS ASTM A105,ASME B16.11, TE02C0207
FITTING (THD)
CAP 1/2 - 11/2 3000# THD IBR CS ASTM A105,ASME B16.11, CP02D0207 T
PLUG 1/2 - 11/2 THD IBR CS ASTM A105,ASME B16.11,ROUND HEAD PG02D0200
THREDOLET 1/2 - 48 3000# THD IBR CS ASTM A105,MSS SP 97, TL02D3307
NIPPLE
NIPPLE 1/2 - 11/2 SCH160 PLN-PLN IBR SMLS,ASTM A106 GR.B,ASME B36.10, NP03E1312 1
NIPPLE 1/2 - 11/2 SCH160 PLN-THD IBR SMLS,ASTM A106 GR.B,ASME B36.10,NPT NP03F1312 2
NIPPLE 1/2 - 11/2 SCH160 THD IBR SMLS,ASTM A106 GR.B,ASME B36.10,NPT NP03D1312 3
SWAGE NIPPLE
SWAGE (CONC) 1/2 - 11/2 PE IBR ASTM A234 WPB-SMLS,MSS SP 95, NC73Q4500 P
SWAGE (CONC) 1/2 - 11/2 PLN-THD IBR ASTM A234 WPB-SMLS,MSS SP 95, NC73F4500 T
SWAGE (ECC) 1/2 - 11/2 PE IBR ASTM A234 WPB-SMLS,MSS SP 95, NE73Q4500 P
SWAGE (ECC) 1/2 - 11/2 PLN-THD IBR ASTM A234 WPB-SMLS,MSS SP 95, NE73F4500 T
VALVES
GATE VALVE 1/2 - 11/2 800# SOCW IBR CS BODY ASTM A105,GAV201S, GAV201S
GATE VALVE 2 - 48 150# FLG IBR CS BODY ASTM A216 GR WCB,GAV210S, GAV210S
GLOBE VALVE 1/2 - 11/2 800# SOCW IBR CS BODY ASTM A105,GLV201S, GLV201S
GLOBE VALVE 2 - 12 150# FLG IBR CS BODY ASTM A216 GR WCB,GLV210S, GLV210S
CHECK VALVE 1/2 - 11/2 800# SOCW IBR CS BODY ASTM A105,CHV201S, CHV201S
CHECK VALVE 2 - 24 150# FLG IBR CS BODY ASTM A216 GR WCB,CHV210S, CHV210S
:
Rev.:0.
Class: B24FL PROJECTS AND DEVELOPMENT INDIA LIMITED
EFFLUENT,ACIDIC H2O ETC.
Ref.SI Ref.SI

150# FF NONE CS FRP LND.
PIPE
PIPE 1 - 11/4 SCH XS FLGD CS,SMLS,API 5L GR.B,FRP LND.,ASME B36.10,THK OF LING AS PER MFR. PP5661300
PIPE 11/2 - 11/2 SCH XS FLGD CS,SMLS,API 5L GR.B,FRP LND.,ASME B36.10,THK OF LING AS PER MFR. PP5661300
PIPE 2 - 21/2 SCHSTD FLGD CS,SMLS,API 5L GR.B,FRP LND.,ASME B36.10,THK OF LING AS PER MFR. PP5661300
PIPE 3 - 4 SCHSTD FLGD CS,SMLS,API 5L GR.B,FRP LND.,ASME B36.10,THK OF LING AS PER MFR. PP5661300
PIPE 5 - 6 SCHSTD FLGD CS,SMLS,API 5L GR.B,FRP LND.,ASME B36.10,THK OF LING AS PER MFR. PP5661300
PIPE 8 - 10 SCH 20 FLGD CS,ERW,API 5L GR.B,FRP LND,ASME B36.10,THK OF LING AS PER MFR. PP5761300
PIPE 12 - 12 SCH 20 FLGD CS,ERW,API 5L GR.B,FRP LND,ASME B36.10,THK OF LING AS PER MFR. PP5761300
FLANGE
FLANGE 1 - 2 150# SO-FF CS,ASTM A105,FRP LND.,ASME B16.5,THK OF LING AS PER MFR. FL5850801
W.N.FLANGE 1 - 12 150# WN-FF CS,ASTM A105,FRP LND.,ASME B16.5,THK OF LING AS PER MFR. WN58M0801
SPECL BLIND 1 - 12 150# FF CS PLT,ASTM A516 GR.60,FRP LND.,ASME B16.48,THK OF LING AS PER SP641PO01
MFR.
BLIND FLANGE
BLIND FLANGE 1 - 12 150# FF CS,ASTM A105,FRP LND.,ASME B16.5,THK OF LING AS PER MFR. BF5810801
GASKET
GASKET 1 - 12 150# FLAT GASKET,SOFT RUBBER,ASME B16.21,3MM THK. GSW190401
STUD & NUTS

HEX
FITTING
ELBOW 1 - 6 FLGD CS,ASTM A234 WPB-SMLS,FRP LND,ASME B16.9,THK OF LING AS PER EL62Z0900
MFR.
ELBOW 8 - 12 FLGD CS,ASTM A234 WPB-WLDD,FRP LND.,ASME B16.9,THK OF LING AS PER EL63Z0900
MFR.
REDUCER CONC. 1 - 6 FLGD CS,ASTM A234 WPB-SMLS,FRP LND,ASME B16.9,THK OF LING AS PER RC62Z0900
MFR.
REDUCER CONC. 8 - 12 FLGD CS,ASTM A234 WPB-WLDD,FRP LND.,ASME B16.9,THK OF LING AS PER RC63Z0900
MFR.
REDUCER ECC. 1 - 6 FLGD CS,ASTM A234 WPB-SMLS,FRP LND,ASME B16.9,THK OF LING AS PER RE62Z0900
MFR.
REDUCER ECC. 8 - 12 FLGD CS,ASTM A234 WPB-WLDD,FRP LND.,ASME B16.9,THK OF LING AS PER RE63Z0900
MFR.
TEE 1 - 6 FLGD CS,ASTM A234 WPB-SMLS,FRP LND,ASME B16.9,THK OF LING AS PER TE62Z0900
MFR.
TEE 8 - 12 FLGD CS,ASTM A234 WPB-WLDD,FRP LND.,ASME B16.9,THK OF LING AS PER TE63Z0900
MFR.
VALVES
GATE VALVE 2 - 12 150# FLG SS BODY ASTM A351 GR CF8,GAV510, GAV510
GLOBE VALVE 2 - 12 150# FLG SS BODY ASTM A351 GR CF8,GLV510, GLV510
BUTTERFLY VALVE 2 - 12 150# FF CS BODY ASTM A216 GR.WCB RUBBER LINED,BUV203,LUG TYPE BUV203
NOTE: 1. S.O. Flanges shall be used with pipe spools.

2. All fittings shall have ends connected to flanges.
Rev.:0.
Class: B24P PROJECTS AND DEVELOPMENT INDIA LIMITED
STRONG CAUSTIC ACID,ETP
Ref.SI Ref.SI

150# FF NONE CPVC
PIPE
PIPE 2 - 3 SCH 80 PE CPVC,ASTM F441,MF.STD/ASTM F441,PLASTIC PIPE PP552QC00
PIPE 1/2 - 3/4 SCH 80 PE CPVC,ASTM F441,MF.STD/ASTM F441,PLASTIC PIPE PP552QC00
PIPE 1 - 11/2 SCH 80 PE CPVC,ASTM F441,MF.STD/ASTM F441,PLASTIC PIPE PP552QC00
FLANGE
FLANGE 1/2 - 12 150# FF CPVC,ASTM F441,MF.STD/ASTM F441,SCH80 FL551QC01
BLIND FLANGE
BLIND FLANGE 1/2 - 12 150# FF CPVC,ASTM F441,MF.STD/ASTM F441, BF551QC01
GASKET
GASKET 1/2 - 12 150# 3.0 MM THK FF EPDM,MF.STD./ASME B16.21,FULL FACE GS788PA01
STUD & NUTS

HEX
FITTING (BW)
BRANCH WELD WITH 1/2 - 12 PE CPVC,ASTM F441,MF.STD/ASTM F441, WB55JQC00
RP
FITTING (THD)
CAP 1/2 - 11/2 3000# THD CPVC,ASTM F441,MF.STD/ASTM F441, CP554QC07
FITTING
ELBOW 1/2 - 12 PE CPVC,ASTM F441,MF.STD/ASTM F441, EL55JQC00
REDUCER CONC. 1/2 - 12 PE CPVC,ASTM F441,MF.STD/ASTM F441, RC55JQC00
REDUCER ECC. 1/2 - 12 PE CPVC,ASTM F441,MF.STD/ASTM F441, RE55JQC00
TEE 1/2 - 12 PE CPVC,ASTM F441,MF.STD/ASTM F441, TE55JQC00
UNION (GJ) 1/2 - 12 PE CPVC,ASTM F441,MF.STD/ASTM F441, UN55JQC00
NIPPLE
NIPPLE 1/2 - 11/2 SCH160 PLN-PLN CPVC,ASTM F441,MF.STD/ASTM F441, NP555QC12 1
NIPPLE 1/2 - 11/2 SCH160 PLN-THD CPVC,ASTM F441,MF.STD/ASTM F441,PLASTIC PIPE NPT NP556QC12 2
NIPPLE 1/2 - 11/2 SCH160 THD CPVC,ASTM F441,MF.STD/ASTM F441,PLASTIC PIPE NPT NP554QC12 3
VALVES
GATE VALVE 1/2 - 12 150# FF CPVC BODY W/ PP PLUG & EPDM SEATS,GAV500C, GAV500C
CHECK VALVE 1/2 - 12 150# FF CPVC BODY,CHV500C, CHV500C
BALL VALVE 1/2 - 2 150# FF CPVC BODY WITH CPVC BALL,BAV500C, BAV500C
BALL VALVE 3 - 6 150# FF CPVC BODY WITH CPVC BALL,BAV501C, BAV501C
:
Rev.:0.
Class: B24RL PROJECTS AND DEVELOPMENT INDIA LIMITED
DIL.CAUSTIC ACID,COAGULANT,CHLORINATED
Ref.SI Ref.SI
WATER

150# FF 1.5 MM CSRL
PIPE
PIPE 1/2 - 3/4 SCH 80 FLGD CS,SMLS,API 5L GR.B,NATURAL RBR LND,ASME B36.10,3MM THK LING PPX761300
PIPE 1 - 11/4 SCH 80 FLGD CS,SMLS,API 5L GR.B,NATURAL RBR LND,ASME B36.10,3MM THK LING PPX761300
PIPE 11/2 - 11/2 SCH 80 FLGD CS,SMLS,API 5L GR.B,NATURAL RBR LND,ASME B36.10,3MM THK LING PPX761300
PIPE 2 - 21/2 SCH 40 FLGD CS,SMLS,API 5L GR.B,NATURAL RBR LND,ASME B36.10,3MM THK LING PPX761300
PIPE 3 - 4 SCHSTD FLGD CS,SMLS,API 5L GR.B,NATURAL RBR LND,ASME B36.10,3MM THK LING PPX761300
PIPE 5 - 6 SCHSTD FLGD CS,SMLS,API 5L GR.B,NATURAL RBR LND,ASME B36.10,3MM THK LING PPX761300
PIPE 8 - 10 SCHSTD FLGD CS,ERW,API 5L GR.B,NATURAL RBR LND,ASME B36.10,3MM THK LING PP2A61300
PIPE 12 - 12 SCHSTD FLGD CS,ERW,API 5L GR.B,NATURAL RBR LND,ASME B36.10,3MM THK LING PP2A61300
FLANGE
FLANGE 1/2 - 12 150# SO-FF CS,ASTM A105,NATURAL RBR LND,ASME B16.5,3MM THK LING FLX650801
SPECL BLIND 1 - 12 150# FF CS PLT,ASTM A516 GR.60,NATURAL RBR LND,ASME B16.48,3MM THK LING SPX81PO01
BLIND FLANGE
BLIND FLANGE 1 - 12 150# FF CS,ASTM A105,NATURAL RBR LND,ASME B16.5,3MM THK LING BFX610801
GASKET
GASKET 1 - 12 150# FLAT GASKET,SOFT RUBBER,ASME B16.21,3MM THK. GSW190401
STUD & NUTS

HEX
FITTING
DIAPH. VALVE 1 - 12 150# FLG CS BODY ASTM A216 GR.WCB RUBBER LINED,CHV512W, CHV512W
ELBOW 1/2 - 6 FLGD CS,ASTM A234 WPB-SMLS,NATURAL RBR LND,ASME B16.9,3MM THK LING ELX9Z0900
ELBOW 8 - 12 FLGD CS,ASTM A234 WPB-WLDD,NATURAL RBR LND,ASME B16.9,3MM THK LING EL3AZ0900
REDUCER CONC. 1/2 - 6 FLGD CS,ASTM A234 WPB-SMLS,NATURAL RBR LND,ASME B16.9,3MM THK LING RCX9Z0900
REDUCER CONC. 8 - 12 FLGD CS,ASTM A234 WPB-WLDD,NATURAL RBR LND,ASME B16.9,3MM THK LING RC3AZ0900
REDUCER ECC. 1/2 - 6 FLGD CS,ASTM A234 WPB-SMLS,NATURAL RBR LND,ASME B16.9,3MM THK LING REX9Z0900
REDUCER ECC. 8 - 12 FLGD CS,ASTM A234 WPB-WLDD,NATURAL RBR LND,ASME B16.9,3MM THK LING RE3AZ0900
TEE 1/2 - 6 FLGD CS,ASTM A234 WPB-SMLS,NATURAL RBR LND,ASME B16.9,3MM THK LING TEX9Z0900
TEE 8 - 12 FLGD CS,ASTM A234 WPB-WLDD,NATURAL RBR LND,ASME B16.9,3MM THK LING TE3AZ0900
VALVES
GATE VALVE 1/2 - 12 150# FLG SS BODY ASTM A351 GR CF8,GAV510, GAV510
GLOBE VALVE 1/2 - 12 150# FLG SS BODY ASTM A351 GR CF8,GLV510, GLV510
BUTTERFLY VALVE 2 - 12 150# FF CS BODY ASTM A216 GR.WCB RUBBER LINED,BUV203,LUG TYPE BUV203
NOTE: 1. S.O. Flanges shall be used with pipe spools.

2. All fittings shall have ends connected to flanges.
Rev.:0.
AF,AW,CD,DM,HZ,IA,MDA,PC,PH,VS,CH
Ref.SI Ref.SI

150# RF NONE SS 304
PIPE
PIPE 26 - 28 06.35 MM BE EFW,ASTM A358 GR.TP304 CL.2,ASME B36.10, PP4111300
PIPE 30 - 32 SCH 10 BE EFW,ASTM A358 GR.TP304 CL.2,ASME B36.10, PP4111300
PIPE 38 - 40 SCHSTD BE EFW,ASTM A358 GR.TP304 CL.2,ASME B36.10, PP4111300
PIPE 1/2 - 3/4 SCH40S PE SMLS,ASTM A312 TP304,ASME B36.19, PPPE21400
PIPE 1 - 11/4 SCH40S PE SMLS,ASTM A312 TP304,ASME B36.19, PPPE21400
PIPE 2 - 4 SCH10S BE EFW,STR.WELD,ASTM A312 TP304,ASME B36.19, PPZ111400
FLANGE
W.N.FLANGE 26 - 48 150# WN-RF 125 AARH ASTM A182 F304,ASME B16.47 SR.B,WELD NECK WN0670701
W.N.FLANGE 1/2 - 24 150# WN-RF 125 AARH ASTM A182 F304,ASME B16.5,WELD NECK WN0670801
SPACER AND BLIND 14 - 24 150# RF 125 AARH ASTM A182 F304,ASME B16.48, RS062PO01
SPECL BLIND 1/2 - 12 150# RF 125 AARH ASTM A182 F304,ASME B16.48, SP062PO01
BLIND FLANGE
BLIND FLANGE 26 - 48 150# RF 125 AARH ASTM A182 F304,ASME B16.47 SR.B, BF0620701
BLIND FLANGE 1/2 - 24 150# RF 125 AARH ASTM A182 F304,ASME B16.5, BF0620801
GASKET
GASKET 1/2 - 24 150# SPRL-WND RF TP304 SS WDG; GPH FLR; TP304 SS INR RNG/ OTR RNG,ASME B16.20, GSQL30301
GASKET 26 - 48 150# SPRL-WND RF TP304 SS WDG; GPH FLR; TP304 SS INR RNG/ OTR RNG,ASME GSQL3QJ01
B16.20/B16.47 SR.B,
STUD & NUTS

STUD & 2NUTS HVY - ASTM A193 GR.B8 CL.2/ASTM A194 GR.8,, SNA600000
HEX
DRIP RING
DRIP RING 3 - 3 150# RF 125 AARH ASTM A182 F304,PDIL-PDS-600, DR062QK01
FITTING (BW)
BRANCH WELD 2 - 48 BW STAINLESS STEEL,ASME B31.3, RWOK11200
BRANCH WELD WITH 2 - 48 BW STAINLESS STEEL,ASME B31.3, WBOK11200

RP
CAP 2 - 48 BW ASTM A403 WP304-SMLS,ASME B16.9, CP7410900
ELBOW 2 - 48 BW ASTM A403 WP304-WLDD,ASME B16.9, ELZ410900
REDUCER CONC. 2 - 48 BW ASTM A403 WP304-WLDD,ASME B16.9, RCZ410900
REDUCER ECC. 2 - 48 BW ASTM A403 WP304-WLDD,ASME B16.9, REZ410900
TEE 2 - 48 BW ASTM A403 WP304-WLDD,ASME B16.9, TEZ410900
WELDOLET 2 - 48 BW ASTM A182 F304,MSS SP 97, WL0613300
FITTING (SW)
CAP 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, CP0630207 W
COUPLING 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, CN0630207
ELBOW 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, EL0630207
HALF COUPLING 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, HF0630207
SOCKOLET 1/2 - 48 3000# SOCW ASTM A182 F304,MSS SP 97, SL0633307
TEE 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, TE0630207
FITTING (THD)
CAP 1/2 - 11/2 3000# THD ASTM A182 F304,ASME B16.11, CP0640207 T
Rev.:0.
AF,AW,CD,DM,HZ,IA,MDA,PC,PH,VS,CH
Ref.SI Ref.SI

150# RF NONE SS 304
PLUG 1/2 - 11/2 THD ASTM A182 F304,ASME B16.11,ROUND HEAD PG0640200
THREDOLET 1/2 - 48 3000# THD ASTM A182 F304,MSS SP 97, TL0643307
NIPPLE
NIPPLE 1/2 - 11/2 SCH80S PLN-PLN SMLS,ASTM A312 TP304,ASME B36.19, NPPE51413 1
NIPPLE 1/2 - 11/2 SCH80S PLN-THD SMLS,ASTM A312 TP304,ASME B36.19,NPT NPPE61413 2
NIPPLE 1/2 - 11/2 SCH80S THD SMLS,ASTM A312 TP304,ASME B36.19,NPT NPPE41413 3
SWAGE NIPPLE
SWAGE (CONC) 1/2 - 11/2 PE ASTM A403 WP304-SMLS,MSS SP 95, NC74J4500 P
SWAGE (CONC) 1/2 - 11/2 PLN-THD ASTM A403 WP304-SMLS,MSS SP 95, NC7464500 T
SWAGE (ECC) 1/2 - 11/2 PE ASTM A403 WP304-SMLS,MSS SP 95, NE74J4500 P
SWAGE (ECC) 1/2 - 11/2 PLN-THD ASTM A403 WP304-SMLS,MSS SP 95, NE7464500 T
STRAINER
T-TYPE STRAINER 2 - 24 150# FLGD SS ASTM A351 GR CF8,TTS510, TTS510
Y-TYPE STRAINER 2 - 24 150# FLGD SS ASTM A351 GR CF8,YTS510, YTS510
Y-TYPE STRAINER 1/2 - 11/2 600# SOCW ASTM A182 F304,YTS501, YTS501
VALVES
GATE VALVE 1/2 - 11/2 800# SOCW SS BODY ASTM A182 GR F304,GAV501, GAV501
GATE VALVE 2 - 24 150# FLG SS BODY ASTM A351 GR CF8,GAV510, GAV510
GLOBE VALVE 1/2 - 11/2 800# SOCW SS BODY ASTM A182 GR F304,GLV501, GLV501
GLOBE VALVE 2 - 12 150# FLG SS BODY ASTM A351 GR CF8,GLV510, GLV510
CHECK VALVE 1/2 - 11/2 800# SOCW SS BODY ASTM A182 GR F304,CHV501, CHV501
CHECK VALVE 2 - 24 150# FLG SS BODY ASTM A351 GR CF8,CHV510, CHV510
CHECK VALVE 26 - 36 150# FLG SS BODY ASTM A351 GR CF8,CHV520, CHV520
BALL VALVE 1/2 - 11/2 800# THRD SS BODY AISI 316,BAV501, BAV501
BUTTERFLY VALVE 6 - 48 150# RF SS BODY ASTM A351 GR CF8,BUV510,WAFER TYPE BUV510
PLUG VALVE 1/2 - 1 600# THRD SS BODY AISI 316,PLV501, PLV501
PLUG VALVE 11/2 - 6 150# FLG SS BODY ASTM A351 GR CF8M,PLV510, PLV510
:
Rev.:0.
UV,RO.Pr.
Ref.SI Ref.SI

150# RF NONE SS 316
PIPE
PIPE 1/2 - 3/4 SCH40S PE SS,SMLS,ASTM A312 TP316,ASME B36.19, PPV821400 0
PIPE 1 - 11/2 SCH40S PE SS,SMLS,ASTM A312 TP316,ASME B36.19, PPV821400 0
PIPE 2 - 2 SCH10S PE SS,SMLS,ASTM A312 TP316,ASME B36.19, PPV821400 0
PIPE 3 - 4 SCH10S BE SS,SMLS,ASTM A312 TP316,ASME B36.19, PPV811400 0
PIPE 6 - 6 SCH10S BE SS,SMLS,ASTM A312 TP316,ASME B36.19, PPV811400 0
PIPE 8 - 10 SCH10S BE SS,EFW,ASTM A358 GR.TP316 CL.1,ASME B36.19, PPV911400 0
FLANGE
FLANGE 1/2 - 2 150# SW-RF 125 AARH SS,ASTM A182 F316,ASME B16.5,SOCKET WELD FLUAL0801 5 0
FLANGE 1/2 - 2 300# SW-RF 125 AARH SS,ASTM A182 F316,ASME B16.5,SOCKET WELD FLUAL0802 6 0
W.N.FLANGE 3 - 4 150# WN-RF 125 AARH SS,ASTM A182 F316,ASME B16.5,WELD NECK WNUA70801 5 0
W.N.FLANGE 6 - 18 150# WN-RF 125 AARH SS,ASTM A182 F316,ASME B16.5,WELD NECK WNUA70801 0
W.N.FLANGE 3 - 4 300# WN-RF 125 AARH SS,ASTM A182 F316,ASME B16.5,WELD NECK WNUA70802 6 0
SPACER AND BLIND 18 - 18 150# RF 125 AARH ASTM A240 TP316,ASME B16.48, RSUB2PO01 0
SPECL BLIND 1/2 - 16 150# RF 125 AARH ASTM A240 TP316,ASME B16.48, SPUB2PO01 0
BLIND FLANGE
BLIND FLANGE 1/2 - 18 150# RF 125 AARH SS,ASTM A182 F316,ASME B16.5, BFUA20801 0
GASKET
GASKET 1/2 - 4 150# SPRL-WND RF GASKET,TP316 SS WDG;GPH FLR;TP316 SS INR RNG/ OTR RNG,ASME GSQQ30301 5 0
B16.20,
GASKET 6 - 18 150# SPRL-WND RF GASKET,TP316 SS WDG;GPH FLR;TP316 SS INR RNG/ OTR RNG,ASME GSQQ30301 0
B16.20,
GASKET 1/2 - 4 300# SPRL-WND RF GASKET,TP316 SS WDG;GPH FLR;TP316 SS INR RNG/ OTR RNG,ASME GSQQ30302 6 0
B16.20,
STUD & NUTS

STUD & 2NUTS HVY - ASTM A193 GR.B7/ASTM A194 GR.2H,, SNDE00000 0
HEX
FITTING (BW)
CAP 3 - 18 BW SS,ASTM A403 WP316-SMLS,ASME B16.9, CPUC10900 0
ELBOW 3 - 6 BW SS,ASTM A403 WP316-SMLS,ASME B16.9, ELUC10900 0
ELBOW 8 - 18 BW SS,ASTM A403 WP316-WLDD,ASME B16.9, ELUD10900 0
REDUCER CONC. 3 - 6 BW SS,ASTM A403 WP316-SMLS,ASME B16.9, RCUC10900 0
REDUCER CONC. 8 - 18 BW SS,ASTM A403 WP316-WLDD,ASME B16.9, RCUD10900 0
REDUCER ECC. 3 - 6 BW SS,ASTM A403 WP316-SMLS,ASME B16.9, REUC10900 0
REDUCER ECC. 8 - 18 BW SS,ASTM A403 WP316-WLDD,ASME B16.9, REUD10900 0
TEE 3 - 6 BW SS,ASTM A403 WP316-SMLS,ASME B16.9, TEUC10900 0
TEE 8 - 18 BW SS,ASTM A403 WP316-WLDD,ASME B16.9, TEUD10900 0
WELDOLET 2 - 18 BW SS,ASTM A182 F316,MSS SP 97, WLUA13300 0
FITTING (SW)
CAP 1/2 - 2 3000# SOCW SS,ASTM A182 F316,ASME B16.11, CPUA30207 0
COUPLING 1/2 - 2 3000# SOCW SS,ASTM A182 F316,ASME B16.11, CNUA30207 W 0
ELBOW 1/2 - 2 3000# SOCW SS,ASTM A182 F316,ASME B16.11, ELUA30207 0
HALF COUPLING 1/2 - 11/2 3000# SOCW SS,ASTM A182 F316,ASME B16.11, HFUA30207 W 0
SOCKOLET 1/2 - 18 3000# SOCW SS,ASTM A182 F316,MSS SP 97, SLUA33307 0
TEE 1/2 - 2 3000# SOCW SS,ASTM A182 F316,ASME B16.11, TEUA30207 0
FITTING (THD)
COUPLING 1/2 - 2 3000# THD SS,ASTM A182 F316,ASME B16.11, CNUA40207 T 0
ELBOLET 1/2 - 18 3000# THD SS,ASTM A182 F316,MSS SP 97, ETUA43307 0
HALF COUPLING 1/2 - 11/2 3000# THD SS,ASTM A182 F316,ASME B16.11, HFUA40207 T 0
PLUG 1/2 - 2 THD SS,ASTM A182 F316,ASME B16.11,ROUND HEAD PGUA40200 0

Rev.:0.
UV,RO.Pr.
Ref.SI Ref.SI

150# RF NONE SS 316
THREDOLET 1/2 - 18 3000# THD SS,ASTM A182 F316,MSS SP 97, TLUA43307 0
NIPPLE
NIPPLE 1/2 - 2 SCH80S PLN-PLN SS,SMLS,ASTM A312 TP316,ASME B36.19, NPV851413 1 0
NIPPLE 1/2 - 2 SCH80S PLN-THD SS,SMLS,ASTM A312 TP316,ASME B36.19, NPV861413 2 0
NIPPLE 1/2 - 2 SCH80S THD SS,SMLS,ASTM A312 TP316,ASME B36.19, NPV841413 3 0
SWAGE NIPPLE
SWAGE (CONC) 1/2 - 2 PE SS,ASTM A182 F316,MSS SP 95, NCUAJ4500 0
SWAGE (ECC) 1/2 - 2 PE SS,ASTM A182 F316,MSS SP 95, NEUAJ4500 0
VALVES
GATE VALVE 1/2 - 11/2 800# SOCW SS BODY ASTM A182 GR F316,316SS TRIM,GAV401, GAV401 0
GATE VALVE 2 - 6 150# FLG SS(TP316) BODY ASTM A351 GR CF8M,316SS TRIM,GAV410, GAV410 0
GLOBE VALVE 1/2 - 11/2 800# SOCW SS BODY ASTM A182 GR F316,316SS TRIM,GLV401, GLV401 0
GLOBE VALVE 2 - 6 150# FLG SS(TP316) BODY ASTM A351 GR CF8M,316SS TRIM,GLV410, GLV410 0
CHECK VALVE 1/2 - 11/2 800# SOCW SS BODY ASTM A182 GR F316,316SS TRIM,CHV401, CHV401 0
CHECK VALVE 2 - 12 150# FLG SS(TP316) BODY ASTM A351 GR CF8M,316SS TRIM,CHV410, CHV410 0
BUTTERFLY VALVE 6 - 18 150# RF SS(TP316) BODY ASTM A351 GR CF8M,316SS DISC & BUV410 0
STEM,BUV410,WAFER TYPE
:
Rev.:0.
Class: D24 PROJECTS AND DEVELOPMENT INDIA LIMITED
AG,AL,AW,FG,FN,HG,IAH,IAW,NG,NI,PA,PN,VS
Ref SI Ref SI
ETC.

300# RF 1.5 MM(MIN) CS
PIPE
PIPE 16 - 18 SCH XS BE SMLS,API 5L GR.B,ASME B36.10, PPA111300
PIPE 20 - 20 SCH XS BE SMLS,API 5L GR.B,ASME B36.10, PPA111300
PIPE 22 - 22 17.48 MM BE SMLS,API 5L GR.B,ASME B36.10, PPA111300
PIPE 26 - 28 17.40 MM BE SMLS,API 5L GR.B,ASME B36.10, PPA111300
FLANGE
W.N.FLANGE 26 - 28 300# WN-RF 125 AARH CS ASTM A105,ASME B16.47 SR.B,WELD NECK WN0270702
W.N.FLANGE 1/2 - 24 300# WN-RF 125 AARH CS ASTM A105,ASME B16.5,WELD NECK WN0270802
BLIND FLANGE
BLIND FLANGE 26 - 28 300# RF 125 AARH CS ASTM A105,ASME B16.47 SR.B, BF0220702
GASKET
B16.20/B16.47 SR.B,
STUD & NUTS

HEX
DRIP RING
DRIP RING 3 - 3 300# RF 125 AARH CS ASTM A105,PDIL-PDS-600, DR022QK02
FITTING (BW)

RP
FITTING (SW)
FITTING (THD)

Rev.:0.
AG,AL,AW,FG,FN,HG,IAH,IAW,NG,NI,PA,PN,VS
Ref SI Ref SI
ETC.

300# RF 1.5 MM(MIN) CS
NIPPLE
SWAGE NIPPLE
VALVES
BALL VALVE 1/2 - 11/2 800# SOCW CS BODY ASTM A105,BAV202, BAV202
BUTTERFLY VALVE 3 - 24 300# RF CS BODY ASTM A216 GR WCB,BUV202,WAFER TYPE BUV202
:
Rev.:0.
AF,DM,MD,IA
Ref SI Ref SI

300# RF NONE SS 304
PIPE
PIPE 14 - 14 SCHSTD BE EFW,STR.WELD,ASTM A312 TP304,ASME B36.10, PPZ111300
PIPE 16 - 18 SCH XS BE EFW,ASTM A358 GR.TP304 CL.2,ASME B36.10, PP4111300
PIPE 20 - 20 SCH XS BE EFW,ASTM A358 GR.TP304 CL.2,ASME B36.10, PP4111300
PIPE 26 - 28 17.48 MM BE EFW,ASTM A358 GR.TP304 CL.2,ASME B36.10, PP4111300
PIPE 1 - 11/4 SCH40S PE SMLS,ASTM A312 TP304,ASME B36.19, PPPE21400
FLANGE
W.N.FLANGE 26 - 28 300# WN-RF 125 AARH ASTM A182 F304,ASME B16.47 SR.B,WELD NECK WN0670702
W.N.FLANGE 1/2 - 24 300# WN-RF 125 AARH ASTM A182 F304,ASME B16.5,WELD NECK WN0670802
SPACER AND BLIND 14 - 28 300# RF 125 AARH ASTM A182 F304,ASME B16.48, RS062PO02
SPECL BLIND 1/2 - 12 300# RF 125 AARH ASTM A182 F304,ASME B16.48, SP062PO02
BLIND FLANGE
BLIND FLANGE 26 - 28 300# RF 125 AARH ASTM A182 F304,ASME B16.47 SR.B, BF0620702
BLIND FLANGE 1/2 - 28 300# RF 125 AARH ASTM A182 F304,ASME B16.5, BF0620802
GASKET
GASKET 1/2 - 24 300# SPRL-WND RF TP304 SS WDG; GPH FLR; TP304 SS INR RNG/ OTR RNG,ASME B16.20, GSQL30302
GASKET 26 - 28 300# SPRL-WND RF TP304 SS WDG; GPH FLR; TP304 SS INR RNG/ OTR RNG,ASME GSQL3QJ02
B16.20/B16.47 SR.B,
STUD & NUTS

STUD & 2NUTS HVY - ASTM A193 GR.B8T CL.2/ASTM A194 GR.8TA,, SNQG00000
HEX
DRIP RING
DRIP RING 3 - 12 300# RF 125 AARH ASTM A182 F304,PDIL-PDS-600, DR062QK02
FITTING (BW)
BRANCH WELD 2 - 28 BW STAINLESS STEEL,ASME B31.3, RWOK11200
BRANCH WELD WITH 2 - 28 BW STAINLESS STEEL,ASME B31.3, WBOK11200

RP
CAP 2 - 24 BW ASTM A403 WP304-SMLS,ASME B16.9, CP7410900
ELBOW 2 - 28 BW ASTM A403 WP304-WLDD,ASME B16.9, ELZ410900 L
ELBOW 2 - 28 19.05 MM BW ASTM A403 WP304-WLDD,PDIL-PDS-600,R=3D ELZ41QK60 3
REDUCER CONC. 2 - 28 BW ASTM A403 WP304-WLDD,ASME B16.9, RCZ410900
REDUCER ECC. 2 - 28 BW ASTM A403 WP304-WLDD,ASME B16.9, REZ410900
TEE 2 - 28 BW ASTM A403 WP304-WLDD,ASME B16.9, TEZ410900
WELDOLET 2 - 28 BW ASTM A182 F304,MSS SP 97, WL0613300
FITTING (SW)
CAP 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, CP0630207 W
COUPLING 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, CN0630207
ELBOW 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, EL0630207
HALF COUPLING 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, HF0630207
SOCKOLET 1/2 - 28 3000# SOCW ASTM A182 F304,MSS SP 97, SL0633307
TEE 1/2 - 11/2 3000# SOCW ASTM A182 F304,ASME B16.11, TE0630207
FITTING (THD)
CAP 1/2 - 11/2 3000# THD ASTM A182 F304,ASME B16.11, CP0640207 T
PLUG 1/2 - 11/2 THD ASTM A182 F304,ASME B16.11,ROUND HEAD PG0640200
THREDOLET 1/2 - 28 3000# THD ASTM A182 F304,MSS SP 97, TL0643307
NIPPLE
Rev.:0.
AF,DM,MD,IA
Ref SI Ref SI

300# RF NONE SS 304
NIPPLE 1/2 - 11/2 SCH80S PLN-PLN SMLS,ASTM A312 TP304,ASME B36.19, NPPE51413 1
NIPPLE 1/2 - 11/2 SCH80S PLN-THD SMLS,ASTM A312 TP304,ASME B36.19,NPT NPPE61413 2
NIPPLE 1/2 - 11/2 SCH80S THD SMLS,ASTM A312 TP304,ASME B36.19,NPT NPPE41413 3
SWAGE NIPPLE
SWAGE (CONC) 1/2 - 11/2 PE ASTM A403 WP304-SMLS,MSS SP 95, NC74J4500 P
SWAGE (CONC) 1/2 - 11/2 PLN-THD ASTM A403 WP304-SMLS,MSS SP 95, NC7464500 T
SWAGE (ECC) 1/2 - 11/2 PE ASTM A403 WP304-SMLS,MSS SP 95, NE74J4500 P
SWAGE (ECC) 1/2 - 11/2 PLN-THD ASTM A403 WP304-SMLS,MSS SP 95, NE7464500 T
VALVES
GATE VALVE 1/2 - 1 800# SOCW SS BODY ASTM A182 GR F304,GAV501, GAV501
GATE VALVE 11/2 - 11/2 800# SOCW SS BODY ASTM A182 GR F304,GAV501, GAV501 W
GATE VALVE 11/2 - 11/2 300# FLG SS BODY ASTM A351 GR CF8M,GAV511, GAV511 F
GATE VALVE 2 - 24 300# FLG SS BODY ASTM A351 GR CF8M,GAV511, GAV511
GLOBE VALVE 1/2 - 11/2 800# SOCW SS BODY ASTM A182 GR F304,GLV501, GLV501
GLOBE VALVE 2 - 12 300# FLG SS BODY ASTM A351 GR CF8M,GLV511, GLV511
CHECK VALVE 1/2 - 11/2 800# SOCW SS BODY ASTM A182 GR F304,CHV501, CHV501
CHECK VALVE 2 - 24 300# FLG SS BODY ASTM A351 GR CF8M,CHV511, CHV511
BALL VALVE 1/2 - 11/2 800# THRD SS BODY AISI 316,BAV501, BAV501
PLUG VALVE 1/2 - 1 600# THRD SS BODY AISI 316,PLV501, PLV501
PLUG VALVE 11/2 - 6 300# FLG SS BODY ASTM A351 GR CF8M,PLV511, PLV511
:
Rev.:0.
Class: F24 PROJECTS AND DEVELOPMENT INDIA LIMITED
AW,HG,NG,PA,PC,PN,SG,VS
Ref SI Ref SI

600# RF 1.5 MM(MIN.) CS
PIPE
FLANGE
W.N.FLANGE 1/2 - 24 600# WN-RF 125 AARH CS ASTM A105,ASME B16.5,WELD NECK WN0270803
BLIND FLANGE
GASKET
STUD & NUTS

HEX
FITTING (BW)

RP
FITTING (SW)
FITTING (THD)
NIPPLE
SWAGE NIPPLE

Rev.:0.
Class: F24 PROJECTS AND DEVELOPMENT INDIA LIMITED
AW,HG,NG,PA,PC,PN,SG,VS
Ref SI Ref SI

600# RF 1.5 MM(MIN.) CS
VALVES
GATE VALVE 11/2 - 11/2 600# FLG CS BODY ASTM A216 GR WCB,GAV212, GAV212 F
GATE VALVE 1/2 - 1 800# SOCW CS BODY ASTM A105,GAV201, GAV201
GATE VALVE 11/2 - 11/2 800# SOCW CS BODY ASTM A105,GAV201, GAV201 W
NEEDLE VALVE 1/2 - 1/2 800# SOCW SS BODY ASTM A182 GR F316,NEV501, NEV501
:
TFL-PDS-600 0
BRANCH TABLE : TABLE-A1

APPLICABLE PIPING MATERIAL SPECIFICATIONS:B20,B22IS,B24,D24,B24S.
PRESSURE RATING <= 300#
<-----------------------B R A N C H S I Z E---------------------------->
3 1 1 2 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5
M Q 1 Q M 2 M 3 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8
M T
3Q E T
1 E E T
1Q
1M E E E T
2 S S S E T
2M S S S E E T
3 S S S E E E T
4 S S S S E E E T
6 S S S S W W E E T
8 S S S S W W W E E T
10 S S S S W W W W E E T
12 S S S S W W W W W E E T
14 S S S S W W W W W W E E T
16 S S S S W W W W W W P E E T
18 S S S S W W W W W W P P E E T
20 S S S S W W W W W W P P P E E T
22 S S S S W W W W W W P P P P E E T
24 S S S S W W W W W W P P P P P E E T
26 S S S S P P P P P P P P P P P P E E T
28 S S S S P P P P P P P P P P P P P E E T
30 S S S S P P P P P P P P P P P P P P E E T
32 S S S S P P P P P P P P P P P P P P P E E T
34 S S S S P P P P P P P P P P P P P P P P E E T
36 S S S S P P P P P P P P P P P P P P P P P E E T
38 S S S S P P P P P P P P P P P P P P P P P P E E T
40 S S S S P P P P P P P P P P P P P P P P P P P E E T
42 S S S S P P P P P P P P P P P P P P P P P P P P E E T
44 S S S S P P P P P P P P P P P P P P P P P P P P P E E T
46 S S S S P P P P P P P P P P P P P P P P P P P P P P E E T
48 S S S S P P P P P P P P P P P P P P P P P P P P P P P E E T
50
52
54
56
58
A-
E TE REDUCING TEE
P WB BRANCH WELD WITH RP
S SL SOCKOLET
T TE EQUAL TEE
W WL WELDOLET
TFL-PDS-600 0
BRANCH TABLE: TABLE-A2

APPLICABLE PIPING MATERIAL SPECIFICATIONS: B50, B52, D50.
PRESSURE RATING <=300#
<-----------------------B R A N C H S I Z E---------------------------->
3 1 1 2 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5
M Q 1 Q M 2 M 3 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8
M T
3Q E T
1 E E T
1Q
1M E E E T
2 S S S E T
2M
3 S S S E E T
4 S S S S E E T
6 S S S S P E E T
8 S S S S P P E E T
10 S S S S P P P E E T
12 S S S S P P P P E E T
14 S S S S P P P P P E E T
16 S S S S P P P P P P E E T
18 S S S S P P P P P P P E E T
20 S S S S P P P P P P P P E E T
22 S S S S P P P P P P P P P E E T
24 S S S S P P P P P P P P P P E E T
26 S S S S P P P P P P P P P P P E E T
28 S S S S P P P P P P P P P P P P E E T
30 S S S S P P P P P P P P P P P P P E E T
32 S S S S P P P P P P P P P P P P P P E E T
34 S S S S P P P P P P P P P P P P P P P E E T
36 S S S S P P P P P P P P P P P P P P P P E E T
38 S S S S P P P P P P P P P P P P P P P P P E E T
40 S S S S P P P P P P P P P P P P P P P P P P E E T
42 S S S S P P P P P P P P P P P P P P P P P P P E E T
44 S S S S P P P P P P P P P P P P P P P P P P P P E E T
46 S S S S P P P P P P P P P P P P P P P P P P P P P E E T
48 S S S S P P P P P P P P P P P P P P P P P P P P P P E E T
50
52
54
56
58
A-
E TE REDUCING TEE
S SL SOCKOLET
T TE EQUAL TEE
TFL-PDS-600 0
BRANCH TABLE : TABLE-A3

APPLICABLE PIPING MATERIAL
SPECIFICATIONS:F24
<-----------------------B R A N C H S I Z E---------------------------->
3 1 1 2 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5
M Q 1 Q M 2 M 3 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8
M T
3Q E T
1 E E T
1Q
1M E E E T
2 S S S E T
2M
3 S S S E E T
4 S S S S E E T
6 S S S S W E E T
8 S S S S W W E E T
10 S S S S W W W E E T
12 S S S S W W W W E E T
14 S S S S W W W W W E E T
16 S S S S W W W W W W E E T
18 S S S S W W W W W W W E E T
20 S S S S W W W W W W W W E E T
22 S S S S W W W W W W W W W E E T
24 S S S S W W W W W W W W W W E E T
26 S S S S W W W W W W W W W W W E E T
28 S S S S W W W W W W W W W W W W E E T
30 S S S S W W W W W W W W W W W W W E E T
32 S S S S W W W W W W W W W W W W W W E E T
34 S S S S W W W W W W W W W W W W W W W E E T
36 S S S S W W W W W W W W W W W W W W W W E E T
38
40
42
44
46
48
50
52
54
56
58
A-
E TE TEE
S SL SOCKOLET
T TE TEE
W WL WELDOLET
TFL-PDS-600
0
BRANCH TABLE : TABLE-R1

APPLICABLE PIPING MATERIAL SPECIFICATIONS: B22G,B24RL,B24FL.
<-----------------B R A N C H S I Z E------------>
3 1 1 2 1 1
M Q 1 Q M 2 M 3 4 6 8 0 2
M
3Q
1 T
1Q
1M E T
2 E E T
2M
3 E E E T
4 E E E E T
6 E E E E E T
8 E E E E E E T
10 E E P P E E E T
12 E E P P P E E E T
A-
E TE REDUCING TEE
T TE EQUAL TEE
TFL-PDS-600 0
BRANCH TABLE : TABLE-R2

APPLICABLE PIPING MATERIAL SPECIFICATIONS: B24D, B24P.
<-----------------------B R A N C H S I Z E-------->
3 1 1 2 1 1
M Q 1 Q M 2 M 3 4 6 8 0 2
M
3Q
1
1Q
1M
2 T
2M
3 E T
4 E E T
6 E E E T
8 E E E E T
10 E E E E E T
12 E E E E E E T
A-
E TE REDUCING TEE
T TE EQUAL TEE
TFL-PDS-600 0
DOCUMENT NO REV
VALVE DATA SHEETS

2
2
24”
24”
2.
2.
2.
2.
2.
GRAFOIL
> = 8"
6"
13 Cr Stellited.
207
201
sw
THD
207
THD
CHV 210DD
A216 GR.WCB RUBBER LINED

CHV 511F
150
(NO CASTING)
GRAFOIL /GRAPHITE
GRAPHITE
207
THD
(NO CASTING)
GRAFOIL /GRAPHITE
(NO CASTING)
GRAFOIL /GRAPHITE
GRAPHITE
(NO CASTING)
GRAFOIL /GRAPHITE
GRAFOIL
GAV 401
A182 GR.F316
A182 GR.F316
A182 GR.F316
A182 GR.F316
GRAFOIL /GRAPHITE
GRAFOIL /GRAPHITE
GRAFOIL /GRAPHITE
(NO CASTING)
GRAFOIL
GRAFOIL/GRAPHITE
GRAPHITE
(NO CASTING)
GRAFOIL
GRAFOIL/GRAPHITE
GRAPHITE
(NO CASTING)
GRAFOIL
Grafoil
GLV 410
2”-24”
A 351 GR.CF8M
A182 GR.F316
AISI 316
A 276 GR.F316
GRAFOIL
GRAFOIL
GRAFOIL
GRAFOIL

GAV500C :FLANGED GATE VALVE ; 150# ;CPVC BODY(ASTM F441);POLY PROPYLENE PLUG;
EPDM SEALS ;TAPERED CYLINDRICAL PLUG DESIGN; BOLTED BONNET; FLAT FACE; FLANGE
DIMENSIONASPERASMEB16.1.
CHV500C:SOCKETWELDCHECKVALVE;150#;HORV;UNIONORBOLTEDCOVER;BALLTYPE
CPVC BODY(ASTM F441);TRIM AS PER BODY MATERIAL ; SOCKET WELD ENDS AS PER ASME
B16.11MANUFACTURER’SSTANDARDCONSTRUCTION.
BAV500C:SOCKETWELDBALLVALVE;150#;FLOATINGBALL;FULLPORT;WRENCHOPERATED
; CPVC BODY(ASTM F441);CPVC BALL;VITON O RING SEALS; SOCKET WELD ENDS AS PER ASME
B16.11MANUFACTURER’SSTANDARDCONSTRUCTION.
BAV501C: FLANGED BALL VALVE ; 150# ; FLOATING BALL;FULL PORT ;WRENCH OPERATED ;
CPVC BODY(ASTM F441);CPVC BALL;VITON O RING SEALS; FLAT FACE; FLANGE DIMENSION AS
PERASMEB16.1;MANUFACTURER’SSTANDARDCONSTRUCTION.

TFL-PDS-600 0
STRAINER DATA SHEETS

T T
TT T
TFL-PDS-600 0
DOCUMENT NO REV
OTHER STANDARDS/DATASHEETS
PC161-PDS-600 P1
MITER BENDS WITH 5SEGMENTS
DOCUMENT NO REV
PROJECT:HURL PLANT:OSBL SHEET 1 OF 1
MITRE BENDS
45° 45°
TYPE A TYPE B 60° TYPE C
30° 221/2°
111/4°
221/2°
/2°
E
221
E
15°
30°
F
F
1/2 E
F
1/2E
1/2 F
1/2E
R
1/2F
R R
NOM OUTSIDE R 221/2o DIMENSION

SIZE DIAM =1.5D 30o 45o 90o
INCH D mm 60o
mm
TYPE A TYPE B TYPE C
E F E F E F
mm mm mm mm mm mm
2 60.3 76 B A A C 88 38 57 24 42 18
3 88.9 114 B A A C 131 58 85 37 63 28
4 114.3 152 B A A C 173 79 112 51 83 38
6 168.3 229 B A A C 259 120 168 78 125 58
8 219.1 305 B A B C 343 162 222 105 165 78
10 273.1 381 B A B C 429 203 277 131 206 97
12 323.9 457 B A B C 513 244 332 158 246 117
14 355.6 533 B C B C 381 190 283 141
16 406.4 610 B C B C 436 218 323 162
18 457 686 B C B C 490 245 364 182
20 508 762 B C B C 544 272 404 202
22 559 838 B C B C 599 300 445 222
24 610 914 B C B C 654 327 485 243
26 660 991 B C C C 707 354 525 263
28 711 1,067 B C C C 762 381 566 283
30 762 1,143 B C C C 817 408 606 303
32 813 1,219 B C C C 871 436 647 323
34 864 1,295 B C C C 926 463 687 344
36 914 1,372 B C C C 980 490 727 364
38 965 1,448 B C C C 1,034 517 768 384
40 1,016 1,524 B C C C 1,089 544 808 404
42 1,067 1,600 B C C C 1,144 572 849 424
44 1,118 1,677 B C C C 1,198 599 890 445
46 1,168 1,752 B C C C 1,252 626 929 465
48 1,219 1,829 B C C C 1,307 653 970 485
52 1,321 1,982 B C C C 1,416 708 1,051 526
56 1,422 2,134 B C C C 1,524 762 1,131 566
60 1,524 2,286 B C C C 1,633 817 1,213 606
64 1,626 2,439 B C C C 1,743 871 1,294 647
68 1,727 2,591 B C C C 1,851 925 1,374 687
72 1,829 2,743 B C C C 1,960 980 1,455 728
76 1,931 2,897 B C C C - - 1536 768
P1 27.12.2017 FOR REVIEW/COMMENT NAZ NS GL/HOD

P 21.10.2017 FOR REVIEW/COMMENT NAZ NS DM
REV REV DATE EFFDATE PURPOSE PREPD REVWD APPD
PC150/E/4004/SecVI-5.3
0
(PART-A)
PROJECTS & DEVELOPMENT INDIA LIMITED
Document No. Rev
Sheet 1 of 83
SECTION VI- 5.3
DESIGN PHILOSOPHY- ELECTRICAL
PLANT : RAW WATER TREATMENT PLANT- DM WATER-

PROJECT : INTEGRATED COAL BASED FERTILISER

COMPLEX, AT TALCHER, ANGUL DISTRICT,
ODISHA (INDIA)
0 01.09.2020 01.09.2020 Issued for Tender RK SS SKB

PC150/E/4004/SecVI-5.3
RWTP, DMW & CPU PLANT 0
(PART-A)
TALCHER FERTILIZERS LIMITED
DESIGN PHILOSOPHY – ELECTRICAL Document No. Rev
Sheet 2 of 83
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 Scope
2.0 Basis of Design
3.0 Area Classification
4.0 System Details and Utilization Voltages
5.0 Power Supply and Distribution
6.0 Sub Station
7.0 Protection & Metering
8.0 Control and Monitoring
9.0 Equipment Specification
10.0 Cabling
11.0 Illumination System
12.0 Earthing and Lightning Protection
13.0 Cathodic Protection System.
14.0 Capacitor Banks
15.0 Communication System
16.0 Fire Detection and Alarm System
17.0 Structure
18.0 Spares
19.0 Vendor’s Services
20.0 Testing & Inspection
21.0 Documentation
22.0 Tools & Tackles
23.0 Review of Drawings & Documents by Owner/ Consultant
24.0 Training
25.0 Vendor List
26.0 Installation, Testing and Commissioning
27.0 Testing of Installation after Erection
28.0 Quality Assurance
29.0 Coordination with Other Contractors
30.0 Deviations
Annexure-I Illumination Levels

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 3 of 83
LIST OF ATTACHMENTS
Technical
Description
Specification No.
PC150-TS-0801 Public Address System
PC150-TS-0802 Uninterrupted Power Supply System
PC150-TS-0803 Power Transformers
PC150-TS-0804 Neutral Earthing Resistor
PC150-TS-0805 Medium Voltage Switch Boards
PC150-TS-0806 High Voltage Switch Boards
PC150-TS-0807 Bus Duct
PC150-TS-0808 Sheet Steel Distribution Boards
PC150-TS-0809 Lighting Sub Distribution Boards
PC150-TS-0810 Induction Motors
PC150-TS-0811 Interlocking Sw. Socket and Plug
PC150-TS-0813 Battery Charger
PC150-TS-0814 Battery
PC150-TS-0815 Cables
PC150-TS-0817 Local Control Stations
PC150-TS-0818 Junction Box
PC150-TS-0819 Electricals for Over Head Cranes and Hoists
PC150-TS-0820A Variable Frequency AC Drives (High Voltage)
PC150-TS-0820B Variable Frequency AC Drives (Medium Voltage)
PC150-TS-0821 Communication & Fire Alarm Cables
PC150-TS-0822 Capacitor Bank & Associated Equipment
PC150-TS-0823 Cathodic Protection Power Supply Module (CPPSM)
PC150-TS-0824 Cathodic Protection Transformer Rectifier Unit
PC150-TS-0825 Impressed Current Cathodic Protection System
PC150-TS-0826 Fire Detection and Alarm System
PC150-TS-0828 Soft Starter
PC150-TS-0829 Auxiliary Service Transformer
-- Conceptual SLD - 11 kV Switchboard (Drg. No. PC150-1231)

-- Conceptual SLD - 3.3 kV Switchboard (Drg. No. PC150-1232)
-- Conceptual SLD - 415V Switchboard (Drg. No. PC150-1233)

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 4 of 83
Electrical Sketches Description

PC150-PDS:E 113 Foundation Details of 11/0.433kV Transformers
PC150-PDS:E 114 Foundation Details of 11/3.45kV Transformers
PC150-PDS:E 115 Typical Details of Transformer Room Door
PC150-PDS:E 116 Sump Pit for Transformer Oil
PC150-PDS:E 119 Typical Foundation Arrangement for Panels in Sub-Station
PC150-PDS:E 120 Typical Foundation Details for HT/LT Circuit Breaker Panels
PC150-PDS:E 203 Steel Tubular Lighting Pole
PC150-PDS:E 204 Installation of Electrical Poles
PC150-PDS:E 206 Installation Arrangement Street Lighting Fixtures
PC150-PDS:E 207 Details of Bracket Arm for Street Lighting Pole
PC150-PDS:E 208 Installation Arrangement Area Lighting Fixtures
PC150-PDS:E 210 Junction Box for Street Lighting Pole
PC150-PDS:E 213 Typical Street Lighting Pole
PC150-PDS:E 402 Component rating for DOL starter
PC150-PDS:E 464 Schematic Diagram Panic Light
PC150-PDS:E 510 Details of Concrete Cable Trench
PC150-PDS:E 511 Cable Rack Arrangement in Trenches
PC150-PDS:E 516 Typical Arrangement of Cables buried in slit
PC150-PDS:E 602 Earthing Conductor Details
PC150-PDS:E 603 Arrangement of Connections of Earth Conductors
PC150-PDS:E 604 Typical Details of Connection in Earth Pit
PC150-PDS:E 605 Earth Pit Details
PC150-PDS:E 606 Typical Arrangement of Earthing for Motor and Start Stop Push Button
PC150-PDS:E 610 3.8 M GI Electrode for Earthing
PC150-PDS:E 611 GI/Al Accessories for Earth Electrode
PC150-PDS:E 613 Earthing of storage tank & vessel
PC150-PDS:E 615 GI Earth Bus
PC150-PDS:E 617 Typical Arrangement for Neutral and Equipment Earthing

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 5 of 83
1.0 SCOPE
1.1 The scope includes work/service for the complete design, engineering, manufacture, testing
at works, supply of all electrical equipment, dispatch, storage, handling, erection, testing at
site and commissioning of complete electrical system required for ‘Raw Water Treatment
Plant - DM Water - Condensate Polishing Unit along with its Associated Utility facilities’.
Although every item of supply and/ or installation might not have been described, the LSTK
Contractor shall supply anything and everything to complete the project.
1.2 This specification shall be read in conjunction with all drawing and documents attached and
other relevant reference as specified therein.
1.3 The scope of work/ services of LSTK Contractor shall comprise complete electrics of the
Raw Water Treatment Plant - DM Water - Condensate Polishing Unit. The scope of work/
services shall broadly comprise but not limited to the following:
1.2.1 Design & detailed engineering, Coordination, General Services etc
a. Basic as well as detailed engineering.
b. Preparation of drawings/ document/ to suit Project implementation schedule. Preparation
of drawings/ documents/ calculations/ formats/ test reports/ test certificates; Erection,
Testing & Commission Manuals/ Operations & maintenance Manuals/ Reports/ QAP etc
for approval/ Review/ reference/ record and/ or for any other requirement; submission to
Owner/ Consultant in requisite sets, getting approval from Owner/ Consultant, making
approved copies available to manufacturers, inspectors, erection & commissioning
engineers, supervisors, owner/ Consultant etc as required in requisite sets well before
those are actually required by them to fulfil their obligations.
c. Design, manufacture, testing of equipment/ cables/ cable trays/ earthing and other
erection materials etc at manufacturer’s works, submission of documents with
manufacturer’s test reports/ type test reports to Owner/ Consultant prior to inspection
call.
d. Quality Assurance at each stage of manufacture including procurement of raw materials/
bought out items and arranging inspections by Owner/ Consultant/ third party.
e. Obtaining dispatch clearance from Owner in writing.
f. Packing, loading, forwarding, delivery at site/ store, loading/ unloading, storage as per
manufacturer’s recommendation; shifting from stores and handling in store as well as at
site for erection.
g. Arrangement of testing/ checking instruments/ kits/ sets/ apparatus with valid calibration
certificates issued by duly accredited laboratories/ institutions, to carry out tests
stipulated in specification and documents referred therein/ other applicable standards.
h. Deputing electrical contractors, supervisors’ electricians, cable jointers etc. on full time
basis. for carrying out electrical work.
i. Installations of equipment/ cables/ materials.
j. Conducting pre-energisation tests to ensure that installation is fit to be energized.
k. Erection shall not be considered complete unless pre-energisation tests are carried out,
results are tabulated & submitted to owner/ consultant and results are found satisfactory.
l. Conducting functional/ pre-commissioning checks/ Cold trial runs; no-load & load tests,
m. Commissioning the installation.
n. Conducting Performance Guarantee tests and taking corrective steps (inclusive of
replacement of equipment/ materials if required) till results are satisfactory/ acceptable.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 6 of 83
o. Conducting Pre-Acceptance Tests/ checks and tabulating the results/ observations

p. Liquidations of defects/ discrepancies/ observations noted during erection, pre-
energisation tests, commissioning, trial runs, performance guarantee tests, Pre-
acceptance tests/ checks etc.
q. Submissions of all final/ ‘As built’ drawings/ documents after incorporation of changes
made in soft as well as hard copies, duly certified by LSTK Contractor to the effect that
those are ‘Final’ and/ or ‘As built’
r. Conducting Final Acceptance Tests/ Checks
s. Co-ordinate with the Owner/ Consultant, other contractors/ agencies working at site as
required for proper, smooth and timely execution of work/ implementation of the project
t. Preparation of drawings/ documents, applications for getting the installation inspected
and approved by Electrical Inspectorate of state and/ or Central Electricity Authority and
all coordination for getting the installation approved for energisation & use. Carrying out
all modifications/ alterations required by statutory authorities. All expenses on these
activities shall be carried out and borne by LSTK Contractor. The obligation of owner
shall be limited to
 Signing of application as owner of installation and
 Payment of fee for inspection of installation.
Approved drawings and certificates shall be submitted to the Owner/Consultants well
ahead of schedule so that the actual commissioning of equipment does not get delayed
for want of inspection and approval by the Electrical Inspectorate and other statutory
bodies. The actual inspection work by the Electrical Inspector shall be arranged by the
LSTK Contractor and necessary coordination and liaison work in this regard shall be the
responsibility of the LSTK Contractor.
1.2.2 Manufacture, testing at works, getting inspected by owner and/ or their consultant/ third
party, packing, transportation and delivery to site in well packed condition, insurance during
transit and till commissioning & handing over, storing at site as per recommendation of
manufacturer/ supplier/ direction of supervising engineer of Owner/ Consultant until required
for erection, transportation to work place. Erection, testing & commissioning, handing over of
complete electrical system of ‘Raw Water Treatment Plant - DM Water - Condensate
Polishing Unit (hereinafter referred as Plant in short) comprising, but not limited to :
a. Bus Ducts
b. Transformers viz.
 11/3.45 , 11/0.433 kV, 3.3./0.433 V Transformers, as required
 Lighting Transformers
c. Switchgears:
 11 kV / 3.3 kV ICOG Panel, as required
 11 kV Switchgears/ switchboards, as required
 3.3 kV Switchgears/ switchboards, as required.
 415 Volt Switchgears/ switchboards including PCCs, PMCCs, MCCs, EPMCCs
MLDBs, ASPBs, LSDB, PDB, Junction boxes etc as required.
 Local control Panels, Local Control stations, Switch Sockets .
 Variable Frequency Drive Panels / Soft starters, as required
d. 11kV, 3.3kV, 415V Motors and other special application/ voltage motors as required.
e. All Cables viz
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 7 of 83
 Power Cables (11kV, 3.3kV and 1.1kV)

 Control Cables,
 Earthing Cable
 Signal cables,
 Optical fibre cables
 Data Cables
 Communication cables
 Special application cables
f. Erection/ installation & all sundry materials for installation, testing & commissioning of
equipment/ panels/ fittings/ cables (including jointing & termination of cables) comprising
(but not limited to) following:
 Foundations,
 Brackets, support structures, erection materials & accessories, as required
 Cable trays, racks, pipes, ducts, cable channels etc as required.
 Testing checking kits/ instruments
g. Illumination system - Normal, Emergency and Panic Lighting
h. Aviation lighting, as required.
i. Neutral Grounding, NER.
j. Earthing of equipment & structures.
k. Protection against lightning.
l. 110V DC Batteries, Battery Charger and DC Distribution Boards.
m. 115V AC UPS Panels with batteries & UPS & UPS Power Distribution Boards for
Instrument.
n. 240V AC UPS with batteries & UPS & UPS Power Distribution Boards for Electrical.
o. Complete Electrics for Air Conditioning and Ventilation systems.
p. Complete Electrics for Chemical Dosing System.
q. Complete Electrics for fire fighting system,
r. Complete Electrics for EOT Crane, Hoists,
s. Plant Communication system
t. Cathodic Protection System.
u. Public Address System for Plant and Interface & Seamless Integration of same with
Owner’s Public Address System.
v. Fire Detection & Alarm System for Plant and Interface & Seamless Integration same with
Centralised Fire Detection & Alarm System.
w. Cable trench/Cable tray with supporting structure.
x. Substation (for Raw Water Treatment Plant), Substation (for DM Water Plant and
Condensate Polishing Unit) all alongwith Transformer Rooms.
y. Fire fighting systems for Electrical Equipment/ Panels by gas flooding.
z. The scope shall also include the erection, testing, commissioning of above equipments.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 8 of 83
The contractor shall clear the site after commissioning of the equipments / system and
obtain the Site Clearance Certificate from owner’s Engineer-in-charge
aa. Any and all other Materials, Equipment and Services so as to make a totally integrated
and functional system together with all accessories and associated equipment, ensuring
safety, maintainability and reliability in compliance with all applicable codes, standards,
guidelines, statutory regulations and safety requirements in force.
bb. Any other equipment, not specified, but required for safe, proper, trouble free and
efficient operation of the system
cc. LSTK Contractor shall consider any other requirement which is not covered in this NIT,
but required for successful operation of the plant.
dd. Spares & consumables for complete electrics as follows:
 Commissioning Spares (as per Clause No. 18.0 of Design Philosophy-Electrical) and
Spares (Mandatory/Insurance) for all equipments (as per Section 10.0: Spare Parts)
shall be supplied by the Contractor as part of LSTK contract.
 LSTK Contractor shall recommend 2 years Operational Spares (other than
mandatory/ Insurance spare) for all the equipment (item-wise) with recommended
quantity & unit price with validity of 2 Years. The same shall not be part of LSTK
price.
 Spares and consumables required and first oil fills including short fall during erection,
testing, cold trials, commissioning, performance evaluation tests, guarantee tests etc
and till handing over of installation.
ee. Tools & Tackles.
ff. Testing Equipments/ instruments
gg. Arranging services of major equipment suppliers during installation and commissioning.
hh. Training of Owner’s Personnel for Operation & maintenance of the Plant.
ii. Any and all other items/ facilities/ services not specifically mentioned but essential/
required for completeness of the systems/ equipments/ facilities.
1.4 LSTK Contractor shall consider following additional feeders in their 3.3 kV Switchboard /
415 V Switchboards / UPS Distribution Board of Raw Water Treatment Plant Substation for
Owner’s use
a) 3 Nos. additional feeder of 250 KW (2W + 1S) for Raw Water Pumps motors in their
3.3 kV Switchboard. These motors shall be located in Water Reservoir Pump House
b) 1 Nos. additional feeder of 250 KW for Fire Water Make-up Pump motor in their 3.3
kV Switchboard. This motor shall be fed from Emergency Power. Considering the
same, 3.3 kV Switchboard shall have 3 Nos. Incomers 2 Normal, 1 emergency. This
motor shall be located in Water Reservoir Pump House.
c) 1 No. additional Spare feeder of 250 KW motor in their 3.3 kV Switchboard.
d) 3 Nos. 125A power feeders in their 415 V EPMCC for EOT and other Loads of Water
Reservoir .
e) 2 Nos. 125 A Feeders (Indoor Bus) and 1 No. 125A Feeder (Outdoor Bus) in MLDB
for Lighting Loads of Water Reservoir.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 9 of 83
f) 2 Nos. 125A Feeders in ASDB for Switch Sockets of Water Reservoir.
g) 1 No. 32A power feeders in their 115 V AC UPS Distribution Board for UPS Loads of
Water Reservoir .
h) 3 Nos. 125 A Feeders (Indoor Bus) and 2 No. 125A Feeder (Outdoor Bus) in MLDB
for Lighting Loads of Owner Use .
i) 3 Nos. 125 A Feeders (Indoor Bus) and 2 No. 125A Feeder (Outdoor Bus) in MLDB
for Lighting Loads of Owner Use .
j) 2 Nos. 125A power feeders in their 415 V EPMCC for Owner use.
LSTK Contractor to provide required provision in their transformers, Switchboards and

other associated equipments for feeding these loads.
1.5 Separate PMCC and separate EPMCC shall be provided for Raw Water Treatment Plant, DM
Water Plant, CPU Plant with Trivector meter in incomers.
1.6 Normal power supply shall be tapped from 2 Nos. 11KV feeders at Owner’s Offsite &
Utilities Substation and further distribution shall be in LSTK Contractor’s scope.
Emergency power supply shall be tapped from 1 Nos. 11KV feeders (Emergency Bus) at
Owner’s Offsite & Utilities Substation and further distribution shall be in LSTK Contractor’s
scope.
Bidder shall indicate the details of Normal Loads and Emergency Loads in the bid. Tentative
Location of Offsite & Utilities Substation is marked in Plot plan.
1.7 This design philosophy contains specifications of the major equipments to indicate the basic
requirement and serve as a guideline. However, it shall be the responsibility of the contractor
to offer a complete quality electrical system of superior quality, even if the specifications of
certain items are not given.. The items for which technical specifications are not indicated
herein shall be of IS/IEC standard and specifications of these shall be subject to owner’s
approval in case of order.
1.8 The bidder shall offer the best and proven most suitable type of energy efficient equipments
manufactured by well known reputed manufacturers having proven performance track record
of minimum 2 years , as per vendor list appended in this bid package. However for the sake
of standardization of the electrical equipment and material used for the electrical installation,
the LSTK Contractor shall supply all items of a particular type or make for whole plant of the
same manufacturing company for ease of maintenance and less spares inventory.
1.9 1 No. 415 V Feeder (400 A) at Existing Substation near 132 KV Switchyard shall be made
available. Tapping of Construction Power (on chargeable basis) from this feeder (including
supply & erection of all required materials like structural supports for cable tray, cable trays,
power cables, control cables, protection & metering, cable termination etc. as well as
underground cabling work) and further distribution shall be in LSTK Contractor’s scope.
Bidder shall ensure that the minimum power factor of 0.9 shall be maintained at their end by
providing suitable power factor improvement devices.
LSTK contractor shall have to distribute construction power with adequately rated distribution
and sub distribution boards/feeder pillars, power supply cables and other associated
materials for feeding loads to carry out construction and fabrication activities at his own cost.
Bidder shall indicate details of construction power in the bid with month-wise breakup for the
entire duration of project.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 10 of 83
However during non availability of construction power, LSTK contractor shall have to arrange
emergency power, if required, through DG set at their own cost.
1.10 Contractor shall provide adequate area lighting at site of construction, fabrication yards,
storage yard and office etc. by means of suitable lighting fixture, lighting masts, flood lighting
poles etc. which are to be supplied and maintained by the contractor as per safety aspect.
1.11 Relay Co-ordination & Relay Settings etc. of the entire electrical installation of ‘Raw Water
Treatment Plant - DM Water - Condensate Polishing Unit ‘shall be conducted by the LSTK
Contractor using latest software preferably ETAP at appropriate stage of design-engineering.
. All the Electrical equipments shall be designed and selected according to the Short Circuit
Study Report.
In case equipment is ordered before studies are completed and revision of rating or design is
required as a result of Electrical System Study then inclusion of such revisions shall be in
LSTK Contractor’s scope without any cost and time implication.
1.12 For control, monitoring, load management, data logging and printing of status of all important
electrical equipment and feeders, a Programmable Logic Controller (PLC) based Load
Management System (LMS) shall be provided by Electrical Distribution System (EDS) LSTK
Contractor. However, LSTK Contractor has to provide the required multifunctional dual
channel transducers (Only where Current Data is critical and used in process control) ,
Digital Multi-function Meters, latest version numerical/Communicable type protective relays
with non-volatile memory, comprehensive unit providing protection, metering, control &
communication with communication port & interlinked with Online Energy/Load Management
System and required microprocessor based devices if any in panels , communicable door
mounted Motor Protection Relays in all motor feeders of PMCC & MCC, proper
communication facility in supplied UPS, Battery Chargers, VFD, Soft starter , MOV and
other critical equipment for proper communication with LMS / DCS system. The interface of
electrical equipments with LMS / DCS shall be through IEC 61850 communication protocol
for Numerical relays and IEC 61850/Modbus for Multifunction Digital Meters, Motor
Protection Relay (MPR) and other equipment, Ethernet communication module shall also be
used. 100% redundancy shall be provided for communication i.e. the relay should have
minimum 2 Nos. IEC-61850 communication port in addition to Front Port.
LSTK Contractor shall provide separate room for local LMS equipments (Data Concentrator
Panels, OWS, EWS, PC console, chairs, furniture etc.) in substations of Raw Water
Treatment Plant - DM Water - Condensate Polishing Unit’. Provision of future expansion of
Data Concentrator Panels etc. shall also be considered while designing separate room.
1.13 The scope shall also include obtaining all required statutory approvals from all statutory
bodies. Contractor shall carry out all modifications/alterations required by statutory bodies.
All approvals for permanent installations shall be obtained in the name of Owner. Approval
for equipment & installation for Construction Power shall be in LSTK Contractor’s name.
1.14 In case of any discrepancies between Design Philosophy – Electrical and Technical
Specification of equipment/item/work in respect of description of equipment/ item/work, the
details indicated in the Design Philosophy – Electrical shall prevail.
1.15 Final location of equipments as well as route of cable trays shall be rechecked in 3D
modelling.
1.16 All electrical equipments installed in the areas classified as hazardous shall be certified for
such use by a recognized certifying authority such as CIMFR Dhanbad / PESO, Nagpur etc.
1.17 All electrical works associated with the followings but not limited to, shall be considered
a) Raw Water Treatment Plant - DM Water - Condensate Polishing Unit ’
b) Air conditioning systems
c) Chemical Dosing System.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 11 of 83
d) Fire fighting system,

e) Fire protection system
f) Cranes, Hoist, elevators
g) Pollution control and monitoring equipment
h) q) All auxiliary building & associated electrical building/rooms.
1.18 Following Interfaces are envisage presently of LSTK Contractor ;
- Protection for outgoing feeder of 11 kV Switchboard at Offsite & Utilities Substation to
LSTK Contractor Switchboard (Inter tripping, Cable Protection etc.)
- Interface and Seamless Integration with Centralised Fire Detection & Alarm System.
- Interface and Seamless Integration with Owner’s PA System.
However, any other interface and Seamless Integration requirement or any other unforeseen
which may arise during detailed engineering/ execution stage, same shall also be in the
LSTK Contractor’s scope without any cost and time implication.
1.19 All the sub stations shall be provided with following equipment :
- CO2 fire extinguishers (4.5 litre capacity) as per applicable NFPA.
- DCP fire extinguishers
- Synthetic insulating mats on front and back side of the switchboards.
(LV as well as HV) as per latest IS.
- Framed single line diagram in Aluminum frame with glass,
- Do’s & Don’t chart as per Indian Electricity Rules in Aluminium frame with glass.
- Shock treatment chart written in English and Local language duly framed and
approved by engineer-in-charge.
- Caution boards / dangers boards written in ENGLISH & HINDI for all the voltage
levels.
- CPR (CARDIO PULMONARY RESUSCITATION) Charts.
- High Voltage / Low Voltage danger signage (Skull & bones).
- Exit Route / Emergency Exit Route Signage.
- Cable Route Marker, wherever cable is in underground.
- Earthing rod.- Minimum 1 No. for each Voltage level.
- Sets of Sand buckets with stand (each with at least 3 sand buckets) for substations
and transformer yards.
- HT discharge rod.
- HT and LT hand Gloves (3 Sets each for each substation).
- A Type FRP ladder 3 feet & 8 feet – 2 no each type for each substations.
- First Aid Box
Other requirement or any other unforeseen which may arises during detailed engineering
shall also be in LSTK Contractor ’s scope
2.0 BASIS OF DESIGN
2.1 General
2.1.1 The electrical installation shall be designed to provide:
 Necessary amount of power
 Flexibility
 Service reliability
 Ease of expansion
 Ease of operation and maintenance & inter changeability of equipment
 Safety of personnel
The design of electrical installation shall ensure provision of a safe, efficient and reliable
supply of electricity at all times including adverse system conditions. Safe conditions shall be
ensured under all operating conditions including those associated with start up and shut
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 12 of 83
down of plant as well as those arising out of failure of electrical equipment. The isolation of
part of system of electrical equipment due to either maintenance or shut down shall not
compromise safety aspects.
2.1.2 The design of electrical installation shall ensure provision of a safe and reliable supply of
electricity at all times. Safe conditions shall be ensured under all operating conditions
including those associated with start up and shut down of plant as well as those arising out
of failure of electrical equipment, climatic conditions like lightning and earthquake etc. The
isolation of part of system of electrical equipment due to either maintenance or shut down
shall not compromise safety. All electrical equipments shall be of proven design and
technology.
System shall be designed considering following aspects in general: -
 To facilitate inspection, cleaning and maintenance with the care to safety in operation and
personnel protection.
 To minimize turnaround time.
 To provide safety, reliability and flexibility of service.
 Adequate provision for future extension and modification.
 Maximum interchangeability of equipment.
 Desired level of operator interface to achieve coordinated efficient and fail-safe operation,
data logging and maintenance of the equipment.
 To decide redundancy, stand by, spares and overload capacities to achieve desired
reliability and flexibility requirement.
 To get cost effective and techno commercially proven technology. Economic
considerations shall cover capital and running costs and an assessment of the reliability
of the system.
2.1.3 All the electrical consumers within the battery limit shall be identified and listed to have
complete details of rating, efficiency, power factor, operating duty cycle (continuous,
intermittent, standby), category of supply required (emergency, normal, critical) etc.
2.1.4 Required redundancy (based on specific process/operating needs) shall be built in
substation which feeds power supply to process units/important facilities so that in case of
tripping of one feeder, the unit may not be adversely affected and continuity in operation at
full capacity is achieved.
2.1.5 While sizing the system necessary consideration shall be given to restrict the system voltage
drop within permissible limits during starting of large rated motors. At the same time, the
short circuit current shall be kept within limits keeping in view of the market availability of
switchgears rating. For this purpose current limiting reactors/unit ratio transformers if
required may be used.
2.1.6 LSTK contractor while performing design and engineering activities shall adhere to following
guidelines.
a) If any equipment is not covered in this design philosophy but required for successful
operation of the project, LSTK contractor shall prepare additional specifications for
equipment or bulk material taking reference of Indian/International Codes and good
engineering practices prevalent in fertilizer industry and obtain owner’s approval for the
same.
b) The standard drawings attached with this package define the basic system design and
distribution philosophy for the package. This is for guidance purpose only. LSTK
contractor shall develop detailed drawings and submit for owner’s approval.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 13 of 83
c) LSTK contractor shall be responsible to verify the rating and consider providing
equipment with adequate rating but not less than the specified rating. Compliance
should be without any extra cost and time implications.
d) LSTK contractor shall consider any other requirement which is not covered in this bid
package, but required for successful operation of the plants without any extra cost and
time implications.
e) Contractor shall obtain approval from all statutory authorities such as Central Electricity
Authority (CEA)/Electrical Inspectorate, Chief Controller of Explosives (CCoE), CPCB
etc. for all electrical facilities including electrical switchboards & panels supplied and
installed by LSTK contractor.
f) LSTK contractor shall assist in Liaison and in all interface coordination with contractors
of other units of project at construction, erection, testing & commissioning phase for any
common facility and for smooth execution.
g) Equipment specification sheet/data sheets for all equipment shall be prepared by the
contractor based on relevant codes and Technical specifications/ Data sheets attached
as reference. Data sheet shall contain all technical data and information which are
essential for review and technical acceptability, detailed engineering, installation,
testing, repair and maintenance, replacement etc.
h) Contractor shall clearly specify in their purchase specifications the requirement of
conducting special tests/type tests, which are envisaged for various electrical equipment
which shall have no impact on cost and time.
i) Bidder shall must visit the site and collect all relevant information required for designing
of complete system before quoting. Bidder shall make themselves familiar with the work
actually involved and actual site conditions. Failure to do so shall not absolve the Bidder
of their responsibilities based on adverse site conditions.
j) All the electrical equipments shall be of proven design and technology.
k) Normal & Emergency Load details (rating of all motor, Lighting, Switch socket etc.) load
shall be submitted.
l) Load Summary shall be prepared by LSTK contractor to determine ratings of electrical
equipments (transformer, switchgears, cables etc.), to evenly distribute plant loads
among the various substations and switchgear, and to evaluate the need for power
factor correction. All calculation shall be necessarily reviewed/approved by
Owner/Consultant.
Motors, heaters etc. shall be designed as per Section 4.0 : Design Basis of NIT.
The maximum normal running load and the peak load shall be calculated as follows:
Maximum Normal Running Load = (100% of sum of all continuous load) + (40% of sum
of all intermittent loads or largest intermittent load, whichever is higher).
Peak Load = (100% of sum of all continuous load) + (40% of sum of all intermittent
loads or largest intermittent load, whichever is higher) + (20% of sum of all standby
loads or largest standby load, whichever is higher).
Electrical System shall be designed for continuous Peak Load operation.
Note: If electrical motor is stand-by to non-electrical driven equipment (for e.g. turbine
driven equipment), then in such case standby motor shall be considered as continuous
load.
All the electrical equipments shall be designed / sized considering motor input power
(i.e. BKW divided by motor efficiency).
Margin for future requirement shall be as per clause 2.1.6 m over the above.
Line loss of 2% to be considered for equipment sizing.
Minimum P.F. shall be maintained as 0.95 at every voltage level.
All the electrical equipments like Transformers, Switchboards etc. shall be suitable for
starting of the largest motor, while other loads are running, considering peak load
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 14 of 83
condition.
m) Electrical equipments i.e. Transformers, Switchgears, MCCs, PCCs etc. shall have
capacity for future requirements. The Margin shall be as follows:
i) HV Transformer: 25% is added to the Continuous Peak Load.
LV Transformer: 30% is added to the Continuous Peak Load.
ii) Switchgear: Switchgear bus bar current rating as well as breaker shall be equivalent
(nearer or higher standard rating size) to full load current of upstream Transformer.
iii) Switchboards and MCCs fed from other switchboards: Shall be rated for 125% of
peak load.
n) The actual fault levels shall be arrived at on the basis of incoming power source,
transformers, contribution of motors, etc.
o) Prospective touch and step voltages shall not be adverse to the stipulations of relevant
publications of Bureau of Indian Standards / IEC/IEEE-80.
p) Sizing calculations for all the electrical equipments shall be submitted for
review/approval, in case of award of order. Owner/Consultant’s Comments, if any on
the same shall also be considered and modification in any equipment shall be done
accordingly, without any price implication.
q) Seismic zone as applicable shall be considered for design of all electrical equipment.
2.2 Load Grouping
Electrical consumers shall be classified as 'normal / non-essential, emergency / essential or
vital / critical loads as per the concepts defined below:
2.2.1 'Emergency' or 'essential' loads shall be identified on the criteria that, when failing in
operation or when failing if called upon, will affect the continuity of operation, the quality or
the quantity of product. For such loads, reliable source shall be ensured. Such feeders shall
be grouped on a separate bus section in the respective Switchboards/ MCCs / PCCs.
2.2.2 Some of the loads which can be identified as emergency / essential load but not essentially
limited to following:
- Electrical loads required for continuous operation of process plants utility in case of
normal supply failure.
- Electrical loads required for safe shut down of facilities in case of normal supply failure.
- Emergency lighting & communication facilities.
- Fire Detection and Alarm System.
- AC & DC UPS / Battery charging equipment.
- Control room AC equipment -Essential ventilation system for offices / Manned areas of
other buildings.
- Motorised valves as per process requirement
- PA & Paging system.
- AC Emergency Lub Oil Pump
- Any other load (To be indicated by LSTK Contractor )
2.2.3 Critical’ or 'vital' loads shall be identified on the criteria that, when failing in operation or when
called upon, can cause an unsafe condition of the installation, jeopardize life or cause a
major damage to the installation. For critical loads if any, UPS shall be provided to facilitate
uninterrupted supply. The loads on UPS are AVR / PLC / DCS / Auxiliary supply for drives
etc. Critical drives if any shall be provided with DC motors.
2.2.4 Some of the load which can be identified as critical / vital load but not essentially limited to
following:
- Loads providing control and protection to plant equipment.
- Loads serving critical equipment for safety of plant, equipment and / or personnel
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 15 of 83
2.2.5 Non-essential service is a service, which is neither 'essential' nor 'vital'. Hence the non-
essential load does not require any special measure such as standby feeder or standby
source to safeguard the continuity of service.
2.3 Statutory requirement Codes and Standards

2.3.1 The design, installation, testing & commissioning shall conform to compliance of following
statutory requirements :
- Indian Electricity Act
- Indian Electricity Rules
- The Indian Factories Act
- The Indian Explosives Act.
- Statutory requirement of Govt of Odisha and Govt. of India.
- Guidelines, instructions, directions issued by Pollution control Boards of state as well
as central government. Guidelines, instructions, directions issued by Chief Controller of
Explosives (CCoE), CPCB, CMRI, DGMS, CEA etc.
- Guidelines of Tariff Advisory Committee
- Guidelines of Insurance Companies Association.
- Any other applicable Rules/Acts/Regulations.
The design, installation, testing & commissioning shall be in accordance with established
codes, good engineering practices and latest versions of following documents valid/
applicable on the date of acceptance of bid. The stipulations in these documents shall be
considered as minimum requirements:
- Indian Standard Specification or equivalent IEC Standards
- Publications of IEEE
- API Standards
- National Electrical safety Code(NESC)
- Standards of Underwrites laboratory(UL)
- American Society for Testing Material (ASTM)
- American National Standards Institute (ANSI)
- Other International Standards
LSTK contractor shall be responsible for obtaining necessary statutory approvals from all the
statutory bodies/authorities e.g. Electrical Inspectorate, PESO (earlier CCoE) as applicable
before commissioning of electrical facilities. The CEA clearance for electrical equipment and
components thereof shall be obtained by the contractor.
LSTK Contractor shall carry out all modifications / alterations required by all statutory bodies.
However, necessary statutory fee shall be deposited by the Owner.
2.4 Some of the bare minimum relevant Indian Standards are as listed below. However,
system/equipment design shall be in line with latest edition of all applicable standards.
IS: 325, Three phase induction motors
IEC:60034
IS: 335 New insulating oil for transformers and switchgears
IS: 722 AC electricity meters
Code of practice for electrical wiring installations system voltages not
IS: 732
exceeding 650V
Specification for wrought aluminum and aluminum alloys, sheet and
IS: 737
strip (for engineering purpose)
IS: 996, Single phase AC motors

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 16 of 83
IEC:60034
Direct acting analogue electrical measuring instruments and their
IS:1248
accessories:
IS: 1367 Part- Hot dip galvanised coatings on threaded fasteners.
13
IS: 1646 Code of practice for fire safety of buildings and electrical installations
General and safety requirements for Luminaries (Tubular fluorescent
IS: 1913
Lamp)
IS: 2071 Method of high voltage testing
IS: 2099 High voltage porcelain bushings
Code of practice for the protection of buildings and allied structures
IEC:62305
against lightning
IS/IEC60079 Electrical apparatus for Explosive gas atmosphere
Porcelain post Insulators for system with normal voltage greater than
IS: 2544
1000 volts
IS: 2633 Methods of testing uniformity of coating on zinc coated articles
IS: 2705 Current Transformers
Code of practice for fire safety of industrial buildings, electrical
IS: 3034
generating distributing stations.
IS: 3043 Code of practice for earthing
Instrument transformers — General requirements
IEC 61869-1
IEC 61869-2 Additional requirements for current transformers

IEC 61869-3 Additional requirements for inductive voltage transformers
IS: 3177 Crane duty motors
IEC60034
IS: 3347 Dimensions for porcelain transformer bushings
IS: 3637 Gas operated relays
IS: 3639 Fittings and accessories for power transformers
IS: 3646 Interior illumination: Part I & Part II
IS: 3716 Application guide for insulation co-ordination
Degree of protection provided by enclosure for rotating electrical
IS/IEC:60529
machinery
IS: 4722 DC motors
IS: 4759 Hot dip zinc coating on structural steel and allied products
Specification for wrought Aluminum alloys bars, rods, tubes and
IS: 5082
sections for electrical purposes
IS: 5561 Electric power connectors
IS: 5571 Guide for selection of electrical equipment for hazardous areas
IS: 5572 Hazardous areas other than mines for electrical insulations area having

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 17 of 83
flammable gases and vapours

IS: 5578 Guide for marking of insulated conductors (1st rev)
IS: 6362 Designation of methods of cooling of rotating electrical machines
IS: 6600 Guide for loading of oil immersed transformers
IS: 6665 Code of practice for Industrial lighting
IS: 7689 Guide for control of undesirable static electricity
Interconnecting Bus bars for AC voltage above 1 KV upto and including
IS: 8084
36 KV
IS: 9676 Reference ambient temperature for electrical equipment
Code of practice for selection, installation and maintenance of
IS: 10028
transformers
IS: 10322-1 Specification for Luminaries,Part-1,General requirements
Guide for uniform system of marking & identification of conductor &
IS: 11353
apparatus terminals
IS: 11448 Application Guide for AC electricity meters
Voltage bands for electrical installations including preferred voltage and
IS: 12360
Frequency
IS: 12459 Code of practice for fire protection of cable runs
IS: 12615 Energy efficient motors
IS: 13234 Guide for short circuit calculations
General requirements for electrical apparatus for explosive gas
IS: 13346
atmosphere.
Code of practice for the selection, installation and maintenance of
IS: 13408
electrical apparatus for use in potentially explosive atmospheres
ISIEC: 60947 Low voltage switchgear and control gear
Degree of protection provided by Integral design of rotating electrical
IS: 60034-5
machines
IS: 60079-0 Explosive atmospheres, Equipment General Requirements
Explosive gas atmospheres – Part-1 Equipment protection by Flame
IS: 60079-1
proof enclosures “d”.
IS: 60079-7 Equipment protection by increased safety “e”
SP: 30 National Electrical Codes (NEC) - BIS Publication
IS/IEC 62271 HV Switchboard.
IEC 60947 LV switchboard.
IEC 61439-1/2 LV switchboard (PCC/PMCC/MCC) for TOTAL TYPE TESTED (TTA).

Type Test Certificates for short circuit withstand of 50kA for 1 sec.
along with ACB mounted in the Switchboards shall apply.
IEC 61641 Switch Board with INTERNAL ARC CONTAINMENT test.
ANSI C-37:23 Metal enclosed bus
ANSI C-37:24 Effect of Solar radiation on metal enclosed bus.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 18 of 83
IEC 60034 Rotating Electrical Machinery
IEC 61131 Programmable controllers

IEC 60871-1 Shunt Capacitors for AC power Systems Specifications
/IS 13925
Any other standard may be followed provided it is equivalent or more stringent than the
standards specified above.
2.5 In case of any conflict/deviation amongst various documents the order of precedence shall
be as follows:
 Statutory rules/regulation
 Design Philosophy
 Data sheets
 Technical specification/Installation Standards, etc.
 Applicable IS/IES standards
In case of contradiction / conflict among documents and statutory requirement, LSTK
Contractor shall refer to Owner for clarification. However, most stringent specification shall
be followed with Owner’s approval. Owner decision shall be considered as final.
2.6 Site Conditions
The equipment shall be designed for the following site conditions:-
 Minimum ambient Temperature 1 deg.C
 Maximum ambient Temperature 46 deg.C
 Design Reference Temperature 50 deg.C
 Relative Humidity 100%
 Altitude above mean sea level Lower than 1000 Mtrs.
 Atmospheric pollution Dusty due to presence of Coal Dust & Urea
Dust and corrosive due to presence vapours
of Ammonia.
Equipment/ cables selected shall be derated for (a) higher ambient temperature, (b)
restriction in temperature rise (c) variation in voltage, (d) variation in frequency (e)
installation conditions viz. proximity to heat sources, bunching, layering, separation from
others/ laying in conduits etc. with respect to the conditions for which it was designed &
manufactured. Various de-rating factors considered shall be informed with supporting
documents.
Equipment to be installed in MCC rooms/ Electrical Rooms/ Control rooms shall be
designed for + 50º C so that in case of failure of Air-conditioning/ ventilation facilities, the
operation/ functioning of equipment is not be affected.
3.0 AREA CLASSIFICATION.

3.1 The hazardous zones within the project area shall be classified according to the requirement
of IS/IEC. The bidder shall furnish area classification drawing with Technical part of the Bid.
PESO approved Hazardous Area Classification Drawing shall be submitted during detailed
engineering.
3.2 All electrical equipments installed in the areas classified as hazardous shall be certified for
such use by a recognized international certifying authority such as CIMFR earlier CMRI,

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 19 of 83
Dhanbad. The item shall in addition bear the valid certification from PESO (earlier CCoE)
and also the manufacturer shall hold a valid Bureau of Indian Standards (BIS) license.
For those items where overseas OEM vendor will supply the electrical equipment certificate
from international authority can be accepted but the certification shall be approved by PESO
(earlier CCoE), Nagpur India.
3.3 The electrical equipment for hazardous areas shall be selected as per IS-5571 and
petroleum rules and Gas group shall be selected based on the approved hazardous area
classification drawing . The minimum requirement is summarized below:
Equipment Zone-1 Zone-2
MV Motors Ex-de Ex-n
HV Motors Ex-de / Ex-p Ex-n/Ex-de/Ex-p
Push Button Station Ex-d Ex-d
Motor Starters Ex-d Ex-d
Plug & Socket Ex-d Ex-d
Welding Receptacle Ex-d Ex-d
Lighting fitting Ex-d Ex-nR
Control Gear Box Ex-d Ex-nR/Ex-d
Junction Boxes Ex-d Ex-d
Transformer Unit Ex-d Ex-d
Break Glass Unit Ex-d Ex-d
(Fire Alarm System)
Lighting Panel/Power Panel Ex-d Ex-d
Transformers Hermetically sealed with surface temperature not exceeding
200º C
Notes:
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 or hydrocarbon mixtures having more than 30% hydrogen, the gas group to be
considered shall be IIC.
As additional safety features, the following requirements for electrical equipment shall be
followed :
1. All electric motors for agitators/mixers and metering pumps handling flammable
material shall be flameproof type (Ex-de) irrespective of the area being classified as
zone-2 or zone-1.
2. All electric motors for vertical sump pumps handling flammable material shall be
flameproof type (Exde).
3. Irrespective of the area classification (whether zone-1 or zone-2), all lighting fixtures
within the storage areas shall be flameproof type (Ex-d).
4. Irrespective of the area classification (whether zone-1 or zone-2), all motors and
lighting fittings within the pump house near the offsite tank farm and within the
loading/unloading gantries shall be of flameproof type (Ex-d).
5. All emergency/critical lighting fixtures and associated junction boxes in hazardous
areas (whether zone-1 and zone-2) shall be flameproof type (Ex-d).
6. Even though fired heaters in process units are not considered for area classification, all
electrical equipments associated with fired heaters in process units shall as a minimum
be suitable for installation in Zone-2 area.
7. Where air conditioning system is designed considering ammonia as refrigerant, the
room housing air conditioning equipment shall be adequately ventilated to classify it as
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 hermetically sealed.
- AC plant room motors with type`e' protection.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 20 of 83
- Lighting in AC plant room suitable for zone-2 area.

8. Building such as Compressor sheds inside the process area shall be designed to allow
adequate ventilation to allow area classification as Zone-2.Lighting equipment, EOT
crane etc. in the shed shall be flameproof type (Ex-d). All other electrical equipment
shall be suitable for Zone-1 or Zone-2 area depending on extent of hazard.
9. All HV motors for hazardous area Zone-1 shall preferably be flameproof type (Ex-de).
Pressurised motors may be provided in exceptional cases.
10. Ex-n motors without pre-start ventilation as permitted by Indian Standard unless any
other type is specified by Process Licensor , shall be provided, except for the following
cases as listed below:
- HV motors for Centrifugal compressors (As Ex-n motors are not recommended for
use for such applications as per IS/IEC-60079-15 and therefore Ex-de or Ex-p
motors shall be provided for these applications)
- For motors in Zone-2 areas having frequent start/ stop requirements e.g. EOT
cranes/ Elevators, MOV actuators etc., Ex-de motors shall be used.
11. For Zone-2 areas, motors with ratings above 100kW having average starting frequency
of more than one per week, Ex-n motors with pre-start ventilation provision or Ex-de or
Ex-p motors shall be used.
12. Ex-p motors shall be used for large rating motors where Ex-de or Ex-n motors are not
available.
4.0 SYSTEM DETAILS AND UTILIZATION VOLTAGES

4.1 The various voltage levels for in plant power distribution shall be as follows:
A. Normal Power 11KV ± 10%, 50Hz ± 5%, 3Ph, 3 W
B. Emergency Power Voltage Variation ± 5%, 50Hz ± 3%, 3Ph, 3 W
C. Distribution Equipment a) 11KV ± 10%, 50 Hz ± 5%, 3 Ph, 3 W with
resistance earthed neutral
b) 3.3KV ± 10%, 50 Hz ± 5%, 3 Ph, 3 W with
resistance earthed neutral
c) 415V±10%, 3 Ph, 4 W/240V ± 10%, 1 Ph,
2W, 50 Hz ± 5% solidly grounded neutral.
Combined variation in voltage ± 10%
& frequency
Control Supply for:
- 415V motors AC 240V ± 10%, 50 Hz ± 5%, 1Ph (For contactor
controlled motors)- Electrical UPS located in
Substation.
DC 110V ± 5% (For breaker controlled motors) –
Battery Charger
- Switch Gear Breaker
controlled feeders:
a. Closing, tripping & spring
DC 110V ± 5%, 2 W - Battery Charger
charging motor
AC 240V ± 10%, 50 Hz ± 5%, 1Ph, 2W
b. Auxiliary power
- Instrumentation and AC 115 V ± 10%, 50 Hz ± 3% 1Ph, 2W –
Instrumentation UPS located at Control Room
Automation, DCS &
Auxiliaries

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 21 of 83
Voltage Ratings
- Motors above 1000 KW 11 KV, 3 Ph AC
- Motors above 150 KW up to 3.3 KV, 3 Ph AC
1000 KW.
-Motors up to150 KW 415 V, 3 Ph AC
- Space heaters 240V, 1 Ph AC
- Lighting 415V/240V AC
- Panic Lights 110V DC
- Power Sockets/Receptacle 415V, 3 Ph AC/240V, 1 Ph AC
- Portable safety lamps & 24V AC
Tools
4.2 The actual fault levels shall be arrived at on the basis of incoming power source,
transformers, contribution of motors, etc. and shall be indicated in the Bid.
All switch boards of the same voltage shall be rated for identical fault level. Minimum fault
level to be considered for design and selection of equipment shall be as follows:
11 kV Switchgear – 40KA for 3 Seconds.
3.3 kV Switchgear – 26.24KA for 3 Seconds.
The fault level for 415V switchboards shall be 50KA for 1 sec.
Impedance of transformers shall be selected suitably (tap position at principal) without
comprising voltage drop at receiving end.
11kV/0.433kV or 3.3kV/0.433kV Transformer rating shall not be more than 2000kVA.
Fault level of DC System shall be decided by the LSTK Contractor after substantiating
the same by calculation.
4.3 System Earthing
The neutral of 11 KV and 3.3 KV systems shall be non-effectively earthed through
resistance. The earth fault current of 11 KV and 3.3 KV shall be limited to full load current of
the transformer or 400 A, whichever is less.
The neutral of 415V supply system shall be solidly earthed.
The DC system shall have positive pole earthed through high impedance. Prospective touch
voltage earthing shall comply with the requirements of relevant Indian/IEC standards.
5.0 POWER SUPPLY AND DISTRIBUTION.
5.1 Power supply from 11 KV switch board in Offsite & Utilities Substation of Plant
5.1.1 2 Nos. 11 kV Feeders and 1 No. 11 kV Feeders (Emergency Bus) shall be made available
in 11 kV Switchboard at Offsite & Utilities Substation. Tapping of power supply from 11 kV
Switchboard at Offsite & Utilities Substation (including supply of all required material),
structural supports for cable tray, cable trays, cables, cable termination etc. shall be in LSTK
Contractor’s scope. Further distribution to equipment at 11 KV, 3.3 KV, 415/240 V, 115 V
(UPS) AC, 240 V (UPS) AC, 110 V DC etc. through proper type and size of cables, their
supply, erection, testing and commissioning etc. shall be in LSTK Contractor’s scope.
LSTK Contractor shall consider 11kV/3.45kV, 11kV/0.433kV or 3.3kV/0.433kV transformers
for downstream distribution. The supply system shall be designed for maximum power
requirement of the plant. Double radial system of power supply, each suitable for 125% of
full load shall be followed for entire plants.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 22 of 83
LSTK Contractor shall indicate details of power requirement and the Rating of 11kV Feeders
at offsite & Utilities Substation in the Bid.
5.1.2 2 Nos. Separate substation shall be provided for Raw Water Treatment Plant and DM Water
Plant & CPU Plant. Tapping of power among these substations shall be in scope of LSTK
Contractor.
5.1.3 In the event of failure of normal power in the plants, the plants shall be brought to safe shut
down condition through Emergency power. Emergency power shall cater to the load of
emergency lighting, UPS system, battery charger, motorized valves, Fire alarm system, PA
& Paging system in addition to the process loads for safe shutdown of the Plant and
wherever required as per detail design.
Emergency power supply shall be tapped from 2 numbers of feeders (of required voltage
level) at Owner’s Offsite & Utilities Substation and further distribution shall be in LSTK
Contractor’s scope. However, Bidder shall indicate the details of Emergency Loads in the
bid.
5.1.4 The electrical system layout and interconnections (power as well as control) shall be such
that the problem in electrical system of one plant should not affect the electrical system of
other plant and vice versa.
5.1.5 The insulation system of cable, 11 kV & 3.3 kV equipments shall be based on unearthed
system only.
5.1.6 Each incoming feeder shall be sized for 125% load of the switch board. The outgoing
feeders shall be sized for the nominal load. Breaker rating of all the outgoing feeders of
11KV switchboards & & 3.3 KV switchboards shall be same considering provision of
interchangeability.
5.1.7 Primary connections of transformers shall be provided with cables of suitable size and
secondary connections shall be through cables/bus duct.
5.1.8 The entry of cables in the switchboards shall be from bottom only.
5.1.9 All switchboards shall be provided with minimum two incoming feeders and one bus tie
having auto/manual changeover facility.
5.1.10 It shall be possible to have momentary paralleling of power sources at 11 kV, 3.3 kV
switchboards and 415V PMCC /PCC/MCC and trip the desired circuit breakers.
5.1.11 The normal operation of the 11 kV, 3.3 kV Switchgears, Power & Motor Control Centre
(PMCC) and Motor Control Centre (MCC) shall be as under:
i. Bus-coupler shall be provided between all the sources. Incomer and Bus-coupler
breaker rating shall be same for all the switchboards. Each incoming feeder shall
independently feed the loads on respective buses with full rated bus tie breaker open
and the load on each bus balanced. In order to ensure maximum degree of reliability
and continuity, automatic transfer from one incoming feeder to other shall be possible
through auto/manual closing of bus tie breaker in case of sustained loss of power on any
bus section.
ii. The bus tie breaker shall be provided with auto/manual selection. The bus tie breaker
shall be independent in manual mode. In auto selection mode, the bus tie breaker is
electrically interlocked with incoming circuit breakers, so that it cannot be closed unless
one of the incoming breakers is open.
iii. When one of the incoming feeder trips, the bus tie breaker is closed automatically based
on the philosophy described and the total load is transferred to other healthy incoming
feeder which is capable of carrying the entire load. Sufficient switchgear capacity is to
be provided. Time for changeover is suitably selected based on downstream system
requirement of reacceleration of motors etc.
iv. Auto Change Over scheme shall be provided for incomer feeders and bus coupler
feeder of 11kV switchboard, 3.3kV Switchboards and 415V Switchboards. Under
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 23 of 83
normal operating conditions, incomer-1 and incomer-2 breakers shall be closed and bus
coupler breaker shall remain open with ‘Local-Remote-Off’ switch in ‘Remote’ position.
The bus coupler breaker shall close automatically under the following conditions being
fulfilled:
 Either of the incoming breaker trips due to under voltage (70% or below).
 Voltage on the healthy bus is more than 80% for the set period.
 Residual voltage on the bus with no power supply comes down to 30% or below.
Required nos. of bus PT, line PT and under voltage relays shall be provided to achieve
the desired automatic changeover.
v. Auto transfer shall take place only on sustained loss of power on either of bus sections.
Auto transfer shall be blocked in case of fault on either of bus sections or no power on
both incomers.
vi. Paralleling of two incoming feeders is not foreseen. However, facility for momentary
paralleling shall be provided for intentional changeover without interruption of supply
with synchro check relay in Bus Coupler panel. There shall also be provision of selective
tripping of one feeder out of three feeders with a Delay (two incoming feeders and one
Bus Coupler).
5.1.12 HV emergency board shall also have 1 Normal and 1 Normal/Emergency incomer. EPMCC
shall have 1 Normal and 1 Normal/Emergency incomer feeding critical load of plant whereas
PMCC & MCC shall have 2 Nos. Normal Power Incomers feeding non-critical loads. DC
Battery Charger, UPS System etc. shall be fed from EPMCC. PMCC shall fed breaker
controlled feeders and various power feeders whereas MCC shall fed contactor controlled
load and various power feeders. PMCC and MCC shall be separate.
5.1.13 Auxiliary Services Power Board (ASPB) having essential bus (to be fed from Emergency Bus
of EPMCC) and nonessential bus (to be fed from Normal Bus of EPMCC) shall be provided
in the plant for supplying power to welding switch sockets, lighting load, EOT crane and
other auxiliary loads.
5.1.14 Separate MCCs be provided for air conditioning and ventilation systems.
5.1.15 For the use of the Owner during plant shut down period, each area shall be provided with
indoor type feeder pillar, which shall be located in a separate room other than substation
building and away from hazardous area. The feeder pillar shall be fed from the 415 V
switchboards (PMCC) of the nearby substation. Each feeder pillar shall comprise of 1 No.
630 A 4 P MCCB incomer, 2 Nos. of 250 A TPN MCCB outgoing feeders, 2 Nos. 125 A TPN
MCCB outgoing feeders and 4 Nos. 63 A TPN MCCB outgoing feeders. Other construction
details shall be as per specification of sheet steel distribution board (PC150-TS-0808).
Location of feeder pillar shall be decided during detailed engineering.
5.2 Instrumentation Power
5.2.1 The power supply for instrument shall be 115V, 1Ph from UPS System.
5.2.2 Provision for 240V, 1 Ph power for lighting of instrument panels shall be provided from
LSDB.
5.2.3 All instrument panels shall have two UPS incomer supply (one from different bus of UPS
DBs) to avoid any type of power obstruction in case of failure of one supply.
5.2.4 Separate 240VAC UPS System shall be provided to feed MCC control supply, Control Room
(to meet 250 lux in case of UPS Supply only) ) & Substation lights (30% of total light) , LMS
Equipment, Fire Detection & Alarm System etc. This UPS System along with associated
Battery (Ni-Cd) and UPS distribution Board shall be located at Substation.
5.3 Lighting Distribution
5.3.1 In each substation a Main Lighting Distribution Board (MLDB) shall be in provided. MLDBs
shall have two incomers from PMCC through 415/433 V Lighting Transformers. Two Incomer
of MLDB to be feed from two separate Bus section of PMCC. However, in other areas the
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 24 of 83
Lighting Distribution Boards shall receive power from MLDB. One third lighting load shall be
connected to the emergency power (DG Source) to provide emergency light during failure of
normal power. Both the MLDB Incomers and Incomers of other LSDB (excluding field
mounted LSDBs) shall have Metering facility with Digital communicable Multi-function
Meters.
Both the lighting transformers feeding MLDB and their respective circuit breakers shall have
same rating. Both the lighting transformers shall be designed for 100% load of MLDB.
33 % of total light of plant excluding Substation & Control Room shall be fed from
Emergency Power (DG Power), in case of failure of Normal Power.
10% of light or required Number of lights for safe evacuation at strategic locations, whichever
is higher, shall be used as panic light (110V DC), in case of complete shutdown for the
plant area excluding Substation & Control Room.
5.3.2 The both normal and emergency section of Main Lighting Distribution Board shall have
separate Sections of busbars for indoor and outdoor lighting. Indoor / Outdoor bus Sections
shall be connected by means of suitably rated contactor operated through photo-cells /
digital clock timer.
5.3.3 Manual by-pass circuit for outdoor lighting shall be wired up to a switch located in
Electrical control room / shift office, so that outdoor lighting can be switched ON or OFF
manually to bypass the automatic switching.
5.3.4 All outdoor lighting fixtures and outside lighting of Sub-Stations, Offices, Control Rooms etc.,
shall receive power from outdoor lighting bus.
5.3.5 All Lighting fixtures / electrical equipment in Analyzer room shall be flame proof type.
5.3.6 Main Lighting distribution board shall feed Lighting Sub Distribution board having 63A 4 Pole
MCB and ELCB as incomer, 16Amp DP MCB and ELCB as outgoing . The outgoing
ELCB shall have rating of 300 /100 mA. Six, Nine or Twelve way Lighting Sub Distribution
board shall be used having 30 % as spare outgoing MCB feeder.
5.3.7 Welding outlets shall be fed from ASPB having 3 phase supply for welding connection. All
welding outlets shall be provided with CBCT ELCB of 100 mA and Digital Earth Fault Relay
with display.
5.4 DC Power
5.4.1 110 V DC system shall be provided for control of circuit breaker feeders and panic lighting. It
shall be obtained from Ni-Cd batteries.
5.4.2 The battery shall be provided with SCR controlled automatic rectifier-cum battery chargers
and shall consist of Main Float cum Load charger, Standby Float cum Load charger and
Boost Charger and 2 Nos. Battery Bank each of 60% capacity (of 5 hours backup at 100%
capacity) with isolation facility for ease of operation & maintenance.
5.4.3 Each rectifier-cum- battery charger shall have independent power supply to be fed from the
emergency source.
5.4.4 Each Substation requiring 110V DC shall have 2 sources with auto changeover facility in
case of failure of 1 source.
5.4.5 DC Battery Charger, AC UPS and HVAC for control room shall be fed from emergency
switchboard.
5.4.6 Battery end cell voltage shall 1.1V. Aging factor shall considered 125% and spare capacity
shall have 120%.
5.4.7 For Temperature derating factor shall be based upon Minimum Ambient Temperature i.e.
50C.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 25 of 83
5.4.8 Battery Charger shall have at least 20% extra capacity for future load requirement. Battery
Charger shall have 110 V DC system.
5.4.9 Separate Rectifier-Cum-Battery Charger with DC Distribution Board and Battery Bank shall
be provided for each Substation.
5.4.10 The battery and charger combinations shall be such as to ensure continuity of D.C. supply at
load terminals without even momentary interruption.
5.4.11 AC Ammeter and AC Voltmeter on Charger Input; DC Ammeter, DC Voltmeter for charger
output/ battery voltage and on demand type Battery Charge / Discharge Ammeter shall be
provided.
5.4.12 For all other specifications of Battery Charger , refer PC150-TS-0813.
5.4.13 For all other specifications of Battery Bank, refer PC150-TS-0814.
6.0 SUB-STATION
6.1 Elevated with trays in cable cellar : Yes
6.2 Air-conditioned room for operator : Yes
6.3 Roof slab for
a Power transformer : Yes
b Distribution transformer : Yes
6.4 Batteries in substation and control Rooms : Separate room
6.5 Switchgear room : Air-conditioned substation
6.6 Battery charger in substation : Air conditioned
6.7 Variable speed drive panels : Air-conditioned substation
6.8 Thyristor controlled panels : Air-conditioned substation
6.9 240V UPS System : Air conditioned control room
6.10 Nickel- Cadmium Battery : Separate room (Ventilated)
6.11 Annunciation panel (HMI) : Operator Room in substation
6.12 The Sub-Stations shall be located near the load centres but away from hazardous areas as
per IS/IEC. Actual size of substations shall be based on the final dimensions of substation
equipments. Each Substation shall include Maintenance Room, Engineer Rom, Shift Office
(Staff Room), Gents toilet (both Indian and western WC), Ladies toilet (both Indian and
western WC) etc.
6.13 The sub-station building shall have double storey construction. The ground floor shall have
cable gallery and first floor shall have all switchboards, control panels etc. The switch room
shall have epoxy flooring. False ceiling shall be provided in VFD room, staff room &
Engineers room.
6.14 The cable gallery shall have a minimum clear height of 2.2 M (i.e. lowest cable tray should
run at a height of 2.2 mtr. from finished floor level of cable cellar) and shall be closed on all 4
sides with two entries, preferably on opposite sides. It shall house all cable trays and their
supports
6.15 Transformer floor shall be at least 300 mm above the finished floor level of cable cellar room.
6.16 In addition to the entry to substation for operating personnel, a separate entry of minimum
3.5M (H) X 3M(W) with rolling shutter shall be provided for all equipment entry. The rolling
shutters should be manually operated with gear box. The Sub-station shall also have an
emergency door opening outwards.
6.17 Sub-station wall adjacent to the transformer bays and walls separating transformers shall be
355 mm thick (inclusive of plastering) in case of brick construction or 240 mm thick in case of
RCC construction upto roof slab. RCC roof slab shall be provided for Transformer, Series
Reactor, capacitor and Cathodic Protection Equipment. The gate of Transformers shall be
designed to prohibit bird entry.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 26 of 83
6.18 Adequate number of Portable Fire Extinguishers of Dry Chemical Powder and Carbon
dioxide shall be provided in suitable location in Substation, Transformer bays, Control room
building etc. . These extinguishers will be used during the early phase of fire to prevent its
spread and costly damage.
All extinguishers shall be supplied with initial charge and accessories as required.
Portable type extinguishers shall be provided with suitable clamps for mounting on walls or
columns.
All extinguishers shall be painted with durable enamel paint of fire red colour conforming to
relevant Indian Standards.
Dry chemical powder type extinguisher shall conform to IS: 2171.
Carbon Dioxide type extinguisher shall conform to IS: 2878.
6.19 Sub-station building shall be without any columns within the switchgear room to ensure
optimum space utilization.
6.20 The layout of equipment shall be such that it shall have adequate space for installation,
operation, maintenance and future expansion. The clearance of equipment from the
walls/other equipment shall be adequate to ensure safety of working personnel. Generally
the following norms shall be maintained for 33/11 KV/3.3 KV/415 V Switchboards:
a) The clear space of 2.5 M at rear side of 33/11kV/3.3 kV Switchboard.
b) A clear space of 1.5M behind the double front switchboards and 1M for single front.
c) A clear space of 3.0M between the two boards facing each other.
d) A clear space of 2.5M on either side at entrance/exit.
e) A clear space of 2.0M between two boards in same line after future panel space of
switchboard.
f) A clear space of 1M in switch room from top of equipment.
6.21 The substation Switchgear Room, UPS & Battery Charger room, LMS room, Maintenance
room, Engineer Room, and Shift Office shall be fully air conditioned through HVAC with
(n+1) system, however all the equipment shall be suitable for operation under specified
ambient condition even on failure of air conditioning system. The substation shall have
HVAC system so that the temperature inside the substation is maintained at 25 Deg.C in all
conditions. Provision for remote alarm on failure of air conditioning system shall be provided.
Indication of substation and control room temperature shall be provided. Heat load to be
calculated on the basis of heat generation in the substation during peak summer period. Fire
damper to be provided in the ventilation duct of the HVAC. There should be a separate room
for installation of the HVAC Units located at ground floor.
6.22 Epoxy flooring shall be done to reduce the heat load and improve the aesthetic look.
6.23 The battery room shall form a part of the sub-station. Battery room shall be provided with
minimum two flameproof exhaust fans and louvered opening in opposite wall/door. A sink
with water tap shall be provided with water connection. Eye wash shower shall also be
provided. Floor of the battery room and walls up to 2 M height shall have acid/alkali resistant
protective epoxy coating. Light fittings, exhaust fan, on/off switches etc. in this room shall be
chemical resistant type and flame proof type.
6.24 Location of battery charger shall be nearer to battery room.
6.25 To the extent possible Bus duct shall be in straight position. Bending of bus duct shall be
avoided.
6.26 Staircases (with SS Handrail) and other rooms shall be paved with Kota stone.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 27 of 83
6.27 Fixed type glass ventilators on all sides shall be provided near the ceiling height for natural
lighting.
6.28 Arrangement shall be provided for lifting heavy equipment to be brought into the sub-station.
6.29 Sufficient nos. of entrances (min. 2) shall be provided for each floor.
a. All doors of sub-station shall be air-tight fire proof steel doors except doors of control
rooms/ PLC rooms which may have anodised aluminium frame with toughened glass
panel. All doors shall open towards exit.
b. Windows shall have anodised aluminium frame and provided with toughened glass.
c. In case height is more than 10 meters, elevators (of capacity for 10 persons) shall be
provided. Elevator shall be suitable for the area of installation.
d. 1000 mm wide insulated rubber mat of appropriate voltage grade shall be provided in
front as well as rear of each panel.
6.30 The Sub-stations shall also have an emergency door opening outwards.
6.31 The sub-station shall house all the electrical power, control and monitoring equipment except
those required for operation in the field. The equipment shall broadly include the following: -
 Transformers located in separate Bay/Room.
 High Voltage Switch Boards
 Power Control Centres
 Power & Motor control centres
 Emergency Power & Motor control centres
 Motor Control Centres
 Auxiliary Service Panel Boards
 Lighting Transformer (Indoor / Outdoor as per requirement)
 Main Light Distribution Board
 Lighting Distribution Boards
 Lighting Sub-Distribution Boards
 Battery Sets
 Rectifier-Cum-Battery Charger
 DC Distribution Boards
 Rectifier-inverter Sets
 UPS System alongwith UPS distribution board.
 Neutral Earthling Resistors (Indoor / Outdoor as per requirement)
 Input / Output Panels
 VFD System
 Any other equipment required
6.32 All static devices such as Rectifier-Cum-Battery Chargers, Variable Speed Drive Panels, Soft
Starter etc., shall be housed in a separate room. Heat load for panel to be taken by panel
manufacturer.
6.33 Separation walls between transformers in all substations and safe inter transformer
distances for switchyard transformers shall be provided.
6.34 Transformers shall be located in bays adjacent to the sub-station building. All bays shall
have oil drained floor, surfaced with gravel or other suitable material.
6.35 In order to prevent leaking oil from reaching and polluting the water bearing stratum,
transformers shall have the following provisions, depending on the oil capacity of the
transformer.
Oil Capacity up to 2,000 litres:
Transformers installed adjacent to sub-station shall be provided with oil soak pit with a
layer of pebbles of about 40 mm granulation.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 28 of 83
Oil Capacity exceeding 2,000 litres:

Transformers installed adjacent to sub-station shall be provided with oil collection pit and
sump pit as per Drg. No. PC150-PDS:E 114 for draining away of any oil, which may
escape or leak from the tanks, to a waste oil tank..
6.36 A clear space of at least 1.5 meter shall be maintained all around the transformers after
installation of Nitrogen Fire Protection & Extinguishing System etc. Nitrogen Fire Protection
& Extinguishing System complete with piping as required shall be separate for each
transformer.
6.37 Separate common oil pits are required for Transformers.
The volume of common oil pit will be 125% of the volume of oil of the transformer, which
contains the largest volume of oil in transformers.
The oil pit will be closed type of water-proof concrete construction.
The oil pit will be connected to individual pit under each transformer and drain line of each
transformer will be at least 150 mm dia pipe with a minimum slope of 1:96 as per TAC
Regulation.
Transformer fire/drainage of oil will be considered for only one transformer at a time.
Level of pit will be so selected that there would not be accumulation of oil/water/oil-water
mixture in the pit under each transformer.
Pit shall be provided with 2 x 100% sump pump for common oil sump.1 No. Portable sump
pump shall also be provided.
Oil Pit under Transformer and its Cooler Bank: Gravel filled open oil pit will be provided
under each transformer and its cooler bank. The pit shall be such that it can take oil/water
surge of 20% of the volume of the transformer oil. Level of pit shall be such that there will not
be accumulation of oil/water in the pit. The gravel size will be 60 mm. Each pit will be
connected to the drain line leading to new common oil pit.
6.38 In all substations/MCC rooms, space for future extension of switchboards shall be provided.
Two panel extension space on each side (for each bus section) shall be provided for all HV
Switchboards, PCCs. One panel extension space on each side (for each bus section) or two
panel extension space on one side (in exceptional cases) shall be provided for all PMCCs,
MCCs and ASPBs.
In addition, space for future extension of the substation/MCC room building shall be
considered. Substations shall have provision for future expansion Minimum 5 Mtrs space for
future horizontal expansion.
6.39 Fire protection for substations shall be provided to comply with requirements of relevant BIS
(Bureau of Indian Standards) and other Indian/ International standards, as applicable. In
case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA/NFPA or equivalent agency shall be applicable.
In case of contradiction / conflict, most stringent specification shall be followed.
Substations shall be provided with smoke detectors and fire alarm system as specified
elsewhere in the ITB and as per relevant Indian Standard.
6.40 Fire barriers shall be provided at cable/bus-duct entry/exit point. Cable shall have fire
protection paint for 1 m length at building entry points for above ground cables.
7.0 PROTECTION & METERING
7.1 Selection and co-ordination of protection and metering system shall be such as to ensure:
 Selective, sensitive and reliable protection of equipment against damage due to internal or
external faults or atmospheric discharge.
 Isolation of fault in the shortest possible time.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 29 of 83
 Simplicity of the scheme with maximum protection.

 Uninterrupted operation of healthy system.
 Personnel & plant safety.
7.2 Protective relays shall be of latest version, numerical / communicable type with non-volatile
memory, comprehensive unit providing protection, metering, control and communicable with
communication port for interlinking with online energy/Load Management System. 100%
redundancy shall be provided for communication i.e. the Relay should have minimum 2 Nos.
IEC-61850 communication port in addition to Front Port.. Numerical Relay shall have
communication on IEC-61850 protocol in redundant mode and meters shall have
communication on MODBUS protocol. Relay shall have 4 CT input for O/C and E/F
protection. There should be option for derivation of E/F internally.
Relay shall meet the requirement for withstanding electromagnetic interference
according to relevant parts of IEC 60255 / IEC 61850. Failure of single component
within the equipment shall neither cause unwanted operation nor lead to a complete
system breakdown.
The relay should support (tested for) IEC 61850 Edition 2 with parallel redundancy protocol
as per IEC 62439-3 with two nos. of port and one additional port at front for local
communication. Use of any type of converter is not acceptable.
7.3 Numerical relay shall indicate MWH, MVAR, MVA, V, A, Hz, PF. It shall have future provision
for connecting with substation HMI. Separate multifunction meter with communication (for
centralized energy monitoring) shall be used and shall not be part of protective device.
7.4 Relays shall support features like remote relay parameterization, disturbance recorder etc. It
shall be possible to set/operate the relay from the front facia. Lock out relay shall be
conventional type with hand reset facility.
7.5 Contractor shall supply licensed (lifetime) software along with required communication
cables for Parameterization and viewing of disturbances, events, etc. through Laptop for all
Make and models of Numerical relays. 1 No. Laptop complete (8GB RAM, 1 TB hard Disk,
latest processor) with all required software shall also be provided.
7.6 Special protection if required for any feeder such as differential, restricted earth fault,
directional distance power relays etc. shall also be through numerical relay having serial port
for monitoring.
7.7 In general all protection shall be through microprocessor based numerical relay. However
high speed tripping relay shall be separate.
7.8 All Auto-changeover logic to be built in Numerical Relay. Numerical Relays shall have
sufficient I/O to cater the same and there should be minimum 10 % spare I/O for future use.
External I/O Card/ Module are not acceptable.
7.9 All Process Stop and other important Parameters shall be routed through Numerical relays
for recording and Time-stamping. Hardware Annunciator is not required. Common Audio
Visual Alarm for each Bus section of Switchboard shall be provided through Numerical
relays.
7.10 Bare minimum protection for power distribution system shall be as indicated below.
However, LSTK contractor shall provide any other necessary protection required for
complete protection of system:.
Protection devices for power distribution system shall be as indicated below (Figure inside
bracket refers to note below) (YES – Applicable)
Sl. Relay Description Relay HV Tr. HV Tr. HV /LV O/G O/G I/C I/C
No. No. Fdr. Sec Fdr. Sec Motor Fdr., Bkr. HV Bkr. EHV/ MV
Wdg. Wdg. HV Breaker Plant MV HV PMCC
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 30 of 83
Volt=> Volt< controlled Fdr. PMCC
3.3 KV 3.3 KV contactor
controlled
1. IDMTL Over-Current 51 YES YES ------- YES YES YES YES
Relay (2)
2. IDMTL Earth-Fault 51N YES YES ------- YES YES YES YES
Relay (4) (2)
3. Standby / Backup 51G YES YES ------- ------- ------- ------- -------
Earth Fault Relay (11) (24) (24)
(earthed neutral)
4. Motor Protection 99 ------- ------- YES ------- YES ------- -------
Relay with (50, 50N,
46, 49, 50L/R, 95)
5. Instantaneous 64R ------- ------- ------- ------- ------- YES YES
Restricted Earth (11) (25)
Fault Relay (Earthed
side)
6. Instantaneous Over 50 YES YES ------- ------- ------- ------- -------
current Relay
7. Instantaneous Earth 50N YES YES ------- ------- ------- ------- -------
Fault Relay (5)
8. Differential 87 YES ------- YES YES ------- ------- -------
Protection Relay (6) (7) (8)
9. High speed tripping 86 YES YES YES YES YES YES YES
relay (20)
10. Trip Circuit 95 YES YES YES YES YES YES YES
Supervision Relay (20)
11. Transformer 63 YES YES ------- ------- ------- ------- -------
Auxiliary Relay
12. Under Voltage Relay 27 / 2 ------- ------- YES ------- ------- YES YES
with timer (9) (9)
13. Check 25 ------- ------- ------- ------- ------- YES YES
Synchronisation (10) (10)
Relay
14.
Notes for Relay Protection Philosophy
1. All the numerical relays shall be of communicable type and connected to LMS on IEC
61850 (Ethernet based) communication protocol with time stamping and time
synchronization.
2. In case of HV switchboards with continuous parallel operation of incomers, following
additional relays shall be provided:
a. One set of 87B (Bus differential) and 95 B (Bus wire supervision) for each bus
section.
b. 32 (Directional IDMTL over current and earth fault) relays for the incomers.
3. In case of grid power supply EHV incomer following additional relays shall also be
provided:
a. Relay 21 for distance protection, Relay 59 for overvoltage protection with timer, Relay
67 for directional over current protection, Relay 67N for directional earth fault
protection, Relay 81 for under frequency / df/dt protection and Relay 98 as dead bus
charging relay.
b. Minimum protection relays for EHV Transformer shall be 50, 50N, 51, 51G, 51N,
63TX, 64R, 86, 87T, 87F & 95.
4. Instantaneous earth fault (50N) shall be provided only for transformer with delta primary.
5. Directional IDMTL earth fault (67N) shall be provided for transformer with star primary.
6. For transformers rated 5 MVA and above.
7. For motors rated 1500 kW and above, excluding VFD fed motors.
8. .
9. Wherever auto-transfer feature is provided.
10. For switchgears where continuous or momentary paralleling of Incomers is envisaged,
check synchronizing relay shall be provided.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 31 of 83
11. 51G and 64R relays for input transformer of VFD system shall be decided by VFD
Manufacturer.
12. The bus tie feeders in HV switchboards shall be provided with 51, 51N, 86 and 95
relays.
13. HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage), 60 (Neutral
displacement), 86 and 95 relays.
14. 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
a. HV and MV capacitor feeders.
b. HV and MV breaker controlled motor feeders.
c. Contactor controlled motor feeders with DC control supply.
Numerical relays where ever provided for motor and capacitor feeders shall use in built
under voltage relay and timer for delayed tripping on bus under voltage.
15. One no. DC supply supervision relay (80) shall be provided for each incoming DC
supply to the switchboard.
16. .
17. In case of numerical relays, all relays shall be comprehensive units including all
protection, metering and control.
18. Under voltage and over voltage function along with associated timer shall be part of the
numerical relays.
19. Auto changeover scheme control & logic between Incomers and bus coupler shall be
built in the numerical relay.
20. Tripping relays (86) shall be separate relay. There shall be two nos. high speed tripping
relay for motor feeder. One for electrical fault and one for process fault. Electrical fault
relay shall be hand reset type and process fault relay shall be self reset.
21. Breaker control switch shall be hardwired type.
22. Stand by earth fault relay 51G shall be provided in the incomer of switchboard fed from
transformers where transformer & switchboard both are located remotely from HV
substation as well as in same HV substation.
23. For transformers located remotely away from HV Substation, a local power isolating
device in the form of breaker panel without any protection relay shall be provided before
transformer. A local emergency stop push button (Lockable) shall also be provided in
transformer bay for tripping remote breaker.
24. Restricted earth fault relay 64R shall be provided for transformer rating >= 1 MVA in the
incomer of switchboard fed from transformers having secondary winding star connected.
This shall trip the HV side breaker.
25. .
26. Relay 87 and 64R shall be separate numerical relay. Hence shall not be part of main
comprehensive numerical relay. CT for 87 and 64R can be clubbed, as two core of
single CT.
27. Accuracy class of the current transformers shall be
- Class PS for differential and special requirements.
- Class 0.5 / 0.2 S for metering purpose.
- Class 5P20 for protection purpose
All the CTs shall have rated burden of minimum 15 VA and secondary rated current of 1
A.
28. Accuracy class of the potential / voltage transformers shall be
- Class 5P for protection purpose.
- Class 0.5 / 0.2 S for metering purpose.
All the PTs shall have secondary voltage 110 V or 110 V / sqrt.3 and rated burden of
minimum 50 VA per phase for both metering and protection core.
29. All the incoming, outgoing and tie breaker feeders of any HV & MV Switchboard shall be
provided with numerical relays only with communication facility as protection devices.
Releases shall not be acceptable in any case. The relays for outdoor 66 kV EHV
switchyard shall also be of numerical type with communication facility.
30. Numerical relays in all HV motor feeders shall be suitable for RTD / BTD inputs.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 32 of 83
31. Each bus section shall be provided with separate under voltage relays.
32. Multifunction meter shall be provided to keep a record of power consumption and
supervision of all concerned parameters like current, voltage, power, frequency, power
factor etc. as specified. All the metering instruments shall be flush mounted.
33. Separate Communicable Digital Multifunctional meters shall be provided in all feeders
with Numerical Relays for communication with LMS system.
34. Motors shall also be provided with Unbalanced (-Ve) Sequence Protection Relay (46),
as required.
35. Numerical under voltage relays (27) with time delay relay including VT fuse failure relay
shall be provided for Bus VTs.
36. All Motor feeders of PMCC & MCC (irrespective of Rating) shall have door mounted
communicable (Modbus / Profibus) type Motor Protection relay (MPR) with display.
37. No Meters, transducers or measuring equipments to be installed in the Protection CT
circuit.
38. Cable Differential relays for both the end to be supplied by Downstream user contractor
i.e. LSTK Contractor. Cable Differential relay will be of Fiber Optic Cable based
communication only.
39. All required Alarms and Trips shall be incorporated in the Numerical relays. Sufficient
LED shall be available in the Relays.
40. Trip Circuit Supervision relay shall be part of Numerical relay.
41. All Motors above 5.5KW and Outgoing Feeders above 100A shall Earth Fault protection
with CBCT and Digital Earth Fault Relay with display.
7.11 Metering instruments shall be provided to keep record of power consumption and
supervision of all concerned parameters like current, voltage, power (Active, Apparent and
Reactive), frequency, power factor, Energy (Active & Reactive) etc. All the instruments shall
be flush mounted. All meters shall be digital multifunctional meters with communication port
for Load management at remote location. Additionally digital type ammeter, voltmeter and
Hour Meter shall be provided separately for various feeders as indicated below :
The metering devices in HV and MV switchboards shall be as below:
- Type of metering: Analogue/As part of the Numerical relay

(Figure inside bracket refers to note below) (YES - Applicable)
Sl. Feeder type A V Hz PF MW MWH HM MVAR MVAH MVA
No.
1. HV Incomer YES YES YES YES YES YES ---- YES YES YES (1)
2. HV Bus Tie YES ---- ---- ---- ---- ---- ---- ---- ---- ----
3. HV YES ---- ---- ---- YES YES ---- ---- ---- ----
Transformer
4. HV Bus PT ---- YES ---- ---- ---- ---- ---- ---- ---- ----
5. HV Plant YES ---- ---- ---- ---- YES ---- ---- ---- ----
Feeder
6. HV Motor YES ---- ---- ---- ---- YES YES ---- ---- ----
(kWh)
7. HV Capacitor YES YES ---- ---- ---- ---- ---- YES ---- ----
8. PMCC Incomer YES YES ---- YES ---- YES ---- ---- ---- ----
(kWh)
9. PMCC Bus Tie YES ---- ---- ---- ---- ---- ---- ---- ---- ----
10. PMCC Bus PT ---- YES ---- ---- ---- ---- ---- ---- ---- ----
11. ACB Outgoing YES ---- ---- ---- ---- YES ---- ---- ---- ----
(Non Motor) (kWh)
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 33 of 83
12. MV Motor YES ---- ---- ---- ---- ---- ---- ---- ---- ----
(>55 KW)
13. MCC / ASB YES YES ---- ---- ---- ---- ---- ---- ---- ----
Incomer
14. MCCB O/G YES ---- ---- ---- ---- YES ---- ---- ---- ----
(250A and (kWh)
above)
15. MLDB Incomer YES YES ---- ---- ---- YES ---- ---- ---- ----
(kWh)
Notes for Metering:-
1. MVA meter in external power supply incomers shall include maximum demand indication
also.
2. Separate analogue type voltmeters with voltmeter selector switch and analogue type
ammeters with ammeter selector switch shall be provided for incomers of all
switchboards.
3. Ammeter (size 48mm x 48mm) shall be provided in space heater circuit of breaker fed
HV & MV motors.
4. Apart from metering which shall be part of the numerical relays, Communicable digital
multi-function meters of Accuracy Class 0.5 with suitable Metering CT shall be provided
in all the breaker feeders of HV & MV Switchboard i.e. in incomers, bus coupler,
outgoing plant feeders, transformer feeders, motor feeders, capacitor bank feeders, etc.
5. Multi function meters with serial communication over RS-485 or fiber optic cable,
preferably with IEC protocol shall be provided in all the breaker feeders.
6. Power factor meter shall be provided for synchronous motors in addition to the metering
provided for induction motors.
7. For current feedback to DCS/PLC and VFD feeders motor current transducers shall be
provided and mounted in switchgear panel.
8. CT operated Ammeter for all motor feeders above 5.5 KW, all MOV and LOPs shall be
provided at both LCS and feeder end of switchboard.
9. All ammeters for LV motors shall be connected through CT. Only HV motors shall have 3
ammeters or ammeter selector switch or Voltmeter and Voltmeter Selector Switch.
10. Hour run meter shall be provided in all breaker controlled motor feeder.
8.0 CONTROL AND MONITORING
The following provision shall be made for control and monitoring of following electrical
equipments.
8.1 Transformers
 TNC switch in primary & secondary side of switchgear.
 Emergency trip from secondary side for tripping primary side of transformer.
 VCB with all required protection to be considered in all the 33kV, 11kV & 3.3kV
switchboards. .
 Lockable ‘OFF’ push button in transformer room to trip sending end switchgear.
 Indication lamp for ‘ON’ ‘OFF’ ‘Auto-trip, ‘Non-trip’ and ‘Trip Circuit Healthy’.
 Ammeter and voltmeter on both primary and secondary side.
 Load break switch with Earthing Switch on transformer primary side (only where primary
side circuit breaker is not located in the same sub-station).
8.2 Motors Controlled Through Circuit Breakers

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 34 of 83
 OFF- ON switch with Ammeter on LCS

 - OFF-AUTO/MAN-L/R-ON switch with Ammeter on DCS.
 Ammeter in LCS.
 Current monitoring at DCS/PLC through Dual Channel Current Transducer with Display
facility installed at switchgear end, where required from process point of view.
 Indication Lamps in switchgear for ‘ON’, ‘OFF’, ‘Auto-trip’ and ‘Trip Circuit Healthy’, ‘Ready
for Service’, ‘Test’, ‘Service’, ‘Space Heater ON’.
 Emergency trip in switchgear.
 Winding and bearing temperatures of motors shall be available at DCS in control room.
 Process interlock in CCR, where required.
 Indication lamp for ‘ON’, ‘OFF’ and “Ready to Start “ in remote (DCS/PLC etc.)
 Motors controlled through Circuit breakers should also be provided with ammeter, KVAh,
KWH and running hour counter. Theses shall be incorporated in Numerical relay Or Multi-
function Meter.
8.3 Medium Voltage Motors Controlled Through Contactors
 OFF- ON switch on LCS
 OFF-AUTO/MAN-L/R-ON switch on DCS.
 Current monitoring in DCS, where required from process point of view.
 Emergency Trip in PCC/MCC.
 Process interlock in CCR, where required shall be wired through separate auxiliary relay.
 Indication lamp for ‘ON’, ‘OFF’ and ‘Fault’ in switchgear.
 Indication lamp for ‘ON’, OFF’ and “Ready to Start “ in remote (DCS/PLC etc.)
 Motor space heater & Panel board space heater shall be provided with Ammeter & LED in
Switchgear.
 All Motor feeders of PMCC & MCC (irrespective of Rating) shall have door mounted
communicable (Modbus / Profibus) type Motor Protection relay ( MPR) with Earth fault
protection and display.
9.0 EQUIPMENT SPECIFICATION
9.1 General Features
9.1.1 The equipment shall be suitable for tropical climate conditions and corrosive and saline
atmosphere.
All electrical equipment accessories and wiring shall have fungus protection involving special
treatment of insulation and metal against fungus, insects and corrosion.
Fine mesh screen of corrosion resistant material shall be furnish on all ventilating openings
to prevent entry of insects.
9.1.2 The equipment to be installed in indoor plant area shall be enclosed in dust, damp and
vermin proof enclosure equivalent to IP 54 as per relevant Indian Standards/IEC.
9.1.3 The equipment excluding motors to be installed in outdoor plant area shall have IP 65
enclosure. Motors of plant shall have IP 55 enclosure.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 35 of 83
9.1.4 4 mm FRP (fire retardant and UV stabilized) canopies shall be provided for all outdoor
equipments like motors, starters, LCS, SDBs, sw. sockets etc. PA stations shall have
acoustic hood.
9.1.5 All the water plants being highly corrosive - Cable tray ,LCS, Junction boxes, Lighting JB and
Lighting poles in plant area shall be strictly of FRP with SS fasteners only to avoid
corrosion
9.1.6 The switch boards, to be installed inside the building shall have enclosure IP 4X for HV
switchgear, for LV switchgear degree of protection shall be IP 52 up to 1600A rating and
IP-4X above 1600A rating. Equipment requiring ventilation opening such as battery
charger/UPS etc. located in air conditioning room may have IP 43 enclosure however,
opening for the ventilation shall be covered with fine wire mesh.
9.1.7 Creepage distance shall be 31mm/kV (for highest system voltage) for all equipment.
9.1.8 All the electrical equipment shall be provided with rolled aluminium/stainless steel heavy
duty double compression type cable glands and crimping lugs for the cable terminations
9.1.9 The outside surface of all equipment shall be painted after suitable pre-treatment by the
application of two coats of anti-rust and corrosion resisting epoxy based paints.
9.1.10 All similar equipment ( viz. HV Switchboard, LV Switchboard – PCC, PMCC, MCC, EPMCC,
ASB, LDB, DCDB, Transformers, Numerical relays, UPS, Battery Chargers, Motors, etc.)
supplied against a package should be of single Make only – for ease of O&M and spare
management.
9.2 Power Transformers
9.2.1 The transformers shall be double wound, copper conductor, and Dyn11 type. Transformers
shall rated for 11/3.45 kV, 11/0.433 kV , 3.3./0.433 kV, as required. Transformer with 3.45
KV Secondary winding shall be considered for the substation only, where 3.3 KV
switchboard is to be installed for feeding 3.3 KV motors.
9.2.2 The rating of power transformers shall be selected on the basis of load and future load
growth. For future load growth the following provision shall be made:-
- 25% spare capacity in HV transformers above continuous peak load.
- 30% spare capacity in LV transformers above continuous peak load.
9.2.3 The rating of power transformers shall be selected keeping following into considerations:
(a) Duty : Continuous
(b) Outdoor type : ONAN/ ONAF (ONAN rating shall have 25% spare capacity
above continuous peak load. ONAF rating shall be minimum
15% above ONAN rating).
(c) Indoor type : Dry Type
Epoxy cast resin/ resin encapsulated type
(d) Maximum loading : 80% when one of the transformers is out of service
(e) Peak efficiency at : 35% - 40% of load
(f) Class of Insulation : B or better for oil filled
: F or better for dry type
(g) Tap changer : OFF load type for less than 10 MVA
: ON load type for 10 MVA & above
9.2.4 Maximum temperature rise over ambient of 50 Degree Celsius shall be limited to:
(a) Outdoor transformers:

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 36 of 83
Top oil (measured by thermometer) : 50 0 C

Winding (measured by resistance) : 55 0 C
(b) Indoor transformers:
Winding (by resistance method) : 90 0 C or lower as permissible for class
of insulation offered
9.2.5 Special consideration shall be given in specifying the percentage impedance of the
transformers to suit the switchgear short-circuit capacity available..
9.2.6 Transformers generally up to 10 MVA shall have ONAN cooling, while ratings above 10 MVA
shall be ONAN/ONAF cooled. Bare minimum protection devices for transformer have been
as indicated below; however LSTK contractor shall provide any other necessary protection
relays required for complete protection of system.
Primary Side.
IDMTL Over Current, IDMTL Earth Fault, High Set Over Current, Instantaneous Earth Fault,
Standby Earth Fault, Restricted Earth Fault , Differential (for sizes of 5 MVA and above),
*Buchholz Alarm and Trip,*Winding Temperature Alarm,* Trip, *Oil Temperature Alarm, *Oil
Level Alarm & Trip, *Trip for Winding Temperature and Oil Temperature. All protection
except REF shall be provided on secondary side, if the primary side circuit breaker is located
in other sub-station. REF protection shall trip the primary Inter-tripping of primary and
secondary circuit breaker of transformer shall be provided for all faults through lockout
relays.
CT for Restricted Earth Fault protection shall be provided in the transformer.
9.2.7 Nitrogen Injection Fire Protection & Extinguishing System (NIFPES) shall be considered for
transformers having oil capacity more than 2000 Ltrs.
9.2.8 Following Push buttons shall be provided for transformers :
- Lockable ‘OFF’ push button in transformer room to trip the breakers on primary side.
- Push button shall be provided on breaker on secondary side for permission to close
breaker on primary side
- Emergency trip PB on breaker on secondary side for tripping breaker on primary side
of transformer.
9.2.9 The instruments such as OTI/WTI, Buchholz relay and MOG shall have Magnetic Reed
Switches. The mercury switch contacts are not acceptable.
9.2.10 For all transformers, conservators shall be provided with Magnetic Oil Gauge (MOG) having
1NO contact activated on Low oil level. For transformers where the oil capacity is more than
2000 Ltrs, Air cell shall be provided in the conservator.
9.2.11 Transformer rooms shall have slab and shall be under shed.
9.2.12 Routine test on all transformers and heat run test on one transformer of each rating shall be
performed in presence of Owner/Consultant.
9.2.13 All Routine, Heat Run Tests shall be performed in compliance with B.S.171, IEC publication
No.60076, IS 2026 (parts I to V), CBIP and IS: 2026 (Part III) including SFRA Test before
dispatch from Manufacturer’s works and at erection site during commissioning or latest
editions or any other authoritative standard. Certificates for Type Tests on similar type
Transformers shall be submitted.
9.2.14 All Power transformers above 5 MVA shall have facility for Remote display (in LMS) of Oil
Temperature, Winding temperature, Conservator Oil Level and moisture ppm of Oil through
4-20 mA signal / Modbus communication.
9.2.15 For all other specification refer PC150-TS-0803.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 37 of 83
9.3 Neutral Earthing Resistor (NER)

9.3.1 The NER shall be provided to earth the neutral of 11 kV and 3.3 kV systems. Neutral of 415V
supply system shall be solidly earthed.
9.3.2 Neutral earthing resistor shall be outdoor type made of AISI 304/406 punched stainless steel
grid element. . The earth fault current of 11 kV & 3.3 kV shall be limited to full load current of
transformer or 400 A, whichever is less.
9.3.3 All NER not requiring operation shall be provided with isolator.
9.3.4 For all other specification refer PC150-TS-0804.
9.4 Switchboards
9.4.1 General
9.4.1.1. There shall be three positions for Breaker/Contactor trolley: - Service, Test and Isolate. In
service position, the power connections shall be made; but in test and isolate mode, the
power connection of bus bars shall be automatically removed.
ACB feeder for PCC, PMCC & MCC shall be single front for ease of operation &
maintenance. Non-ACB feeders for motors or power may be double front type.
Breaker duty cycle shall be O-0.3sec-CO-3min-CO.
Separate CT shall be provided for differential/REF protection.
LV circuit breaker shall be 4 Pole type except for outgoing motor feeders which shall be 3
Pole type.
9.4.1.2. Suitable shutter arrangement shall be provided to protect the person from accidental
contact with live bus in trolley chamber.
9.4.1.3. The degree of protection shall be IP 4X for HV switchboards and IP 52 for LV Switchboard
up to 1600A rating and IP-4X for LV switchboards above 1600A rating.
9.4.1.4. All HV, MV & LV Switchboards shall be LOTO compliance.
9.4.1.5. 11 kV & 3.3 kV Switchboard shall conforms to IS/IEC 62271-200, IAC-A FLR-50KA/40KA 1
Sec, PM, LSC 2B which means that the switchgear panels shall be four side internal arc
tested, shall have metal partitions and shall confirm to loss of service continuity. LV
switchboard shall conform to IEC 60947. All 3 compartments (Busbars, Circuit breaker &
Cable compartment) shall be tested for Internal arc for the said rating.
9.4.1.6. LV switchboard (EPMCC/PMCC/MCC) shall be TOTAL TYPE TESTED (TTA) design as
per IEC 61439-1/2. Type Test Certificates for short circuit withstand of 50kA for 1 sec along
with ACB mounted in the Switchboards shall be provided.
9.4.1.7. LV switchboard (EPMCC/PMCC/MCC) shall comply with Internal Arc Containment test as
per IEC 61641.
9.4.1.8. The busbars and connection shall be made of electrolytic grade copper only. Aluminium
busbars are not acceptable. All busbars of 11kV & 3.3kV switchgear including bus duct
shall have Raychem sleeving.
9.4.1.9. Tripping and closing coils shall be of continuous rating type.
9.4.1.10. Clearance between gland plate to cable termination point in all switchboards shall be
adequate but not less than 300mm to ensure proper cable termination.
9.4.1.11. FRP supports shall be used for bus bars with adequate clearances and creepage
distance to prevent flash over due to effect of dust moisture.
9.4.1.12. Protective relays shall be mounted on the front of the switchgear panel.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 38 of 83
9.4.1.13. All logic like, Auto/Manual changeover etc. shall be build in the Numerical relay.
Adequate number of I/Os shall be provided to meet the requirement. 10% spare I/Os shall
also be provided. External I/O Card/ Module is not acceptable.
9.4.1.14. All relays used for protection shall be microprocessor based numerical type only with
latest communication protocol IEC-61850 and shall have large graphical display. All
relays shall have coating for protection against harsh environment conditions. All
numerical relays shall be of one make only. Selected models of numerical relays shall
have metering, control, status and protective functions. It shall be possible to save
minimum 5 records of each event.
9.4.1.15. LSTK contractor shall supply minimum 1 No. laptops with licensed software for
communication & configuration of all make & Type of Numerical Relays.
9.4.1.16. GPS system and associated hardware & software shall be provided for synchronisation of
clocks of numerical relay and metering LA & LMS
9.4.1.17. All meters shall be digital multifunctional meters with backlight LCD display and
communication port. Additionally digital type ammeter, voltmeter and Hour Meter shall be
provided separately for various feeders as indicated above.
9.4.1.18. All the motor / capacitor feeders controlled through vacuum circuit breakers shall be
provided with surge arrestors. Lightning Arrestor (LA) shall be provided on each bus of
11KV Switchboard.
9.4.1.19. A continuous ground bus shall be provided at the bottom of the switchgear and in cable
connection side for grounding the switchgear, breaker trolley as well as to ground the
cable glands.
One no. breaker handling trolley shall be provided for the switchboards as below:
a) Each HV switchboard.
b) Each LV switchboard.
9.4.1.20. 11KV & 3.3KV Breaker shall be with Integral Earthing switch system with proper
interlocks.
9.4.1.21. Control supply bus and space heater supply bus-bars (Copper) of adequate rating shall
be provided throughout the length of switchboards with as many sections as sections in
power bus-bars.
9.4.1.22. Control supply shall be tapped from control bus in each cubicle/ panel itself through DP
MCB of suitable rating.
9.4.1.23. The minimum thickness of sheet steel used in HV and LV switchgear including charger,
UPS, ASPB etc. shall be as under:-
a) Base Channel minimum 3.0 mm
b) Load Bearing Members minimum 2.0 mm
c) Doors and covers minimum 1.6 mm
9.4.1.24. A bottom channel of not less than 100 mm shall be provided.
9.4.1.25. The maximum height of the switchboard and other control panels shall be limited to 2200
MM. Maximum height of component requiring operation shall be limited to 1800MM.
9.4.1.26. The switchboards shall have adequate short-circuit ratings and be suitably sized for the
load and spare capacity foreseen. The short time rating of bus bar shall be 3 seconds for
HV switch boards and 1 second for other boards.
9.4.1.27. The HV switch boards and power control centres shall normally have four spare circuit
breaker panel (size shall be as per largest outgoing feeder breaker), two on each side of
bus-section.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 39 of 83
9.4.1.28. For other boards (PMCCs, MCCs, MLDBs, ASPBs, DCDBs etc.) sufficient number of
spare feeders to the extent of min. 20% for each type & rating shall be provided.
9.4.1.29. The 415V switch boards shall have PVC insulated bus bar system suitable for rated
voltage. At joints of these bus bars removable shrouds shall be provided.
9.4.1.30. All HV & LV Switchgear, UPS, Battery Charger etc. shall have designated space in each
Bus section for Network Switches and other communication equipments.
9.4.1.31. For interfacing with DCS system, separate marshalling panels (with 20% spare terminals)
shall be provided on each bus section in all HV & MV switchboards in the same panel
line-up. The marshalling panels shall be of full height same as that of switchboards. The
horizontal bus bar chamber at the top shall be continuous through this marshalling panel
also, for future extension of the MV switchboard. All critical control signals for DCS
interface shall be hardwired between substations and DCS. Other non-critical data of
Electrical system will be sent to DCS with redundant communication facility between DCS
and LMS.
Hardwired signals (with minimum requirement specified below) from various Motor feeders
of a bus section for DCS interface shall be wired and terminated in the marshalling cabinet:
- DCS Start permissive
- Process Start command (Auto)
- Remote Start command (Manual)
- Process Stop command
- Process Trip command (for breaker controlled motor feeder)
- Breaker/Contactor ‘ON’ indication
- Breaker/Contactor ‘OFF’ indication
- Ready to Start indication
- Electrical Fault Trip indication
9.4.1.32. Following monitoring signals, as a minimum, shall be taken from substation to DCS
interface, through redundant MODBUS SERIAL LINK communication from LMS system.
- Load Data viz. KW, PF, A, etc.
- L/R indication
- Process Trip indication
- Electrical Fault Trip indication
- Trip Details
9.4.1.33. Auto changeover scheme shall be provided for incomers and bus couplers on all 11 KV
switch boards, 3.3 KV switch boards and PMCCs/PCCs/ MCCs. Under normal operating
conditions, incomer-1 and incomer-2 breakers would be closed and bus coupler breaker
would remain open with ‘auto-manual’ switch in ‘auto’ position. The bus coupler switch
would close automatically under the following condition being fulfilled:-
i. Either of the incoming breaker trips due to under voltage (70% or below).
ii. Voltage on the healthy bus is more than 80% for the set period.
iii. Residual voltage on the bus with no power supply comes down to 30%.
iv. Auto change over shall be locked on loss of power on both the incomers.
Auto changeover shall also be provided on switchboards catering to emergency loads.
9.4.1.34. Paralleling of two incoming feeders is not foreseen. However, facility for momentary
paralleling shall be provided for intentional changeover without interruption of supply.
9.4.1.35. Every enclosure door that provides access to live parts operating at 240 V AC and above
shall be mechanically interlocked with a circuit interrupting device on the supply side such
that when the door is open, the equipment is de energised.
9.4.1.36. Separate redundant AC and DC control supply shall be provided for each Switchboard.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 40 of 83
9.4.1.37. Control supply for motor feeders having MCCB in PMCC/MCC/ASB etc. and VFD panels
etc. shall be feed from 240V UPS ( Electrical) and motor controlled with breaker shall
have 110 V DC control supply irrespective of its being HV or LV.
9.4.1.38. For motors with auto-starting provision, trip of a running motor shall start standby motor
automatically.
9.4.1.39. All the HV/LV switchgear shall be fed through two separate transformers, each
transformer having capability to take care of 100% load of the associated switchgear and
shall have the facility of auto changeover in case of failure of one transformer as well as
option of manual changeover for maintenance purpose.
9.4.1.40. Max. 3 runs of 400 sq.mm power HV cable shall be terminated in single panel. For more
than 3 runs of cable complete dummy/adaptor panel shall be provided.
9.4.1.41. The CB ON and OFF lamp shall be provided at rear and front side of 11kV/3.3kV
switchboards.
9.4.1.42. All breakers service ON/OFF contact multiplier contactors shall be mechanically latched
type and independent of control supply. Loss of supply and restoring the supply shall not
affect the status of the relay/ contactor.
9.4.1.43. All breakers shall be electrically operable and mechanical operation from the breaker
shall be possible locally. Manual breakers are not acceptable.
9.4.1.44. Separate Ammeter shall be provided for panel and motor feeder Space heater circuit for
each panel.
9.4.1.45. The terminal strips used shall be of stud and nut type and control wiring shall be done
with ring tong lugs only.
9.4.1.46. Dual channel output with display type current transducer for all HV and LV switchboard
feeder shall be provided requiring Ammeter at control panel.
9.4.1.47. All motor (HV/LV) power feeders shall have separate earth fault protection through CBCT
and earth fault relay. LV motor (above 5.5. KW) and power feeder above 100A shall
have CBCT and Digital earth leakage relay with display.
9.4.1.48. All external hardware shall be of stainless steel only.
9.4.1.49. The control compartment and power compartment shall be separate.
9.4.1.50. All HV and LV breakers shall have remote switching facility as well as ON/OFF/TRIP
indication at LMS.
9.4.1.51. Following Set of accessories as detailed below shall be provided for each 11kV/3.3 kV
Switchboard :
a) Breaker handling trolley – 2 Nos.
Following Set of accessories as listed below shall be provided for each 415 V Switchboard
:
a) Breaker lifting and handling trolley : Minimum 2 nos.
b) Test cabinet with coupling cables for testing the breaker in draw out position : Minimum
1 No.
c) Racking in/out handle for breakers : Minimum 4 nos.
d) Racking in/out handle for draw out MCC modules : Minimum 2 for each MCC
9.4.1.52. Alarm relays with reverse flag shall be provided to annunciate failure of main incoming
A.C. and D.C. power supplies and annunciation D.C. supply in each panel. Lamp
indications shall be provided individually for main D.C. supply-1 fail, main D.C. supply-2
fail, and panel annunciation D.C. supply fail. A common A.C. electric bell shall be
provided to give an audible alarm in case of failure of D.C. supply-1/D.C. supply-

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 41 of 83
2/annunciation D.C. supply in any panel. A common push-button shall also be provided
for cancellation of lamp indications and audible alarm.
9.4.1.53. Gland plate for single core cables shall be non-magnetic.
9.4.1.54. For all other specifications, refer PC150-TS-0805, PC150-TS-0806, PC150-TS- 0808 and
PC150-TS-0809.
9.4.1.55. Separate panel shall be considered for incomer Line PT & Bus PT (11 kV & 3.3 kV
Switchboards) and PT shall be draw out type. 4 pole MCB shall be provided on LV side of
Bus & Line PT.
9.4.1.56. Inspection window shall be provided for HV termination in the switchboard for carrying out
thermography, provided internal arc test certificates for this design is available with the
bidder.
9.4.1.57. All Incomers and bus couplers shall be provided with synchronising facility. Synchrocheck
relay shall be provided in each bus PT & contacts shall be multiplied and wired in each
outgoing feeders of each bus section.
9.4.1.58. All 11kV, 3.3. kV and 415 V Switchboards shall preferably be of same make for ease of
operation & maintenance.
9.4.1.59. Supervision of installation, testing and commissioning including testing of Relays of all
switchboards shall be done through OEM only.
9.4.1.60. All Cable Differential Relays shall be FO Cable type only. Supply & termination of the FO
cable & associated HDPE duct, as required, for feeder differential protection shall be
included LSTK Contractor’s scope.
9.4.1.61. All Numerical Relays shall be of same Make and Model (series).
9.4.1.62. 11kV & 3.3kV Circuit Breaker shall have integrated earth Switch with proper Mechanical &
Electrical Interlocks& Electrical Interlocks.
9.4.1.63. 11kV & 3.3kV Breaker rack in rack out facility should be operable when breaker panel
door is closed position.
9.4.1.64. LV Switchgear design shall be such that the feeder doors should not open in locked out
tagged out condition .
9.4.1.65. Current transformers shall be in accordance with IEC 61869-1 & 61869-2. The rated
output shall match the requirements of the equipment connected. The secondary current
rating shall be 1 A. Unless otherwise specified, cores for measuring instruments shall
have accuracy classes of not more than 0.5 % and saturation factors less than 5.
9.4.2 11 KV Switchboard
9.4.2.1 The 11 KV switchboard shall be indoor, metal enclosed, draw out type, equipped with VCBs,
stored energy mechanism working on 110 V DC and shall feed power to the various
substations through transformers and other outgoing feeders.
9.4.2.2 Degree of protection shall be IP4X as per IS/IEC 60529,IEC 60298. Switchgear sizes and
configuration shall be rationalized to minimum spare holding.
9.4.2.3 A study shall be conducted to determine the rated short circuit capacity for the selection of
equipment. However, Rated short circuit breaking capacity shall be as determined by the
study or 40 KA for 3 sec, whichever is higher. HV Switchboard shall be suitable for Internal
Arc (AFLR) withstand current of “rated short circuit current” for 1 sec.
9.4.2.4 Incoming, bus coupler and outgoing feeders shall be provided with ON, OFF, Trip, Trip
Circuit Healthy indications. Process trip lamp/annunciator window to be provided wherever
applicable.
9.4.2.5 Control supply shall be 110 V DC.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 42 of 83
9.4.2.6 Extra anti-condensing space heater shall be provided in Bus –Bar and Cable chamber of
11KV Switchboard.
9.4.3 3.3 KV Switchboard.
9.4.3.1 The 3.3 KV switchboard shall be indoor, metal enclosed, draw out type, equipped with
Vacuum Circuit Breakers (VCBs), stored energy mechanism working on 110 V DC. for all
feeders.
9.4.3.2 The minimum degree of protection shall be IP4X as per IS/IEC 60529,IEC 60298.
Switchgear sizes and configuration shall be rationalized to minimum spare holding.
9.4.3.3 A study shall be conducted to determine the rated short circuit capacity for the selection of
equipment. However, rated short circuit breaking capacity shall be as determined by the
study or 26.24kA for 3 sec, whichever is higher. HV Switchboard shall be suitable for Internal
Arc (AFLR) withstand current of “rated short circuit current” for 1 sec.
9.4.3.4 Incoming, bus coupler and outgoing feeders shall be provided with ON, OFF, Trip, Trip
Circuit Healthy, Spring Charged indications. Process trip lamp/annunciator window to be
provided wherever applicable.
9.4.3.5 Control supply shall be 110 V DC.
9.4.3.6 Extra anti-condensing space heater shall be provided in Bus –Bar and Cable chamber of
3.3KV Switchboard.
9.4.4 Low Voltage Switchgears
9.4.4.1 415 V switchboards shall include the following:
a) Power Control Centres (PCCs)
b) Power-cum-Motor Control Centres (PMCCs)
c) Emergency Power-cum-Motor Control Centres (EPMCCs)
d) Motor Control Centres (MCCs)
e) Main Lighting Distribution Boards (MLDBs)
f) Auxiliary Services Power Boards (ASPBs)
g) Emergency Power Distribution Boards
EPMCC shall be separate from PMCC.
9.4.4.2 Low voltage switchboards shall be metal clad, arranged with self supporting units and
assembled together in a row. The degree of protection shall be IP 52.
9.4.4.3 Internal physical separation / segregation of 415 V Switchboards shall be 3 B for Non-ACB
feeders and 4 B for ACB feeders.
9.4.4.4 The switchboards shall be suitable for extension at both the ends.
9.4.4.5 Bus bars shall be of uniform cross section and supported on non-hydroscopic FRP insulators
with adequate clearances and creepage distance to prevent flash over due to effect of
dust/moisture.
9.4.4.6 The horizontal busbars as well as vertical droppers of LV switchboards shall have heat
shrinkable insulated sleeves.
9.4.4.7 Sufficient bus supports shall be given to give adequate mechanical strength during short
circuits.
9.4.4.8 A continuous ground bus shall be provided at the bottom in the PCC/PMCC/MCC for
grounding the PCC/PMCC/MCC.
9.4.4.9 Rated short circuit breaking capacity shall be 50 KA for 1 sec.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 43 of 83
9.4.4.10 The PCC, MCC, Main lighting distribution board and auxiliary services power board shall
be provided with withdraw able air circuit breakers for incoming feeders and bus ties.
9.4.4.11 All ACBs shall be electrically operated- EDO type only. Manual breakers are not
acceptable. Each electrically operated breaker shall be provided with antipumping (94),
Breaker fail (52BF) and trip free feature, trip annunciation (30) and lockout (86) relays.
Lockout relay shall be hand reset type.
9.4.4.12 All ACBs shall be without any internal releases. The required protections shall be wired by
means of external numerical relays.
9.4.4.13 Motor feeders below 75 KW rating shall be contactor controlled and 75 KW & above,
these shall be ACB controlled with combined motor protection relay. All other feeders of
415 V switchboards shall be provided with MCCB except feeder rated more than 400A,
for which ACB shall be provided. All outgoing feeders shall be draw-out type in all the
switchboards.
9.4.4.14
9.4.4.15 Switchboards shall be provided with thermostatically controlled anti-condensation
heaters.
9.4.4.16 All units in the MCC shall be completely accessible and removable from front. Both power
and control connections shall be stab-in type.
9.4.4.17 Bus bar clearances shall conform to relevant Indian Standard/IEC for equipment voltages
up to and including 500 V AC.
9.4.4.18 The switchboards shall be compartmentalized and individual feeder modules shall be
draw-out type. Fixed type modules shall not be acceptable.
9.4.4.19 The draw out modules shall be standardized and it shall be possible to interchange any
module with a module of same size. The components to control the equipment like
MCCB, starter, auxiliary relay etc. shall be wired as a unit on the individual module. Safety
shutter shall be provided to prevent direct access to live parts when the chassis is
removed.
9.4.4.20 The entire draw out construction should be designed for safe operation during placement
or removal of chassis. An earthing arrangement shall be provided which will make contact
first before the power contacts are made and break last. Each module shall control one
motor in general.
9.4.4.21 The door shall be interlocked so that it cannot be opened unless the isolating
switch on that module is OFF. However, it shall be provided with a door defect
mechanism for intentional opening when on line for testing and inspection purpose.
9.4.4.22 Control switches for breaker control shall be provided in each breaker cubicle. Circuit
breaker shall be interlocked to prevent withdrawal of a closed breaker or insertion of a
closed breaker. Each breaker shall be provided with anti pumping device.
9.4.4.23 Provisions shall be made to manually close/trip circuit breakers on loss of control voltage.
9.4.4.24 The LV PMCC/MCC/PCC control supply shall be 240VAC, 50Hz UPS supply fed from
UPS Distribution Board of Separate 240 V AC UPS System dedicated for MCC control
supply; Control Room & Substation lights, LMS Equipment, Fire Detection & Alarm
System etc. Breaker control supply shall be 110V DC.
9.4.4.25 All low voltage switchboards shall be provided with 20% spare outgoing feeders or
minimum one of each rating (fully wired) and with all the components.
9.4.4.26 The timers shall be electronic type only. Pneumatic or synchronous type timers are not
acceptable.
9.4.4.27 Each outgoing motor feeder shall consist of a number of components mounted in a
module duly wired. In general outgoing feeder rated below 75 KW shall consist of:
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 44 of 83
a) MCCB.
b) Control supply On/Off switch and fuse
c) Power Contactor
d) Electronic Digital Motor Protection Relay with built-in Earth Fault, Overload, Stalling,
Single phase protection, etc. Thermal Overload Relay are not acceptable.
e) C.T for metering
f) Overload reset button.
g) Process Trip / ON / OFF indicating lamp with separate indicator fuse.
h) Auxiliary contactors for multiplication / control.
i) Test position limit switch and test PB
j) CT operated Ammeter for all motor feeders above1.5 KW, all MOV and LOPs at both
LCS and Feeder end.
k) Selector switches as per requirement.
9.4.4.28 Provision for indication of minimum following electrical parameters in 415V PCC / PMCC/
MCC shall be made:
a) ON OFF, TRIP, TRIP CIRCUIT HEALTHY, TEST, SERVICE Position, indication in
ACB feeders.
b) The KWH meters on incomers shall have provisions for sealing for tariff purpose, as
required.
c) MCC shall conform to the following as a minimum :
- Motor starters rated for utilisation category AC3 and protection equipment with a
minimum of type 2 co-ordination.
- The number of modules per tier shall not exceed 6.
- MCC incomer sizes and configurations rationalised to minimise spares holdings.
9.4.5 Auxiliary Supply Power Board
The ASPB shall generally be single front, floor mounted draw out type having essential and
non-essential bus. Non-essential bus shall be disconnected in case of failure of normal
supply through a contactor. Each Substation station shall have separate ASPB.
9.4.6 Lighting Sub Distribution Boards
The Distribution Boards shall be single front, non-draw out wall mounted type.
9.4.7 UPS Distribution Boards
9.4.7.1 The UPS Distribution Boards shall be single front, floor mounted non-drawout type for
supply of 115 V AC / 240 V AC.
9.4.8 Direct Current Distribution Boards
9.4.8.1 The Direct Current Distribution Boards (DCDBs) shall be single front, floor mounted non-
drawout type for supply of 110 V DC control power to switchgears and panic lighting. Each
Substation station shall have separate DCDB.
9.4.8.2 Following potential free contact shall be available for each Motor feeders for indication in
LMS in addition to process requirement:
 Motor ON
 Motor OFF
 Motor Process Trip
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 45 of 83
 Motor Elect Trip

9.5 Motors
9.5.1 The rating of LV and HV motors shall be selected from the sizes as recommended in
relevant Indian Standard/IEC.
9.5.2 All electric motors shall meet the standard IEC 60034-30-1.
9.5.3 The margin between the installed power and absorbed power shall be as recommended by
the driven machine supplier but shall not be less than the following:-
Motor Rating Margin above Driven M/C Absorbed Power
Less than 22 KW 25%
22 KW to 55 KW 15%
75 KW and above 10%
9.5.4 Voltage Ratings:
Voltage rating for the motors of different ratings shall be as below:
Upto 150 KW: 415 V, 3-phase, 50 Hz AC
Above 150 KW - 1000 KW: 3.3 KV, 3-phase, 50 Hz AC
Above 1000 KW: 11 KV, 3-phase, 50 Hz AC
All motors shall be designed for 3-Phase supply only.
9.5.5 The motors shall have maximum continuous rated duty S1 as per relevant Indian
Standard/IEC. Rated duty for special duty motors wherever required e.g. cranes etc. Shall be
considered as per driven equipment requirement.
9.5.6 All LV motors shall be TEFC type as per relevant Indian Standards/IEC while HV motors
shall be TEFC/CACA type. All motors shall be Class-F insulated with temperature rise limited
to that of Class-B.
9.5.7 Normally the motors shall be suitable for DOL starting. However, motors started through
VFD shall be suitable to run at 30% to 100% of rated speed and compatible with the VFD.
9.5.8 All motors 30 KW and above shall have space heater provision.
9.5.9 All HV motors shall have winding, hot air and bearing RTDs. All the temperature signals shall
be terminated to DCS as well as LMS.
9.5.10 All LV motors shall be of efficiency class 'IE3' as per latest applicable version of IS: 12615.
All HV Motors shall be of high efficient and high power factor type.
9.5.11 The starting current i.e. breakaway current of 415 V Motors shall not exceed the values
indicated in IS: 12615. Also there shall be no further positive tolerance on the values of of
starting current.
9.5.12 The starting current of 11 KV & 3.3 KV motors shall not exceed 550% of FLC. No positive
tolerance is acceptable over 550% FLC.
9.5.13 Type test certificate of similar motor for use in specified hazardous area (if applicable) shall
be furnished.
9.5.14 The duty cycle of the motor shall meet the process and driven machine requirement.
9.5.15 In case of 11 KV & 3.3 KV motor, the terminal box shall be suitably designed for proper
termination of XLPE insulated Aluminium cables through heat shrink termination kit.
9.5.16 The mechanical parameters such as duty, mounting type, shaft extension, direction of
rotation, starting torque requirements etc. shall be adequate for the application. Sleeve or
anti friction type bearings shall be used. Vertical motors shall have thrust bearings suitable

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 46 of 83
for the load imposed by the driven machinery. Motors with sleeve bearings may require
proximity probes to measure shaft vibration adjacent and relative to the bearings.
9.5.17 Motor rated above 30 KW shall have on line greasing provision and for motor rated above 45
KW, grease outlet feature shall be provided.
9.5.18 All HV motors shall have safety factor not less than 1.1.
9.5.19 Motors rated 1000 kW and above shall have suitable measures to prevent flow of shaft
currents and shall have 2 sets (i.e. 6 nos.) of PS class CTs for differential protection.
9.5.20 The motor shall be capable of withstanding the electro dynamic stress and heating imposed
if it is started along with the driven equipment at voltage of 110% of the rated value.
9.5.21 During starting of large motor, the voltage may drop to 80% of the rated voltage for a period
of 60 seconds. All electrical equipment, while running, shall successfully ride over such
period without affecting system performance.
9.5.22 D.C. motor provided for emergency service shall be shunt/compound wound type. Motor
shall be sized for operation with fixed resistance starter for maximum reliability.
DC starters shall be complete with MCCB, contactors, resistors, relays, meters, push-
buttons, lamps, etc. DC contactor shall be Class I – Category DC3. Switch Duty shall be
DC22. The resistor enclosure shall be provided with ventilating louvers and wire mesh guard
and shall have a degree of protection IP-23.
9.5.23 The motor may be subjected to sudden application of 150% rated voltage during bus
transfer, due to the phase difference between the incoming voltage and motor residual
voltage. The motor shall be designed to withstand any torsional and/or high current stresses,
which may result, without experiencing any deterioration in the normal life and performance
characteristics.
9.5.24 Shaft voltage shall be limited to 200 mV.
9.5.25 For all other specifications, refer PC150-TS-0810.
9.6 Rectifier-cum-Battery Charger
9.6.1 The Rectifier-Cum-Battery Charger shall be fully automatic using silicon controlled rectifier
and shall consist of units as described below:-
i) Main Float cum Load charger: To supply continuous load and keep the battery in
healthy state.
ii) Standby Float cum Load charger: To supply continuous load & keep the battery in
healthy state in case any abnormality in Main charger.
iii) Boost charger: To charge the battery set initially and recharge (after meeting
emergency or sudden application of heavy loads.)
9.6.2 Battery Charger shall have at least 20% extra capacity for future load requirement. Battery
Charger shall have 110 V DC system.
9.6.3 Each substation shall be provided with redundant battery charger with 2x100% battery banks
and connected to each Charger.
9.6.4 The battery and charger combinations shall be such as to ensure continuity of D.C. supply at
load terminals without even momentary interruption.
9.6.5 AC Ammeter and AC Voltmeter on Charger Input; DC Ammeter, DC Voltmeter for charger
output/ battery voltage and on demand type Battery Charge / Discharge Ammeter shall be
provided.
9.6.6 Following analog signals through suitable transducer shall also be provided for hook-up in
LMS:
 Status of charging current (float & boost charging)
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 47 of 83
 Battery current
 Incoming voltage
9.6.7 Following potential free contacts shall also be provided for hook-up in LMS
 DC under voltage
 DC overvoltage
 DC earth leakage
 AC incoming power supply failure
 AC input fuse blown-off
 Thyristor/ diode failure
 DC output fuse blown-off
 DC battery fuse blown-off
 Filter Capacitor fuse blown-off
 Load on Battery (using current direction sensing with time delay)
 Battery undervoltage/ Disconnected during discharge (using zero current sensing)
 Cubicle fan failure/ cubicle temperature high (for chargers with forced cooling).
9.7 Battery Sets.
9.7.1 These shall be Ni-Cd Battery Sets shall be rated to meet the total DC power requirement for
5 hour after complete power failure.
9.7.2 Spare capacity of 20% for future use shall be considered.
9.7.3 Battery shall be designed with minimum temperature as 50C.
9.8 Uninterruptible Power Supply System (UPS)
9.8.1 115 V AC UPS System with UPS Distribution Board shall be provided to feed 115 V AC, 50
Hz, 1Phase power supply to the instrumentation system, DCS etc. This UPS System along
with associated Battery and UPS distribution Board shall be located at Control Room.
Separate 240VAC UPS System with UPS Distribution Board shall be provided to feed PMCC
& MCC control supply, Control Room & Substation lights, LMS Equipment, Fire Detection &
Alarm System etc. This UPS System along with associated Battery and UPS distribution
Board shall be located at Substation. Block Diagram of 115 V UPS System shall be followed
but with 240 V in place of 115 V
Both 115 V AC UPS System and 240 V AC UPS System complete with Battery, UPS
Distribution Board etc. shall be separate.
Both the UPS i.e. 240V AC and 115 V AC shall have with 20% margin for future use.
9.8.2 Both 115 V AC UPS with UPS Distribution Board and Battery Bank and 240 V AC UPS with
UPS Distribution Board and Battery Bank shall be provided for each Substation.
9.8.3 The UPS System shall have IGBT type with touch screen LCD display and shall be backed
up by nickel cadmium (Ni-Cd) battery rated for 2 hour at rated capacity of the UPS. Battery
(100% Capacity) shall be separate for each Inverter.
9.8.4 UPS system construction shall be such that each charger, inverter module can be made fully
isolated for maintenance. No common devices/wiring shall be installed. Further there shall
be no common device between main & 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.
9.8.5 UPS system shall have facility for built in Online battery bank monitoring & testing facility for
displaying/calculating expected battery bank back-up time ( during testing if battery bank

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 48 of 83
does not have sufficient back up time, test shall be terminated & load shall be shifted to
charger automatically).
9.8.6 UPS shall be suitable for 100% step load.
9.8.7 Battery Load cycle test shall be carried out by the vendor at site .
9.8.8 The UPS rating shall be such that in any case the load on the individual UPS shall not
exceed 40% of the rated capacity.
9.8.9 The over load capacity of UPS shall be 200% for 10 cycles, 150% for 60sec & 125% for
10min.
9.8.10 All four sections, i.e. Rectifier-I, Rectifier-II, Bypass – I and Bypass - II shall be fed through
four separate feeders of emergency bus of PMCC.
9.8.11 UPS shall be PWM based using IGBT. Each charger and SCVS shall have isolating
transformer at the input.
9.8.12 The salient features of the UPS shall be as under:
a) High Efficiency
b) Compatible to feed nonlinear, high crest factor loads
c) Microprocessor based monitoring system for UPS status and fault indications
d) High transient performance
e) Low audible noise
9.8.13 Each UPS shall be provided with SNMP software so that all the parameters of UPS and
alarms/faults can be viewed into the remote computer. These logs/trends of load can later be
printed. Web based parameter and status monitoring shall be used. It shall be hooked to
LMS and DCS System.
9.8.14 The transfer time of UPS from inverter to bypass, in case of failure of both inverters, shall be
so selected that during this transition period, instrumentation/DCS etc. which leads to
tripping of plant shall not fail. Typically, it shall be as below :
In synchronism : No break transfer i.e. within 6 milliseconds (Maximum)
In asynchronous mode : Within 16 milliseconds (Maximum).
9.8.15 The technical parameters of UPS shall be as under:
Input
a) Rated Voltage 415 V ± 10%
b) Rated Frequency 50 Hz ± 5%
Output
a) Rated Voltage 115 V AC / 240 V AC
Voltage regulation:
Static (0-100% load) ±1%
Dynamic for 100% load change: ±5%
9.8.16 Following potential free contacts shall be made available on the UPS,
- Rectifier ON
- Inverter ON
- Battery CBB ON
- Load on Inverter
- Inverter fail
- Rectifier Fail
- Inverter O/P undervoltage
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 49 of 83
- Inverter Sync.
- Load on battery
- Bypass Fail
- Load on bypass
- Load transferred. etc
Note: A separate common potential free contact for all the faults/alarms (in UPS / SCVS)
shall be made available
9.8.17 Operation Philosophy of UPS:
 2 sets of rectifiers and inverter 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 2X50% batteries and simultaneously to inverters. In
case of failure in one rectifier, the other rectifier shall feed the complete load and the
batteries without any interruption.
 In case of Incoming supply failure or failure of both rectifiers the 2X50% batteries shall
feed the inverters without any interruption. Each rectifier shall be designed for
simultaneously feeding complete inverter load and float/rapid charging of the 2X50%
batteries to its rapid capacity. Each rectifier shall be equipped with “ On Line”
automatic as well as manual charging facility.
 Normally both the inverters will be synchronised with each other and with stabilised
bypass supply. Both inverters shall operate in parallel and share the load equally.
 The load sharing controls shall not be subject to common mode failure and any failure
of the load sharing controls shall not result in the loss of the vital power.
 When a disturbance/fault occurs in any 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 the load from the
stabilized bypass supply to the inverter shall be possible in auto as well as in manual
mode.
9.8.18 All alarms & status of UPS shall be communicable through Modbus / Ethernet protocol to
LMS.
Following minimum shall be considered:
 Load on Inverter
 Load on Bypass
 Load on Battery
 Battery on float/ boost charging mode.
 Charger failure.
 Inverter failure
 AC mains failure
 DC under voltage
 DC Over voltage
 Automatic retransfer of load to inverter inhibited.
 Fan failure
 AC Voltage , current & frequency of each inverter
 AC incoming power supply Voltage & voltage.
 DC current at each rectifier output.

9.9 Variable Speed Drives (VSD/VFD)
9.9.1 Microprocessor based variable speed drive shall be communicable type and shall be able to
communicate with LMS/DCS. It shall be possible to set speed from process DCS for
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 50 of 83
optimum performance through 4-20 mA signal. Speed/current/status feedback to DCS shall

be provided. Drive will run at preset speed in the event of loss of signal from DCS.
9.9.2 System shall be highly reliable, efficient and shall provide high power factor, low harmonic
distortion, low noise level etc.
9.9.3 System shall be provided with complete by pass circuit to ensure the power supply reliability
in case of VSD/VFD failure. It shall be possible to start the motor in DOL mode through by-
pass system in case there is any problem/fault in the VFD. The Electrical system and the
process should be capable to operate the Motor in fixed speed (without VFD).
9.9.4 The system shall be suitable for load characteristics, continuous speed control. Drive shall
be able to accelerate the load over the full speed range (0 – 100 %) with incoming line
voltage regulation of 10%.
9.9.5 The system shall be designed for 150% over current withstand for 1 minute. The system
shall be equipped with an automatic restart facility which will restart the system in case of
voltage dip over 20% or power interruptions less than 4 seconds and recovery of voltage to
95% with a facility to block the automatic restart.
9.9.6 The system shall be suitably designed with due care for long length of cables, output filters,
chokes, motor insulation, cable voltage grades etc.
9.9.7 The VSD panel shall be located in the clean air conditioned room in the substation. Required
local control equipment shall have start, stop speed raise and lower push buttons, ammeter,
speed indicator, ON/OFF/READY status selector switches as required and shall be installed
near the motor.
9.9.8 The VFD shall be provided with Input and Output transformer. To prevent harmonics in the
station supply 12 pulse rectifier shall be deployed at Input of the VFD.
9.9.9 "Auto Restart" facility for drive system within preset time, typically 0-15 seconds, in case of
supply system dip or complete loss of power shall be provided.
9.9.10 Preferably screened type cables or cables as recommended by VSD/VFD vendors shall be
used for VSD/VFD systems.
9.9.11 The VSD/VFD panels to be supplied shall be of proven model.
9.9.12 Training of VSD/VFD shall be provided to owner personnel.
9.9.13 For all other specifications, refer PC150-TS-0820A and PC150-TS-0820B.
9.10 Soft Starters
9.10.1 Soft Starter may be considered for large sized motors to overcome the problems of voltage
drop during starting and also over sizing of transformer. However, VFD shall be preferred
over Soft Starter. Soft Starter may be used in exceptional case only after approval of Owner/
Consultant.
9.10.2 The soft starters shall be solid state microprocessor control type with self torque adjustment
(during controlled start) feature with bypass contactor. Soft starters shall be communicable
type and shall be able to communicate with LMS.
9.10.3 Soft starter shall be designed with starting current limited to 250% to 300% (However
Contractor shall ensure that this reduced starting voltage is suitable to develop necessary
starting torque requirement of the respective motor). The soft starters shall be designed for
the optimum voltage drop during starting such that the drive motor and the load get the
required accelerating torque.
9.10.4 Soft starter shall be as per standards IEC 34/BS 4999/IS 325/BS 5000.
9.10.5 The Contractor shall super impose the motor torque vs speed curve at reduced voltage (to
motor terminals at starting) on torque vs speed characteristics of the driven equipment to
confirm correct operation i.e. acceleration to rated speed. The Contractor shall also calculate
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 51 of 83
acceleration time at reduced voltage (based on these torque vs speed curves) required for
accelerating the drive, to full rated speed. This acceleration time shall be sufficiently less
than the hot withstand time of the motor.
9.11 Local Control Stations
9.11.1 Local Control Stations shall be provided for all motors for testing and maintenance purpose
when the selection is made is "LOCAL MODE" Operation. The essential features of the LCS
shall be as given below:
9.11.2 LCS shall be FRP type, dust & vermin proof, weatherproof, suitable for wall or pedestal
mounting with equipment mounted on a base plate inside and behind a front cover (bolted
type).
9.11.3 LCS Enclosure shall be certified for use in hazardous areas.
9.11.4 Provision for pad locking in OFF position shall be provided.
9.11.5 Local control stations for breaker controlled HV and LV motors shall be provided with T-N-C
switch, Ready to Start Indication, ON indication, Space Heater ON Indication, Trip Indication,
Local-OFF-Remote Control switch and ammeter. Moreover, space heater ON indication
lamp, trip indication lamp shall also be provided at the switchgear panel.
9.11.6 Local control stations for contactor controlled LV motors shall be provided with start/stop
push buttons, ammeters and Space Heater ON Indication (for motor rated 30KW and
above), ON indication, Local-Remote switch (as required) for the motors having rating 5.5
KW and above. If required from process point of view, ammeter shall be provided for motors
below 5.5 KW also.
9.11.7 Each element for start and stop shall be provided with 1 NO + 1 NC contact. The push
button construction shall be such to avoid mal-operation due to vibrations.
9.11.8 All local control stations shall have weather proof IP-65 enclosure and be suitable for
installation in relevant hazardous area, gas group and temperature class. Canopies of
suitable size shall be provided with all local control stations.
9.11.9 All components shall be completely wired up to terminal block and also provided with
earthing terminals.
9.11.10 Inscriptions on corrosion resistant metal strips giving drive description, mechanism
number and functional requirement shall be provided.
9.11.11 Two numbers of LCS shall be provided for the motors, which are installed at elevated
platforms. One shall be installed at ground level and the other near the motor.
9.11.12 The ammeter shall be flush mounting, moving iron spring controlled type, of accuracy
class 1.5 as per IS: 1248, with square face of minimum size 72 mm × 72 mm having scale
range 0-90 degree. The ammeter shall be provided with uniform scale up to CT primary
current and compressed end scale up to the 8 times the C.T. primary current. Adjustable
red pointer shall be provided to indicate the full load current of the motors. Zero adjusters
shall be provided for operation from the front of the meter. All ammeters shall be operated
through 1 Amp. CTs only.
9.11.13 Complete Push Button along with its actuator mounted on the cover with wiring done
through flexible cables with proper protection.
9.11.14 Preferably Ring Type lug and suitable TB to be used for connection, to avoid loose
connection.
9.11.15 All spare hole to be plugged with suitable metal plugs.
9.12 Switch Sockets
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 52 of 83
9.12.1 Sufficient number of inter-locked type 125A/63A, 415V, 3 Ph and 16A, 240V, 1 Ph switch
sockets shall be provided in various plant locations as per hazardous area classification to
facilitate the maintenance work. Supply to switch-sockets shall be taken from ASPB through
suitably rated RCCB.
9.12.2 Minimum 2 Nos. 24 V 10 A Switch socket shall be provided near all man-hole of vessels for
maintenance to which 24 V hand lamps can be connected and carried inside.
9.12.3 Both 3 Phase switch sockets and 1 Phase switch sockets shall be provided at Min. 20 M
interval. Maximum 2 Nos. 63A switch sockets and 2 Nos. 16A switch sockets shall be
connected in one circuit.
9.12.4 For all Other Specifications, Refer PC150-TS-0811.
9.13 Conduits
9.13.1 Conduits shall be of heavy gauge with minimum wall thickness of 1.4 mm (upto 25 mm dia)
and 2 mm (above 25 mm dia) rigid steel, hot-dip galvanized, cut square, reamed, threaded
and screwed tight at all joints.
9.13.2 Conduits entrances to pull boxes and switches shall have double lock nuts & insulating
bushings. No running thread shall be used.
9.13.3 Flexible metallic conduit shall be used for connection to equipment which are subject to
vibration and also for connection to level /limit/pressure switches. Conduit runs shall be
supported at an interval of 750 mm for vertical run and 1000 mm for horizontal run.
Conduits shall be sized so that conduit fill (ratio of total cable area to conduit area)
shall not exceed the following :
One Cable : 53%
Two Cable : 31%
Three Cables & Up : 40%
9.14 Bus-Duct
9.14.1 The bus bars and connection shall be made of electrolytic grade copper only. Aluminium
busbars are not acceptable. All busbars shall be insulated with Raychem sleeving.
9.14.2 It shall be suitably supported at regular intervals and both bus bars and supports shall be
adequately sized and clamped to withstand rated short circuit current without permanent
deformation.
9.14.3 The bus bar insulators shall be non-hygroscopic, non-inflammable material. Earth bus shall
run along the full length of bus duct without any break.
9.14.4 Outdoor bus-duct shall be weatherproof to IP-65 and shall be provided with canopy, silica gel
breather. Construction of outdoor Bus duct shall be such that water gets drain off easily.
Extra thickness shall be provided at the corners where water accumulation is likely to
happen.
9.14.5 Bus duct shall be supplied with bus bar flexible links for connection at both the ends and
expansion joints for every 3M of bus-duct and bus duct support materials.
9.14.6 Openings with cover at suitable locations shall be provided on bus duct for accessing the
bus bars for maintenance.
9.14.7 Silica-gel breather shall be provided on both indoor and outdoor portions of the busduct.
(shall not be required for pressurized busduct).
9.14.8 For all other specifications refer, PC150-TS-0807.
9.15 Load Management System.
9.15.1 Centralised Load Management System (LMS) shall be provided for Supervision, control,
monitoring, data acquisition, data logging & printing of status of all important electrical
equipment& feeders and Load Shedding Scheme as per the recommendations of the
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 53 of 83
system study report as per process requirement and in consultation with Owner/Consultant
for entire fertilizer complex, by EDS LSTK Contractor.
Data concentrator Panel and other LMS System Equipments including PC console, chairs,
furniture etc. for Raw Water Treatment Plant - DM Water - Condensate Polishing Unit - shall
be in EDS LSTK Contractor‘s scope. However, LSTK contractor has to consider space for
same in separate room in Substations, as per NIT.
LSTK Contractor shall provide multifunctional dual channel transducers in all the breaker
feeders as well as contactor feeders of all important & critical Loads. Also, supply &
installation of Network Switches and extend all signals up to Network Switches shall be in
the scope of LSTK Contractor. Network Switch shall have 20 % spare ports. Specification of
Network Switches has to be finalised in co-ordination with EDS LSTK Contractor.
Minimum Inputs and Outputs to be considered for LMS for proper operation/control, effective
monitoring and load management shall be inclusive of but not limited to the following:
a. Transformers:
Oil Temperature, Winding temperature, Conservator Oil Level and moisture ppm of Oil
through 4-20 mA signal / Modbus communication and status of Buchholz Relay.
b. Incomer /Bus coupler/ Feeder ( Power/Motor)
KW, KVA, KVAR, KWh, PF, VOLTAGE, CURRENT
ON, OFF, TEST, SERVICE, TRIP ON FAULT, TRIP CIRCUIT HEALTHY, CONTROL
SUPPLY ON, RELAY WATCH DOG, FAULT DETAILS, DISTURBANCES
RECORDER.
Remote ON & OFF Control from LMS.
c. LT motor feeder of breaker controlled motors in EPMC/PMCC/MCC
ON, OFF, TEST, SERVICE, TRIP ON FAULT, TRIP CIRCUIT HEALTHY, READY TO
START, PROCESS TRIP, EMERGENCY STOP, LOCAL/REMOTE selection on LCS,
CONTROL SUPPLY ON, RELAY WATCH DOG, FAULT DETAILS, DISTURBANCES
RECORDER.
d. LT motor feeder of Contractor controlled motors in EPMC/PMCC/MCC
ON, OFF, TRIP ON FAULT, READY TO START, PROCESS TRIP.
e. Breaker Controlled Power feeder in PCC/MCC/ASPB
ON, OFF, TEST, SERVICE, TRIP ON FAULT, TRIP CIRCUIT HEALTHY, CONTROL
SUPPLY ON, RELAY WATCH DOG, FAULT DETAILS, DISTURBANCES
RECORDER.
f. UPS
Load on Inverter, Load on Bypass, Load on Battery, Battery on float/ boost charging
mode , Charger failure , Inverter failure ,AC mains failure, DC under voltage, DC Over
voltage ,Automatic retransfer of load to inverter inhibited ,
Fan failure ,AC Voltage , current & frequency of each inverter , AC incoming power
supply Voltage & voltage , DC current at each rectifier output.
g. Battery & Battery Charger

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 54 of 83
Status of charging current (float & boost charging) , Battery current ,Incoming
voltage, Load Voltage DC, Load current DC, DC under voltage
DC overvoltage , DC earth leakage ,AC incoming power supply failure ,AC input fuse
blown-off ,Thyristor/ diode failure ,DC output fuse blown-off ,DC battery fuse blown-
off ,Filter Capacitor fuse blown-off ,Load on Battery (using current direction sensing
with time delay) ,Battery under voltage/ Disconnected during discharge (using zero
current sensing) ,Cubicle fan failure/ cubicle temperature high (for chargers with
forced cooling).
h. VFD
KW, KVA, KVAR, KWh, PF, VOLTAGE, CURRENT, SPEED , SPEED REFERANCE.
ON, OFF, TRIP ON FAULT, TRIP CIRCUIT HEALTHY, FAULT DETAILS
All Multi-function Meters of all HT, LT Switchboard , LDB, etc. to be connected with
LMS.
All connection/ wiring up to I/O Rack shall be in the scope of LSTK Contractor.
Connection/wiring from Network Switch toData Concentrator Panel &Centralized LMS shall
be in EDS LSTK Contractor’s scope. However, cable tray, support for cable trays etc. for
Cables from Network Switch to Data concentrator Panel & Centralized LMS System (within
battery limit of Raw Water Treatment Plant - DM Water - Condensate Polishing Unit) shall be
in LSTK Contractor’s scope.
Redundant Power Supply from 240 V UPS Distribution Board to all LMS equipment, OWSs,
EWSs etc. (up to termination to I/O Racks, OWSs, EWSs etc.) shall be in LSTK Contractor’s
scope.
9.15.2 All relays and energy meters shall have communication facility for serial communication
(Relays on IEC-61850 protocol and Meters on MODBUS protocol).
10.0 CABLING
10.1 Cables
10.1.1 All HV & LV power and control cables for HV/LV switchgear shall be supplied and laid by
the contractor. Terminations at switchgear end and at the equipment end shall be in
contractor’s scope. Supporting and laying of these cables shall also be in contractor’s
scope. Termination of HV/LV cables at HV/LV motor end and HV switch gear end including
supply of heat shrink type termination kit for HV cables shall be in contractor’s scope.
Supply and execution of heat shrink type straight through jointing kits for HV cables shall
be in the scope of the LSTK Contractor (if required).
10.1.2 Cables shall be sized considering the following factors.
 Maximum continuous load current
 Voltage drop
 System voltage
 Laying conditions
 De rating due to ambient air temperature, ground temperature, grouping and
proximity of cables with each other, thermal resistivity of soil etc. shall be taken into
account
 Short circuit withstand criteria.
10.1.3 All HV power cables shall be made of stranded aluminium conductor with XLPE insulation,
PVC inner sheathed FRLS type, armoured, PVC outer sheathed FRLS type, conductor
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 55 of 83
screen, insulation screen and construction as per IS: 7098 (Part 2). HV cables shall be of
unearthed type.
Single core HV Power cable shall be of aluminium conductor. The construction of same
shall be as per above.
10.1.4 All LV power cables shall be with stranded aluminium/copper conductor with XLPE
insulation, PVC inner sheathed FRLS type , armoured, PVC outer sheathed FRLS type and
construction as per IS: 7098 (Part 1). Power cables with conductor size upto and including
16 sq. mm shall be with copper conductor, conductor size 35 sq. mm and above shall be
aluminium conductor.
Single core LV Power cable shall be of aluminium conductor. The construction of same
shall be as per above
10.1.5 All control cables shall be with 2.5 sq. mm, stranded copper conductor with XLPE
insulation, PVC inner sheathed FRLS type, armoured, PVC outer sheathed FRLS type and
construction as per IS: 7098 (Part 1). Control cables shall be twisted pair or shielded
wherever electro-magnetic/electrostatic interference is anticipated.
10.1.6 All control cables shall have 20 % spare cores. All cores shall be identified with numerical
core numbers printed on core in addition to colour coding.
10.1.7 All cables shall be armoured and shall have extruded inner and outer sheath.
10.1.8 Cables connected in parallel shall be of the same type, cross section and terminations.
10.1.9 All power and control cables shall be in continuous lengths (except for very long feeders)
without any joints. The cables used for lighting and wires in conduits shall have appropriate
junction boxes with adequately sized terminals. Cable joints in hazardous areas shall not
be permitted.
10.1.10 The maximum voltage drops in various sections of the electrical system shall be within
limits stated in the following table:
Sl.No. System Element Maximum Permissible

Voltage Drop
a) High voltage cables for general distribution 1%
b) Bus duct / Cable between transformer secondary 0.5%
and Switchboards
c) Cable between PMCC and MCC or auxiliary
switchboard
i) MCC / Auxiliary Switchboard near PMCC
0.5% Note-3b
ii) MCC / Auxiliary Switchboard situated remote
from PMCC 2 to 2.5% Note-3a
d) Cables between HV Switchboard and HV Motor 3%
(during running)
e) Cable between PMCC and motor (during running) 5%
f) Cable between MCC (situated near PMCC) and 5%
motors
g) Cable between MCC (situated remote from PMCC) 3%
and motors
h) Cable between Auxiliary Switchboard / MLDB and 1 to 1.5% (Note-2)
Lighting Panel / Power Panel

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 56 of 83
i) Circuit between lighting panels and lighting points 4% (Note-2)

j) DC Supply Circuit (electrical Controls) 5% and/or as per
instrumentation
requirement
k) DCDB to Control Room 2% (Note-1)
l) UPS outgoing circuit 5% (Note-1)
Note-1
Minimum voltage available across any instrument in the field / control room / satellite rack
room shall be as per instrumentation design basis. Distribution system for instrumentation
supplies shall be designed accordingly. In case of any conflict between electrical
equipment specification sheet and instrumentation design basis report, the latter shall
govern regarding instrumentation power supplies.
Note-2
In case of difficulty in achieving specified voltage drops in cables up to lighting panel, 5%
drop from Auxiliary Switchboard / MLDB up to lighting points may be permitted.
Note-3
a) Higher voltage drop may be permitted between PMCC and remote mounted MCC /
ASB; if overall voltage drop up to motor (from PMCC) is limited within 5.5%.
b) For large substations 1% drop may be permitted.
The maximum voltage drop at various buses during start-up of large motor and / or motor
reacceleration conditions shall be within the limits stated below:-
Sl. System Element Operating Condition Maximum
No. Permissible
Voltage Drop
a) At the bus bars of the worst Start-up of the large HV 10%
affected Switchboard motor with other loads on the
bus or reacceleration of a
group of HV motors
(Simultaneous start-up or
group reacceleration of HV
motors is not envisaged)
b) At the bus bars of the worst Start-up of large LV motor 10%
affected LV Switchboard with other loads on the bus,
(PMCC / MCC) or reacceleration of a group
of LV motors.
c) Cables between HV Motor start-up or 5% (Note-a)
Switchboard and motor reacceleration
d) Cable between MV Motor start-up or 10% (Note-a)
Switchboard (PMCC / MCC) reacceleration
and motor
Notes:
a) Higher voltage drop in motor cables may be permitted, in case the conditions given in
Note b), c) and d) are complied.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 57 of 83
b) 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.
c) For medium voltage motors, the voltage available at the motor terminals must not be
less than 80% of the rated value during start-up or reacceleration.
d) For high voltage motors, the voltage available at the motor terminals must not be less
than 85% of the rated value during start-up or reacceleration.
e) Soft Starter / VFD Starter shall be considered for starting large HV motors if essential /
unavoidable as per system design requirement / equipment design limitation. For cases
other than starting limitation, requirement of soft starter / VFD for any drive shall be
confirmed by Process Department.
f) Unless otherwise specified as in clause e), all HV motors and MV motors shall be
suitable for Direct on Line (DOL) starting.
10.1.11 MINIMUM CABLE SIZES FOR 415V MOTORS
Direct on line (D.O.L) start motors (2/4 pole motors)
MOTOR CABLE DETAILS
RATING NUMBER NO. OF CONDUCTOR CONDUCTO
OF RUNS CORES MATERIAL R
PER RUN SIZE ( MM² )
Below 3.7 KW 1 3 Cu 2.5

3.7 KW 1 3 Cu 4
5.5 KW 1 3 Cu 10
7.5 KW 1 3 Cu 10
9.3 KW 1 3 Cu 16
11 KW 1 3 Cu 16
15 KW 1 3 Cu 16
18.5KW 1 3 Al 35
22 KW 1 3 Al 35
30 KW 1 3 Al 50
37 KW 1 3 Al 70
45 KW 1 3 Al 95
55 KW 1 3 Al 120
75 KW 1 3 Al 185
90 KW 2 3 Al 95
110 KW 2 3 Al 120
125/132 KW 2 3 Al 150
160 KW 2 3 Al 185

Cables sizes as indicated above are for 2/4 poles motors fed from MCCs located near
PCCs and PMCCs.
 Cable sizes for motors not confirming to above table (e.g. for 2/4 poles motors rated
up to 150kw & motors with high starting pf), extended distance, reduced voltage
starting, low speed motors, VFD driven etc. shall be worked out on case to case basis.
 However cable sizing calculation shall be submitted for approval.
10.1.12 Design Criteria for Cables/Bus Duct & Short Circuit Withstand Time:
a) Design criteria for cables/bus duct
Sr. Design Criteria 3.3 kV / 11 kV 415 V

No.
1. Loads beyond 1000A rating and Bus Duct / Bus Duct /
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 58 of 83
located near the transformer 1-core cable 1-core cable

2. Loads located up to 200 M Cable Cable
3. Loads located 200 - 1000 M 1-core cable / 1-core cable /
3-core cable 3.5-core cable
4. Loads located beyond 1 KM Cable Cable
5. Recommended limiting size of 3 Core x 400 / 3.5 Core x 300 /
multi-core cable (sq.mm) / Single 1 Core x 630 1 Core x 630
Core (sqmm)
6. Insulation voltage grade 3.3 kV / 1100 V Earthed
11 kV Unearthed
6. Type of cable insulation XLPE Power: XLPE
Control: XLPE
7. Power, Control & Earthing Cables Armoured Armoured
For breaker control motor circuits the selection of size will be made ensuring that the cable
shall withstand a short circuit fault directly for 0.2 sec.
Suitable derating factors based on the site ambient conditions, method of laying and the
no. of cables laid together shall also be applied.
b) Short circuit withstand time (seconds) shall be as follows for Breaker controlled
feeders.
Bus duct 1 Sec.
Feeders to motors and transformer 0.25 sec
Feeders from PCC/PMCC to MCC 0.6 sec
Main 11 KV primary distribution feeders 0.7 sec
11 KV cable from transformer to switch board 1 sec
Incomer from other switchboard 0.6 sec
10.1.13 The minimum size of power cables shall be 2.5 sq. mm (Cu).
10.1.14 The control cables shall be 2.5 sq. mm (Cu). However, wiring in the panel/switch boards
may be by means of 1.5 sq. mm (Cu) cables except for CT wiring which shall be 2.5 sq.
mm. All the control and power wiring shall be carried by using FRLS wires only.
10.2 Cable Laying
10.2.1 The cables shall generally be laid on overhead racks. Pipe racks where available, shall
be used to support the cable racks.
HV power cable shall be laid on cable tray in single layer having 1D spacing between the
cables. LV power and control cable shall be laid on cable tray in touching formation in
single layer.
HV Power, LV Power and Control shall be on separate trays. Instrument and electrical
cable trays shall be separate.
Cables shall be clamped properly on the cable rack in such a way that position and layout
of a particular cable shall not change throughout the rack so that it can be easily traced
during maintenance jobs.
Walkway to be considered for access to Electrical / Instrument cables on pipe rack.
From substations to various electrical consumers, cable shall be laid overhead. However,
wherever overhead cable routing is not feasible LSTK Contractor can go for cable trench /
slit (Refer PDS attached with the NIT) as per the site requirement.
Wherever, pipe rack is not available and space for overhead cable laying is possible then
dedicated structure for cable shall be made for cable laying.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 59 of 83
10.2.2 The cable racks shall be ladder type, pre-fabricated from suitable heavy duty FRP (fire
retardant and UV stabilized) material. Maximum cable tray size shall be 600mm wide.
Maximum supporting span shall be 2 Mtrs. Cable trays shall be designed considering 25%
margin for future use.
All cable racks must be provided with GI flat strip of size 75mm X12 mm as running earth
all along the tray.
10.2.3 FRP Cable Tray shall be as per NEMA FGI-198X. FRP Cable Tray shall be UV exposed as
per ASTM G 154 fro 1000 Hrs and the mechanical properties shall not be deteriorate more
than 5%. Glass content shall be greater than 55%. The run spacing shall be 250m.
10.2.4 All cables shall be terminated using suitable cable lugs.
10.2.5 All HV terminations and joints shall be of RAYCHEM make only.
10.2.6 Bimetallic lugs shall be provided, as required.
10.2.7 In Control Room (excluding false ceiling) and Substation, lighting cable shall be laid in
concealed conduit.
11.0 ILLUMINATION SYSTEM
11.1 General
11.1.1 LED type lighting shall be provided. The average illumination levels in the various sections of
the plants shall be as indicated in Annexure-I. All the plants and area lighting shall be energy
efficient.
11.1.2 LED type lighting shall be provided for all areas. The minimum illumination levels in the
various sections of the plants shall be as indicated in Annexure-I.
LED shall conform to the following types and standards:-
Product Type Safety Standard Performance Standard
Self ballasted LED lamps for IEC 62560 Latest Edition IEC 62612 / PAS Publicly
general lighting services > 50 available specification
V
Control gear for LED modules IEC 61347-2-13 Latest IEC 62384 Latest Edition
Edition
LED modules for general IEC 62031 Latest Edition IEC / PAS 62717 Latest
lighting Edition
LED luminaries IEC 60598-1 Latest IEC / PAS 62722-2-1 Latest
Edition Edition Luminaries
performance – Part 2-1:
particular requirements for
LED
LEDs and LED modules IEC TS 62504 Terms and Definitions for LEDs and LED
modules in general lighting.
Maintenance factor for indoor lighting shall be considered as 0.7 and for Outdoor lighting
0.6.
The colour rendering index shall not be less than 90%.
The LED lights shall work satisfactorily at the design temperature of 50 Degree Celsius.
All the LED fittings shall be selected in accordance with Hazardous Area Classification.
The life assessment of LEDs shall include control gears/ driver as well.
11.1.3 The specified illumination level shall be maintained after considering maintenance factor 0.5
for Coal Dust Area , 0.6 for plant & outdoor areas (other than Coal Dust Area) & 0.7 for

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 60 of 83
indoor areas and utilisation factor as per manufacturer catalogues for size of room & type of
fixture.
11.1.4 Separate area wise panic lights, fed from 110 V DCDB, shall be provided at strategic
locations for safe evacuation of operation personnel. These shall be switched ‘ON’
automatically on failure of power supply to main lighting board and shall switch ‘OFF’
automatically on resumption of mains or after 1 hour of power failure to avoid draining of the
battery. Location of these lights shall be judiciously decided from safety considerations. The
outdoor lighting shall be photocell/timer controlled.
11.1.5 Voltage drop at the fixture from the MLDB bus shall not exceed 3%.
11.1.6 Aviation lights shall be provided on tall structures and all isolated structures. . Aviation
Lighting shall be in accordance with International Civil Aviation Organization (ICAO)
Publication Annexure 14 and to Indian Standards, together with the approval of local aviation
authority..
LED type Low Intensity Aviation Obstruction Light suitable for 240V, 50 Hz supply. It shall be
covered under Indian patent act (Govt of India) No. 188995. Degree of protection shall be IP-
65.
The illumination intensity of aviation lights and mounting height shall be considered based on
vicinity of civilian air terminal within 1 kM radius. Aviation lights at each location shall be fed
from two separate and distinct DBs (one fed from normal bus and another fed from
emergency bus of MLDB). Incase aviation lights are not switched ON for any reason,
whatsoever, a signal shall be sent to control room which will sound buzzer and also result in
flashing of red light. On acknowledgement, buzzer shall stop but flasher will continue unless
aviation lights are turned ON.
The fixtures shall have body of corrosion resistant aluminium alloy casting and shall be
suitable for outdoor use and mounting on 40 mm NB G.I. pipe. Necessary electrical threading
shall be tapped in the fixture for mounting.
11.1.7 Plant lighting circuits shall be single phase (Phase & Neutral) rated 240 V AC. Each circuit
shall be rated to 16A but not loaded more than 8A. A minimum of 25% of MCBs of each
board shall be left as spares. The load on one lighting sub-circuit of lighting sub-distribution
board and junction box shall be limited to 1000W approx.
11.1.8 The lighting sub-distribution board for control of lighting shall be standardized as 18-way, 15-
way, 12-way, 9-way and 6-way type.
11.1.9 In plant office rooms, wall mounting boards shall be installed to control the lighting. These
boards shall include switches for lights, fans, 15A/5A plug sockets and fan regulators etc.
11.1.10 15A plug sockets shall be fed through separate circuit of lighting sub-distribution
boards/junction box having ELCB of 30mA.
11.1.11 16A plug sockets shall be fed through separate circuit of lighting sub-
distribution boards/junction box.
11.1.12 Illuminated exit sign shall be provided in substation / Control Room .
11.1.13 Power factor of complete fitting shall be 0.95 min. at 230 V.
11.1.14 Lights from LED’s shall be soothing to eye and without any bright spots on the floor/objects
illuminated by the luminaries.
11.1.15 The driver shall be mounted internally and be replaceable with the aid of commonly
available hand tools.
11.1.16 The LED module or array shall be designed in such a way that the failure of one LED shall
not affect additional LED’s.
11.1.17 Life expectancy of LED Luminaries shall be minimum of 50000 hrs with greater than 70%
of rated lumen output.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 61 of 83
11.1.18 Min. efficiency of LED driver: The minimum efficiency of LED driver shall be 85% for driver
power output rating <=40W and 87% for driver power output rating> 40W.
11.1.19 Short circuit protection /Open load protection shall be required for LED fixtures.
11.1.20 Surge Protection for minimum 2kV for indoor and minimum 3kV for Outdoor LED systems
shall be provided. However, If a site is prone to lightning and surges 10kV surge protection
shall be required. In case of outdoor luminaires, the Surge Protection Device (SPD) should
be series type with fail safe.
11.1.21 Color temperature of LED Luminaries: 5700K
11.1.22 Cover type for outdoor type fittings shall be Toughened glass or UV stabilized
polycarbonate whereas, whereas, for indoor and non-weather proof items, UV stabilized
Poly Carbonate can be used.
11.1.23 For more details, refer PDS attached.
11.1.24 For lighting fixtures and 16 Amp plug socket circuits, 3 core 2.5 sq. mm (Cu) cable shall be
used.
11.2 LED Tube Lighting Fixtures (inside Substations)
a) High quality LED fluorescent tube twin batten type complete with 2 X 20W tube eco
friendly, no UV radiation as per the specification tabulated below:
Sl. No. Parameter Technical Specification
1. Degree of Protection IP-20
2. Lumen output per Lamp ≥ 2000
3. CCT 6500K
4. Luminous efficacy ≥ 100 lm/watt
5. CRI >80
6. Guaranteed Life ≥ 50000 burning hours
7. PF >0.95
8. THD <10%
11.3 Street Lighting And Security Lighting
11.3.1 63A TPN outlet from outdoor lighting bus of main lighting board shall be taken direct to the
TPN junction box to be mounted on pole through cable and looped from pole to pole.
11.3.2 FRP poles of suitable mounting height shall be used for street light and plant lighting
(platforms/ structures/ access ways/ walk ways/ pump house/ pump bay etc.)
11.3.3 Hot dip galvanized octagonal high mast lighting shall be used for yard and general area
lighting. LED type fittings may be used.
11.3.4 LED Street Lighting Fixtures
a) LED Street Light Fitting with cool white light in Pressure Die Cast Aluminium Housing
with UV Stabilized Poly Carbonate Cover with in-built power unit of 3500 lumen
suitable for 240V, 50 Hz, System shall be used.
b) Lighting fixture shall have 50000 hrs. Life Time, CRI>75, IP-65.
11.3.5 High Mast
In Coal Handling Area and other open area, High Masts shall be provided.
a) Structure
The High mast shall be of continuously tapered, polygonal cross section, at least 16 sided,
presenting a good and pleasing appearance and shall be based on proven In-tension
design conforming to the standards referred, to give an assured performance, and reliable
service.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 62 of 83
The mast height shall be 30m, with minimum diameter of 150mm at the top and 610mm at
the bottom. Minimum plate thickness of bottom section shall be 5mm and other sections
4mm.The structure shall be suitable for wind loading as per IS 875 Part III,1987 & for 9
Nos. 2x200W & 3 Nos. 1x200W LED flood light fittings. The PCD of the mast flange shall
be minimum 740mm.
b) Construction
The mast shall be capable of safely withstanding the strong winds prevailing at site. The
deflection at the top during heavy monsoon periods shall therefore be considered in the
design and the mast designed in such way that the above deflection during worst periods is
kept to a minimum value.
The High mast shall be fabricated from special steel plates, conforming to BS-EN10025,
cut and folded to form a polygonal section and shall be telescopically jointed and fillet
welded. The welding shall be in accordance with BS: 5135. The procedural weld geometry
and the workmanship shall be exhaustively tested on the completed welds. Mast shall be
delivered in multiple sections of length approx.10 metres. Thus a 30 meter mast shall be
delivered in three sections.
Each mast section, delivered to site, shall include one no. circumferential welded
diaphragm stiffener to reduce the deflection of the mast in heavy winds. At site, the
sections shall be joined together by slip-stressed-fit method. No site welding or bolted joint
shall be done on the mast. The minimum overlap distance shall be 1.5 times the diameter
at penetration.
The mast shall be provided with full penetrated flange which shall be free from any
lamination or incursion. The welded connection of the base flange shall be fully developed
to the strength of the entire section. The base flange shall be provided with supplementary
gussets between the bolt holes to ensure elimination of helical stress concentration. For
the environmental protection of the mast, the entire fabricated system shall be hot dip
galvanised, internally and externally, having a uniform thickness of 65 microns for the
bottom and top sections.
c) Door Opening
An adequate door opening of size 1000mm x 300mm shall be provided at the base of the
mast and the opening shall be such that it permits clear access to equipment like winches,
cables, plug and socket, etc. and also facilitate easy removal of the winch. The door
opening shall be complete with a close fitting, vandal resistant, weather proof door,
provided with a heavy duty double internal lock with special paddle key.
The door opening shall be carefully designed and reinforced with welded steel section, so
that mast section at the base shall be unaffected and undue buckling of the cut portion is
prevented.
d) Dynamic Loading for the Mast
The mast structure shall be suitable to sustain an assumed reaction arising from a wind
speed as per IS: 875 (three second gust), and shall be measured at height of 10m above
ground level. The design life of the mast shall be a minimum of 25 years. Wind excited
oscillations shall be dampened by the method of construction and adequate allowance
shall be made for the related stresses.
e) Earthing Terminals
3 Nos. earthing terminals, one for lightning protection and other two for electrical earthing
of the mast, using 12 mm dia. stainless steel bolts shall be provided at convenient location
on the base of the mast.
f) Lantern Carriage
i) Fabrication
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 63 of 83
A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fittings
and control gear boxes. The Lantern Carriage shall be of special design and shall be of
steel tube construction, the tubes acting as conduits for wires, with holes fully protected by
grommets. The Lantern Carriage shall be so designed and fabricated to hold the required
number of flood light fittings and the control gear boxes, and also have a perfect self
balance.
The Lantern Carriage shall be fabricated in two halves and joined by bolted flanges with
stainless steel bolts and plastic lock type stainless steel nuts to enable easy installation or
removal from the erected mast. The inner lining of the carriage shall be provided with
protective PVC arrangement, so that no damage is caused to the surface of the mast
during raising and lowering operation of the carriage. The entire Lantern Carriage shall be
hot dip galvanised after fabrication.
ii) Junction Box
Weather proof junction box with IP65 enclosure, made of FRP cast Aluminium shall be
provided on the Carriage assembly as required, from which the inter-connections to the
designed number of the flood light luminaries and associated control gears fixed on the
carriage, shall be made.
g) Raising and lowering mechanism
For the installation and maintenance of the luminaries and lamps, it will be necessary to
lower and raise the Lantern Carriage assembly. To enable this, a suitable winch
arrangement shall be provided, with the winch fixed at the base of the mast and the
specially designed head frame assembly at the top.
i) Winch
The winch shall be of completely self sustaining type, without the need for brake shoe,
springs or clutches. Each driving spindle of the winch shall be positively locked when not in
use, gravity activated PAWLS. Individual drum also should be operated for fine adjustment
of lantern carriage. The capacity, operating speed, safe working load of the winch and the
recommended lubrication and serial number of the winch shall be clearly marked on each
winch.
The gear ratio may be according to manufacturer’s standard. However, the minimum
working load shall not be less than 750Kg. The winch shall be self lubricating type by
means of an oil bath and the oil shall be readily available grades of reputed producers.
The winch drums shall be grooved to ensure perfect seat for stable and tidy rope lay, with
no chances of rope slippage. The rope termination in the winch shall be such that distortion
or twisting is eliminated and at least 5 to 6 turns of rope remains on the drum even when
the lantern is fully lowered and rested on the rest pads.
It should be possible to operate the winch manually by a suitable handle and / or by an
external power tool. It shall be possible to remove the double drum after dismantling,
through the door opening provided at the base of the mast.
Also, a winch gear box for simultaneous and reversible operation of the double drum winch
shall be provided as part of the contract. A test certificate shall be furnished by the Bidder
from the original equipment manufacturer, for each winch in support of the maximum load
operated by the winch.
ii) Head Frame
The head frame, which is to be designed as a capping unit of the mast, shall be of welded
steel construction, galvanised both internally and externally after assembly.
The top pulley shall be of appropriate diameter, large enough to accommodate the
stainless steel wire ropes and the multicore electric cable. The pulley block shall be made
of non-corrodible material, and shall be of die cast Aluminium alloy (LM-6). Pulley made of
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 64 of 83
synthetic materials such as plastic or PVC is not acceptable. Self lubricating bearings and
stainless steel shaft shall be provided to facilitate smooth and maintenance free operation
for a long period. The pulley assembly shall be fully protected by a canopy galvanised
internally and externally.
Close fitting guides and sleeves shall be provided to ensure that the ropes and cables do
not get dislodged from their respective positions in the grooves. The head frame shall be
provided with guides and stops with PVC buffer for docking the lantern carriage.
iii) Stainless Steel Wire Ropes
The suspension system shall essentially be without any intermediate joint and shall consist
of only non-corrodible stainless steel of AISI 316 or better grade. The stainless steel wire
ropes shall be of 7/19 construction, the central core being of the same material. The overall
diameter of the rope shall not be less than 6mm. The breaking load of each rope shall not
be less than 2350Kg individually, giving a factor of safety of over 5 for the system at full
load as per the TR-7 referred to in the beginning of this specification. The end
constructions of ropes to the winch drum shall be fitted with telluric.
The thimbles shall be secured on ropes by compression splices. Two continuous lengths of
stainless steel wire ropes shall be used in the system and no intermediate joints are
acceptable in view of the required safety. No intermediate joint either bolted or else is
provided on the wire ropes between winch and lantern carriage.
h) Electrical System, cable and Cable Connections
The electrical connection from bottom to top shall be made with at least 5 core 2.5 sq. mm
flexible round sheath power cables using copper conductors of appropriate rating. A
suitable flameproof socket arrangement shall be provided at the bottom of the mast. The
trailing cable shall also have an FLP plug connected at the bottom end. Also, suitable
provision shall be made at the base compartment of the mast to facilitate the operation of
externally mounted, electrically operated FLP power tool for raising and lowering of the
lantern carriage assembly. The trailing cables at the top shall be terminated in the weather
proof junction box.
i) Power Tool for the Winch
A suitable, high powered, electrically driven, flameproof, integral mounted power tool, with
manual handle together with an operating stand shall be supplied for the raising and
lowering of the lantern carriage for maintenance purposes. The speed of the power tool
may, preferably, be slow of 1.5 to 1.8 metre/minute, so that vibrations associated with high
speed operation are avoided. The power tool shall be single speed, provided with a
flameproof motor of required rating, suitable for trolley mounting. The power tool shall be
supplied with suitable reversible starter in flameproof enclosure. The capacity and speed of
the electric motor used in the power tool shall be suitable for the lifting of the design load
installed on the lantern carriage. The power tool trolley shall be so designed that it will not
only be self supporting but also aligns the power tool perfectly with respect to the winch
spindle during the operations. Also, a handle for the manual operation of the winch in case
of problems with electrically operated tool, shall be provided and shall incorporate a torque
limiter.
j) Lightning Finial
One number heavy duty, hot dip galvanised, lightning finial shall be provided for each mast.
The lightning finial shall be minimum 1.2m in length and shall be provided at the centre of
the head frame. It shall be bolted solidly to the head frame to get a direct conducting path
to the earth through the mast body. The lightning finial shall not be provided on the lantern
carriage under any circumstances in view of safety of the system.
k) Luminaries

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 65 of 83
i) Each mast shall be fitted with required numbers of specially designed non integral type
high mast luminaries (IP-65) complete with separate control gear box (IP-65) suitable for
200W LED lamps. Two types of fittings shall be used, viz. 2X200W LED (asymmetrical)
and 1X200W LED (symmetrical).
ii) Twin dome LED type (2x40W) Aviation Obstruction Lights of reliable design and reputed
manufacturer shall be provided on top of each mast. It shall have cast aluminium housing
finished in aviation yellow colour, suitable rated step-up transformer, thick glass dome
mounted on cast aluminium ring and spring loaded high tension porcelain socket fitted with
neon cold cathode helix light source. The light source shall be designed to give Omni-
directional red colour light distribution to have maximum light output in the zone between
10oC to 90oC above horizontal plane.
11.3.6 24 V Portable Module
The 24V A.C. supply modules (with air-cooled two winding, 500VA, 1-phase, 50HZ, 240/24V
transformer with HRC fuses on both primary & secondary side and necessary 240V and 24V
terminals for incoming and outgoing connections ) shall be sheet steel enclosed with louvers
and shall be suitable for outdoor use. The 240V terminals of 24V AC supply module shall be
fed from respective lighting panels / 5/15A Switch socket.
240 V AC Terminal shall be 20 Mtr PVC insulated PVC sheathed cables and 5/15 A Plug
Top.
24 V Output shall be complete with 50 Mtr PVC insulated PVC sheathed cables, 24 V 20 W
LED hand lamps with suitable hook.
12.0 EARTHING AND LIGHTNING PROTECTION
12.1 Earthing
12.1.1 Complete earthing installation shall be done as per IS: 3043, IEEE-80, IE Rules and IEC
recommendations. The earthing system shall be designed to:
(a) Provide a permanent & continuous path from equipment and conductor enclosures to
earth from circuits for flow of fault current.
(b) Provide sufficient current carrying capacity to conduct safely any current liable to be
imposed on it.
(c) Provide sufficient low resistance to earth to limit the potential between metalwork and
earth within safe limits.
(d) Provide equal distribution of potential and minimum potential difference for safety of
personnel.
(e) Ensure sufficient current in case of fault to facilitate the operation of relays, over
current devices, fuses etc. provided in the circuit.
12.1.2 Common underground earthing grid shall be provided covering sub-stations and plants
which is further connected to overall Earthing Grid. The overall earth resistance (dry) shall
be limited to 1 ohm.
12.1.3 Earthing rings shall be provided around sub-stations and plants which in turn shall be
connected to the common earthing grid. Minimum size of main grid shall be 75mm×12mm.
Anti-corrosive bituminous paint shall be provided at each joint of earth flat after necessary
finishing and priming treatment .
12.1.4 Earthing grid/ring shall comprise of buried GI earth strips and GI pipes/electrodes.
12.1.5 Separate earth electrodes shall be provided for system neutral earthing. For equipment
earthing, minimum two numbers of electrodes shall be provided around each plant/section.
However, all these earth electrodes shall be interconnected.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 66 of 83
12.1.6 Inter-connecting pits having an earth bus in an enclosed brick chamber without earth
electrode shall be provided in the common underground earthing grid for convenience of
taking earth conductors inside the plants.
12.1.7 As far as possible, the reinforcement rods inside concrete column shall be connected to the
earthing grid/ring to reduce the overall earth resistance.
12.1.8 Individual electrical equipment shall be earthed by GI strip/GI wire/Cu/Al cable. Earth buses
shall be provided in plants for earthing groups of electrical/non-electrical equipment to
earthing grid/rings.
12.1.9 Size of earthing grid/ring and earth conductors of equipment for generating station and sub-
stations shall be as per relevant standards. The fault current magnitude shall be decided
based on system fault level. The time duration shall be taken as 1 second for voltage level
above 66 kV and 3 seconds for voltage upto 66 kV as per IS -3043.
12.1.10 All equipment rated above 250 V shall have two external earth connections and those rated
up to 250 V shall have one external earth connection. However, for lighting fixtures,
earthing shall be done through 3rd core of the cable in safe as well as in hazardous area.
12.1.11 Flameproof equipment, in addition, shall have one internal earth connection. This means
that 4 core cables to be used for all the flameproof equipments and 3.5 core cables to be
used for all flameproof motors located at hazardous area.
12.1.12 All steel structures, tanks, vessels, pipes, pipe joints, valves etc. shall be earthed against
static charge accumulation by 50x6 mm GI strip. The no. of earth connections shall be as
follows:
Equipment having diameter Hazardous area Non hazardous area
30 M 2 2
More than 30 M 3 2
12.1.13 Wherever process equipments are mounted on steel structures, the structures shall be
earthed instead of earthing the individual equipment.
12.1.14 The pipe structures shall be earthed at not more than 25M apart.
12.1.15 For all equipment in hazardous area, in addition to external earthing one internal earthing
shall be provided.
12.1.16 Minimum sizes of earth conductors to be used shall be as given below.
Sl.No. Equipment GI conductor size Al conductor Size

HV/LV switch board, transformers,
1. 50mm×8mm 150 sq. mm
HV motors
2. Motors rated 75 KW and above 50mm×6mm 150 sq. mm
Motors rated 30 KW to less than 75
3. 35mm×6mm 95 sq. mm
KW and vessel earthing
Motors rated 5.5 KW to less than
4. 25mm×6mm 25 sq. mm
30 KW
5. Motors less than 5.5 KW 8 SWG 6 sq. mm
All minor equipment rated 250V &
6. 10 SWG 6 sq. mm
above.
7. Earth Grid 75mm x 12 mm. -
Vendor to calculate the actual size. However, higher size of calculated one or above-
mentioned size shall be provided.
All GI conductors shall meet the galvanizing requirement as per IS.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 67 of 83
12.1.17 The main ground grid shall be buried in earth at a minimum depth of 1000 mm below
finished grade level unless stated otherwise
12.2 Lightning Protection
12.2.1 All structure shall be protected against lightning strokes by suitable lightning protection
system to be designed and installed as per IS/IEC-62305.
12.2.2 The number of down conductors shall be minimum two.
12.2.3 Bare metallic structures shall not have any air termination rods at the top. The earth
connections shall be welded to the bottom of structure at 300 mm above floor level.
However, tall metallic columns with insulation at top shall be provided with air termination
rods. Separate earth electrodes shall be provided for each down conductor of lightning
protection. However, these shall be inter-connected with the other electrodes in main grid.
12.2.4 Air Terminal
The vertical air terminal rods shall be installed at the roof of buildings to protect from
lightning strokes.
The vertical air terminal shall be made of 20 mm dia galvanized steel rod. The projected
length of the rod shall be as required to protect the object (on which the rod is fixed) from
lightning stroke.
The air terminal rod shall be properly fixed on the top of the building/structure to withstand
very high wind pressure. In case the air terminal rod is embedded at the top of roof of
building: the portion embedded inside the concrete shall not touch the reinforcement bars
and shall be duly insulated from them.
All the vertical air terminal rods shall be electrically connected together by means of
horizontal conductors of size 50 x 6 mm galvanized steel flats.
The shielding angle for one vertical air termination shall be 45 degrees. For more than one
rod, shielding angle between the rods shall be taken as 60 degrees.
Horizontal air termination (i.e. G.S. Flat conductor) shall be so laid that no part of the rood
will be more than nine (9) metres from the nearest roof conductor.
12.2.5 Shielding Masts
The shielding mast for lightning protection shall be installed at the top of steel columns cap
plates of power house main building.
The shielding mast shall be made of galvanized steel pipe and the height of the same shall
be decided considering the zones to be protected.
Each shielding mast shall be connected to grounding grid by a down conductor 50 x 6 mm.
Galvanized steel flat run along the building column. In addition all power house building
columns joints shall be electrically bonded.
12.2.6 Down Conductors
The down conductors shall be 50 x 6 mm galvanized steel flats. The connection between
each down conductor and earth electrode shall be made via test link located at
approximately 1500 mm above ground level.
13.0 CATHODIC PROTECTION SYSTEM
13.1 Entire underground pipe work including those laid in concrete trench and filled with sand, the
steel structures (within battery limit), tank bottom etc. shall be provided with cathodic
protection in their battery limit. The scope shall include, site surveying to collect required
information, design, supply, installation, commissioning, maintenance, monitoring and
performance guarantee of impressed current cathodic protection system as per relevant
Indian/IEC/BS/NACE Standards and codes of practices. Contractor shall have to design and

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 68 of 83
engineering of complete CP system for their battery limit. The design life of CP System shall
be 30 years.
Following shall be excluded from Cathodic Protection system.
‐ Underground Pipes with SS material / GRP Material,
‐ Above Ground reinforcements bars of reinforced concrete,
‐ Reinforcements bars of reinforced concrete foundations.
‐ Reinforcement bars in concrete piles.
13.2 LSTK Contractor shall carryout the detail site survey to confirm the desired limits of
polarized potential as per standard, functionality check , vetting / confirmation of the system
by NACE -4 Level certified person having more than 3 years’ experience in the plant
structure CP WORKS.
13.3 The SCOPE shall include but not limited to the CP system consisting of TR Units, Various
types of anode beds, associated system and for monitoring the parameters SCADA System
is provided.
13.4 There shall be centralised SCADA system to control and monitor the CP system of the
complete plant. CP system of individual unit shall have the provision for hook-up with
centralised CP SCADA system.
13.5 Shed shall be provided for all Cathodic Protection equipment installed in the field. .
13.6 Solid State Polarization Cell shall have short time fault current withstand capacity:- 5 kA/
5000 A @ 30 Cycles and Lightening Surge Current rating : 50000 A Crest for 8 to 20 μ
seconds with DC Blocking voltage range of - 3.0 V to + 1.0 V.
13.7 Surge over voltage diverter shall be provided across each monolithic isolation joint.
13.8 For all other specifications, refer PC150-TS-0823, PC150-TS-0824, PC150-TS-0825.
14.0 CAPACITOR BANKS
14.1 The LSTK Contractor shall ensure that the power factor remains minimum 0.95 lag
(inductive) in all the Bus of HV, MV& LV Switchboards.
Suitable capacitor bank shall be designed and installed at 415 V voltage level in the
substation.
Capacitor bank at 3.3 kV or 11 kV may also be considered, if required.
The capacitor bank shall utilize the Automatic Power Factor Controllers to maintain the
power factor of individual plant. Under no circumstances power factor shall become leading
(capacitive) and all necessary protections to avoid this shall be used.
14.2 For all other specifications, refer PC150-TS-0822.
15.0 COMMUNICATION SYSTEM (PA & Paging System)
15.1 Public Address system suitable to provide reliable and quick source of communication
among operating personnel shall be provided. The system shall be microprocessor based
with modular construction for ease of expansion capabilities and capacity. The system shall
have speakers, calling points etc. suitable to area of classification for that location.
Substation shall be connected with the PA System.
PA system shall be located in respective control room.
Minimum no. of field call stations of PA System shall be 8 Nos.
Minimum No. of PA Speakers shall be 12 Nos.
1 Nos. Master Call Station shall be considered and to be install at control room. Additionally
Call Station shall also be provided in Substation.
All required furniture, PC console with chairs for complete PA System shall be in scope of
LSTK Contractor.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 69 of 83
15.2 Close talk mode shall be provided for conversation between two or more stations through
close talk channel. Speeches from any hand set shall be heard over all the speakers. The
system shall have the following facility:-
i) Alert tone facility
ii) Paging facility
iii) Private conversation facility
iv) Loud speaker mute facility
i) Emergency tone facility.
15.3 The system may be centrally located at a particular plant but the location shall in no way
affect the performance of system. If required separate but interconnected system shall be
provided. The microphone system shall be capable to suppress the environmental noise
which will be present in the plant due to machineries.
15.4 It shall be possible to have automatic testing, monitoring, fault diagnosis etc. through
interface PC. The system programming shall be user friendly through interface PC.
15.5 Separate dedicated UPS with battery back-up of 8 hours shall be considered for PA System.
Ni-Cd Battery shall be provided.
15.6 Paging speakers provided in areas having ambient noise levels shall produce a paging
sound level at least 10 dB above the anticipated ambient noise level. Where it is not possible
to achieve the sound level of above 10 dB above the ambient, rotating beacons shall be
installed such a way that that the operator is alerted in the area. Acoustic hoods shall be
provided for call stations located in high noise areas.
15.7 The design of the system shall be such as to provide two channel communication i.e. Page &
Party in each zone. Page & Party system shall comprise of one channel for paging & one
channel for party talk.
15.8 It shall be possible to communicate between two field stations without the interference of the
MCS / operator. Also it shall be possible to have direct communication with the MCS.
15.9 The equipment shall be sturdy, impact resistant, dust & damp proof generally conforming to
minimum IP 66 degree of protection. For classified hazardous areas flameproof equipment
shall be provided duly certified by recognised certifying authority for the area of installation.
15.10 Acoustic hood for PA stations in noisy area shall be considered.
15.11 Paging system shall be interfaced with EPABX and Fire Alarm System.
15.12 Each PA System shall have 20% spare capacity.
15.13 Separate PA System of entire fertiliser complex shall be provided by EDS LSTK Contractor.
However Interface & Seamless Integration of PA System of Raw Water Treatment Plant -
DM Water - Condensate Polishing Unit with Owner’s PA System shall be in LSTK
Contractor’s scope. All interfacing equipment as well as cabling required for hook-up shall be
in LSTK Contractor’s scope.
15.14 All cables (including communication cable) shall be armoured type only.
15.15 For all other specifications refer PC150-TS-0801.
16.0 FIRE DETECTION AND ALARM SYSTEM
16.1 LSTK Contractor shall provide the Fire Detection and Alarm System which shall be an
independent system comprising of individual break glass type manual call points, automatic
sensors e.g. smoke and heat detectors, main panel, repeater panel, hooter, battery, battery
charger and any other hardware.
16.2 The system shall be designed to provide audio-visual indication at the main panel to be
located in Control Room and repeater panels shall be provided in fire station.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 70 of 83
16.3 The manual call points shall be provided at strategic locations with access along all exit
routes and roads.
16.4 Electrical sirens shall be provided to cover entire Raw Water Treatment Plant - DM Water -
Condensate Polishing Unit. Hooters and exit lights shall be provided at required locations in
the buildings.
16.5 The fire detection system shall be interfaced with fire suppression system.
16.6 Supply, installation, testing and commissioning of above mentioned components/equipment
for plant area, substation & control room shall be by the Contractor along with necessary
supply and laying of required signals cables.
16.7 The required nos. of MCPs and detectors in substation & control room shall be calculated as
per IS norms and contractor shall get approval from client during detailed engineering stage.
16.8 Separate Centralised Fire Alarm & Detection System of entire fertiliser complex shall be
provided by EDS LSTK Contractor. Fire Alarm & Detection System of Raw Water Treatment
Plant - DM Water - Condensate Polishing Unit shall be hooked-up with the Centralized Fire
Alarm System and shall be in LSTK Contractor’s scope. All interfacing equipment as well as
cabling required for hook-up shall be in LSTK Contractor’s scope.
16.9 All cables (including communication cables) shall be armoured type only.
16.10 For all other specifications refer PC150-TS-0826.
17.0 MOUNTING STRUCTURES
Switch sockets, cable trays, DBs etc shall be mounted / supported on suitable
structure fabricated out of standard sections of mild steel, i.e. channels, angels, flats
etc conforming to IS: 2066.
18.0 SPARES
18.1 Commissioning Spares
LSTK Contractor shall recommend list of commissioning spares for all the equipments, as
required. The commissioning spares shall form an integral part of the scope of supply. LSTK
Contractor shall be responsible for the quantification of the commissioning spares for the
smooth start up of the plant/ package system. Item wise list of commissioning spares with
recommended quantity shall be furnished for information. The same shall be Part of LSTK
Price.
18.2 Mandatory/Insurance spares
Contractor shall supply Mandatory / Insurance spares for all equipments as per Section 10.0:
Spare Parts of this bid package. The same shall be Part of LSTK Price.
18.3 2 Years Bidder’s Recommended Operational Spares (Other than Mandatory/ Insurance
spare) )
Bidder shall recommend 2 years Operational Spares (other than mandatory/ Insurance
spare) for all the equipment (item-wise) with recommended quantity and unit price. The item-
wise price shall be with validity of 2 Years.
The same shall not be part of LSTK price.
18.4 All spare parts shall be identical to the parts used in the equipments.
18.5 Any other spare parts or special tools not specified, but required, shall also be quoted along
with the offer.
19.0 VENDORS’ SERVICES
19.1 The LSTK Contractor shall consider the services of major equipment suppliers during
installation, testing and commissioning in their scope as required.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 71 of 83
19.2 The services of engineers of following equipments’ (OEM)manufacturers are envisaged and
required during installation, Testing and commissioning. LSTK contractor shall arrange for
the same without any additional cost implication:
- AC UPS
- DC Panels
- Variable Speed Drives / Soft Starter
- Numerical relay
- MOV
- Power Transformer
- HV & LV Switchboard
- Cathodic Protection System
- Public Address System
- Fire Detection & Alarm System
19.3 Site Testing, parameterization and commissioning of the Numerical relays shall be done by
OEM expert only.
20.0 TESTING & INSPECTION
20.1 Testing of all electrical equipments shall be done in accordance with relevant IEC/BIS codes
in presence of owner’s representative at manufacturer's works before despatch / at site
before installation. All such tests shall be arranged by the contractor and testing charges, if
any, shall be borne by the contractor.
20.2 The LSTK Contractor shall submit the certificates of type tests performed on identical
equipment as evidence of the compliance of the equipment with the type tests.
20.3 The LSTK Contractor shall submit the certificates of routine and acceptance tests
conducted on the purchased equipments.
20.4 All the routine/acceptance tests shall be performed at the manufacturer’s works in the
presence of owner’s representative.
20.5 Stage Inspection of Electrical Equipment shall be considered. The owner or their
representative shall be allowed to visit the manufacturing works for stage inspection during
manufacturing stage.
20.6 The equipment shall be dispatched from works only after receipt of Owner written approval
of the test reports.
20.7 The LSTK Contractor shall intimate the owner 4 weeks in advance of the tests and submit
the detailed schedule of tests.
20.8 In addition, the equipment shall be inspected at site for final acceptance.
20.9 Certified reports of all the tests carried out at the works shall be furnished in six (6) copies for
approval of the Owner.
20.10 Electrical installation work shall be subjected to inspection by owner / his authorized
representative, statutory bodies like Electrical Inspector, Factory Inspector and where
applicable by equipment supplier’s engineer. The contractor shall carry out without extra cost
to owner rectifications / modifications desired by the above authorities to make the
installation conforming to I.E. Rules etc.
20.11 The owner may reject any portion of the work considered defective or of poor workmanship
and the contractor shall make good these defects without extra cost to owner.
21.0 DOCUMENTATION
21.1 The LSTK Contractor shall submit the documents for electrical equipments (MS-word, MS-
excel and AutoCAD) as per the drawing and documentation schedule as given in this bid
package.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 72 of 83
21.2 Sizing of Electrical system and Equipments shall be submitted during detailed engineering
stage.
21.3 A dedicated PC with licensed copy of documentation software shall be included in the scope
of LSTK Contractor for documentation of Electrical Engineering.
21.4 The software shall be used for preparing and updating the various documents such as
general arrangement drawings, cable schedules, single line diagrams, control system
drawings and equipment specifications etc.
21.5 The documentation software shall be same which is used by the LSTK Contractor for
electrical documentation.
21.6 The details of the documentation software shall be furnished in the technical offer.
21.7 LSTK Contractor shall ensure that following shall be mentioned in each sheet of drawings/
documents in the order mentioned below:
(a) Logo and Name of the client
(b) Logo and Name of the consultant
(c) Logo and Name of the contractor (LSTK Contractor )
(d) Logo and Name of the Manufacturer on the drawings prepared by manufacturer, if
applicable
(e) Name of the Project for which drawings are applicable
(f) Title of the drawing (Title shall indicate the details shown in the drawing)
(g) Drawing/ document number with sheet number and number of total sheets in the
drawing (Drawings having different title shall be assigned different drawing number)
(h) All sheets of each drawing shall bear same title, same document number and same
revision number
21.8 At the time of handing over of the installation, LSTK Contractor shall supply as built
drawings taking into consideration the actual execution carried out at site.
21.9 Erection, testing/ checking (inclusive of calibration check) prior to energisation/ after
energisation and commissioning Manuals shall be in bound book format and shall give step
by step procedure for:
(a) Storage, Handling and Erection
(b) Checking/ testing after erection and before energisation.
(c) Pre-commissioning tests/ checks and cold trials
(d) Commissioning
(e) Drawings relevant for erection, operation, maintenance and repair of the equipment.
(f) List of instruments/ testing kits/ sets, measuring instruments etc. required for testing/
checking with specification, ratings, ranges etc.
21.10 Operation & Maintenance Manuals for each of the equipment/ system being shall be in
bound book format and shall be supplied alongwith dispatch of equipment and inclusive of
following:
(a) Log sheets indicating daily/ hourly recordings of parameters to be noted down by
customer's operating personnel.
(b) Procedure for shut down and energisation.
(c) Preventive maintenance schedule.
(d) Safety procedures for safe operation of equipment and complete system.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 73 of 83
(e) Specification of equipment installed. Manufacturer’s catalogues operation and

maintenance manuals for all types of relays/components used.
(f) Test procedures for site tests/ checks.
(g) Spares list for each equipment/ system for 2 years operation and maintenance.
(h) Relevant calculations and protection relay setting table for the equipment/ system
being supplied by him
(i) Instructions for Diagnostic trouble shooting / fault location charts
(j) Tests for checking of proper functioning/ Operation.
(k) Storage and re-conservation Manual
(l) Safety Manual
(m) Drawings relevant for operation, maintenance and repair of the equipment
(n) Instructions for Maintenance and Repair
(o) List of spare parts with ordering specifications and manufacturer's catalogues.
(p) List of consumables with specifications, brand names and annual consumption
figures.
(q) Manufacturer’s catalogues with ordering specification for all items
(r) List of special tools and tackles
(s) QAP, Internal Test Certificates and Inspection Certificates
(t) Procedure for ordering spares.
(u) All as built drawings.
21.11 Drawings/ documents to be submitted with inspection call of equipment:
(a) Type test certificate for identical equipment
(b) Sub-supplier’s/ vendor’s catalogue/technical literature
(c) Test reports for internal inspection
(d) Test certificates of components
(e) Technical specification & data sheets of equipment
(f) All drawings as applicable of category ‘Approved’, ‘Approved with comments’ and
drawings ‘For information/ Reference’ including comments thereon
21.12 The details of equipment layout and cable routing will be designed by the LSTK Contractor
during detail engineering stage and these shall be subject to approval by Owner/Consultant.
Changes as required to achieve a neat layout with adequate working space all around, for
better aesthetics as well as to meet statutory regulation and codes shall be done without any
time and cost implication.
22.0 TOOLS & TACKLES
The LSTK Contractor shall supply at least one set of all special tools for each substation
required for maintenance of the equipment supplied by them and price shall be included in
the offer. List of tools & tackles with quantities shall be mentioned in the offer.
23.0 REVIEW OF DRAWINGS & DOCUMENTS BY OWNER/ CONSULTANT
23.1 The successful Bidder (herein after referred as contractor), shall submit within one month of
placement of LOI; list of drawings/ documents/ Manuals that would be submitted by them.
The list shall mention Serial Number, Title of the drawing/ document/ manual, Category (For
Approval, For review, For Reference, etc) and tentative date of submission. The list shall be

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 74 of 83
prepared taking in to account into consideration stipulations in respect of submission of

drawings/ documents and scheduled date for completion.
23.2 Template for name plate of drawings, documents and drawing/ document numbering system
shall also be submitted by contractor and approval obtained.
23.3 The LSTK Contractor shall ensure that all sheets of the drawings/ documents and top sheet
of manual prepared by manufacturer/ vendor/ supplier & submitted by him or by his
consortium member or by manufacturer or his consultant, are checked by him/ leader of
consortium and vetted by LSTK Contractor / Leader of consortium before submission with
stamp ensuring correctness, completeness, suitability of document for subject work and
compliance with stipulations of order
23.4 The responsibility for delay in approval/ review of drawings/ documents due to
a. Submission of incomplete drawings/ documents not meeting the requirement of
project/ stipulations of order
b. Non-compliance of comments made earlier
c. Drawings are not submitted in requisite copies;
and consequent delay in project shall be that of contractor.
23.5 The contractor shall ensure that in case any model number is mentioned in the drawing,
detailed technical catalogue, literature, explanatory notes to describe the model and its
technical details in full are also submitted along with the drawing. Such drawings/ documents
should be assigned Drawing/ Document Number, Number of sheets in the drawing, Rev
number etc (Unique Identification). Reference of such drawing/ document number should be
mentioned in the drawing.
23.6 The drawings/ documents shall be prepared in such sizes that those can be read easily.
Size of font in print submitted shall not less than size10 Arial or equivalent.
23.7 The drawings/ documents shall be submitted in sizes in which those are prepared.
Photocopies in reduced sizes shall not be accepted.
23.8 The contractor shall leave space on each sheet for stamping the drawing by Owner/
consultant to avoid stamping on contents of drawing making them unreadable. Submission
of drawings in A4 size shall be avoided.
23.9 All sheets of a drawing shall be assigned same title and drawing number. Drawings having
different title shall be assigned different drawing numbers.
23.10 GA drawings, schematic diagrams, single line diagrams, bill of material, data sheets,
characteristics curves, cable schedules and cable termination diagrams shall be assigned
separate drawing numbers.
23.11 Revision shall be clearly marked on all subsequent issue of drawings and documents.
23.12 Inability to incorporate some of the comments shall be clearly stated by contractor with
reasons and without delay. However, to accept or reject the non-compliance based on the
reasons indicated by contractor shall be discretion of Owner/ their consultant.
23.13 In case alterations are considered necessary by the contractor in the drawings already
approved, such drawings shall be resubmitted for approval again stating the considerations
necessitating changes/ alterations. In case, alterations/ changes proposed by contractor are
approved by the consultant/ Owner; all other drawings and data affected by such alterations/
changes shall be duly revised and re-submitted for the approval as stated above.
23.14 Contractor shall depute their concerned engineers (with the engineers of suppliers, if
required) shall visit consultant after submissions of drawings for discussion, modification of
drawings and approval so that project is not delayed for want of approval of drawings.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 75 of 83
23.15 It will be the responsibility of contractor to submit the drawings and obtain approval to meet
the project schedule. Delay in approval of drawings due to following shall be the
responsibility of contractor:
a. non-submission of drawings/ documents/ well before those are actually required and/
or
b. delay in incorporation of comments and/ or
c. non-incorporation of comments by contractor and/ or
d. submission of drawings without checking and ensuring requirement stipulated in
contract/ order
23.16 Contractor shall note that any approval and/ or clearance accorded by Owner or consultant
for manufacture and/ or to proceed further given during discussions or recorded in the
minutes of the meetings shall be valid only after the drawings showing relevant details are
submitted by contractor and clearance/ approval is accorded by Owner/ Consultant by
stamping and signing on the relevant drawings.
23.17 Approval of drawings by Owner / his consultant shall not relieve the contractor of his
contractual obligations and responsibility for engineering, design, workmanship, materials
and performance of the equipment
23.18 Contractor shall furnish, if requested, additional drawings, calculations, information to the
Owner/ Consultant to enable him to examine/ study the drawings submitted.
23.19 Contractor shall note that work shall be carried out exactly as indicated in the approved
drawings and no alterations shall be made without the written approval of the Owner/
Consultant.
24.0 TRAINING
24.1 Training shall be imparted to owner’s personnel at manufacturer’s works as under:
a) AC UPS: Two engineers for one week .
b) Variable Speed Drive / Soft Starter (if required): Four persons for one week.
c) DC System: Two engineers for one week.
d) Numerical relay: Two engineers for one week
25.0 VENDOR LIST
25.1 Make of all electrical equipment shall be as per Section 15.0: Vendor List attached with this
bid package.
25.2 Any other vendor shall be subject to Owner/Consultant’s approval.
25.3 Bidder shall indicate the make of all the equipments in their offer.
25.4 Any other item for which vendors are not mentioned in NIT, LSTK Contractor shall furnish list
of proven suppliers with PTR subject to Owner’s/ Consultant’s approval during detailed
engineering. Document(PTR) shall be in English language only.
26.0 INSTALLATION, TESTING AND COMMISSIONING
26.1 The LSTK Contractor shall undertake installation of all electrical equipment in accordance
with latest code of practices, in conformity with recommendation of the respective equipment
manufacturers, drawings approved by the owner or owner’s representative, direction of
engineer-in-charge, statutory regulations and to the entire satisfaction of the owner.
26.2 The LSTK Contractor shall arrange all the necessary erection tools and tackles, testing and
measuring instruments and shall supply the required erection materials including structural
steel.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 76 of 83
26.3 LSTK Contractor shall furnish field inspection and test data sheets for all equipments for
owner’s approval.
26.4 The LSTK Contractor shall obtain the necessary certificate of compliance/completion
certificate with test results from statutory authorities as required. All necessary drawings and
test certificates as required by them shall be furnished by the vendor.
26.5 The erection work shall be supervised by competent supervisors holding relevant
supervisory license from the Government.
26.6 Installation of Equipment
a. The equipment shall be installed in switchgear rooms, MCC rooms, control rooms
and at shop floors.
b. The scope of work of LSTK Contractor under installation shall be inclusive of but
not limited to the following:
c. Physical inspection and handling
d. Assembly and interconnection of shipping sections, if any, as per
manufacturer's instructions. Supply of materials, fabrication and installation of
supporting frames/ brackets for proper support of equipment/ panels/ devices/
cable trays etc..
e. Installation on foundation/ supports/ brackets.
f. Alignment, leveling and clamping/ welding/ fixing/ grouting with supports/
foundation bolts as required.
g. Mounting loose supplies and connection of wiring.
h. Conducting pre-energisation tests/ checks to ensure that installation is carried out
as per manufacturer’s instructions/ direction of supervising engineer and is healthy/
fit for energisation.
26.7 Cable Installation
26.7.1 General
(a) All Cables to be laid in overhead cable tray only. Cable Tray for HV, LV and Control
cable should be separate. Underground cable to be avoided, Cables to be laid on
racks in underground concrete cable trenches inside the plant only where
overhead structure is not possible. Cables may be laid in ground (slit with HDPE
conduit) where number of cables to be laid are less and do not justify use of
concrete cable trenches.
(b) All the cable tray structures shall be painted with two coats of primer and two coats
of final paint after necessary surface preparation.
(c) Cable OD 40 MM and above shall be clamped individually.
(d) Cables shall be clamped only after the cables are neatly arranged, dressed tailored
and kept in position. Support of cables on edges of cable trays/ structural steelwork
shall be avoided.
(e) Power cables shall be laid in one layer only. Control and other cables may,
however, be laid in two layers. More than two layers shall not be permitted.
(f) All the cable tray network shall be earthed by a continuous earth strip.
26.7.2 Cable laying in Trench/ on Racks/ Trays/ Cleated on Wall/ Structure. For proper support,
access and neatness of appearance of installation; cables shall be laid on racks or cable
trays or cleated on wall and/ or structure taking following into consideration:
(a) Cable racks/ trays shall be 250 mm apart.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 77 of 83
(b) Ladder type FRP cable trays shall be used for laying power cables.
(c) Perforated type FRP cable trays shall be used for laying control, signal, and
communication etc. cables.
(d) Coaxial cables for data transfer from/ to microprocessor based equipments
shall be laid in HDPE conduits with pull boxes fixed to cable supporting racks.
(e) Top tray shall be used/ left vacant for communication, signaling and fire alarm
cables.
(f) Cables shall be laid in separate trays according to voltage and noise classification.
Fire proof partition shall be provided between HV and LV cables.
(g) Power, control and lighting cables shall be laid in separate cable trays.
(h) Large size cables shall be clamped individually. Small size cables may be bunched
together provided that in any bunch all cables have sheath of same material.
(i) Cables in trays shall be clamped at not more than every 1500 mm for horizontal run
and 800 mm for vertical run and near bends.
(j) Cable racks/ trays shall be planned in such a way so that at least 20 % or one rack/
tray (whichever is more) can be added in future and at least 20 % free space shall be
left in each cable tray for cable laying in future..
(k) Support to cable trays shall be provided at intervals as required for proper
support but at interval not more than 1000 mm.
(l) Support to trays shall also be provided at each joint of tray irrespective of it's
distance from adjacent support.
(m) FRP trays shall be fixed using nuts and bolts as welding will not be permitted.
26.7.3 Cable laying in conduits
(a) Cables shall be laid in GI conduits while laying on or crossing floors/ wall/ railway
lines/ roads.
(b) While laying on floor or wall or crossing roads conduits shall be embedded in
concrete/wall.
(c) When laid on floor the top cover shall be minimum 10 mm.
(d) At rail/ road crossings, the conduits shall be laid not less than 1 meter below top
surface of the road.
(e) Mechanical protection by G.I. Pipe shall be provided to all cables up to 1200 mm
from ground/ floor level.
(f) Minimum diameter of G.I. pipes used for laying/ protection of cables shall be 1.6
times the cable diameter.
(g) Only one cable shall be laid in one conduit.
(h) Conduit shall be sealed after cable laying.
(i) Standard bends or fabricated bends shall not be used. wherever required, conduits
shall be bent using bending machine. Bending radius shall not be less than 10 times
the diameter of conduit.
(j) Jointing of the conduits shall be done using sockets which may be welded from
top to avoid ingress of water.
(k) Ends of conduits shall be made smooth to avoid damage to cables.
26.7.4 Cable Jointing
(a) Joints in cable length less than standard drum length shall not be allowed.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 78 of 83
(b) Joints, if unavoidable, shall be made at most suitable places.

(c) Joints shall not be made at passageways or under rail/ road crossings and in
hazardous area.
(d) Joints shall be segregated by not less than 2 meters so as to reduce the
possibility of one joint failure affecting the other.
(e) Individual cores in cables shall always be joined number to number or colour to
colour of the insulation over the conductors.
(f) Continuity and current carrying capacity for earth conductor and/ or armour shall be
provided.
(g) Cable jointing shall be done by joiners who possess certificate of competency for
carrying out particular joint.
(h) Minimum 2 meters cable loops shall be kept near each joint.
26.7.5 Cable Termination
(a) Double compression heavy type glands/ heat shrinkable termination kits and bi-
metallic/ copper lugs shall be used for termination of cables.
(b) Paint of the gland plate at the contact point of gland shall be removed for proper
contact.
(c) Cable glands/ termination kits shall be earthed.
(d) Cables to individual cubicles shall be neatly laid out and supported.
(e) Cables shall be clamped at a distance of 400 mm from gland/ termination.
(f) Conductors of control cables shall be neatly arranged in compact group. The entire
group shall be placed and tied with nylon straps.
(g) Spare cores shall be terminated with sufficient length to permit future connection
to the terminal block associated with control cables.
26.7.6 Identification
(a) Cable tags shall be made of non- corrodible material, preferably SS.
(b) Voltage, cable number etc shall be engraved on each tag.
(c) Cable tags shall be tied to each cable at
(i) All termination (outside as well inside panel/ box.)
(ii) All bends.
(iii) All points before and after which their route cannot be easily identified.
(iv) Entry and exit from conduits.
(v) All joints.
(vi) Every 15 meter for straight run.
27.0 TESTING OF INSTALLATION AFTER ERECTION
27.1 The LSTK Contractor shall carryout tests/ checks after erection of equipment/ cables to
check, ensure and demonstrate the conformity of equipment supplied and installation done
with the specification and statutory requirement.
27.2 Prior to starting the test, the LSTK Contractor shall satisfy himself and ensure that
a. The installation is strictly in accordance with the specification, drawings and statutory
requirement.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 79 of 83
b. Any automatic controls that might vitiate the tests have been relaxed.
c. All instruments to be used for testing are suitable for the purpose and have been
calibrated by a recognised laboratory within the last 12 months and copy of the
calibration certificates have been submitted to the Owner/ Consultant.
d. The testing, commissioning, operation and maintenance manuals are available to the
testing engineer and Owner/ Consultant.
e. Formats for recording test results have been finalised with the Owner/ Consultant and
copies have been distributed to all concerned.
27.3 The skilled manpower to test all the equipment, cables, earthing etc deputed by LSTK
Contractor is well aware of and prepared to perform checks/ tests.
27.4 The tests shall be witnessed by the representatives of Owner/ Consultant.
27.5 The LSTK Contractor shall compile and tabulate all the test results in agreed formats and
submit to Owner/ Consultant for approval prior to acceptance of installation.
27.6 Testing and checking shall be carried out to demonstrate and record prior to completion, that
supply and installation meets the requirement/ performances specified. The installation shall
be tested in presence of Owner/ Consultant.
27.7 The LSTK Contractor shall give at least 24 hours notice to Owner/ Consultant to enable
them to witness the test.
27.8 The LSTK Contractor shall submit to Owner/ Consultant test record sheets on daily basis.
27.9 Equipment or any part of the installation shall be energised only after all pre-energisation
tests are completed and test results are approved by Owner/ Consultant.
27.10 Failure to submit test results as tests are completed may render the LSTK Contractor for
carrying repeat tests.
27.11 The LSTK Contractor shall supply six (6) bound and indexed copies of all tests in agreed
formats prior to preliminary acceptance and handing over of the equipment/ installation, duly
signed by representatives of the Owner/ Consultant who have witnessed the tests.
27.12 It will be the responsibility of the LSTK Contractor to supply/ arrange at his own cost all
necessary testing equipment and measuring equipment required for conducting the tests as
per applicable standards.
27.13 Should any of the tests reveal any discrepancy or non-conformity, the same shall be
attended to and retested before proceeding with any other tests.
27.14 All tests shall be conducted in accordance with this specification, standard specifications of
Bureau of Indian Standards, recommendations of IEC and IE Rules.
27.15 Tests checks to done at site shall be inclusive of but not limited to the following:
a. Physical Check & Verification : All Equipment/Cables etc
b. Tightness of connections : All Equipment/Cables etc
c. Checking for cleanliness : All Equipment/Cables etc
d. Size & No. of Earth connection : All Equipment/Cables etc
e. Erection, alignment, mounting height : All Equipment/Cables etc
and clearances
f. Insulation Resistance test : All Equipment/Cables etc

g. Earth continuity test : All Equipment/Cables etc

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 80 of 83
h. Earth Resistance test : All Equipment/Cables etc

i. Earth loop impedance test : All Equipment/Cables etc
j. No load & rated load current : All Motors/ Loads
k. No load & rated load P.F. : All Motors/ Loads
l. No load & rated load Power : All Motors/ Loads
m. Functional checks : All Equipment & Controls
n. Primary injection test : All switchgear
o. Secondary injection test All protective relays/ devices
p. Ratio and polarity test CTs
q. Power frequency HV test Power & Control circuit
r. Phase sequence checks /C & bus couplers
s. Winding resistance test Motors & Transformers
t. Direction of rotation All motors
u. Free running for 2 Hrs All motors
v. Under voltage tests All U/V Devices
w. Calibration Checks All instruments
x. Load and Performance tests UPS, PLC, & Variable Frequency
equipment, Battery Bank
y. Checking of Voltage, current UPS, PLC, & Variable Frequency
equipment
z. Checking of specific gravity and acid Battery
level
aa. Illumination levels All areas
27.16 It is anticipated that following equipment will be necessary to perform testing of the
installation. The LSTK Contractor shall, therefore, arrange these as well as any other
equipment for testing of the installation.
a. HV Testing Set
b. Primary Injection Set
c. Secondary Injection Set
d. IR Testers
e. Earth Continuity testers
f. Soil resistivity Testers
g. Earth resistance Testers
h. Phase to earth loop impedance testers
i. Mili volt drop testers
j. Micro-ohm meter
k. Phase sequence testers
l. Clip-on ammeters
m. Voltmeters
n. Power factor meter
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 81 of 83
o. Frequency meter
p. 3 Ph 4 wire unbalance load kWh meter
q. Cable fault location equipment
r. Digital multi-meter suitable for testing IC voltage and current levels
s. Analogue Multi-meters
t. Portable multi-range precision ammeters, voltmeters complete with CTs, PTs for AC/
DC circuits.
u. Protection relay test plugs
v. Portable earthing equipment
w. Dual beam oscilloscope with storage facility.
x. UV recorder
y. Illumination level meter
z. Thermometers
aa. Power Analyser / Portable Power Meter
bb. Rpm meter
cc. Noise meter
27.17 At least following tests shall be specifically conducted before commissioning in presence of
owner’s representative. All the test results shall be recorded and submitted to the owner.
a) Insulation Test
b) Continuity Test
c) High Voltage Test
d) Simulation Test
e) Earth Resistance Test
27.18 The major testing equipment that are required to be provided by the LSTK Contractor
(permanent basis) are listed below :
a) Power operated Megger-1 KV and 5 KV Grade (Make – Fluke)
b) Earth Resistance Megger, range 0-1/3/30 Ohms (Make – Fluke).
c)Tong testers of suitable ranges (Make – Fluke).
d)Torque wrench of various sizes.
28.0 QUALITY ASSURANCE

28.1 All equipment, components, materials proposed to be supplied by LSTK Contractor shall be
procured, manufactured, erected, commissioned and tested as per a comprehensive Quality
Assurance Programme (QAP) to be approved by the Owner/ Consultant.
28.2 The Successful Bidder shall submit within 1 Month of from order; Quality Assurance Plan
(QAP) for all the equipment/ panels/ cables/ motors/ devices etc. under their scope of supply.
28.3 All routine and acceptance tests shall be carried out as per relevant IS / IEC/ Other
Standards during inspection at manufacturer’s works in presence of Owner or his
representative.
28.4 The LSTK Contractor shall submit type test certificates for similar equipment supplied by
him elsewhere. In case type test certificates (not more than 5 years old and conducted at
duly accredited laboratory) for similar equipment is not available, the type test shall be

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 82 of 83
conducted in presence of Owner or his representative without any financial implications to

Owner.
28.5 The inspection procedure shall be finalized and approved by Owner and/ or their consultant/
authorized representative.
28.6 Inspection will be carried out as per drawings and quality assurance plan approved by the
Owner/ Consultant. Inspection shall be carried out either at manufacturer’s shop/ works or
any other place where facilities for conducting tests/ checks are available.
28.7 Owner reserves the right to witness any of the tests and verify the documents of the LSTK
Contractor , his supplier/ vendor/ manufacturer.
28.8 Manufacture test certificate for bought out components shall be submitted during inspection.
28.9 No equipment or part items shall be dispatched without final acceptance certificate and
dispatch instructions in writing issued by Owner and/or their authorized representatives.
28.10 The LSTK Contractor shall carry out an inspection and testing programme during
manufacture in his works and/ or that of his vendor’s works to ensure accuracy/ correctness/
completeness of components, compliance with drawings, conformance to functional and / or
performance requirements, identify and acceptability of all materials, parts and equipment.
The LSTK Contractor shall also carry out all tests/ inspections required to establish that the
items/ equipment conform to requirements of the specification and the relevant codes/
standards specified in the specification in addition to carrying out tests as per the approved
Quality Plan.
28.11 Quality audit/ surveillance/ approval of the results of the tests and inspection, approval of
drawings will not, however, prejudice the right of the Owner to reject the equipment at any
subsequent stage if it does not comply with the specification or does not give complete
satisfaction in service and shall in no way limit the liabilities and responsibilities of the LSTK
Contractor of ensuring complete conformance of the materials/ equipment supplied to
relevant specification, standard, data sheets, drawings etc.
28.12 The owner or their representative shall be allowed to visit the manufacturing works for stage
inspection during manufacturing stage.
28.13 The LSTK Contractor shall intimate the owner 4 weeks in advance of the tests and submit
the detailed schedule of tests.
28.14 LSTK Contractor s shall supply reports of type tests, acceptance tests, all requisite factory
tests and site tests in bound volumes.
28.15 All the equipment shall be tested at site to know their condition and to prove suitability for
energisation and required performance.
29.0 COORDINATION WITH OTHER CONTRACTORS
29.1 LSTK Contractor shall coordinate with Owner’s other Contractors and shall freely exchange
all technical information required for this purpose.
29.2 All civil works connected with electrical installation shall be under the LSTK Contractor’s
scope.
30.0 DEVIATIONS
30.1 Deviations, if any from this standard (clause wise) shall be clearly indicated in the offer with
reasons thereof. In the absence of any such deviation the compliance to the clauses shall be
deemed automatically.
30.2 Successful Bidder shall also note that all those deviations mentioned in bid but not accepted
by Owner/Consultant in writing shall be considered as withdrawn by bidder.
30.3 Any and all deviations mentioned anywhere else in the bid but not specifically and
unambiguously mentioned under specific section ‘List of deviations’ shall not be considered.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 83 of 83
ANNEXURE-I
ILLUMINATION LEVELS
Average illumination levels (Mean Lux) for various areas shall be as follows:
Sl. No. AREA LUX

1.0 ROADS
1.1 Plant roads 20
1.2 Security roads 20
2.0 YARD
2.1 Marshalling yard 20
2.2 Loading/unloading areas 50
2.3 Open areas 20
3.0 PLANT
3.1 Operating platforms 100
3.2 Non-operating platform/ general process areas & walk ways 50
3.3 Pipe rack 100
3.6 Pump house/Pump bay 250
3.7 Area near large rotating equipment/plant 200
3.8 Air Conditioning Plant Room 200
3.9 Elevator machine Room 200
4.0 SUB-STATION
4.1 Switch room - Front of panel 250
- Back of panel 150
- Battery room 150
4.2 Transformer room, cable room. 70
4.3 Outdoor/transformer bay 70
5.0 CONTROL ROOMS
5.1 Front of panel 500
5.2 Back of panel 200
6.0 OFFICES 300
7.0 STORES, BATH ROOM 100
8.0 STAIR CASES
8.1 Safe areas 100
8.2 Hazardous areas 100
9.0 PANIC LIGHTING -
Lux level for A.C. Emergency lighting in Control Room shall be 250 lux.

PC150/E/4004/SecVI-5.3
(PART-A)
TALCHER FERTILIZERS LIMITED Document No. Rev
TECHNICAL SPECIFICATION - PA SYSTEM (PC150-TS-0801)
Sheet 1 of 8

TECHNICAL SPECIFICATION
PUBLIC ADDRESS SYSTEM

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 2 of 8

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
2.0 STANDARDS TO BE FOLLOWED
3.0 SERVICE CONDITIONS
4.0 OPERATIONAL REQUIREMENTS
5.0 TECHNICAL REQUIREMENTS
6.0 POWER SUPPLY
7.0 CABLES
8.0 CABLING
9.0 JUNCTION BOXES
10.0 EARTHING
11.0 ERECTION AND COMMISSIONING
12.0 DRAWINGS AND DOCUMENTS
13.0 SPARES
14.0 PACKING
15.0 DEVIATIONS
ANNEXURE - I DOCUMENTION FOR PUBLIC ADDRESSS SYSTEM

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 3 of 8

1.0 SCOPE
1.1 This standard covers the technical requirements of design, manufacture, testing,
delivery installation at site and commissioning of Public Address System along with all
accessories.
1.2 This standard shall be read in conjunction with relevant part of Design Philosophy -
Electrical.
2.1 The design, manufacture and testing of public address system and their accessories
covered by this standard shall comply with the latest issue of the following and other
relevant Indian Standards Equipment complying with equivalent IEC standards shall
also be acceptable.
IS: 1881 - Code of practice for installation of indoor amplifying and sound
distribution systems.
IS: 1882 - Outdoor installation of public address system-code of practice.
IS: 1301 - Code of safety requirements for electric mains-operated audio

amplifiers.
IS: 8061 - Code of practice for design, installation and maintenance of
service lines up to and including 650 V.
IS: 3043 - Code of practice for earthing.
IS: 1490 - Recommendation for minimum performance requirements of
mains-operated public address amplifiers.
IS: 1819 - Recommendation for general requirements of public address
amplifiers.
IS: 1031 - Methods of measurements of loudspeakers and loudspeaker
systems.
IS:1554 (Part1) - PVC insulated (heavy duty) electric cables for working voltages
up to and including 1100 V.
IS: 694 - PVC insulated cables for working voltage up to and including
1100 volts.
BS: 2004 - Electric cables for working voltage up to and including 1100
volts.
2.2 The design and operational features of all the equipments offered shall comply with the
provisions of the latest issue of the Indian Electricity Rules and other Statutory Acts and
Regulations. The supplier shall, wherever necessary, make suitable modifications in the
equipment to comply with the above.
2.3 Wherever any requirement, laid down in this standard, differs from that in Indian
Standard specifications, the requirement specified herein shall prevail.
3.1 Ambient Conditions
These shall be as indicated in Design Philosophy - Electrical.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 4 of 8

3.2 System Details
The public address system and their associated accessories shall be suitable for
operating continuously under the ambient conditions and with the voltage and frequency
variation without exceeding temperature rise limits as per relevant standards and
without detrimental effect on any part.
5.1 The public address system shall be microprocessor based, non-EPABX distributed
amplifier type. It should be designed for communication between various process units
and office areas of an industrial plant and various control room(s).
5.1.1 The band width of the communication system shall not be less than 9 KHz for intelligible
speech reproduction required for industrial environment.
5.1.2 The system shall comprise of:
i) Microprocessor based central exchange
ii) Master control station(s)
iii) Field stations and junction boxes, if any
iv) Power supply unit
v) Cables
vi) Loudspeaker
5.1.3 All other items not specifically mentioned, but required for the completeness of the
system shall be supplied.
5.2 Microprocessor based central exchange
5.2.1 The exchange shall be rack mounted microprocessor controlled. It should be designed
such that future extensions or modification can be easily carried out.
5.2.2 The actual control of communication shall be from the exchange. From the exchange,
various system information and data shall be acquired, processed and communication
links between stations shall be established as per user requirement through master
control station.
5.2.3 The exchange shall be 100% redundant in hot standby mode. The exchange shall have
facility for seamless hooking up with the EPABX system. It shall have two independent
lines of communication viz. page & party.
5.3 Master control stations (MCS)
5.3.1 The MCS shall be desk mounted type and shall comprise of a keyboard with LEDs, a
built-in loudspeaker and a built-in dynamic noise cancelling goose neck microphone. It
should have facility for duplex mode of communication.
5.3.2 The MCS shall have a key to initiate an EPABX call and should have facility to receive
EPABX call.
i) The MCS shall have features to initiate the following type of call:
ii) All call
iii) Alarm call
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 5 of 8

iv) Conferencing
v) Inter MCS call
vi) Call from MCS to field station & vice-versa
vii) Global call
viii) Call from field station of one MCS to field station another MCS
5.3.3 The MCS shall have drop out facility i.e. after connecting two field stations, the MCS, if
required, may drop out of the ongoing conversation. Priorities shall be assigned to the
various calls (Alarm & Global) shall have higher priority than other calls.
5.4 Field Station
5.4.1 It shall be of cast aluminium (LM-6) / FRP / GRP enclosure and shall consist of
adequate capacity amplifiers (Minimum 25 W) for page channel, preferably telephone
type handset & cradle switch, Twin keys & keypad and all other necessary control
switches & push buttons required for satisfactory operation of the system. Each FCS
shall be provided with inbuilt 25 W Amplifier.
5.4.2 Handsets shall be completely factory wired up to terminal blocks and shall be provided
with cable termination accessories for connecting external cables. Each FCS shall be
provided with inbuilt 25W amplifier.
5.4.3 The field stations shall be suitable for hazardous area classification defined as zone I/II,
gas group IIA/IIB/IIC & temperature class T3. All master control station shall be suitable
for outdoor installation with IP-65 protection.
5.5 Loudspeaker (LS)
5.5.1 Loudspeaker shall be highly efficient, high power driver unit designed for non-ringing to
deliver clear reproduction. The driver unit shall be lockable type to avoid pilferage.
5.5.2 Loudspeaker shall be provided with impedance matching transformer. Transformer shall
have the minimum “frequency characteristic” required for public address system.
5.5.3 Loudspeaker for indoor mounting shall be direct radiator, permanent magnet moving
coil type rated for 6W/15W. However, loudspeaker for outdoor mounting and in areas
with high ambient noise level shall be pressure unit operated, projector or horn type,
weatherproof, rugged die-cast aluminium / GRP construction rated for 25W with
Minimum 3 Nos. of Tapping. Outdoor speakers shall be of MEDC/Eaton/DNH Make.
Indoor speakers shall be of IC Audio / DNH Make.
6.0 POWER SUPPLY
6.1 Power supply single phase, 240 V, 50 Hz and further distribution shall be arranged by
the vendor.
6.1.1 DC supply, if required, shall be arranged by the vendor from the dedicated power supply
unit working on single phase 240 V, 50 Hz supply.
6.1.2 The system shall be provided with UPS of eight hour back-up and the battery used shall
be Nickel-Cadmium type.
7.0 CABLES
7.1 Signal and loudspeaker cables shall have annealed tinned copper, twin twisted & colour
coded, XLPE insulated, PVC inner sheathed, GI round wire armoured and PVC outer
sheathed FRLS type. Loudspeaker cables shall be of 24 / 0.2 mm copper and signal
cable shall be of 16 / 0.2 mm copper.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 6 of 8

7.1.1 For power cables, 3 core 2.5 sq. mm annealed tinned copper, XLPE insulation, PVC
inner sheathed FRLS type , armoured, PVC outer sheathed FRLS type cables are
required.
7.1.2 The bidder shall indicate the details & quantity of cables required in tabular form.
8.0 CABLING
The contractor shall supply, lay & connect at both ends all the cables with accessories.
The cables shall be accommodated in the existing overhead cable racks / structures as
far as possible; where racks are not available, the cables shall be laid underground by
using GI protection pipes.
9.0 JUNCTION BOXES
The junction boxes shall be of die cast aluminium powder coated. These shall be
complete with inspection cover, conduit glands and terminal stripes. The cover shall be
gasketted to make it dust & vermin proof and IP-65 protection. Holes for screwing the
covers shall have stainless steel inserts.
10.0 EARTHING
All the equipment and their associated accessories of public address system shall be
provided with earthing terminals and shall be connected to the ground mat by vendor
as per relevant Indian Standard.
11.0 ERECTION & COMMISSIONING
The bidder shall include complete, testing & commissioning along with fittings &
accessories in their scope. Good engineering practice in conformity with latest Indian
Standard & code of practice shall be followed for erection & commissioning of all the
accessories of public address system.

12.1 Drawings and documents as per Annexure-I shall be supplied unless otherwise
specified.
12.2 All drawings and documents shall have the following description written boldly.
i) Name of client
ii) Name of consultant
iii) Enquiry / order number with plant / project name
iv) Equipment Code no. and Description
13.0 SPARES
13.1 Commissioning Spares: Commissioning spares, as required, shall be supplied with the
main equipment. Item-wise list of recommended commissioning spares shall be furnished
for approval.
13.2 Spare Spares for 2 Years operation (Mandatory), as specified shall be supplied.
13.3 Recommend 2 years Operational Spares (other than mandatory spare) alongwith
recommended quantity & item-wise unit price shall be furnished.
13.4 All spare parts shall be identical to the parts used in the equipment

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 7 of 8

14.0 PACKING
The public address system shall be properly packed to safeguard against weather
conditions and handling. It shall be wrapped in polythene bag with an additional
wrapping of bitumen paper to make it completely waterproof before the equipment is
packed in wooden crates.
15.0 DEVIATIONS
15.1 Deviations, if any, from this standard shall be clearly indicated in the offer with
reasoning.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 8 of 8

ANNEXURE - I
DOCUMENTATION FOR PUBLIC ADDRESS SYSTEM
Sl. Documents Required (Y / N)

Documentation
No.
With Bid For Approval Final
1. Guaranteed technical particulars N Y Y
Outline drawing showing dimensions and

2. N Y Y
other details.
Complete assembly drawings of equipments

3. N Y Y
showing plan, elevation and cross section.
4. Schematic of field stations of each type. N Y Y
Cable schedule with complete layout

5. N Y Y
drawings
6. Illustrative and descriptive catalogues N N Y
7. Installation, operation & maintenance manual N N Y
8. Quality assurance program N N N
9. Type test certificate for
i) Hose proof items N N Y
ii) Flame proof items N N Y
10. Test certificates N N Y
11. Guarantee certificates N N Y
Note:
1. 4 hard copies & 1 soft copy shall be supplied for approval after order within 4 weeks from
the date of LOI.
2. 8 hard copies & 2 soft copies in CD shall be submitted as final documents prior to
despatch of the equipment. These shall be made in sets and supplied in fine plastic
coated folder.
Y - Yes, N - No

PC150/E/4004/SecVI-5.3
(PART-A)
TECHNICAL SPECIFICATION - UPS SYSTEM (PC150-TS-0802)
Sheet 1 of 11

UNINTERRUPTED POWER SUPPLY

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 2 of 11

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
3.0 AMBIENT CONDITIONS & ELECTRICAL SYSTEM CHARACTRISTICS
4.0 DESIGN AND OPERATIONAL REQUIREMENTS

5.0 CONSTRUCTIONAL DETAILS
6.0 COMPONENT DETAILS
7.0 OPTIONAL ITEMS
8.0 PAINTING
9.0 TESTS AND INSPECTION
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR UNINTERRUPTED POWER SUPPLY
ANNEXURE - II METERING INDICATIONS AND ALARM SCHEDULE

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 3 of 11

1.0 SCOPE
1.1 The specification covers the design, manufacture, testing at works and despatch in
well packed condition of Uninterrupted Power Supply System required to supply AC
power for non linear loads (i.e. instrumentation loads).
1.2 This standard shall be read in conjunction with block diagram & UPS distribution
diagram.
1.3 The scope shall include the following:
i) Full wave controlled rectifier
ii) Inverter
iii) Static switches
iv) Storage battery
v) Static voltage stabilizer for bypass supply
vi) Manual bypass switches
vii) Isolation / output transformer to achieve desired output voltage
viii) UPS Distribution Boards
ix) Interconnecting cabling between various units of UPS
x) All other items required, but not specified for safe and reliable operation of UPS
system.
2.1 The equipment shall conform to the latest issue of the following and relevant Indian
Standard specifications Equipment complying with equivalent IEC standards shall also
be acceptable.
IS-13314 - Solid state inverters run from storage batteries
IS-11260 - Stabilized power supplies AC output
IEC-146 - Solid state inverters
2.2 The equipment shall also conform to the provision of Indian Electricity Rules, Indian
Supply Act and any other statutory regulations in force from time to time.
3.0 AMBIENT CONDITIONS & ELECTRICAL SYSTEM CHARACTERISTICS
These shall be as specified in the enclosed Design Philosophy - Electrical.
4.1 The UPS unit and its associated equipments shall be suitable for operating at the
specified rating continuously with the specified voltage and frequency variations under
the ambient conditions without exceeding the temperature rise limits specified in
relevant standards and without any detrimental effect on any part.
4.2 The UPS system shall be based on latest generation of IGBT based, pulse width
modulated (PWM) design with proven performance. The basic scheme required for
UPS system shall be as indicated in Block diagram in this specification.
4.3 The UPS shall have Redundant Scheme with Bypass. Under normal operating
conditions, both inverter units should run in parallel sharing 50% load in synchronism
with by-pass power and supply uninterrupted A.C. power to load. On failure of one of
these inverters, the faulty inverter should get automatically disconnected from the load
and healthy inverter should supply 100% load in synchronism with by pass supply. In

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 4 of 11

the event of second inverter also developing a fault, a no-break load transfer to
standby power supply should take place through static switch.
4.4 Output frequency of the inverters must remain synchronised to one another which in
turn shall be synchronised to the standby power supply frequency provided the latter
does not vary by more than +3% to -5%. It should be possible to change the setting of
frequency range of synchronism between above limits by frequency selector switch.
Outside these limits inverter should desynchronise with the bypass and run at its own
frequency. When running at its own frequency, frequency variation shall be maintained
less than ±1.0%. Resynchronisation with bypass power supply must take place
automatically with some time delay when frequency comes back to +3% to -5% range.
Change-over from inverter to bypass or bypass to inverter shall also be possible in
desynchronised mode of operation. Change-over time in both synchronised and
desynchronised mode operation shall be indicated.
4.5 The UPS unit shall be suitable for 0.7 lagging to unity power factor. The overall power
factor may be taken as 0.8 lagging.
4.6 The maximum waveform distortion of the output voltage shall not exceed 5% r.m.s. for
linear loads and 10% r.m.s for non-linear loads. The UPS unit shall be suitable for
operation for non-linear loads having crest factor of 3.
4.7 The inverter steady state output voltage and frequency (free running) variation shall not
exceed ±1% for specified input power supply condition and no-load to full load
condition.
4.8 Voltage dip / rise on sudden application / throw of 100% load or on changeover from
inverter to bypass or vice versa shall not exceed 15% and shall be recovered within
100 m. sec. to rated voltage.
4.9 UPS shall be designed for overload of 125% for 10 min. and 150% for 10 sec. after
which drooping characteristic shall come into operation.
4.10 On failure of the main supply, inverter unit shall continue to supply rated load from the
battery bank for two hours duration.
4.11 Charger shall simultaneously supply entire power necessary for inverter and to keep
the battery of required capacity in fully charged condition. Provision for automatic
charging in both float and boost shall be made.
4.12 Battery shall be Nickel-Cadmium or Lead Acid Plate tubular positive plate or VRLA
type. The battery capacity shall be decided considering load power factor as 0.8,
derating factor for ageing 0.8 and derating for minimum ambient temperature as
applicable.
4.13 The ventilation fans, if provided shall be fully redundant and connected to the output
from the inverter and an audio-visual alarm shall be provided on its failure. It shall be
possible to operate inverter for about half an hour even after the failure of the fan
without temperature rise inside the inverter cubicle exceeding the safe operating
temperature limits.
4.14 In case of inverter failure due to any reason or overload, affected unit shall be isolated
and changeover to other inverter or to bypass shall take place automatically.
4.15 Noise level at a distance or 1m from UPS panels shall not exceed 60 dB.
4.16 UPS system shall be provided with necessary control, protection, metering, indication,
alarm & annunciation for reliable and safe operation of the system. The suggestive list
is indicated in Annexure-II.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 5 of 11

4.17 All semi-conducting devices shall be protected by fast acting semi-conducting fuses.
These fuses shall be co-ordinated with load side HRC fuses.
4.18 The battery may be taken out of service for maintenance during which period it shall be
possible for the inverter to continue operation taking power from the rectifier. The input
filter of the inverter shall be suitably designed to take care of this operational
requirement.
4.19 It shall be possible to vary the output voltage steplessly within ±5% of the specified
output voltage. This adjustment shall be possible to be made when UPS is in
operation.
4.20 UPS system shall be suitable for both floating output and earthing of one leg in case of
single phase system / star-point in case of three phase system.
4.21 The UPS system shall have very high system of reliability having minimum MTBF of
50,000 hrs. Vendor shall furnish the value of MTBF, MTTR & availability factor.
5.0 CONSTRUCTIONAL DETAILS
5.1 The equipment shall preferably be supplied in enclosed, dust & vermin proof, floor
mounted, sheet steel enclosure. In case, it is necessary to provide opening for
ventilation, this should be closed by fine mesh. Minimum degree of protection for
enclosure shall be IP-43 as per IS/IEC-60947.
5.2 Enclosure shall be fabricated with cold rolled sheet annealed steel of minimum
thickness 2.0 mm.
5.3 The door hinges shall be concealed type. The doors and the removable covers shall be
provided with non-deteriorating neoprene gaskets without any discontinuities. Gaskets
shall be held in position in groove in shaped sheet steel work or these shall be of U
type.
5.4 All external hardware shall be cadmium plated steel. Hardware for fixing the removable
parts shall be provided with retaining devices.
5.5 Panels shall be liberally designed. All components shall be so mounted that they are
easily accessible for inspection and maintenance.
5.6 UPS unit shall preferably have separate panels for each rectifier inverter units, bypass
supply, distribution boards etc. Various panels of UPS except distribution boards shall
be mounted side-by-side & bolted together to form compact assembly.
5.7 Distribution boards shall be of fixed type single front execution in fully
compartmentalised design and divided into distinct panels each comprising of bus-bar
chambers, individual feeder modules and vertical cable alley.
5.8 Mounting height of components requiring operation and observations shall not be lower
than 300 mm and higher than 1800 mm.
5.9 All the live parts which are accessible after opening the front cover / back cover shall
be properly insulated or provided with insulating barrier to prevent accidental contact.
Bus bars of distribution boards shall be PVC sleeved.
5.10 Nameplate consisting of black Perspex with white engraving shall be provided for each
panel and for each equipment mounted on the front of the panel. Suitable label
identification for each component mounted inside the panel shall also be provided.
5.11 All the wirings shall be properly laid and ferruled at both ends. PVC channels may be
used for wiring. For control wiring, minimum 1.5 sq. mm copper conductor shall be
used.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 6 of 11

5.12 The power connections shall be made by PVC insulated flexible copper cables or
taped copper / aluminium strip.
5.13 All power & control cables shall enter from the bottom.
5.14 Removable bolted aluminium gland plate, heavy duty compression type rolled
aluminium cable glands, crimping type aluminium cable lugs for Al. cables and copper
cable lugs for Cu. cables, pressure clamp / bolted type terminals etc. shall be provided
for each incoming and outgoing cable.
5.15 Terminal blocks shall be grouped according to circuit functions and suitably numbered.
20% extra terminals shall be provided in the terminal block.
5.16 A suitably sized earth bus shall be provided at the bottom of panel with provision for
earth connection at both ends to purchaser’s earth grid.
5.17 All panels shall be of same height so as to form a bank which shall give good aesthetic
appearance.
6.1 All components shall conform to relevant IS / IEC standards and shall be of reputed
make. Makes of all components shall be subject to owner’s / consultant’s approval.
6.2 Thyristors, diodes and transistors
The thyristors, diodes and transistors shall have adequate safety margins to withstand
specified operating conditions. A factor of safety of minimum 4 shall be taken against
voltage surges.
6.3 PCBs
All electronic control & monitoring printed circuit cards shall preferably be modular plug
in type. Monitoring points shall be provided in each of the PCB, PCBs shall be firmly
clamped in position so that vibration or long usage does not result in loose contacts.
Failure of each PCB shall be indicated by visual alarm and indication. The visual fault
diagnostic shall preferably indicate fault into various sections of the card.
6.4 Transformers and Chokes
All transformers and chokes shall be of dry type and air cooled. This shall be class ‘H’
insulated, vacuum impregnated. Class B insulated cast resin transformers and chokes
shall be also acceptable.
6.5 Electrolytic Capacitors
These shall be polarised aluminium type I, suitable for long life and category I, as per
IS-4317 or equivalent IEC. The capacitor shall preferably be self healing type. These
shall be so located in inverter panels that the operating temperature does not exceed
65ºC maximum.
6.6 Instruments
Ammeters & voltmeters shall be moving coil type of class 1.5 accuracy as per IS-1248.
These shall be flush mounting type of minimum size of 96 mm x 96 mm and shall have
taut band scale of 240º. Frequency meter shall be of reed type having range of 45 Hz
to 55 Hz.
6.7 Static Switches
Static switches shall be naturally commutated type with parallel inverse connected
thyristors. These shall be rated for continuous duty for 100% load. Short time rated
static switches are not acceptable.
6.8 Voltage Stabilizer
Voltage stabilizer shall be static type and shall satisfy the following requirements:
i) Maximum output voltage variation under steady state condition shall be ±3%.
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 7 of 11

ii) Maximum harmonic distortion shall be less than 5%.

iii) The output voltage shall be restored within ±2% of nominal value in less than 2
secs.
6.9 Battery
Battery along with accessories shall conform to Engineering Standard ES-0814.
6.10 Indication Lamps
All indication lamps shall be of LED type suitable for the specified control voltage,
having minimum illumination of 40 milli candela. The colour of the LEDs shall be as
follows:
ON : Red
OFF : Green
FAULT : Yellow
6.11 Moulded Case Circuit Breakers
For isolating devices of various equipment, moulded case circuit breakers shall be
used. These shall be provided with overload and short circuit protective devices and
shall conform to IS 2516.
7.0 OTHER ITEMS
7.1.1 Monitoring SystemMicroprocessor based monitoring system for UPS to supervise the
UPS operation and to print out the following data at a preset time automatically by
using its own printer shall be provided.
i) Output voltage of UPS (Common)
ii) Output current of UPS (Common)
iii) Input DC voltage of each inverter
iv) Input voltage of each rectifier (Ph to Ph)
v) Input current of each rectifier
vi) Output current of each inverter
vii) Output voltage of each inverter
viii) Room temperature
ix) Input frequency of each inverter
x) Output frequency of each inverter
7.1.2 In addition to print out once in a preset time, above data shall also be automatically
printed for the following conditions:
i) Power source change over from mains to battery and vice-versa.
ii) Change over of load from UPS to bypass supply and vice versa.
iii) On failure of UPS
iv) On failure of either inverter
v) Also facility for on demand print out of above data shall be provided.
7.1.3 On failure of UPS, the printer shall print out the waveform of the following:
i) Output voltage of UPS
ii) Output current of UPS
iii) Output voltage of each UPS
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 8 of 11

iv) Output current of each UPS

7.2 Insulation monitoring & automatic earth fault finding system
Insulation monitoring and automatic earth fault finding system shall be provided to
detect earth fault in unearthed system. The system shall preferably be of the type
which injects a low frequency alternating voltage between the earth and the network
which is used for determining the insulation resistance and to detect and locate earth
faults. There shall be fixed detectors located in incoming feeders of main distribution
boards and portable detector for location of fault within a feeder. The fixed detector
shall be connected to a central unit which can display a faulty feeder.
7.3 Potential free contact shall be brought to outgoing terminal for remote monitoring
system for the following:
i) UPS-1 fault
ii) UPS-2 fault
iii) Load on inverter
iv) Load on bypass
8.0 PAINTING
8.1 The enclosure after suitable pre-treatment shall be painted with two coats of anti-rust
paint followed by two coats of anticorrosive paint.
8.2 All paints shall be carefully selected to withstand tropical heat and extremes of
weather. The paint shall not scale off, crinkle or be removed by abrasion due to normal
handling.
8.3 Unless otherwise specified, the finishing shade shall be light grey shade no.631 as per
IS: 5.
8.4 Electrostatic powder paint shall be preferred.
9.1 The UPS units shall be subjected to tests as per relevant standards. The tests shall
include, but not limited to the following:-
i) Rectifier & inverter soft starting
ii) Regulation test
iii) Heat run test for 8 hours
iv) Overload test
v) Test for changeover time in synchronised and desynchronised mode.
vi) Test for dynamic response and transient performance
vii) Sequence & transfer test
viii) Noise level measurement
ix) Test to check the selectivity of protective devices
x) Alarm test (simulation of various fault conditions)
xi) Measurement of harmonic distortion
xii) Ventilation test (operation without fan)
xiii) Insulation test
xiv) Current division in parallel UPS

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 9 of 11

9.2 All the above tests shall be carried out in presence of purchaser’s representative. In
addition, the equipment shall be subjected to stage inspection during process of
manufacture at works and site inspection.
9.3 These inspections, shall, however, not absolve the vendor from his responsibility for
making good any defects which may be noticed subsequently.
10.1 Drawings and documents as per Annexure-I shall be supplied, unless otherwise
specified.
- Name of client
- Name of consultant
- Enquiry / order number with plant / project name
- Equipment Code no. & Description
11.0 SPARES
11.1 Spares for operation and maintenance
Item wise unit prices of spare parts shall be quoted.
Commissioning spares, as required, shall be supplied with the main equipment. Item
wise list of recommended commissioning spares shall be furnished for approval.
11.3 Any other spare parts not specified, but required, shall also be quoted along with the
offer.
12.0 PACKING
12.1 The board shall be properly packed before despatch to avoid damage during transport,
storage and handling.
12.2 The packing box shall contain a copy of the installation, operation and maintenance
manual.
12.3 A sign to indicate the upright position of the panels to be placed during transport and
storage shall be clearly marked. Also proper arrangement shall be provided to handle
the equipment.
13.0 DEVIATIONS
reasoning.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 10 of 11

ANNEXURE - I
DOCUMENTATION FOR UNINTERRUPTED POWER SUPPLY
Documents Required (Y / N)
Sl. No. Description
1. Specification sheet N Y Y
2. Technical Particulars N Y Y
3. Block Diagram N Y Y
4. General Arrangement drawings and N Y Y
foundation plan
5. Calculation for battery sizing N N N
6. Feeder Details for Distribution Boards N Y Y
7. Descriptive literature and catalogues N N Y
8. Bill of materials N Y Y
9. Schematic & Wiring Diagram N Y Y
10. Installation, operation & maintenance N N Y
manual
11. Spare parts list with identification N N Y
12. Test Certificates N N Y
13. Guarantee certificates N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N – No

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 11 of 11

ANNEXURE – II
METERING INDICATIONS AND ALARM SCHEDULE

A. METERING
1. Incoming Voltmeter with selector switches for each incomer

2. Ammeter with selector switches for each incomer
3. Ammeter & Voltmeter at each inverter output and bypass output.
4. Frequency meter & power factor meter at one common point of output
5. Ammeter & Voltmeter at incoming of each UPS distribution boards
6. Ammeter at each rectifier output
7. Battery charge / discharge meter
B. LED INDICATION
1. A.C. Mains ‘ON’

2. Rectifier output ‘ON’
3. Load on inverter
4. Load on bypass
5. Inverter synchronised to mains
6. Battery on float
7. Battery on boost
8. Fault (one lamp for all types of fault)
C. AUDIO-VISUAL ALARM (with Accept, Reset & Test facilities)
1. Mains failure
2. Rectifier failure
3. Inverter output over voltage
4. Inverter output under voltage
5. Inverter fuse failure
6. Rectifier fuse failure
7. Fan failure
8. Inverter temperature high
9. Static switch failure
10. Bypass input failure
11. Inverter desynchronised

RWTP, DMW & CPU PLANT PC150/E/4004/SecVI-5.3

0
TALCHER FERTILIZERS LIMITED (PART-A)
TECHNICAL SPECIFICATION - POWER TRANSFORMERS Document No. Rev
(PC150-TS-0803) Sheet 1 of 21

POWER TRANSFORMERS


0
(PC150-TS-0803) Sheet 2 of 21

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
4.0 OPERATING REQUIREMENTS
5.0 GENERAL DESIGN FEATURES
6.0 CONSTRUCTIONAL FEATURES
7.0 FITTINGS
8.0 PAINTING
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I LIST OF FITTINGS
ANNEXURE - II DOCUMENTATION FOR POWER TRANSFORMERS


0
(PC150-TS-0803) Sheet 3 of 21

1.0 SCOPE
1.1 This standard covers the technical requirements of design, manufacture, testing at
works and despatch in well-packed condition of Power Transformers.
1.2 This standard shall be applicable for 3 phase, core type, separate winding power
transformers of rating 315 KVA and above.
1.3 This standard shall be read in conjunction with the relevant part of Design Philosophy –
Electrical.
2.1 The design, manufacture and testing of the equipment covered by this standard shall
comply with the latest issue of IS 2026, unless otherwise specified. Equipment
complying with equivalent IEC standards shall also be acceptable.
2.2 The design and operational features of the equipment offered shall comply with the
provisions of the latest issue of the Indian Electricity Rules and other relevant Statutory
Acts and Regulations. The supplier shall, wherever necessary, make suitable
modifications in the equipment to comply with the above.
Standard Specifications, the requirement specified herein shall prevail.
These shall be as indicated in Design Philosophy – Electrical.
3.2 System Details
4.1 The transformer shall be suitable for operating at the rated capacity continuously at any
of the taps, under the ambient conditions and with the voltage and frequency variations
without exceeding the permissible temperature rise and without any detrimental effect
on any part.
4.2 The transformer shall also be capable of delivering rated current at a voltage equal to
105 % of the rated voltage.
4.3 The transformer shall be capable of allowing at least three consecutive starts of the
largest Squirrel Cage Induction Motor, while delivering 85% of its rated power without
any harmful effect on its insulation. It shall be possible to repeat the starting cycle once
in eight hours.
4.4 The transformer shall be designed to be loaded as per IS 6600.
4.5 The transformer shall be so designed as to operate in parallel satisfactorily with similar
transformers.


0
(PC150-TS-0803) Sheet 4 of 21

5.1 The design of the transformers shall be in accordance with the latest practice.
5.2 Rated Voltage, Frequency and Phase Connection
5.3 The transformer shall be so designed that it is capable of operation at 125% rated
voltage for a period of one minute and 140% rated voltage for a period of five seconds
due to sudden load throw off.
5.4 Tap Changing Gear
5.4.1 Each transformer shall be provided with on-load/ off-circuit tap changing equipment on
the high voltage winding with taps. It shall be mounted on one side, in an easily
accessible position.
5.4.2 The range of tap changer shall be as indicated and arranged in steps of 2.5%.
5.4.3 The off-circuit tap changing shall be affected by an externally operated handle capable
of being padlocked in any position and provided with tap position indicator and
mechanical stops at the extreme positions.
5.4.4 For transformer specified with on-load tap changer, tap changing gear shall be
complete with tap position indicator, limit switch, lock and key and necessary control
panel. Provision shall be made for auto-manual operation. The manual operation shall
be possible both from the panel as well as from field. In case the tap changer is located
in a separate housing, the housing shall be connected with the conservator for oil
connection. A separate buchholz relay shall be provided in such a case. Emergency
mechanical manual device shall also be provided. A minimum of 2 lakh trouble-free
operations shall be guaranteed.
5.4.5 ON-LOAD TAP-CHANGING MECHANISM (O.L.T.C.)
5.4.5.1 For transformer specified with on-load tap changer, high speed tap changing gear shall
be complete with tap position indicator, limit switch, lock and key and necessary
control panel. Provision shall be made for auto-manual operation. In case the tap
changer is located in a separate housing, the housing shall be connected with the
conservator for oil connection. A separate buchholz relay shall be provided in such a
case. Emergency mechanical manual device shall also be provided. A minimum of 2
lakh trouble-free operations shall be guaranteed. The OLTC gear shall have diverter
resistance and the current diverting contacts shall be housed in a separate oil chamber
segregated from the main tank of the transformer.
5.4.5.2 Transformer shall be provided with an on-load tap changing mechanism, as required.
This shall be designed suitable for remote control operation from switch boards in the
control room in addition to being capable of local manual as well as local electrical
operation.
5.4.5.3 It shall not be possible to use the electric drive when manual gear is in use and it shall
be possible to use only one electrical control at a time. Operation of the local or remote
control switches shall cause one tap movement only until the control switch is returned
to the off position for the next operation.
5.4.5.4 The local electrical control switches shall be mounted in the out door cubicle.
5.4.5.5 The equipment shall be so arranged as to ensure that when a tap change operation
has been commenced it shall be completed independently of the operation of the
control relays and switches. If a failure of the auxiliary supply during a tap change or


0
(PC150-TS-0803) Sheet 5 of 21

any other contingency result in that movement not being completed, adequate means
shall be provided to safeguard the transformer and its auxiliary equipment from
damage. Supervisory indication shall be provided to indicate “The change incomplete”
foul.
5.4.5.6 Limit switches may be connected in the control circuit of the operation motor provided
that a mechanical de-clutching mechanism is incorporated. Otherwise it shall be
directly connected to the operating motor circuit and mechanical stop provided.
5.4.5.7 Thermal devices or other means shall be provided to protect the motor and control
circuits. All relays switches, fuses etc. shall be mounted in the marshalling box and
shall be clearly marked to indicate their purpose.
5.4.5.8 The whole of the apparatus shall be of robust design and capable of giving satisfactory
service without undue maintenance under the conditions to be met in service, including
frequent operation.
5.4.5.9 A five-digit counter shall be fitted to the tap changing mechanism to indicate the
number of operations completed by the equipment.
5.4.5.10 A permanently legible lubrication chart shall be fitted within the driving mechanism
chamber.
5.4.5.11 The ON-LOAD Tap Changer shall include the following :-
a) An oil immersed tap selector and arcing switch or arc-suppressing tap selector,
provided with resistor for reduction of make and break arcing voltage, overload and
short circuits.
b) Motor driven mechanism.
c) Control and Protection devices.
d) Local and remote tap-changer position indicator.
e) Manual operating device.
5.4.5.12 The on-load tap changer shall be designed so that the contacts shall not interrupt arc
within the main tank of the transformer. The tap selector and arcing switch or arc
suppressing tap selector switch shall be located in one oil filled compartment. The
compartment shall be provided with a means of releasing the gas produced by the
arcing. It shall be designed so as to prevent the oil in the tap selector compartment
from mixing with the oil in the transformer tank.
5.4.5.13 The oil in those compartments of the main tap-changing apparatus which do not
contain contacts used for making or breaking current shall be maintained under
conservator head by means of an adequate diameter pipe corresponding dia of OLTC
oil surge relays connection from the highest point of the chamber connection
corresponding to the dia. of OLTC oil surge relay from the highest point of the chamber
to the conservator. This connection shall be controlled by a suitable valve and shall be
arranged so that any gas leaving the chamber will pass into the gas and oil actuated
relay.
5.4.5.14 The tap changer shall be capable of permitting parallel operation with other
transformers for which necessary wiring and accessories, if any, shall be provided.
5.4.5.15 The centre of manual operating device shall be located at a height of 1500 mm from
rail top so that it can be operated by a person standing at the ground level. The
arrangement shall be strong and robust in construction. The transformer shall give full
load output on all tap positions.


0
(PC150-TS-0803) Sheet 6 of 21

The mechanism shall be complete with normal accessories including at least the
following:-
- A mechanical tap position indicator (Rated tap voltages shall be marked on the
diagram plate).
- A mechanical operation counter.
- Mechanical stops to prevent over cranking of the mechanism beyond extreme tap
positions.
5.4.5.16 The control scheme for the tap changer shall be provided for independent control of the
tap changers when the transformers are in independent service. In addition, provision
shall be made to enable parallel operation control also at time so that the tap changer
will be operated simultaneously when one unit is in parallel with another will not
become out of step and this will eliminate circulating current.
Additional features like Master / Follower and visual indication during the operation of
motor shall also be incorporated.
Control circuit shall incorporate the following:
a) Local/remote manual electrical operation.
b) Device to ensure a positive and full completion of tap change once it is initiated even
if there is loss of power.
c) An interlock to cut-off electrical control automatically upon recourse being taken to
manual mechanical control in emergency.
d) Electrical interlock to cut-off a counter impulse for a reverse tap change, being
initiated during a progressive tap change and until the mechanism comes to rest and
resets circuits for a fresh operation.
e) All auxiliaries and devices for electrical control of OLTC gear should be housed in a
weather-proof cabinet mounted on the transformer and shall include:
- Local tap position indicator
- 5 digit operation counter
- Cubicle lighting
- Thermostatically controlled space heater.
- Miniature circuit breaker with magnetic and thermal overload devices for controlling
the incoming supply to the OLTC motor.
- Padlocking arrangement for the hinged cabinet door.
- Removable plate with cable glands.
- Inside tag with control scheme indelibly marked.
5.4.5.17 Necessary interlock, blocking independent control when the units are in parallel, shall
be provided.
5.4.5.18 Under abnormal conditions such as may occur if the contactor controlling one tap
changer sticks, the arrangement must be such as to switch off supply to the motor so
that an out of step condition is limited to one tap difference between the units. Details
of out of step protection provided for the taps should be furnished in the bid.
5.4.5.19 The contactor and associated gear for the tap change driving motors shall be housed
in a local kiosk mounted adjacent to the transformer. The motors shall be suitable for
operation on 230 V single phase or 3-phase 440 V, 50 cycle external power supply.
The kiosk having space heater, shall be dust and vermin proof and suitable protected
against corrosion or deterioration due to condensation, fungi etc.
5.4.5.20 Indoor cubicle (RTCC panel) shall be provided in the control room which shall contain :


0
(PC150-TS-0803) Sheet 7 of 21

a) Indication of the transformer ratio in use on each transformer and the number
designating the tap in use by means of digital type indicators.
b) Raise and lower push Button switch and AVR Relay.
c) Independent/Master/Follower selector switch.
d) Remote tap position indicator with indicating lamp.
e) Repeater dial of winding temperature indicator for remote indication with a device for
indicating hottest spot winding temperature in addition to a pointer to register the
highest temperature reached.
f) An indication lamp showing tap change in progress.
g) Necessary audible and visual alarms.
h) Pressure relief device operation alarm.
i) Out of step relay with two spare contacts (2 NC and 2 NO).
j) The remote indoor cubicle in addition to the above indications shall also have the
following trip and non-trip alarm windows facias with 5 spare windows suitable for
110V DC supply.
i) Oil Temperature alarm
ii) Winding Temperature alarm
iii) Winding temperature trip
iv) Buchholz alarm
v) Buchholz trip
vi) Sudden Pressure trip (Main tank)
vii) Surge Relay trip (OLTC Gear)
viii) Tap changer out of step alarm
ix) Low oil level alarm
x) Cooling fans working indication
xi) Oil pumps on and off indication
xii) Failure of group of fans alarm
xiii) Failure of group of oil pumps alarm
xiv) Failure of supply
xv) Oil flow alarm
Each relay for tripping function shall have two normally open and two normally closed
contacts for connection.
5.4.5.21 The OLTC shall be provided on the conservator side of the Power Transformer and not
in front of H.V. Bushings.
5.4.5.22 OLTC shall be suitable for bi-directional power flow.
5.5 Impedance Voltage
The impedance voltage of the transformer at 75OC shall be as per relevant IS / IEC.
This shall be guaranteed within limits specified in relevant IS / IEC at principal tap
position.
5.6 Losses
The losses under the full load condition, at the rated voltage and frequency shall be
indicated by the vendor at 75OC. These shall be guaranteed within the tolerable limits
specified in IS: 2026 at principal tap position. The purchaser has the right to impose
penalty charges or reject the transformer in case of any difference in the test and
guaranteed values.
5.7 Temperature Rise
The temperature rise of the winding, oil and core shall not exceed the values specified
in IS: 2026 when the transformer is delivering its rated output continuously under the
service conditions.


0
(PC150-TS-0803) Sheet 8 of 21

5.8 Insulation Level
All windings up to maximum system voltage of 72 KV shall have uniform insulation to

earth. For windings having higher maximum system voltage, graded insulation is
acceptable.
5.9 Terminal Arrangements
The HV and LV side terminal arrangement shall be provided as required.

Disconnecting link chambers shall be provided on the transformer primary side in all
cases as well as on secondary side, except where the termination is through bus duct.
The disconnecting chambers shall be oil filled, preferably connected with the main tank
through an isolating valve and also provided with a drain valve. However for system not
exceeding 11 KV, air filled disconnecting chamber may be accepted. Suitable cable
end box complete with cable glands and lugs shall be provided for termination of
cables. Gland plate for single core cables shall be non-magnetic.
5.10 The transformer shall be able to withstand the electro-dynamic and thermal stresses
due to terminal short circuit of the secondary, assuming the primary side fed from an
infinite bus. All leads and windings in cores shall be properly supported, clamped and
tightened after vacuum drying to ensure the short circuit withstand capacity. The short
circuit withstand duration shall be 3 Secs.
5.11 The short circuit test results for similar transformers shall be furnished.
5.12 The transformer shall be so designed as to minimise any undue noise and vibration.
The noise level shall be limited to the value specified by latest NEMA Standard / CBIP.
5.13 Due attention shall be given in the design for the suppression of harmonics.
5.14 Cooling System
5.14.1 The cooling system shall be provided as required. In case the transformer is designed
for two types of cooling, the output rating for each type shall be indicated in the offer.
The minimum acceptable output shall be 70% of rated output when forced type of
cooling system is not in operation.
5.14.2 Wherever ONAF Cooling is specified, the cooling fans shall be adequately rated and
shall be suitable for auto/manual and local/remote operation. Auto operation shall be
through winding temperature indicator contact..
5.14.3 Transformer shall have multiple cooling units with standby cooling units.
5.14.4 Cooling fans for each radiator bank shall be housed in fan box to prevent ingress of
rain water. Each fan shall be suitably protected by galvanized wire mesh guard. It shall
be possible to remove the cooling fan with motors without disturbing and dismantling
the cooler structural frame work.
5.14.5 Where OFAF cooling is applicable, two numbers of centrifugal oil pumps shall be used.
Measures shall be taken to prevent mal-operation of Buchholz relay or sudden
pressure relay when all oil pumps are simultaneously put into service. The pumps shall
be so designed that on failure of power supply to the pump motor, the pump impeller
will not limit the natural circulation of oil.
5.14.6 Cooling fans and oil pump motors shall be of squirrel cage, totally enclosed whether
proof type suitable for operation on 400 volts, three phase, 50 Hz power supply. All
motors having ball and roller bearings and grease lubricators shall be fitted with
hexagonal nipples conforming to relevant Indian Standard.


0
(PC150-TS-0803) Sheet 9 of 21

5.14.7 An oil flow indicator with alarm contacts shall be provided for the confirmation of the oil
pump operating in a normal state. An indication shall be provided on the control panel
to indicate that the pump is running.
5.14.8 The coolers and theirs accessories shall be hot dip galvanized or corrosive resistant
painted.
5.14.9 The supporting arrangement for the cooler units or for radiator banks shall be in such a
manner that the stresses if developed, shall not be transferred to the flanges of the
butterfly valves.
5.14.10 The shut off valves shall be provided on the tank at each point of connection of cooler
units radiators to the transformer tank. Removable blanking plates shall be provided to
permit blanking off the oil connection to cooler radiators.
5.14.11 All valves shall be of gun metal or cast steel or may have cast iron bodies with gun
metal fittings. They shall be of full way type with internal screw and shall be opened by
turning counter clock-wise when facing the hand wheel.
5.14.12 Means shall be provided for pad locking of valves in the open and closed position.
5.14.13 Every valve shall be provided with indicator to show clearly the position of the valve
whether open or closed.
5.14.14 All valves shall be provided with flanges having machined faces.
5.14.15 The drilling of valve flanges shall comply with the requirements of IS:3639.
5.14.16 CONTROL OF COOLER OPERATION
5.14.16.1 Each motor or group of motors shall be provided with an electrically operated contactor
and with control gear of suitable design both for starting and stopping the motor
manually and also automatically from the contacts on the winding temperature
indicating device as specified. Additional terminal for remote manual electrical control
of motors shall be provided. Overload and single phasing protection shall be provided.
HRC fuses shall be provided for short circuit protection. This equipment shall be
accommodated in the marshalling box. The power supply shall be adequately and
properly fused.
5.14.16.2 Where small motors are connected in groups, the group protection shall be arranged
so that it operates satisfactorily in the event of a fault occurring on a single motor.
5.14.16.3 Where fans and oil pumps are provided, the connection shall be arranged as to allow
the motors or groups of motors to be started up and shutdown either collectively or
individually.
5.14.16.4 All motor contactors and their associated apparatus shall be capable of holding in and
operating satisfactorily and without over heating for a period of ten minutes if the
supply voltage falls for that period, to 75% of normal value and at normal frequency.
The motor contactors and associated apparatus shall be capable of normal operation
with a supply voltage of 85 % of the normal value and at normal frequency.
5.14.16.5 All contacts and other parts which may require renewal, adjustment or inspection shall
be readily accessible.


0
(PC150-TS-0803) Sheet 10 of 21

5.14.16.6 The control arrangements are to be so designed as to prevent the simultaneous
starting of motors of total rating of more than 20 HP where such an eventually may
arise, two step operation shall be preferred.
5.14.16.7 Alarm indication for failure of group of fans and oil pump shall be provided.
5.14.16.8 Alarm indication shall be provided to indicate failure of power supply.
5.14.16.9 Provision in the cooler control circuit may be made such that tripping of transformer
breaker on Differential or Sudden Pressure should lead to supply disconnection to
motor of the cooler pump.
6.1 Core
6.1.1 The transformer core shall be of high grade, non-ageing, electrical silicon cold rolled
magnetic sheet steel of low hysteresis loss and high permeability. The maximum flux
density in any part of the core and yoke at rated voltage and frequency shall not
exceed 1.7 Tesla. The core structure shall be securely grounded to prevent
electrostatic potential. Lifting eyes and lugs shall be provided on the limbs and coils
assembly. Preferably no bolt shall be used in the cores. Clamping shall be done
external to the limb. Bolts passing through the yoke, if any, shall be insulated for 2 KV
for transformers rated up to 33 KV and 5 KV for higher voltage ratings.
6.1.2 The temperature of the core shall not exceed that permitted in IS.
6.2 Tank
6.2.1 The tank shall be made of good commercial grade low carbon steel plate of adequate
thickness capable of withstanding stress not less than 0.40 kg/cm2, properly welded
and gusseted to ensure a rigid construction. It shall also be able to withstand normal
transportation shocks without any deformation and shall be capable of withstanding
following vacuum.
Highest System Voltage MVA Rating Vacuum in mm of Hg
Up to 72 KV Up to 1.6 250
Above 1.6 to 20 500
Above 20 760
Above 72 KV For all Ratings 760
6.2.2 For outdoor transformer, the top of the tank, the marshalling box and the headers of
radiators, shall be of such a construction so as to prevent accumulation of water.
6.2.3 Guides shall be provided to facilitate tanking and untanking of the core with the coil
assembly. The details of anchoring of core and coil assembly of the tank shall be
furnished.
6.2.4 Radiators, where necessary, shall be provided on the tank to facilitate cooling. These
shall be detachable type and shall be provided with isolating valves at ends, drain plug
and air release plug. The radiators shall be fabricated out of minimum 1.25 mm thick
seamless steel tubing or pressed sheet steel. For sizes up to 500 KVA, cooling tubes
shall be acceptable.
6.2.5 Means for lifting and jacking of the transformer shall be provided.
6.3 Windings


0
(PC150-TS-0803) Sheet 11 of 21

6.3.1 Each coil shall be made out of paper insulated electrolytic grade copper conductor.
Similar coils shall be interchangeable. Successive coils of a winding shall be
connected by accessible joints and shall be brazed and finished smooth to prevent
abrasive damage to insulation. There shall be no sharp bends in the connecting leads
to prevent corona discharge. Aluminium foil wound transformer will also be acceptable.
6.3.2 The winding assembly shall be dried and impregnated in the vacuum with tested
insulating oil. The insulation resistance and polarization index of the winding measured
after impregnation shall be furnished in the test certificate.
6.3.3 For transformers rated 20 MVA and above vapour phase drying shall be adopted.
6.3.4 The magnitude of impulse surges transferred from HV to the LV winding by inductive
and capacitive coupling shall be limited to a value below the rated impulse strength of
the LV winding. The impulse voltage test results and surge distribution on windings for
similar transformer shall be furnished.
6.4 Insulation Materials
6.4.1 Class ‘A’ insulating materials specified in IS 1271 shall be used. Paper insulation shall
be new and free from punctures. Wood insulation, where used, shall be well seasoned
and treated.
6.4.2 The mineral oil shall comply with IS: 335. 10% extra oil shall be supplied along with the
transformer in non-returnable drums.
6.4.3 For the transformers required to be filled up with inert gas for transport purpose, the
required amount of oil including 10% extra shall be supplied in non-returnable drums.
6.5 Bushing
The bushing insulator shall be rated for the maximum system voltage and shall comply
with the requirements laid down in IS. The minimum current rating shall be 400 Amps.
in case of overhead line connected transformers, the bushings shall be outdoor type
having creepage distances of 31mm/kV and complete with arcing horns. In case of
transformers connected with bus duct or cable, the bushings shall be enclosed in the
terminal box. In either case, they shall be detachable from outside of the tank. The
hardware shall be of tinned copper or nickel plated brass suitable to receive the
conductors. Separate neutral bushings shall be provided for earthing the neutral, as
required. All bushings shall be marked with the symbols corresponding to the
connection diagram indicated in the diagram plate and in accordance with IS.
Bushing rated 52 KV class and above shall be oil impregnated paper condenser
bushings. Bushing rated below 52KV voltage class shall be solid porcelain or oil
communicating type.
7.0 FITTINGS
7.1 Fittings as listed in Annexure - I shall be provided. Any other fittings which may be
necessary for the satisfactory operation of the transformer shall also be provided on
each transformer.
7.2 All fittings shall conform to relevant Indian Standard Specifications.
7.3 Fittings such as conservator and associated pipes, explosion vent pipe etc. shall be
designed to withstand vacuum as specified in Clause 6.2.1 against atmospheric
pressure.
7.4 Fittings such as rating plate, dehydrating breather, off-circuit tapping switch, dial type
thermometer etc. which need to be observed/ operated, shall be mounted at


0
(PC150-TS-0803) Sheet 12 of 21

convenient heights of not more than 1.5 M from the base of the transformer and
located so as to be clearly visible from the front.
7.5 All opening shall be provided with gasketted metallic covers for protection during
transportation.
7.6 All valves shall be of globe/butterfly type provided with blanking plates. The valve body
shall be made of either Carbon Steel with trim of 13 Cr. steel or gun metal.
7.7 The rating plate, the terminal diagram and terminal marking plates shall be made of
Aluminium and shall contain relevant details as per IS 2026. The Code No. of
equipment shall be marked on a separate plate.
7.8 All terminals shall be anti loosening type and complete with connectors of required
size. The earthing terminals shall have identification marks.
7.9 Winding Temperature Indicator
Winding temperature indicator for measuring hot spot temperature of the winding shall
comprise of current transformer image coil, temperature sensing element, capillary
tube jacketed with PVC sleeve, 150 mm dia. local indicating instrument with two pairs
of contacts one for alarm and other for trip and maximum point indicator capable of
being reset by hand without tools.
7.10 Oil Temperature Indicator
Oil temperature indicator for measuring top oil temperature shall comprise of 150 mm
dial type thermometer, thermometer pocket and capillary tube jacketed with PVC
sleeve. Thermometer shall have two pairs of contacts, one for alarm and other for trip
and maximum point indicator capable of being reset by hand without tools.
7.11 Buchholz Relay
The Buchholz relay as per IS 3637 shall be of double float type, provided with, two
pairs of contacts, one for alarm and other for trip, facility for testing by injection of air by
hand pump and with a cock for draining and venting of air. The relay shall be provided
with shutoff valves on the conservator side as well as on the tank side.
7.12 The alarm and trip contacts of all protective devices shall be potential free and rated for
1 Amp at 110 V / 220 V D.C.
7.13 Marshalling Box
7.13.1 A marshalling box shall be provided to accommodate all auxiliary devices except those
which are to be located directly on transformer or housed in a separate panel.
7.13.2 The marshalling box shall be dust, weather and vermin proof type made of sheet steel
of not less than 2 mm thick. The box shall be rectangular in shape having sufficient
space for easy termination of cables. The terminal block shall be pressure clamp type.
10% spare terminals shall be provided.
7.13.3 Suitable heavy duty double compression type rolled Aluminium cable glands for all
incoming and outgoing cables shall be provided..
7.14 Current Transformers
The current transformers shall be provided and shall comply with IS 2705. The C.T.
terminals shall be accessible through a weatherproof removable cover for the purpose


0
(PC150-TS-0803) Sheet 13 of 21

of testing etc. CT polarity shall be clearly marked. The C.T. for standby earth fault
protection shall be 15 VA, 5P10. The C.T’s for differential and restricted earth fault
protection shall be of Class PS accuracy. The values of Vk and Imag for these CTs
shall be furnished at the order stage.
7.15 Wiring
All controls, indication and protective devices provided on the transformer shall be
wired upto the terminal block inside the marshalling box, by means of stranded copper
heat resistant PVC insulated armoured cable of 1.1 KV grade and size not less than
2.5 sq. mm. Wiring shall be properly fixed on cable tray with at least 100 mm clearance
from the transformer body. Suitable identification mark shall be provided on all wires.
7.16 All bought out items shall be of reputed make to be approved by Consultant/
Purchaser.
8.0 NITROGEN INJECTION FIRE PREVENTION AND EXTINGUISHING SYSTEM

8.1 Nitrogen Injection Fire Prevention and Extinguishing System shall be provided for fire
protection of Transformer against fire due to an arc, during internal faults and external
fires is for preventing tank explosion. The system design shall also conform to TAC/
NFPA norms.
8.2 The system should comprise the following :-
i. Fire Extinguishing Cubicle with base frame and containing, oil drain assembly,
nitrogen cylinder, electric mechanical control unit for oil drain and nitrogen
release detections necessary for monitoring system flanges on top panel for
connecting pipe connections from transformer, panel lighting etc.
ii. Control Box for monitoring system operation, automatic control and remote
operation, with alarms, indication light switches, push buttons, audio signal,
suitable for tripping and signaling on 110V DC supply.
iii. Pre-stressed non-return valve (PNRV) working on transformer oil flow rate, with
proximity switch for remote alarm indication and with visual position indicator.
iv. Required number of fire detectors rated for 1410C for heat sensing, each fitted
with two number cable glands.
v. Signal box for terminating cable connections from PNRV and fire detectors.
vi. Pressure relief valve with limit switch.
8.3 The following arrangements are required to be made on the transformer Tank at the
time of fabrication of the tank :-
i. Oil drain opening with pipe, flange and manual gate valve at about 120mm
below the top cover. Pipe size DN125 for 100 MVA and higher ratings.
ii. Nitrogen Injection openings with pipe size DN 25 with flange and manual gate
valve on tank sides at about 100-200 mm from the bottom plate.
iii. Flanges having 4 Nos. 18 dia. holes with pcd as 155mm and dummy pipe on the
conservator pipe between buchholz relay and conservator tank manual gate
valve, for fixing PNRV.
iv. Fire detector brackets on top cover.
v. brackets for fixing signal box at a suitable location on top cover or tank size wall.
8.4 ACTIVATION OF NIFPES:


0
(PC150-TS-0803) Sheet 14 of 21

Mal-functioning of fire prevention / extinguishing systems is their major shortcoming
which leads to interruption in power supply. The Contractor shall ensure that the
chances of malfunctioning of NIFPES are practically nil. To achieve this objective, the
Contractor shall work out their scheme of activating signals which, while preventing
mal-operation, should not be to rigorous to make the operation of NIFPES
impracticable in case of actual need. Transformer isolation shall be the mandatory pre-
requisite for activation of the system in Automatic mode or Remote mode in the control
room.
In addition, at least following electrical-signals shall be provided in series for activating

NIFPES.
8.4.1 Auto Mode
a) For Prevention of Fire : i) Differential Relay Operation
ii) Buchholz Relay parallel with Pressure Relief
Valve or RPRR. (Rapid Pressure Release Relay)
iii) Tripping of all concerned breakers is a
prerequisite for initiation of system activation.
b) For Extinguishing Fire : i) Fire Detector

ii) Buchholz Relay paralleled with Pressure Relief
Valve or RPRR.
iii) Tripping of all connected breakers is a
prerequisite for initiation of system activation.
8.4.2 Manual Mode (Local/Remote) : Tripping of all connected breakers is a pre-requisite for
initiation of system activation.
8.4.3 Manual Mode (Mechanical) : Tripping of all connected breakers is a pre-requisite
for initiation of system activation.
8.5 General Description of NIFPES
8.5.1 Schematic of the System
NIFPES should be a stand alone dedicated system for oil filled. It should have a fire
extinguishing FE) cubicle placed on a plinth at a distance of 6-10 mtrs. from the
transformer. The F.E. cubicle may be connected to the transformer oil tank (near its
top) and to the oil pit from its bottom through oil pipes with gate valves. The F.E.
cubicle should house a pressurized nitrogen cylinder connected to the transformer oil
tank (near its bottom). Cable connections are to be provided from signal box placed on
the transformer to the control box in the control room and from control box to F.E.
cubicle. Fire detectors placed at the top of transformer are to be connected in parallel
to the signal box. The signal box may be connected to a pre-stressed non-return valve
fitted between the conservator tank and Buchholz relay. Control box is also to be
connected to relay panel is control room for system activation signals.
8.5.2 Operation
On receipt of all activating signals, drain of pre-determined quantity of oil commences
thus removing high temp. top oil layer. Simultaneously nitrogen is injected under high
pressure at a pre-fixed rate, string the oil thus bringing the temperature of top oil layer
down. Nitrogen occupies the space created by oil drained out and acts as an insulating


0
(PC150-TS-0803) Sheet 15 of 21

layer between the tank oil & fire on top cover. Pre-stressed non return valve blocks oil
flow form conservator tank, thus isolating it & preventing aggravation of fire.
8.5.3 System Components
Broadly, NIFPES shall consist of the following components. It is emphasized that all
components, necessary for fast reliable & effective working of NIFPES shall be
considered within the scope.
8.5.4 Fire Extinguishing Cubicle
It shall be made of 3mm thick steel sheet, painted dark red from inside & outside with
hinged split doors fitted with high quality tamper proof lock. It shall be complete with
the base frame and the following :-
- Nitrogen gas cylinder with regulator and falling pressure electrical contact manometer
- Oil drain pipe with mechanical quick drain valve.
- Electro mechanical control equipment for oil drain and pre-determined regulated
nitrogen release.
- Pressure monitoring switch for back-up protection for nitrogen release.
- Limit switches for monitoring of the system.
- Flanges on top panel for connecting oil drain and nitrogen injection pipes for
transformer.
- Panel lighting (CFL Type)
- Oil drain pipe extension of suitable sizes for connecting pipes to oil pit.
8.6 Control Box
Control Box for monitoring system operation, automatic control and remote operation,
with following alarms indication, light switches, push buttons, audio signal, line fault
detection suitable for tripping and signaling on 110V DC supply :
‐ System on*
‐ PNRV open*
‐ Oil drain valve closed*
‐ Gas inlet valve closed*
‐ PNRV closed^
‐ Fire Detector Trip^
‐ Buchholz Relay Trip^
‐ Oil drain valve open^
‐ Extinction in pressure^
‐ Cylinder pressure low^
‐ Differential relay trip^
‐ PRV/RPRR trip^
‐ Transformer trip^
‐ System out of service
‐ Line fault free detector
‐ Line fault differential relay


0
(PC150-TS-0803) Sheet 16 of 21

‐ Line fault buchholz relay

‐ Line fault PRV
‐ Line fault transformer trip
‐ Line fault PNRV
‐ Auto/Manual/Off
‐ Extinction release on
‐ Extinction release off
‐ Lamp test
‐ Visual / Audio Alarm
‐ Visual / Audio alarm for DC supply fail
The signals marked (*) shall be in the topmost row of control box panel. The signals
marked (^) shall follow next.
8.7 Pre-stressed Non Return Valve (PNRV)
PNRV is to be fitted in the conservator pipe line between conservator & Buccholz relay.
It shall have the proximity switch for remote alarm, indication and with visual position
indicator. The PNRV should be of the best quality because malfunction of PNRV shall
be of serious consequence as its closing leads to stoppage of breathing of transformer.
8.8 Fire Detectors
The system shall be complete with adequate number of fire detectors fitted on the top
of oil tank, OLTC/Off ckt. Tap changer rated for 1410C for heat sensing each fitted with
two no. cable glands (water proof/weather proof).
8.9 Signal Box
It shall be fitted on the transformer for terminating cable connections from PNRV & fire
detectors and for further connection to the control box.
8.10 Cables
Fire survival cables, able to withstand 7500C, 4 core x 1.5mm sq. for connection of fire
detectors in parallel shall be used. Fire retardant low smoke (FRLS) cable 12 core x
1.5mm sq. for connection between transformer signal box/marshalling box to control
box and control box to fire extinguishing cubicle shall be used.
Fire retardant low smoke (FRLS) cable 4 core x 1.5mm sq. for connection between
control box to DC supply source and fire extinguishing cubicle to AC supply source,
signal box marshalling box to prestressed non return valve connection on transformer
shall be used.
8.11 Pipes
Pipes, complete with connections, flanges, bends, tees etc. shall be supplied alongwith
the system.
8.12 Other items
a) Oil drain and nitrogen injection openings with gate valves on transformer tank at
suitable locations
b) Flanges with dummy piece in conservator pipe between Buchholz relay and
conservator tank for fixing PNRV.
c) Fire detector brackets on transformer top cover.


0
(PC150-TS-0803) Sheet 17 of 21

d) Spare potential free contacts for system activating signals i.e. differential relay,
buchholz relay, pressure relief valve, transformer isolation (master trip relay).
e) Pipe connections between transformer to fire extinguishing cubicle and fire
extinguishing cubicle to oil pit.
f) Cabling on transformer top cover for fire detectors to be connected in parallel and
inter cabling between signal box to control box and control box to fire extinguishing
cubicle
g) Mild steel oil tank with moisture proof coating with capacity as minimum 10% of total
oil quantity of transformer, with water tight cover, to be place in the oil pit. This tank
shall be provided with the manhole, air vent pipe through silica gel breather, drain
valve and a spare gate valve at the top.
h) Gate valves on oil drain pipe & nitrogen injection pipe should be able to withstand
full vacuum. A non-return valve shall also be fitted on nitrogen injection pipe
between transformers & gate valve.
i) Pressure relief valve, wherever not fitted on the transformer.
j) The F.E. cubicle shall be painted with post office red colour (Shade 538 of IS-5). All
the exposed parts i.e. pipes, supports, signal box etc. shall be painted with
enameled paint.
8.13 Modification on the transformer
No modification on the transformer shall be allowed which affects its performance (i.e.
efficiency, losses, heat dissipation ability etc.), safety, life etc. or its any other useful
parameter. This requirement shall be of paramount importance and shall be followed.
However, in any case, performance of transformer should not be affected in any
manner by having NIFPES system and the Contractor shall give an undertaking to this
effect. All pipes should be washed/rinsed with transformer oil. If any damage is done to
the transformer and/or any connected equipment during installation & commissioning
full recovery therefore shall be effected from the Contractor.
It shall be solely the responsibility of Contractor/Sub-Contractor to install, carry out pre-
commissioning tests & commission NIFPES at Ridge Valley indicated in this
Specification, to the entire satisfaction of the Owner/Consultant..
8.14 Interlocks
It shall be ensured that once the NIFPES gets activated manually or in auto mode, all
the connected breakers shall not close until the system is actually put in OFF mode.
Also PNRV shall get closed only if all the connected breakers are open.
8.15 In general, following Fire Extinction period and other data shall be followed :
On commencement of Nitrogen : Maximum 30 seconds
Injection
From the moment of system : : Maximum 3 minutes
activation to complete cooling
Fire detectors heat sensing : 1410C
temperature
Heat sensing area : 800mm radius
Pre-stressed non return valve : minimum 60 ltr. Per minute
setting for Operation
Capacity of Nitrogen cylinder : : Minimum 68 litre water capacity And shall

hold minimum 10 cubic Meter gas to 150


0
(PC150-TS-0803) Sheet 18 of 21

. bar pressure
Power Source :
Control Box 220VDC
Fire extinguishing cubicle for 230VAC
lighting
8.16 The following information in detail shall be provided :
a) The maintenance and testing schedule for NIFPES.
b) All the steps required to be undertaken for restarting the transformer and
connected equipment after operation and mal-operation (if any) of the NIFPES.
c) The process of venting nitrogen in case nitrogen pressure in the cylinder exceeds
the stipulated maximum value.
9.0 PAINTING
9.1 The surface to be painted shall be shot or sand blasted to remove all dust, scale and
foreign adhering matter. All traces of oil and greases should be removed by suitable
treatment.
9.2 All steel surfaces in contact with insulating oil shall be painted with heat resistant oil
insoluble insulating varnish.
9.3 All steel surfaces exposed to outside shall be painted with suitable anti-rust and
anticorrosive paints. Epoxy paints shall be used.
handling.
9.5 Unless otherwise specified, the finishing shade shall be light grey Shade No. 631 as
per IS 5.
9.6 1 litre of paint per transformer shall be supplied for touch up at Site.
10.1 All transformers shall be routine tested as per IS 2026. Transformer oil shall be tested
as per IS 335.
10.2 Additional tests, wherever specified, shall be carried out on one transformer of each
rating.
10.3 All the above mentioned tests shall be carried out in the presence of Purchaser’s
representative. In addition, the transformers shall be subject to stage inspection at
works and inspection at site for final acceptance.
10.4 These inspections shall, however, not absolve the Vendor from their responsibility for
making good any defect which may be noticed subsequently.
11.1 The drawings and documents as per Annexure-III shall be furnished, unless otherwise
specified.


0
(PC150-TS-0803) Sheet 19 of 21

11.2 All drawings and documents shall have the following descriptions written boldly:
-- Name of Client
-- Name of Consultant
-- Enquiry / order number with plant / project name
-- Equipment Code No. and Description
11.3 The transformer shall be suitably packed to avoid damage in transit and shall be
properly sealed so as to completely exclude oxygen and moisture from coming in
contact with oil. Bushing shall be wrapped in straw ropes or similar material and
complete transformer shall be packed in wooden crates.
manual.
11.5 All loose pieces shall be separately wrapped in moisture resistant paper and marked
with identification mark of the corresponding transformer.
12.0 SPARES
offer.
12.4 All spare parts shall be identical to the parts used in the equipment.
13.0 PACKING
13.1 The transformer shall be suitably packed to avoid damage in transit and shall be
properly sealed so as to completely exclude oxygen and moisture from coming in
contact with oil. Bushing shall be wrapped in straw ropes or similar material and
complete transformer shall be packed in wooden crates.
manual.
13.3 All loose pieces shall be separately wrapped in moisture resistant paper and marked
with identification mark of the corresponding transformer.
14.0 DEVIATIONS
reasoning.


0
(PC150-TS-0803) Sheet 20 of 21

ANNEXURE - I
LIST OF FITTINGS
I. The fittings as given below shall be provided for all the ratings of transformers.
1. Oil Sampling Valve.

2. Filter valves with plug.
3. Radiator shutoff valves on top and bottom for each unit.
4. Buchholz relay shutoff valves.
5. Winding temperature indicator for 1000 KVA and above.
6. Oil temperature indicator.
7. Oil level indicator with minimum marking.
8. Oil conservator complete with drain plug and oil filling hole with cover.
9. Buchholz relay with air release device and alarm and trip contacts.
10. Silica gel breather with oil seal and connecting pipe.
11. Explosion vent.
12. Bi-directional rollers.
13. Inspection holes with cover.
14. Marshalling Box.
15. Rating Plate.
16. Diagram and Terminal marking plate.
17. Lifting lugs.
18. Jacking pad.
19. Earthing Terminals.
20. Air release device.
21. Neutral bushing for earthing.
22. Ladder with safety device for access to the top of transformer tank.
II. The additional fittings as given below shall also be provided, as per requirement :
1. Magnetic oil level gauge with low oil level alarm contact.
2. Hauling lugs for extra high voltage transformers.
3. Protective CTs for
a) Stand-by earth fault.
b) Restricted earth fault.
c) Differential protection.
4. Bi-directional wheels if already bi-directional rollers not considered.
5. Skids.
6. Cooler units complete with valves, fans, pumps, oil flow indicators, supporting
structure with fixing and foundation bolts etc as required and Cooler Control
panel.
7. Tap-changing gear complete with tap position indicator, operation counter etc.
For OLTC gear(where specified), oil surge relay(OSL) with shut-off valve, Local
control cabinet.
8. Nitrogen Injection Fire Prevention and Extinguishing System


0
(PC150-TS-0803) Sheet 21 of 21

. ANNEXURE - II
DOCUMENTATION FOR POWER TRANSFORMERS

Description
No.
1. Specification Sheet N Y Y
2 Technical Particulars N Y Y
3 Dimensional drawing for complete N Y Y
Transformer, Marshalling Box,
disconnecting chamber, terminal chambers
etc.
4. Schematic and Wiring Diagram N Y Y
5. Terminal arrangement drawing N Y Y
6. Installation, operation and maintenance N N Y
manual
7. Catalogues and test certificates for bought N N Y
out accessories
8. Type test certificates of similar transformer N N Y
10. Guarantee Certificates N N Y
11. Spare parts list with identification marks N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N - No

0
TECHNICAL SPECIFICATION - NEUTRAL EARTHING Document No. Rev
RESISTORS (PC150-TS-0804)) Sheet 1 of 7

NEUTRAL EARTHING RESISTOR

0

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
5.0 GENERAL DESIGN AND CONSTRUCTIONAL FEATURES
6.0 ACCESSORIES
7.0 PAINTING
10.0 SPARES
11.0 PACKING
12.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR NEUTRAL EARTHING RESISTORS

0

1.0 SCOPE
works and despatch in well packed condition of Neutral Earthing Resistor for earthing
the neutral of power transformers / generators for limiting the line to ground fault
current.
1.2 This standard shall be read in conjunction with the relevant part of Design Philosophy –
Electrical.
comply with the latest issue of IS 3043, unless otherwise specified. Equipment
2.2 The design and operational features of the equipment shall also comply with the
provisions of latest issue of the Indian Electricity Rules and other relevant Statutory Acts
and Regulations. The supplier shall, wherever necessary, make suitable modifications
in the equipment to comply with the above.
3.2 System Details
4.1 The neutral earthing resistor shall be suitable for carrying the rated current for duration
of 30 seconds under the specified ambient conditions and voltage and frequency
variations without the temperature exceeding 350ºC.
4.2 The resistor shall be designed to carry continuously 20% of the rated short time current
without any harmful effect.
4.3 The housing shall be sized such that temperature rise of the metal parts through which
current is not required to pass, when rated current is passed for the specified period,
shall not exceed 40ºC.
5.0 GENERAL DESIGN AND CONTRUCTIONAL FEATURES
5.1 Resistors
5.1.1 The resistance bank shall be of heavy duty non-inductive type having high specific
resistance and low temperature co-efficient.
5.1.2 The resistor elements shall be made of joint-less, non-corroding, sturdy and oxidation
resistant AISI 304 / AISI 406 stainless steel of punched / formed construction.
0

5.1.3 The contact between elements shall be made by individually bolting the terminals of two
adjacent elements and connecting them in series, parallel or combination of both to
achieve the specified resistance. The interconnecting link shall be zinc plated copper of
uniform cross section throughout.
5.1.4 The resistance grid shall be properly supported so that damage due to vibration and
thermal or mechanical stresses is avoided.
5.1.5 Porcelain / Epoxy insulators rated for the highest system voltage shall be used to
insulate the resistor elements from the body of the housing.
5.1.6 Insulation level for resistor bank shall be as follows:
Highest system voltage Power frequency withstand Impulse withstand
voltage Voltage
Up to 3.6 KV peak 10 KV RMS 40 KV

7.2 KV peak 20 KV RMS 60 KV
5.2 Metal clad housing
5.2.1 The housing shall be fabricated out of 3 mm thick sheet steel fitted on a 6 mm thick mild
steel frame work. This shall be floor mounting type and rectangular in shape.
5.2.2 It shall be suitable for outdoor installation and shall have minimum degree of protection
IP: 43 as per IS 2147. Ventilating louvers, if provided, shall be covered by fine wire
mesh from inside and shall be such that the above degree of protection for the
enclosure is not altered. Top cover of the housing shall be slopping construction to
prevent accumulation of water.
5.2.3 All external hardware below 8 mm size shall be of stainless steel and those of higher
size of mild steel cadmium plated or zinc passivated.
5.3 Isolation Arrangement
5.3.1 An isolator shall be provided on the incoming side to isolate the resistors from the main
equipment.
5.3.2 The isolating switch shall be single pole knife type having a rating of 1.5 times the rated
current of the resistor. The switch shall have four sets of potential free auxiliary
contacts, 2 NO and 2 NC for remote indication, wired to a terminal block. An external
handle, suitably insulated and lockable both in the ON and OFF positions, shall be
provided for the switch. The handle shall preferably be mounted at a height of 1.5
meters from the base of the housing.

Epoxy moulded current transformer of accuracy 5P for stand by earth fault protection
and PS for restricted earth fault protection shall be provided, as per requirement. The
CT connections shall be brought to separate terminal box with shorting arrangement.
5.5 Terminal Arrangement
5.5.1 For incoming connection, either bushing or cable box arrangement shall be provided. In
case of bushing connection, the bushing shall be provided on top of the housing. In
case of cable box connection, the same shall be mounted on the side of the housing.
5.5.2 For the outgoing connection, cable box arrangement is to be considered in all cases.
The cable box shall be mounted on the side of the housing.

0

5.5.3 Heavy duty double compression type rolled aluminium cable glands shall be provided
for all the incoming and outgoing cables.
5.5.4 The equipment terminals shall be anti loosening type and complete with tinned copper
cable lugs suitable for cables of specified size. For bushing connections, suitable tinned
copper conductor shall be provided as per conductor size specified.
6.0 ACCESSORIES
6.1 The equipment shall be complete with cable glands, cable lugs, drain plug, lifting hook,
name plate, foundation bolts and all other accessories required to make the equipment
complete in all respects.
6.2 Name Plate
6.2.1 Name plate shall be of stainless steel with letters embossed on them.
6.2.2 The name plate shall contain all the required details and shall include at least the
following:
i) Make
ii) Description of code no. of equipment
iii) Short time rating
a) Current
b) Duration
iv) Rated voltage
v) Maximum temperature rise over ambient
vi) Total resistance at ambient temp.
vii) Materials of resistors
viii) Degree of protection of enclosure
7.0 PAINTING
7.1 The enclosure, after suitable pre-treatment shall be painted with two coats of antirust
paint followed by two coats of anti-corrosive paints.
7.2 Epoxy based paints shall be used.
7.3 All paints shall be carefully selected to withstand tropical heat and extremes of weather.
The paint shall not scale off, crinkle or be removed by abrasion due to normal handling.
7.4 The finishing paint shall be light grey shade no. 631 as per IS 5.
8.1 Following tests shall be carried out on the neutral earthing resistors:
8.1.1 Routine Tests

i) Resistance value measurement at room temperature.
ii) Power frequency high voltage test for one minute.
iii) Insulation resistance test.
8.1.2 Type test
i) Heat run test.
0

8.2 The above mentioned tests shall be carried out in the presence of purchaser’s
representative. In addition, the equipment shall be subjected to stage inspection during
process of manufacture at works and inspection at site for final acceptance.
8.3 The purchaser’s inspection shall, however, not absolve the vendor from his
responsibility for making good any defects which may be noticed subsequently.
9.1 The drawings and documents as per Annexure-I shall be furnished unless otherwise
specified.
9.2 All drawings and documents shall have following descriptions written boldly.
- Name of the client
- Equipment code no. and Description.
10.0 SPARES


offer.
11.0 PACKING
11.1 The neutral earthing resistor shall be properly packed to safeguard against weather
conditions and handling. It shall be wrapped in polythene bag with an additional
wrapping of bitumen paper to make it completely waterproof before the equipment is
packed in wooden crates.
11.2 A sign to indicate the upright position of the panel for placing during transport and
storage shall be clearly marked.
11.3 Packing box shall include one copy of the installation operation and maintenance
manual
12.0 DEVIATIONS
reasoning.

0

ANNEXURE - I
DOCUMENTATION FOR NEUTRAL EARTHING RESISTORS

Description
No. With Bid For Approval Final
3. General arrangement drawings N Y Y
4. Illustrative and descriptive catalogues N N Y
5. Installation, Operation and maintenance N N Y

manual
Note:
the date of LOI.
coated folder.
Y - Yes, N - No


0
TECHNICAL SPECIFICATION - MEDIUM VOLTAGE SWITCH Document No. Rev
BOARDS (PC150-TS-0805) Sheet 1 of 17

MEDIUM VOLTAGE SWITCH BOARDS


0

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
5.0 DESIGN AND CONSTRUCTIONAL FEATURES
7.0 ACCESSORIES
8.0 PAINTING
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR MEDIUM VOLTAGE SWITCH BOARDS


0

1.0 SCOPE
works and delivery in well-packed condition of Medium Voltage Switchboards.
1.2 This standard shall be applicable for the Power Control Centres, Power cum Motor
Control Centres and Motor Control Centres.
1.3 This standard shall be read in conjunction with relevant part of Design Philosophy –
Electrical, Schematic diagrams etc.
2.1 The design, manufacture and testing of the equipment shall comply with the latest issue
of the following Indian Standards, unless otherwise Specified. Equipment complying
with equivalent IEC standards shall also be acceptable.
IS 8623 - Specification for low voltage switchgear and control gear

assemblies
IS/IEC 60947 - Low-voltage switchgear and control gear (General Rules)
IS 5578 - Guide for marking of insulated conductors

IS 10118 - Code of practice for selection, installation and maintenance of
switchgear and control gear
IS 11353 - Guide for uniform system of marking and identification of
conductors and apparatus terminals
Various components housed in the switchboards shall conform to the Indian Standard
specifications as mentioned against the component details or IEC specifications.
2.2 The design and operational features of all the equipment offered shall also comply with
the provisions of the latest issue of the Indian Electricity Rules and other Statutory Acts
and Regulations, as applicable. The supplier shall, wherever necessary, make suitable
Standard Specification / IEC Specification, the requirement specified herein shall
prevail.
3.2 System Details
The Medium Voltage Switchboards shall be suitable for operating at the specified rating
continuously, with the specified voltage and frequency variations under the ambient


0

conditions, without exceeding the permissible temperature rise and without any
detrimental effect on any part.
5.1 General
5.1.1 The switchboards shall consist of an assembly of a series of floor mounting, identical,
metal clad, dead front type sheet steel panels of unitized design. The panels shall be
placed side by side to form a compact assembly and shall be extensible on either side.
5.1.2 The complete assembly shall be dust, damp and vermin proof having minimum degree
of protection equivalent to IP-52 as per IS/IEC:60947.
5.1.3 The frame work of the cubicles shall be of bolted/welded construction. The minimum
thickness of sheet steel shall be 2 mm for load bearing members, 1.6 mm for non-load
bearing members and 3 mm for base channel. The doors and covers shall be fabricated
from cold rolled sheets. Suitable reinforcement, wherever necessary, shall be provided.
5.1.4 The door hinges shall be concealed type.
5.1.5 All external hardwares shall be cadmium plated. The hardwares for fixing the removable
5.1.6 The doors and the removable covers shall be provided with non-deteriorating neoprene
gaskets. Gaskets without any discontinuity shall be preferred. Gaskets shall be held in
position in groove, in shaped sheet steel work or these shall be of U type. Adhesive
cement, if used, shall be of good quality so that the gaskets do not come off during
service.
5.1.7 All the components shall be accessible for inspection and maintenance without the
necessity for removal of the adjacent ones.
5.1.8 The layout of the component inside the module shall be liberal to facilitate maintenance
and interconnecting wiring between the components shall not be subjected to any
undue stresses at the bends.
5.1.9 Mounting height of components requiring operations and observation shall not be lower
5.1.10 Inter panel barriers shall be provided.
5.1.11 All the live parts which are accessible after opening of front cover/cable alley cover/back
cover shall be properly insulated or provided with insulating barrier to prevent accidental
contact. Removal facility shall be provided for all such parts.
5.1.12 Adequate arrangement for earthing shall be provided to safeguard the operator or other
personnel from electric hazards under all conditions of operation.
5.2 Panel Arrangement
The Switchboards shall be in fixed/draw out, single front execution, fully

compartmentalised type and divided into distinct panels, each comprising of :
i) A completely metal enclosed bus-bars compartment running horizontally the top.
ii) Individual feeder modules.
iii) Enclosed vertical bus-bars serving all modules, in case of multi-tier panels.
iv) A vertical cable alley.
v) Separate horizontal enclosure for all auxiliary power and control buses.
5.3 Circuit Breaker Controlled Feeders


0

5.3.1 The panels housing circuit breaker feeders shall be in single front draw out execution.
The incoming and bus coupler circuit breaker feeders shall be in single tier formation
while the outgoing circuit breaker feeders may be in double tier formation.
5.3.2 A suitable barrier shall be provided between the circuit breaker and the associated
control, protective and indication devices including instrument transformers.
5.3.3 All the protective relays and meters shall be flush mounted type. The relays and meters
pertaining to a particular circuit breaker shall be mounted on the same panel. Where it is
not possible to accommodate all the relays and meters in the same panel, one metering
panel shall be provided adjacent to the circuit breaker panel exclusively for that feeder.
Location of these in the adjacent panel of other feeders shall not be acceptable.
5.3.4 A spacious cable chamber suitable for accommodation, support and termination of
required number of power cables shall be provided at the back. No bare bus-bars or live
connection shall intrude into the cabling space.
5.3.5 The switchboard shall be provided with following inter locks and safety features:
i) It shall not be possible to open the compartment door unless the breaker is drawn
to isolated position.
ii) The withdrawn and engagement of a circuit breaker shall not be possible unless it
is in open position.
iii) The operation of a circuit breaker shall not be possible unless it is in fully service,
test or isolated position.
iv) It shall not be possible to close the circuit breaker in service position unless all
auxiliary and control circuits are connected.
v) A breaker of the lower rating shall be prevented from engaging with the stationary
element of higher rating.
vi) Insertion of the manual mechanism shall render the motorised mechanism in
operation.
vii) Circuit breaker ‘ON’, ‘OFF’ indication shall be provided at the back of each panel.
Alternatively, alarm shall be provided in case panel back door is opened with
breaker “ON”.
viii) Caution nameplate shall be provided at the back of incomer’s panels where
terminals are likely to remain live and isolation is possible only from remote end.
ix) Automatic safety shutter, with Padlocking facility for locking in closed position, to
completely cover the spouts for the bus-bars and cable connection when the
breaker is withdrawn.
5.4 Switch/MCCB Controlled Feeders
5.4.1 The panels housing motor starter or other feeders shall be either fixed or draw out type
in single front execution.
5.4.2 All components of one feeder shall be mounted on a rigid sheet steel chassis.
5.4.3 Each panel shall be divided into a number of modules in tier formation placed one
above the other. These modules shall be closed on all sides.
5.4.4 The modules shall be so placed that largest one is placed at the bottom of the panel.
Type modules shall be at least 300 mm from the base channel.
5.4.5 The number of modules shall be so decided that the cables in the cable alley are not
over crowded. However the number of module in any panel shall not exceed six.
5.4.6 The minimum size of module shall be 300 mm and 200 mm for starter and switch fuse
feeders respectively.
5.4.7 The minimum clear width of cable alley shall be 250 mm.


0

5.4.8 For MCC rated above 630 Amp. The incomer and bus coupler modules shall be located
in individual single panel. For MCC rated for 630 Amp. and below the incomer and bus
coupler modules shall be half the panel size.
5.4.9 The module door shall be so interlocked that it shall not be possible to open the door
with switch in closed position and close the door unless the module is fully plugged in.
Defeat interlock facility shall be provided.
5.5 Special Features of Draw out Modules
5.5.1 The module shall be fully draw out type with sheet steel chassis moving freely on the
guides. Chassis of the same size shall be fully interchangeable.
5.5.2 The module shall have the following distinct mechanical positions:
i) Service -- In which both power and control contacts shall be made.
ii) Test -- In which power contacts shall be isolated but control contacts
shall be made.
iii) Isolated -- In which both power and control contacts shall be Isolated.
Maintenance position shall be preferred.
5.5.3 Each position shall be clearly marked. Padlocking facility shall be provided to padlock
the chassis in any of the position.
5.5.4 The movement of the chassis from one position to the other shall be controlled by using
an appropriate racking mechanism. Stopper shall be provided to prevent over travel of
the chassis beyond the isolated position.
5.5.5 The guiding system shall permit smooth movement of the module and the power and
control contacts shall be self-aligning type so that accurate alignment of the contacts is
ensured.
5.5.6 No wiring shall be taken to the door. Only the actuators of the push buttons and
switches, lenses for the indicating lamps and Perspex cover for meters shall be
mounted on the door.
5.5.7 The power contacts shall be of plug-in/stab-in type made of silver plated copper, spring
loaded and of adequate current carrying capacity. The contacts shall be so designed
that contact pressure is maintained both under normal and short circuit conditions.
5.5.8 The parting contacts, both on bus-bar side and outgoing cable side, shall always be
copper to copper and both sides silver plated. A bimetallic strip shall be used where two
dissimilar materials are in contact.
5.6 Bus-Bars and Connections
5.6.1 The bus-bars shall be for three phase and neutral. The main bus-bars and connections
shall be made of electrolytic grade copper of rectangular cross-section. Auxiliary bus-
bars for control supply, space heater supply etc. shall be made of electrolytic copper.
5.6.2 The horizontal bus-bars shall be insulated with heat shrinkable PVC sleeves of reputed
make to protect against approach to live parts. The vertical bus-bars shall be sleeved or
shrouded by barriers. Removable type insulating shrouds shall be provided for all joints
of horizontal bus-bars.
5.6.3 The bus-bars shall be amply sized to carry the rated continuous current under the
specified ambient temperature without exceeding temperature limits specified in IS:
8084. The thermal rating of the bus-bars shall be designed to withstand the system fault
current for 1 second without exceeding the limiting temperature of 200ºC for bare
Aluminium/Copper. Calculation for bus-bars sizing shall be furnished along with the
offer.


0

5.6.4 Horizontal bus-bars shall be of the same cross-section through out. Stepped bus-bars
shall not be acceptable.
5.6.5 The bus-bars shall be arranged and colour coded according to IS: 5578 / IS: 11353.
5.6.6 The bus-bar chamber shall be sufficiently spacious and shall have separate screwed
covers for maintenance purpose.
5.6.7 The bus-bars shall be rigidly supported at equal intervals to withstand maximum short
circuit stresses. The supports shall be of moulded construction with built-in anti-tracking
barriers. The support materials shall be of DMC or fibreglass reinforced thermosetting
plastic.
5.6.8 Bus-bar joints shall be between the two transporting sections only.
5.6.9 A minimum of two bolts shall be used in bus-bar joints. Only high tensile electric
galvanized bolts, nuts and washers shall be used.
5.6.10 In case of Aluminium bus-bars, all joints shall be suitably treated to avoid oxidation of
contact surfaces and bimetallic corrosion.
5.7 Earth Bus
A continuous earth bus of electrolytic grade copper, running along the entire length of
the lower part of the switchboard shall be provided with lugs at two ends for external
connections. The minimum size of earth bus shall be suitable for carrying three phase
fault current for 1 sec.
5.8 Bus Duct
5.8.1 Suitable extension of bus-bars in proper phase sequence on the top, with the
connecting bolts shall be provided where connection of transformer to switchboard is
specified to be through bus duct.
5.8.2 Bus duct between two halves of a switchboard, if required, shall be supplied by the
switchboard manufacturer. The bus-bars of interconnecting bust duct shall be similar to
the main bus-bars of the switchboard and as specified above.
5.8.3 Bust duct between transformer and incoming breaker panel, if included in Vendor’s
scope, shall conform to ES-8062.
5.9 Clearances and Creepage Distances
5.9.1 The clearances and creepage distances shall not be lower than the values specified
below:
i) Minimum clearance between two live conductors -- 20 mm
ii) Minimum clearance between live parts and accidentally -- 20 mm
dangerous part
iii) Minimum creepage distance -- 28 mm
5.9.2 The clearances and creepage, as specified above, shall definitely be maintained in the
bus-bar system. Provision of bus-bar insulation, separators or barriers shall not be
considered to reduce the clearance from the values specified above.
5.9.3 At the termination points in the equipment e.g. switches, contactors, thermal relays etc.
It is realized that above clearances may not always be possible to be maintained. All
such points, where above clearances and creepage distances are not possible to be
maintained, shall be insulated or taped.
5.10 Insulation


0

5.10.1 The insulation used shall be non-hygroscopic and may be of porcelain, epoxy resins or
fibreglass moulded with plastic. It shall be of adequate electrical, mechanical and
thermal strength to give trouble free service during normal operation and short circuit
conditions.
5.10.2 The insulation shall be treated suitably to withstand the tropical conditions and
atmospheric pollution.
5.11 Power Wiring
5.11.1 The connections from bus-bar to individual functional unit on the modules shall be of
PVC insulated flexible copper cables or taped Copper/Aluminium strip.
5.11.2 The power wiring size shall be decided based on rating of the switch/breaker after using
a rating factor of not more than 50% over the current rating in free air.
5.11.3 Power wiring size selected for breaker controlled module shall also be able to withstand
full short circuit current for duration of 0.25 sec.
5.11.4 In any case minimum size of power wiring shall not be less than 4 sq. mm copper.
5.11.5 The size of connection from incomer to horizontal bus-bar and from horizontal bus-bar
to bus-coupler shall not be less than the size adopted for horizontal bus-bar.
5.12 Control Wiring
5.12.1 The switchboard shall be completely factory wired and ready for external connections.
5.12.2 The wiring shall be carried out with flexible stranded PVC insulated copper conductor
cables of 1100 Volt grade. The size of wires shall be as follows:
C.T. Circuit -- 2.5 sq. mm
V.T. and Control Circuits -- 1.5 sq. mm
5.12.3 All wiring shall be provided with dependent both ends marking as per IS: 5578.
Numbered ferrules, reading from the terminals outwards, shall be provided at both ends
of all wiring for easy identification. These shall be interlocking type plastic ferrules.
5.12.4 Control wiring circuits, fed from a supply common to a number of panels, shall be so
protected that failure of a circuit in one panel does not effect the operation of the other
panels.
5.12.5 The wiring to the equipment mounted on the doors shall be carried out with flexible multi
strand copper conductor cable and so supported that on opening of the door there is no
undue strain on wire leads.
5.12.6 The control cables shall be neatly arranged and property supported.
5.13 External Cable Termination
5.13.1 All power and control cables shall enter the switchboard from the bottom. Sufficient
space shall be provided for ease of connection and termination of cables.
5.13.2 The type, number and sizes of cables shall be as indicated in Feeder details.
5.13.3 Compression type cable glands along with the cable lugs as required shall be provided
for termination of cables.
5.13.4 The cable glands shall be of rolled Aluminium heavy duty double compression type and
shall be mounted on a removable gland plate, provided at a minimum height of 75 mm
from the bottom of the switchboard. Two number spare knockouts of size 20 mm shall
also be provided on the gland plates for future use. Gland for termination of single core
cables shall be nonmagnetic type.


0

5.13.5 For all power cables, crimped type Aluminium lugs for Aluminium cables and tinned
Copper lugs for Copper cables shall be provided.
5.13.6 The terminal blocks shall be pressure clamp type up to 35 sq. mm cable sizes and
bolted lug type for higher sizes of cables. These shall be protected type and rated for
1100 Volts service. The minimum current rating of terminal block shall be 16 Amp. The
construction shall be such that after the connection of cables by means of lugs,
necessary clearance and creepage distance are available.
5.13.7 Where more than two cables in parallel are required to be terminated, a system of bus
links shall be provided with adequate clearance and spacing.
5.13.8 Suitable clamps to support the vertical run of cables shall be provided.
5.13.9 The terminal block shall be grouped according to circuit functions and suitably
numbered. 20% extra terminals shall be provided in the terminal block.
5.13.10 For power connections, suitable marking on the terminals shall be provided to identify
the phases.
5.14 Feeder Details
5.14.1 The requirements of incomer, bus coupler and outgoing feeders shall be as indicated in
the single line diagram, feeder details and corresponding schematic diagrams.
5.14.2 Interlocks shall be provided between incomers and bus section panels. The interlocks
shall be either electrical or mechanical type. In addition, arrangement for defeating the
interlock shall also be provided to facilitate manual changeover.
5.14.3 Auto changeover scheme, wherever specified, shall be provided.
5.15 Dummy Panels

Dummy panels complete with bus-bar system in 400 mm width may be required for
which unit price shall be indicated.
5.16 Control Power Supply
5.16.1 D.C. Power required for closing, tripping and indication of circuit breaker feeders shall
be supplied at the bus coupler panel through two completely separate circuits by owner,
one for tripping and other for closing and indication.
5.16.2 For receiving each external control supply, a double pole miniature circuit breaker shall
be provided. This power shall be distributed inside the switchboard for each circuit
breaker feeder having its MCB unit.
5.17 Space Heater Power Supply
5.17.1 Panel space heater shall be fed from a separate bus common for the whole board. This
bus shall be fed from owner’s supply for which a double pole MCB shall be provided in
bus section panel.
5.17.2 Power supply for space heaters of motors shall be tapped from this bus by means of a
MCB located in the motor feeder compartment. These MCBs shall be of triple pole and
rated for 15 Amp.
Components of the switchgear shall ensure type of coordination ‘C’ as per IS:60947
(Part 4/ Section 1). Makes of all components shall be subject to owner’s / consultant’s
approval


0

6.1 Circuit Breaker
6.1.1 The circuit breakers shall comply with the requirement of IS/IEC 60947.
6.1.2 All circuit breakers shall be of P2 (0-3 min - CO - 3 min - CO) category, capable of
carrying the specified current at the site conditions and making/breaking of the system
fault current.
6.1.3 Type test certificates from an independent testing authority shall be furnished along with
the offer for each circuit breaker rating and type.
6.1.4 The circuit breakers controlling motors shall be suitable for DOL starting and stopping of
induction motor a number of times.
6.1.5 The circuit breakers controlling capacitors shall be suitable for energizing and de-
energizing the rated capacitor bank.
6.1.6 The circuit breakers shall be of the 3 phase, 4 pole horizontal draw out, horizontal
isolation, air break type.
6.1.7 The circuit breaker shall be suitable for electrical or manual closing as specified. Manual
operated breakers shall have independent manual spring closing mechanism. In case of
electrically operated breaker, it shall have motor wound spring mechanism. In all cases
tripping shall be by means of shunt trip coil.
6.1.8 All circuit breaker units of the same rating shall be physically and electrically
interchangeable.
6.1.9 The circuit breakers shall be electrically and mechanically trip free and provided with
anti-pumping feature.
6.1.10 Provision shall be made for slow closing for maintenance purposes. A suitable handle
shall be provided one for each board for this purpose.
6.1.11 The circuit breakers shall have three positions i.e. service, test and isolated with the
cubicle door closed. Necessary stoppers shall be provided to prevent the excessive
movement of the breaker cradle than desired for the position. Service and test positions
of the breaker shall have monitoring switch having 1NO+1NC contacts.
6.1.12 The circuit breaker shall be provided with emergency manual trip device, mechanical
‘ON’, ‘OFF’ and ‘ISOLATED’ position indicators and operation counter.
6.1.13 A maintenance truck/device for raising, lowering and withdrawal of the circuit breaker
shall be supplied for each switch board.
6.1.14 The arc interrupting devices shall be capable of interrupting satisfactorily current from
zero to the rated interrupting current when used on predominantly capacitive or
inductive circuits, without requiring excessive maintenance of the contacts. The arc
shall be restricted within the interrupting chamber and no emission of flame shall be
allowed which may cause electrical breakdown or damage to insulation on the
apparatus.
6.1.15 The main contacts shall be self aligning, adjustable and replaceable type.
6.1.16 The arcing contacts shall be easily accessible for maintenance and inspection and shall
be easily replaceable type. They shall be provided with, contact face of special arc-
resisting and non-pitting metal.
6.1.17 Mechanical safety interlock shall be provided for safe operation and movement of the
breaker.
6.1.18 The circuit breakers shall be provided with minimum of four normally open and four
normally closed auxiliary switch contacts, over and above those required for its own
control scheme, for Owner’s use. The contacts shall be wired separately to the terminal
board.


0

6.2.1 The circuit breaker shall conform to IS/IEC 60947 and shall be of P2 category having
rupturing capacity as per system requirement and mounted on a draw out chassis.
6.2.2 The circuit breaker shall be provided with spring assisted quick make quick break type
manually operated trip free mechanism, mechanical ‘ON’, ‘OFF’ position indicators,
thermal tripping devices of inverse characteristics, instantaneous short circuit tripping
devices and necessary auxiliary and alarm switches. The MCCB Chassis shall be
provided with service, test and isolated position and automatic safety shutter.
6.2.3 The thermal and short circuit tripping devices shall be adjustable type.
6.2.4 When used for motor circuits, shunt trip device shall be provided and the let through
power of controlling MCCB shall be lower than the respective contactor.
6.2.5 In addition, under voltage trip shall be provided.
6.3 Switches
6.3.1 The switches shall be motor duty type AC 23 Category and shall comply with the
requirements laid down in IS/IEC 60947. Switches up to 63 Amps shall be rotary type
and those of 100 Amps. & above, link type.
6.3.2 ‘ON’ and ‘OFF’ position of the switches shall be indicated on the module. Provision shall
be made to lock the switch in the ‘OFF’ position.
6.3.3 The fixed contacts shall be shrouded type. All contacts shall be silver plated.
6.4 Fuses
6.4.1 The fuses shall be of non-deteriorating HRC cartridge link type and shall conform to IS:
13703. They shall be suitable for the load and service required in the circuit.
6.4.2 One fuse puller shall be supplied along with each board.
6.5 Air Break Contactors
6.5.1 The Air Break Contactors shall be of Category AC3/AC4, unless otherwise specified,
conforming to IS: 60947 and flapper type.
6.5.2 The dropout voltage shall not exceed 65% of rated voltage.
6.5.3 Each contactor shall be provided with auxiliary contacts as required. The rating of the
auxiliary contacts shall be 5 Amps. AC or 1 Amp DC at the specified control voltages.
The spare auxiliary contacts shall also be wired up to the terminal blocks.
6.6 Bimetal Thermal Overload Relays
6.6.1 The contactor shall be provided with three pole bimetal thermal overload relays, unless
other-wise specified. The bimetal relays shall be of suitable range, ambient temperature
compensated and shall be separate mounting type. They shall be adjustable through
graduated scale and shall be provided with changeover contact. Thermal relays having
long time/current characteristics, operated through saturated C.T.s shall be supplied,
wherever required.
6.6.2 Bimetal thermal relays shall conform to IS: 3231 and IS/IEC 60947 and shall have built-
in single phasing preventor.
6.6.3 The bimetal relays shall be provided with a manual resetting device resetable after
opening module door. Auto reset thermal relays are not acceptable.


0

6.7.1 The current transformers shall conform to IS: 2705.

6.7.2 C.T.s shall be Class F insulated and vacuum impregnated or resin cast. The C.T.s shall
be rigidly mounted and shall be easily accessible for maintenance and testing.
6.7.3 The short time thermal withstand ratings of C.T.s shall be same as the thermal
withstand rating of the breakers.
6.7.4 The C.T.s output shall be minimum 15VA for breaker feeders and 7.5 VA for the other
feeders per phase and in any case, the output shall be adequate for the protection and
metering duties involved with sufficient margin. The C.T.s shall have the following
accuracies for the various applications:
Application Class of accuracy as per
IS: 2705
i) For metering service - 1
ii) For use with protective relays - 5P
iii) For use with restricted earth fault and differential - PS

relays
6.7.5 The C.T. cores for metering and protection shall be separate.
6.7.6 The ratio of C.T.s shall be as specified in Feeder details.
6.7.7 All the C.T.s shall be provided with terminals and shorting links. One of the terminals of
the C.T. shall be earthed. The polarity of the C.T.s shall be clearly marked.
6.7.8 Provision of Interposing C.T.s is not acceptable.
6.7.9 The C.T.s shall be capable of withstanding momentary open circuit on the secondary
side without injurious effects.
6.8 Voltage Transformers
6.8.1 The V.T.s shall be Class F insulated and vacuum impregnated or resin cast conforming
to IS: 3156.
6.8.2 The primary nominal voltage shall be equal to the system nominal voltage. The
secondary terminal voltage shall be 110 V.
6.8.3 The primary and secondary winding shall be protected by HRC fuses in each phase
except in the ground phase of the secondary side.
6.8.4 The V.T.s shall be mounted on separate withdrawable carriage. The accuracy Class of
V.T.s shall be 1.
6.8.5 The rated output of each V.T. shall be adequate for the relays, meters and associated
wiring connected to it and shall not be less than 50 VA per phase.
6.9 Control Transformers
These shall be air cooled Class F insulated and vacuum impregnated. The rating of
control transformer shall be twice the hold on VA of all contactor/relays or 2.5 KVA
whichever is high. It shall be free from hum and rigidly mounted. Epoxy cast
transformers shall be preferred.


0

6.10 Transformers for Kondorffer Starting
These shall be three phase core type, Class F insulated and vacuum impregnated.
Tapping at 90%, 80%, 70% & 60% shall be provided and terminals shall be brought out
for easy change of tapping at site. The operating temperature shall not exceed 80ºC.
The transformers shall be suitable for taking 7.5 times the specified full load current of
the motor continuously for 120 secs.
6.11 Relays
6.11.1 All protective relays shall be of latest version, microprocessor based numerical type with
communication port and interlinked with online energy management system. 100%
redundancy shall be provided for communication.
6.12 Timers
The timers shall be electronic pneumatic or synchronous type with manual/auto reset
features as per the functional requirements. The time delay shall be ‘ON’ delay or ‘OFF’
delay type as specified. The repeat accuracy shall be 0.5% or better.
6.13 Single Phasing Preventor
6.13.1 Single phasing preventor relay shall be of the current operated type, suitable for the
system voltage. The relay shall not operate for normal system voltage but operate
positively in the event of unbalanced voltage more than the normal. The relay shall not
operate in case of total interruption of power.
6.13.2 The relay shall be fail safe, self reset type and provided with flag indication. The relay
operation shall be independent of the motor rating, loading and speed.
6.14 Instruments and Meters
6.14.1 All instruments shall be flush mounting type with square face of 96 mm x 96 mm. They
shall be tropicalized and dust tight.
6.14.2 Meters shall be digital multifunctional meters with communication port for energy
management at remote location.
6.14.3 All ammeters and voltmeters, to be provided separately, shall have 0-90º scale and
shall be moving iron spring controlled type of class 1.5 accuracy as per IS: 1248. The
scale range of the ammeters and voltmeters shall be as indicated in the Feeder details.
6.14.4 In case of motor feeders, the ammeters shall be graduated uniformly upto C.T. primary
current and with compressed end scale upto 6 times C.T. primary current. Red pointer
shall be provided, which shall be adjusted at site for indicating full load current of the
motor.
6.15 Push Buttons and Control Switches
6.15.1 The switches and push buttons shall conform to utilization category AC11/DC11 as per
IS: 60947. The contact shall be rated to make, break and carry inductive current of 5
Amp at 415 V AC and 1 Amp at 220 V DC.
6.15.2 The control switches shall be spring return rotary type, unless otherwise specified and
provided with pistol grip type handle. The control switches for circuit breakers shall be
additionally fitted with lost motion devices and sequencing devices.
6.15.3 The selector switches shall be stay put rotary type and provided with oval shape
handles.


0

6.15.4 The push buttons shall be of momentary contact spring loaded type with a set of
normally close and open contacts. The push button for ‘Start’ shall be shrouded type
and coloured green, stop push button shall be un-shrouded type and coloured red and
other push buttons shall be un-shrouded type coloured black. The fixing ring shall be
metallic white.
6.15.5 Emergency stop push buttons, if specified, shall be lockable in pushed position.
6.16 Miniature Circuit Breakers
6.16.1 The miniature circuit breakers shall conform to IS: 8828 and shall be of duty category
M-9.
6.16.2 It shall be provided with overload and short circuit protective devices in a heat resistant
housing.
6.16.3 A certificate for short circuit rating and Current-Time tripping curve shall be furnished
6.17 Signal Lamps
6.17.1 Signal lamps shall be provided to indicate the various circuit conditions as shown in
scheme drawings. The colour of the lamps for various functions shall be as follows :
Red -- Circuit breaker/switch/contactor closed.
Green -- Circuit breaker/switch/contactor open.
White -- Trip circuit healthy.
Amber -- Alarm and auto trip.
Blue -- Non-Trip
6.17.2 All lamps shall be of LED type with lumen output of 200 mili candela in axial direction.
7.0 ACCESSORIES
7.1 The supply shall include the following accessories:
-- Maintenance truck/device for raising, lowering and withdrawal of circuit breaker, if

required.
-- Fuse puller.
-- Test plug for relays.
-- Test plug for kWh meters.
7.2 Space Heater
Each vertical section shall be provided with a thermostatically controlled space heater,
rated for 240 V, 50 Hz and controlled through double pole miniature circuit breaker.
7.3 Name Plates
7.3.1 The switchboard shall have large name plate on the top indicating its Name,
Designation and Code No.
7.3.2 Each feeder shall be provided with name plate. Each single front panel shall have name
plate indicating panel number both in front and back.
7.3.3 All control switches, push buttons, lamps etc. shall have functional identification labels.
7.3.4 Name plate shall be of black Perspex with white engraving and of minimum 3mm thick.
7.4 Any other accessories required, but not specified, shall also be supplied to make the
switchboard complete in all respects and ensure safe and proper operation.


0

8.0 PAINTING
8.1 The enclosure, after degreasing, pickling in acid, cold rinsing, phosphatising,
passivating etc. shall be painted with two coats of anti-rust paint followed by two coats
of anticorrosive paint.
8.2 Epoxy based paint shall be used.
8.4 Unless otherwise specified, the finishing shade shall be light grey having Shade No.631
as per IS: 5.
8.5 One litre of paint shall be supplied along with each board for touch up at site.
9.1 All the switchboards shall be subjected to routine test as per IS: 8623 and their
components as per relevant standards.
9.2 Additional tests, wherever specified, shall be carried out.
9.3 All the above tests shall be carried out in presence of Purchaser’s representative. In
9.4 These inspections shall however, not absolve the vendor from their responsibility for
specified.
10.2 All drawings and documents shall have the following description written boldly:
-- Name of Client
-- Name of Consultant
-- Enquiry / Order Number with Project / Plant Name
-- Code No. & Description
11.0 SPARES


offer.
11.4 All spare parts shall be identical to the parts used in the switch boards.


0

12.0 PACKING
manual.
the equipment.
13.0 DEVIATIONS
reasoning.


0

ANNEXURE - I
DOCUMENTATION FOR MEDIUM VOLTAGE SWITCHBOARDS
Sl.No. Documentation Description
1. Specification Sheets N Y Y
3. Feeder Details N Y Y
4. General arrangement and Foundation Drgs. N Y Y
5. Schematic and Wiring Diagrams N Y Y
6. Calculation for Bus-bar sizing N Y N
7. Terminal Arrangement Drgs. N Y Y
8. Illustrative and Descriptive Literature N N Y
9. Catalogues for bought out accessories. N N Y
10. Installation, Operation and maintenance manual. N N Y
11. Test Certificates

i) Type -- Switchboard N N N
-- Circuit Breaker N N N
-- MCCB’s N N
ii) Routine N Y
13. Spare Parts List N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N – No


0
TECHNICAL SPECIFICATION - HIGH VOLTAGE Document No. Rev
SWITCHBOARDS (PC150-TS-0806) Sheet 1 of 13

HIGH VOLTAGE SWITCH BOARDS


0

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
7.0 ACCESSORIES
8.0 PAINTING
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR HIGH VOLTAGE SWITCHBOARDS


0

1.0 SCOPE
works and delivery in well-packed condition of High Voltage Switch Boards.
Electrical , Schematic diagrams etc.
2.1 The design, manufacture and testing of the equipment shall comply with the latest
issues of the following standard, unless otherwise specified. Equipment complying with
equivalent IEC standards shall also be acceptable.
IS: 3427 A.C. Metal enclosed switchgear and control gear for rated voltages above 1 kV
up to and including 52 kV.
IS: 13118 Specification for high voltage alternating current circuit breakers.
IS: 5578 Guide for marking of insulated conductors.
IS: 11353 Guide for uniform system of marking and identification of conductors
and apparatus terminals.
IS: 10118 Code of Practice for selection, installation and maintenance of
switchgear and control gear.
Various components housed in the switchboards shall conform to the Indian Standards
Specification as mentioned against the component details or IEC Specifications.
the provisions of the latest issue of the Indian Electricity Rules and other Statutory Acts
and Regulations. The supplier shall, wherever necessary, make suitable modifications
in the equipment to comply with the above.
Standard Specifications / IEC Specification, the requirement specified herein shall
prevail.
3.2 System Details
The switchboards shall be suitable for operating at the specified rating continuously,
with the specified voltage and frequency variations under the ambient conditions,
on any part.
5.1 General
5.1.1 The switchboards shall consist of an assembly of a series of floor mounting, identical,


0

metal clad, cubicle type panels placed side by side to form a compact assembly and
shall be extensible on either side.
of protection equivalent to IP4X as per IS/IEC:60529. However, in case some ventilation
openings are to be provided, these may be permitted for equipment located indoors and
such openings shall be covered by fine wire mesh ensuring minimum IP3X protection.
5.1.3 The framework of the cubicles shall be bolted / welded construction. The minimum
thickness of sheet steel shall be 3 mm for base channel and 2 mm for other members.
The doors and covers shall be fabricated from cold rolled sheet steel. Suitable
reinforcement, wherever necessary, shall be provided.
5.1.4 The switchboard shall be mounted on the channel which shall be included in the
vendor’s scope.
5.1.5 Each cubicle shall be provided with front access door with handle lock and key for
breaker compartment and a removable back cover. The door hinges shall be concealed
type. Front doors of the panels shall mechanically stop in full open position to facilitate
removal of breakers and for ease of maintenance.
5.1.6 All external hardwares shall be cadmium plated. The hardwares for fixing removable
position in groove, in shaped sheet steel work or these shall be U-type.
5.1.8 Each cubicle shall have separate compartment within the cubicle for circuit breaker,
bus-bars, instrument transformers, metering and relaying devices and cable termination.
5.1.9 Inter-panel and inter-compartment fire resistant barrier shall be provided. Cast resin
seal off bushing shall be provided in the bus compartment, through which connections
to breaker compartment/cable compartment/bus compartment of adjacent panel shall
be taken. Failure of one of the equipment shall not effect the equipment in the adjacent
compartment.
necessity of removing the adjacent ones. Their mounting shall be accessible and
ensure the necessary degree of safety.
5.1.11 The layout of the components inside the cubicle shall be liberal to facilitate maintenance
and the interconnecting wiring between components shall not be subjected to undue
stresses at the bends.
5.1.12 Mounting height of components requiring operation and maintenance shall not be lower
5.1.13 All live parts which are accessible after opening of front and back door/cover shall be
properly insulated or provided with insulating barrier to prevent accidental contact.
Phase insulating barriers shall be provided between the breaker poles. Removal facility
shall be provided for all such barriers.
5.1.15 The switchboard shall be provided with following interlocks and safety features:
i) The withdrawal and engagement of a circuit breaker shall not be possible unless it
is in open position.
ii) The operation of a circuit breaker shall not be possible unless it is in fully service,
test or isolated position.
iii) It shall not be possible to close the circuit breaker in service position unless all


0

auxiliary and control circuits are connected.
iv) A breaker of the lower rating shall be prevented from engaging with the stationary
element of higher rating.
v) Insertion of the manual mechanism shall render the motorized mechanism
inoperable.
vi) Circuit breaker “ON”, “OFF” indication shall be provided at the back of each panel.
vii) Caution name plate shall be provided at the back of incomer panels where
terminals are likely to remain live and isolation is possible only from remote end.
viii) Automatic safety shutter, with padlocking facility for locking in closed position, to
completely cover the spouts for bus-bars and cable connection when the breaker
is withdrawn.
5.2 Bus-Bars and Connections
5.2.1 The bus-bars shall be for three phases. The bus-bars and connection shall be made of
electrolytic grade copper of rectangular cross-section.
5.2.2 Bus-bars and connections shall be sleeved to protect against approach to live parts and
to eliminate potential arcing points. Sleeving material shall have adequate electrical,
thermal and mechanical properties to withstand impulse level, temperature rise during
normal and short circuit condition and allow easy bending of bus bars.
5.2.3 The bus-bars shall be amply sized to carry the rated continuous current under the
specified ambient temperature without exceeding the limits specified in IS: 8084. The
thermal rating of the bus-bars shall be designed to withstand the system fault current for
3 seconds without exceeding the limiting temperature of 250ºC for bare copper.
Calculation for bus-bar sizing shall be furnished along with the offer.
5.2.4 Horizontal bus-bars shall run in a separate compartment through the entire length of the
board and shall be of same cross-section throughout. Stepped bus-bars shall not be
acceptable.
5.2.5 The bus-bars shall be arranged and colour coded according to IS: 5578 & IS: 11353.
5.2.6 The bus-bars chamber shall be sufficiently spacious and shall have separate screwed
covers for maintenance purpose. It shall be adequately ventilated and shall allow the
escape of the hot gases.
5.2.7 The bus-bars shall be rigidly supported at equal intervals to withstand the stresses due
to full short circuit and also to take care of thermal expansion.
5.2.8 A minimum of two bolts shall be used per bus-bar joint. Only high tensile electro
galvanized cadmium plated bolts, nuts and washers shall be used. The washers shall
be spring and plain type. The bus-bar supports shall be of molded construction with
built-in anti-tracking barriers. The support materials shall be of DMC or fiber glass
reinforced thermosetting plastic.
5.2.9 The bus-bars, both horizontal and vertical, shall be PVC sleeved. Insulating shrouds
shall be provided for all joints of insulated bus-bars.
5.3 Earth Bus

A continuous earth bus of Aluminium running along the lower part of the switchboard
shall be provided with two end terminals with lugs for external connection. The earth
bus shall be rated to carry three phase fault current for a period of 3 sec.
5.4 Bus Duct


0

5.4.1 Suitable extension of bus-bars in proper phase sequence on the top, with connecting
bolts shall be provided where connections between transformer and switchboard or
between two halves of the switchboard is specified to be through bus duct.
5.4.2 Bus duct between two halves of the switchboard, if required, shall be supplied by the
switchboard manufacturer. The bus-bars of interconnecting bus duct shall be similar to
the main bus-bars of switchboard as specified above and shall conform to IS: 8084.
5.4.3 Bus duct between transformer and switchboard, if included in vendor’s scope shall
conform to IS: 8084.
5.5 Clearances and Creepage Distance
The clearance and creepage distance shall be adequate to meet the BIL of the
equipment.
5.6 Insulation
5.6.1 The insulation used shall be non-hygroscopic and shall be of porcelain, epoxy resins or
fiber glass molded with plastic. It shall be of adequate electrical, mechanical and
thermal strength to give trouble free service during normal operation and short circuit
conditions.
5.7 Control Wiring
5.7.1 The switchboard shall be completely factory wired and ready for external connections.
5.7.2 The wiring shall be complete in all respect so as to ensure proper functioning of control,
interlocking, protection, metering, indications and annunciations.
cables of 1100 Volt grade. The minimum size of wires shall be as follows:
C.T. Circuit -- 2.5 Sq. mm
V.T. and Control Circuits -- 1.5 Sq. mm
5.7.4 All wiring shall be provided with dependent both ends marking as per IS: 5578.
Numbered ferrules, reading from the terminal outwards, shall be provided at both ends
5.7.5 Control wiring circuits, fed from a supply common to a number of panels, shall be so
protected that failure of a circuit in one panel does not affect the operation of other
panels.
5.7.6 The wiring to the equipment mounted on the doors shall be carried out with flexible
multi-strand copper conductor cable and so supported that on opening of the door,
there is no undue strain on wire leads.
5.7.7 The control cables shall be neatly arranged and properly supported.
5.8.1 All power and control cables shall enter the switchboard from the bottom on the back of
the panel. Sufficient space shall be provided for ease of connection and termination of
cables.
5.8.2 All power cables and control cables shall be of type, number and size as indicated in
Feeder Details.
5.8.3 The termination arrangement for single core cables shall be such that so as to minimize
flow of eddy current and heating due to eddy currents.
5.8.4 Heavy duty double compression type rolled Aluminium cable glands along with the


0

cable lugs, as required shall be provided for termination of control cables and auxiliary
power supply cables.
5.8.5 The cable glands shall be mounted on a removable gland plate, provided at a minimum
height of 75 mm from the bottom of the switchboard. Two number spare knockouts of
size 20 mm shall also be provided on the gland plate for future use.
5.8.6 Terminal blocks shall be provided at suitable locations inside the panels for termination
of control and auxiliary power supply wiring. These terminal blocks shall be pressure
clamp type up to 35 sq. mm cables and bolted lug type for higher sizes of cables. These
shall be protected type and rated for 1100 Volt service. The minimum current rating of
the terminal block shall be 16 Amp.
5.8.8 The terminal block shall be grouped according to circuit functions and numbered
suitably. 20% extra terminals shall be provided in the terminal block.
the phases.
5.9 Feeder Details
the single line diagram, feeder details and corresponding schematic diagrams.
5.9.2 Non-paralleling interlocks shall be provided between incomers and bus section panels.
The interlocks shall be either electrical or mechanical type. Arrangement for defeating
the interlock shall also be provided.
5.9.3 Auto changeover scheme, wherever specified, shall be provided.
5.10 Dummy Panels
Dummy panels complete with bus-bar system in 400 mm width shall be required for
which unit price shall be indicated.
5.11 Control Power Supply
5.11.1 D.C. power required for closing, tripping and indication shall be supplied at the bus
coupler panel through two completely separate circuits by the owner, one for tripping
and another for closing and indication for the whole board.
5.11.2 For receiving each external control power supply, a double pole miniature circuit
breaker shall be provided. This power shall be distributed inside the switchboard for
each feeder having its MCB unit.
5.12 Space Heater Power Supply
5.12.1 Panel space heaters shall be fed from a separate bus, common for the whole board.
This bus shall be fed from owner’s supply for which a double pole MCB shall be
provided in bus section panel.
5.12.2 Power supply for space heaters of motors shall be tapped from this bus by means of
miniature circuit breakers located in the motor feeder panels. These MCB’s shall be of
triple pole and rated for 15 Amp.
Makes of all components shall be subject to owner’s / consultant’s approval
6.1 Circuit Breakers


0

6.1.1 The circuit breakers shall comply with the requirements of IS: 13118.
6.1.2 All circuit breakers shall be of 0-3 min-CO-3 min-CO rated operating sequence capable
of carrying the specified current at the site conditions and making/breaking of the
system fault current.
6.1.3 Type test certificates from an independent testing authority shall be furnished along with
the offer for each circuit breaker rating and type.
6.1.4 The circuit breakers controlling motors shall be suitable for DOL starting and stopping
induction motor a number of times and shall have provision to limit over voltage to the
value safe for motor insulation. Unless otherwise specified this value shall be taken as
2.5 times the rated voltage. The magnitude of the voltage surge produced by the
breaker when switching off the smallest motor shall be indicated.
6.1.5 The circuit breakers controlling capacitors shall be suitable for energizing and de-
energizing the rated capacitor bank.
6.1.6 The circuit breakers shall be of the 3 phase, single/double break, horizontal draw-out,
vertical/horizontal isolation type. The medium of arc quenching shall be minimum
Oil/Bulk oil/vacuum/SF6 as specified elsewhere.
6.1.7 The circuit breakers shall be suitable for electrical/manual closing as specified in Feeder
details. Electrically operated circuit breakers shall preferably have motor wound spring
closing mechanism with provision for manual closing arrangement. Manually operated
circuit breakers shall have independent manual spring closing mechanism. In all cases
tripping shall be by means of shunt trip coil.
6.1.8 All circuit breaker units of the same rating shall be physically and electrically
interchangeable.
6.1.9 The circuit breakers shall be electrically and mechanically trip free and provided with
anti-pumping feature.
6.1.10 The circuit breakers shall have three positions, i.e. service, test and isolated with the
cubicle door closed. Necessary stoppers shall be provided to prevent the excessive
movement of the breaker cradle than desired for the position. Service and test positions
of the breaker shall have monitoring switch having 1NO+1NC contacts.
6.1.11 The circuit breakers shall be provided with emergency manual trip device, mechanical
‘ON’, ‘OFF’, ‘ISOLATED’ position and spring ‘CHARGED’, ‘DISCHARGED’ indicators
and operation counter.
6.1.12 A maintenance truck/device, if required, for raising, lowering and withdrawals of the
circuit breaker shall be supplied for each switchboard.
6.1.13 The arc interrupting devices shall be capable of interrupting satisfactorily current from
zero to the rated interrupting current when used on predominantly capacitive or
inductive circuits, without requiring excessive maintenance of the contacts. The arc
shall be restricted within the interrupting chamber and no emission of flame shall be
allowed which may cause electrical breakdown or damage to insulation on the
apparatus.
6.1.14 Mechanical safety interlock shall be provided for safe operating and movement of the
breaker.
6.1.15 The circuit breakers shall be provided with minimum of four normally open and four
normally closed auxiliary switch contacts, over and above those required for its own
control scheme, for owner’s use. These contacts shall be wired separately to the
terminal board.
6.1.16 The closing coil and other associated auxiliary relays shall operate satisfactorily at all
voltages between 85% and 110% of the rated control voltage. The tripping coil and


0

other associated relays shall operate satisfactorily at all voltages between 70% and
110% of the rated control voltage.
6.1.17 Cable earthing facility shall be provided in the circuit breaker for discharging of power
cable through the circuit breaker contact with circuit breaker in drawn-out position. An
integral earthing arrangement shall be preferred. In case the integral earthing
arrangement is not feasible due to circuit breaker design, a separate earthing truck,
which shall be inserted in place of circuit breaker, shall be provided per board.
6.1.18 Positive earthing of circuit breaker frame shall be maintained at every position of circuit
breaker. The earthing contact shall be line/scrapping type and not of point type.
6.2.2 C.T.s shall be class F insulated and vacuum impregnated or resin cast type. The C.T.s
shall be rigidly mounted and shall be easily accessible for maintenance and testing.
6.2.3 The short time thermal withstand ratings of the C.T.s shall be same as the thermal
withstand ratings of the breakers.
6.2.4 The C.T.s output shall be minimum 15 VA per phase and in any case, the output shall
be adequate for the protection and metering duties involved with sufficient margin. The
C.T.s shall have the following accuracies for the various applications:
Application Class of Accuracy as per IS: 2705
i) For metering service 1
ii) For use with protective relays 5P
iii) For use with restricted earth fault PS
and differential relays
6.2.5 The C.T. cores for metering and protection shall be separate.
6.2.6 The ratios of the current transformers shall be as indicated in Feeder details.
6.2.7 All the C.T.s shall be provided with terminals and shorting links. One of the terminals of
the C.T. shall be earthed. The polarity of the C.T. shall be clearly marked.
6.2.8 Provision of interposing C.T. is not acceptable.
6.2.9 The C.T.s shall be capable of withstanding momentary open-circuit on the secondary
6.3 Voltage Transformers
6.3.1 The V.T.s shall be class F insulated and vacuum impregnated or resin cast type
conforming to IS: 3156.
6.3.2 The primary nominal voltage shall be equal to the system nominal voltage. The
secondary terminal voltage shall be 110 / √3 V.
6.3.3 The rated output of each VT shall be adequate for the relays, meters and associated
wiring connected to it with sufficient margin and shall not be less than 200 VA per
phase.
6.3.4 The accuracy class of V.T.s shall be 1 as per IS: 3156.
6.3.5 The primary and secondary winding shall be protected by HRC fuses in each phase
except in the grounded phase of the secondary side.
6.3.6 The V.T. shall be mounted on a with-drawable carriage. Shutters with padlocking
facility, provided on high voltage sides, shall be so arranged that the live orifices are
automatically closed when the V.T. is withdrawn.


0

6.3.7 Mechanical interlocking arrangement shall be provided so that the access to the high
voltage fuse is possible only when the V.T. is fully withdrawn.
6.4 Relays
6.4.1 All protective relays shall be of latest version, microprocessor based numerical type with
communication port and interlinked with online energy management system. 100%
redundancy shall be provided for communication.
6.5 Timers
6.5.1 The timers shall be electronic, pneumatic or synchronous type with manual/ auto reset
features as per the functional requirements. The timers shall be ‘ON’ delay or ‘OFF’
delay type as specified. The repeat accuracy shall be 0.5% or better.
6.6.1 All instruments shall be flush mounting type with square face of 96 mm x 96 mm. They
shall be tropicalized and dust tight.
6.6.2 Meters shall be digital multifunctional meters with communication port for energy
management at remote location.
6.6.3 All ammeters and voltmeters, to be provided separately, shall have 0-90º scale and
shall be moving iron spring controlled type of class 1.5 accuracy as per IS: 1248. The
scale range of the ammeters and voltmeters shall be as indicated in the Feeder details.
6.6.4 In case of motor feeders, the ammeters shall be graduated uniformly upto C.T. primary
current and with compressed end scale upto 6 times C.T. primary current. Red pointer
shall be provided, which shall be adjusted at site for indicating full load current of the
motor.
6.7 Push Buttons and Control Switches
6.7.1 The switches and push buttons shall conform to utilization category AC11/DC11 as per
IS/IEC:60947. The contact shall be rated to make, break and carry inductive current of 5
Amps. at 415 V AC and 1 Amp. at 220 V DC.
6.7.2 The control switches shall be spring return rotary type, unless otherwise specified and
provided with Pistol grip type handle. The control switches for circuit breakers shall be
additionally fitted with lost motion devices and sequencing devices, if required.
6.7.3 The selector switches shall be stay put rotary type and provided with oval shape
handles.
normally close and open contacts. The start push button shall be shrouded type and
coloured green. The stop push button shall be un-shrouded type and coloured red and
other push buttons shall be un-shrouded type and coloured black. The fixing ring shall
be metallic white.
6.8 Control Fuses

6.8.1 The fuses shall be non-deteriorating HRC cartridge link type and shall conform to IS:
13703. They shall be suitable for load and service required in the circuit.
6.8.2 One fuse puller shall be supplied along with each board.
M-9.


0

housing.
6.9.3 Type test certificate for short circuit rating and current time tripping curve shall be
furnished along with the offer.
6.10 Signal Lamps
scheme drawings. The colour of the lamps for various functions shall be as follow:
Red - Circuit breaker ‘ON’
Green - Circuit breaker ‘OFF’
White - Trip circuit healthy
Amber - Alarm and auto trip
Blue - Non-Trip
6.10.2 The lamps shall LED type with lumen output of 200 millicandella in axial direction.
7.0 ACCESSORIES
7.1 The supply shall include the following accessories.
- Maintenance truck/device for raising, lowering and withdrawal of circuit breaker, if
required.
- Earthing truck, in case the integral earthing arrangement is not feasible in the
circuit breaker.
- Fuse puller.
- Test plug for relays.
- Test plug for kWh meters.
- Special tools and tackles, as required.
7.2 Space Heater
7.2.1 Each panel shall be provided with a thermostatically controlled space heater, rated for
240 V, 50 Hz and controlled through double pole miniature circuit breaker.
7.3 Name Plates
7.3.1 The switchboard shall have large name plate on the top to indicate its name and
designation.
7.3.2 Each panel shall be provided with name plate both in front and back.
7.3.4 Name plate shall be of black Perspex with white engraving and of minimum 3 mm thick.
7.4 Any other accessories required, but not specified, shall also be supplied to make the
switchboard complete in all respects and ensure safe and proper operation.
8.0 PAINTING
8.1 The enclosure, after degreasing, pickling in acid, cold rinsing, phosphatising,
passivating etc. shall be painted with two coats of anti-rust paint followed by two coals
of anti-corrosive paint.


0

8.4 Unless otherwise specified, the finishing shade shall be light grey having shade No.631
as per IS: 5.
9.1 All the switchboards shall be subjected to routine test as per IS: 3427 and their
components as per relevant standards.
9.4 These inspection shall, however, not absolve the vendor from his responsibility for
making good any defect which shall be noticed subsequently.
specified.
- Name of client
- Enquiry / Order Number with plant / project name
- Code No. and Description
11.0 SPARES
Commissioning Spares, as required, shall be supplied with the main equipment. Item
offer.
12.0 PACKING
12.1 The switchboard shall be properly packed before dispatch to avoid damage during
transport, storage and handling.
manual.
the equipment.
13.0 DEVIATIONS
reasoning.


0

ANNEXURE - I
DOCUMENTATION FOR HIGH VOLTAGE SWITCHBOARDS
Sl. No. Description
1. Specification Sheets N Y Y
4. General arrangement and Foundation N Y Y

Drawings
5. Schematic/Wiring Diagrams N Y Y
7. Terminal Arrangement Drawings N Y Y
8. Illustrative and Descriptive Literature N N Y
9. Catalogues for bought out accessories Y N Y
10. Installation, Operation and maintenance

N N Y
manual
11.
Test Certificates
i) Type - Switchboard N N N
- Circuit Breaker N N N
- MCB N N N
ii) Routine N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N – No

PC150/E/4004/SecVI-5.3
(PART-A)
TECHNICAL SPECIFICATION - BUS DUCT (PC150-TS-0807)
Sheet 1 of 8

BUS DUCT

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 2 of 8

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
6.0 ACCESSORIES
7.0 LAYOUT
8.0 PAINTING
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR BUS DUCT

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 3 of 8

1.0 SCOPE
1.1 This standard covers the technical requirements of design, manufacture testing at works
and despatch in well packed condition of bus duct.
Electrical.
comply with the latest issue of following Indian Standards unless otherwise specified.
Equipment complying with equivalent IEC standards shall also be acceptable.
IS: 8084 - Interconnecting bus-bars for A.C. Voltage above 1 KV up to
and including 36 KV.
IS: 8623 - Specification for low voltage switchgear and control gear
assemblies.
IS: 5578 - Guide for marking of insulated conductors.
IS: 11353 - Guide for uniform system of marking and identification of
conductors and apparatus terminals.
the provisions of the latest issue of the Indian Electricity Rules and other relevant
Statutory Acts and Regulations. The supplier shall wherever necessary, make suitable
2.3 Wherever any requirement, laid down in this standard differs from those in Indian
3.1 Ambient conditions

3.2 System Details

The bus duct shall be suitable for operating at the rated capacity continuously under the
ambient conditions and with the voltage and frequency variations without exceeding the
permissible temperature rise and without any detrimental effect on any part.
5.1 Enclosures
5.1.1 The sheet steel enclosure for enclosing and supporting the bus-bars shall be made out
of 14 SWG sheet steel, bolted on the angle iron frame work.
5.1.2 The enclosure shall completely enclose the bus bars from all sides. It shall have degree
of protection IP: 52 for indoor installation and IP: 55 with rain protection canopy for
outdoor installation as per IS/IEC:60947. Where part of the bus duct is required for
indoor installation and part for outdoor installation, the complete section shall be
suitable for outdoor installation. Ventilation louvers, if necessary, shall be provided with
fine wire mesh from inside, in that case the degree of protection shall be IP: 42.
Neoprene gasket shall be provided on covers at joints.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 4 of 8

5.1.3 Whether bus duct (with louvers) is installed outdoor or indoor, suitably rated space
heater with thermostat control shall be provided at different locations inside the bus duct
to avoid moisture condensation.
5.1.4 All external hardwares of diameter less than 8 mm shall be stainless steel and those of
diameter 8 mm and above shall be mild steel cadmium plated or zinc passivated.
5.2 Bus Bars and Connections
5.2.1 The bus-bars in LV Bus duct shall be of three phase and neutral, non-segregated and
air insulated type.
The bus-bars in HV Bus duct shall be of three phase, phase-segregated with insulating
material.
5.2.2 The bus bars shall be amply sized to carry the rated continuous current under the
specified ambient temperature without exceeding the temperature limits specified in IS:
8084. The bus bars shall be designed to withstand the system fault current for one
second without exceeding the total temperature of 200ºC. Type test certificate of similar
bus duct shall be furnished.
5.2.3 The bus-bars material shall be high conductivity Aluminium alloy conforming to grade
E91E of IS: 5082/electrolytic grade copper.
5.2.4 The bus-bars shall be rectangular in shape and cross-sectional area of neutral bus-bars
shall be half of phase bus-bars.
5.2.5 The sizes of bus-bars selected shall be subjected to approval by PDIL. The vendor shall
furnish supporting calculations for bus-bars and enclosure sizes both under normal load
and short circuit conditions as well as that of temperature rise along with the offer.
5.2.6 All the bus-bars shall be bare and without any painting. The bus-bars shall be arranged
and provided with proper phase identification as per IS: 5578/11353.
5.3 Joints and Bends
5.3.1 Only lap joints shall be used for jointing the bus bars. The over lap shall be equal to the
width of the bus bars.
5.3.2 The contact surfaces of the overlapping bus-bars shall be thoroughly cleaned followed
by application of good quality electrical grease and bolted immediately. In case of
Aluminium to copper joints, copper bus-bars in addition shall be preferably tinned.
5.3.3 The bolting schedule adopted shall ensure proper contact pressure. A minimum of two
bolts shall be used per joint.
5.3.4 The contact pressure shall be 100-140 kg/cm2. Only high tensile, zinc passivated or
galvanized steel bolts shall be used along with large diameter flat washers of adequate
thickness.
5.3.5 At the bends, the bus-bars shall bend at a radius of 2t where the ‘t’ is the thickness of
the bus-bars and the radius is measured to the inside of bus-bars.
5.4 Flexible Joints
Flexible joints and connections shall consist of tinned laminated copper strips or
Aluminium strips of required cross sectional area. Precautions as mentioned under
5.3.2 shall also be observed while marking joints with laminated copper plates. Filler
plates of Aluminium as required shall be used.
5.5 Expansion Joints
Expansion joints, where necessary, to allow for longitudinal expansion and contraction
of bus-bars and bus enclosures caused by temperature variation shall be provided.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 5 of 8

5.6 Bus Bar Supports

5.6.1 The bus-bars shall be rigidly supported at equal intervals. The bus-bars supports shall
be such that they withstand stresses to which they may be subjected under normal and
short circuit conditions.
5.6.2 The supports shall be of moulded construction of fibre glass reinforced with
thermosetting plastics or superior materials. The supports, where necessary, shall either
have built-in anti-tracking barriers or painted with anti-tracking varnishes.
5.7 Clearances and Creepage Distance
5.7.1 The clearances and creepage distance shall not be lower than the values specified
below for any part of the bus duct.
i) Minimum clearance between two live parts - 25 mm
ii) Minimum clearance between a live part and - 25 mm
accidentally dangerous part
iii) Creepage distance - 30 mm
5.7.2 The clearances and creepage distance, as specified above, shall definitely be
maintained throughout the bus bars system. Provision of bus-bar separators or barriers
shall not be considered to reduce the clearances from the values specified above.
5.8 Terminal Chambers at Switchgear and Transformer End
5.8.1 The bus duct shall be suitable for bolting to the flanges provided at the transformer and
switchgear end. The exact dimensions and details of these terminal chambers shall be
made available at the time of execution.
5.8.2 Phase changeover arrangement wherever required shall be provided in one of the
terminal chambers to connect the bus-bars between same phase terminals at
switchgear and transformer ends.
6.0 ACCESSORIES
6.1 Earthing
Two continuous earth strips of Aluminium having minimum 300 sq. mm size shall be
provided throughout the length of bus duct or shall be suitable for full short circuit fault
current for 1 sec. whichever is more.
6.2 Drain Plug
Bus duct shall be provided with drain plug to remove condensed moisture when
required.
6.3 Fire Barriers
Two sets of epoxy moulded fire barriers shall be provided on switchgear end as well as
transformer end.
6.4 Name Plates
6.4.1 Each bus duct shall be provided with a name plate of stainless steel with letter
embossed on them and located at convenient location.
6.4.2 The name plate shall contain all details as per IS: 8084.
6.5 Hardware
Required number of hardwares like bolts, nuts, plain washers, spring washers etc. shall
be provided for jointing the bus duct with transformer as well as switchgears.
7.0 LAYOUT
7.1 The proposed bus duct routing between transformer and associated switchgear shall be
as shown in the drawing enclosed with NIT. Where no layout drawing is enclosed, the

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 6 of 8

schedule of quantities shall be followed for bidding. However, the exact routing and
details of switchgear and transformer end chambers shall be supplied at the time of
order or drawing approval.
7.2 The successful vendor shall prepare final layout drawing for each bus duct with bill of
materials and submit the same for PDIL/Purchaser’s approval.
8.0 PAINTING
8.1 The enclosure after degreasing, pickling in acid, rinsing, phosphatising, passivating etc.
shall be painted with two coats of anti-rust paint followed by two coats of anticorrosive
paint.
8.4 Unless otherwise specified, the finishing shade shall be light grey having shade no. 631
as per IS: 5.
9.1 The bus duct shall be subjected to routine tests as per relevant standard.
9.2 Wherever specified, temperature rise tests shall be carried out on a minimum 5 metre
length bus duct of each rating.
9.3 The test shall be carried out in manufacturer’s works in presence of purchaser’s
representative. In addition, the bus ducts shall be subjected to stage inspection at works
and inspection at site for final acceptance.
9.4 These inspections shall, however, not absolve the vendor from his responsibility of
10.1 Drawings and documents as per Annexure - I shall be supplied, unless otherwise
specified.
10.2 All drawings and documents shall have the following descriptions written boldly
- Name of client
11.0 SPARES


offer.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 7 of 8

12.0 PACKING
12.1 The bus duct shall be properly packed before despatch to avoid damage during
transport, storage and handling. It shall be wrapped in polythene bags to make it
waterproof. An additional wrapping with bitumen paper shall also be provided to make
it completely water proof before the equipment is packed in wooden crates.
manual.
13.0 DEVIATIONS
reasoning.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 8 of 8

ANNEXURE - I
DOCUMENTATION FOR BUS DUCT
Sl.No. Description
1. General arrangement for each bus N Y Y
duct showing the complete layout.
2. Design calculations N Y N
a) Bus bars sizing
b) Flexible sizing
c) Temperature Rise
d) Support Span
3. Specification sheet & Technical N Y Y
Particulars
4. Switchgear end termination details for N Y Y
each rating of bus duct.
5. Transformer end termination details N Y Y
for each rating of bus duct.
6. Assembly drawing of rigid bends. N Y Y
7. Assembly drawing of bends with N Y Y
flexible
8. Assembly drawing of straight run N Y Y
9. Transposition chamber details N Y Y
10. Installation, operation & maintenance N Y Y
manual
i) Type N N N
ii) Routine & others N N Y
13. List of spare parts N N N
Note:
the date of LOI.
coated folder.
Y - Yes, N - No


0
TECHNICAL SPECIFICATION - SHEET STEEL DISTRIBUTION Document No. Rev

SHEET STEEL DISTRIBUTION BOARDS


0

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
7.0 ACCESSORIES
8.0 PAINTING
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR SHEET STEEL DISTRIBUTION BOARDS


0

1.0 SCOPE
works and delivery in well-packed condition of Sheet Steel Distribution Boards.
Electrical.
2.1 The design, manufacture and testing of the equipment shall comply with the latest issue
of the following Indian Standards, unless otherwise specified. Equipment complying with
assemblies.
IS/IEC:60947 - Specification for Low-voltage Switchgear and Control gear
IS: 5578 - Guide for marking of insulated conductors.
IS: 11353 - Guide for uniform system of marking and identification of
IS: 10118 - Code of practice for selection, installation and maintenance of
switchgear and control gear.
Various components housed in the distribution board shall conform to the Indian
Standard Specification as mentioned against the component details.
2.2 The design and operational features of the equipment offered shall also comply with the
Standard Specification the requirement specified herein shall prevail.
3.2 System Details
The distribution board shall be suitable for operating at the specified rating continuously
with the specified voltage and frequency variations under the ambient conditions,
on any part.
5.1 General
5.1.1 The distribution board shall consist of an assembly of a series of floor mounting,
identical, metal clad, dead front type panels of unitized design. The panels shall be
placed side by side to form a compact assembly and shall be extensible on either side.
of protection equivalent to IP-52 as per IS/IEC:60947.
5.1.3 The frame work of the cubicles shall be of bolted/welded construction. The minimum
thickness of steel shall be 2 mm for load bearing members, 1.6 mm for non-load bearing


0

members and 3 mm for base channel. The doors and covers shall be fabricated from
cold rolled sheet steel. Suitable reinforcement, wherever necessary, shall be provided.
5.1.4 The door hinges shall be concealed type.
5.1.5 All external hardware shall be cadmium plated/zinc passivated. The hardware for fixing
the removable parts shall be provided with retaining devices.
position in groove of shaped sheet steel work or these shall be of U type. Adhesive
cement, if used, shall be of good quality so that the gaskets do not come off during
service.
necessity for removal of the adjacent ones. In case of single front design all
components shall be accessible from the front for maintenance and back opening
doors/ openable covers for maintenance shall not be acceptable.
5.1.8 The layout of the components inside a module shall be liberal to facilitate maintenance
and the interconnection of wiring between the components shall not be subjected to any
undue stress at the bends.
5.1.9 Mounting height of components requiring operation and observation shall not be lower
5.1.10 Inter panel barriers shall be provided.
5.2 Panel Arrangement
5.2.1 The distribution board shall be non-drawout type in single front configuration.
5.2.2 Each Panel shall have its horizontal bus-bar chamber running on the top with multi-tier
module units in the centre and having vertical bus-bar chamber and cable alley on
either side.
5.2.3 The modules shall be enclosed on all sides and shall be so arranged that larger ones
are placed at the bottom portion of the panel. Fixed type modules shall be at least 300
mm from the base channel.
5.2.4 The number of modules in the panel shall not exceed six for motor starter feeders and
eight for switch fuse/MCB/MCCB feeders. The minimum size of module shall be 300
mm and 200 mm for starter and switch fuse feeders. The incomer and bus coupler
module sizes for ratings up to 400 A shall be half the panel size. For higher ratings they
shall be housed in single panel.
5.2.5 The module door shall be so interlocked that it shall not be possible to open the door
with switch in closed position. Defeat interlock facility shall be provided.
5.2.6 The relay, meters, switches and lamps shall be flush mounted. All components of one
module shall be mounted on the same module on a rigid sheet steel chassis. A 20 mm
dia. rotating knob on the door shall be provided for closing and opening.
5.3 Bus Bars and Connections
5.3.1 The bus-bar shall be suitable for the supply system. The bus-bar and connections shall
be made of electrolytic copper or high conductivity aluminium alloy conforming to Grade
E91E of IS: 5082.
5.3.2 The bus-bar shall be amply sized to carry the rated continuous current under the
specified ambient temperature without exceeding the temperature of 90ºC. The bus-
bars shall also be designed to withstand the system fault current for 1 second without


0

exceeding the temperature of 200ºC for bare aluminium and 250ºC for bare copper. The
minimum acceptable size of bus-bars shall be 250 sq. mm (Al). Calculation for the
bus-bar sizing shall be furnished along with the offer.
5.3.3 In case of double front arrangement of distribution boards, different sets of vertical bus-
bars shall be provided. The vertical bus-bars shall be PVC sleeved or shrouded by
insulating barriers which shall have cut-outs to permit entry of power wires. It shall be
possible to remove the shroud for inspection and maintenance. Neutral-bars shall be
provided in this chamber.
5.3.4 Horizontal bus-bars shall be of same cross-section through out. Stepped bus-bars shall
not be acceptable.
5.3.5 All bus-bars shall be arranged and colours coded according to IS: 5578/11353.
5.3.6 The horizontal bus-bar shall run in a separate bus chamber located at the top shall have
separate screwed cover for inspection purpose.
5.3.7 The bus-bars shall be rigidly supported at equal intervals to withstand maximum short
circuit stresses. The supports shall be of moulded construction with built in anti tracking
barriers. The support material shall be of fibre glass reinforced thermosetting plastic.
5.3.8 All joints shall be suitably treated to avoid oxidation of contact surfaces and bimetallic
corrosion. A minimum of two bolts with spring washers shall be used for horizontal bus-
bar joints.
5.3.9 Horizontal bus bars shall be insulated with heat shrinkable PVC sleeves of reputed
makes. Insulating shrouds shall be provided for all joints of insulated bus-bars.
5.4 Clearance and Creepage Distances
5.4.1 The clearance and creepage distances shall not be lower than the values specified
below :
i) Minimum clearance between two live conductors -- 20 mm
ii) Minimum clearance between live part and accidentally -- 20 mm
dangerous part
iii) Minimum creepage distance -- 28 mm
5.4.2 The clearances and the creepage, as specified above, shall definitely be maintained in
the bus-bar system. Provision of bus-bar insulations, separator or barriers shall not be
considered to reduce the clearance from the values specified above.
5.4.3 At the termination points in the equipment, e.g. switches, contactors, thermal relays, etc.
it is realized that above clearance shall not always be possible to be maintained. All
such points where above clearance are not possible to be maintained shall, therefore,
be insulated or taped.
5.5 Insulation
5.5.1 The insulation used shall be non-hygroscopic and shall be of porcelain, Epoxy- resins or
fibre glass moulded with plastic. It shall be of adequate electrical and mechanical
strength to give trouble free service during normal operation and short circuit conditions.
5.6 Power Wiring
5.6.1 The connections from bus-bar including neutral to individual units on the modules shall
consist of PVC insulated flexible copper cable or tapped copper strip.


0

5.6.2 The power wiring size shall be decided based on the rating of the switch, after using a
rating factor of not more than 50% over the current rating in free air. In any case the
minimum size of power wiring shall not be less than 4 sq. mm copper.
5.6.3 The size of connection from incomer to horizontal bus-bar and from horizontal bus-bar
to bus coupler shall not be less than the size adopted for horizontal bus-bar.
5.7 Control Wiring
5.7.1 The switch board shall be completely factory wired and ready for external connections.
cables of 1100 Volt grade. The size of wires shall be as follows:
C.T. Circuit -- 2.5 sq. mm
V.T. and Control Circuits -- 1.5 sq. mm
5.7.3 All wiring shall be provided with dependent both end marking as per IS: 5578.
5.7.4 Control wiring circuits, fed from a supply common to a number of feeders, shall be so
protected that failure of a circuit in one feeder does not affect the operation of the other
feeders.
5.7.5 The wiring to the equipment mounted on the doors shall be carried out with flexible multi
strand copper conductor cable and supported so that opening of the door, there is no
undue strain on wire leads.
5.7.6 The control cables shall be neatly arranged and properly supported.
5.8.1 All power and control cables shall enter the distribution board from the bottom. Sufficient
space shall be provided for ease of connection and termination of cables.
5.8.2 All cables shall be of 1.1 KV grade PVC insulated armoured and PVC sheathed except
for single core cable which shall be unarmoured. The number and sizes of cable shall
be as indicated in Feeder details.
5.8.3 Compression type cable glands along with the cable lugs as required shall be provided
for termination of cables.
5.8.4 The cable glands shall be of rolled Aluminium heavy duty double compression type and
shall be mounted on a removable gland plate, provided at a minimum height of 75 mm
from the bottom of the distribution board. Two numbers spare knockouts of size 20 mm
shall also be provided on the gland plates for future use.
5.8.5 For all power cables crimped type aluminium lugs for aluminium cables and tinned
copper lugs for copper cables shall be provided.
5.8.6 The terminal blocks shall be pressure clamp type up to 35 sq. mm cable and bolted lug
type for higher sizes of cables. These shall be protected type and rated for 1100 Volts
service. The minimum current rating of terminal block shall be 16 Amp. The construction
shall be such that after the connection of cables by means of lugs, necessary clearance
and creepage distance are available.
5.8.9 The terminal block shall be grouped according to circuit functions and suitably


0

the phases.
5.9 Feeder Details
the single line diagram, feeder details and corresponding schematic diagram.
5.9.2 The bus coupler shall be so located that it is possible to maintain half of the bus-bars
while the other half is still alive. Complete segregation of bus-bar connections to bus
coupler shall be provided.
5.9.3 Castle key type mechanical interlocks shall be provided between incomers and bus
section modules to avoid paralleling of incomers. In addition padlocking facilities shall
be provided in OFF position.
5.9.4 Single phase loads shall be distributed as far as possible on all the three phases.
The components shall conform to type of co-ordination C as per IS/IEC:60947. Makes
of all components shall be subject to owner’s / consultant’s approval
6.1.1 The circuit breaker shall conform to IS/IEC:60947 and shall be of P2 category having
rupturing capacity as per system requirement.
6.1.2 The circuit breaker shall be provided with spring assisted quick make quick break type
manually operated trip free mechanism, mechanical ON/OFF position indicators,
thermal tripping devices of inverse characteristics, instantaneous short circuit tripping
devices and necessary auxiliary and alarm switches. The MCCB cubicle shall be
provided with service, test and isolated position and automatic safety shutter.
6.1.3 The thermal and short circuit tripping device shall be adjustable type.
6.1.4 When used for motor circuit shunt trip devices shall be provided and the let through
power of controlling MCCB shall be lower than the respective contactor.
6.1.5 In addition, under voltage trip shall be provided, if specified.
6.2 Switches
6.2.1 The switches shall be Motor duty type AC23 category and shall comply with the
requirements laid down in IS/IEC:60947. Switches up to 63 Amps shall be rotary type
and those of 100 Amp and above shall be link type.
6.2.2 ‘ON’ and ‘OFF’ positions of the switches shall be indicated on the panel. Provision shall
be made to lock the switch in the ‘OFF’ position.
6.2.3 The fixed contacts shall be shrouded and the contacts shall be silver plated.
6.2.4 Two Pole switches shall also isolate the neutral circuit along with phase circuit.
4 Pole / 2 Pole switches shall be used for 3 Phase/1 Phase circuits respectively.
6.3 Fuses
The fuses shall be of non-deteriorating HRC cartridge link type and conform to IS:
13703. They shall be suitable for the load and the service required in the circuit.
6.4 Air Break Contactors
6.4.1 The Air Break Contactor shall be of AC3 category unless otherwise specified,
conforming to IS/IEC:60947 and flapper type. Gravity operated contactors are not
acceptable.
6.4.2 The dropout voltage shall not exceed 65% of rated voltage.


0

6.4.3 Each contactor shall be provided with auxiliary contacts as required. The rating of the
auxiliary contacts shall be 5 Amps. AC or 1 Amp DC at the specified control voltages.
The spare auxiliary contacts shall also be wired terminal block.
6.5 Bimetal Thermal Overload Relays
6.5.1 The contactor shall be provided with three pole bimetal thermal overload relays unless
otherwise specified. The bimetal relays shall be of suitable range, ambient temperature
compensated and shall be separate mounting type. They shall be adjustable through
graduated scale and shall be provided with changeover contact.
6.5.2 Bimetal relays shall conform to IS: 3231 and shall have built in single phasing preventor.
6.5.3 The bimetal relays shall be provided with a manual reset device resetable after opening
the cubicle door. Auto reset thermal relays are not acceptable.
6.6.2 Current Transformers shall be Class-F insulated and vacuum impregnated. The Current
Transformers shall be rigidly mounted and shall be easily accessible for maintenance
and testing.
6.6.3 The Current Transformers shall be of 7.5 VA output. The output shall be adequate for
the instrument and metering duties involved with sufficient margin. The Current
Transformers shall have the accuracy Class-1 for the metering duty.
6.6.4 All the Current Transformers shall be provided with terminals and shorting links. One of
the terminals of C.T. shall be earthed. The polarity of the C.T. shall be clearly marked.
6.6.5 The C.T.s shall be capable of withstanding momentary open-circuit on the secondary
6.7.1 All instruments shall be flush mounting type with square face and shall be tropicalized
and dust tight.
6.7.2 The size of the instruments shall be 96 mm x 96 mm for full and half size modules and
72 mm x 72 mm for lower size modules.
6.7.3 Dials shall be parallax free with scale marked in black on white background and shall be
suitable for direct reading.
6.7.4 Zero adjusters shall be provided for operation from the front of the cases.
6.7.5 All ammeters and voltmeters shall have 0 - 240º scale moving iron spring controlled
type and of Class 1.5 accuracy as per IS: 1248. The scale range of the ammeter and
voltmeter shall be as indicated in the feeder details.
6.7.6 In case of motor feeders, the ammeter shall be graduated uniformly upto C.T. primary
current and with a compressed end scale upto 6 times the C.T. primary current. Red
pointer shall be provided, which can be adjusted at site for indicating full load current.
6.7.7 KWH meter shall be 3 phase 4 wire type. These shall conform to the requirements of
relevant IS and shall be C.T. operated. The current coil shall be rated for 5 Amp.
6.7.8 All kWh meters shall be provided with test blocks for current and voltage coils for testing
them at site without interrupting their recording while in service.
6.8 Push Button and Control Switches
6.8.1 The switches and push buttons shall conform to utilization category AC 11/DC 11 as per
IS/IEC:60947 . The contact shall be rated to make, break and carry inductive current of
5 Amp. at 415 V AC and 1 Amp at 220 V DC.


0

6.8.2 The control switches shall be spring return rotary type unless otherwise specified and
provided with pistol grip type handle. The control switches for circuit breakers shall be
additionally fitted with lost motion devices and sequencing devices.
6.8.3 The selector switches shall be stay-put rotary type and provided with oval shape
handles.
normally close and open contacts. The push button for ‘Start’ shall be shrouded type
and coloured green, stop push button shall be un-shrouded type and coloured red and
other push buttons shall be un-shrouded type coloured black. The fixing ring shall be
metallic white.
M-9.
housing.
6.9.3 A certificate of short circuit rating and current time tripping curve shall be furnished
alongwith the offer.
6.10 Signal Lamps
scheme drawings. The colour of the lamps for various functions shall be as follows:
Red -- Switch/Contactor closed.

Green -- Switch/Contactor open.
6.10.2 The lamps shall be LED type having lumen output 200 milli candela in axial direction.
6.10.3 It shall be possible to remove the globe from outside for replacement of lamps.
7.0 ACCESSORIES
7.1 The supplier shall include the following accessories.
-- Fuse Puller.
-- Test plug for kWh meters.
7.2 Space Heater
Each vertical section shall be provided with a thermostatically controlled space heater,
rated for 240 V, 50 Hz and controlled through double pole miniature circuit breaker.
7.3 Name Plates
7.3.1 The distribution board shall have large name plate on the top to indicate its name and
designation.
7.3.2 Each feeder shall be provided with name plate. Each single front panel shall have name
plate both in front and back.
7.3.4 Name plate shall be of black perspex with white engraving and of minimum 3 mm thick.
7.3.5 Any other accessories required, but not specified shall also be supplied to make the
distribution board complete in all respects to ensure safe and proper operation.


0

8.0 PAINTING
8.1 The enclosure after degreasing, pickling in acid, cold rinsing phosphatising, passivating
etc. shall be painted with two coats of anti-rust paint followed by two coats of
anticorrosive paint.
8.4 Unless otherwise specified, the finishing shade shall be light grey Shade No.631 as per
IS: 5.
9.1 The distribution boards shall be subjected to routine test as per IS: 8623.
9.4 These inspections shall however, not absolve the vendor from his responsibility for
making good any defect which shall be noticed subsequently.
specified.
- Name of client
11.0 SPARES
offer.
12.0 PACKING
12.1 The distribution board shall be properly packed before despatch to avoid damage during
transport, storage and handling.
manual.


0

the equipment.
13.0 DEVIATIONS
reasoning.


0

ANNEXURE - I
DOCUMENTATION FOR SHEET STEEL DISTRIBUTION BOARDS
Sl.No. Documents
4. General Arrangement and Foundation N Y Y
Drawings
5. Schematic Diagrams with Terminal N Y Y
arrangement drawings
7. Illustrative and Descriptive literature N N Y
8. Catalogues for bought out accessories N N Y
9. Installation, Operation and Maintenance N N Y
Manual
-- Type (for MCCB & MCB) N N N
-- Routine N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N - No


0
TECHNICAL SPECIFICATION - LIGHTING SUB DISTRIBUTION Document No. Rev

LIGHTING SUB DISTRIBUTION BOARDS


0

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0
SCOPE
6.0 SPECIAL FEATURES FOR FLAME PROOF LIGHTING SUB

DISTRIBUTION BOARDS
8.0 PAINTING
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR LIGHTING SUB DISTRIBUTION BOARDS


0

1.0 SCOPE
1.1 This standard covers the technical requirements of design, manufacture, testing at works
and delivery in well packed condition of lighting sub distribution boards.
Electrical.
comply with the latest issue of the following Indian Standards. Equipment complying with
equivalent IEC standards shall also be acceptable
IS/IEC:60947 - Low voltage switchgear and control gear
assemblies
provisions of latest issue of the Indian Electricity Rules and other relevant statutory acts and
regulations. The supplier shall, wherever necessary, make suitable modification in the
2.3 Wherever any requirement, laid down in this standard, differs from that in Indian Standard
Specifications, the requirement specified herein shall prevail.

3.2 System Details

The lighting sub-distribution boards shall be suitable for operating continuously under the
ambient conditions and with the voltage and frequency variations, without exceeding the
specified temperature rise and without any detrimental effect on any part.
5.1 The lighting sub distribution boards shall be fabricated out of 2.5 mm thick cold rolled sheet
steel and shall be suitable for mounting on wall/structure. These shall have dust and vermin
proof construction conforming to IP-54 as per IS/IEC:60947. For outdoor installation, the
enclosure shall conform to IPW-55. Suitable canopy made out of 2 mm thick Aluminium
sheet shall be supplied along with the board.
5.2 The miniature circuit breakers shall be so mounted inside the enclosure that their operating
knobs project outside for easy operation. The cut-out for the knobs on the enclosure shall
be lined with gasket for dust proofness. For further protection against ingress of dust, the
portion where the knobs have protruded out, shall be provided with another external front
cover, internally hinged at the top, gravity operated and with a knurled knob at the bottom.
The external cover shall be flushed with the main cover. Continuous neoprene gasket shall
be provided to make the board completely dust and weather proof.
5.3 All external hard ware of diameter less than 8 mm shall be of stainless steel and those of
diameter 8 mm and above shall be of mild steel cadmium plated or zinc passivated.


0

5.4 The sub-distribution boards to be located indoors shall have top entry arrangement for
outgoing cables and bottom entry for incoming cable. However for outdoor locations, all
cable entries shall be from the bottom only.
5.5 Three phase and neutral bus bar system of adequate size shall be provided to which all
outgoing and incoming MCB’s shall be connected.
5.6 The internal wiring shall be carried out by means of single core PVC insulated 2.5 sq. mm
stranded copper conductor cables.
5.7 Two earthing terminals outside the board shall be provided.
5.8 Suitable label inscription consisting of black perspex with engraving for the board and circuit
nos. of all outgoing feeders shall be provided. The label inscription of the board shall
contain description and code no. The circuit nos. of outgoing feeders shall be serially
indicated as 1L, 2L.........17L, 18L.
5.9 The board shall be complete with terminal block, cable glands, cable lugs and other
accessories as specified.
6.0 SPECIAL FEATURES FOR FLAME PROOF LIGHTING SUB DISTRIBUTION BOARDS
6.1 The enclosure shall be in addition of flame proof execution as per IS: 2148.
6.2 The enclosure group and temperature class shall be as indicated in Design Philosophy –
Electrical.
6.3 The enclosure shall be of cast iron/cast Aluminium alloy (4600 as per IS: 617).
6.4 Cables shall enter the terminal chamber through flame proof compression type cable
glands. From terminal chamber to the main enclosure connection shall be made through
bushings. Direct entry of external cables into the main enclosure shall not be accepted.
6.5 The sub-distribution board shall be of 6 way type.
6.6 Individual earth terminals shall be provided for the earth conductor of the outgoing cables
beside the phase and neutral terminals.
6.7 The sub-distribution board must be certified by Central Mining Research Institute, Dhanbad
or other statutory authority for use in specified hazardous area.
7.1 The lighting sub-distribution board shall be wired and have components as per SD-8083
(copy attached).
7.2 Miniature Circuit Breaker (MCB)
The MCB shall be of duty category M-9 and shall conform to IS/IEC:60898-1:2002. It shall
be provided with overload and short circuit protective devices. MCB shall be of C Curve
Type.
7.2.1 The incoming MCB’s or switches shall be of triple pole and switched neutral type and
outgoing MCB’s of single pole and switched neutral type, single phase earth leakage
protection in each phase of the incomer shall be provided.
7.3 Terminal Block
Pressure clamp type terminal blocks shall be provided both for incoming and outgoing
cables. The rating of the terminal block shall be at least 1.5 times the rating of the MCB.
7.4 Cable Glands
Heavy duty double compression type Aluminium cable glands suitable for PVC insulated,
armoured and PVC sheathed 1.1 KV grade incoming and outgoing cables shall be
provided.


0

8.0 PAINTING
8.1 The enclosure after suitable pre-treatment shall be painted with two coats of anti rust paint
followed by two coats or anticorrosive paint.
8.4 The finishing shade shall be light grey shade no.631 as per IS: 5.
9.1 All the lighting sub-distribution boards shall be subjected to routine tests as per IS: 8623.
9.2 Additional tests, wherever specified, shall be carried out on one lighting sub-distribution
board of each type.
9.3 The above mentioned tests shall be carried out in the manufacturer’s works in the presence
of purchaser’s representative. In addition, the equipment shall be subjected to stage
inspection at works and inspection at site for final acceptance.
9.4 The purchaser’s inspection shall, however, not absolve the vendor from his responsibility for
10.1 Drawings and documents as per Annexure-I shall be supplied, unless otherwise specified.
- Name of client
11.0 SPARES

Commissioning spares, as required, shall be supplied with the main equipment. Item wise
list of recommended commissioning spares shall be furnished for approval.
11.3 Any other spare parts not specified, but required, shall also be quoted along with the offer.
12.0 PACKING
12.1 The equipment shall be properly packed to safeguard against weather conditions and
handling during transit. It shall be wrapped in polythene bags and an additional wrapping
of bitumen paper shall also be provided to make it completely water proof before the
equipment is packed in wooden crates.
manual.
13.0 DEVIATIONS
13.1 Deviations, if any, from this standard shall be clearly indicated in the offer with reasoning.


0

ANNEXURE - I
DOCUMENTATION FOR LIGHTING SUB DISTRIBUTION BOARDS
SL.N
Description
O.
2. Technical particulars N Y Y
3. General arrangement Drgs. N Y Y
4. Certificate for flameproofness from N N Y
statutory testing authority wherever
applicable
5. Schematic diagram N Y Y
6. Descriptive literature of Various equipment N N Y
7. Guarantee certificate N N Y
8. Test certificate N N Y
Note:
1. 4 hard copies & 1 soft copy shall be supplied for approval after order within 4 weeks from the
date of LOI.
2. 8 hard copies & 2 soft copies in CD shall be submitted as final documents prior to despatch of
the equipment. These shall be made in sets and supplied in fine plastic coated folder.
Y - Yes, N - No


0
TECHNICAL SPECIFICATION - INDUCTION MOTOR Document No. Rev
(PC150-TS-0810) Sheet 1 of 12

INDUCTION MOTOR


0
(PC150-TS-0810) Sheet 2 of 12

CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
5.0 PERFORMANCE
6.0 COUPLING DETAILS
7.0 ACCESSORIES
8.0 VIBRATIONS
9.0 NOISE LEVEL
10.0 PAINTING
12.0 PACKING
14.0 SPARES
15.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR INDUCTION MOTORS


0
(PC150-TS-0810) Sheet 3 of 12

1.0 SCOPE
works and delivery in well-packed condition of medium voltage and high voltage
induction motors.
Electrical.
comply with the latest issue of IS-325 and other relevant Indian Standards, unless
otherwise specified. Equipment complying with equivalent IEC standards shall also be
acceptable.
provisions of latest issue of the Indian Electricity Rules and other relevant Statutory
Rules & Regulations. The supplier shall, whenever necessary, make suitable
modification in the equipment to comply with the above mentioned rules.
2.3 Flame proof motors shall, in addition, comply with the requirements laid down in IS:
2148.
2.4 Increased safety motors shall, in addition, comply with the requirements laid down in IS:
6381.
2.5 Motors with type of protection “n” shall, in addition, comply with the requirements laid
down in IS: 9628.
2.6 Wherever any requirement laid down in this standard differs from that in Indian Standard
Specifications, the requirement specified herein shall prevail.
The ambient conditions shall be as indicated in the Design Philosophy - Electrical.
3.2 System Details
3.2.1 The details of power system to which the motors will be connected shall be as indicated
in the Design Philosophy - Electrical.
3.2.2 The motors shall be suitable for connection to a power system where transient
disturbances are very likely to occur. During the transient disturbances, voltage of the
system may completely disappear and return in a short time with the motors still running
and connected. Under this condition, the return of voltage may occur at such an instant
that the induced e.m.f. in the motor is in phase with the applied voltage giving rise to
current surges which may reach a value equal to 1.6 times the starting current and also
cause transient torques of large magnitudes.
4.1 Enclosure
4.1.1 The enclosure of motors for indoor and outdoor services shall be IP-54 and IPW-55
respectively as per IS/IEC:60529, unless otherwise specified.
4.1.2 Motors for outdoor service shall be provided with special seals for the enclosure, joints,
bearing housing, terminal boxes etc. so that no extra protective covering for ingress of
water shall be required.
4.1.3 Vertical motors for outdoor installation shall be provided with a rain protective hood.


0
(PC150-TS-0810) Sheet 4 of 12

4.1.4 All external hardware shall be zinc passivated or cadmium plated.

4.1.5 The enclosure shall be provided with threaded metallic plug to permit drainage of
condensed water from the inside.
4.2 Cooling
4.2.1 All motors shall be totally enclosed fan cooled conforming to IC-0141 as per IS: 6362
unless otherwise specified.
4.2.2 In case of CACA construction, the same shall conform to IC-0161 as per IS: 6362.
4.2.3 In case of CACW construction, the same shall conform to ICW 37A 91 as per IS: 6362.
4.2.4 Wherever service conditions are such that corrosive agents are present in the
surroundings, the following materials of construction for cooling tubes shall be adopted,
For CACA motor - Aluminium tubes having minimum thickness of 1.6 mm
For CACW motor - Low carbon alloy steel

4.2.5 In case of CACW motors, the cooling tubes and flanges shall also be suitable for the
cooling water analysis. Trays shall be provided for collection of leaking water with
arrangement for its drainage.
4.2.6 The cooling fans shall be suitable for bidirectional rotation of motors. These shall be
fastened to the motor shaft by means of compensating rings or will be balanced
independent of the motor. Guide key or reference points shall be supplied to prevent
wrong assembly. The cooling air shall be sucked from the non-driving end.
4.2.7 The cooling fans shall be made of non-sparking materials such as cast Aluminium (LM-
6 alloy) / cast iron.
4.3 Direction of Rotation
4.3.1 Motors shall be suitable for both directions of rotation. In case of any design limitation,
the same shall be indicated in the offer.
4.3.2 In either case, a plate showing the direction of rotation corresponding to the phase
terminal markings shall be fitted at the driving end shield of the motors.
4.4 Stator
4.4.1 The stator laminations shall be made from suitable magnetic sheet iron varnished on
both sides. Where ventilation is required, these shall be arranged in suitable packs,
each pack being separated by spacers to form ventilating ducts for circulation of air.
4.4.2 The slot shall be open type with coils so arranged that the coils can be easily removed
for inspection and repair.
4.5 Rotor
4.5.1 The rotor shall be of squirrel cage construction, unless otherwise specified.
4.5.2 For small motors, the squirrel cage shall preferably be of pressure die-cast construction.
For large motors, the rotor bars and the end rings shall be of copper or copper alloy.
The bars shall be firmly placed in slots to prevent vibration during start up / locked rotor
condition. Conductor ends shall be securely fixed to the end rings using the latest
brazing techniques. Retaining rings shall be provided for high speed machines for the
end rings. The rotor cage shall be designed for the required starting and duty cycles.
4.5.3 Wherever wound rotor is specified, the windings shall have the same features as
detailed for the stator windings. The rotor voltage shall not exceed the stator voltage.


0
(PC150-TS-0810) Sheet 5 of 12

4.5.4 The rotor shall be dynamically balanced and shall rotate perfectly with no preferential
stop points. The rotor shall be constructed such as to allow the removal or addition of
material for balancing.
4.5.5 The rotor shaft shall be electrically and magnetically so balanced that the induced shaft
voltage does not exceed 200 millivolt. Otherwise the bearing housing at non-driving end
shall be insulated for 2 KV.
4.6 Windings and Insulation
4.6.1 The motor coils shall be made out of insulated electrolytic grade copper conductor.
Successive coils shall be connected by accessible joints, well brazed and finished
smooth to prevent damage to insulation.
4.6.2 The motors shall be insulated assuming the power system neutral as isolated.
4.6.3 All motors shall be insulated with F insulation with tropical and fungicidal treatments.
4.6.4 Wherever class F insulation is specified, the windings shall be easily replaceable type
and the temperature rise shall not exceed that of class B insulation.
4.6.5 The winding coils shall be dried, properly impregnated with suitable varnishes to
withstand the site conditions and properly baked. At least two additional impregnations
and baking shall be applied to the assembled stator coil, making a total of three
impregnations and baking. Finally the windings shall be painted with special anti-acid
and anti-alkali paints to withstand the site conditions.
4.6.6 The windings shall be well brazed and capable of withstanding thermally and
mechanically the transient disturbances specified under clause 3.2.2.
4.6.7 Lead-in wire between the windings and the outside terminals shall be made through
bushings in H.V. motors. For M.V. motors, heat resistant insulated conductors shall be
used as lead-in wire.
4.6.8 The windings shall be star connected for high voltage motors and delta connected for
medium voltage motors.
4.7 Slip Rings and Brushes
4.7.1 Slip rings shall be located in the non-driving side. The material of construction shall be
copper alloy. The slip rings and the brush gear shall be cooled by the motor cooling fan.
4.7.2 For explosion proof motors, the slip rings and brush gear shall be housed in a
flameproof housing. In case this is not possible, the housing shall be pressurised type
with flameproof pressure switch for interlocking with the motor. In either case, glass
covers shall be provided for inspection.
4.7.3 The starting rheostats shall be designed for intermittent duty and rated for 10 minutes.
Where speed regulation is required, the rheostats and the controllers shall be suitable
for such duty and be continuously rated. Auxiliary contacts shall be provided on the
controllers for connections to the motor supply controls to prevent wrong operations
during starting.
4.8 Bearings
4.8.1 All motors shall be provided with bearings suitable for the application. The bearings
must be guaranteed to ensure a smooth operation and a life not shorter than 30,000
hrs.
4.8.2 Where external thrusts are specified, the motors shall be fitted with special roller thrust
bearings capable of withstanding the specified thrust. In such cases, the guaranteed life
of the bearings shall not be less than 20,000 hours.
4.8.3 The bearing housing shall be effectively sealed against ingress of dust and water and
creep age of lubricants along the shaft.


0
(PC150-TS-0810) Sheet 6 of 12

4.8.4 The bearing shall be suitable for both directions of rotation of the motor.
4.8.5 All motors shall be provided with on-line grease lubrication arrangement for both DE
and NDE side bearings except for motors of frame size 112 and less and flange
mounted M.V. motors. The arrangement shall be complete with grease nipple and drain
plug located at convenient locations.
4.8.6 All oil lubricated bearings shall be fitted with oil level indicator and resistance
temperature detector/dial type thermometer with alarm and trip contacts.
4.8.7 Self cooled bearing system shall be preferred.
4.8.8 The manufacturer shall specify the type of lubricant and the time interval of lubrication
for the bearings of each motor.
4.8.9 The bearing temperature shall not exceed 90ºC for grease lubricated bearings and
70ºC for oil lubricated bearings.
4.8.10 Wherever shaft end-play has been specified, the bearings shall be capable of providing
the specified end-play.
4.9 Terminal Box
4.9.1 All the terminal boxes shall have identical degree of protection as that of the motor.
4.9.2 The power terminal box shall be mounted on the right hand side of the motor as viewed
from the coupling end. For M.V. Motors, design of terminal boxes shall be such that it
may be possible to arrange top/bottom/side entry of cables at site.
4.9.3 The power terminal boxes shall be as follows:
a) For H.V. motors - Phase segregated type capable of with standing the system fault
level for 0.2 Sec. or more.
b) For M.V. motors - Manufacturer’s standard box with epoxy or SRBF moulded
terminal board.
4.9.4 The mounting arrangement of power and neutral side terminal boxes for HV motors
shall be identical so that it shall be possible to interchange the boxes at site.
4.9.5 In case of H.V. motors, all the six leads of the motors shall be taken out, three on one
side and three on the other side to separate terminal boxes. However, neutral shorting
link shall be provided on the neutral box for star connection.
4.9.6 In case of M.V. motors, all the six leads of the motors shall be taken out to a common
terminal box. Shorting links for delta connections shall be provided in the terminal box
for motors 112 frame and above.
4.9.7 For increased safety motors and for motors with type of protection “n”, the terminals
shall be provided with positive locking device so that they do not become loose during
normal operation.
4.9.8 The power terminal boxes shall have adequate clearances in between the terminals
and also between the terminals and cable gland for proper termination of cables. Where
more than one cable is required to be terminated in parallel, the spacing in the box shall
be adequate for easy termination.
4.9.9 Separate terminal boxes shall be provided for connection of power, control and space
heater cables.
4.9.10 All terminal boxes shall be complete with heavy duty double compression type cable
glands and lugs/connectors to receive the external cables.
4.9.11 Where cross linked polyethylene cables are specified, the terminal box shall be suitably
designed for proper termination of such cables.


0
(PC150-TS-0810) Sheet 7 of 12

4.9.12 The cable lugs shall be of tinned copper and suitable for crimping.
4.10 Geared Motors
Where geared motors are specified, the gears shall be oil lubricated, heavy duty as per
AGMA class III and capable of transmitting the rated motor power continuously. They
shall be capable of withstanding moderate shock loads having a service factor of 2 and
the starting duties. They shall be silent and smooth in operation. Inspection glass shall
be provided to indicate the oil level in the gear box.
5.0 PERFORMANCE
5.1 Starting
5.1.1 The motors shall be capable of being started direct-on-line, unless otherwise specified.
5.1.2 The starting torque of each motor shall be higher than the initial resisting torque of the
driven load throughout the starting period even at a feeding voltage of 85% of the rated
voltage for normal purpose motor and 80% of the rated voltage for special purpose
motor.
5.1.3 The starting current of 415 V Motors shall not exceed the values indicated in IS: 12615.
Also there shall be no further positive tolerance on the values of starting current.
The starting current of 11 KV & 3.3 KV motors shall not exceed 550% of FLC. No
positive tolerance is acceptable over 550% FLC.
5.1.4 The motors shall be suitable for the following starting cycle:
a) With the motor at ambient temperature - 2 successive starts and 3rd start after 5
minutes.
b) With the motor at steady state load temperature - 1 immediate start and 2nd start
after 5 minutes. This sequence shall be repeated in the next hour.
5.1.5 Speed switch shall be provided, wherever required, to fulfil the starting conditions.
5.2 Locked Rotor Condition
5.2.1 The locked rotor withstand time (tE), under hot condition at 110% of rated voltage shall
be more than the starting time of the motor coupled to the load even at the lowest
stipulated starting voltage by 2 secs. for motors, having starting time up to 10 secs. and
by 5 secs. for motors, having starting time more than 10 secs.
5.2.2 For increased safety motors, tE under hot condition shall not be less than 10 secs. The
value of tE shall be determined in the presence of purchaser’s representative unless
test certificate from an independent testing authority is submitted for similar motors. The
time tE and the locked rotor current shall be stamped on the name plate as well as
indicated in the test certificates.
5.2.3 For deciding the time tE in all cases, the temperature of the insulated stator and rotor
shall not exceed the value stipulated under clause no. 5.4.3.
5.3 Running
5.3.1 All motors shall be continuous maximum rated (S1 duty as per IS: 325), unless
otherwise specified.
5.3.2 The motors shall be capable of delivering the rated output without exceeding the
specified temperature rise under the system voltage and frequency variation conditions.
5.3.3 The motors shall be suitable for running at the rated load for 5 minutes duration at 80%
voltage and for 1 Sec. duration at 70% voltage, without exceeding the specified
temperature rise.
5.4 Temperature Rise


0
(PC150-TS-0810) Sheet 8 of 12

5.4.1 The total temperature of the stator winding under full load running condition shall not
exceed the values permissible for the specified insulation class. For increased safety
motors, the total temperature shall be 10ºC less than for normal motors.
5.4.2 For explosion proof motors, the maximum surface temperature shall not exceed the
values applicable for temperature class of the hazardous gases / vapours present in the
surrounding area. However for type ‘n’ motors, the maximum allowable temperature
shall not exceed 200ºC.
5.4.3 In case of starting and locked rotor conditions stipulated under clause nos. 5.1.4 and
5.2.1 respectively, the maximum temperature in the rotor shall not exceed the following
values:
For squirrel cage rotor - 300ºC
For wound rotor - As applicable to the insulation class
For explosion proof motor - As per temperature class of the hazardous
gases / vapours, without exceeding the above
temperature as applicable
6.0 COUPLING DETAILS

6.1 Unless otherwise specified, all motors shall be coupled to the driven equipment through
flexible coupling.
6.2 Normally the coupling half for the motor shaft shall be supplied by the driven equipment
supplier. The coupling half shall be keyed on the shaft with a tapered joint or shrunk
with a straight joint. For this purpose, the motor manufacturer shall coordinate all details
of the coupling system with the driven equipment manufacturer, wherever required.
6.3 Where rigid coupling is specified, the motor shaft shall have the desired class of
accuracy.
6.4 For all vertical flange mounted motors, the limitations on shaft extension, run out,
perpendicularity and eccentricity, as required by the driven machine supplier shall be
complied with by the motor supplier.
6.5 i) If the motor is to be coupled to a reciprocating pump or compressor requiring
fluctuating torque, the motor supplier shall ensure that the inertia of the driving
and driven machine assembly shall be such that the variation in the armature
current shall not exceed ±66% of the rated current while delivering full load.
ii) The measurement of armature current shall be done with the oscillograph.
iii) The additional fly wheel, if any, shall be assembled at such a distance from the
motor so as to allow easy inspection of the windings.
iv) All necessary coordination with driven equipment manufacturer shall be carried
out by the motor manufacturer.
6.6 i) Wherever belt drive is specified, the motor supplier shall ensure that the shaft
extension and the bearings are suitable for the duty specified.
ii) Unless otherwise specified, the slide rails for all belt driven motors shall be
supplied by the motor manufacturer.
7.0 ACCESSORIES
The motors shall be complete with all the accessories.

7.1 Space Heaters


0
(PC150-TS-0810) Sheet 9 of 12

7.1.1 Space heaters rated for 240 V A.C. shall be provided to keep the winding dry for all high
and medium voltage motors, except for motors rated below 30 KW which shall be
suitable for space heating by connecting 24 V A.C to any of the two motor winding
terminals.
7.1.2 The location of the space heaters shall be such as to allow easy access for inspection,
maintenance and replacement.
7.2 Name Plates
7.2.1 The name plates shall be of stainless steel with letters embossed on them.
7.2.2 The name plate shall contain all the relevant details as per IS: 325 and in addition shall
indicate the following:
i) The description and code no. of motor
ii) Degree of protection of enclosure
iii) Temperature rise of windings under running condition
iv) Designation of bearings
v) Recommended type of lubricant and interval of lubrication

vi) Direction of rotation
vii) Mounting Arrangement
7.2.3 Flameproof motors shall have additional name plate containing relevant particulars as
per IS: 2148.
7.2.4 Increased safety motors shall have additional name plate containing relevant particulars
as per IS: 6381.
7.2.5 Motors with type of protection “n” shall have additional name plate containing relevant
particulars as per IS: 9628.
7.3 Embedded Temperature Detectors
7.3.1 All high voltage motors shall be provided with 6 nos. of evenly distributed embedded
resistance temperature detectors for measurement of winding temperature. These shall
be located in positions at which the highest temperatures are likely to occur.
7.3.2 In addition, the high voltage motors shall be provided with
i) 1 no. RTD for hot air temperature measurement
ii) 2 nos. RTDs (1 on each side) for bearing temperature measurement of oil
lubricated bearings. For grease lubricated bearings, RTD shall be provided only
where specified
7.3.3 These RTDs shall be of platinum having 100 ohm resistance at 0ºC and temperature
coefficient as 3.850 x 10-3.
7.3.4 The RTDs shall be 3 lead type having power frequency insulation level of 2KV.
7.3.5 The RTDs shall comply with the requirements laid down in IS: 2848.
7.4 Dial Type Thermometers
7.4.1 In high voltage motors, the measurement of hot air and bearing temperature (of oil
lubricated bearings) by dial type thermometers shall be provided wherever specified.
7.4.2 The arrangement shall consist of a dial type of mercury-in-steel thermometer so
mounted that its stem shall be located in the maximum temperature region.


0
(PC150-TS-0810) Sheet 10 of 12

7.4.3 The thermometer shall have two potential free contacts for alarm and trip.
7.4.4 All contacts shall be rated for 2 Amps. at 110 V D.C.
7.4.5 For bearing temperature measurement, separate thermometers shall be provided for
each bearing.
7.4.6 For grease lubricated bearings, temperature measurement arrangement shall be
provided only where specified.
7.5 Oil Supply System
7.5.1 For large sized motors, where forced oil lubrication system is considered, a common oil
supply system for the motor and the driven equipment shall be provided by the driven
equipment manufacturer.
7.5.2 However, the motor supplier shall quote separate price for the complete oil system of
the motor.
7.5.3 The system shall be suitable for location near the motor.
7.5.4 The oil supply system for each motor shall include:
i) 2 Nos. 100% rated motor driven pumps with motors
ii) 1 No. oil tank complete with oil level gauge and thermometer
iii) 1 No. oil cooler
iv) 1 No. oil filter
v) 1 No. differential pressure switch for filter
vi) 2 Nos. pressure switches
vii) Necessary piping
viii) Necessary control and interlocks
8.0 VIBRATIONS
The motor vibrations measured at the bearings must not exceed the limits specified in
IS: 12075.
9.0 NOISE LEVEL
The motor noise level shall not exceed 85 dB measured at a distance of 1 metre from
the motor.
10.0 PAINTING
10.1 Enclosures of the motor and its accessories shall be painted with two coats of anti-rust
paint and two coats of anti-corrosive paint after suitable pre-treatment.
10.2 Epoxy paint shall be used.
10.3 Unless otherwise specified, the finishing shade shall be light grey having shade No. 631
as per IS: 5.
11.1 All motors shall be routine tested as per relevant standards.
11.2 Additional tests, wherever specified, shall be carried out on one motor of each rating.
11.3 For high voltage motors of each rating, polarization index test shall also be carried out.


0
(PC150-TS-0810) Sheet 11 of 12

11.4 All the above mentioned tests shall be carried out in the presence of purchaser’s
representative. In addition, the motor shall be subject to stage inspection at works and
inspection at site for final acceptance.
11.5 These inspections shall, however, not absolve the vendor from their responsibility for
12.0 PACKING
12.1 The motors shall be properly packed to safeguard against weather conditions and
handling during transit.
12.2 The shaft shall be properly clamped / supported.
12.3 Rust inhibiting agents shall be applied to fittings and sliding surfaces.
12.4 All flanges shall be closed with blanking plates to avoid entry of foreign materials.
12.5 The loose pieces of the motor / spare parts / Instruments shall be separately wrapped
in moisture resistant paper and marked with identification marks and name plate of the
corresponding motors.
12.6 The packing box / crate shall include a copy of installation, operation and maintenance
manual.
specified.
- Name of client
- Motor Code No. and Description
14.0 SPARES
offer.
14.4 All spare parts shall be identical to the parts used in the motors.
15.0 DEVIATIONS
reasoning.


0
(PC150-TS-0810) Sheet 12 of 12

ANNEXURE - I
DOCUMENTATION FOR INDUCTION MOTORS
Sl. No. Document Description
1. Specification Sheet and Technical Particulars N Y Y
2. Dimensional Drawings N Y Y
3. Drawings and data for air / water heat N Y Y
exchangers, if necessary
4. Drawings and data for oil system, if necessary N Y Y
5. Characteristic curves
a) Thermal withstand curve N Y Y
b) Load Vs FL current N Y Y
c) Load Vs Efficiency N Y Y
d) Load Vs Power factor N Y Y
e) Load Vs Speed N Y Y
f) Voltage Vs Thermal Withstand time N Y Y
g) Starting current Vs Time N Y Y
6. Connection diagram for RTDs, thermometer etc. N Y Y
7. Terminal Box drawings N Y Y

8. Illustrative and Descriptive catalogues N N Y
9. Catalogues of bought out accessories N N Y
10. Spare parts list N N Y
11. Installation, Operation and Maintenance manual N N Y
12. Test certificates
a) Routine N N Y
b) Type N N Y
c) For enclosure N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N - No

0
TECHNICAL SPECIFICATION - INTERLOCKING SWITCH SOCKET Document No. Rev
AND PLUG (PC150-TS-0811) Sheet 1 of 8
INTERLOCKING SWITCH SOCKET AND PLUG

0
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
6.0 SPECIAL FEATURES FOR FLAME PROOF SWITCH SOCKET AND

PLUGS
8.0 PAINTING
11.0 PACKING
12.0 SPARES
13.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR INTERLOCKING SWITCH SOCKET AND PLUG

0
1.0 SCOPE
1.1 The standard covers the technical requirements of design, manufacture, testing at works
and delivery in well packed condition of interlocking switch socket and plug.
1.2 The standard shall be read in conjunction with relevant part of Design Philosophy -
Electrical.
comply with the latest issue of IS-4160/ IEC-309 and other relevant Indian Standards,
unless otherwise specified. Equipment complying with equivalent IEC standards shall
also be acceptable.
provisions of latest issue of Indian Electricity Rules and other statutory acts and
regulations. The supplier shall, wherever necessary, make suitable modifications in the
2.3 Wherever any requirement, laid down in this standard differs from that in Indian
3.1 Ambient conditions
3.2 System details
The equipment shall be suitable for operating at the rated capacity continuously without
exceeding the specified temperature rise and without any detrimental effect on any part.
5.1 The switch socket shall be heavy duty industrial type. The interlocking arrangement shall
be such that it is not possible to insert or withdraw the plug with the switch in ‘ON’
position.
5.2 The switch sockets shall have dust, hose and weather proof construction conforming to
IPW55 as per IS/IEC:60947 and shall be suitable for outdoor use without any extra
protection. All jointing surfaces shall be smoothly machined and of sufficient width to
prevent ingress or dust. Further the covers shall be provided with continuous gaskets
made of neoprene to prevent ingress of dust and moisture.
5.3 The enclosure of switch sockets and plugs shall be of cast aluminium alloy 4600 and
suitable for fixing on wall / structure.
5.4 The enclosure shall be largely dimensioned in order to avoid temperature rise inside it
which may damage the insulating materials and gaskets employed therein.

0
5.5 The insulating materials used shall be non-hygroscopic, mould proof and treated with
suitable varnish to withstand the ambient conditions.
5.6 All external hardware of diameter less than 8 mm shall be of stainless steel and those of
diameter 8 mm or above shall be of mild steel cadmium plated or zinc passivated.
5.7 Suitable arrangement for looping of cables from one switch socket to the other shall be
provided. For switch sockets rated above 63A, looping shall be done from busbars and
for switch sockets rated 63A and below, looping may be done from terminal block.
Necessary terminals, cable glands and lugs for looping shall be provided. Also one no.
The readed plug for each switch socket shall be supplied loose.
5.8 All the relevant information shall be provided on engraved name plate made of
aluminium.
5.9 The enclosure shall be provided with two earthing terminals outside the body.
6.0 SPECIAL FEATURES FOR FLAME PROOF SWITCH SOCKET AND PLUGS
6.1 The enclosure shall be in addition of flame proof execution as per IS: 2148.
6.2 The enclosure group and temperature class shall be as indicated in Design Philosophy -
Electrical.
6.3 Cable shall enter the terminal chamber through flame proof compression type cable
glands. From the terminal to the main enclosure, the connection shall be made through
proper bushings. Direct entry of external cables into the main enclosure shall not be
accepted.
6.4 An additional earthing terminal inside the terminal chamber shall be provided.
6.5 Switch socket, plug and cable glands must be certified by the Central Mining Research
Institute, Dhanbad or any other statutory authority for use in the specified hazardous
area.
6.6 Further interlocking shall be provided so that the contacts cannot be energised when the
plug and socket are separated.
Makes of all components shall be subject to owner’s / consultant’s approval

7.1 Air Break Switches
7.1.1 The switches shall be quick make, quick break rotary type and of utilisation category AC-
23 as per IS/IEC:60947.
7.1.2 Switches shall be hand operated from outside the cover. The switch handle shall remain
fixed to the front cover while removing the front cover.
7.2 H.R.C. Fuses

7.2.1 The sockets shall be provided with link type HRC fuses.
7.2.2 The fuses shall be capable of withstanding a short circuit current of 50 KA and shall be
delayed action type conforming to IS: 13703. These shall be mounted on a shrouded
base.
7.3 Socket Outlets

0
7.3.1 The socket outlet shall be located in the lower part of the enclosure and shall be
provided with a threaded aluminium cover attached to the body with G.I. chain, to protect
the socket after extraction of the plug. Spring loaded automatic shutter shall not be
acceptable.
7.3.2 The socket contacts shall maintain satisfactory spring pressure and contact with the
corresponding plug under normal service conditions.
7.3.3 The socket contacts shall be sunk well below the surface of the socket- outlets so as to
make it impossible to be touched unintentionally.
7.3.4 An earthing contact shall be provided in the socket outlet which shall ensure making and
breaking respectively of its contact with the earthing pin of the plug before and after
making and breaking of the corresponding current carrying contacts.
7.4 Plugs
7.4.1 The plugs shall be so constructed so that these can be easily fitted in to the socket
outlets.
7.4.2 These shall be provided with knurled knob arrangement for screwing on the body of the
socket so that it can be securely fixed on the top.
7.4.3 The plug base and cover shall be firmly secured to each other and shall be sufficiently
robust in construction to withstand normal usage.
7.4.4 The plug pins shall preferably be of single part. The earthing pin shall be slotted with a
single slot and shall be larger in dimension than other pins.
7.4.5 The plug and socket contacts shall be self aligning type with best electrical continuity.
7.4.6 The plug shall be provided with dust proof cable entry suitable for receiving TRS flexible
heavy duty copper conductor cable of specified size. The arrangement shall be such that
the conductors are relieved from strain including twisting where they are connected to
the terminals and that the outer surface of the cable at the place of entry is not
damaged.
7.4.7 Insulating barriers forming an integral part of the plug shall ensure separation of metals
and bare flexible conductors at different potentials.
7.5 Cable Termination

7.5.1 Switch socket shall have cable termination arrangement on the upper part of the housing
and shall be provided with side entries, one on either side, through heavy duty double
compression type rolled aluminium cable glands suitable for 1.1 KV grade PVC insulated
armoured and PVC sheathed cables of size.
7.5.2 The terminal blocks shall be pressure clamp type for switch socket rated up to 63A and
bolted lug type for higher ratings. The terminals shall be rated for at least 1.5 times the
switch rating.
8.0 PAINTING
paint followed by two coats of anti-corrosive paint.

0
8.4 The finishing shade shall be light grey shade no.631 as per IS: 5, unless specified
otherwise.
9.1 The switch sockets and plugs shall be subjected to routine tests as per IS-4160 and
other relevant standards.
9.2 Wherever specified, additional tests shall be carried out on one switch socket and plug
of each rating.
9.3 The tests shall be carried out in the manufacturer’s works in the presence of purchaser’s
representative. In addition to the above tests, the equipment shall be subject to stage
inspection at works and inspection at site for final acceptance.
specified.
10.2 All drawings and documents shall have the following descriptions written boldly.
- Name of client
11.0 PACKING
11.1 The switch socket and plug shall be properly packed to safeguard against weather
conditions and handling during transit. It shall be wrapped in polythene bags and an
additional wrapping of bitumen paper shall also be provided to make it completely water
proof before the equipment is packed in wooden crates.
manual.
12.0 SPARES

offer.

0
13.0 DEVIATIONS
reasoning.

0
ANNEXURE – I
DOCUMENTATION FOR INTERLOCKING SWITCH SOCKET AND PLUG
Sl.No. Description
3. General arrangement and foundation N Y Y
drawing
4. Schematic / wiring diagram N Y Y
5. Illustrative and descriptive literature N N Y
6. Catalogue for bought out accessories N N Y
7. Installation operation and maintenance N N Y
manual
a) Type N N Y
b) Routine N N Y
9. Guarantee Certificate N N Y
10. Certificate of flameproofness from N N Y
statutory testing authority wherever
applicable.
Note:
the date of LOI.
coated folder.
Y - Yes, N - No

0
TECHNICAL SPECIFICATION - BATTERY CHARGER Document No. Rev
(PC150-TS-0813) Sheet 1 of 13
BATTERY CHARGER

0
(PC150-TS-0813) Sheet 2 of 13
CONTENTS
SECTION DESCRIPTION
NUMBER
1.0 SCOPE
7.0 ACCESSORIES
8.0 PAINTING
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I REQUIREMENT OF PROTECTIONS, METERING, CONTROL AND

INDICATIONS / ANNUNCIATIONS FOR BATTERY CHARGER
ANNEXURE - II DOCUMENTATION FOR BATTERY CHARGER

0
(PC150-TS-0813) Sheet 3 of 13
1.0 SCOPE
works and delivery in well packed condition of Battery Charger Units.
Electrical.
2.1 The design, manufacture and testing of the equipment covered by this specification
shall comply with the latest issue of IS: 8623 Specification for low voltage switchgear
and control gear assemblies and other relevant Indian Standards, unless otherwise
specified. Equipment complying with equivalent IEC standards shall also be acceptable.
2.2 The design and operational features of the equipment shall also comply with provisions
of the latest issue of the Indian electricity Rules and other relevant Statutory Acts and
Regulations. The supplier shall, wherever necessary, make suitable modifications to
comply with the above.
3.2 System Details
4.1 The Battery Charger Unit and its components shall be suitable for operating at the
specified rating continuously with the specified voltage and frequency variations under
the ambient conditions without exceeding the temperature rise limits specified in
relevant standards and without any detrimental effect on any part.
4.2 The battery charger board shall consist of two units as follows:
(a) Float cum load cum -- To supply continuous load and keep the
Boost Charger battery in state in float mode. In Boost mode,
for Initial charging of Battery and after power
restoration subsequent to failure, to recharge
the battery while simultaneously supplying load
current.
(b) A stand by unit for (a) above.
4.3 The rated voltage of the float charger for lead acid battery shall be 2.2 Volt/ Cell and
final charging voltage of the boost charger shall be 2.75 Volt/ Cell. The rated voltage of
the float charger for Ni-Cd shall be minimum 1.4 Volt/ Cell and final charging voltage of
the boost charger shall be minimum 1.7 Volt/ Cell. The rated output voltage of the
charger under 4.2 (a) above shall be adjustable by ± 5% of the rated value manually.

0
(PC150-TS-0813) Sheet 4 of 13
4.4 Charging unit stated under 4.2 (a) above shall be fully automatic using silicon controlled
rectifiers (SCR) common for Float and Boost service. Charger D.C. output voltage shall
be maintained within  2% irrespective of the input supply variations and load variation
of 0 to 100% by closed loop voltage feed back control system. The charger shall be
provided with current limit feature.
4.5 The output voltage of the float charger shall be monitored and in case voltage falls
below 90% of the rated voltage the stand by charger shall be automatically switched
‘ON’ with audio-visual alarm and annunciation. Time delay features shall be
incorporated to avoid spurious changeover.
4.6 Boost charging shall be achieved through the same silicon controlled rectifier (SCR)
which shall regulate the charger output automatically by current control closed loop
system. Provision for manual adjustment of charger output shall also be made. Charger
shall maintain its output current constant at starting rate/ finishing rate of battery
charging current irrespective of variation in input supply and battery condition.
4.7 Transfer from float charging to boost charging and vice versa shall be automatic as per
the battery charge condition.
4.8 During boost charging operation, arrangement shall be made so that DC power to load
is not interrupted even if AC power fails during this operation. During Boost charge
period, battery backup to load shall be arranged by a tapping from suitable point of the
battery.
4.9 Suitable dropper diodes shall be provided to reduce the voltage across the load to
105% of the rated voltage at rated load current. When power supply to the charger fails,
the dropper diodes shall be by-passed automatically through contactor so that full
battery output voltage is available to the load.
4.10 Provision of suitable filters shall be made so that the ripple in output voltage shall not
exceed 3% and 10% for float and boost charger respectively.
4.11 It shall be ensured that during boost charging, no over/under charging of cells takes
place.
4.12 All the automatic features specified above shall also have provision of manual
arrangement for control of charging rates and transfer from one charger to others.
4.13 Charger unit shall be provided with all required indication, metering, protection, control
and alarm annunciation devices for safe and reliable operation and shall include at least
as indicated in Annexure-I.
5.1 Each of the charger units shall be housed in separate metal clad cubicles of identical
size suitable for floor mounting and arranged to form a compact switchboard.
5.2 The complete assembly shall be dust, damp and vermin proof type equivalent to IP-43
as per IS/IEC:60947. In case it is necessary to provide openings for ventilation, these
shall be closed from inside by fine wire mesh. Forced ventilated panel shall not be
acceptable.
5.3 The frame work of cubicles shall be of bolted/welded construction, fabricated out of cold
rolled sheet steel of not less than 2 mm thickness. The thickness of base channel shall
not be less than 3 mm, suitable reinforcement, wherever necessary, shall be provided.

0
(PC150-TS-0813) Sheet 5 of 13
5.4 Hinged doors shall be provided on both the front and back side for easy access. The
door hinges shall be concealed type.
5.5 The doors and the removable covers shall be provided with non-deteriorating neoprene
position in groove in shaped steel work or these shall be ‘U’ type. Only one joint per
gasket shall be permitted. Adhesive cement, if used, shall be of good quality so that the
gaskets do not come off during service.
5.6 The mounting of the components shall be such that these are accessible for checking
and replacement without the necessity of removing the adjacent ones, at the same time
ensuring necessary degree of safety.
5.7 It shall be possible to carry out maintenance of one charger when the other is in
operation.
5.8 The meters, switches and lamps shall be flush mounted type. All components of one
unit shall be mounted on the same unit.
5.9 All the live parts shall be insulated. Parts which can not be insulated shall be provided
with insulating barriers. These barriers shall provide shielding of all live parts to prevent
accidental contact when the door is open. However, for the parts requiring handling
normally, such as fuses/lamps etc., separate barriers shall be provided. The barriers in
all cases shall cover the cable lug portions and shall be firmly secured, stable and
durable. It shall, however, be possible to remove such barriers, if required.
5.10 At the equipment termination points, insulated phase barriers, PVC bolt caps, PVC
hoses or insulating ribs shall be provided.
5.11 The outgoing terminal blocks shall be shrouded type or provided with insulating barriers.
5.12 Adequate arrangement for earthing shall be provided to safeguard the Operator or other
5.13 Clearances and Creepage
The clearances and creepage distances shall not be lower than the values specified
below:
i) Minimum clearance between two live parts : 20 mm
ii) Minimum clearance between a live part & earth : 20 mm
iii) Minimum creepage distance : 28 mm
5.14 Insulation
5.14.1 The insulation used shall be non-hygroscopic and may be of porcelain, epoxy resin or
glass fibre moulded with plastic. It shall be of adequate electrical and mechanical
strength to give trouble free service during normal operation and short circuit conditions.
atmospheric pollution as specified.
5.15 Wiring
5.15.1 The switch board shall be completely factory wired and ready for external connections.

0
(PC150-TS-0813) Sheet 6 of 13
5.15.2 The wiring shall be complete in all respect so as to ensure proper functioning of control,
protection, interlocking and measurement.
cables of 1100 V grade of minimum 1.5 Sq.mm size.
5.15.4 All wiring shall be marked with dependent both ends marking as per IS: 5578.
for easy identification. These shall be interlocking type plastic ferrules.
5.15.5 The control cables shall be neatly arranged and properly supported on PVC wiring
channel.
5.16 Cable Termination
5.16.1 The boards shall be designed for bottom entry of the power and control cables.
Sufficient space shall be provided for ease of connection and termination of cable.
5.16.2 Provision for receiving one 415 V, 3 phase 4 wire incoming supply lines, one for each
charger shall be made. However, DC output for battery and load shall be looped inside
the panel and only one outgoing supply each for battery and load shall be provided.
5.16.3 The termination of cables shall be done through cable glands which shall be suitable for
the cables.
5.16.4 Heavy duty double compression type rolled Aluminium cable glands shall be provided.
The cable glands shall be mounted on a removable gland plate, provided at a minimum
height of 75 mm from the bottom of the switchboard. Two spare knockouts of size 20
mm shall also be provided on the gland plate for future addition of control cables.
5.16.5 For all power cables, crimped type cable lugs of same material as of conductor shall be
provided.
5.16.6 The internal power wiring shall be terminated in the terminal blocks for connection to the
outgoing cables, These terminal blocks shall be pressure clamp type up to 35 Sq.mm,
cable and bolted lug type for higher sizes of cables, These shall be protected type and
rated for 1100 V service. The minimum current rating of terminal block shall be 16 Amp.
The construction shall be such that after the connection of cables by means of lugs,
necessary clearances and creepage distances are available.
5.16.7 Not more than two wires shall be connected to any terminal. If necessary a number of
terminals shall be jumpered together to provide wiring points.
5.16.8 Wherever necessary, suitable clamps to support the vertical run of cables shall be
provided.
5.16.9 The terminal blocks shall be grouped according to circuit functions and suitably
5.16.10 For power connection, suitable marking on the terminals shall be provided to identify the
phases.
5.17 Earth Bus
5.17.1 A continuous earth bus of Aluminium of suitable size minimum 32 x 6 mm shall be run
all over the length in the lower part of the board with two ends connected to the external
earth terminals of the board.
6.1 Rectifier Transformer

0
(PC150-TS-0813) Sheet 7 of 13
This shall be double wound, air cooled, 3 phase type. Class ‘F’ insulating materials shall
be used, with temperature rise limited to Class ‘B’. The windings shall be vacuum
impregnated.
6.2 Thyristors and Diodes
The thyristors and diodes shall be properly selected to have adequate safety margin. A
factor of safety of minimum 4 shall be taken for voltage surges and 2 for current ratings.
The thyristors and diodes shall be mounted on their respective heat sinks which shall
preferably be made of extruded Aluminium properly machined and providing intimate
contact with the stud for heat dissipation. Each thyristor/ diode shall be protected with
properly designed snubber circuit.
6.3 Air Break Switches
The switches shall be heavy duty quick make, quick break type conforming to IS/IEC
60947. Switches shall be snap action rotary type. ‘ON’-‘OFF’ position of the switch shall
be boldly indicated. The handle of switches shall remain fastened to the door even
when the door is opened after turning the switch ‘OFF’. The AC input switch shall not be
directly mounted on the door.
6.4 Fuses
For protection of thyristors/ diodes, semi-conductor fuses shall be provided. All other
fuses shall be HRC cartridge link type. They shall be suitable for the load and service
required.
6.5 Contactors
The contactor shall be air break type of category AC-3/ DC-1 as per IS/IEC 60947. DC
contactor shall be provided with arc chutes and magnetic blow out coil. The contactors
shall not drop out even when the coil voltage drops to 65% of rated voltage.
6.6 Thermal Overload Relays
Adjustable bimetal thermal overload relays shall be provided. The bimetal relays shall
be ambient temperature compensated. The thermal relays shall be provided with a
manual resetting device on the door.
6.7 All ammeters and voltmeters shall be class 1.5 as per IS 1248 and shall be flush
mounted type of minimum size 96 x 96 mm. Ammeters and Voltmeters for A.C. service
shall be of moving iron type and that for D.C. service shall be moving iron or moving coil
type. Zero adjuster shall be provided for operation from the front of the cases.
6.8 Printed Circuit Boards (PCBs)
The PCBs shall conform to IS 7405. These shall be of fibre or epoxy glass moulded of
minimum thickness 1.5 mm and shall have gold plated contacts and silver or nickel
plated tracks. All PCBs shall be of plug-in type contained in a dust proof box. PCBs
shall be self diagnostic type and shall be provided with status indication. Metering points
shall be provided on each PCB and the PCBs shall be clamped in position so that
vibration or long usage does not result in loose contacts.
6.9 Timers

0
(PC150-TS-0813) Sheet 8 of 13
The timers shall be electronic, pneumatic or synchronous type conforming to IS:

5834 with manual/auto reset features as per the functional requirements. The repeat
accuracy shall be within 5%.
6.10 Control and Selector Switches
6.10.1 All the control and selector switches shall be of rotary type with thermal utilization
category of AC 11 or DC 11 as per IS/IEC:60947.
6.10.2 The control switches shall be spring return type and provided with pistol grip type
handles.
6.10.3 The selector switches shall be stay-put type and provided with oval handle.
6.11 Signal Lamps
6.11.1 Signal lamps shall be provided to indicate the various circuit conditions and these shall
be placed at a suitable height. The colour of the lamps for various functions shall be as
follows:
Red -- Circuit ‘ON’
Green -- Circuit ‘OFF’
Amber -- Alarm and auto trip.
6.11.2 The lamps shall be LED type having lumen output of 200 millicandella in axial direction.
6.12 Audio Visual Alarm Annunciation
6.12.1 A solid state audio-visual alarm annunciation system shall be provided for the board.
Audible annunciation shall be provided by means of hooter with provision of remote
alarm and acknowledgment. Visual annunciation shall be provided by flashing of the
respective facia window. The facia window shall have translucent glass or plastic cover
with inscription in black letters. Each facia window shall be provided with two lamps
connected in parallel. The cover plate of the facia window shall be flush with the panel
and shall be capable of easy removal to facilitate replacement of lamps.
6.12.2 The following operating sequence shall be adopted for audio visual alarm and
indication:
System Condition Visual Signal Audible Signal
Normal OFF OFF

Abnormal Flashing ON
Acknowledge Steady ON OFF
Return to normal OFF OFF
Test Steady ON ON
7.0 ACCESSORIES
7.1 The supply shall include the following accessories:
7.1.1 Space Heater

Each cubicle of the board shall be provided with a thermostatically controlled space
heater, rated for 240 V, 50 Hz and controlled through double pole miniature circuit
breaker. The space heater supply shall be tapped from incomer power supply.
7.1.2 Name Plates

0
(PC150-TS-0813) Sheet 9 of 13
7.1.2.1 The board shall have a large name plate on the top to indicate its name and
designation.
7.1.2.2 Each cubicle shall be provided with a name plate.
7.1.2.3 All control switches, push buttons, lamps etc. shall have function identification labels.
7.1.2.4 Name plate shall be of black perspex with white engraving of minimum 3 mm
thickness.
7.1.3 Fuse Puller
7.2 Any other accessories required but not specified shall also be supplied to make the
board complete in all respects and ensure its safe and proper operation.
8.0 PAINTING
paint followed by two coats of anti-corrosive paint.
8.4 Unless otherwise specified the finishing shade shall be light grey having Shade No. 631
as per IS 5.
9.1 The board shall be subjected to routine tests as per IS 8623 and other relevant
standards. Heat run test, if required, shall be carried out.
9.2 Additional tests, wherever specified shall be carried out on one board of each rating.
9.4 These inspections shall however, not absolve the vendor from his responsibility for
10.1 Drawings and documents as per Annexure-II shall be supplied unless otherwise
specified.
- Name of client
11.0 SPARES

0
(PC150-TS-0813) Sheet 10 of 13

offer.
12.0 PACKING
manual along with one set of drawings.
the equipment.
13.0 DEVIATIONS
reasoning.

0
(PC150-TS-0813) Sheet 11 of 13
ANNEXURE - I
REQUIREMENT OF PROTECTIONS, METERING, CONTROL AND INDICATIONS /
ANNUNCIATIONS FOR BATTERY CHARGER
To be mounted on
Sl. No. Description Float cum Standby Float cum Boost
Load Charger Load Charger Charger
1 2 3 4 5
1. A.C. Input Side
i) ON/OFF Switch Yes Yes Yes
ii) HRC Fuses Yes Yes Yes
iii) Contactor Yes Yes Yes
iv) Thermal O/L Relay Yes Yes Yes
v) Single phasing and Phase Yes Yes Yes
Reversal
vi) Voltmeter with SS
Yes Yes Yes
vii) Ammeter with SS
Yes Yes Yes
viii) Signal Lamp (ON/OFF)
Yes Yes Yes
2. Rectifiers
i) Semiconductor fuses Yes Yes Yes
ii) Filters with fuses Yes Yes Yes
iii) Surge Suppressors Yes Yes Yes
3. DC Output Side
i) ON/OFF Switch Yes Yes Yes
ii) HRC Fuses Yes Yes Yes
iii) Blocking Diodes Yes Yes Yes
iv) Voltmeter Yes Yes Yes
v) Ammeter Yes Yes Yes
vi) Signal Lamp (ON/OFF) Yes Yes Yes
viii) Charging Ammeter (on Yes Yes Yes
demand type)

0
(PC150-TS-0813) Sheet 12 of 13
To be mounted on
Sl.
Description Float cum Load Standby Float cum Boost Charger
No.
Charger Load Charger
1 2 3 4 5
4. Common Items
i) Droper Diodes Yes
ii) Solid State facia Yes Yes Yes
annunciator for :
-- Automatic changeover
from one charger to
another
-- Rectifier fuse failure in
float/standby float/boost
-- Incoming supply failure
float/standby float/boost
-- DC output under voltage
-- Earth fault
-- Single phasing and phase
reversal
-- Filter fuse failure float/
standby float/boost
iii) Battery isolating switch Yes

and HRC fuses
iv) Battery under voltage relay Yes
v) Battery earth fault relay Yes
vi) DC Contactor Yes
NOTE: Any other components as required for satisfactory operation of the battery charger shall
be provided.

0
(PC150-TS-0813) Sheet 13 of 13
ANNEXURE - II
DOCUMENTATION FOR BATTERY CHARGER
Sl.No. Description
3. General arrangement drawings N Y Y
showing overall dimensions of the
charger board and mounting details of
various equipment inside the charger
panel
4. Foundation plan indicating certified N Y Y
dimensions, floor openings, weight,
clearance etc.
5. Schematic and Wiring Diagrams N Y Y
6. Descriptive literature of the charger and N N Y
various components mounted in the
panel.
7. Characteristics curves for the charger N N Y
and all other static and control devices,
relays etc.
8. Installation, Operation and N N Y
Maintenance manual
Note:
the date of LOI.
coated folder.
Y - Yes, N - No

PC150/E/4004/SecVI-5.3
(PART-A)
TECHNICAL SPECIFICATION – BATTERY (PC150-TS-0814)
Sheet 1 of 6
BATTERY

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 2 of 6
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
6.0 ACCESSORIES
9.0 SPARES
10.0 PACKING
11.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR BATTERY

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 3 of 6
1.0 SCOPE
works and despatch in well packed condition of batteries and accessories.
1.2 This standard shall be read in conjunction with the relevant part of Design Philosophy -
Electrical.
2.1 The design, manufacture and testing of the battery shall conform to the latest issue of
the following standards:
IS: 1651 -- Stationary cells & batteries, lead-acid type (with tubular positive
plate)
IS: 1652 -- Stationary cells & batteries, lead-acid type with plante positive
plates.
IS: 10918 -- Vented type nickel cadmium batteries
All accessories shall also conform to the relevant Indian Standard. Equipment
Standard specifications, the requirement specified herein shall prevail.
3.2 System Details
The battery shall be able to deliver rated ampere hours when discharged at the 10
hours rate of discharge to a final voltage of 1.85 V per cell for Lead Acid and at the 5
hours rate of discharge to a final voltage of 1.1 V per cell for Ni-Cd battery under the
ambient conditions indicated in Design Philosophy - Electrical.
5.1 The battery shall be of lead acid plante type and rated for 220V. Each battery bank shall
consist of 110 number of cells.
5.2 Each cell shall be contained in a closed top container preferably transparent and
unbreakable and shall incorporate positive plates, negative plates and separators of
adequate dimensions. Lead acid battery shall be of plante plate type (positive plate).

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 4 of 6
5.3 The battery bank shall be complete with all necessary components such as lids, plugs,
separators and buffers, inter-cell connectors, lead coated bolts and nuts, cell insulators
etc.
5.4 The required quantity of electrolyte plus 10% extra quantity shall be supplied in suitable
non-returnable containers along with the battery.
6.0 ACCESSORIES
The following accessories shall be supplied with each battery bank:-
(a) 1 Set -- Battery Stand constructed out of teak wood without the use of
any metal fastenings and coated with 3 coats of anti-acid paint.
The stand shall be properly designed so that each cell shall be
easily accessible for inspection, topping up etc. However, for
Ni-Cd battery mild steel stand with alkali resistant paint may
also be accepted
(b) 1 Set -- Inter-row, inter-tier and inter-stand connectors and takeoffs.
These shall be sized suitably to have adequate current carrying
capacity and mechanical strength
(c) 1 Set -- Cell Insulators
(d) 1 Set -- Stand Insulators
(e) 1 No. -- Centre zero cell testing voltmeter scaled 3-0-3 volts
(f) 2 Nos. -- Syringe type Hydrometers for measuring the specific gravity of
the electrolyte
(g) 2 Nos. -- Gravity correction thermometers, mercury-in-glass type
(h) 1 Set -- Connecting bolt wrenches
(i) 1 No. -- Rubber syringe for tapping cells
(j) 1 No. -- Wall mounting type teak wood holder for Hydrometer and
Thermometer.
(k) 1 No. -- Acid/Alkali resisting funnel.
(l) 1 No. -- Acid/Alkali resisting jug.
(m) 1 Pair -- Rubber gloves.
(n) 1 No. -- Rubber Apron.
All other accessories, not specified above, but required for satisfactory operation and
maintenance shall also be supplied.
7.1 Type tests shall be carried out as per relevant standards on two cells in the presence of
Purchaser’s representative.
7.2 Acceptance tests shall be carried out as per relevant standards on each cell after
installation at site.
7.3 In addition, the battery shall be subjected to stage inspection at works and inspection at
site for final acceptance.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 5 of 6
7.4 These inspections shall, however, not absolve the vendor from his responsibilities for
8.1 Drawings and documents as per Annexure-I shall be furnished by the Vendor unless
otherwise specified.
8.2 All drawings and documents shall have following description written boldly:
- Name of client
9.0 SPARES
9.1 Any other spare parts required, but not specified, shall also be quoted.
10.0 PACKING
The battery cells and accessories shall be properly packed to safeguard against
weather conditions and rough handling. It shall be wrapped in polythene bags with an
additional wrapping bitumen paper to make it completely water proof before it is packed
in crates. The packing box shall contain a copy of the installation operation and
maintenance manual.
11.0 DEVIATIONS
reasoning.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 6 of 6
ANNEXURE – I
DOCUMENTATION FOR BATTERY
Sl. No. Description
3. Dimensional drawings showing the N Y Y

cell arrangement on stand (Plan,
front and side elevation) for each
type of battery.

giving the complete details of
construction of battery
5. Operation and maintenance N N Y

instructions
-- Type N N N
-- Acceptance N N Y
8. Spare Parts lists N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N - No

PC150/E/4004/SecVI-5.3
(PART-A)
TECHNICAL SPECIFICATION - CABLES (PC150-TS-0815)
Sheet 1 of 7
CABLES

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 2 of 7
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
6.0 SPECIAL PURPOSE CABLES
7.0 CABLE DRUM
10.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR CABLES

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 3 of 7
1.0 SCOPE
works and dispatch in well packed condition of power and control cables.
Electrical and other relevant references as specified therein.
2.1 The design, manufacture and testing of cables covered by this standard shall comply
with the latest issue of following Indian Standards, unless otherwise specified.
IS: 1554 Part (I) -- PVC insulated (heavy duty) electric cables for working
voltages upto and including 1100 volts.
IS: 1554 Part (II) -- PVC insulated (heavy duty) electric cables for working
voltages from 3.3 KV upto and including 11 KV.
IS: 7098 Part (I) -- Cross linked polyethylene insulated PVC sheathed cables
for working voltages upto and including 1100 volts.
IS: 7098 Part (II) -- Cross linked polyethylene insulated PVC sheathed cables
for working voltages from 3.3 KV upto and including 33 KV
IS: 694 -- PVC insulated cables for working voltages upto and
including 1100 volts
IS: 5831 -- PVC insulation and sheath of electric cables
2.2 The design and operational features of the cables offered shall also comply with the
provisions of latest issue of the Indian Electricity Rules and other relevant Statutory
Rules & Regulations. The supplier shall, whenever necessary, make suitable
modification in the cables to comply with the above mentioned rules.
These shall be as indicated elsewhere in Design Philosophy - Electrical.
3.2 System Details
The cables shall be suitable for operating continuously at the rated capacity as specified
in relevant I.S. under the ambient conditions without exceeding the permissible
temperature rise and without any detrimental effect on any part.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 4 of 7
5.1 The design, manufacture and workmanship of cables shall be in accordance with the
latest practice.
5.2 All materials to be used shall be new, unused and of the best quality.
5.3 Conductors
The power cables shall be of stranded Aluminium / copper round or shaped conductors
and control cables shall be of annealed high conductivity stranded copper round
conductors. The conductors shall comply with the requirements of IS: 8130.
5.4 Insulation
The conductor insulation shall be XLPE and shall comply with relevant IS.
5.5 Fillers
The cables shall have suitable fillers wherever required, laid up with conductors to
provide substantially circular cross section before the inner sheath is applied.
5.6 Inner Sheath
Inner sheath, wherever applicable shall be ST1/ ST2 type compound applied by
extrusion process except for paper cables for which it shall be of lead or lead alloy.
5.7 Armouring
All power and control cables shall be armoured. The single core cables shall be
armoured with hard drawn Aluminium taps/ wires or any other suitable nonmagnetic
material. All other cables shall have galvanized steel wire / strip armouring.
5.8 Outer Sheath
The outer sheath shall be ST1/ ST2 type compound applied by extrusion process and
suitable to withstand atmospheric pollution, resistance to termites, fire retardant and
coloured black.
5.9 Screening
Screening over conductor and insulation shall be provided as per relevant standard
unless specified otherwise. The screening for control cables if specified shall be of
aluminium, mylor or equivalent and provided with tinned drain wire which shall be
continuous and permanently connected to the screen.
5.10 Identification
The individual cores of cables shall be coloured as per relevant IS. Where it is not
possible to distinguish the cores by colour, coloured strip shall be applied on the cores
or core nos. shall be marked on each core at regular intervals. All cables shall carry the
manufacturer’s name or trade mark, the cable size, voltage rating and year of
manufacture at intervals not exceeding 100 meters. Running meter markings shall also
be provided throughout the length of the cable.
5.11 Dimension
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 5 of 7
The overall dia. and dia. under armour of the cables shall be indicated by the vendor in
the technical particulars. These shall be guaranteed with a tolerance of ± 5% but not
exceeding 2 mm.
5.12 The cut ends of the cables shall be sealed by means of non-hygroscopic materials.
6.0 SPECIAL PURPOSE CABLES
6.1 Flame Retardant Low Smoke Cables
Flame retardant low smoke cables shall have outer sheath of PVC having following
values.
- Minimum oxygen index - 29%

- Minimum temperature index - 250ºC
- Maximum acid gas generation - 20%
- Maximum smoke density rating - 60%
6.2 Heat Resistant Cables
Heat resistant cables shall be of silicon rubber insulated laid circular with asbestos
worming and overall glass fibre braided and varnished. Silicon rubber insulating
compound shall conform to IS: 6380 and the constructional features shall conform
generally to IS: 9968.
7.0 CABLE DRUM
7.1 The cables shall be supplied in non-returnable wooden drums (or steel drums if
specified) of heavy construction. The wood used for construction of the drums shall be
properly seasoned, sound and free from defects.
7.2 Cables shall be supplied in specified drum lengths. Where no such indication is given,
standard drum lengths may be offered.
7.3 The tolerance on each drum of cable shall not exceed ± 2.5%. However, no negative
tolerance on HV cables is acceptable.
7.4 All cable drums shall have stencilled data as per relevant IS as well as the purchaser’s
order no., item no. & drum no.
8.1 The following tests shall be carried out on the cables as per relevant IS.
i) Routine Tests - On all cables

ii) Acceptance tests - On representative length of each size
iii) Type tests - Wherever specified on one cable drum of each size
8.2 In addition, the following tests shall be carried out on all fire retardant low smoke cables
as per IS or as per the following standards:
i) Oxygen and temperature index test as per ASTM-D-2863

ii) Acid gas emission test as per IEC-754 Part-I

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 6 of 7
iii) Smoke density test as per ASTM-D-2843

iv) Flammability test as per IEC-332 Part-I or IS-10810
representative. In addition, the cables shall be subjected to stage inspection at works
8.4 These tests and inspections shall, however, not absolve the vendor from their
responsibility for making good any defect which may be noticed subsequently.
specified.
- Name of client
10.0 DEVIATIONS
reasoning.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 7 of 7
ANNEXURE - I
DOCUMENTATION FOR CABLES

4. Installation, Termination and Jointing N N Y

Instructions
a) Routine N N Y
b) Type N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N - No

0
TECHNICAL SPECIFICATION - LOCAL CONTROL STATION Document No. Rev
(PC150-TS-0817) Sheet 1 of 9
LOCAL CONTROL STATION

0
(PC150-TS-0817) Sheet 2 of 9
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0
SCOPE
5.0 GENERAL DESIGN & CONSTRUCTIONAL FEATURES
6.0 SPECIAL FEATURES FOR FLAMEPROOF LOCAL CONTROL STATION
8.0 PAINTING
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR LOCAL CONTROL STATIONS

0
(PC150-TS-0817) Sheet 3 of 9
1.0 SCOPE
works and delivery in well-packed condition of Local Control Stations.
Electrical and other relevant references as specified therein.
comply with the latest issue of IS/IEC:60947 and other relevant Indian Standards,
unless otherwise specified. Equipment complying with equivalent IEC standards shall
also be acceptable.
2.2 The design and operational features of the equipment offered shall also comply with
the provisions of latest issue of the Indian Electricity rules and other relevant statutory
Acts and Regulations. The supplier shall, wherever necessary, make suitable
modification in the equipment to comply with the above.
2.3 Wherever any requirement, laid down in this standard differs from that in Indian
3.2 System Details
This equipment and associated components shall be suitable for operating

satisfactorily under the specified ambient and system conditions.
5.1 The Control Stations shall be suitable for control voltage not exceeding 500V, 50 Hz
AC or 220V D.C.
5.2 The enclosure shall be of die cast Aluminium alloy LM-6. As an alternative to cast
Aluminium, fibre glass enclosure is also acceptable.
5.3 The equipment shall have dust, hose and weather proof construction equivalent to
IPW-55 as per IS/IEC:60947. These shall be suitable for outdoor location without any
additional protection or cover.
5.4 A rain-hood shall be offered as an additional item. It shall be made of 14 gauge

Aluminium sheet bent to shape. In case of fibre glass enclosure, these can be made of
fibre glass.

0
(PC150-TS-0817) Sheet 4 of 9
5.5 All external hardware of diameter less than 8 mm shall be of stainless steel and those
of diameter 8 mm and above shall be of mild steel cadmium plated or zinc passivated.
For fibre glass enclosure Nylon PVC bolts of diameter 8 mm may be used.
5.6 The control station shall preferably be with bolted cover. The bolts for retaining the
cover in position shall be provided with 10 mm dia. stainless steel and these shall be
so arranged that they do not pierce into the door gasket.
5.7 All the components shall be mounted on a base plate inside the enclosure. Necessary
actuating system for control switch, push button, non yellowing acrylic/ glass cover for
ammeter and indication lamps shall be provided on the front cover. No wiring shall be
carried out on the front cover.
5.8 The layout of components in the control station shall be liberal and standardised.
5.9 All mating surfaces shall be smoothly machined and shall be of sufficient width of at
least 6 mm. The covers shall be provided with continuous gasket made of neoprene or
synthetic rubber to prevent ingress of dust and moisture. The gasket shall be held in
position in groove provided in the enclosure and shall be pressed all around uniformly
by suitably shaped projection of the door. Gaskets simply glued to the surface are not
acceptable.
5.10 The enclosure shall be suitable for mounting on wall or on steel structure. 4 Nos. holes
suitable for 12 mm bolts shall be provided outside the enclosure for fixing the control
stations.
5.11 The internal wiring shall be carried by means of single core PVC insulated 1.5 sq. mm
stranded copper conductor cable. All termination shall be made with crimping type
proper size lugs and shall be properly ferruled.
5.12 The control stations shall be completely factory wired and ready for external cable
connection.
5.13 For easy identification, numbering ferrules shall be provided on all wiring at both ends
i.e. equipment end and terminal block end. Terminals for external wiring shall be
numbered
5.14 The enclosure shall be provided with two earthing terminals with studs of 8 mm. dia.
projecting outside the enclosure for connection to earth. These terminals shall not
pierce through the enclosure and shall be marked with earthing symbol.
5.15 Each control station shall be provided with minimum 2 mm thick stainless steel name
plates or consisting of black Perspex with white engraving indicating the code number
and description of the equipment controlled by it. Similar labels shall be provided for all
indication lamps, push buttons and control switches. The name plate and label shall be
fixed with screws only.
6.0 SPECIAL FEATURES FOR FLAME PROOF LOCAL CONTROL STATION
6.1 The enclosure shall be in addition, of flameproof execution as per IS: 2148.
6.2 The control stations shall be suitable for hazardous area of enclosure group and
temperature class as indicated in Design Philosophy - Electrical.
6.3 Cables shall enter the terminal box through flame proof cable gland. From the terminal
chamber to the main enclosure, the connections shall be made through proper

0
(PC150-TS-0817) Sheet 5 of 9
bushings. Direct entry of external cables into the main enclosure shall not be accepted.
All entries shall be provided with stainless steel inserts.
6.5 Local control stations and cable gland must be certified by the Central Mining
Research Institute, Dhanbad or any other statutory authority for use in the specified
hazardous area.
7.1 Trip-Neutral-Close Switch
TRIP-NEUTRAL-CLOSE switch shall be double pole, 3 position, pistol grip, rotary type
having self spring return feature to neutral position. The contacts shall be of phosphor
bronze and shall be provided with two breaks in series. Mechanical sequence device
to prevent two successive movements to the same position shall be fitted. The switch
shall be capable of being padlocked in the ‘TRIP’ position.
7.2 ‘Auto-Manual’ Switch
‘Auto-Manual’ switch shall be single pole stay put type having three positions “AUTO-
OFF-MANUAL”. Provision shall be made to padlock the switch in the “OFF” position.
7.3 Selector Switch / Lock Service Switch
These shall be single pole stay put type having two position with a pistol grip handle
and capable of being padlocked in one of the position.
7.4 All the switches shall be rotary type with snap or wiping action contact and having a
set of normally open and closed contacts in each position. All switches shall be
provided with pistol grip handle.
7.5 ‘Off-Auto-On’ Switch
7.5.1 ‘OFF-AUTO-ON’ switch shall be in minimum three stack configuration, each stack
having three positions with spring return from ‘ON’ to ‘Auto’ position and lockable in
‘OFF’ position by means of padlock.
7.5.2 The switch shall have sliding contact between ‘AUTO’ and ‘ON’ position. In ‘OFF’
position the contact shall be completely broken from ‘AUTO’ position.
7.6 Push Buttons
These shall be spring loaded, with a set of normally closed and open contacts. The
push buttons for ‘start’ shall be shrouded type and coloured green while ‘stop’ push
buttons shall be un-shrouded type and coloured red. Provision shall be made to
padlock the ‘stop’ push button in ‘OFF’ position. The fixing ring shall be metallic white.
An oil proof rubber cap shall preferably be provided.
7.7 The switches and push buttons shall conform to utilization category AC11/ DC11 as
per IS/IEC:60947. The contact shall be rated to make, break and carry inductive
current of 5 Amp. at 415 V AC and 1 Amp of 220V DC. The contact arrangement shall
be as shown in the terminal drawings. Built in locks instead of padlocking are not
acceptable.

0
(PC150-TS-0817) Sheet 6 of 9
7.8 Indication Lamps
7.8.1 LED type indication lamps shall be provided to indicate the various circuit conditions as
shown in the terminal drawings.
7.8.2 The LEDs shall provide good illumination through a viewing angle of 180º. The LEDs
shall have lumen output of 200 milli Candella in the axial direction.
7.8.3 The colour of the LED indication for various functions shall be as follows:-
RED : For ‘ON’ Indication
GREEN : For ‘OFF’ Indication
WHITE : For “Ready for Service” Indication
7.9 A.C. Ammeters
The ammeter shall be flush mounting, moving iron spring controlled type, of accuracy
class 1.5 as per IS:1248, with square face of minimum size 72 mm x 72 mm having
scale range 0-240º. The ammeter shall be provided with uniform scale up to CT
primary current and compressed end scale up to 6 times the CT primary current.
Adjustable red pointer shall be provided to indicate the full load current of the motors.
Zero adjusters shall be provided for operation from the front of the meter. All ammeters
shall be operated through 1Amp. CTs only.
7.10 D.C. Ammeters
The D.C. ammeter shall be shunt operated. These shall be moving coil or moving iron
type of accuracy class 1.5 as per IS: 1248.
7.11 Terminal Blocks
All control stations shall be provided with terminal blocks. Terminal blocks shall be
located at a minimum distance of 50 mm from the bottom of the enclosure. The
terminal blocks for the control station shall be suitable for conductor sizes of 2.5 mm2.
These shall be of pressure clamp type design mounted on the base channel. The
minimum rating of terminal block shall be 16 Amp.
7.12 Cable Glands
The cables for the external connections, shall enter the terminal chamber through
heavy duty double compression type rolled Aluminium cable glands suitable for 2.5 sq.
mm PVC insulated, armoured, and PVC sheathed copper conductor 1.1 KV grade
cables. The number and cores of control cables shall be as per requirement. The cable
gland shall be fitted in a threaded hole.
8.0 PAINTING
paint followed by two coats of anticorrosive paint.
handling.

0
(PC150-TS-0817) Sheet 7 of 9
8.4 Unless otherwise specified, the finishing shade shall be of light grey having shade no.
631 as per IS: 5.
9.1 All equipment shall be routine tested as per relevant standards.
representative. In addition, the equipment shall be subjected to stage inspection at
specified.
- Name of client
11.0 SPARES

offer.
12.0 PACKING
12.1 The local control stations shall be properly packed to safeguard against weather
conditions and handling during transit. It shall be wrapped in polythene bags and an
additional wrapping of bitumen paper shall also be provided to make it completely
water proof before the equipment is packed in wooden crates.
manual.

0
(PC150-TS-0817) Sheet 8 of 9
13.0 DEVIATIONS
reasoning.

0
(PC150-TS-0817) Sheet 9 of 9
ANNEXURE - I
DOCUMENTATION FOR LOCAL CONTROL STATIONS
3. General Arrangement Drawings N Y Y
4. Schematic Diagrams N Y Y
6. Catalogues of bought out accessories N N Y
8. Installation, Operation and Maintenance N N Y

manual
a) Routine N N Y
b) Type (only for flameproof equipment) N N Y
c) For enclosure N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N - No

PC150/E/4004/SecVI-5.3
(PART-A)
TECHNICAL SPECIFICATION - JUNCTION BOX (PC150-TS-0818)
Sheet 1 of 7
JUNCTION BOX
CONTENTS
PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 2 of 7
SECTION
DESCRIPTION
NUMBER
1.0
SCOPE
5.0 SPECIAL FEATURES FOR JUNCTION BOXES FOR HAZARDOUS

AREA
6.0 PAINTING
7.0 TESTS & INSPECTION
8.0 PACKING
10.0 SPARES
11.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR JUNCTION BOXES

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 3 of 7
1.0 SCOPE
1.1 This standard covers the technical requirements of design, manufacture, testing and
inspection at works and delivery in well packed condition of junction boxes.
Electrical and other relevant references as specified their in.
comply with the latest issue of relevant Indian standards unless otherwise specified.
2.2 Flameproof & increased safety junction boxes shall in addition, comply with the requirement
as laid down in IS: 2148 & IS: 6381 respectively.
2.3 The design and constructional features of the junction boxes offered shall also comply with
the provision of latest issue of the Indian Electricity Rules and other relevant Statutory
Rules & Regulations. The supplier shall, whenever necessary, make suitable modification in
the equipment to comply with the above mentioned rules.
2.4 Wherever any requirement laid down in this standard differs from that in Indian Standard
specifications, the requirement specified herein shall prevail.
3.2 System Details
The details of power supply system shall be as indicated in Design Philosophy – Electrical.

4.1 The junction boxes shall be dust and weather proof and suitable for installation outdoors
without extra protection. The degree of protection shall be IP-55 as per IS/IEC:60529.
4.2 The junction boxes shall be of die cast aluminium alloy LM-6 with domed / suspension
covers.
4.3 The casting of the junction boxes and their cover shall be pressure die cast. The casting
shall be uniform and free from blow holes. All mechanical surfaces shall be free from burrs,
dents and internal roughness.
diameter 8 mm and above shall be of mild steel cadmium plated or zinc passivated. For
fibre glass enclosure Nylon PVC bolts of diameter 8 mm may be used.
4.5 The clearances and creepage distances shall be maintained inside the junction boxes as
per relevant Indian standard.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 4 of 7
4.6 The junction boxes shall be suitable for wall / structure / ceiling mounting and necessary
arrangement for mounting the same shall be provided.
4.7 The junction boxes shall be provided with continuous gasket made of neoprene or synthetic
rubber to prevent ingress of dust. The gasket shall be held in position in groove provided in
the enclosure and shall be pressed all around uniformly by suitably shaped projection of the
door. Gaskets simply glued to the surface are not acceptable.
4.8 The junction boxes housing terminal block shall be moulded type made of DMC / Fibre
glass. Threaded terminals shall be made of brass (nickel plated or tinned) and provided
with two tightening threaded nuts and four washers all made of brass (nickel plated or
tinned). The terminals shall have two shorting links each horizontally placed connecting
three terminals.
4.9 The terminal block shall be fitted with junction boxes base by means of 2 nos. 1/2” long
nickel plated brass screws.
4.10 The junction boxes shall be provided with two nos. external earthing terminals and 1 no.
internal earthing terminal.
4.11 All live parts inside the junction boxes shall be insulated and shall withstand a test voltage
of 2.5 KV for 1 minute.
4.12 The junction boxes shall be provided with heavy duty double compression type rolled Al
cable glands to suit the cable entries.
4.13 Threaded blanking plugs shall be provided for junction boxes to plug out the entries not in
use as indicated in bill of quantities enclosed.
4.14 The junction boxes shall be provided with a blank stainless steel tag plate fastened to the
junction box top cover with two stainless steel screws. The plate shall be at least 25 mm
wide, 100 mm long and 1 mm thick.
4.15 For flameproof / increased safety junction boxes, the manufacturer shall submit copies of
test certificates from statutory authorities clearly stating that the junction boxes as well as
cable glands / blanking plugs are suitable for hazardous area.
4.16 15 Amp. Junction Box
4.16.1 The junction boxes shall be 4 way dome cover type.
4.16.2 The dimensions of the junction boxes with their cover and accessories shall be generally as
per PDS: E-547.
4.16.3 The junction boxes housing terminal block shall be moulded type made of DMC / Fibre
glass as per Drg. no. PDS: E-557.
4.17 63 Amp. Junction Box
4.17.1 The junction boxes shall be 3 / 4 way dome cover type.

4.17.2 The minimum internal diameter of the box shall be 240 mm.
5.0 SPECIAL FEATURES FOR JUNCTION BOXES FOR HAZARDOUS AREA

5.1 For increased safety junction boxes, the terminals shall be provided with positive locking
device against loosening.

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 5 of 7
5.2 The enclosure shall be in addition, of increased safety execution, Exe, as per relevant
standard and shall be suitable for installation in classified hazardous area.
5.3 The junction boxes shall be liberally dimensioned in order to avoid temperature rise inside
the enclosure which may damage the insulating materials or gaskets employed therein.
5.4 Cables shall enter the terminal box through increased safety compression type cable
glands. From the terminal chamber to the main enclosure, the connections shall be made
through proper bushings.
5.6 The junction boxes shall be provided with Brass-Nickel plated shorted links. The terminal
block shall be made of non-hygroscopic compound. Bakelite / Hylam shall not acceptable.
5.7 All screws / bolts and nuts shall be of stainless steel.
5.8 Junction boxes and cable glands must be certified by Statutory Authorities for use in the
specified hazardous area. Equipments certified by overseas authorities shall obtain
certificate of compliance / letter of opinion from respective statutory authorities.
5.9 Duly wired prototype samples for junction boxes shall be submitted for scrutiny as and
when called for.
5.10 Type Test certificates for increased safety type junction boxes and cable glands along with
blanking plugs shall be supplied.
6.0 PAINTING
6.1 Epoxy based electrostatic powder coating paint shall be provided on exterior surface while
the interior of junction boxes shall be painted with anti-condensate paint. The painting shall
be able to withstand corrosive atmosphere.
6.2 Unless otherwise specified, the finishing shade shall be grey having shade no. 632 as per
IS-5.
6.3 The terminal block of junction boxes shall be painted with Red, Yellow, Blue & Black colour
for phase indication.
7.1 The junction boxes shall be routine tested as per relevant standards.
7.2 Additional tests, wherever specified, shall be carried out on one unit of each rating.
7.3 The procedure & extent of the physical checks, routine & type test shall be governed by
Quality Assurance Plan mutually agreed and approved by Inspection Authority.
representative. In addition, the equipment shall be subjected to stage inspection at works

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 6 of 7
8.0 PACKING
Each junction box and cable gland shall be suitably packed and protected from damage due
to transportation, loading and unloading. Threaded fittings shall have plastic caps to protect
the threading.
9.1 Drawings and documents as per Annexure-I shall be supplied, unless otherwise specified.
- Name of client
- Motor Code No. and Description
10.0 SPARES

11.0 DEVIATIONS

PC150/E/4004/SecVI-5.3
(PART-A)
Sheet 7 of 7
ANNEXURE - I
DOCUMENTATION FOR JUNCTION BOXES
3. Certified dimensional drawing, including N Y Y

mounting details
4. Drawing showing constructional details N Y Y
7. FLP/Exe certificates for junction boxes and N N Y

terminals conforming to IEC/ISS (CMRI, CCE,
DGFASLI and BARC for terminals)
8. Certificate for weather proof construction for N N Y

junction boxes as per IPW-55
Note:
1. 4 hard copies & 1 soft copy shall be supplied for approval after order within 4 weeks from the
date of LOI.
2. 8 hard copies & 2 soft copies in CD shall be submitted as final documents prior to despatch of
the equipment. These shall be made in sets and supplied in fine plastic coated folder.
Y - Yes, N - No

0
TECHNICAL SPECIFICATION - ELECTRICALS FOR OVERHEAD Document No. Rev
CRANES & HOISTS (PC150-TS-0819) Sheet 1 of 11
ELECTRICALS FOR OVERHEAD CRANES & HOISTS

0
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
4.0 GENERAL DESIGN AND CONSTRUCTIONAL REQUIREMENTS
6.0 CABLES, CABLE TERMINATION AND CONNECTIONS
7.0 EARTHING
8.0 CONTROL DESK / CONTROL STATION
9.0 PAINTING
10.0 MAKE OF ELECTRICAL ITEMS
14.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR ELECTRICALS FOR OVERHEAD CRANES &

HOISTS

0
1.0 SCOPE
1.1 This standard covers the technical requirements of design, engineering, manufacture,
testing at works, supply at site, erection, site testing and commissioning of the complete
electrical equipment and accessories as required for the overhead travelling crane and
hoists.
1.2 This standard shall be read in conjunction with relevant mechanical specifications, other
relevant standards / specifications.
1.3 The scope of work shall include but not limited to the following items:
i) Drive motors
ii) Starting resistors (in case of slip ring motors)
iii) Power control panel
iv) Control stations
v) Limit switches
vi) Electromagnetic brakes
vii) Power and control cables with accessories
viii) Earthing of all equipment
ix) All other items, not specified but, required for safe and proper operation
1.4 The owner shall provide one no. medium voltage feeder for each crane / hoist and
terminate the feeder cable in an isolator located at one end of the bay at a height of 1.5
m from the operating floor. The vendor shall indicate the exact power requirement
(running and peak) to enable the owner to size and provide the power supply feeder.
1.5 Further distribution of power from this isolator onwards shall be in the vendor’s scope.
2.1 The design, manufacture, testing and installation of the equipment shall comply with the
latest issue of IS-6547, IS-807 and other relevant Indian Standard specifications and
codes of practices. Equipment complying with equivalent IEC standards shall also be
acceptable.
2.2 The equipment and installation shall also comply with the provisions of latest issue of
Indian Electricity rules and other statutory acts and regulations.
Standard Specification, the requirement specified here-in shall prevail.
3.2 System Details

0
3.3 The owner shall provide only three phase power at the specified medium voltage. For
lighting, control and plug supply the vendor shall provide necessary single phase step-
down transformers.
3.4 All the electrical equipment shall be so designed that enable the crane / hoist to operate
at its rated capacity and specified duty cycle with the system variation under the
ambient conditions without exceeding the permissible temperature rise and without any
detrimental effect on any part.
4.0 GENERAL DESIGN AND CONSTRUCTIONAL REQUIREMENTS
4.1 The electrical system and installation shall be designed as per latest practice to provide
maximum reliability, flexibility, safety to personnel and equipment and ease of operation
and maintenance.
4.2 All equipment shall have adequate and standard ratings as per ISS.
4.3 All electrical equipment to be located in indoor plant area shall be enclosed in dust,
damp and vermin proof enclosure equivalent to IP-54 as per IS/IEC:60529.
4.4 Equipment to be located outdoor shall be weather proof and have IPW-55 protection as
per IS/IEC:60529 and shall also be provided with canopy as far as practicable.
4.5 The equipment to be located in hazardous area shall have additional protection as
follows:
a) Zone – I All the equipment shall be in flameproof execution.
b) Zone – II The equipment producing sparks under normal operation shall be in
flameproof execution and others shall be in increased safety
execution.
The equipment shall be suitable for the enclosure group and temperature class as
indicated in Design Philosophy - Electrical. The equipment selected shall conform to
relevant Indian Standard Specification and must be certified by Central Mining
Research Institute, Dhanbad or any other statutory authority for use in the specified
hazardous area.
4.6 The pendant push button shall be light weight enclosure of aluminium/ polypropylene
etc. In case of hazardous areas, the loop between the pendant push button and the
crane control panel shall be made intrinsically safe by using suitable isolators.
Alternatively certified flame proof components and increased safety terminals can be
hosed in the hose proof aluminium / polypropylene enclosure.
4.7 Special care shall be taken to ensure that the parts to be opened for inspection and
maintenance retain their dust tightness even after repeated opening and closing
operations.
4.8 All mating surfaces shall be properly machined. Neoprene gaskets shall be used for
dust and weather proofing. The gaskets shall be without any discontinuity.
4.9 Only non-hygroscopic materials shall be used for insulation. All insulation shall be
specially impregnated to withstand ambient conditions and atmospheric pollution.
4.10 All live parts shall be adequately protected to prevent inadvertent or accidental contact.

0
4.11 The minimum clearance and creepage distance of M.V. equipment shall be 20 and 28
mm respectively and shall be positively maintained after connections.
diameter 8 mm and above shall be of mild steel cadmium plated or zinc passivated.
4.13 Earthing terminals complete with sockets and identification marks shall be provided on
the enclosure of all electrical equipment. The number of terminals shall be two for
equipment rated above 240V and one for those rated 240V and below. Additional
internal earthing arrangement shall be provided for flameproof equipment.
4.14 All equipment shall be provided with stainless steel name plates containing the
particulars as per relevant IS along with the description and code nos. of equipment
4.15 All the electrical equipment shall be provided with separate terminal box, heavy duty
double compression type rolled aluminium cable glands, proper crimping lugs and anti-
vibration type terminals suitable for the cable sizes required.
4.16 Enclosure for limit switches, pendant push button, junction boxes and magnets etc. shall
be of cast aluminium. Enclosure for control panel, transformer and resistors may be of
sheet steel. The thickness of the sheet steel for the enclosure shall not be less than 2.5
mm. All enclosures shall be suitably painted to withstand atmospheric pollution as
mentioned in the Design Philosophy - Electrical.
4.17 The doors or inspection covers shall be provided with threaded knobs or butterfly nuts
made of plated carbon steel. Copper or copper alloys shall not be used outside the
enclosures.
4.18 To facilitate maintenance and testing of all electrical equipment:
a) Disconnecting links shall be provided where necessary.

b) All cable lugs and terminals shall be numbered in a permanent form
corresponding to the wiring diagram.
c) Easy access and adequate working space shall be provided around all motors,
panels, limit switches etc. safety railing shall be provided, where necessary.
5.1 Power Connection
5.1.1 The main supply shall be obtained by flexible cable or otherwise as per requirement.
5.1.2 In case of overhead bare conductors, they shall be of copper and mounted on side of
the crane bridge. Four number of gunmetal type current collector with renewable carbon
inserts shall be used for power connection. One end of the bare conductor shall be
connected to the owner’s isolator by means of fixed cable.
5.1.3 In case of flexible cable arrangement, the cable shall be connected at one end of the
crane and the other end to owner’s isolator. The cable shall be hung at intervals by
festooned type arrangement.
5.1.4 In either case the power fed to the trolley shall be by means of flexible cables fixed and
supported by festooned arrangement.

0
5.1.5 The arrangement of fixing and supporting the flexible cables shall be such that the cable
is not damaged due to repeated travelling of the crane and trolley. Supporting G.I. wire
shall be provided, wherever required.
5.1.6 The collector rollers and shoes shall be designed to avoid sparking.
5.2 Power Control Panel
5.2.1 The panel shall house all the necessary electrical equipment for distribution of power
and control of individual equipment / circuit.
5.2.2 The panel shall be totally enclosed, floor mounting, dead front, free standing type in
cubicle construction.
5.2.3 The panel shall house the following:
i) For incoming supply
- Triple pole switch fuse units
- Supply ‘ON’ signal lamps (LED Type)
The above switch shall cut off all power driven and associated equipment on the crane
except lighting and plug supply circuits.
ii) For motors
- Reversing type starter with necessary contactors and timers.
- Other controlling relays and devices.
iii) For lighting, control and plug supply
- Single phase transformers
- Isolating switch fuse units on primary and secondary sides.
5.2.4 All switches shall be motor duty type (AC 23) and rated for 1.5 times of the full load
current of the circuit. The incoming switch shall be interlocked with the panel door.
5.2.5 All contactors shall be air break type and of AC4 utilization categories. The thermal
rating of the contactor shall be 1.5 times the full load current of the circuit.
5.2.6 The power contactors shall be interlocked electrically and mechanically so that there
shall be no possibility of simultaneous operation of two contactors for the same motor.
5.2.7 Electrical interlock shall be provided between main hoist and micro hoist motors.
5.2.8 All thermal overload relays shall have in-built single phasing feature and ambient
compensated, separately mounting and hand reset type. The reset push bottom for
thermal overload relays shall be provided on the cover of the control panel so that it is
possible to reset the relay from outside without opening the cover of the panel. Also
indication shall be provided for hoisting/travel motors tripping on overload.
5.2.9 The panel shall be installed on properly levelled base frame fabricated out of channels
of suitable size.
5.3 Motors
5.3.1 The design and specification of all motors shall comply with requirements stated
elsewhere in the specifications.
5.3.2 The power rating of the motors shall be 25% higher than the design requirement of the
driven equipment, under the specified service and duty conditions.

0
5.3.3 All motors shall preferably be of squirrel cage type and so designed that smooth
acceleration or deceleration of the load is possible without any jerks. Further a
maximum displacement of 2 mm when starting and stopping the motor in quick
succession shall be guaranteed.
5.3.4 The motors for main hoist and micro hoist shall be suitable for intermittent duty type S4
with 60% C.D.E. and 300 starts / stops per hour. The motors for long travel and cross
travel shall be suitable for S2 duty for 60 minutes.
5.3.5 The motors shall be so located that all parts are accessible for inspection and
maintenance without affecting normal ventilation.
5.4 Brakes
5.4.1 The brakes for each motor shall be suitable for duties as specified below:
a) Main / Micro hoist S4 duty
b) Long / cross travel S2 duty
5.4.2 The coil of the brake shall be wound with fibre glass covered annealed copper
conductor suitable for class H application. An additional covering with glass taps shall
be provided over the coil. The maximum temperature of the coil for continuous operation
shall be limited to 140º C. The coil shall be vacuum impregnated.
5.4.3 For other design details refer mechanical engineering standard.
5.5 Limit Switches
5.5.1 Limit switches of both shunt and series type shall be used in control and power circuit.
5.5.2 These shall be heavy duty type and of sturdy construction in cast aluminium enclosure.
5.5.3 The mode of operation of these limit switches shall be positive and direct acting type.
5.5.4 The contacts shall be rated 50% more than the required current ratings.
5.5.5 The width of the roller of limit switches shall be sufficient to avoid slippage of contact
with the striker.
5.5.6 The striker provided for operating these limit switches shall have rubber padding on
surface which will make contact with roller to actuate it. The limit switches and its roller
should be designed to withstand the frequent impact pressure.
5.5.7 Switches in which the contacts are operated by spring or gravity or both on the
withdrawal of a chain or similar devices, shall not be used.
5.6 Transformers
5.6.1 These shall be of dry type, class H insulated, air cooled, double wound and mounted
inside the panel.
5.6.2 The transformers shall be provided with switch fuse unit on their primary side of suitable
rating. One side of secondary windings of the transformers shall be earthed and other
shall be provided with fuse of suitable rating.
5.6.3 The rating of the transformers shall be at least 2.5 times the continuous load.
5.7 Junction Box
Junction boxes shall be of cast aluminium construction and adequately sized to enable
easy termination of cables.
0
5.8 Hand Lamps
5.8.1 Provision shall be made in the crane for use of hand lamps by installing 2 nos. 24 volts,
2 pin metal clad switch sockets. One of the sockets shall be on the bridge (outside the
panel) and the other on the trolley.
5.8.2 The transformer primary and secondary voltage shall be 250V and 25V respectively.
6.0 CABLES, CABLE TERMINATION AND CONNECTIONS
6.1 The cables used for fixed wiring shall be 1.1 KV grade PVC insulated armoured and
PVC sheathed overall, and shall conform to IS: 1554 Part-I.
6.2 The flexible cable used for power supply to crane and also for interconnection of
equipment mounted on moving and fixed part of the crane shall be 1.1 KV grade heavy
duty type.
6.3 All cables shall be properly laid and supported with adequately sized aluminium clamps
at 500 mm interval.
6.4 Cable entry on all electrical equipment e.g. panels, motors, limit switches, brakes,
junction boxes etc. shall be through double compression type rolled aluminium cable
glands.
6.5 The internal power wiring of panels shall be carried out by PVC insulated stranded
copper flexible cable.
6.6 The wiring shall be arranged in a neat fashion and supported on PVC channel or PVC
stand of screw support.
6.7 For equipment mounted on the doors, the wiring shall be carried out with flexible
stranded copper cables in such a way that no strain is put on the wires and equipment
when the door is opened for inspection and maintenance.
6.8 External looping of wires shall be done through separate dust tight junction boxes.
6.9 The sizes of power cables to be used shall be subject to owner’s approval. The
minimum size of power and control cables shall be 16 sq. mm (Al) & 2.5 sq. mm (Cu)
respectively.
7.0 EARTHING
7.1 The earthing of all electrical equipment shall be carried out in accordance with IS: 3043.
7.2 The enclosures of electrical equipment shall be connected to an aluminium earth ring on
the crane which in turn shall have effective electrical connection with the bridge.
7.3 The crane bridge shall be earthed through the bridge travel runway rails on both sides
which in turn shall be earthed to owner’s earth ring located on the ground floor.
7.4 Further the power supply cable for the crane shall have an additional conductor for
earth connection. Both sides of this conductor shall be earthed.
7.5 All earth conductors shall be of aluminium.

0
7.6 This size of earth conductor shall be equal to half the size of the power conductor
subject to a minimum size of 10 sq. mm.
8.0 CONTROL DESK / CONTROL STATION
8.1 The crane shall be controlled either from the floor by means of a pendant control station
or from bridge mounted control desk as indicated in the mechanical data sheet.
8.2 In either case, the units shall have the following control devices:
- Main off push button with padlocking arrangement.
- Indication lamps for supply ‘ON’
- Control push buttons, as specified in the mechanical data sheet.
- All other devices required for safe and proper operation of the crane / hoist.
8.3 All push buttons shall be momentary contact type, coloured as per IS: 6875 and have 1
NO and 1 NC contacts.
8.4 The bridge mounted control desk, where specified, shall be of totally enclosed and dust
tight construction. All controlling equipment shall be mounted on the top. It shall be
located at most convenient location to allow movement of the operator. The installation
shall be equipped with adjustable chair, fan, light and main isolating switch.
8.5 The pendant control station, where specified, shall be in a single enclosure and in totally
enclosed dust light execution. The unit shall be suspended and supported from the
bridge platform by flexible steel wire rope. The connection shall be made with a multi
core flexible copper conductor cable and shall have 20% spare cores. One core shall be
provided for earth connection of the circuit.
9.0 PAINTING
Enclosures of all electrical equipment shall be painted with two coats of epoxy based
primers after suitable pre-treatment. Two coats epoxy based paint of approved colour
shall be provided.
10.1 All equipment shall be routine tested as per relevant Indian Standard Specifications.
10.2 Additional tests, wherever specified, shall be carried out on one equipment of each
rating.
10.3 All the above mentioned tests shall be carried out in presence of owner’s
representative.
10.4 The owner’s inspection shall, however, not absolve the vendor from his responsibility for
10.5 Despatch of materials shall be subject to written consent of owner or his representative.

0
11.1 The vendor shall undertake installation of all electrical equipment in accordance with
latest code of practices, in conformity with recommendation of the respective equipment
manufacturer, drawings approved by the owner or owner’s representative, direction of
Engineer-in-charge, statutory regulations and to the entire satisfaction of the owner.
11.2 The vendor shall arrange all the necessary erection tools and tackles, testing and
measuring instruments and shall supply the required erection materials including
structural steel.
11.3 Following tests shall be specifically conducted before commissioning in presence of

owner’s representative. All the test results shall be recorded and submitted to the
owner.
i) Insulation test.
ii) Continuity test.
iii) High voltage test.
iv) Simulation test.
specified.
12.2 All drawings and documents shall have the following description written boldly :
- Name of client
13.0 SPARES


offer.
14.0 DEVIATIONS
reasoning.

0
ANNEXURE - I
DOCUMENTENTATION FOR ELECTRICALS FOR OVERHEAD CRANES & HOISTS
Sl. No. Description
1. Specification sheet and technical N Y Y

particulars
2. Composite schematic diagram N Y Y
3. Dimensional drawing showing the
mounting details and general
arrangement for the following equipment
a) Motors N Y Y
N Y Y
b) Power control panel
N Y Y
c) Control station N Y Y
d) Limit switches etc.
4. Down shop lead and power supply N Y Y
arrangement with civil scope.
5. Inter-connection with terminal diagram N Y Y
and cable details
6. Operating and maintenance instruction N N Y
manual
7. Catalogues of bought out items N N Y
8. Test certificates N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N - No
i) The tenderer shall also quote for any other spares as deemed necessary to be kept
in stock for stipulated time.

0
TECHNICAL SPECIFICATION – HIGH VOLTAGE VARIABLE Document No. Rev
FREQUENCY DRIVES (PC150-TS-0820A) Sheet 1 of 15
HIGH VOLTAGE VARIABLE FREQUENCY DRIVE SYSTEM

0
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
3.0 GENERAL REQUIREMENTS
4.0 SITE CONDITIONS
6.0 INSPECTION, TESTING AND ACCEPTANCE
7.0 SPARES
8.0 DOCUMENTS
9.0 CERTIFICATE
10.0 PACKING AND DESPATCH

0
1.0 SCOPE
1.1 The scope of this specification is to define the minimum technical requirements for the
design, manufacture, testing and supply of High Voltage, AC Variable Frequency Drive
system. The VFD system shall be complete with Squirrel Cage Induction Motor/ Synchronous
Motor as specified in data sheet, Converter, Converter input transformer, drive output
transformer, DC link reactor with associated auxiliaries, harmonic filters and field mounted
local motor control panel.
1.2 The Vendor shall be responsible for engineering and functioning of the complete system,
meeting the intent and requirement of this specification and data sheets. This shall include
but not be limited to inverter sizing, transformer sizing, transformer impedance selection,
vector group, input and output harmonic filter design and sizing, output dv/dt filter sizing,
motor cable selection and motor sizing/selection.
1.3 This specification applies to drive systems having converter input voltage above 1000 V AC
and up to and including 11OOOV AC.
2.1 The equipment shall comply with the requirements of latest revision of the following standards
issued by BIS, unless otherwise specified:
IS:325 Three-phase Induction Motors

IS:3700 Essential Ratings and Characteristics of Semiconductor Devices
IS:3715 Letter symbols for semi-conducting devices
IS:4411 Code of designation of semi-conducting devices
IS:5001 Guide for preparation of drawings of semiconductor devices and Integrated
Circuits
IS:5469 Code of practice for the use of semiconductor Junction Devices
IS:14901 Semi-conductor devices- Discrete devices & Integrated Circuits
IS:15880 Three Phase Cage Induction motors when fed from IGBT Converters Application
Guide
IS:8789 Values of Performance characteristics for Three Phase induction motor
IS: 12615 Energy Efficient Induction Motors - Three Phase Squirrel Cage
IS:12729 Common specification for High-Voltage Switchgear and Control gear
standards
IEC:60 146-1-3Semiconductor Convertors general requirements and line commutated
convertors-Transformer & reactors
IEC:61800 Adjustable speed electrical power drive systems
IEEE:519 Recommended Practices and requirements for Harmonics Control in Electrical
power system
2.2 In case of imported equipment, standards of the country of origin shall be applicable, if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other
statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by
IEC/BSNDE/IEEE/NEMA or equivalent agency shall be applicable.

0
2.5 In case of any contradiction between various referred standards/specifications/data sheet and
statutory regulations the following order of priority shall govern:
- Statutory regulations
- Data sheets
- Job specification
- This specification
- Codes and standards
3.1 The offered equipment shall be brand new with state of art technology and proven field
track record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment for at least 15 years from the date of supply
3.3 Vendor shall give a notice of at least one year to the end user of equipment before phasing
out the product/spares to enable the end user for placement of order for spares and services.
3.4 Vendor shall ensure proper co-ordination with the driven equipment supplier in
selection/sizing of offered variable frequency drive system.
4.0 SITE CONDITIONS
4.1 The drive system shall be designed to operate under specified site conditions as specified in
the data sheets. If not specifically mentioned therein, a design ambient temperature of
50°C.and an altitude not exceeding 1000 metres above mean sea level shall be considered.
4.2 The AC drive shall be installed indoors in a non-hazardous, air-conditioned or pressurized

room, as specified in data sheet. Transformer installation (outdoor/ indoor) shall be as
indicated in datasheet. Motor shall be installed outdoors in safe or hazardous area as
specified in datasheet.
4.3 All the equipment shall be designed for continuous duty as per nameplate rating under the
specified ambient conditions.
5.0 DESIGN AND FABRICATION REQUIEMENTS
5.1 Performance Requirement
5.1.1 The system shall be energy efficient, designed as standard product and shall provide very
high reliability, high power factor, low harmonic distortion and low vibration/ wear / noise. It
shall be easy to install in minimum time and expense and no special tools shall be required
for routine maintenance.
5.1.2 The system shall be designed to deliver the motor input current and torque for the complete
speed torque characteristics of the driven equipment, with input supply variation of ±10% and
frequency variation of ±3%. The system shall be suitable for the load characteristics and the
operational duty of the driven equipment. It shall be capable of withstanding the thermal and
dynamic stresses and the transient mechanical torque, resulting from short-circuit.
5.1.3 The drive system shall be designed to operate in one or more of the following operating
modes as to suit characteristics of the driven equipment or specified in the data sheet:

0
a. Variable torque changing as a function of speed i.e. Speed squared

b. Constant torque over a specific speed range
c. Constant power over a specific speed range where the torque decreases when speed
Increases
d. Any other as specified in data sheet
5.1.4 The drive controller shall be equipped with microprocessor based digital regulator with
programmable functions. The power control regulator logic shall provide for an
acceleration/deceleration current limit curve and shall be capable of field adjustments without
shutting the system down. Linear acceleration and deceleration shall be separately
programmable from 0.1 to 20 seconds.
5.1.5 The System shall be suitable for single quadrant operation and the speed variation shall be
with range 10-100 % unless otherwise specified in data sheet with speed set accuracy of
±1% of rated maximum speed and steady state regulation of±0.5% of rated speed.
5.1.6 The total harmonic distortion (THD) of the voltage and current at inverter output shall be as
per IEC 61800 and same shall be considered in the design of the motor. The dv/dt limits &
Vpeak shall also be as per IEC-61800-2.
5.1.7 Harmonics at the supply side of the drive system at primary of the main input transformer
shall be restricted within the maximum allowable levels of current and voltage distortion as
per recommendations in the latest edition of IEEE-519. The vendor shall perform design
calculation for harmonic filter system considering VFD connected to the power system and
including the supply of harmonic filters along with all accessories which shall be installed at
owner's power system unless otherwise specified. These harmonic studies shall be
conducted with maximum and minimum system fault level, cable capacitance, system
equipment reactance etc. The studies shall highlight but not be limited to maximum load
current, expected resonant frequencies, need of harmonic filters, sequence of switching of
filters, voltage wave form, rating of equipments/ feeder for feeding filters from owner's
switchgear etc.
5.1.8 Unless otherwise specified, the overload capacity of the controller shall be 150% of rated
current of motor for one minute for constant torque applications, and 110% of rated current
for one minute for variable torque applications at rated voltage. If the motor load exceeds the
limit, the drive shall automatically reduce the frequency and voltage to the motor to guard
against overload. If load demands exceed the current limit for more than 1 minute, the drive
shall shutdown to prevent over heating of the motor and damage to the drive.
5.1.9 During operation, the system shall be capable of developing sufficient torque under all load
conditions to respond to a 20% alteration in speed set point within a time limit upto 60
seconds.
5.1.10 The integrator action of the speed set point alteration shall be independently adjustable for
both an upward and a downward alteration. The minimum time interval between set point
adjustments by the distributed control system shall be considered as 10 seconds.
5.1.11 The drive shall trip in case the speed exceeds 105%of the maximum operational speed or
reduces to 95% of the minimum operational speed for more than 10 seconds.
5.1.12 Maximum noise level from the drive at 1-meter distance, under rated load with all normal
cooling fans operating shall not exceed 85 dBA.
5.1.13 Variable frequency drive shall be arranged so that it can be operated in an open circuit mode,
disconnected from the motor for start up adjustments and troubleshooting/ maintenance.

0
5.1.14 Voltage at motor neutral shall be maintained at ground potential for the total operating
condition.
5.2 Control Requirement
5.2.1 The system shall operate on constant V/f supply with required voltage boost capability in low
frequency mode of operation.
5.2.2 Short time voltage dips up to 20% of nominal voltage (e.g. in case of a large motor start up
connected to the same bus as VFD) shall not cause the control system to stop functioning
and shall not trip the drive system.
5.2.3 The system shall also be equipped with a momentary powerloss ride through feature which
will restart the system in case of voltage dip over 20% or power interruptions for less than 2
seconds, with recovery of the voltage to its nominal value .. The drive shall have the facility to
block this feature, if required by the operator. Upon restart, the converter shall be capable of
synchronizing onto a rotating motor and develop full acceleration torque within 10 seconds.
5.2.4 The system shall be suitable for number of starts as per attached specification for High
Voltage Motors.
5.2.5 The power controller shall be controlled to always start the motor in the forward direction.
Logic shall be provided to prevent the motor from being started in the reverse direction.
5.2.6 The drive motor shall be speed controlled corresponding to 4-20mA or 0-10 V reference input
signal. Unless otherwise specified, upon complete loss of the user's speed reference signal,
the drive shall automatically run at constant speed as at 80-100% of the last speed reference
available prior to the loss of signal.
5.2.7 It shall be possible to vary the speed of the drive in either manual or auto mode. Auto/Manual
selection shall be from VFD panel unless otherwise specified.
a. With the selector switch in "manual" mode, the operator shall be able to set the speed
through key pad (mounted on front of the drive panel) or from speed increase/decrease push
buttons (from the field). Motor operated potentiometer shall be provided as a speed set point
device.
b. With the selector switch in "auto" mode, speed of the motor shall be controlled from a 4-20
mA signal, from owner's PLC/DCS (Process Control) system. Necessary equipment required
for interfacing with PLC/DCS shall also be provided in the VFD panel.
c. Local/Remote selector switch shall be provided in local control station (in Field). With the
selector switch in "Local" mode, the operator shall be able to start and set the speed through
local control station (in Field). With the selector switch in "Remote" mode, speed of the motor
shall be controlled either from VFD panel or from Owner's PLC/DCS as explained in a) and b)
above.
5.2.8 The required provision for the interface with remote PLC/DCS located at control room shall be
either through hardwired connection (with potential free contacts and transducers as
described elsewhere in this specification) or through serial communication link as defined in
the datasheet.
5.2.9 Drive system shall have provision for interface with upper level automation such as
Substation monitoring system or electrical control system in case specified in the data
sheet/job specification.

0
5.2.10 The closed loop control feed back for the drive system having out put transformer shall be
tapped from the secondary side of the output transformer.
5.3 Panel Construction
5.3.1 The panel shall include suitable semi conducting power devices (Diodes/IGBT/IGCT/
IEGT/SGCT) modules with protective devices, reactors (if required) , filters, control circuit,
control accessories, indication and annunciation etc. The construction of the panel shall
provide effective protection against electromagnetic emissions and shall meet the design
requirement of relevant standards.
5.3.2 Upstream breaker 'ON/OFF/TRIP' indications and remote breaker closing and trip push
buttons shall be provided on the front door.
5.3.3 Safety Interlock shall be provided so that power cabinet can't be opened unless the upstream
breaker is disconnected, safety-grounding switch is closed and DC link capacitor is
discharged. Power source breaker can only be closed once the earthing switch is open and
panel door is closed with lock defeat facility.
5.3.4 The drive shall be suitably housed in sheet steel panels and shall be fabricated using cold
rolled sheet steel. The sheet steel used for the panel shall be of minimum 2 mm CRCA. The
panel shall be suitable for indoor installation, if not otherwise specified. The panel shall be
free standing with degree of enclosure protection as IP-31. Maximum and minimum operating
height shall be 1900 mm and 300 mm respectively.
5.3.5 Bolted un-drilled gland plate shall be provided at bottom. Clamp type terminals shall be used
for connection of all wires up to 10 mm2, and terminal for higher sizes shall be bolted type
suitable for cable lugs. Minimum space for power cable termination shall be 600mm clear
from bottom of the cable gland plate.
5.3.6 Bus bars shall be of electrolytic copper/aluminium, sleeved, color coded separately for AC
and DC system. All the live parts shall be sleeved / shrouded to ensure complete safety to
personnel intending to carry out routine inspection by opening the panel doors. All the
equipment inside the panel and on the doors shall be provided with suitable nameplate.
5.3.7 All the switches, component and accessories which are essential for normal and emergency
operation shall preferably be mounted on the door and shall be operable externally. All the
analogue instruments, where provided, shall be switchboard type, back connected & of size
96x96mm. Scale shall have red mark indicating maximum permissible operating rating.
5.3.8 Each panel shall be provided with illuminating lamp/11 W CFL with switch and fuse. 5/15A,
240V power socket with switch and fuse shall be provided. Each panel shall have space
heater with switch fuse and variable setting thermostat.
5.3.9 Copper earth bus of min. 30x6 sq.mm. upto short circuit withstand capacity of 31.5kA and
50x6 sq.mm. for a short circuit withstand capacity above 31.5kA shall be provided in the
panel with provision for connection to owner's plant earth grid. All the non-metallic
components/parts shall be connected to the main earth bus bar. Separate earth bus bar and
stud for electronic control system if required shall be provided.
5.3.10 All panels shall be of same height so as to form a uniform line-up, to give good aesthetic
appearance.
5.3.11 All the control wiring shall be enclosed in plastic/ metal channel. Each wire shall be identified
at both ends by self-sticking wire marker tapes or PVC ferrules. Power and control wiring

0
inside the panel shall be done with BIS approved, PVC insulated, fire retardant, low smoke,
copper conductor wire 1.5mm2 size wire shall normally be used provided the control fuse
rating is 10 Amps or less and 2.5 mm2' size for control fuse rating above 16 A for electrical
circuits and 0.5mm2 for electronic circuits. All wires shall be ferruled and terminals shall be
properly numbered, minimum 20% spare terminals shall be provided.
5.3.12 All electronic modules and components shall be accessible from front of panel only. Modular
assemblies for both the system control electronic equipments and power electronic
equipments shall be used.
5.3.13 Low voltage compartment and cabling shall be electrically and physically separated from the
high voltage compartment.
5.3.14 DC link capacitor and pre-charging & discharging circuit shall be preferably mounted in the
rear of the panel.
5.3.15 Suitable eyebolts/ lifting clamps/ strap & cradle arrangement shall be provided for lifting of the
panel/shipping section. The bolts, when removed shall not leave any opening in the panel.
5.3.16 Acrylic type transparent insulating material shall be used for covering live components.
5.3.17 Drive keypad, operator control panel required for control, monitoring and measurements shall
be supplied and installed outside the panel on the front door. It shall be accessible for
operation without opening the front door and shall be non-removable type.
5.3.18 All equipment shall be complete with cable glands, lugs etc. and cable glands shall be single
or double compression type for indoor and outdoor equipment respectively. Cable glands
shall also be suitable for the hazardous area application if specified in data sheet.
5.4 Cooling
5.4.1 The drive panel shall be naturally cooled or water cooled type as per manufacturer's
standards. However, it is preferred to have natural air cooled system. If unavoidable, forced
type-cooling system shall be provided. Cooling system shall include well-dimensioned panel,
adequate cooling airflow path, modular cooling fan and if necessary, panel cooling fan or
water-cooling system shall be considered. Vendor shall ensure that the panel dimensions and
flow paths have been designed for continuous running at the specified ambient without
overheating. For fan cooled drives, redundant ventilating fans (N+ 1) shall be provided. In
case redundant cooling fan is not possible to be mounted in the panel, same shall be
supplied loose.
5.4.2 For water-cooled drives, entire cooling system including but not limited to heat exchanger,
flow and pressure meters and pumps shall be in vendor's scope. The system shall be
provided with closed circuit water cooling system, requiring only make up water required for
topping up. The cooling water pumps, in case provided, shall have 100% redundancy. Water
quality/characteristics shall be as defined in the data sheet and selected cooling water system
components/material shall be suitable for the same. Adequate safety measures shall be
incorporated in water cooled drives such that no leakage is there which results in
malfunctioning of electronic devices. Proper segregation between water cooling system and
other equipment shall be provided. It is preferred that cooling cabinet panel shall be
separated from the main panels.
5.4.3 Necessary starters shall be provided within the VFD panels for the Ventilation fans, Cooling
Water circulation pumps, any other auxiliary motor etc. The system provided shall be
interfaced with drive starting and shutdown so that safety interlocks such as start permit from

0
cooling system to drive and trip signal from cooling system to drive in case of cooling system
failure etc., are incorporated in the overall sequence logic.
5.4.4 MCB for motor space heater, auxiliary power supply if required for local panel, drive panel
space heater etc. shall be included and mounted in easy accessible location.
5.5 Equipment/ Component Specification
5.5.1 Motor
The motor shall be designed, constructed and tested in accordance with the latest revision of
Specification /data sheet for High Voltage Induction / Synchronous Motor, in addition to the
following requirements:
a. The motor shall be suitable for operation with a solid-state power supply consisting of an
adjustable frequency inverter for speed control.
b. The motor shall be suitable for the current waveforms produced by the power supply including
the harmonics generated by the drive.
c. The motor shall be designed to operate continuously at any speed over the range (10-100%)
of rated speed unless otherwise specified in data sheet.
d. The permitted voltage variation should take into account the steady state voltage drop across
the AC drive and all other system components upstream of the motor.
e. Motors required to be transferred to DOL by-pass mode shall be rated for specified variations
in system line voltage and frequency. Starting current of motor in DOL bypass mode shall be
limited to value specified in motor specifications, unless otherwise specified in datasheets.
f. The motor shall be constructed to withstand torque pulsations resulting from harmonics
generated by the solid-state power supply.
g. The motor insulation shall be designed to accept the applied voltage waveform, within the
Vpeak and dv/dt limits as per IEC-61800-4 and necessary co-ordination between the VPD
manufacturer & motor manufacturer W.r.t. incorporation of VPD output parameter in the
design of motor shall be carried out.
h. The drive manufacturer shall be solely responsible for proper selection of the motor for the
given load application and the output characteristics ofthe drive.
i. Motors shall be provided with Resistance Temperature Detectors (RTDs).
5.5.2 Converter Transformer/ Output transformer
a. The converter transformer shall be dry type or oil filled type as specified in the data sheet. In
case of the dry type transformer, it shall be mounted in the drive system panel unless
specified otherwise in the datasheet. Offered transformer shall be as per enclosed
Specifications/data sheet.
b. The impedances of converter input transformers with more than one secondary windings for
12/18/24/36 pulse systems shall be selected to ensure equal load/current sharing between
the secondary windings, the converters and the motor windings under all operational
conditions including starting and restarting.

0
c. Drive out put transformer considered only for the purpose of meeting standard rated motor
voltage i.e. 3300, 6600V, 11000V shall not be provided unless otherwise agreed between
purchaser and the manufacturer.
5.5.3 Power Converter
a. The static power converter shall consist of a line side power converter for operation as a
rectifier and a load side power converter for operation as a fully controlled inverter. Power
converter shall be fast switching, most efficient and low loss type.
b. Adequate short circuit and over voltage protection shall be provided for the converter and
inverter system.
c. All power converter devices shall include protective devices, snubber networks and dv/dt
networks as required.
d. The current rating of the converter's semi-conductor components shall not be less than 120%
of the nominal current flowing through the elements at full load of the VFD through the entire
speed range.
e. All power diodes shall be of silicon type with minimum VBO rating as 2.5 times the rated
operating voltage.
f. The power converter circuit shall be designed so that motor can be powered at its full
nameplate rating continuously without exceeding its rated temperature rise due to harmonic
currents generated by the inverter operation.
g. The conversion devices and associated heat sinks shall be assembled such that individual
devices can be replaced without requiring the use of any special precautions/tooIs.
h. The cooling system of the electronic components, if provided, shall be monitored and
necessary alarms shall be provided to prevent any consequential damage to the power
control devices.
i. Offered system shall also take into account the distance between Drive panel and motor and
system shall include all material and accessories to make system suitable for a distance of
350m unless otherwise specified in the data sheet.
5.5.4 DC Link Reactor
a. Smoothing reactors for the DC link shall be designed to sufficiently decouple the rectifier and
inverter portion of the converter and to limit fault currents in this circuit.
b. Unless otherwise specified, the reactor shall be air-cooled or fan cooled type located within
the panel.
c. Reactor shall be suitable for operation with the non-sinusoidal current wave shapes and DC
components under all operational conditions of the system without exceeding its temperature
limits.
5.5.5 Output Filter
VFD output current waveform should be inherently sinusoidal at all speeds, with harmonic
limits as specified in this specification. Output filter shall be provided, if required. Output filter
capacitors shall be provided with discharge circuits to ensure that all residual stored charge is

0
reduced to less than 50 V DC within 300 seconds after a loss of AC voltage. All capacitor
shall be maintenance-free and self-healing type.
The VFD system shall inherently protect motor from high voltage dv/dt stress, independent of
cable length to motor. Output filter shall be an integral part of the VFD system and included
within the VFD enclosure.
5.5.6 Bypass Feature
a. Bypass feature along with motor protection relay and output side isolator/breaker shall be
provided by purchaser unless otherwise specified in the datasheet. All necessary interlocks
as required for safe and reliable operation of VFD system along with bypass feeder and
output side isolator/breaker provided by Purchaser shall be provided in VFD system.
b. Bypass starter shall be in separate compartment and switching scheme shall be such that in
case of drive mal-operation, the motor could be taken on bypass control manually, while the
drive could be attended independently. Suitable interlock shall be provided such that bypass
mode and VFD mode shall not operate simultaneously.
5.5.7 Local Motor Control Station
a. The local motor control station, to be installed in the field near the motor shall conform to the
attached specifications. Components and accessories that are required in the local motor
control station may be mounted on the local field mounted panel envisaged for the driven
equipment.
b. Meters in the local control station shall be suitable for 4-20mA transducer outputs and shall
be calibrated for the actual motor current. Further, for drives with bypass facility, the meters
shall be capable of reading bypass mode full load and starting currents as well as the VFD
mode drive current.
5.6 Protection, Control, Metering, Indication and Annunciation
5.6.1 The system vendor shall provide all the necessary system control, protection, alarm and
metering equipment for the entire drive system and its auxiliary equipment.
5.6.2 Automatic sequence control shall include start-up of cooling system, auxiliary system of the
motor, interlock checking, automatic start and run-up of drive, planned and emergency
shutdown. The same shall be processed through microprocessor-based system.
5.6.3 Operator Control Panel
a. Each drive shall be equipped with a front mounted operator control console consisting of a
backlit alphanumeric display and a keypad with keys for parameterization and adjusting
parameter which shall not be limited to Start/Stop, Local/Remote, Auto/Manual,
Increase/Decrease, menu navigation and protection and measurement parameter selection,
etc.
b. All parameter names, fault messages, warnings and other information shall be displayed in
complete English words or standard English abbreviations to allow the user to understand the
display without the use of a manual or cross-reference table. This shall also be used for the
modification of all electrical values, configuration parameters, drive menu parameters,
application and activity function access, faults, local control, adjustment storage, self test and
diagnostics. Keypad shall be operable with password for changing the protection setting,
safety interlock etc. However, the parameters such as measurements, setting, mode of drive
etc. shall be allowed to be viewed without any password.

0
c. Operator console shall have facility/ port to connect external hardware such as Laptop etc.
Console shall have facility to upload and download all parameter settings from one drive to
another identical drive for start-up and operation.
d. Drive system control shall also have facility to receive tripping signal from upstream breaker
for tripping and also provision for closing upstream breaker after all required process
parameters are achieved.
e. User-friendly software for operation and fault diagnostic shall be loaded in the drive system
panel before commissioning.
5.6.4 Protective Features
The system shall incorporate adequate protective features, properly coordinated for the drive
control and for the motor but not limited to the following:
I. Incoming line surge protection

II. Under / Over voltage protection
III. Phase loss protection.
IV. Programmable over current protection and under load protection.
V. Inverter Fault.
VI. Over frequency/Over speed of motor
VII. Ventilation loss (In case same is not provided, drive shall generate an over
temperature fault alarm and suitable sensors, as required for same, shall be
provided).
VIII. Over temperature of equipment.
IX. Specific motor protection, including motor winding, bearing temperatures, over
current, overload, negative phase sequence and earth fault protections etc.
X. System earth fault protection.
XI. Excitation system protection for synchronous motor
XII. Over and under frequency, rotor earth fault (if applicable), field failure protection for
synchronous motor
XIII. Additional protection, if any for the drive system
5.6.5 Control
The following controls shall be provided as a part of the Operator Control Panel or through
separate switches.
I. Start/Stop
II. Speed control (Raise/Lower)
III. Forward/Reverse (if specified)
IV. Auto/Manual /Test mode
V. Local/Remote
VI. Emergency stop
VII. Start/Stop for bypass starter (where specified)
VIII. Trip-Remote Breaker
IX. Excitation control system for synchronous motors
X. Sequential switching of filters
5.6.6 Indications
Vendor shall provide indications as required for normal operation and for ease of
maintenance, which shall not be limited to the following indications.
I. Motor running
II. Motor stopped

0
III. VFD System Fault

IV. System ready to start
V. AC mains ON
VI. Motor over speed
VII. Rectifier output 'ON'
VIII. Motor zero speed
IX. Remote breaker trip
X. Excitation system healthy for synchronous motors
Above indications may be provided as a part of the operator control panel, i.e. door mounted
keypad or through hardwired LEDs. LEDs provided for indication shall be cluster type with
adequate brightness and minimum 2 Nos LEDs chips per light. LEDs shall be connected in
parallel and each LED chip having diameter not less than 3mm.
Potential free contacts for items i to iv shall be wired separately for remote indications in DCS
system.
5.6.7 Metering
Digital display of the following parameters shall be as a part of the Operator Control Panel,
selectable by the operator.
I. Output voltage
II. Output current-VFD model Bypass mode
III. Output frequency
IV. Drive thermal state
V. Motor speed
VI. Motor energy meter
VII. Hour Run
VIII. Voltage and current meter for excitation system of synchronous motor
IX. KVAR, power factor meter for synchronous motors
X. Necessary transducer shall be provided with 4-20mA output for indicating motor
XI. speed and motor current in DCS unless otherwise specified for other parameters.
5.7 Fault Diagnostic
Fault diagnostic shall be built into the system to supervise the operation and failure of the
system. The information regarding failure of any of the system including, shutdown of the
system, shall be available for a period of minimum 4 days (96 hours) after a shutdown, even
though no supply would be available to the system. The system may be totally de-energized
for maintenance or otherwise. It shall be possible to retrieve the record of events prior to
tripping of the system or de-energisation. Auxiliary supply to the system components or to the
electronics (firmware) for the diagnostics / display shall be taken care by the manufacturer for
this purpose.
5.8 External Power supply for auxiliary and Control Circuit

Auxiliary power supply for devices external to VFD module, space heater supply for Motor,
VFD panel space heater, auxiliary power supply for transformers, cubicle 11W CFL lamps,
indicating lamps, digital meters (Ammeter, Speedometer) etc. shall operate on 240 volts
single phase AC supply provided by purchaser.
All control circuit shall operate at maximum voltage of 240V AC or 220V DC unless
otherwise specified in the datasheet.
Vendor shall include supply of all control transformers, protective devices, associated

0
accessories etc. and any other control supply voltage required for the system shall be derived
by the vendor from the power supply made available by purchaser.
5.9 Reliability Features
The expected lifetime of the drive system shall be min. 20 years. The system including all
individual components forming part of the system shall have an availability of minimum 0.997
and a minimum MTBF of 4 years.
5.10 Maintenance features
The controller design shall incorporate the following maintenance features:
Modular construction
All components shall be easily accessible.
Standard diagnostics to aid maintenance personnel. These shall include LED or
alphanumeric displays, test or measurement points.
5.11 Painting
5.11.1 After preparation of the under surface, the panel shall be spray painted with two coats of
epoxy based final paint or shall be powder coated. The colour shade of final paint shall be as
RAL 7032, unless specified otherwise. Panel finish shall be free from imperfections like
pinholes, orange peels, runoff paint, etc.
5.11.2 All unpainted steel parts shall be zinc passivated, cadmium plated or suitably treated to
prevent rust and corrosion. If these parts are moving elements, then these shall be greased.
6.1 During fabrication, the drive shall be subject to inspection by PDIL / Owner, or by an agency
authorized by the Owner, to assess the progress of work, as well as to ascertain that only
quality raw material is used.
6.2 All tests shall be carried out at the manufacturer's works under his care and expense. The
tests shall be witnessed by an inspector of PDIL/Owner or of an agency authorized by the
owner. Prior notice of minimum 4 weeks shall be given to the inspector for witnessing the
tests.
6.3 All Routine & Type Tests shall be conducted as per the NIT for HV variable frequency drive 6-
81-1050 as per IEC 61800-2. However, combined test for VFD and motor at vendor's works
shall be carried out if specified in the datasheet.
6.4 String Test with driven equipment
If a string test with driven equipment is specified in the data sheet of the driven equipment, it
shall be carried out with the job equipment.
7.0 SPARES



0
8.0 DRAWINGS
8.1 Vendor shall submit to Purchaser, for approval, before completion of manufacturing and
assembly of equipment following drawings and literature.
(i) Installation and maintenance manual including trouble-shooting chart.

(ii) Panel drawings and cable schedule
(iii) Block diagram and control logic.
9.0 CERTIFICATION
The motors and associated Variable frequency drive system equipment shall have test
certificates issued by recognized independent test house (CIMFRI BASEEFA/ LCIE/UL/FM or
equivalent). All indigenous motors shall conform to Indian Standards and shall be certified by
Indian testing agencies. All motors (indigenous and imported) shall also have valid statutory
approvals as applicable for the specified hazardous location. All indigenous flameproof
motors shall have valid BIS license and marking as required by statutory authorities.
Also the motor nameplate shall clearly indicate that the motor is suitable for operation with
variable frequency drive along with VFD make and model number.
All the equipment shall be divided in to several shipping sections for protection and ease of
handling during transportation. The equipment shall be properly packed for selected mode of
transportation i.e. ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets
before being placed in wooden crates/cases to prevent damage to the finish. Crates/cases
shall have skid bottoms for handling. Special notations such as 'Fragile', 'This side up',
'Weight', 'Owner's particulars', 'PO nos.' etc., shall be clearly marked on the package together
with other details as per purchaser for scrutiny. The equipment may be stored outdoors for
long periods before installation. The packing shall be completely suitable for outdoor storage,
in areas with heavy rains/high ambient temperature.

0
TECHNICAL SPECIFICATION – MEDIUM VOLTAGE VARIABLE Document No. Rev
FREQUENCY DRIVES (PC150-TS-0820B) Sheet 1 of 16
MEDIUM VOLTAGE VARIABLE FREQUENCY DRIVE SYSTEM

0
CONTENTS
1.0 SCOPE
4.0 SITE CONDITIONS
7.0 SPARES
8.0 DOCUMENTS
9.0 CERTIFICATE

0
1.0 SCOPE
1.1 The scope of this specification is to define the minimum technical requirements for the
design, manufacture, testing and supply of Medium Voltage, AC Variable Frequency Drive
system. The VFD system shall be complete with Squirrel Cage Induction Motor/ Synchronous
Motor as specified in data sheet, Converter, Converter input transformer, drive output
transformer, DC link reactor with associated auxiliaries, harmonic filters and field mounted
local motor control panel.
1.2 The Vendor shall be responsible for engineering and functioning of the complete system,
meeting the intent and requirement of this specification and data sheets. This shall include
but not be limited to inverter sizing, transformer sizing, transformer impedance selection,
vector group, input and output harmonic filter design and sizing, output dv/dt filter sizing,
motor cable selection and motor sizing/selection.
1.3 This specification applies to drives connected to line voltage up to 1000 V, AC.
2.1 The equipment shall comply with the requirements of latest revision of the following standards
issued by BIS, unless otherwise specified:
IS:325 Three-phase Induction Motors

IS:3700 Essential Ratings and Characteristics of Semiconductor Devices
IS:3715 Letter symbols for semi-conducting devices
IS:4411 Code of designation of semi-conducting devices
IS:5001 Guide for preparation of drawings of semiconductor devices and Integrated
Circuits
IS:5469 Code of practice for the use of semiconductor Junction Devices
IS:14901 Semi-conductor devices- Discrete devices & Integrated Circuits
IS:15880 Three Phase Cage Induction motors when fed from IGBT Converters Application
Guide
IS:8789 Values of Performance characteristics for Three Phase induction motor
IS: 12615 Energy Efficient Induction Motors - Three Phase Squirrel Cage
IS/IEC:60947 Low Voltage Switchgear and Control gear
IEC:60 146-1-3Semiconductor Convertors general requirements and line commutated
convertors-Transformer & reactors
IEC:61800 Adjustable speed electrical power drive systems
IEEE:519 Recommended Practices and requirements for Harmonics Control in Electrical
power system
2.2 In case of imported equipment, standards of the country of origin shall be applicable, if these
standards are equivalent or stringent than the applicable Indian standards.
2.4 In case Indian standards are not available for any equipment, standards issued by
IEC/BSNDE/IEEE/NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standards/specifications/data sheet and

0
- Data sheets
- Job specification
offered equipment for at least 15 years from the date of supply
3.3 Vendor shall give a notice of at least one year to the end user of equipment before phasing
out the product/spares to enable the end user for placement of order for spares and services.
3.4 The vendor shall be responsible for design, engineering and manufacturing of the complete
VFD system to fully meet the intent and requirements of this specification and attached data
sheets.
4.0 SITE CONDITIONS
4.1 The AC drive system shall be designed to operate under specified site conditions as specified
in the data sheets. If not specifically mentioned therein, a design ambient temperature of
50°C.and an altitude not exceeding 1000 metres above mean sea level shall be considered.
4.2 The AC drive shall be installed indoors in a non-hazardous, air-conditioned or pressurized

room, as specified in data sheet.
4.3 All the equipment shall be designed for continuous duty as per nameplate rating under the
specified ambient conditions.
5.0 DESIGN AND FABRICATION REQUIEMENTS
5.1 Performance Requirement
5.1.1 The system shall be energy efficient, designed as standard product and shall provide very
high reliability, high power factor, low harmonic distortion and low vibration/ wear/noise. It
shall be easy to install in minimum time and expense and no special tools shall be required
for routine maintenance.
5.1.2 The system shall be designed to deliver the motor input current and torque for the complete
speed torque characteristics of the driven equipment, with input supply variation of ±10% and
frequency variation of ±3%. The system shall be suitable for the load characteristics and the
operational duty of the driven equipment. It shall be capable of withstanding the thermal and
dynamic stresses and the transient mechanical torque, resulting from short-circuit.
5.1.3 The drive system shall be designed to operate in one or more of the following operating
modes as to suit characteristics of the driven equipment or specified in the data sheet:
a. Variable torque changing as a function of speed i.e. Speed squared

b. Constant torque over a specific speed range
c. Constant power over a specific speed range where the torque decreases when speed
Increases
d. Any other as specified in data sheet
0
5.1.4 The drive controller shall be equipped with microprocessor based digital regulator with
programmable functions. The power control regulator logic shall provide for an
acceleration/deceleration current limit curve and shall be capable of field adjustments without
shutting the system down. Linear acceleration and deceleration shall be separately
programmable from 0.1 to 20 seconds.
5.1.5 The System shall be suitable for single quadrant operation and the speed variation shall be
with range 1:100 unless otherwise specified in data sheet with speed set accuracy of ±1% of
rated maximum speed and steady state regulation of±0.5% of rated speed.
5.1.6 The total harmonic distortion (THO) of the voltage and current at inverter output shall be as
per IEC 61800 and same shall be considered in the design of the motor. The dv/dt limits &
Vpeak shall also be as per IEC-61800-2.
5.1.7 Harmonics at the supply side of the drive system at primary of the main input transformer
shall be restricted within the maximum allowable levels of current and voltage distortion as
per recommendations in the latest edition of IEEE-519. The vendor shall perform design
calculation for harmonic filter system considering VFD connected to the power system and
including the supply of harmonic filters along with all accessories which shall be installed at
owner's power system unless otherwise specified. These harmonic studies shall be
conducted with maximum and minimum system fault level, cable capacitance, system
equipment reactance etc.
5.1.8 The controller output overload capacity shall be 150% of rated current of motor for one
minute for constant torque applications, and 110% of rated current for one minute for variable
torque applications at rated voltage. If the motor load exceeds the limit, the drive shall
automatically reduce the frequency and voltage to the motor to guard against overload. If load
demand exceeds the current limit for more than 1 minute, the drive shall shut down to prevent
over heating of the motor and damage to the drive.
5.1.9 During operation, the system shall be capable of developing sufficient torque under all load
conditions to respond to a 20% alteration in speed set point within a time limit upto 60
seconds.
5.1.10 The integrator action of the speed set point alteration shall be independently adjustable for
both an upward and a downward alteration. The minimum time interval between set point
adjustments by the distributed control system shall be considered as 10 seconds.
5.1.11 The drive shall trip in case the speed exceeds 105%of the maximum operational speed or
reduces to 95% of the minimum operational speed for more than 10 seconds.
5.1.12 Maximum noise level from the drive at 1-meter distance, under rated load with all normal
cooling fans operating shall not exceed 85 dBA.
5.1.13 Variable frequency drive shall be arranged so that it can be operated in an open circuit mode,
disconnected from the motor for start up adjustments and troubleshooting/ maintenance.
5.2 Control Requirement
5.2.1 The system shall operate on constant V/f supply with required voltage boost capability in low
frequency mode of operation.
5.2.2 Short time voltage dips up to 20% of nominal voltage (e.g. in case of a large motor start up
connected to the same bus as VFD) shall not cause the control system to stop functioning
and shall not trip the drive system.
0
5.2.3 The system shall also be equipped with a momentary powerloss ride through feature which
will restart the system in case of voltage dip over 20% or power interruptions for less than 2
seconds, with recovery of the voltage to its nominal value .. The drive shall have the facility to
block this feature, if required by the operator. Upon restart, the converter shall be capable of
synchronizing onto a rotating motor and develop full acceleration torque within 10 seconds.
5.2.4 The system shall be suitable for number of starts as per attached specification for Medium
Voltage Motors.
5.2.5 The power controller shall be regulated to always start the motor in the forward direction.
Logic shall be provided to prevent the motor from being started in the reverse direction.
5.2.6 The drive motor shall be speed controlled corresponding to 4-20mA or 0-10 V reference input
signal. Upon complete loss of the user's speed reference signal, the drive shall automatically
run at constant speed as at 80-100% of the last speed reference available prior to the loss of
signal.
5.2.7 It shall be possible to vary the speed of the drive in either manual or auto mode. Auto/Manual
selection shall be from VFD panel unless otherwise specified.
a. With the selector switch in "manual" mode, the operator shall be able to set the speed
through key pad (mounted on front ofthe drive panel) or from speed increase/decrease push
buttons (from the field). Motor operated potentiometer shall be provided as a speed set point
device.
b. With the selector switch in "auto" mode, speed of the motor shall be controlled from a 4-20
mA signal, from owner's PLC/DCS (Process Control) system. Necessary equipment required
for interfacing with PLC/DCS shall also be provided in the VFD panel.
c. Local/Remote selector switch shall be provided in local control station (in Field). With the
selector switch in "Local" mode, the operator shall be able to start and set the speed through
local control station (in Field). With the selector switch in "Remote" mode, speed of the motor
shall be controlled either from VFD panel or from Owner's PLC/DCS as explained in a) and b)
above.
5.2.8 The required provision for the interface with PLC/DCS (located at remote control room)
including the details of communication module and data transfer facility, 1/0 details shall be
furnished. The communication interface shall be via serial communication link with industry
standard open protocol i.e. MODBUS/IEC-61850/ RS-485 etc. and same shall be coordinated
with the interfacing equipment. In case the vendor is using their proprietary software, the
interface software for use with owner's system (software) shall be provided.
5.2.9 Drive system shall have provision for interface with upper level automation such as
Substation monitoring system or electrical control system in case specified in the data
sheet/job specification.
5.2.10 The closed loop control feed back for the drive system having output transformer shall be
tapped from the secondary side of the output transformer.
5.3 Panel Construction
5.3.1 The panel shall include suitable isolating device (i.e. Circuit breaker/MCCB/ Switch fuse) for
main supply, contactors, semi conducting power devices (Diodes / IGBT) modules with
protective devices, reactors, filters, output isolating device, control circuit, control accessories,
indication and annunciation etc.

0
5.3.2 Main isolating device shall function as a manual disconnect and shall be an AC thermal
magnetic circuit breaker or a fused switch with dual element fuse to trip automatically on fault
currents, as specified in data sheet. Devices shall be lockable in the open position and shall
have a minimum interrupting capacity as specified in data sheet. Interlock shall be provided
between the door, so that door cannot be opened unless the breaker/switch is open.
5.3.3 Safety Interlock shall be provided so that power cabinet can't be opened unless the upstream
breaker is disconnected, safety-grounding switch is closed and DC link capacitor is
discharged. Power source breaker can only be closed once the earthing switch is open and
panel door is closed with lock defeat facility.
5.3.4 The drive shall be suitably housed in sheet steel panels and shall be fabricated using cold
rolled sheet steel. The sheet steel used for the panel shall be of minimum 2 mm CRCA
except the doors & covers that may be made of 2mm CRCA. The panel shall be suitable for
indoor installation, if not otherwise specified. The panel shall be free standing with degree of
enclosure protection as IP-31. Maximum and minimum operating height shall be 1900 mm
and 300 mm respectively.
5.3.5 Bolted un-drilled gland plate shall be provided at bottom. Clamp type terminals shall be used
for connection of all wires up to 10 mm2 and terminal for higher sizes shall be bolted type
suitable for cable lugs. Minimum space for power cable termination shall be 300mm clear.
5.3.6 Bus bars shall be of electrolytic copper/aluminium, sleeved, color coded separately for AC
and DC system. All the live parts shall be sleeved / shrouded to ensure complete safety to
personnel intending to carry out routine inspection by opening the panel doors. All the
equipment inside the panel and on the doors shall be provided with suitable nameplate. All
wires shall be ferruled and terminals shall be properly numbered, minimum 20% spare
terminals shall be provided.
5.3.7 All the power and control switches shall preferably be mounted on the door and shall be
operable externally. All the analogue instruments, wherever provided, shall be switch board
type, back connected, 96x96mm size. Scale shall have red mark indicating maximum
permissible operating rating.
5.3.8 Each panel shall be provided with illuminating lamp/ll W CFL with switch and fuse. 5/15A,
240V power socket with switch and fuse shall be provided. Each panel shall have space
heater with switch fuse and variable setting thermostat.
5.3.9 Copper earth bus of min. 30X6 mm size shall be provided at the bottom of the panel
extending outside the panel on both sides. All the non-metallic components/parts shall be
connected to the main earth bus bar. In case a separate earth bus for electronic control
system is required, the same shall be indicated in the drawings.
5.3.10 All panels shall be of same height so as to form a uniform line-up, to give good aesthetic
appearance.
5.3.11 All the control wiring shall be enclosed in plastic/ metal channel. Each wire shall be identified
at both ends by self-sticking wire marker tapes or PVC ferrules. Power and control wiring
inside the panel shall be done with BIS approved, PVC insulated, fire retardant, low smoke,
copper conductor wire 1.5mm2 size wire shall normally be used provided the control fuse
rating is 10 Amps or less and 2.5 mm2 size for control fuse rating above 16 A for electrical
circuits and 0.5mm2 for electronic circuits. All wires shall be ferruled and terminals shall be
properly numbered, minimum 20% spare terminals shall be provided.

0
5.3.12 All electronic modules and components shall be accessible from front of panel only. Modular
assemblies for both the system control electronic equipments and power electronic
equipments shall be used.
5.3.13 DC link capacitor and pre-charging & discharging circuit shall be preferably mounted in the
rear of the panel.
5.3.14 Suitable eyebolts/ lifting clamps/ strap & cradle arrangement shall be provided for lifting of the
panel/shipping section. The bolts, when removed shall not leave any opening in the panel.
5.3.15 Acrylic type transparent insulating material shall be used for covering live components.
5.3.16 All equipment shall be complete with cable glands, lugs etc. and cable glands shall be single
or double compression type for indoor and outdoor equipment respectively. Cable glands
shall also be suitable for the hazardous area application if specified in data sheet.
5.4 Cooling
5.4.1 Cooling system shall include well-dimensioned panel, adequate cooling airflow path, module
cooling fan and if necessary, panel cooling fan. Vendor shall ensure that the panel
dimensions and flow paths have been designed for continuous running at the specified
ambient without overheating. For fan cooled drives, redundant ventilating fans (N+1) shall be
provided. Necessary starters shall be provided within the VFD panels for these fans. In case
redundant cooling fan is not possible to be mounted, same shall be supplied loose.
5.4.2 MCB for motor space heater, auxiliary power supply if required for local panel, drive panel
space heater etc. shall be included and mounted in easy accessible location.
5.5 Equipment/ Component Specification
5.5.1 Motor
The motor shall be designed, constructed and tested in accordance with the attached
standard specification for Medium Voltage Induction Motor, in addition to the following
requirements:
a. The motor shall be suitable for operation with a solid-state power supply consisting of an
adjustable frequency inverter for speed control.
b. The motor shall be suitable for the current waveforms produced by the power supply including
the harmonics generated by the drive.
c. The motor shall be designed to operate continuously at any speed over the range (10-100%)
of rated speed unless otherwise specified in data sheet.
d. Motor shall be provided with thermistor type temperature detector
e. The motors shall be provided with Class 'F' insulation with temperature rise limited to Class
`B’.
f. The permitted voltage variation should take into account the steady state voltage drop across
the AC drive and all other system components upstream of the motor.
g. Motors required to be transferred to DOL by-pass mode shall be rated for specified variations
in system line voltage and frequency. Starting current of motor in DOL bypass mode shall be
limited to value specified in motor specifications, unless otherwise specified in datasheets.
0
h. The motor shall be constructed to withstand torque pulsations resulting from harmonics
generated by the solid-state power supply.
i. The motor insulation shall be designed to accept the applied voltage waveform, within the
Vpeak and dv/dt limits as per IEC-61800-2.
j. The drive manufacturer shall be solely responsible for proper selection of the motor for the
given load application and the output characteristics of the drive.
k. Motors shall be provided with Resistance Temperature Detectors (RTDs).
l. Induced voltage at the shaft end of the motor at no load shall not exceed 250 mV rms for
roller and ball bearings and 400 mV 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.
5.5.2 Converter Transformer/ Output transformer
The converter transformer shall be suitable for use with the variable frequency drive system.
The impedances of transformers with two secondary windings for 12 pulse systems shall be
selected to ensure equal load/current sharing between the two secondary windings, the
converters and the motor windings under all operational conditions including starting and
restarting. The transformer shall be provided with ± 5% off circuit taps in steps of ± 2.5%.
5.5.3 Power Converter
a. The static power converter shall consist of a line side power converter for operation as a
rectifier and a load side power converter for operation as a fully controlled inverter. Power
converter shall be fast switching, most efficient and low loss type.
a. Normally, for all output short circuits, the inverter shall interrupt the current before any semi-
conductor fuse blows. For internal short circuits, semi-conductor fuse protection shall be
provided, and for faults upstream of semi-conductor fuses, the converter shall be able to
withstand a three-phase short circuit current until interrupted by normal breaker operation. In
case of fuseless design, the failure shall be limited to the particular device, without causing
any damage to other parts of the power module. There must be clear annunciation of the
failure of the device.
b. All power converter devices shall include protective devices, snubber networks and dv/dt
networks as required.
c. The current rating of the converter's semi-conductor components shall not be less than 120%
of the nominal current flowing through the elements at full load of the VFD through the entire
speed range.
d. All power diodes shall be of silicon type with minimum VBO rating as 2.5 times the rated
operating voltage.
e. The power converter circuit shall be designed so that motor can be powered at its full
nameplate rating continuously without exceeding its rated temperature rise due to harmonic
currents generated by the inverter operation.
f. The conversion devices and associated heat sinks shall be assembled such that individual
devices can be replaced without requiring the use of any special precautions/tooIs.

0
g. The cooling system of the electronic components, if provided, shall be monitored and
necessary alarms shall be provided to prevent any consequential damage to the power
control devices.
h. All the power transistors, thyristors and diodes shall be protected with high-speed
semiconductor grade fuse. I2t particulars of the power controller devices and the fuses shall
be properly co-ordinated for the selection of fuses.
5.5.4 DC Link Reactor
a. Smoothing reactors for the DC link shall be designed to sufficiently decouple the rectifier and
inverter portion of the converter and to limit fault currents in this circuit. AC line reactors, if
provided as per standard vendor design, shall be suitable for harmonic suppression and fault
current limitation.
b. The reactor shall be dry type, air cooled or fan cooled type located within the panel. In case of
fan cooled type, operation of fans shall be monitored.
c. Reactor shall be suitable for operation with the non-sinusoidal current wave shapes and DC
components under all operational conditions of the system without exceeding its temperature
limits.
5.5.5 Output Filter
VFD output current waveform shall be inherently sinusoidal at all speeds, with harmonic limits
as per C1.5.1.6. Output filter capacitors shall be provided with discharge circuits to ensure
that all residual stored charge is reduced to less than 50 V DC within 60 seconds after a loss
of AC voltage. The VFD system shall inherently protect motor from high voltage dv/dt stress,
independent of cable length to motor. Output filter shall be an integral part of the VFD system
and included within the VFD enclosure.
5.5.6 Bypass Feature
5.5.6.1 Output contactor/Load Break Switch shall be provided for isolation between the output of the
controller and the motor for VFD systems with Bypass feature.
5.5.6.2 Bypass feature shall be provided, if specified in the data sheet. Accordingly Bypass feature
with Bypass starter shall meet the following requirements, unless otherwise specified in the
data sheet:-
Bypass starter shall comprise of switch-fuse, contactor, bimetal relay meeting the
requirements of Type-2 coordination as per IS/IEC-60947. CBCT and ELR shall be provided
for motors rated above 22kW & upto 55kW unless otherwise specified in the data sheet.
Heavy duty starters shall be provided with saturable type current transformer operated
overload relay only, which shall be suitable for motor starting time of 15-60 seconds. For
motors rated above 55kW, ACB/MCCB and motor protection relay along with necessary
metering shall be provided.
Bypass starter shall be in separate compartment and it shall be possible to isolate and
maintain the VFD while drive motor runs in Bypass mode. Three contactors/ breakers shall be
used for this purpose, one contactor in the bypass and two contactors across the drive, such
that in case of drive mal-operation, the motor could be taken on bypass control, while the drive
could be attended by opening its contactors. Suitable interlock shall be provided such that
bypass mode and VFD mode shall not operate simultaneously.
5.5.7 Local Motor Control Station

0
a. The local motor control station, to be installed in the field near the motor shall conform to the
attached specifications. Components and accessories that are required in the local motor
control station may be mounted on the local field mounted panel envisaged for the driven
equipment.
b. Meters in the local control station for motors rated above 5.5kW shall be suitable for 4-20mA
transducer outputs and shall be calibrated for the actual motor current unless specified
otherwise. Further, for drives with bypass facility, the meters shall be capable of reading
bypass full load and starting currents, as well as the drive current. Local-off-Remote selector
switch shall be provided in the LCS for selection of control from Local (i.e. LCS in Field) and
Remote (i.e. from VFD panel / DCS / PLC).
5.6 Protection, Control, Metering, Indication and Annunciation
5.6.1 The system vendor shall provide all the necessary system control, protection, alarm and
metering equipment for the entire drive system and its auxiliary equipment.
5.6.2 Automatic sequence control shall include start-up of cooling system, auxiliary system of the
motor, interlock checking, automatic start and run-up of drive, planned and emergency
shutdown. The same shall be processed through microprocessor-based system.
5.6.3 Operator Control Panel
a. Each drive shall be equipped with a front mounted operator control console consisting of a
backlit alphanumeric display and a keypad with keys for parameterization and adjusting
parameter which shall not be limited to Start/Stop, Local/Remote, Auto/Manual,
Increase/Decrease, menu navigation and protection and measurement parameter selection,
etc.
b. All parameter names, fault messages, warnings and other information shall be displayed in
complete English words or standard English abbreviations to allow the user to understand the
display without the use of a manual or cross-reference table. This shall also be used for the
modification of all electrical values, configuration parameters, drive menu parameters,
application and activity function access, faults, local control, adjustment storage, self test and
diagnostics. Keypad shall be operable with password for changing the protection setting,
safety interlock etc. However, the parameters such as measurements, setting, mode of drive
etc. shall be allowed to be viewed without any password.
c. Operator console shall have facility/ port to connect external hardware such as Laptop etc.
Console shall have facility to upload and download all parameter settings from one drive to
another identical drive for start-up and operation.
d. Drive system control shall also have facility to receive tripping signal from upstream breaker
for tripping and also provision for closing upstream breaker after all required process
parameters are achieved.
e. User-friendly software for operation and fault diagnostic shall be loaded in the drive system
panel before commissioning.
5.6.4 Protective Features
The system shall incorporate adequate protective features, properly coordinated for the drive
control and for the motor but not limited to the following:
I. Incoming line surge protection

II. Under / Over voltage protection
0
III. Phase loss protection.

IV. Programmable over current protection and under load protection.
V. Inverter Fault.
VI. Over frequency/Over speed of motor
VII. Ventilation loss (In case same is not provided, drive shall generate an over
temperature fault alarm and suitable sensors, as required for same, shall be
provided).
VIII. Over temperature of equipment.
IX. Specific motor protection, including motor winding, bearing temperatures, over
current, overload, negative phase sequence and earth fault protections etc.
X. System earth fault protection.
XI. Excitation system protection for synchronous motor
XII. Over and under frequency, rotor earth fault (if applicable), field failure protection for
synchronous motor
XIII. Additional protection, if any for the drive system
5.6.5 Alarms
The system shall incorporate protection alarms, required for various fault conditions, for the
Drive motor, Supply cables, Converter Transformer, DC Reactor and the Converter. Alarms
shall also be included for the failure of various auxiliaries together with identification of the
failing unit, loss of cooling system, various protection devices provided for converter
transformer etc.
5.6.6 Control
The following controls shall be provided as a part of the Operator Control Panel or through
separate switches.
I. Start/Stop
II. Speed control (Raise/Lower)
III. Forward/Reverse (if specified)
IV. Auto/Manual /Test mode
V. Local/Remote
VI. Emergency stop
VII. Start/Stop for bypass starter (where specified)
VIII. Trip-Remote Breaker
IX. Excitation control system for synchronous motors
X. Sequential switching of filters
5.6.7 Indications
Vendor shall provide indications as required for normal operation and for ease of
maintenance, which shall not be limited to the following indications.
I. Motor running
II. Motor stopped
III. VFD System Fault
IV. System ready to start
V. AC mains ON
VI. Motor over speed
VII. Rectifier output 'ON'
VIII. Motor zero speed
IX. Remote breaker trip

0
X. Excitation system healthy for synchronous motors
Above indications may be provided as a part of the operator control panel, i.e. door mounted
keypad or through hardwired LEDs. LEDs provided for indication shall be cluster type with
adequate brightness and minimum 2 Nos LEDs chips per light. LEDs shall be connected in
parallel and each LED chip having diameter not less than 3mm.
Potential free contacts for items i to iv shall be wired separately for remote indications in DCS
system.
5.6.8 Metering
Digital display of the following parameters shall be as a part of the Operator Control Panel,
selectable by the operator.
I. Output voltage
II. Output current-VFD model Bypass mode
III. Output frequency
IV. Drive thermal state
V. Motor speed
VI. Motor energy meter
VII. Hour Run
VIII. Voltage and current meter for excitation system of synchronous motor
IX. KVAR, power factor meter for synchronous motors
X. Necessary transducer shall be provided with 4-20mA output for indicating motor
XI. speed and motor current in DCS unless otherwise specified for other parameters.
5.6.9 Annunciations
Potential free contacts shall be provided for following annunciations and shall be wired up to
terminal block for owner's use for remote monitoring:
I. Rectifier fuse failure/Drive fault

II. Main AC failure
III. Inverter fuse failure/Drive fault
IV. Inverter overload
V. Inverter high temperature/Drive fault
VI. Failure of panel cooling system
VII. Motor failed to start/Drive fault
All drive internal faults will be annunciated as drive fault.
5.7 Fault Diagnostic
Fault diagnostic shall be built into the system to supervise the operation and failure of the
system. The information regarding failure of any of the system including, shutdown of the
system, shall be available for a period of minimum 4 days (96 hours) after a shutdown, even
though no supply would be available to the system. The system may be totally de-energized
for maintenance or otherwise. It shall be possible to retrieve the record of events prior to
tripping of the system or de-energisation. Auxiliary supply to the system components or to the
electronics (firmware) for the diagnostics / display shall be taken care by the manufacturer for
this purpose.
5.8 External Power supply for auxiliary and Control Circuit

0
Control supply for devices external to VFD module i.e contactors control, space heater supply
for Motor / VFD, indicating lamps digital meters (Ammeter, Speedometer) etc. shall operate
on 240 V control supply derived from single-phase control supply transformer, with switchfuse
provided in primary and MCB in secondary, located inside the drive controller.
5.9 Reliability Features
The expected life time of the VFD shall be minimum 20 years. The VFD including all
individual components forming part of the system shall have an availability of minimum 0.997
and a minimum MTBF of 4 years.
The controller design shall incorporate the following reliability features:
- Pre-tested components with power components to be 100% tested under dynamic

conditions.
- Printed circuit boards shall be computer tested and adjusted.
- Printed circuit boards shall be temperature cycled for a minimum of 40 hours.
- Printed circuit boards shall be treated for tropical, humid and corrosive environment.
5.10 Maintenance features
The controller design shall incorporate the following maintenance features:

Modular construction
Printed circuit boards shall be plug connected.
All components shall be easily accessible.
Standard diagnostics to aid maintenance personnel. These shall include LED or
alphanumeric displays, test or measurement points.
5.11 Painting
5.11.1 After preparation of the under surface, the panel shall be spray painted with two coats of
epoxy based final paint or shall be powder coated. The color shade of final paint shall be as
RAL 7032, unless specified otherwise. Panel finish shall be free from imperfections like
pinholes, orange peels, runoff paint, etc.
5.11.2 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 finishing coat.
5.11.3 All unpainted steel parts shall be zinc passivated, cadmium plated or suitably treated to
prevent rust and corrosion. If these parts are moving elements, then these shall be greased.
6.1 All tests shall be carried out at the manufacturer's works under his care and expense. The
tests shall be witnessed by an inspector of PDIL/ Owner or of an agency authorized by
the owner. Prior notice of minimum 4 weeks shall be given to the inspector for witnessing the
tests.
6.2 During fabrication, the drive shall be subject to inspection by PDIL / Owner, or by an agency
authorized by the Owner, to assess the progress of work, as well as to ascertain that only
quality raw material is used.

0
6.3 All Routine & Type Tests shall be conducted as per the NIT for HV variable frequency drive 6-
81-1050 as per IEC 61800-2. However, combined test for VFD and motor at vendor's works
shall be carried out if specified in the datasheet.
6.4 String Test with driven equipment
If a string test with driven equipment is specified in the data sheet of the driven equipment, it
shall be carried out with the job equipment.
7.0 SPARES


8.0 DRAWINGS
Vendor shall submit to Purchaser, for approval, before completion of manufacturing and
assembly of equipment following drawings and literature.
(i) Installation and maintenance manual including trouble-shooting chart.

(ii) Panel drawings and cable schedule
(iii) Block diagram and control logic.
9.0 CERTIFICATION
The motors and associated Variable frequency drive system equipment shall have test
certificates issued by recognized independent test house (CIMFRI BASEEFA/ LCIE/UL/FM or
equivalent). All indigenous motors shall conform to Indian Standards and shall be certified by
Indian testing agencies. All motors (indigenous and imported) shall also have valid statutory
approvals as applicable for the specified hazardous location. All indigenous flameproof
motors shall have valid BIS license and marking as required by statutory authorities.
Also the motor nameplate shall clearly indicate that the motor is suitable for operation with
variable frequency drive along with VFD make and model number.
All the equipment shall be divided in to several shipping sections for protection and ease of
handling during transportation. The equipment shall be properly packed for selected mode of
transportation i.e. ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets
before being placed in wooden crates/cases to prevent damage to the finish. Crates/cases
shall have skid bottoms for handling. Special notations such as 'Fragile', 'This side up',
'Weight', 'Owner's particulars', 'PO nos. etc., shall be clearly marked on the package together
with other details as per purchaser for scrutiny. The equipment may be stored outdoors for

0
long periods before installation. The packing shall be completely suitable for outdoor storage,
in areas with heavy rains/high ambient temperature.

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
TECHNICAL SPECIFICATION - COMMUNICATION AND FIRE
ALARM CABLES (PC150-TS-0821) Sheet 1 of 10
COMMUNICATION AND FIRE ALARM CABLES

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
3.0 SITE CONDITIONS
4.0 TECHNICAL REQUIREMENTS -NON JELLY FILLED CABLES
5.0 TECHNICAL REQUIREMENTS FOR JELLY FILLED CABLES

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
1.0 SCOPE
The intent of this specification is to define the requirements for design, manufacture and
supply of Flame Retardant type PVC sheathed cables for use in plant communication and
fire alarm systems and Jelly filled telecommunication cables.
2.1 The equipment shall comply with the requirements of the latest revision of the following
standards issued by BIS and DOT, unless otherwise specified:
2.1.1 BIS standards:
IS-694 PVC insulated cables for working voltages upto and

including 1100V.
IS-1554 (Part-I) PVC insulated (heavy duty) electric cables-(Part-l for

working voltages up to and including 1100V).
IS-5831 PVC insulation and sheath of electric cable.
IS-8130 Conductors for insulated cables and flexible cords.
IS-9938 Recommended Colours for PVC insulation for LF wires and

cables.
IS-10418 Drums for electric cables.
IS-10462 (Part-1) Fictitious calculation method for determination of

dimensions of protective coverings of cables:(Part-l
Elastomeric and thermoplastic insulated cables).
IS-10810 (Part-58) Methods of test for cables (Part 58. Oxygen Index test).
IS-10810 (Part- 61) Methods of test for cables (Part 61. Flame retardant test)
IS-10810 (Part-62) Methods of test for cables (Part 62. Fire resistance test for
bunched cables).
IS-12444 Continuously cast and rolled electrolytic copper wire rods for
electrical conductors.
2.2 DOT Standards:
GRJWIR-06/03 Specification for cable - switchboard (Screened and

Unscreened) Generic Requirements.
G/CUG-O1/02 Specification for solid polythene insulated fully filled,

Polythene sheathed underground telecom cables.
2.3 In case of imported cables, standards of the country of origin shall be applicable, if these
standards are equivalent to or stringent than the applicable Indian standards.
2.4 The cables shall also conform to the provisions of the Indian Electricity rules and other

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
2.5 In case Indian standards are not available for any material, standards issued by IEC / BS
/ VDE / IEEE / NEMA or equivalent agency shall be applicable.
2.6 In case of any contradiction between various referred standards/ specifications/

datasheets and statutory regulations the following order of priority shall govern:
- Statutory regulations.
- This specification.
- Codes and standards.
3.0 SITE CONDITIONS
Cables shall be suitable for installation in following conditions:
i. Above ground in open-air locations (trays / ducts) in tropical, humid and corrosive
atmosphere prevalent in refineries/petrochemical plants with severe weathering and
exposure to solar radiation.
ii. Directly buried in underground trenches, conduits with uncontrolled back-fill and
possibility of flooding by water and chemicals.
iii. Unless otherwise specified, the design ambient air temperature of 45° C / ground
temperature of 30° C.
iv. Cables shall be operating near electromagnetic radiations due to high voltage
installation and other wireless equipments. Adequate screening shall be provided to
make build the electromagnetic immunity.
4.0 TECHNICAL REQUIREMENTS -NON JELLY FILLED CABLES
4.1 Conductors
4.1.1 The size of conductor shall be as per job requirement.
4.1.2 The conductors shall consist of annealed, high conductivity solid copper wire, smoothly
drawn, circular in cross-section, uniform in quality, free from defects and uniformly coated
with pure tin and shall conform to Cl. 3.0 of DOT specification GR/WIR-06/03. For
telecommunication cables conductor shall be 0.5 mm and for PA system conductot dia
shall be 0.6 mm as minimum. For fire larm cables size of conductor shall be chosen
based on sum of the current drain of all field points in that circuit.
4.2 Insulation
4.2.1 The core insulation shall be with PVC compound applied over the conductor by extrusion.
4.2.2 PVC insulation, when used shall meet the following requirements:
Conductor Diameter Type of Insulation Thickness of Insulation

(Area)
Upto 0.63 mm Type-2 of Table-3 as As per Table-l of DOT

(0.3mm2) per IS-13176 Specs. GR/WIR-09/02
Above 0.63mm (Above Type-A as per IS-5831 Table-2 as per IS-1554

3.0 MM2) (Part-I)

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
4.2.3 The colours used for insulation shall conform as nearly as practicable to the standard
colours as per 18-9938. The wire insulation shall have colours in accordance with Table-
2 of DOT specification GR/WIR-06/03. The applied colour shall neither have deleterious
effect on the electrical, mechanical or ageing properties of basic insulation nor shall get
damaged by any friction etc.
4.2.4 For single pair cables, the colour shall be incorporated in the insulation.
4.2.5 For multi pair cables, cores shall have uniform pattern of continuous spiral (Pitch not
exceeding 25mm) to facilitate easy identification. This may be done by the application of
one or more coloured strips on a base colour or by direct extrusion.
4.2.6 Alternately, colouring may consist of concentric coloured rings or dots or dashes on the
base colour. The coloured rings, dots or dashes shall have a width of not less than
1.0mm and shall be repeated along the length of the insulation at an interval not less than
15mm and not more than 25mm.
4.2.7 The dots or dashes shall be applied on diametrically opposite sides of the insulation, so
that all colours are visible when the insulation is viewed from any side.
4.3 Twisting
The two insulated conductors of a pair shall be uniformly twisted with a suitable right
hand lay, which shall not exceed 80mm.
4.4 Core Formation
The core formation shall conform to C1.6.0 of DOT specification no. GR/WIR-06/03.
4.5 Screen
4.5.1 Unless otherwise specified the cables used for fire alarm and detection shall be provided
with overall screen. The screen shall be of aluminium tape with minimum thickness of
0.04mm. The overlap shall be minimum 3mm for cables up to 50 pair & minimum 6mm
for cables above 50 Pair. The screen shall be backed by an outer protective layer of
0.13mm PVC tape or other non hygroscopic material lapped applied longitudinally or
helically with overlap.
4.5.2 The cables shall be provided with a drain wire. Drain wire shall have a minimum cross-
section of 0.5mm2, shall be composed of multistrand bare tinned annealed copper
conductor. The drain wire shall be in continuous contact with the aluminium side of the
overall screen. The drain wire resistance including screen shall not exceed 30 ohm/km.
4.6 Ripcord
A non-metallic ripcord of suitable quality shall be laid longitudinally under the inner sheath
& screen. The ripcord when pulled shall cut through the sheath and strip the core.
4.7 Inner Sheath
4.7.1 An extruded inner sheath of type ST1 PVC, as per IS-5831, with minimum thickness as
per Table-4 of IS-1554 (Part-1) shall be applied over the laid up core, by extrusion to fit
closely on it.
4.7.2 The inner sheath shall be as circular as possible. It shall be possible to remove the inner
sheath without damage to the insulation.

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
4.7.3 When one or more layers of non-hygroscopic tape is helically applied over the laid up
cores, as a binder, the thickness of such tape(s) shall not be construed as a part of the
inner sheath.
4.8 Armour
4.8.1 The cables shall be provided with armouring, made of hot dip galvanised steel wire /strip
over the inner sheath.
4.8.2 The armour shall be by means of 1o4mm thick round wires for cables with under armour
diameter upto 13mm. For cables with an under armour diameter above 13mm, the
armour shall either be of steel strip or round wire with thickness as per IS-1554 (Part-1).
4.9 Outer Sheath
4.9.1 The cables shall be provided with an extruded PVC sheath for external protection. The
PVC shall be type ST1 PVC, as per IS-5831.
4.9.2 The other sheath shall be with oxygen index 29 at 27±20C and possess flame retardant
properties meeting the requirements of IS 10810 Part-62 category - AF. In addition,
suitable chemicals shall be added to the PVC compound of the outer sheath to protect
the cable against rodent and termite attack.
4.9.3 The thickness of outer sheath shall be as per IS-1554 (Part 1).
4.9.4 The outer sheath shall fit tightly on the armour and shall be applied in such a manner that
no undue residual strain is left in the material.
4.9.5 The outer sheath shall be grey in colour except for cables to be used for fire alarm
system where it shall be red.
4.9.6 Sequential marking of the length of the cable, in meters, shall be provided on the outer
sheath at every one meter. The marking shall be legible and indelible by suitable method.
4.9.7 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.
4.10 Cable Capacitance
4.10.1 The core to core capacitance of the cables shall not exceed 100nF/Km at 1KHz.
4.10.2 The core to screen capacitance for the screened cables shall not exceed 250nF/Km at
1KHz.
5.0 TECHNICAL REQUIREMENTS FOR JELLY FILLED CABLES
5.1 Jelly filled telecom cables shall in general conform to the requirements of DOT
specification G/CUG-01/02, unless otherwise specified in this specification.
5.2 Conductors
5.2.1 The conductors shall consist of annealed, high conductivity solid copper wire, smoothly
drawn, circular in cross-section, uniform in quality, free from defects and uniformly coated
with pure tin and shall conform to cl. 3.0 of DOT specification G/CUG-01/02.
5.3 Insulation

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
5.3.1 Each conductor shall be insulated with insulating grade PE conforming to C1.4.0 of DOT
specification G/CUG-O1/02.
5.4 Twisting
The two insulated conductors of a pair shall be uniformly twisted with a suitable right
hand lay, which shall not exceed 150mm.
5.5 Core Formation
The core formation shall conform to C1.6.0 of DOT specification G/CUG-01/02.
5.6 Filling Compound
5.6.1 The cable shall be filled with a suitable stable water resistant compound, which shall be
compatible with the insulation, binders and tapes used in the cable.
5.6.2 It shall be homogeneous and uniformly mixed material containing an anti-oxidant.
5.6.3 The compound shall not obscure the identification of the colour of the insulation of the
conductors.
5.6.4 It shall not contain dirt, metallic particles or other foreign matter.
5.6.5 The compound shall be readily removable from the insulated conductors by wiping.
5.6.6 It shall be free from any unpleasant odour and shall have no toxic or dermatic hazards.
5.6.7 The flash point of the compound shall not be less than 200°C.
5.6.8 The volume Resistivity measured at 100°C shall not be less than 1010 ohm-ern.
5.6.9 The permittivity at 1 MHz tested as per ASTM 0-924 shall not be greater than 2.3 at
20°C.
5.7 Core Wrapping
At least one closed helical or longitudinal application of a non-hygroscopic and non-

wicking polyester tape or tape of any other suitable material shall be provided over the
cable core.
5.8 Screen
5.8.1 The cables shall be provided with overall screen. The screen shall be of aluminium tape
with minimum thickness of 0.2mm. The overlap shall be minimum 3mm for cables having
maximum diameter over inner sheath < 30mm & minimum 6mm for cables having
maximum diameter over inner sheath ~ 30mm. The screen shall be coated with 0.05 mm
nominal thickness polythene/copolymer on both sides. The thickness of the composite
tape shall be 0.3mm±15%.
5.8.2 The aluminium tape shall be electrically continuous throughout the length of the cable.
5.9 Inner Sheath
5.9.1 The inner sheath shall be as circular as possible and free from pinholes and other
defects. It shall be possible to remove the inner sheath without damage to the insulation.

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
5.9.2 The inner sheath shall be of polythene conforming to type 03C or H03C of BS 6234 and
shall contain a suitable antioxidant system. The material shall be virgin as per ASTM 0-
883 and meet the following requirements.
Density 0.910 to 0.940 glee for 03C and> 0.940 glee for H03C
Melt Flow index Maximum 1.0 g/10 minutes (190 °e, 2160 g load)
5.9.3 The thickness of inner sheath shall conform to Table - 6 of DOT specification no.
G/CUG01/02.
5.9.4 The maximum diameter over inner sheath shall conform to Table - 7 of DOT specification
no. G/CUG-O 1/02.
5.10 Armour
5.10.1 The cables shall be provided with bedding and armour over the inner sheath.
5.10.2 The bedding shall consist of two close helical lappings of polythene or polypropylene
tape. Each tape shall be applied with a minimum of 5% overlap.
5.10.3 The armour shall be made of hot dip galvanised steel tape of thickness as per Table - 8
of DOT specification G/CUG-01/02.
5.11 Outer Sheath
5.11.1 The external protection shall consist of a polythene sheath conforming to the material
specification defined in Clause 5.9 above.
5.11.2 The thickness of outer sheath shall conform to Table - 9 of DOT specification G/CUG-
01/02.
5.11.3 The outer sheath shall be as circular as possible and free from pinholes and other
defects. It shall be possible to remove the inner sheath without damage to the insulation.
5.11.4 The outer sheath shall be grey in colour except for cables to be used for fire alarm
system where it shall be red.
5.11.5 The maximum diameter over outer sheath shall conform to Table - 7 of DOT specification
G/CUG-01/02.
5.12 Cable Capacitance
The average mutual capacitance of the pairs measured at 800 to 1000Hz shall be 52 ± 3
nF/km.
However, the mutual capacitance of individual pairs shall be within the limits of 52 ±4.5
nF/km.
6.1 The cables shall be tested and examined at the manufacturer's works. All the materials
employed in the manufacture of the cable shall be subjected to examination, testing and
approval by PDlL/Owner. Manufacturer shall furnish all necessary information concerning
the supply to PDlL/Owner's inspectors. The inspector shall have free access to the
manufacturer's works for the purpose of inspecting the process of manufacture in all its
stages and he will have the power to reject any material, which appears to be of
unsuitable description or of unsatisfactory quality.

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
6.2 The following acceptance tests shall be conducted on the completed jelly filled cables as
per the test procedures given in DOT specification G/CUG-01/02 and this specification:
i. Measurement of diameter of conductor, over inner sheath & over outer sheath.
ii. Measurement of Thickness of insulation, inner sheath, screen, armour & outer
sheath.
iii. Measurement of Resistance of conductor.
iv. Measurement of Resistance unbalance.
v. Continuity Check & Measurement of Resistance of Poly-al tape.
vi. Colour coding.
vii. Conductor continuity test.
viii. Mutual Capacitance test.
ix. Capacitance Unbalance test.
x. Cross talk test.
xi. Attenuation test.
xii. Insulation resistance test.
xiii. Dielectric strength test.
xiv. Drip test.
xv. Armour Galvanisation Test.
xvi. Conductor Annealing Test.
xvii. Measurement of drum length.
6.3 The following tests shall be conducted on the completed non jelly filled cables as per the
test procedures given in DOT specification GR/WIR-06/03 and this specification:
6.3.1 Acceptance tests:
i. Measurement of diameter of conductor, over inner sheath & over outer sheath.
ii. Measurement of Thickness of insulation, inner sheath, screen, armour & outer
sheath.
iii. Measurement of Resistance of conductor.
iv. Colour coding.
v. Conductor continuity test.
vi. Mutual Capacitance test.
vii. Capacitance Unbalance test.
viii. Insulation resistance test.
ix. High Voltage test.

PC150/E/4004/SecVI-5.3
(PART-A)
Document No. Rev
x. Armour Galvanisation Test.
xi. Conductor Annealing Test.
xii. Measurement of drum length.
6.3.2 Special Tests
The non jelly filled cables shall also be subjected to following special tests.
i. Oxygen Index test as per IS-l 0810 (Part 58).
ii. Flammability test on finished cable as per IS-I0810 (part 61 & 62).
The special test shall be conducted on one sample from each lot. The sample will be
selected by the inspector.
7.1 Cables shall be despatched in non-returnable wooden 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
defects. Wood 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
and storage.
7.2 On the flange of the drum, necessary information such as project title, manufacturer's
name, type, size, length of cable in meters, drum no., cable code, BIS certification mark,
gross weight, 'Owner's particulars', 'P.O. numbers' etc., shall be printed. An arrow shall
be printed on the drum with suitable instructions to show the direction of rotation of the
drum.
7.3 Cables shall be supplied in drum lengths of 1000 meters, if not specified otherwise.
7.4 For non jelly filled cable, 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 moisture/water during transit and
storage.
7.5 For jelly filled telephone cables, the ends of the cable shall be sealed by thermo
shrinkable end caps of adequate wall thickness. Alternately ends may be sealed by
enclosing them in rubber or PVC caps of wall thickness not less than 1.8mm. The caps
shall be secured to the outer sheath with hose clips or ties or black adhesive tape or heat
shrinkable sleeves.
7.6 The cables may be stored outdoors for long periods before installation. The packing shall
be suitable for outdoor storage in areas with heavy rains / high ambient temperature,
unless otherwise agreed.

0
TECHNICAL SPECIFICATION - CAPACITOR BANK AND Document No. Rev
ASSOCIATED EQUIPMENT (PC150-TS-0822) Sheet 1 of 12
CAPACITOR BANK & ASSOCIATED EQUIPMENT

0
CONTENTS
SECTION DESCRIPTION
NUMBER
1.0 SCOPE
6.0 PROTECTIVE SCHEME (PROVIDED BY PURCHASER)
7.0 ACCESSORIES
8.0 PAINTING
11.0 SPARES
12.0 PACKING
13.0 DEVIATIONS
ANNEXURE - I DOCUMENTATION FOR CAPACITOR BANK & ASSOCIATED

EQUIPMENT

0
1.0 SCOPE
works and delivery in packed condition of “ Indoor type Shunt Capacitor Bank &
Associated Equipment” required for system power factor improvement.
Electrical.
1.3 The capacitor bank and associated equipment shall generally consist of the following.
i) Basic Star connected capacitor bank
ii) Basic capacitor unit with built in fuse
iii) Discharge resistor
iv) Series reactor
v) Residual V. T. for mounting voltage unbalance
vi) Set of Raychem make heat insulated sleeved of suitable voltage rating for bus
bars.
vii) Copper bus bar interconnecting the basic units.
viii) Set of supporting insulators
ix) Hot dip galvanised Steel stand/racks / cabinets of mounting capacitor units
complete with interconnection insulator etc.
x) Door limit switch
xi) Control panel for automatic operation
xii) Any other equipment not specified, but required for safe & proper operation of
the system.
2.1 The design, manufacture & testing of the equipment covered by this specification shall
comply with the latest issues of following Indian standards, unless otherwise specified.
IS: 13925-1,2,3 /IEC Shunt Capacitor for power system
60871
IS:5553/IEC60289 / Series reactors
IEC60076-6/IEC 726
IEC60186 Voltage Transformers
IEC:593/IS 12672 Internal Fuse for shunt capacitor
IS/IEC:60947 Switch gear and control-gear for voltage up to & including
1000V & 1200V DC
IS/IEC:60947 General requirements for switchgear and control-gear for
voltage not exceeding 1000V & 1200V DC
IS :9921 AC Isolator & Earthing switches for voltage above 1000V
IS 2099/ IEC 60137 Bushing for voltage above 1000V

IS 13067 Impregnant For power capacitors
IS 5 Colour of mixed paints
IS 2629 Recommended practice for Hot-Dip Galvanizing of Iron and
Steel
IS 4759 Hot-dip zinc coatings on structural steels and other allied
products.
IS 60270 High Voltage test technique-Partial Discharge
measurements
IS 8084 Interconnecting Bus bars for AC voltage above 1 kV up to
and including 36 kV.

0
IEEE 1036 Guide for application of shunt power capacitors

IEEE 18 Standard for shunt power capacitors
IE Act Indian Electricity Act
2.2 The design & operation features of equipment shall also comply with provision of the
latest issue of the Indian Electricity Rules & other relevant statutory acts & regulation.
The supplier shall, wherever, necessary, make suitable modification in the equipment to
comply with the above.
2.3 Wherever, any requirement laid down in this standard differs, from that in Indian
standard specification, the requirement specified herein shall prevail. Equipment
3.0 SERVICE CODITIONS
3.2 System Details
4.0 OPERATING REQUIRMENTS
4.1 The capacitor bank and associated equipment shall be suitable for operating at the
specified rating continuously with the specified voltage and frequency variation under
the ambient condition without exceeding the permissible temperature rise and without
any detrimental effect on any part of equipment.
4.2 The capacitor bank and associated equipment shall be suitable for parallel switching
and withstand the thermal and dynamic stresses caused by transient during switching
operations.
5.1 Capacitor Unit
5.1.1 The capacitor bank / sub bank shall comprise of appropriate number of basic single
phase units & which shall be connected in star formation to obtain rated KVAR at rated
voltage.
5.1.2 Each unit shall have required number of capacitor elements housed in hermetically
sealed, leak proof, sheet steel container. The container shall be provided with suitable
brackets, supporting insulators, terminal & bushing for external connections.
5.1.3 Each element of basic units has its own built in fuse which shall isolate the faulty
element automatically without affecting the healthy elements.
5.1.4 The capacitor units shall have overload capacity as per IS 13925.The capacitor bank
shall be suitable for continuous operation at 110% of rated RMS voltage and at 130% of
rated RMS current.
5.1.5 Capacitor units shall be all high grade All Polypropylene type with non-PCB base, bio
degradable, non-toxic impregnant. The capacitors offered shall be built from best
material and shall develop minimum losses. Capacitor bank losses shall be given at

0
45ºC.Capacitor shall be compact in size, metal enclosed and hermetically sealed.

Internal silver wire fuses shall be provided for protection of each capacitor element.
5.1.6 The Capacitor bank and associated equipments shall be suitable for parallel
switching and withstand the thermal and dynamic stresses by transient during
switching operation.
5.1.7 All the fasteners and bolts shall be hot dip galvanized or zinc passivated.
5.1.8 Capacitors shall be provided with Overpressure protection as necessary for safety.
Overpressure switches shall be fitted to the capacitor units and connected to trip the
capacitor bank.
5.1.9 Each unit shall have required number of capacitor elements housed in sealed, leak
proof, sheet steel container. The container shall be provided with suitable mounting
brackets, supporting insulators, terminal & bushing for external connections.
5.1.10 The indoor capacitor bank units shall be installed in metallic housing with minimum
IP-43 protection.
5.1.11 Each capacitor unit shall be mounted so that it can be easily removed from the racks
and replaced without removing other units, de-assembling any part of the rack.
5.1.12 The outside of the capacitor units and other structures should have smooth and tidy
look and should be coated with weather-proof, corrosion resistant epoxy paint of light
gray shade, shade no. 631 of IS 5. The structure shall be suitably GI coated.
Minimum coating shall not less than 600 micron / sq meters.
5.1.13 Each element of basic units has its own built in fuse which shall isolate the faulty
element automatically without affecting the healthy elements. In case of one element
failure, harmful over voltage shall not be generated across remaining elements and
shall not make appreciable change in the operation of capacitor bank. An operation
of a single fuse element does not cause cascaded fuse blowing. Permissible over
voltages and surges do not cause fuse blowing.
5.1.14 The operating & design temperature category of the capacitor unit shall be +5ºC as
per IS-13925 part-1. Only 5ºC temperature rise is permissible above the design
temperature of 45ºC. So maximum temperature in any case shall not exceed 50º C
{i.e. 45ºC (design) +5ºC (temperature rise}.
5.1.15 The capacitor shall have low value of loss which shall not exceed 0.2 watt per KVAR.
The loss value of discharge device/resistor and capacitor unit shall be indicated. The
tan delta characteristics of the capacitor units shall be furnished. The losses in watts
for each capacitor unit including losses in fuses and discharge resistors forming
integral part of the capacitors along with losses for series reactor shall be
guaranteed. If these figures of capacitor losses exceed 0.2 watt per KVAR, the
capacitors will be liable for rejection. However owner reserve the right to use the
faulty capacitor unit till the same are replaced/rectified. The loss temperature
characteristics, capacity temperature characteristics and insulation resistance
temperature characteristics shall also be furnished.
5.1.16 The bidder shall furnish calculations for rise in voltage in other units in the event of
failure of element(s) of a capacitor unit. The maximum rise in voltage shall not be
more than 10% of rated voltage even if the entire capacitor unit failed/short circuited
and relevant calculations in support of this shall also be furnished.
5.1.17 The bidder shall furnish calculation of voltage drop at rated capacitor unit per phase
& losses of the reactor.
5.1.18 For both capacitor and reactor, mounting arrangement and minimum clearance
required from live parts shall be indicated clearly and shall be as per Indian
Electricity Act/BS162 & IS-13925-Part2 / IEC-60871-2.
0
5.2 Discharge Device
5.2.1 A suitable discharge resistor of adequate rating shall be permanently connected across
the terminals inside the container to discharge the residual voltage to 50V or less within
1 minute for capacitor rated upto 650V and within 5 minute for capacitor rated above
650V.
5.3 PROTECTIVE FUSES

5.3.1 An internal current limiting fuse with high rupturing capacity conforming to relevant
IS/IEC and the specific requirements mentioned in IS13925-Part-3/IEC 60871- 3,
shall be provided. The characteristics of the fuse shall be such that it shall isolate the
faulty unit only, and protect it against mechanical destruction due to internal failure.
The fuses shall not melt or deteriorate when subjected to inrush currents which occur
during the life of the bank.
5.3.2 The fuses shall not make any healthy capacitor element out of circuit, either in
course of isolating the faulty element or due to any external fault.
5.3.3 The selection of fuse to be done in such a manner that characteristic of fuse shall
match suitably with over-current withstand characteristic of associated capacitor unit.
5.3.4 The fuses shall be of adequate thermal capacity to cater for the increased heating
which may occur due to harmonics and capacitor current fluctuations.
5.3.5 The number of externally connected capacitors and the available short-circuit
current of the supply system should not affect the current-limiting of internal fuses.
5.3.6 It may be noted that provided internal fuses do not lead to case rupture.
5.4 Series Reactor
5.4.1 A suitable series reactor conforming to IS: 5553 to limit the inrush current and suppress
the harmonics shall also be provided whenever required.
5.4.2 The reactor shall be copper wound, non-magnetically shielded, oil immersed, natural
cooled, sealed type and shall be provided with following fittings.
i) Oil sampling cum drain valves.
ii) Filter valves with plugs.
iii) Buchholz relay with shut off valves, air release device & alarm and trip contact.
iv) Oil temperature indicator with minimum marking.
v) Oil level indicator with minimum marking.
vi) Oil conservator complete with drain plugs and oil filling hole with cover.
vii) Silica gel breather with oil seal & connecting pipes.
viii) Explosion vent.
ix) Bi-directional rollers.
x) Thermometer pocket.
xi) Radiator with isolating valves.
xii) Marshalling box.
xiii) Rating plate, wiring diagram plate & terminal marking plate.
xiv) Lifting lugs.
xv) Earthing terminals.
xvi) Air release device.
xvii) Cable termination arrangement for incoming & outgoing device.

0
5.4.3 Dry type/ Oil filled reactor shall only be offered. Such reactors shall be class F/H
insulated.
5.4.4 The reactor shall have linear volt ampere characteristics upto 150% of rated capacitor
current.
5.5 Residual voltage transformer
5.5.1 3 phase dry type residual voltage transformer of adequate capacity to facilitate neutral
unbalance protection and rapid discharging of capacitor shall be provided.
5.5.2 The primary winding of voltage transformer shall be star connected while the secondary
winding shall be in open delta for connection to neutral phase displacement relay.
5.5.3 The accuracy class shall be 3P for protection & 1 for metering.
5.5.4 RVT shall have primary and secondary windings made of copper.
5.6 Door limit switch
5.6.1 A door limit switch suitable for mounting on the door frame of the capacitor room shall
be provided for each bank. This door limit switch shall l be used to trip the power supply
to capacitors with initiation of opening action of the door of the capacitor room.
5.6.2 A door limit switch shall be totally enclosed in the aluminium / cast iron housing, fully oil,
water & dust tight and shall conform to utilization category AC11 / DC11 as per IS:
6875. This shall be fast actuation type provided with 6 sets of 1 NO & 1 NC contacts
rated for 5 amps at 415V AC and 1A at 220V DC.
5.7 Capacitor control panel
5.7.1 Capacitor control panel for control, protection and automatic switching operation of MV
capacitor bank shall be provided.
5.7.2 Capacitor control panel shall be of dust, damp & vermin proof construction having
enclosure class IP-51 as per IS/IEC:60947.
5.7.3 The enclosure shall be fabricated out of the cold rolled sheet steel having minimum
thickness of 2 mm. the doors shall have concealed hinges & provided with neoprene
gaskets.
5.7.4 The panel shall be liberally designed. All the components shall be accessible from the
front. It shall be possible to attend any component without the necessary removing
adjacent ones. All the relays, meters, push buttons including lamps etc. shall be flush
mounted. The mounting height of components requiring operation & observation shall
not be lower than 300 mm & higher than 1800 mm.
5.7.5 The capacitor control panel shall control the capacitor bank which in turn shall have a
number of sub banks for easy of control & to maintain the desired power factor under
varying load conditions.
The owner shall arrange C.T supply to sense the power factor. Necessary C.T., selector
switch, power factor meter and power factor correction relay shall be provided in the
control panel. In addition, the control panel shall have Photo manual selector switch and
P.F. raise lower push buttons for manual operation. These common features shall be
located near the incoming unit.
5.7.6 Each control shall be provided with TPN switch, voltmeter with selector switch, Ammeter
with selector switch and other auxiliaries, as required to receive the incoming power.

0
5.7.7 No. of out going feeders for the control panel shall be decided as per the no. of sub
banks to be controlled by it. Each feeder shall be provided with TP switch, fuses,
contacts, “ON”& “OFF” indication lamps and other auxiliaries as required.
5.7.8 Required no. and size of heavy duty double compression type Aluminium cable glands
suitable for incoming and out going power and control cables shall be mounted on
removal gland plate provided at a minimum height of 75 mm from the bottom of the
panel. Crimping type Aluminium and copper lugs for aluminium and for copper cable
respectively shall be provided for termination of cables.
5.7.9 The control panel shall be complete with its base channels, foundation bolt etc.
5.7.10 A continuous earth bus of aluminium, running along the entire length of the lower part of
the control panel shall be provided with lugs at two ends for connection with external
earth grid. The minimum size of earth bus shall be 150 sq. mm.
5.7.11 Components Details
5.7.11.1 The switches shall be of capacitor duty type rated for 1.5 times the rated capacitor
current with a minimum rating of 25 A and shall conform to IS/IEC:60947.
5.7.11.2 The fuses shall be of non-deteriorating HRC link type and suitably rated for capacitor
switching. These shall conform to IS: 13703.
5.7.11.3 All contactors shall be of capacitor duty type rated for 50% higher than rated capacitor
current & shall conform to IS/IEC:60947. Control supply voltage shall be 240V single
phase AC unless otherwise stated. One set of NO & NC potential free contacts shall be
made available as spare.
5.7.11.4 Ammeter, Voltmeter & power factor meter shall be of accuracy class 1.5 as per IS: 1248
of minimum 96 sq.mm size & shall have 0-2400 scale.
5.7.11.5 The push buttons & selector switches shall conform to utilisation category AC11/ DC11
as per IS: 6875. Contacts shall be rated for 5A at 415V AC and 1A at 220V DC. The
push button shall be of momentary contact spring loaded type with a set of 1 NO & 1
NC contacts. The selector switches shall be stay put type and provided with oval
shaped handless.
5.7.11.6 The signal lamps shall be LED type. Colour of lamp shall be “Red” for “ON” & “Green”
for “OFF” signals.
5.7.11.7 Terminal blocks shall be pressure clamp type up to 35 sq. mm. cable and bolted lugs
type for higher sizes of cables. The minimum current rating of terminal block shall
be16A. 20% extra terminals shall be provided in the terminal block.
5.8 BUS BARS
5.8.1 All bus bars interconnecting the basic units shall be of copper and shall be fully
insulated by using Raychem make heat shrinkable sleeves. All bus bar joints and tap-off
connections shall be provided with removable FRP shrouds. The sleeves shall be rated
to withstand the system Line-to-Line voltage for 1 minute.
5.8.2 The minimum clearances shall be as per relevant standards suitable for the nominal
voltage of capacitor banks.
5.9 External cable termination
5.9.1 Each capacitor bank / sub bank shall be provided with proper termination arrangement
where terminal connection from all the three phases shall be brought for connection with
external cable. The termination arrangement shall include cable glands, cable lugs,
termination kits, supporting arrangements etc. complete in all respect.
0
5.9.2 A cable box for termination of control cables shall be provided on the RVT. The cable
boxes shall be provided with adequately sized cable entries and suitable double
compression cable glands made of stainless steel. Tinned copper lugs shall be provided
for the connection of all cable cores.
5.10 Interlocks
All necessary interlocks to ensure correct & safe operation of capacitor banks shall also
be provided.
5.11 Earthing
Each basic capacitor unit shall be connected to the earth strip provided on the steel
racks which in turn shall be connected to the main earth grid through two nos. suitable
earth terminals provided on the racks.
6.0 PROTECTIVE SCHEME (PROVIDED BY PURCHASER)
6.1 The vendor shall confirm the adequacy of these protective devices and also suggest the
setting and any other additional protective devices required.
7.0 ACCESSORIES
The supply shall include the following accessories.

7.1 Control panel space heater
The control panel shall be provided with a thermostatically controlled space heater,
rated for 240V, 50Hz & controlled through double pole miniature circuit breaker.
7.2 Name plate
7.2.1 All the equipment shall be provided with name plates containing all the information’s as
per relevant standard.
7.2.3 Name plate of capacitor control panel shall be of black prespex with white engraving
and of minimum 3 mm thickness while those on other equipment shall be of stainless
steel.
7.3 WARNING PLATES
7.3.1 Warning plates shall be provided on the door and inside of the equipment, comprising
following information:
CAUTION: HIGH VOLTAGE CAPACITORS.
AT BLOWN FUSES, CHARGES MAY REMAIN
7.3.2 The warning plates shall be UV resistant engraved plastic.
7.4 Steel racks
7.4.1 Sheet steel racks shall be provided to house the capacitor units, residual P. T. etc. in
tier formation.
7.4.2 The racks shall be suitable for assembly at site. The racks & hardware used for
assembly shall be hot dip galvanized.
7.4.3 The rack shall be complete with rack insulators, foundation bolts or any other hardware
etc. for assembly into complete bank.
7.4.4 Complete assembly of capacitor bank shall be mounted on a pedestal GI frame, which
shall be 300 mm high.

0
7.4.5 Any other accessories required but not specified, shall be supplied to make the
capacitor installation complete in all respect and ensure safe & proper operation.
8.0 PAINTING
8.1 The sheet steel enclosure after degreasing, pickling in acid, cold rinsing, phosphatising
passivating etc. shall be painted with two coat of anti-rust paints followed by two coats
anti corrosive paints.
8.3 All paint shall be carefully selected to withstand tropical heat and extremes of weather.
The paint shall not scale off, crinkle or be removed by abrasion due to normal handing.
8.4 Unless otherwise specified, the finishing shade shall be light gray shade no. 631 as per
IS: 5.
9.1 All capacitor banks and control panel shall be subjected to routine tests as per IS: 2834
and its associated equipment as per relevant standards.
manufacture at works & site inspection.
9.4 These inspections shall, however, not absolve the vendor from his responsibility for
specified.
10.2 All drawings and documents shall have following description written boldly.
- Name of client
11.0 SPARES



0
offer.
12.0 PACKING
12.1 All the equipment shall be properly packed before despatch to avoid damage during
transport, storage & handling.
12.2 The packing box shall contain a copy of the installation, operation & maintenance
manual.
12.3 A sign to indicate the upright position on the position of the package to be placed during
transport and storage shall be clearly marked. Also proper arrangement shall be
provided to handle the equipment.
13.0 DEVIATIONS
reasoning.

0
ANNEXURE - I
DOCUMENTATION FOR CAPACITOR BANK & ASSOCIATED EQUIPMENT
Sl.
Description
No. With Bid For Approval Final
3. General Arrangement Drgs. with Overall N Y Y
dimensions of the following equipment.
- Capacitor bank
- Reactor
- Control panel
4. Foundation plan indicating certified N Y Y
dimensions floor opening, weight,
clearance etc.
- Capacitor bank
- Reactor
- Control panel
5. Schematic & wiring diagram N N Y
6. Descriptive literature of Various equipment N N Y
7. Installation, operation & maintenance N N Y
manual
9. Test certificate N N Y
Note:
the date of LOI.
coated folder.
Y - Yes, N - No

0
TECHNICAL SPECIFICATION - CATHODIC PROTECTION Document No. Rev
POWER SUPPLY MODULE (PC150-TS-0823) Sheet 1 of 13
CATHODIC PROTECTION POWER SUPPLY MODULE (CPPSM)

0
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
3.0 SITE CONDITION
6.0 EQUIPMENT DESCRIPTION
7.0 TESTS AND ACCEPTANCE
9.0 DEVIATIONS

0
1.0 SCOPE
This specification covers the requirements for the design, manufacture and testing of
Cathodic Protection Power Supply Module (CPPSM) working on controlled switch mode
principle intended to supply power to cathodic protection system
2.1 The system design, performance and materials to be supplied shall conform to the
requirements of the latest revision of following standards:
IS: 1248 (Parts-I, 2, 8 & 9) Direct acting indicating analogue electrical

measuring instruments and accessories.
IS: 3700 (Parts-I to 11) Essential rating and characteristics of

semiconductor devices
IS: 3715 (Parts-I to 4) Letter symbols for semiconductor devices

IS: 4411 Code of designation of semiconductor devices.
IS: 5469 (Parts-I to 4) Code of practice for the use of semiconductor
junction devices.
IS: 6619 Safety code for semiconductor rectifier

equipment.
IS:7204 (Parts-I to 4) Stabilised power supplies DC output.
IS: 12021 (Parts-I to 4) Control transformers for switchgear and control
gear for voltages not exceeding 1000 V AC.
IS: 13703 (Parts-I to 4) Low voltage fuses for voltages not exceeding
1000 V AC or 1500 V DC.
IS/IEC:60947 Low voltage switchgear and control gear.
2.2 In case of imported equipment, standards of the country of origin shall be applicable if
these standards are equivalent or stringent than the applicable Indian standards.
2.4 In case of any contradiction between various referred standards/ specifications/ and
- Codes and standards.
3.0 SITE CONDITION
The CPPSM shall be suitable for installation in non air-conditioned room with restricted
ventilation or in outdoor kiosk in locations having generally corrosive, warm, humid and
dusty atmosphere. Service conditions shall be as per actual site conditions. If not
specifically mentioned therein, a design ambient temperature of 45°C and an altitude not
exceeding 1000 m above mean sea level shall be considered.
The offered equipment shall be brand new with state of art technology and proven field

0
offered equipment for at least 15 years from the date of supply.
4.2 Vendor shall give a notice of at least one year to the end user of equipment and owner
before phasing out the product / spares to enable the end user for placement of order for
spares and services.
5.1 Fabrication and General Details
CPPSM shall be housed in sheet steel enclosure. The front, rear walls and doors shall be
made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum
1.6 mm thick sheet steel. Wherever required, suitable stiffeners shall be provided. The
Unit shall be freestanding type. Hinged doors "Shall be provided at the front and back as
required. The unit shall be natural cooled type. Louvered openings with wire mesh for
natural ventilation may be provided. Degree of protection for the panel shall be minimum
IP-41. The CPPSM panel shall, preferably, not need rear access for operation,
maintenance and shall be suitable for mounting flushed to the wall.
5.1.2 Suitable hooks shall be provided for lifting the panel. These hooks when removed shall
not leave any hole in the panel or imperfection in the paint finish.
5.1.3 All instruments shall be panel mounted type and back connected. All fuses shall be
provided inside the panel and shall be of link type. 660 V grade PVC insulated BIS
approved wires with stranded copper conductor of size minimum 2.5 mm2' shall be used
for power and auxiliary wiring. Control wiring for electronic circuits shall be through flat
ribbon cable or through copper wire of minimum 0.5 mm diameter. All wirings shall be
ferruled with PVC ferrules at both ends for ease of identification. Clamp type terminals
suitable for termination up to 10 mm" conductor shall be provided for all control cable
connection. Suitable power terminals shall be provided for power cables. Minimum 20%
spare terminals shall be provided. The terminal blocks shall be mounted minimum 300
mm above the gland plate.
5.1.4 All live parts shall be properly shrouded. This shall ensure complete safety to personnel
intending routine maintenance by opening the panel doors.
5.1.5 CPPSM shall be suitable for bottom cable entry unless otherwise specified and shall be
supplied complete with crimping type tinned copper lugs and cable glands. Cable glands
shall be of rolled aluminium single compression type for indoor installations and double
compression type for outdoor installations. The space in the terminal chamber shall be
adequate for termination of required number and sizes of cables.
5.1.6 The CPPSM shall be field proven. The design, internal component layout and rating of
component shall ensure high MTBF and low MTTR. Prototype equipment shall not be
acceptable. Layout of panel components shall enable easy access to the components for
maintenance.
5.1.7 All the control equipment like switches, push buttons, potentiometers etc. shall be located
at a convenient height of minimum 300 mm and maximum 1800 mm from the bottom of
the panel.
5.1.8 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB
tracks shall be tinned and solder masked. The PCB shall be coated with suitable lacquer
to make it immune to dust, moisture and fungal growth. Where plug in type of PCBs are
used gold plated male-female connectors shall be used for the purpose.

0
5.1.9 If required the panel shall be provided with space heater to prevent moisture
condensation. The space heaters shall be located at the bottom of the panel and shall be
provided with a manually operated switch and HRC fuse. The space heater shall have
porcelain-insulated connectors. Where space heater is not provided, the electronic
PCBs/components and other control devices shall be made immune to moisture
condensation.
5.1.10 Panel shall be provided with integral base frame channel. The integral base frame of
panel shall be suitable for directly bolting with the help of foundation bolts and shall also
be suitable for tack welding to purchaser's insert plate/flat/channel embedded in the floor.
Amply dimensioned oblong holes shall be provided at the bottom of the panel for its
bolting to the embedded insert plate/channel.
5.1.11 An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminium shall be
provided throughout the length of the panel. Provision shall be made for connecting this
earth bus at two ends with the plant earth grid by means of (40x5) mm" GI flat. All non-
current carrying metallic parts of the panel and mounted equipment shall be connected to
the panel earth bus. All doors and movable parts shall be connected to the earth bus by
flexible copper cables.
5.1.12 All panel mounted equipments (e.g. lamps, push buttons, switches, meters, PCBs, etc.)
shall be provided with suitable nameplates. Nameplates shall be engraved out of 3-ply
(black-whiteblack) lamicoid sheets or anodised aluminium. Back-engraved perspex sheet
nameplates may also be acceptable. Engraving shall be done with groove cutters. Hard
paper or self-adhesive plastic tape nameplates shall not be acceptable. Nameplates shall
be fastened by screws and not by adhesive. Labels shall be provided for every
component on the cards, connecting wires as well as for the terminals in the terminal
strip inside the panel.
5.1.13 Where specified, the CPPSM shall be housed in an outdoor kiosk. The kiosk shall be
made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and
external surfaces. Hinged lockable doors shall be provided at the front and back. Acrylic
transparent glass window shall be provided on the front door of the kiosk so that the
meters, indications and positions of the control switches on the CPPSM can be seen
without opening the door of theꞏ kiosk. The kiosk shall be suitable for outdoor mounting
and shall give proper protection to the CPPSM against rain, other harsh weather
conditions. Necessary ventilation arrangement with louvers and wire mesh shall be
provided for proper operation of the CPPSM. The cable entry to the kiosk shall be from
bottom through cable glands. Suitable canopy shall be provided on the top of the kiosk.
5.1.14 Painting
All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust,
grease and dirt.
Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The
under surface shall be prepared by applying a coat of phosphate paint and a coat of
yellow zinc chromate primer. The undersurface shall be made free from all imperfections
before undertaking the finishing coat.
After preparation of the under surface, the panel shall be spray painted with two coats of
final paint or shall be powder coated. Colour shade of final paint shall be approved by the
purchaser before final painting is started. The finished panels shall be dried in stowing
ovens in dust free atmosphere. Panel finish shall be free from imperfections like pin
holes, orange peels, run off paint, etc.

0
All unpainted steel parts shall be cadmium plated or suitably treated to prevent corrosion.
If these parts are moving elements, then they shall be greased.
The CPPSM shall be complete with following main sections:

- Input controls.
- Power converter and filters.
- Output protections
- System controls
- Current interrupter
- Control, indication and metering
6.1 Input Controls
6.1.1 A moulded case circuit breaker with thermal over load and short circuit release (rated for
the input power supply short circuit current) shall be provided at the input for power
supply control.
6.2 Power Converter and Filters
6.2.1 The CPPSM shall convert and control the input DC power supply voltage/current into
variable DC output voltage/current through switching power semiconductor devices
(Thyristor/power transistor/power MOSFET, etc.). The variation in the output
voltage/current shall be achieved through control of duty cycle of conduction of the
switching power semiconductor devices. The current and voltage ratings of the power
semiconductor devices shall be at least two times the maximum device current and min.
two times the maximum voltage coming across it respectively. The voltage rating of the
power semi-conductor devices shall be co-coordinated with the breakdown voltage of
lightning arrestor provided at the output so that the power semiconductor devices are
protected from any voltage surge coming from the pipeline. Shunt zeners / MOV shall be
provided across the power semiconductor devices for protection. The power
semiconductor devices shall have humidity/moisture resistant finish and mounted in
sufficiently sized heat sink designed to provide adequate cooling under worst conditions
of operation. The power semiconductor devices shall have adequate protection against
high dv/dt and di/dt.
6.2.2 Where specified, the converter shall electrically isolate the input power to CPPSM from
its output so that the grounding of the positive output of the CPPSM through anode
ground bed shall not affect the grounding system of the input power supply. Alternatively,
a separate DC to DC converter having electrical isolation between input and output
power supply shall be provided at the input of the CPPSM.
6.2.3 The power semiconductor devices shall be protected by semiconductor fuses or the
system shall have instantaneous short circuit-current limit feature to protect the devices
against output short circuits. An adjustable output over current limit feature shall be
provided.
6.2.4 Filter shall be provided in the input power supply circuit to minimise the AC injected into
the DC input power supply system.
6.2.5 Adequate filtering shall be provided on the DC output of the converter to limit the ripple
content in the output to less than 5% at rated output.
6.2.6 The converter system shall be of natural air cooled type.

0
6.2.7 For CPPSMs with multiple output circuits, each output circuit shall have independent
output converter and output filters.
6.3 Output Protections
Two pole moulded case circuit breaker or miniature circuit breaker rated for the DC
output current, short circuit current and having thermal over load, short circuit release
shall be provided in the output. A lightning arrestor rated for minimum 10KA impulse
current discharge capacity and rated voltage & max. spark over voltage rating suitable to
protect the CPPSM components against lightning and switching surges shall be provided
at the output. For CPPSMs with multiple output circuits, each output circuit shall have
independent protections.
6.4 System Controls
6.4.1 The CPPSM shall have two distinct modes of operation (independent for each output
circuit) as below:
a) Constant Voltage - Constant Current Mode (CVCC)
In this mode the output voltage (Vos) of CPPSM shall be continuously adjustable
from 0.5V DC to the rated output voltage. Current limit feature shall be provided in
this mode of operation. The current limit (los) shall be continuously adjustable from
zero to rated output current.
For constant voltage mode of operation the output current limit shall be set at
maximum and output voltage setting shall be varied. Irrespective of output current
demand the chosen value of the output voltage shall be maintained by the control
system till the current limit is reached. After that the output current limit shall be
maintained and output voltage shall decrease to keep the current constant.
For constant current mode of operation the output voltage shall be set at maximum
and output current shall be varied through varying the setting of output current limit.
Irrespective of output voltage requirement the control system shall maintain the
output current to the set current limit value till the voltage limit is reached. After that
the output voltage limit shall be maintained and output current shall decrease to
keep the voltage constant.
b) Auto PSP Mode
In this mode of operation the output of the CPPSM shall operate in an external
closed loop with pipe-to -soil potential (PSP) in feedback loop. The CPPSM control
shall adjust the output voltage such that the PSP as measured by reference cell
always remains equal to the set potential on the unit. The set potential (Vps) shall
have high long time stability and minimum temperature drift. The set potential shall
be continuously adjustable over the range as required. An adjustable over current
limit shall be provided to limit the maximum output current.
The unit shall be designed to operate with the number of reference cells connected
to it (to be provided by others). In case of more than one reference cell being
specified, CPPSM shall have feature to automatically select the reference cell
having less negative potential than the others and use the same for auto control of
the unit (e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be
provided in selecting the less negative potential reference cell, to avoid hunting
between the reference cells at change over conditions.
In case of open circuit or short circuit of the reference cell or potential being less
negative than a minimum set potential (Vrs), for the controlling reference cell, the
0
unit shall sense these conditions as reference cell failure and shall automatically
switch over to the other healthy reference cell for control. Should fault occur in all
the reference cells, the output voltage or current of the CPPSM shall adjust
automatically to a preset value (Vas/las), which shall be adjustable.
In both CVCC and auto PSP modes of operation the electronic over current limit
shall be fast enough to protect the active devices of the unit and fast enough to act
before tripping of MCCB/MCB or blowing of fuse.
6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shall be
provided in case of PSP either exceeding the specified maximum limit (Vpm ) or
remaining lower than the specified minimum limit (Vpn).
6.4.3 The output voltage regulation for no load to full load variation with input voltage variation
from maximum to minimum shall not be more than 2.5 % of rated voltage throughout the
range of output voltage and over the specified ambient temperature variation, in CVCC-
constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation
for no load to full load variation with input voltage variation from maximum to minimum
shall be within 20mV throughout the PSP setting range specified.
In CVCC- constant current mode of operation, the current regulation for minimum to
maximum output voltage and minimum to maximum variation in input voltage shall not be
more than 2.5% throughout the range of output current.
6.4.4 The output of the unit shall be ungrounded and shall allow grounding of positive terminal
of the output through the anode ground bed.
control system.
6.5 Current Interrupter
6.5.1 If required a current interrupter for CPPSM output current interruption shall be provided.
6.5.2 The current interrupter shall have an output contactor with current rating minimum 125%
of the output current rating of the CPPSM and a digital timer to operate it.
6.5.3 The timer shall have 'ON' and 'OFF' timings. When the timer is turned on the 'ON' timing
shall start and shall close the output contactor till the end of the 'ON' timing. At the end of
the 'ON' timing the 'OFF' timing shall start and keep the contactor open till the end of the
'OFF' timing. At the end of the 'OFF' timing the 'ON' timing shall start again. This process
of 'ON' and 'OFF' timing shall continue.
6.5.4 The 'ON' and 'OFF' timings of the timer shall be settable by separate 2 digit thumbwheel
switches, each settable from 1 to 99 seconds. The timing error of the timer shall be less
than 5 parts per million. In case of microprocessor based system keypad with display
may be provided in place of thumbwheel switches.
6.5.5 Whenever the timer is switched on it shall always start with ON 'timing'. A timer-reset
push button shall be provided. On pressing this pushbutton during operation of the timer,
the timer shall get reset and upon release of the button, the timer shall restart with 'ON'
timing.
6.5.6 The power required for operation of the timer and contactor shall be derived from the
main power supply to the CPPSM.

0
6.5.7 The following controls and indications shall be provided for current interrupter. The
controls shall be housed in a lockable cover, so that normally they are not accessible.
The indications shall be mounted on the door.
a) Controls
- Timer power 'ON' / 'OFF'
- Timer reset
- Thumb wheel switch for 'ON' timing
- Thumb wheel switch for 'OFF' timing
In case of microprocessor based system, keypad with display may be provided in
place of thumbwheel switches.
b) Indications (LED)
- Timer power 'ON'
- 'ON' timing
- 'OFF' timing
6.5.8 The output contact of the current interrupter contactor shall be wired in the positive DC
output of the CPPSM. A link shall be provided for shorting these terminals whenever the
current interrupter is not in use.
6.5.9 If required the current interrupter shall be an independent unit of portable type. The
interrupter unit shall have terminals for input power supply and terminals of the contactor
in the timer output. The input power supply and the rating of the timer output contactor
shall be as required.
6.5.10 Where the current interrupter is not specified with CPPSM or is specified as portable type
external to the CPPSM, then the CPPSM shall have provision for connection of input
power supply terminals and output contacts of external current interrupter for current
interruption test. A link shall be provided for shorting the output terminals provided in
CPPSM for current interruption, whenever the current interrupter is not connected.
current interrupter.
6.6 Controls, Indication and Metering
6.6.1 Following controls shall be provided on CPPSM front door.
a) ON/OFF control for input through MCCB.
b) ON /OFF control for output through MCCB/MCB.
c) Auto/CVCC mode selector switch.
d) Potentiometers for Vos, Vps and los settings.
e) Selector switch for selecting indication of PSP set and PSP actual for all the
reference cells.
6.6.2 Following controls shall be provided inside the module at user accessible common
location:
a) Potentiometer for Vrs, Vpm, Vpn and Vas/las settings.
b) Controls for current interrupter:
- Timer reset

0
6.6.3 CPPSM shall have following indicating lights (lamps or minimum 5 mm dia LEDs):
a) CPPSM ON/OFF
b) Unit in auto/CVCC (2 lamps)
c) Reference cell controlling the closed loop control of the CPPSM (number of lamps
same as number of reference cells).
d) Reference cell faulty (number of lamps same as number of reference cells).
e) Pipeline over protected.
f) Pipeline under protected
g) Indications for current interrupter:
- Timer power 'ON'
- 'ON' timing
- 'OFF' timing
It shall be possible to switch-off all the indication lamps by a single switch. In case of LED
indication lights this facility may not be provided.
6.6.4 Following meters having min cl. 1.5 accuracy shall be provided on the CPPSM:
a) Digital meter for output voltage
b) Digital meter for output current
c) Digital voltmeter to measure PSP set (Vps) and PSP actual for all the reference
cells. The meter shall have range from (-) 4 V to 0 V and shall have cl. 0.5
accuracy.
e) Digital meters for measuring Vrs, Vpm, Vpn and Vas/las settings.
f) Meters for input voltage and current
It shall be possible to switch-off all the digital meters preferably by a single switch.
6.6.5 If specified, CPPSM shall incorporate provision for remote monitoring of the unit through
SCADA system as below:
a) Potential free contacts for the following:
- All the reference cells failed. (Contact open on alarm condition)
- Pipeline overprotected. (Contact open on alarm condition)
- Pipeline under protected. (Contact open on alarm condition)
- System in auto-mode. (Contact close in auto condition)
- System in CVCC mode. (Contact close in CVCC mode)

0
b) 4 to 20 mA electrically isolated signal for the following:
- PSP (-4V to OV)
- CPPSM output voltage
- CPPSM output current
The transducers shall have electrical isolation between input and output. The isolation
insulation shall withstand 2 kV, 50 Hz for minimum 1 minute. The accuracy class of the
transducer shall be 0.5. The transducers shall be protected against input and output
voltage surges. The transducer shall be suitable for driving upto 600 ohms load
impedance located upto 500 m away and wired with 0.5 mm- copper conductor cable.
The transducers shall be suitable for minimum 125% continuous over load in the input
voltage/current parameter.
6.6.6 For units having multiple outputs, each output circuit shall have independent controls,
indication and metering.
7.1 During fabrication, the equipment shall be subjected to inspection by owner or his
authorised representative to assess the progress of the work as well as to ascertain that
only quality raw materials are used for the same. He shall be given all assistance to carry
out the inspection.
7.2 Final acceptance test shall be carried out at manufacturer's works under his care and
expense. Instruments and equipments required for testing shall be arranged by
manufacturer. Owner's representative shall be given minimum 2 weeks prior notice for
witnessing the tests. Test certificates indicating test results shall be furnished by the
manufacturer. Acceptance tests shall include but not be limited to the tests listed below.
7.2.1 Visual Inspection
This shall include-
- Completeness of the equipment in line with specification.
- Checking of all settings.
- All labels provided and satisfactory.
- Dimensional checking.
- Proper mounting of components and neatness of wiring etc.
- Model number.
7.2.2 Insulation tests
The voltage specified in the table below shall be applied for one minute to the circuits
indicated:
Withstand voltage Control Power electronics Auxiliary circuits Un2

electronics <60V Un1

0
To earth 700VD.C. 2xUn1 + 1000V 2xUn2+ 1000V
To control - 2xUn1+ 1000V 2xUn2+ 1000V

electronics
To power electronics 2xUn2+ 1000V - 2xUn2+ 1000V
To auxiliary circuits 2xUn2+ 1000V 2xUn1 + 1000V -
(Un, and Un2 are nominal voltage rating of power electronics and auxiliary circuits
respectively).
D.C. test voltages may be applied instead of A.C. The magnitude of D.C. test voltages to
be applied shall be 2 times the above-mentioned A.C. (r.m.s) Values.
Insulation resistance test shall be conducted before and after heat run test.
7.2.3 Heat run test
All CPPSMs shall be subjected to a heat run test performed at rated voltage for period
not less than 16 hours prior to execution of functional tests.
At least one CPPSM of each rating shall be loaded to its rated output throughout 16 hour
test period. All other CPPSMs shall be energized under partial load or zero load current
condition throughout the test period.
7.2.4 Functional tests
Functional tests as below shall be performed on each CPPSM. If during execution of

functional tests, any electronic component of the unit is required to be replaced e.g. due
to malfunction or failure of the unit to fulfil the performance requirements of the
specification, then the load test shall be repeated at rated current following which
functional tests shall be carried out.
7.2.4.1 CVCC mode operation testing
a) Constant voltage operation
During the test, current limit shall be set to rated output current. Performance
testing shall be carried out for various output voltage settings and load varying from
zero to maximum. The verification of operation of the control functions,
measurement of output voltage, current, input voltage, current, ripple in the output,
input, evaluation of output voltage regulation and efficiency of the unit shall be
carried out during the testing.
b) Constant current operation
During the test, voltage limit shall be set to rated output voltage. Performance
testing shall be carried out for various output current limit settings and load
resistance varied to achieve output voltage from minimum to maximum. The
verification of operation of the control functions, measurement of output voltage,
current, input voltage, current, ripple in the output, input, evaluation of output
current regulation of the unit shall be carried out during the testing.
7.2.4.2 Auto PSP mode operation

0
Suitable set-up shall be arranged for output loading and reference cell feedback. The
closed loop performance and regulation shall be checked with the PSP set voltage varied
from 0.85V to 1.2V.
Disconnecting the reference cell feedback connection in the above set up shall simulate
the reference cell failed condition. The output voltage/current of the unit shall go to the
value set on the potentiometer Vas/las provided inside the CPPSM. The settings on
Vas/las shall be varied and the output voltage/current shall be observed.
7.2.4.3 Operation of sensors for pipeline over protection, under protection, reference cell failure
and reference cell selection logic in auto PSP mode shall be verified by connecting
variable external voltage sources to reference cell inputs of the CPPSM. The number of
external voltage sources shall be same as number of reference cell inputs specified for
the CPPSM.
7.2.4.4 The unit shall be checked for operation of the current limit by over loading the unit in both
CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not
provided for protection of the power semiconductor device, the protection of same shall.
be tested as below:
A switch rated for making and carrying CPPSM output short circuit current shall be
connected to the output terminals of the unit. The output voltage and the output current
limit settings of the unit shall be set to the maximum rated values. The switch connected
in the output shall be shorted quickly.
The unit shall go to current limit mode and shall not damage any active component of the
unit.
7.2.4.5 The current interrupter shall be tested for time interval settings and specified operation.
The equipment shall be properly packed for selected mode of transportation i.e. by
ship/rail or trailer. The panels shall be wrapped in polythene sheets before being placed
in crates to prevent damage to finish. Crates shall have skid bottom for handling. Special
notations such as
'Fragile', 'This side up', 'Centre 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
shall be completely suitable for outdoor storage in areas with heavy rains/high ambient
temperature.
9.0 DEVIATIONS
reasoning.

0
TRANSFORMER RECTIFIER UNIT (PC150-TS-0824) Sheet 1 of 13
CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

0
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
3.0 SITE CONDITION
9.0 DEVIATIONS

0
1.0 SCOPE
This specification covers the requirements for the design, manufacture and testing of
Cathodic Protection Transformer Rectifier units (CPTR units) working on controlled
rectification principle intended to supply power to cathodic protection system for
underground pipelines/ structures.
requirements of the latest revision of following standards:
IS: 1248 (Parts-I, 2,8 & 9) Direct acting indicating analogue electrical
measuring instruments and accessories.
IS: 3700 (Parts-I to 11) Essential rating and characteristics of
semiconductor devices
IS: 3715 (Parts-l to 4) Letter symbols for semiconductor devices
IS: 4411 Code of designation of semiconductor devices.
IS: 5469 (Parts-l to 4) Code of practice for the use of semiconductor
junction devices.
IS: 6619 Safety code for semiconductor rectifier
equipment.
IS:7204 (Parts-l to 4) Stabilized power supplies DC output
IS: 12021 (Parts-l to 4) Control transformers for switchgear and control
gear for voltages not exceeding1000 V AC.
IS: 13703 (Parts-l to 4) Low voltage fuses for voltages not exceeding
1000 V AC or 1500 V DC.
IS/IEC:60947 Low voltage switchgear and control gear.
2.2 In case of imported equipment, standards of the country of origin shall be applicable if
2.4 In case of any contradiction between various referred standards/ specifications and
3.0 SITE CONDITIONS
The CPTR unit shall be suitable for installation in non air-conditioned room with restricted
ventilation or in outdoor kiosk, in locations having generally corrosive, warm, humid and
dusty atmosphere. Service conditions shall be as actual site conditions. If not specifically
mentioned therein, a design ambient temperature of 45°C and an altitude not exceeding
1000 m above mean sea level shall be considered.

0
offered equipment for at least 15 years from the date of supply.
4.3 Vendor shall give a notice of at least one year to the end user of equipment and PDlL
before phasing out the product/spares to enable the end user for placement of order for
spares and services.
5.1 Fabrication and General Details
5.1.1 CPTR unit shall be housed in sheet steel enclosure. The front, rear walls and doors shall be
made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum
1.6 mm thick sheet steel. Wherever required, suitable stiffeners shall be provided. The Unit
shall be freestanding type. Hinged doors shall be provided at the front and back as
required. The unit shall be natural cooled type. Louvered openings with wire mesh for
natural ventilation may be provided. Degree of protection for the panel shall be minimum IP-
41. The CPTR unit panel shall, preferably, not need rear access for operation, maintenance
and shall be suitable for mounting flushed to the wall.
5.1.2 Suitable hooks shall be provided for lifting the panel. These hooks when removed shall not
leave any hole in the panel or imperfection in the paint finish.
5.1.3 All instruments shall be panel mounted type and back connected. All fuses shall be
provided inside the panel and shall be of link type. 660 V grade PVC insulated BIS
approved wires with stranded copper conductor of size minimum 2.5 mm2 shall be used for
power and auxiliary wiring. Control wiring for electronic circuits shall be through flat ribbon
cable or through copper wire of minimum 0.5 mm diameter. All wirings shall be ferruled with
PVC ferrules at both ends for ease of identification. Clamp type terminals suitable for
termination up to 10 mm conductor shall be provided for all control cable connection.
Suitable power terminals shall be provided for power cables. Minimum 20% spare terminals
shall be provided. The terminal blocks shall be mounted minimum 300 mm above the gland
plate.
5.1.4 All live parts shall be properly shrouded. This shall ensure complete safety to personnel
intending routine maintenance by opening the panel doors.
5.1.5 CPTR unit shall be suitable for bottom cable entry unless otherwise specified and shall be
supplied complete with crimping type cable termination lugs and cable glands. Cable glands
shall be of rolled aluminium, single compression type for indoor installations and double
compression type for outdoor installations. The space in the terminal chamber shall be
adequate for termination of required number and sizes of cables.
5.1.6 The input power factor of the unit at rated load shall be 0.8 lag or better.
5.1.7 The CPTR unit shall be field proven. The design, internal component layout and rating of
component shall ensure high MTBF and low MTTR. Prototype equipment shall not be
acceptable.
5.1.8 All the control equipment like switches, pushbuttons, potentiometers etc. shall be located
at a convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the
panel.
5.1.9 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB
tracks shall be tinned and solder masked. The PCB shall be coated with suitable lacquer to

0
make it immune to dust, moisture and fungal growth. Where plug in type of PCBs are used
gold plated male-female connectors shall be used for the purpose.
5.1.10 If required the panel shall be provided with space heater to prevent moisture condensation.
The space heaters shall be located at the bottom of the panel. and shall be provided with a
manually operated switch, HRC fuse and link for phase and neutral respectively. The
space heater shall have porcelain connectors. Where space heater is not provided the
electronic PCBs/components and other control devices shall be made immune to moisture
condensation.
5.1.11 Panel shall be provided with integral base frame channel. The integral base frame of panel
shall be suitable for directly bolting with the help of foundation bolts and shall also be
suitable for tack welding to purchaser's insert plate/flat/channel embedded in the floor.
Amply dimensioned oblong holes shall be provided at the bottom of the panel for its bolting
to the embedded insert plate/channel.
5.1.12 An earth bus bar of minimum (25 x 3) m2 copper or equivalent aluminium shall be provided
throughout the length of the panel. Provision shall be made for connecting this earth bus at
two ends with the plant earth grid by means of (40x5) mm- GI flat. All non-current carrying
metallic parts of the panel and mounted equipment shall be connected to the panel earth
bus. All doors and movable parts shall be connected to the earth bus by flexible copper
cables.
5.1.13 All panel mounted equipments (e.g. lamps, pushbuttons, switches, meters, PCBs, etc.)
shall be provided with suitable nameplates. Nameplates shall be engraved out of 3-ply
(black-whiteblack) lamicoid sheets or anodised aluminium. Back-engraved Perspex sheet
nameplates may also be acceptable. Engraving shall be done with groove cutters. Hard
paper or self-adhesive plastic tape nameplates shall not be acceptable. Nameplates shall
be fastened by screws and not by adhesive. Labels shall be provided for every component
on the cards, connecting wires as well as for the terminals in the terminal strip inside the
panel.
5.1.14 Where specified, the CPTR unit shall be housed in an outdoor kiosk. The kiosk shall be
made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and
external surfaces. Hinged lockable doors shall be provided at the front and back. The kiosk
shall be suitable for outdoor mounting and shall give proper protection to the CPTR unit
against rain, other harsh weather conditions. Necessary ventilation arrangement with
louvers and wire mesh shall be provided for proper operation of the CPTR unit. The cable
entry to the kiosk shall be from bottom through cable glands. Suitable canopy shall be
provided on the top of the Kiosk.
5.1.15 Painting
All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust,
grease and dirt.
Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The
under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow
zinc chromate primer. The under surface shall be made free from all imperfections before
undertaking the finishing coat.
After preparation of the under surface, the panel shall be spray painted with two coats of
final paint or shall be powder coated. Colour shade of final paint shall be approved by the
purchaser before final painting is started. The finished panels shall be dried in stowing
ovens in dust free atmosphere. Panel finish shall be free from imperfections like pin holes,
orange peels, run off paint, etc. All unpainted steel parts shall be suitably treated to
prevent corrosion. If these parts are moving elements, then they shall be greased.

0
The CPTR unit shall be complete with following main sections:

- Transformer and input controls.
- Rectifier and filter
- Output protections
- System controls
- Control, indication and metering
6.1 Transformer and Input Controls
6.1.1 The transformer shall be natural cooled dry type with separate primary and secondary
windings.
An intermediate earth screen shall be provided between primary and secondary windings.
CPTR Units having multiple output circuits shall have separate secondary windings for
each output circuit. Transformer shall be vacuum impregnated with epoxy varnish and
baked. The safety factor for transformer rating shall be minimum 125%.
6.1.2 Single-phase transformers may be provided up to 50V, 50A DC output rating of the CPTR
units. Beyond this rating, 3 phase transformers shall be provided. A moulded case circuit
breaker with thermal over load and short circuit release shall be provided at the input of the
transformer. Miniature circuit breaker with thermal overload and short circuit release in
place of moulded case circuit breaker may be provided, where the miniature circuit breaker
rated for the incoming AC supply short circuit current.
6.2 Rectifier and Filters
6.2.1 The rectifier shall be made of thyristors and diodes as basic components. The CPTR unit
shall be suitable for 415 V AC, 3-ph power supply. Rectifier shall be 3 phase full wave type
and controlled type. For CPTR units rated 50V, 50A DC or less, the unit may be suitable
for 240V AC, 1 ph power supply and the rectifier shall be full wave type and controlled
type. Alternatively, for single phase AC CPTR units, diode rectifier of full wave type in the
secondary of the transformer and triac or back to back connected thyristors in the
transformer primary AC supply circuit may be provided. The current and voltage ratings of
thyristors, diodes shall be at least two times the actual maximum device current and
minimum two times the actual maximum voltage coming across the device respectively.
The thyristors/ triac/ rectifier elements shall be protected against voltage surges coming
from the incoming power supply and from output side from the pipeline. Required shunt
zeners / MOV shall be provided across the rectifier elements for protection.
The rectifier elements shall have humidity/moisture resistant finish and mounted in
sufficiently sized heat sink designed to provide adequate cooling under worst conditions of
operation. The rectifier elements shall have adequate protection against high dv/dt and di/
dt. 6.2.2 The thyristors/triacs shall be protected by semiconductor fuses. For units rated
50V, 50A DC or less, if the thyristors or triacs are adequately over rated and system has
enough inductance so that in case of sudden output short circuit the over current limit
feature comes into action before short circuit current rises beyond the rating of the
thyristors/triacs, then the semiconductor fuses may not be provided. This feature shall be
demonstrated during testing of the unit at works.
6.2.3 Adequate filtering shall be provided on the DC output of the rectifier to limit the ripple
content in the output to less than 5% at rated output.
6.2.4 The rectifier system shall be of natural air cooled type.
6.2.5 For CPTR units with multiple output circuits, each output circuit shall have independent
rectifier and filter.

0
6.3 Output Protections
Two pole moulded case circuit breaker or miniature circuit breaker (if available) rated for
the DC output current, short circuit current and having thermal over load, short circuit
release shall be provided in the output. A lightning arrestor rated for minimum 10KA
impulse current discharge capacity and rated voltage & maximum spark over voltage rating
suitable to protect the CPTR unit components against lightning and switching surges shall
be provided at the output. For CPTR units with multiple output circuits, each output circuit
shall be provided with circuit breaker and lightning arrestor.
6.4 System Controls
6.4.1 The CPTR unit shall have two distinct modes of operation (independent for each output
circuit) as below:
a) Constant Voltage and Constant Current Mode (CVCC)
In this mode the output voltage of CPTR unit shall be continuously adjustable from
O.5V DC to the rated output voltage. The set output voltage (Vos) shall remain
constant irrespective of output current. Current limit feature shall be provided. The
current limit (los) shall be continuously adjustable from zero to rated output current.
For constant voltage mode of operation the output current limit shall be set at
maximum and output voltage setting shall be varied. Irrespective of output current
demand the chosen value of the output voltage shall be maintained by the control
system till the current limit is reached. After that the output current limit shall be
maintained and output voltage shall decrease to keep the current constant.
For constant current mode of operation the output voltage shall be set at maximum
and output current shall be varied through varying the setting of output current limit.
Irrespective of output voltage requirement the control system shall maintain the output
current to the set current limit value till the voltage limit is reached. After that the
output voltage limit shall be maintained and output current shall decrease to keep the
voltage constant.
b) Auto PSP Mode
In this mode of operation the output of the CPTR unit shall operate in an external
closed loop with pipe to soil potential (PSP), measured by reference cell, in feedback
loop. The CPTR unit control shall adjust the output voltage such that the PSP as
measured by reference cell always remains equal to the set potential on the unit. The
set potential (Vps) shall have high long time stability and minimum temperature drift.
The set potential shall be continuously adjustable over the range required.
The unit shall be designed to operate with number of reference cells connected to it
(to be provided by others). In case of more than one reference cell being specified,
CPTR unit shall have feature to automatically select the reference cell having less
negative potential than the others and use the same for auto control of the unit (e.g. (-
) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be provided in
selecting the less negative potential reference cell, to avoid hunting between the
reference cells at change over conditions.
In case of open circuit or short circuit of reference cell or potential being less negative
than a minimum set potential (Vrs), the unit shall sense these conditions as reference
cell failure and shall automatically switch over to the other healthy reference cell for
control. Should fault occur in all the reference cells, the output voltage or current of

0
the CPTR unit shall adjust automatically to a preset value (Vas/Ias), which shall be
adjustable.
In both CVCC and auto PSP modes of operation a fast acting electronic over current
limit protection shall be provided. This protection shall be fast enough to protect the
active devices of the unit and fast enough to act before tripping of MCCB/MCB or
blowing of fuse.
6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shall be provided
in case of PSP either exceeding the specified maximum limit (Vpm) or remaining lower
than the specified minimum limit (Vpn).
6.4.3 The output voltage regulation for no load to full load variation with input voltage variation
from maximum to minimum shall not be more than 2.5 % of rated voltage throughout the
range of output voltage and over the specified ambient temperature variation, in CVCC-
constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation for
no load to full load variation with input voltage variation from maximum to minimum and
PSP feedback varying over the specified range shall be within Zf mV.
In CVCC- constant current mode 'of operation, the current regulation for minimum to
maximum output voltage and minimum to maximum variation in input voltage shall not be
more than 2.5% throughout the range of output current.
6.4.4 The DC output of the CPTR unit shall be floating (ungrounded) in the Unit. However the
CPTR Unit shall allow grounding of positive output terminal through the anode ground bed.
control system.
6.5 Current Interrupter
6.5.1 If required, a current interrupter for CPTR Unit output current interruption shall be provided.
6.5.2 The current interrupter shall have an output contactor with current rating minimum 125% of
the output current rating of the CPTR unit and a digital timer to operate it.
6.5.3 The timer shall have 'ON' and 'OFF' timings. When the timer is turned on the 'ON' timing
shall start and shall close the output contactor till the end of the 'ON' timing. At the end of
the 'ON' timing the 'OFF' timing shall start and keep the contactor open till the end of the
'OFF' timing. At the end of the 'OFF' timing the 'ON' timing shall start again and close the
output contactor. This process of 'ON' and 'OFF' timing shall continue.
6.5.4 The 'ON' and 'OFF' timings of the timer shall be settable by separate 2 digit thumbwheel
switches, each settable from I to 99 seconds. The timing error of the timer shall be less
than 5 parts per million. In case of microprocessor based system keypad with display may
be provided in place of thumbwheel switches.
6.5.5 Whenever the timer is switched on it shall always start with ON 'timing'. A timer-reset push
button shall be provided. On pressing this pushbutton during operation of the timer, the
timer shall get reset and upon release of the button the timer shall restart with 'ON' timing.
6.5.6 The power required for operation of the timer and contactor shall be derived from the main
power supply to the CPTR unit.
6.5.7 The following controls and indications shall be provided for current interrupter. The controls
shall be housed in a lockable cover, so that normally they are not accessible. The
indications shall be mounted on the door.

0
a) Controls
- Timer reset
In case of microprocessor based system keypad with display may be provided in place of
thumbwheel switches.
b) Indications (LED)
- Timer power 'ON'
- 'ON' timing
- 'OFF' timing
6.5.8 The output contact of the current interrupter contactor shall be wired in the positive DC
output of the CPTR unit. A link shall be provided for shorting these terminals whenever the
current interrupter is not in use.
6.5.9 If required the current interrupter shall be an independent unit of portable type. The
interrupter unit shall have terminals for input power supply and terminals of the output
contactor. The input power supply and the rating of the output contactor shall be as
required. Terminals shall be provided in the CPTR unit for taking power supply to the
6.5.10 Where the current interrupter is not specified with CPTR unit or is specified as portable
type external to the CPTR unit, then the CPTR unit shall have provision/ terminals for
connection of input power supply and output contacts of external current interrupter, for
current interruption test. A link shall be provided for shorting the output terminals provided
in CPTR unit whenever the current interrupter is not connected.
6.6 Controls, Indication and Metering
6.6.1 Following controls shall be provided on CPTR unit front door.
a) ON/OFF control for input through MCCB/MCB.
b) ON /OFF control for output through MCCB/MCB.
c) Auto/CVCC mode selector switch.
d) Potentiometers for Vos, Vps and los settings.
e) Selector switch for selecting indication of PSP set and PSP actual for all the
reference cells.
6.6.2 Following controls shall be provided inside the module at user accessible common
location:
a) Potentiometer for Vrs, Vpm, Vpn and Vas/las settings.
b) Controls for current interrupter:

0
- Timer reset
6.6.3 TR unit shall have following indicating lights (lamps or minimum 5 mm dia LEDs):
a) CPTR unit ON/OFF
b) Unit in auto/CVCC (2 lamps)
c) Reference cell controlling the closed loop control of the CPTR unit (number of lamps
same as number of reference cells).
d) Reference cell faulty (number of lamps same as number of reference cells).
e) Pipeline over protected.
f) Pipeline under protected
g) Indications for current interrupter:
- Timer power 'ON'
- 'ON 'timing
- 'OFF' timing
It shall be possible to switch-off all the indication lamps by a single switch. In case of LED
indication lights this facility may not be provided.
6.6.4 Following meters having min cl.1.5 accuracy shall be provided on the CPTR unit:
a) Digital meter for output voltage
b) Digital meter for output current
c) Digital voltmeter to measure PSP set (Vps) and PSP actual for all the reference cells.
The meter shall have range from -4 V to 0 V and shall have cl.0.5 accuracy.
d) Digital meters for measuring Vrs, Vpm, Vpn and Vas/las settings.
e) Meters for input voltage and current
It shall be possible to switch-off all the digital meters preferably by a single switch.
6.6.5 If required, CPTR unit shall incorporate provision for remote monitoring of the unit through
SCADA system as below:
a) Potential free contacts for the following:
- All the reference cells failed. (Contact open on alarm condition)
- Pipeline overprotected. (Contact open on alarm condition)
- Pipeline under protected. (Contact open on alarm condition)
- System in auto-mode. (Contact close in auto condition)
- System in CVCC mode. (Contact close in CVCC mode)

0
b) 4 to 20 mA electrically isolated signal for the following:
- PSP (-4V to OV)
- CPTR unit output voltage
- CPTR unit output current
The transducers shall have electrical isolation between input and output. The isolation
insulation shall withstand 2kV, 50Hz for minimum 1 minute. The accuracy class of the
transducer shall be 0.5. The transducers shall be protected against input and output
voltage surges. The transducer shall be suitable for driving up to 600 ohms load
impedance located up to 500 m away and wired with 0.5 mm? copper conductor cable.
6.6.6 For units having multiple outputs, each output circuit shall have independent controls,
indication and metering.
7.1 During manufacture, the equipment shall be subjected to inspection by owner or his
authorised representative to assess the progress of the work as well as to ascertain that
only quality raw materials are used for the same. He shall be given all assistance to carry
out the inspection.
7.2 Final acceptance test shall be carried out at manufacturer's works under his care and
expense. Instruments and equipments required for testing shall be arranged by
manufacturer. Owner's representative shall be given minimum 2 weeks prior notice for
witnessing the tests. Test certificates indicating test results shall be furnished by the
manufacturer. Acceptance tests shall include but not be limited to the tests listed below.
7.2.1 Visual Inspection
This shall include-
- Completeness of the equipment in line with specification.
- Checking of all settings.
- All labels provided.
- Dimensional checking.
- Proper mounting of components and neatness of wiring etc.
- Model number.
7.2.2 Insulation tests
The voltage specified in the table below shall be applied for one minute to the circuits
indicated:
Withstand voltage Control electronics Power electronics Auxiliary circuits

<60V Un1 Un2
To earth 700VD.C. 2xUn1 + 1000V 2xUn2+ 1000V

To control - 2xUn1+ 1000V 2xUn2+ 1000V
electronics
To power 2xUn2+ 1000V - 2xUn2+ 1000V

0
electronics
To auxiliary 2xUn2+ 1000V 2xUn1 + 1000V -
circuits
(Un, and Un2 are nominal voltage rating of power electronics and auxiliary circuits
respectively).
D.C. test voltages may be applied instead of A.C. The magnitude of D.C. test voltages to
be applied shall be 2 times the above-mentioned A.C. (r.m.s) Values.
Insulation resistance test shall be conducted before and after heat run test.
7.2.3 Heat run test
All CPTR units shall be subjected to a heat run test performed at rated voltage for period
not less than 16 hours prior to execution of functional tests.
At least one CPTR unit of each rating shall be loaded to its rated output through out 16
hour test period. All other CPTR units shall be energized under partial load or zero load
current condition throughout the test period.
7.2.4 Functional tests
Functional tests as below shall be performed on each CPTR unit. If during execution of
functional tests, any electronic component of the unit is required to be replaced e.g. due to
malfunction or failure of the unit to fulfil the performance requirements of the specification,
then the load test shall be repeated at rated current following which functional tests shall
be carried out.
7.2.4.1 CVCC mode operation testing
a. Constant voltage operation
During the test, current limit shall be set to rated output current. Performance testing
shall be carried out for various output voltage settings and load varying from zero to
maximum. The verification of operation of the control functions, measurement of output
voltage, current, input AC voltage, current, power factor, ripple in the output, evaluation of
output voltage regulation and efficiency of the unit shall be carried out during the testing.
b. Constant current operation
During the test, voltage limit shall be set to rated output voltage. Performance testing
shall be carried out for various output current limit settings and load resistance varied to
achieve output voltage from minimum to maximum. The verification of operation of the
control functions, measurement of output voltage, current, input AC voltage, current, power
factor, ripple in the output, evaluation of output current regulation of the unit shall be
carried out during the testing.
7.2.4.2 Auto PSP mode operation
Suitable set up shall be arranged for output loading and reference cell feedback. The
closed loop performance and regulation shall be checked with the PSP set voltage varied
from O.85V to 1.2V.
Disconnecting the reference cell feedback connection in the above set up shall simulate
the reference cell failed condition. The output voltage/current of the unit shall go to the
value set on the potentiometer Vas/las provided inside the CPTR UNIT. The settings on
Vas/Ias shall be varied and the output voltage/current shall be observed.

0
7.2.4.3 Operation of sensors for pipeline over protection, under protection, reference cell failure
and reference cell selection logic in auto PSP mode shall be verified by connecting
variable external voltage sources to reference cell inputs of the CPTR unit. The number of
external voltage sources shall be same as number of reference cell inputs specified for the
CPTR unit.
7.2.4.4 The unit shall be checked for operation of the current limit by over loading the unit in both
CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not
provided for protection of the thyristors/triacs, the protection of same shall be tested as
below:
A switch rated for making and carrying CPTR unit output short circuit current shall be
connected to the output terminals of the unit. The output voltage and the output current
limit settings of the unit shall be set to the maximum rated values. The switch connected in
the output shall be shorted quickly.
The unit shall go to current limit mode and shall not damage any active component of the
unit.
7.2.4.5 The current interrupter shall be tested for time interval settings and specified operation.
The equipment shall be properly packed for selected mode of transportation i.e. by ship/rail
or trailer. The panels shall be wrapped in polythene sheets before being placed in crates to
prevent damage to finish. Crates shall have skid bottom for handling. Special notations
such as 'Fragile', 'This side up’, 'Centre 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 shall
be completely suitable for outdoor storage in areas with heavy rains/high ambient
temperature.
9.0 DEVIATIONS

0
(PART-A)
TECHNICAL SPECIFICATION - IMPRESSED CURRENT CATHODIC Document No. Rev
PROTECTION SYSTEM FOR PIPELINES (PC150-TS-0825) Sheet 1 of 22
IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM
FOR PIPELINES

0
(PART-A)
CONTENTS
SECTION
DESCRIPTION
NUMBER
1.0 SCOPE
3.0 SYSTEM IMPLEMENTATION
4.0 CORROSION SURVEY
5.0 CATHODIC PROTECTION DESIGN PARAMETERS
6.0 CATHODIC PROTECTION DESIGN CRITERIA
7.0 SYSTEM DETAILS
8.0 INSTALLATION
9.0 FIELD TESTING AND COMMISSIONING
10.0 INTERFERENCE MITIGATION
11.0 CLOSE INTERVAL POTENTIAL SURVEY
12.0 DEVIATIONS

0
(PART-A)
1.0 SCOPE
1.1 This specification defines the requirements of system design, engineering, installation,
testing and commissioning of an Impressed Current Cathodic Protection System for
underground pipelines / structures including supplementing of corrosion survey, close
interval potential logging survey, investigations for interaction/interference problems and
mitigation of the same.
1.2 This specification provides the basic parameters to develop a suitable impressed current
cathodic protection system for the pipelines/structures requiring protection. LSTK
contractor shall include, site survey to collect required information, design, supply,
installation, commissioning of impressed current cathodic protection system. All data
required in this context shall be taken into consideration to develop an acceptable design
and for proper engineering of the system.
1.3 In addition to this specification, other requirement, if any, for complete cathodic protection
shall be considered by LSTK contractor.
1.4 Compliance with these specifications, and/or approval of any documents submitted by
contractor shall in no case relieve the contractor of his contractual obligations.
requirements of the latest revision of following standards as a minimum:
i) NACE Standard RP-0I69 : Standard Recommended Practice Control of

External Corrosion on Underground or
Submerged Metallic Piping Systems
ii) NACE Publication l0A190 : Measurement technique related to criteria for

CP of Underground or Submerged Steel
Piping System (as defined in NACE Standard
RPO169-83)
iii) NACE Standard RP-0I77 : Standard Recommended Practice Mitigation

of Alternating Current and Lightning Effects on
Metallic Structures and Corrosion Control
Systems
iv) NACE Standard RP-0286 : Standard Recommended Practice The

Electrical isolation of Cathodically Protected
Pipelines.
v) NACE Publication No. 54276 : Cathodic Protection Monitoring for Buried

Pipelines.

0
(PART-A)
vi) NACE Standard RP-0572 : Standard Recommended Practice Design,

Installation, Operation and of Impressed
Current Deep Ground beds.
vii) DNV RP-B403 : Recommended Practice Monitoring of

Cathodic Protection Systems
viii) DNV RP-B401 : Recommended Practice Cathodic Protection

Design
ix) IS 8062 : Recommended Practice ICCP for

Underground Piping
x) BS 7361 Part I : Code of Practice for Cathodic Protection for

land and marine application.
xi) VDE 0150 : Protection against Corrosion due to Stray

Current from DC Installations.
xii) IS: 1554 Part I : PVC insulated (heavy duty) cables.

2.2 In case of imported equipments standards of the country of origin shall be applicable if
2.3 The equipment shall also confirm to the provisions of Indian Electricity rules and other
2.4. In case of any contradiction between various referred standards/specifications and

3.0 SYSTEM IMPLEMENTATION
All work to be performed and supplies to be effected as a part of contract shall require
specific review by Owner or his authorised representative. Major activities requiring review
i) Corrosion survey data interpretation report and plot plans for land acquisition.
ii) Conceptual system design.
iii) Basic engineering package.
iv) Detailed engineering package.
v) Field testing and commissioning procedures.
vi) Procedures for interference testing and mitigation
vii) Close interval potential logging survey procedure
viii) As built documents.
4.0 CORROSION SURVEY

0
(PART-A)
4.1 General
4.1.1 The details of corrosion survey including soil resistivity data along ROW and other data
required for C.P. design if available with the owner shall be included .However, verification
of its veracity and adequacy shall be the entire responsibility of the contractor. In addition,
contractor shall have to generate/collect additional data as per clause 4.4 below required
for completeness of the job.
Contractor shall carry out soil resistivity survey at anode ground bed locations for design of
ground bed. Contractor shall also carry out corrosion survey along the ROW of the
pipeline.
4.1.2 To carry out soil resistivity measurement Wenner's 4-pin method or an equivalent method
approved by Owner shall be used. Survey instruments shall have maximum AC and DC
ground current rejection feature.
Care shall be taken to ensure that the resistivity observations are not influenced by the
presence of foreign pipelines/structures, and earth currents in the vicinity of EHV/HV lines
and installations using earth return in their power system etc.
4.2 Soil Resistivity Survey at Impressed Current Anode Ground Bed Plot
4.2.1 Each selected anode bed plot shall be sub-divided into sub-plots. Sizes of sub-plots shall
depend upon the expected depth for soil resistivity investigations. Each of these sub-plots
shall be investigated for resistivity data individually. Sufficient observations shall be taken
at each of these sub-plots as required and desired by Owner/Owner's representative to
obtain sufficient information about sub-soil stratification and, wherever possible, to
establish the depth of water table. The number of subplots at each ground bed plot shall
be decided at site in consultation with Owner / Owner's representative.
4.2.2 Number, location, demarcation and size of sub-plots and number of sets of resistivity
observations required for each sub-plot shall be individually decided for each ground bed
plot location.
4.2.3 One or more ground bed plots may be required to be selected and surveyed at each CP
station to form a suitable ground bed.
4.3 Topographic Surveys
Cathodic protection stations consisting of anode ground bed, CP station, etc. As

applicable, along with all associated cabling up to pipeline and any other related
equipment and accessories for CP station shall be demarcated on the ground. Ground
plots so demarcated shall be surveyed for all other topographical and cadastral features
and topo-sheets shall be developed by the CONTRACTOR, which shall be suitable for use
in land acquisition etc.
4.4 Additional Data to be Collected
The following data shall be collected to generate design data for evaluation of interaction/
interference possibilities due to presence of other services in ROW or in its vicinity.
OWNER shall provide assistance for liaison work to the extent possible.
i) Route and types of foreign service/pipeline in and around or crossing the right of
way (including those existing and those which are likely to come up during contract
execution).

0
(PART-A)
ii) Diameter, wall thickness, pressure, soil cover, and coating scheme used, type of
cathodic protection system provided, if any, year of laying/commissioning in case of
foreign pipelines.
iii) Details of the existing cathodic protection systems protecting the services i.e. type
of protection, location, type, rating of anode beds, test station locations and their
connection schemes. Present output current and voltage readings of the CP power
supply units.
iv) Remedial measures existing on foreign pipelines/services to prevent interaction.
v) Graphical representation of existing structure / pipe-to-solid potential records.
vi) Possibility of integration/isolation of CP systems, which may involve negotiations

with owners of other services.
vii) Existing and proposed DC/AC power sources and systems using earth return path
such as HVDC substations/ earthing stations, fabrication yards with electric welding
etc. in the vicinity of the entire pipeline route.
viii) Crossing and parallel running of electrified and non-electrified traction (alongwith
information regarding, operating voltage, AC/DC type etc.) as well as abandoned
tracks near ROW having electrical continuity with the tracks in use.
ix) Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead
power lines along with details of voltage, ACIDC type etc.
x) Voltage rating, phases, sheathing details of underground power cables along ROW
or in its vicinity.
xi) Any other relevant information that may be needed in designing and implementing
proper cathodic protection scheme for the proposed pipeline. Graphical
representation of existing structure/ pipe-to-soil potential records.
Contractor shall conduct necessary potential gradient surveys for any existing
anode ground beds that may interfere with the CP system of the pipelines covered
under this project.
4.5 Report
On completion of all field work, a report incorporating all the results generated from
surveys and details of additional data collected shall be prepared. The report shall also
contain detailed interpretation of survey results and resistivity data, probable interference
prone areas, selected locations for anode ground beds, etc., to form a design basis for the
scheme of cathodic protection. This report shall also include various drawings prepared in
connection with the above work. Soil resistivity values shall be plotted on semilog graph
sheets.
5.0 CATHODIC PROTECTION DESIGN PARAMETERS
A distinctly independent impressed current cathodic protection system shall be provided to

protect the external surfaces of the complete pipeline/structure installation as specified.
Unless otherwise stated, the following parameters shall be used for design of permanent
cathodic protection system:
5.1 Protection Current Density Range
i) Pipelines having coal tar coating with two/three layers of reinforcement.

0
(PART-A)
Pipeline surrounding Minimum Protection Current Density*

( A/m2)
Soil resistivity 10 ohm m to 100 ohm.m 300
Soil resistivity less than 10 ohm.m 2000
Soil resistivity more than 100 ohm.m 200
Sea Water 5000
ii) Pipe lines having fusion bounded epoxy coating:

( A/m2)
iii) Pipe lines having polyethylene coating

( A/m2)

* Actual current density to be adopted shall be decided based upon soil and other
environmental conditions, current drainage survey data, proximity of foreign pipe
lines/structures and other interference areas affecting the installation. Where considered
necessary for satisfactory protection of pipeline the current density shall be suitably
increased by contractor. Also refer to clause 7.1 iv) below.
At HDD (horizontal direction drilling) crossing, the pipe protection current density
applicable for marshy area shall be considered.
5.2 The pipe protection Current Density indicated in the clause 5.1 above shall be applicable
where the temperature of the fluid transported by the pipeline/ the surface temperature of
the buried portion of the pipeline does not exceed 300 C. Where this temperature exceeds
300C, the protection Current Density shall be increased suitably in consultation with the
Owner/PMC.
5.3 Safety factor for current density : 1.3
5.4 Anode utilisation factor : 0.85 for centre connected anode.
(For high silicon cast iron anode) 0.6 for end connected anode.
5.5 Anode surface current density : 10 Amp./Sq.m. (max.)
For high silicon cast iron anode
For continuous operation

0
(PART-A)
5.6 Anode consumption rate : 0.2 Kg./Amp.yr.
5.7 Pipeline natural potential : (-) 0.45 V
5.8 Design life of CP System : 30 years
5.9 Anode ground bed loop resistance: 1 ohm (max.).
including anode to ground resistance,
anode and cathode cable resistances.
(The output voltage rating of the CPTR unit /CPPSM shall in minimum be adequate to
drive the specified end of life cathodic protection current with safety factor, considering the
total anode ground bed loop resistance as the sum of the resistance specified in this
clause and pipe to earth resistance).
5.10 For mixed metal oxide coated titanium anodes the anode utilisation factor, anode surface
current density and anode consumption rate etc. shall be as per the guaranteed values
published by the manufacturer and supported by test certificates/ field proven ness.
6.0 CATHODIC PROTECTION DESIGN CRITERIA
Cathodic protection system shall be designed to meet the following criteria :
i) The pipe to soil potential measurements shall be between (-) 0.9V (OFF) and (-)
1.18V (OFF) with respect to a copper/copper sulphate reference electrode.
ii) In rare circumstances, a minimum polarisation shift of (-) 100 millivolts may be
accepted as an adequate level of cathodic protection for the pipeline with the approval of
Owner.
iii) A positive potential swing of 100 millivolts or more shall be considered sufficient to
indicate the presence of an interaction/interference situation requiring investigation and
incorporation of mitigation measures by the CONTRACTOR.
7.0 SYSTEM DETAILS
The system shall include the following major equipment/sub-systems unless otherwise
specified in project specifications:
- CP stations
- CPTR units/cathodic protection power supply modules (CPPSM).
- Anode ground beds and anodes
- Anode junction box
- Cathode junction box
- Test stations
- Permanent reference cells
- Electrical resistance probes
- Polarisation cell and surge diverter
- Polarisation coupons

0
(PART-A)
- Computerized Test Stations
- CP system at cased crossing
- Cables
All equipment shall be new and procured from approved reputed manufacturers.
Equipment offered shall be field proven. Equipment requiring specialised maintenance or
operation shall be avoided as far as possible. Prototype equipment shall not be accepted.
All equipment/materials shall conform to the relevant specifications included in the tender
document.
All equipment including CPTR unit, CPPSM, test stations, anode lead junction boxes etc.
shall be located in safe non-hazardous areas.
Where it is essential to install the equipment in hazardous area, such equipment shall be
flame proof type and shall meet the requirement of IS: 2148, 5572 or equivalent
international standard and shall be suitable for gas group, temperature class T3 (200°C).
Indigenous equipment shall be certified by CMRI or any other recognised testing body and
shall be approved by the concerned statutory authority. All flameproof equipment shall
carry the BIS license marking as per the requirement of statutory authorities.
All Imported equipment for hazardous area may be tested and certified by an independent
certifying agency of country of equipment origin and shall be approved by the concerned
statutory authority in India.
7.1 Cathodic Protection Stations
The number and exact locations of CP stations shall be worked out based on the corrosion
survey data collected. In addition, the following guidelines shall be followed for selecting
the locations:
i) Number of CP stations and their selected locations shall ensure that these remain
valid and are adequate for the full design life of the system after considering all
foreseeable factors.
ii) As far as possible, the availability of nearby low resistivity areas for location of
associated ground beds must be ensured while selecting the locations of CP stations.
iii) As far as possible, locations of intermediate CP stations shall coincide with the
locations of SV stations.
iv) The locations of CP stations and anode ground bed current ratings shall be suitably
selected. The same shall be verified for adequacy by the contractor. The requisite
current drainage tests/survey shall be conducted by the contractor to establish the
adequacy of CP current requirement indicated in clause 5.0 above and adequacy of
number, ratings of CP stations for permanent CP system selected. The minimum end
of life pipe protection current requirement shall be considered as the current
requirement indicated in the clause 5.0 above or 3 times the current density value
measured by the current drainage survey for polyethylene coated pipeline and 4 times
the current density value measured by the current drainage survey for fusion bonded
epoxy, coal tar enamel with reinforcement coated pipeline, whichever is maximum.
7.2 CP Transformer Rectifier Unit / CPPSM
The supply, installation, testing and commissioning of cathodic protection power supply
module (CPPSM) / indoor type Cathodic Protection Transformer Rectifier Unit (CPTR unit)/
outdoor type CPTR unit installed in kiosk along with kiosk shall be included in contractor's
0
(PART-A)
scope. The CP TR units shall be provided at CP stations where reliable AC power supply
is available. CPPSM shall be provided at other CP stations where reliable DC power
supply instead of reliable AC power supply is available. The CPTR unit / CPPSM shall be
installed in nonhazardous (safe) area.
For more details refer: 4001-TS-0823 & 4001-TS-0824
7.3 Anode Ground Beds
i) Each CP station shall have an independent anode ground bed, which may be of
shallow or deep well construction depending upon the data collected by the
contractor. Deep well ground beds may also be used in the congested locations
where availability of suitable land for spread out ground beds is restricted.
ii) Ground bed shall be located electrically remote from the pipeline and foreign pipeline/
other buried metallic structures. Nearest part of the anode bed shall at least be 100
meters away from the pipeline and foreign pipeline/ other buried metallic structures.
The anodes installed in the ground shall be located in perennially moist strata,
wherever possible. Horizontal ground beds shall be at right angles to the pipeline, as
far as possible.
The location of ground bed shall be checked and ensured for remoteness from the
pipeline and other buried foreign pipelines/structures, building foundations,
switchyards, electrical earthing systems, etc.
iii) Unless otherwise agreed, anodes shall be of high silicon cast iron type or mixed metal
oxide coated titanium anodes.
iv) Sheet steel anode canisters of adequate size shall be provided for each anode.
Anode canisters shall be filled with petroleum coke breeze. In case of deep well
ground beds non-canistered anodes with petroleum coke breeze in the well
surrounding the anodes shall be provided.
v) Each shallow anode-bed shall contain anodes with canisters positioned horizontally or
vertically in the soil with suitable backfill. The depth of anodes (depth of top of anode
in case of vertically laid anodes) shall not be less than 2 meter from grade level
vi) Layout of anode installation in anode bed shall be detailed out in drawings showing
anode installation details, anode grouping, anode wiring, anode cable routing, etc.
The deep well anode ground bed details shall include the details of anodes, deep well
casing, anode positioning, anode cable supporting, deep well gas venting, active,
passive portions of the ground bed, etc.
vii) Anodes shall be supplied complete with tail cables, which shall be long enough for
termination on their associated anode lead junction boxes without intermediate joints.
Exact lengths and termination details shall be indicated in construction drawings.
viii) Potential gradient around the anode bed shall be within safety requirements with
regard to interference on foreign structures and its effective boundary shall be
defined.
ix) In case of two parallel pipelines running in the same ROW, the anode ground beds of
the respective pipelines shall be located on the respective sides of the pipelines.
7.4 Anode Junction Box
Depending on the size and configuration of anode ground beds, one or more anode
junction boxes shall be provided at each ground bed. All cable tails from individual anodes

0
(PART-A)
shall be terminated onto the respective anode junction boxes, which shall be further
connected to the main anode junction box (where applicable). The main anode junction
box shall be connected to the cable coming from CP power source. Each outgoing circuit
in main junction box (where applicable) and each anode circuit in junction shall have
provision for measurement and control of individual circuit/anode current.
7.5 Cathode Junction Box
Where output of the CP power supply unit is connected to multiple pipelines a cathode
junction box shall be provided near the pipelines at the location of connection of the
negative drainage cable to the pipelines.
The negative of the CP power source shall be connected to the incoming circuit of the
cathode junction box. The junction box shall have separate out gong circuit one for each
pipeline to collect the negative drainage currents from each of the parallel pipelines.
The incoming circuit shall have a current measurement facility. Each out going circuits
shall have provision for measurement and control of current.
7.6 Test Stations
7.6.1 Test stations shall be provided along the pipeline ROW for monitoring the performance of
the cathodic protection system at the following locations. Test stations shall be provided at
additional locations, if required, so that distance between any two adjacent test stations
does not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like
forest/deserts:
i) At all insulating joints.
ii) At both sides of metalled road crossings.
iii) At vulnerable locations with drastic changes in soil resistivity .
iv) At locations of surge diverters, pipeline grounding through polarisation cells, zinc
and magnesium anodes.
v) At EHV/HV AC/DC overhead line crossings and selected locations where EHV/HV
overhead line is in the vicinity of the pipeline.
vi) At railway line crossings and at selected locations along lines running parallel to the
pipeline.
vii) At both sides of major river crossings.
viii) At EHV/HV cable crossings or along routes where EHV/HV cables are running in
parallel.
ix) In the vicinity of DC networks or grounding systems and HVDC grounding systems
where interference problems are suspected.
x) At crossings of other pipelines/structures.
xi) At the locations of reference cell, electrical resistance probe and polarization coupon
installation.
xii) At the location of computerised test stations.
xiii) At both sides of cased crossings .
xiv) Locations where interference is expected.

0
(PART-A)
xv) At locations of sectionalising valve (SV) stations.
xvi) At any other locations considered necessary by Owner/Owner's representative
7.6.2 Test stations for bonding shall be provided with shunt and resistor as a means to monitor
and control current flow between the pipeline and foreign pipelines or structures that may
exist in common ROW.
7.6.3 Test stations with current measuring facility shall be provided at each CP station drainage
point (to measure pipeline current on anyone side of pipeline from drainage point at
intermediate CP station and towards protected side of the pipeline at starting, end point CP
stations), at interference prone areas, on both sides of major river crossings, near marshy
areas and minimum one for every 10 km max. along the pipeline.
7.6.4 Test stations shall be installed with the face of the test station facing the pipeline. The
nameplate of test stations shall carry the following minimum information:
- Chainage in km.
- Test station connection scheme
- Distance from pipeline in meter.
- Direction of product flow.
7.6.5 Number of terminals and different schemes of wiring shall be as per the test station
connection scheme. Minimum twenty percent spare terminals shall be provided in each
test station.
7.6.6 Minimum two cables from the pipeline shall be provided at any test station.
7.6.7 The location of all the test stations shall be marked with their connection schemes and
other relevant information on alignment sheets. A detailed test-station schedule shall be
prepared.
7.7 Permanent Reference Cells
7.7.1 High purity copper/copper sulphate reference cells with proven high reliability shall be
provided for stable pipe to soil potential measurement at CP stations, polarization coupons
and computerized test station locations along ROW.
7.7.2 Silver/Silver Chloride reference cells in place of copper/copper sulphate cells shall be
provided at marshy area locations, where water table is high and chloride concentration is
more than 300 ppm. The test station connection scheme shall clearly indicate the type of
the reference electrode (Cu CUS04/Ag AgCl) at these locations.
7.7.3 The life of the reference cells shall be minimum 20 years under the installed conditions.
7.7.4 The cable from reference cells shall be provided up to CP power source at CP stations and
up to test stations at the locations of polarization coupons, computerised test stations. The
cable up to CP power source shall be routed through test stations near pipeline.
7.8 Electrical Resistance Probe
7.8.1 The electrical resistance probes (E/R probes) utilising the electrical resistance technique
shall be provided along the pipeline at marshy areas and at vulnerable locations to monitor
the external corrosion activity on the pipeline. The lead-wires of the probe shall be
connected to pipeline through test station and terminated inside test station enabling

0
(PART-A)
periodic resistance measurement of the probe using a portable probe measuring

instrument.
7.8.2 The material of the E/R probe element shall be of the same alloy as of the pipeline
material. The probes shall be provided preferably at the bottom portion of pipeline.
7.8.3 Sufficient number of E/R probes, the locations of their installation and the number of
portable E/R probe reading instruments shall be provided.
7.9 Polarisation Cell and Surge Diverter
7.9.1 Polarisation Cell
i) Where extra high voltage (66 KV and above) transmission line runs in parallel or
crosses the pipeline, the pipeline shall be grounded through polarisation cell with zinc
galvanic anodes of min. 20 kg net each. Grounding shall be done at regular intervals
of maximum 1 km where transmission lines run parallel within 25 metres of the
pipeline to control any surges in the pipeline potential that may appear in case of
transmission line faults.
ii) Locations along pipeline where continuous induced over-voltage due to EHV/HV line
etc. is expected or observed during commissioning, the pipeline shall be earthed
through polarisation cell to the earth system of the EHV/HV tower causing the voltage
induction or to a separate earthing system of zinc anodes through polarisation cell.
iii) Polarisation cell shall be installed inside test station of suitable size.
7.9.2 Surge Diverter
Explosion proof spark gap surge diverter shall be provided across each insulating joint to
protect it from high voltage surges. surge diverters shall be provided for classified areas.
7.9.3 The total system including cables, cable termination, anodes/surge diverters, polarisation
cell shall be suitable for the anticipated fault current at the location of installation.
7.9.4 The surge diverter and polarisation cell system shall be suitable for the design life of
permanent CP system. The grounding system shall have minimum resistance to earth to
restrict the pipeline voltage as per NACE/VDE criteria but shall not exceed 5 ohms.
7.9.5 The anodes shall be pre packed with special backfill adequately so that the performance of
the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil.
In any case, the thickness of back fill shall not be less than 50mm on all the sides of the
anode.
7.10 Motor operated valves where located on the cathodically protected portion of the pipeline
shall be grounded by a zinc anode of 20 kg net. Magnesium anodes grounding, if any,
provided during temporary CP system shall be disconnected. The MOV power supply
cable armour shall be insulated (by cutting and taping with insulation tape) at MOV end to
avoid armour carrying CP current.
7.11 The above ground cathodically unprotected pipeline at terminals, intermediate SV stations,
pigging stations, etc. shall be earthed with GI earth electrodes. The resistance to earth of
grounding shall be limited to 5 ohms max.
7.12 Polarisation Coupons
The steel coupons of pipeline material shall be provided along the pipeline to monitor the
adequacy of the CP system to polarize/protect coating holidays. Coupon shall be installed
at CP station drainage points, predicted cathodic protection mid points along the pipeline,
0
(PART-A)
at locations where the pipeline is bonded to foreign pipeline/structures, interference prone

areas, marshy areas and at other locations such that minimum one coupon is installed
maximum every 10 km approximately. Coupons shall be installed at bottom 113rd
portion of the pipeline and 250 mm away from the pipe surface.
The coupons shall be constructed from the pipeline material and shall have uncoated
surface of 100 mm x 100 mm exposed to soil. Two cables one for connection to pipeline
for protection and other for potential measurement shall be provided for each coupon. The
protection cable hall be connected through a magnetic reed switch inside the test station to
enable measurement of coupon 'OFF' potential.
A permanent reference electrode shall be installed adjacent to the coupon in a manner so

as to measure the representative potential of the coupon.
Magnets for operation of reed switch shall be provided .
7.13 Computerized Test Stations
Computerized test stations shall be provided along the ROW of the pipeline for
automatically monitoring and recording the pipe to soil potential, pipe current, etc. of the
pipeline, casing pipeline and foreign pipelines, etc, as required. The computer within the
test station shall measure and record these parameters regularly at programmed intervals.
The computers shall have required number of input ports for measurement of potentials
and current as applicable at the location of its installation. Computers shall have real time
clock and record the time of data measurement. Each computer shall an identification
number incorporated in its software, which shall be clearly indicated along with the data
display/print out.
The computers shall be programmed to collect and store all the field parameters at regular
intervals.
Data-retrieval computer of portable type suitable for use in field for programming the field
computers and retrieving the data stored by the field computers.
7.14 CP at Cased Crossing
7.14.1 At cased crossings where casing is coated, the casing shall be protected by sacrificial
anode installations provided at both ends of casing. The anode installation shall be sized
based on the permanent C.P. design parameters and design life of permanent CP system.
At cased crossings where casing is uncoated or painted, additional protection for casing
pipes may not be provided.
7.14.2 The carrier pipe inside the painted or coated casing shall be protected by zinc ribbon
anodes weld connected to the outer surface of bottom of carrier pipe extending up to hour
hand positions of 4 and 8 O'clock. The anodes shall be placed at close intervals as per
design calculations with minimum one number of anode installed between every two
supports provided between carrier and casing. The anodes shall be sized based on the
permanent CP design parameters for marshy area and design life of permanent CP
system.
7.14.3 Where casing is uncoated or unpainted additional protection for carrier pipe may not be
provided.
7.15 Reference Cell Access Points
Reference cell access points shall be provided near insulating joint locations and at SV
stations, where the ground is paved, for measurement of pipe to soil potentials. A
perforated PVC pipe filled with native soil and buried at the location shall be provided for

0
(PART-A)
the purpose. The length of the PVC pipe shall be adequate to reach the native soil below
the paving.
7.16 Cables
7.16.1 Cables shall be with annealed high conductivity stranded copper conductor, PVC
insulated, 650/1100 V grade, armoured, PVC sheathed conforming to IS 1554 part-I,
except for the cables for anode tail, reference cells and pipeline for potential
measurements. The size of the copper conductor shall be minimum 35 sq.mm. for anode
and cathode cables, 6 sq.mm. for current measurement, 10 sq.mm. for anode tail cables
and polarization coupon protection cables. The size of cable for bonding, polarisation cell,
grounding anodes and surge diverter connections shall be suitable for the maximum fault
current subject to minimum 25 sq mm.
7.16.2 The anode tail cables shall be PE insulated, 650V grade, unarmoured, PVC sheathed and
length shall be sufficient for termination on anode lead junction box without any joint in
between.
7.16.3 The cables for reference cells, coupon and pipeline potential measurements shall be of 4
sq.mm copper conductor, PVC insulated, Aluminium backed by mylar/polyster tape
shielded, PVC sheathed, armoured, PVC over all sheathed type.
1.16.4 The CPTR unit incomer cable shall be minimum 4 sq.mm. Copper conductor, 650/1100 V
grade, PVC insulated, armoured, PVC sheathed. The cable shall be of 3 core type for
single phase CPTR units and of 4 core type for 3 phase CPTR units.
7.16.5 The cables for connecting various transducers from CPTR unit/CPPSM to telemetry
interface junction box shall be twisted pair with individual pair shielded and overall shielded
with aluminium backed by mylar/polyster tape, PVC sheathed, armoured, PVC over all
sheathed type.
8.0 INSTALLATION
8.1 Cable Laying
i) Cables shall be laid in accordance with layout drawings to be prepared by the

contractor. No straight through joint shall be permitted. Cable route shall be
carefully measured and cables cut to required length. Minimum half metre cable
slack shall be provided near anodes, anode junction box, pipeline and test stations
to account for any settling.
ii) All cables inside station/plant area shall be laid at a depth of 0.75 metre. Cables
outside station/plant area shall be laid at a depth of minimum 1.5 metres. Cables
shall be laid in sand under brick cover and back filled with normal soil. For cables
laid outside the station/plant area, polyethylene warning mats shall be placed at a
depth of 0.9 metre from the finished grade, to mark the route. iii) In case of above
ground cables, all unarmoured CP cables shall be laid in GI conduits of sufficiently
large size, up to accessible height for protecting against the mechanical damage.
iii) All underground unarmoured cables including anode tail cables shall run through
PE sleeves. Distant measurement cables and permanent reference cell cables
routed along the pipeline shall be carried at the top of the carrier pipe by securely
strapping it at intervals with adhesive tape or equivalent as required.
iv) PVC pipes of proper size shall be provided for all underground cables for road
crossings.

0
(PART-A)
v) Cables shall be neatly arranged in trenches in such a manner that crisscrossing is

avoided and final take-off to equipment is facilitated.
vi) The cables for reference cells and pipeline potential measurement shall be routed
in a separate trench other than the trench provided for the rest of the CP system
cables, AC cables for CPTR Units etc.
vii) The armour of the cables from CP station to test station (potential measurement,
reference cell & drainage cables etc.), CP station to ground bed (anode cable) and
test station to pipeline shall be earthed only at CP station end and test station end
respectively of the cables. The cable armour shall be insulated (by taping with
insulation tape) to avoid armour carrying CP current.
8.2 Permanent Reference Cells
The permanent reference cells shall be installed in natural soil conditions as per the
recommendations of the cell manufacturer. Installations in highly acidic/alkaline soil and
soil contaminated by hydrocarbons shall be avoided.
8.3 Cable to Pipe Connections
Connections of all cables other than cathode drainage cables to the pipeline or to charged
pipelines shall be made by pin brazing. The resistance of the cable to pipe at the pin
brazing connection point shall not exceed 0.1 ohm.
The cathode drainage cable shall be connected to a bolt welded to a metal plate, which is
weld connected to the pipeline. The material of the plate shall be same as that of the
material of the pipeline.
Pipe coating shall be repaired after connection of cable to pipeline. At cathode drainage
point the cable joint including the bolt, metal plate and the exposed portion of the pipeline
shall be covered by the coating repair material against ingress of water/moisture. The
coating repair material shall be compatible with the original coating and shall prevent
ingress of water along the cable surface and at the interface of coating repair with the
original pipe coating.
8.4 Ground Bed Fencing
Chain link fencing shall be provided around the location of each ground bed/anode lead
junction box.
9.0 FIELD TESTING AND COMMISSIONING
9.1 System testing at site
Field tests as per the reviewed field testing and commissioning procedures prepared by
the Contractor shall be carried out on the equipment/systems before these are put into
service. Acceptance of the complete installation shall be contingent upon inspection and
test results. Field testing shall include but not be limited to the following:
i) Contractor shall carry out pre-commissioning operations after completion of

installation of the system including all pre-commissioning checks, setting of all
equipment, control and protective devices. All site tests, reliability and performance
tests shall be carried out by Contractor.
ii) Before the electrical facilities are put into operation, necessary tests shall be carried
out to establish that all equipment and devices have been correctly installed,
connected and are in good working condition as required for the intended operation.

0
(PART-A)
Owner/Owners representative may witness all tests. At least one week's intimation
notice shall be given before commencing the tests.
iii) All tools, equipment and instruments required for testing shall be provided by
Contractor.
iv) Generally, the following minimum tests must be carried out and results shall be
recorded:
- Visual Inspection : Comparison with drawings, specifications,

detailed physical inspection and, if necessary,
by taking apart the component parts.
- Testing : Simulation tests of equipment to determine
a) Cables
- Cable No.
- Voltage grade.
- Conductor cross section
- Continuity check
- Voltage test.
- Insulation resistance values between each core & earth, between cores
(between core and earth for single core cable).
All cables shall be tested by 500 V megger.
b) E/R Probe
- Location/Identification number
- Checking of wiring as per schematics
- Resistance reading of probe
- Installed on top/bottom!side of the pipeline
c) Reference Cell
- Location
- Type of cell
- Potential reading
- Installed on top/bottom level of pipeline
d) Insulating joint
- Location
- Pipe to soil potential of both protected and non-protected sides of the

insulating joint before and after energisation of CP system.
e) Surge diverter

0
(PART-A)
- Location/identification number.
- Rating
- Type
- Check for healthiness.
f) Polarisation Cell
- Rating
- Check for wiring
- Check standby current drain after CP system energisation. (Current drain

with respect to voltage across the cell shall be recorded).
- Details of grounding provided for the polarisation cell.
g) Anode Ground Bed
-Location/Station
-Check for actual layout and compliance with drawings.
-Resistance of each individual anode.
-Current dissipation by each individual anode.
-Total resistance of complete anode bed.
-Mutual interference.
h) Computerised test station
- Checking of wiring as per schematics
- Checking programmed interval for collection of the field data by the computer
- Type of reference cell
i) Polarisation Coupons
- Location
- Exposed area/size of coupon.
- Coupon to soil 'ON' and 'OFF' potentials.
- Type of reference cell.
- Magnetic reed switch rating.
- Operation of magnetic reed switch with magnet.
9.2 CP Commissioning Procedure

0
(PART-A)
A model commissioning procedure for a three stations CP system of a pipeline is given

below for general guidance. Contractor shall develop detailed commissioning procedure as
per this guideline.
i) On completion of installation of anode beds and other systems as envisaged in this

specification, they shall be individually checked, tested and compared against the
agreed specifications and procedure.
ii) Electrical continuity of the entire pipeline shall be verified in conformity with design.
iii) Input resistance of the pipeline at all the drainage points shall be checked and
recorded.
iv) All current measuring test stations shall be calibrated and recorded using portable
battery, variable resistances, voltmeters, ammeters, etc. as required.
v) Temporary protection facilities provided (if any) which do not form part of permanent
CP shall be disconnected from the system & removed unless agreed otherwise.
vi) Anodes provided for grounding at the MOVs on cathodically protected portion of the
pipeline shall be disconnected. Sacrificial anode where provided for the protection of
the casing pipe at cased crossings shall be disconnected.
vii) The pipeline shall be allowed to depolarize for at least 72 hours after switching 'OFF'
the protection (if any) of all other pipelines in the common ROW.
viii) Before the pipelines are put on charge by switching 'ON' any of the CP stations,
natural pipeline to soil, casing pipe to soil and coupon to soil potential values at all
the test stations of the system (coupon to soil potential at the locations of the
coupon installations) shall be measured with respect to Copper/Copper Sulphate
half cell.
ix) CP station no.1 shall be energised without put potential adjusted to achieve a
maximum pipe to soil potential (PSP) as specified, at the test station nearest to the
drainage point. Observations on either spread of protected portion of pipeline and
coupons under this CP station shall be taken for PSP values at each of the installed
test stations (coupon to soil potential at the locations of the coupon installations).
The pipeline current values across the cross section of the pipeline shall also be
determined at all the intended test stations influenced by this station.
x) CP station no.1 shall now be switched 'OFF', CP station no. 3 shall be switched 'ON'
and measurement procedure as detailed in clause ix) above shall be repeated.
xi) Similarly CP station no. 1 and 3 shall now be switched 'OFF', CP station no.2
shall be switched 'ON' and measurement procedure as detailed in clause ix) above
shall be repeated.
xii) All the CP stations of the system shall be switched 'OFF' and the pipelines shall be
allowed to depolarize. All the three CP stations in the system shall then be
simultaneously switched 'ON' and PSP values at the drainage points of pipeline
shall be brought to a value of maximum PSP as specified and a complete set of
observations shall be taken.
Another complete set of pipe to soil and coupon to soil observations shall be taken
after lines have stayed on charge for 48 hours. If there are appreciable differences
in these observations as compared to those of earlier set, a third set of observations
shall be taken after 72 hours. Maximum drainage point protective potentials shall not
be allowed to go beyond the maximum PSP values as specified, in any case.

0
(PART-A)
Coupon to soil 'OFF' potential shall be measured at all locations of coupon

installations by operation of magnetic reed switch in the test station. The PSP of the
coupons shall be within the PSP range specified in clause 6 of this document. The
output of all CP stations shall then be so adjusted that the sites of occurrence of
least negative protective potentials are not less negative than (-) Q.95V (OFF) and
sites of occurrence of the most negative protective potential are not more negative
than (-) 1.18V (OFF). A full set of pipe to soil, coupon to soil observations shall again
be taken 72 hours after the adjustment of potentials and the protection system shall
be left in this state of operation.
xiii) Care shall be exercised to ensure that power supply remains uninterrupted during
the period of commissioning. In case of an interruption, the test in progress shall be
repeated after allowing time for polarisation. More sets of observations shall be
taken in any of the steps specified above, if advised by the Owner/Owner's
representative.
xiv) The zinc anodes for grounding of MOVs at the locations of MOVs on cathodically
protected portion of the pipeline shall be reconnected to the MOVs.
xv) At cased crossings where casing is protected, sacrificial anodes provided for the
casing shall be connected to the casing pipe. The casing to soil potential and anode
output current shall be measured and recorded. Where casing pipe protection is
inadequate or the output current of the anode is more than the designed current,
then additional anodes shall be provided as required.
xvi) PSP values at each of the test stations of the existing pipelines shall be measured,
plotted, where existing pipelines run in parallel to the new pipeline, mutual
interference situations between the pipelines shall be identified and necessary
mitigation measures shall be provided. Interference situations shall also be identified
and mitigated by comparing different sets of readings taken at same test stations at
different intervals of time under identical conditions where positive potential swing is
100 mV or more.
xvii) Current readings at all the current measuring test stations shall be measured and
recorded.
xviii) Where computerized test stations are provided the computer shall be initialized
/started to collect and store the field data of potentials, current readings, etc as
programmed.
xix) After one month of starting the computers to collect the field data, the data stored by
the computers at all the computerized test stations shall be retrieved/down loaded
using the field data-retrieving computer. The data shall be analysed with the help of
a station main computer.
xx) At the locations of the Electrical resistance probe installations the resistance
readings of the probes shall be measured using probe reader.
xxi) Final records of testing and commissioning including graphical representation of

final pipe to soil potential readings shall be compiled with interpretation in
consultation with Owner/Owner's representative and submitted.
xxii) If any deficiencies are found in the system, the same shall be rectified by the
contractor, at no extra cost or time schedule impact, to the complete satisfaction of
Owner/Owner's representative. Such deficiencies shall include mitigation of stray
current electrolysis and interference problems that may be found existing in the
course of testing and commissioning. A set of PSP observations shall also be taken
during the peak of the first dry season after commissioning the system into regular
0
(PART-A)
operation. Any deficiency found in the protection of the pipeline shall be rectified by
the contractor at his own cost.
xxiii) If it is found during commissioning that the sites of occurrence of least negative or
most negative protective potentials are less negative than (-) O.95V (OFF) or more
negative than (-) 1.18V (OFF) respectively even after 72 hours of operation, then the
drainage point potentials shall be adjusted depending upon anode ground bed
currents in consultation with Owner/Owner's representative. In any case, the
protective 'OFF' potential values of pipeline and polarization coupons shall not
exceed the PSP value range specified in cl. 6 of this document, at any location on
the pipeline.
xxiv) The reference cell shall be calibrated minimum once in 24 hours during the
commissioning.
xxv) The current dissipated by individual anodes shall be measured from the anode lead
junction box and corrected for equal dissipation to the extent possible keeping the
total ground bed current same.
10.0 INTERFERENCE MITIGATION
10.1 Investigations shall be made for stray current electrolysis of the pipeline, mutual
interference between the pipeline and foreign pipelines/structures, interference on foreign
pipelines/structures due to the CP of the pipeline and ground bed, interference on metallic
structures which lie in between pipeline and ground bed or near to ground bed, AC
induction on pipeline due to overhead EHV/HV lines, interference due to high voltage DC
lines, HVDC earthing system, electric traction, etc.
10.2 Measurements including pipe/structure to soil potentials and pipe/structure currents etc. on
the pipeline/structure being CP protected and on foreign pipelines/structures, and ground
potential gradient etc. shall be made to investigate the current discharge and pickup
locations. In case of fluctuating stray currents, investigations shall be made continuously
over a period of time and if required simultaneously at different locations to find out the
stray current source(s). Recorders shall preferably be used for long time measurements.
10.3 Wherever foreign pipelines which may or may not be protected by an independent CP
system run in parallel to the protected pipeline, either in the same trench or very near to
the protected pipeline and are not bonded to it, investigations shall be performed for
current discharge points on both the pipelines.
10.4 Mitigative measures shall be provided depending upon the type of stray current
electrolysis/interference. These shall include installation of bond with variable resistor,
diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment/
relocation (if possible) of offending interference source, provision of electrical shield etc.
depending on the type of interference.
10.5 Bonding with foreign pipelines/structures as a mitigation measure shall be provided where
the owners of the foreign pipelines/structures have no objection. Otherwise alternative
mitigation measures shall be provided. Wherever bonding is provided for mitigation, the
bonding resistor shall be adjusted for optimum value for minimum/no interference.
Galvanic anodes installed as a mitigation measure shall be adequately sized for the life
specified for permanent CP system.
10.6 Where transmission lines cross the pipeline or run in parallel with in or more than 25m
from the pipeline, A.C. Voltage measurements shall also be made on the pipeline to find
out continuous induction of voltage. In case of the induced voltage being beyond the safe
limits, the pipeline shall be grounded to the nearest transmission tower earth system

0
(PART-A)
through polarisation cell or to a separate earthing system of zinc anodes of minimum 20 kg

net each through polarisation cell.
11.0 CLOSE INTERVAL POTENTIAL SURVEY
Where specified, contractor shall carry out a close interval 'ON'/'OFF' potential survey over
the entire length of pipeline by computerised potential logging method and identify the
under protected/over protected area, any major coating damage on the pipeline, after the
backfilling has been consolidated sufficiently and CP system has stabilized. Contractor
shall provide required mitigation measures and rectify the under/over protected zones,
identify if any, the major pipeline coating defects, required to be repaired. During the
survey the reference cell shall be calibrated minimum once in 24 hours. Detailed
procedures for running this survey shall be submitted for review.
Additional tests for detailed identification of coating defects shall be conducted by the
contractor.
12.0 DEVIATIONS

0
TECHNICAL SPECIFICATION - FIRE DETECTION AND ALARM Document No. Rev
SYSTEM (PC150-TS-0826) Sheet 1 of 20
FIRE DETECTION AND ALARM SYSTEM

0
CONTENTS
SECTION DESCRIPTION
NUMBER
1.0 SCOPE
4.0 DEFINITIONS
5.0 SYSTEM AND SITE CONDITIONS
6.0 FIRE ALARM SYSTEM DESCRIPTION
7.0 ENGINEERING REQUIREMENTS
8.0 ADDRESSABLE FIRE ALARM SYSTEM
9.0 INTEGRATION WITH VARIOUS PLANT SYSTEMS
10.0 PANEL CONSTRUCTION
11.0 AUTOMATIC FIRE DETECTORS AND ACCESSORIES
12.0 FIELD DEVICES FOR HAZARDOUS AREA
13.0 CABLE AND CABLE ACCESSORIES
16.0 INSTALLATION AND COMMISSIONING
17.0 TRAINING

0
Abbreviations:
BIS Bureau of Indian Standards
BASEEFA British Approvals Service for Electrical Equipment in Flammable Atmosphere
CCE Chief Controller of Explosives
CFAP Central Fire Alarm Panel
CMRI Central Mining Research Institute
CPU Central Processing Unit
DGFAP Data Gathering cum Fire Alarm Panel
ERTL Electronic Regional Test Laboratory
FAT Factory Acceptance Tests
FDD Floppy Disk Drive
FM Factory Mutual
FRP Fibre Reinforced Plastic
FO Fibre Optic
GUI Graphic User Interface
HAB Hooter acknowledgement box (to mute hooters)
HDD Hard Disk Drive
ISDN Integrated Service Digital Network
ITU-T International Telecommunication Union- (Telecom)
LED Light Emitting Diode
LPC Loss Prevention Council
LIFO Last In First Out
MCP Manual call point (break glass unit; BGU)
MMI Man Machine Interface
MR Material Requisition
Ni-Cd Nickel Cadmium (battery)
PO Purchase Order
RF Radio Frequency
SAT Site Acceptance Tests
SOE Sequence Of Event
TAC Tariff Advisory Committee
UWL Under Writers Laboratory
UPS Uninterrupted Power Supply
VRLA Valve Regulated Lead Acid (battery)
WP Weather Proof
ZFAP Zonal Fire Alarm Panel

0
1.0 SCOPE
1.1. The intent of this specification is to define the functional and design requirements for an
Integrated Fire Alarm System for industrial plants and buildings. This specification covers
the requirements for selection, design, and engineering, manufacture, testing at vendor's
works, supply, installation, testing at site and commissioning of the system.
1.2. The Integrated Fire Alarm System shall be microprocessor based analog addressable
system comprising of MCP, detectors, microprocessor based Fire Alarm panels, panels,
hooters, sirens, exit signs, Loop/network/power cables, earthing, Junction box &
associated equipments detailed hereunder and as per codes standards mentioned below
and in Project data sheets/ drawings.
1.3 The fire alarm system shall integrate
2.1 The system and equipment shall comply with relevant BIS (Bureau of Indian Standards)
and other Indian/ International standards, as applicable. In case Indian standards are not
available for any equipment, standards issued by IEC/ BS/ VDE/ IEEE/ NEMAINFPA or
equivalent agency shall be applicable. In case of imported equipment, the standards of
the country of origin shall be applicable if these standards are equivalent or more
stringent than the applicable Indian standards.
2.2 The equipment shall also conform to the special requirement/ provisions of applicable
2.3 In case of any contradiction between various referred standards/ specifications/ data
sheets and statutory regulations, the following order of decreasing priority shall govern:
2.4 The fire alarm system and the components used shall conform to the latest edition of the
following and also the other Indian and International Standards as applicable.
IS-5 Colours for ready Mixed Paint & Enamels.
IS - 513 Specification for cold rolled low carbon steel sheets and strips
IS/IEC:60079 Flameproof enclosures for electrical apparatus
IS - 1646 Code of practice for fire safety of buildings (general): Electrical

Installations
IS - 2175 Specification for heat sensitive fire detectors for use in automatic fire
alarm system
IS - 2189 Code of practice for selection; installation and maintenance of

automatic fire detection and alarm system.
IS - 3034 Code of practice for fire safety of Industrial buildings: Electrical

generating and distributing stations

0
IS - 3700 Essential ratings and characteristics of semi conducting devices

(Applicable parts)
IS - 3826 Connectors for frequencies below 3 kHz General requirements Part-I

and tests
IS/IEC:60079 Code of practice for the use of semi-conductor junction devices

(Applicable parts)
IS - 5780 Specification for Intrinsically safe electrical apparatus and circuits
IS - 11360 Specification for smoke detectors for use in automatic electrical fire
alarm system.
IS - 12459 Code of practice for fire safety in cable runs
IS - 13346 General requirements for electrical apparatus for explosive gas

atmosphere
IS-14154 Part 2 Electrical apparatus with protection of enclosure for use in the
presence of combustible dust
NFPA 72 Vol 4 National Fire Alarm code
LPC Loss prevention council recommendations.
BS - 5839 Specifications for manual call points.
BS-EN 50081-1 EMC (Electromagnetic compatibility test)
BS-EN 50082-1 EMC (Electromagnetic compatibility test)
3. 1 The offered equipment shall be brand new with state of the art technology and a proven
field track record. No prototype equipment shall be offered.
Bidder shall consider adequate nos. of Fire Alarm panels which shall be located at plant
and control room of building/substation.
Bidder shall also consider repeater panels (min 3 nos.) which shall be installed in fire
station. All the fire alarm and repeater panels shall be connected in ring network.
Repeater panel shall be replica of main fire alarm panel.
Minimum 3 nos. Siren shall be provided with 5 Km audio range.
In case of a Fire alarm initiation by a alarm initiating device, the audio-visual fire alarm
shall be generated at Fire Alarm Control Panels (FACP) located at each substation &
building and repeater panels for each Fire Alarm panel at Fire safety station as well as
in CCR which also initiate signal to operate hooters/siren located in various locations in
building and plant area.
The Fire Alarm System envisaged for Building shall be “2-Wire Analog Addressable”
type.
The communication between detectors and the FACP is by means of digital

communication over 2-wire, which further provides power to the detectors, devices &
0
Sounders. There shall be A/D and D/A conversion happening inside the detectors and
FACP.
All the detectors shall be incorporated with microprocessors and shall be provided with
Analog to Digital Converter (ADC), which enables the detector to provide linear output
corresponding to the quantity of smoke or fire, the detector encounter.
All types of detectors offered will be of restorable type i.e. suitable for operating a fresh
after each actuation on alarm without replace mentor adjustment.
The sensitivity of each sensor shall be individually adjusted from the FACP to suit the
conditions of each location. Each detector shall have self-test facility, which is monitored
in the FACP. Each detector shall have drift compensation.
The response sensitivity shall also be field adjustable and not only from fire panel over a
wide range to suit site shall conditions. It be possible to test the sensitivity of a detector in
the field. The sensitivity/threshold value of detectors which are cross zoned must be
compatible.
The FACP shall also check each sensor for contamination of dust/dirt and give signal for
“Service” in case of accumulation of dust/dirt reaches a preset limit.
The fire alarm system shall work without any problem both in networked mode and in
standalone mode.
The electronic circuit shall be of solid state and of failsafe design and virtually
hermetically sealed to have resistance to humidity and corrosion and to prevent its
operation from being impaired by dust and dirt.
The circuit shall be protected against usual electrical transients, electromagnetic and
electrostatic interference (EMI&RFI) present in the Building.
Reverse polarity or fault in the field wiring shall not damage the detector.
No moving parts subject to wear & tear shall be provided.
The system shall have following self diagnostic features:

 Detector cabling shall be completely supervised for open circuit and short circuit
and exact location of fault shall be displayed in the panel under Trouble/Faults.
 Un-authorized removal of a detector head from its base shall be supervised to

give an alarm on the connected control panel.
 Annunciation shall be provided for DC fuse blown and loss of main AC supply etc.
 Alarm verification features.
If the Equipments to be located in hazardous areas, then same shall have test
certificates issued by recognized independent test house such as CIMFR, ERTL,
BASEEFA, UL, FM or equivalent. All indigenous equipment shall conform to Indian
standards and shall be certified by Indian testing agencies. All equipment (indigenous &
imported) shall also have valid statutory approvals e.g. PESO, DGMS as applicable for
the specified location. All indigenous flameproof equipment shall have valid BIS license
and marking as required by statutory authority.
Fire alarm system shall be interfaced with the owner’s system.

0
The system shall be provided with siren/s to be located at a suitable location/s in the
plant and it shall be actuated manually and automatically as selected by operator from
Fire Alarm panel located at fire station/ other buildings.
offered equipment for at least 15 years from the date of supply. The spares shall be
available ex-stock with the vendor.
3.3 Vendor shall give a notice of at .least one year to the end user of equipment and PMC
before phasing out the product/ spares to enable the end user to place order for spares
and services.
3.4 The vendor shall be responsible for design, engineering and manufacturing of the
complete system and equipment to fully meet the intent and requirements of this
specification and attached data sheets.
3.5 All equipment and accessories required for completeness of the system, whether
specifically mentioned or not but considered essential for satisfactory performance, shall
be included as a part of the offered system.
3.6 The system integrator shall coordinate with the manufacturers of various bought-out
items associated with the system, as required, and shall freely and readily supply all
technical information as and when called for.
4.0 DEFINITIONS
4.1 Hazardous Area
An area in which an explosive gas/ dust atmosphere is present, or likely to be present in

quantities such as to require special protection for the construction, installation and use
of electrical apparatus.
5.0 SYSTEM AND SITE CONDITIONS
All equipment shall be designed to operate with power supply and site conditions as
specified below:
5.1 Input Power Supply
5.1.1 Power supply for fire alarm panels shall have battery backup as per IS-2189. Battery AH
rating shall be determined on the basis of maintaining the system in normal operation for
a period of not less than 48 hours (quiescent condition) and successive full load alarm
condition of period not less than 30 min after the failure of normal mains supply.
The switch over from mains to back up, in the event of mains failure, shall be automatic.
Batteries shall be Ni-Cd type. Suitable and adequately rated battery charger shall be
supplied as a part of back up battery system.
The secondary power supply capacity required shall include all power supply loads that
are not automatically disconnected upon the transfer to secondary power supply.
Battery sizing shall consider the maximum quantity of detector/equipment that can be
connected in the loops, as well as 5 hooters and 5 exit signs per loop in Fire Alarm
panels. Battery sizing calculations shall be reviewed during detailed engineering and
there shall be no cost/time implication for providing adequately sized batteries and
chargers of approved rating during the order execution. Separate battery charger shall
be provided in case battery charger part of the Fire Alarm panel cannot cater to the
boost charging requirement of battery.

0
An overall ageing factor of 0.8 and a temperature correction factor corresponding to

minimum temperature of 5°C shall be considered for battery sizing. The battery
calculations shall include a 10 percent safety margin to the calculated amp-hour rating.
Operation on secondary power shall not affect the required performance of a fire alarm
system or supervising station facility. The system shall produce the same alarm,
supervisory and trouble signals and indications.
Operation on secondary power shall not affect the required performance of a fire alarm
system or supervising station facility. The system shall produce the same alarm,
supervisory and trouble signals and indications.
The switch-over from primary source to secondary source, in the event of mains failure,
shall be automatic. Battery shall be Ni-Cd type.
5.2 Site Conditions
The offered equipment shall be capable of operating continuously and maintaining its
guaranteed performance at the site ambient conditions indicated in data sheet.
Unless specified otherwise, fire alarm panels along with associated hardware shall be
suitable for installation and operation in a closed building/ room with restricted ventilation.
Any specific requirements for air conditioned/ dust free environment, etc. for the panels, if
absolutely necessary, shall be clearly highlighted by the vendor in the offer.
6.0 FIRE ALARM SYSTEM DESCRIPTION
6.1 General
Fire alarm system under this specification is envisaged to provide fire monitoring in
industrial plants/ chemical plants/ plant and non- plant buildings. The system shall be
designed to detect incipient fires and generate audio/ visual alarm in case of fire.
The system shall consist of automatic fire detectors and manual call point or break glass
unit. Automatic fire detectors shall work on the principle of sensing of smoke, heat or
infrared rays. Depending on type of smoke, optical or ionization type detectors shall be
used. Detectors shall generally be provided in plant/ non-plant buildings. Manual Call
Point shall be provided at exit doors of the buildings and at exit route of industrial plants.
Number of detectors and break glass unit shall be decided as per guidelines given in
applicable codes and standards.
Alarms, if specified, shall be relayed to repeater panel provided in buildings like control
rooms/administrative buildings to provide zone wise annunciation. In addition facility shall
be provided to actuate siren/ hooter.
For integrated fire alarm system where plant-wide large numbers of fire alarm panels are
envisaged, these panels shall be integrated to CFAP, which shall be located in fire
station or in administrative control room of the building as per the job requirements. The
connectivity shall be achieved using data high way or dedicated cable connection from
each fire alarm panel to CFAP. Mimic at CFAP shall be provided for fire/ fault
annunciation on geographical location in addition to the text/ LED. If defined, CFAP shall
have provision for automatic and manual actuation of plant-wide siren as per operator's
choice. Interface with other systems such as telephone exchange/ plant's public address
system/Pager system shall be provided for communication required for disaster
management.
6.2.3 As specified in data sheet, the system shall be provided with siren/s to be located at a
suitable location/s in the plant and it shall be actuated manually and automatically .
7.0 ENGINEERING REQUIREMENTS

0
vendor shall design entire fire alarm system including design of system architecture with
details of integration, cabling requirement and protocol selection etc. Vendor's scope
shall also include basic design and preparation of layouts for fire alarm system for plant/
buildings as specified in the data sheet/ purchase documents.
8.0 ADDRESSABLE FIRE ALARM SYSTEM
8.1 ANALOGUE ADDRESSABLE FIRE ALARM CONTROL PANEL (FACP)
The FACP used in the Building shall confine to the EN54 standards having the
following features.
i) FACP provided shall have the capacity to expand from at least loop for Future
expansion.
ii) Each loop shall accommodate maximum 250 detectors and devices in any
combination with a loop length capable up to 2kms with 2Cx1.5sqmm cable.
However bidder shall consider maximum number of detectors/ MCP/ addressable
devices in a signal loop shall be 60.
iii) It shall have facility to discriminate between a real fire alarm and false alarms.
iv) FACP will function as fully stand-alone panel& also networked to other FACPs &
repeater with peer to peer communication.
v) Each FACP shall have redundant controller to takeover in case of a Failure in the
Primary Controller and also redundant loop card for each loop to takeover in case of
a Failure in the Primary Loop Card.
vi) Each FACP shall have inbuilt LCD colour touch screen (320*240 pixels) to clearly
indicate the location of fire, type of device activated other indications like service
requirement of a component, etc.
vii) In case of a Loop Card Failure, the FACP shall allow to replace the Loop card
without switching off the panel and reprogramming.
viii) The FACP shall be capable of Public Address system integration with the use of
RS232/RS485 module or with the use of relays.
ix) FACPs shall have inbuilt buzzer to alert the personnel in case of maintenance
requirement.
x) FACP shall have facilities for sequence of events to happen in case of fire like
closing of fire dampers, shutting down supply fans for HVAC, Deactivating the
access control system and activating the hooters with the help of a control relay
module provided near the system to be activated.
xi) The fire alarm control panel shall be suitable for Class-A type of wiring as per NFPA-
72.
xii) The fire alarm control panel shall work on positive sequence as per NFPA – 72.
xiii) The fire alarm control panel shall be capable of disabling an individual detector, a
group and or zone off or building maintenance purposes. Facility shall be provided
on the FACP for simulating the fire condition to enable testing of the various alarm
circuits.
xiv) All the fire alarm modules (loop cards, networking cards, and communication card.
Etc.) should be hot pluggable and hot swappable to facilitate easy replacement of
faulty modules. All the electronic components shall be compatible to non-air-
conditioned environment for working satisfactorily.

0
xv) The fire alarm control panel normal power supply failure shall be annunciated audio-
visually.
xvi) In case of multiple alarms the multiple alarm indication shall be ON. The multiple
alarm indication shall be displayed in chronological order.
xvii) FACP shall have the facility such that each detector can be identified as a separate
zone.
xviii) The FACP shall be reset only by authorized users after the clearance of a fault.
xix) Whenever there is a third party actuation to happen, like closing of fire dampers,
switching off supply/exhaust units etc, the actuation shall happen only when the fire
signal is received from two different initiating devices located in a zone connected to
different fire alarm panels .The communication between the FACPs shall happen
with two pair cables and the fire alarm status of one panel shall be communicated to
the second panel in which the control relay module of the third party device is
connected to. Inter panel communication is a must and needs to be provided for
controlled actuations .All the necessary systems to ensure reliable communications
between panels are to be built into the FACPs.
xx) FACP shall have the facility to silence/ acknowledge/ reset the alarm. Apart from the
FACP.
xxi) The FACP shall have FALSE ALARM REDUCTION algorithms like.
 Alarm Verification, Dual Detector/Group Dependency, and Intermediate Alarm

Storage to eliminate False alarms due to Dirt/Dust/Disturbance values.
 EMC/EMI Monitoring - Signal-to noise ratio shall be high. To inform the

possibility of a false alarm caused due to interferences from sources such as
Motors, power cables, Wi-Fi routers, fluorescent lamps, network switches,
mobile signals…etc. The panel shall display the EMI/EMC Current and Average
Values reported by the detector. The User/Installer shall have access to this
reading during Maintenance (with password protection).
xxii) When fire condition is confirmed, the following sequence of annunciation will take
place on the FACP:
Audible
Alarm Condition Visual Alarm
Alarm
ON FLASHING/Description of area
First Fire Condition ON
of fire origin with detector type
Acknowledge
OFF ON STEADY
(first Alarm)
New Fire Alarm Condition
(after acknowledge of ON ON FLASHING
First alarm)
Acknowledge
OFF ON STEADY
(New fire alarm)
Back to normal OFF ON STEADY
Reset OFF OFF
Reset Before Normal OFF ON STEADY

0
xxiii) System shall provide adequate EEPROM size to store minimum of 200 events fire/
fault. The event shall be stored in LIFO structure. All events shall be time stamped.
FACP shall have real time clock for event time stamping.
xxiv) Software access for either Zone programming or access to plant/ building graphic
on monitor shall be password protected. For viewing status of various field devices
e.g. fire and fault status password protection shall not be given.
xxv) Fire Alarm & repeater panels shall be certified/ approved by an international
approving agency/ approving agency of country of origin as applicable.
xxvi) The FACP shall have a process or which shall be ofat-least32bit,which shall be
designed to accept all the input sand process the outputs within the time stipulated
by the standards.
xxvii) The CPU shall have the facility to communicate with other FACPs and process the
fire signals received from other FACPs to actuate a third party device.
xxviii) The processor shall be designed in such a way that the parameters in the
repeater panel shall be refreshed in 1sec.
xxix) The capacity of the processor shall be adequately designed include all input/output
signals and various functional requirements.
xxx) It shall have its own, built in advanced microprocessor, sophisticated software and
extensive memory for storing the logs of alarms, times and action taken report.
xxxi) Loop module shall have a line length up to 1600m or 3000m depending upon the
configuration & cable type. It shall have an LED test button.
xxxii) The loop module shall be encapsulated & shall be hot pluggable.
xxxiii) The front fascia of the loop cards shall be visible for easy identification of faults.
xxxiv) In case of the failure of loop card, it should be replaced without the need of any
additional programming.
8.2 Repeater Panels
i) These panels shall be required for repeat of alarm in buildings/ plant control
rooms/Fire station.
ii) It shall be a LCD touch screen same as main panel. The MMI shall be the same
as the main Controller.
iii) Repeater panels shall be suitable for Wall mounting which will be displayed from
all the major entrances and staircases which will enable the staff and fire fighting
personnel to exactly locate the fire.
iv) It shall be compatible to received at a from FACPs.
v) Audio visual Alarms during fire shall be generated in case of fire.
vi) All fire alarm panels including repeater panel shall be networked through copper/FO
communication cable.
vii) The Power supply to the Repeater Panel shall be drawn from the Fire Panel
viii) The Repeater Panel shall display Messages like Alarm & Fault similar to the Main
Panel and shall be accessed only by Authorized Users through a passcode.

0
ix) The Repeater Panel shall be connected to the Main Panel and other repeater
panels in such a way – 1 pt Failure in the cable shall not affect the performance
and shall intimate the exact location of failure in all Panels.
x) The Repeater Panel shall be equipped with a Key switch that allows Authorized
users to Acknowledge/Reset Alarms.
xi) The Repeater Panel shall be equipped with 2 different power inputs. On failure of
primary power, the secondary shall take over.
xii) The Repeater panel shall allow the users to login locally or login to the remote
FACP.
xiii) The repeater panels shall integrate with the main panels without any additional
interface or the bidder shall consider necessary accessories required to complete
the system and quote as part of this model.
9.0 INTEGRATION WITH VARIOUS PLANT SYSTEMS
9.1 Fire Alarm System shall have required hardware to have interface with following plant
systems as specified in data sheet.
i. Public Alarm Announcement system
ii. Paging and plant intercom systems.
iii. Plant data network
iv. ISDN telephone exchange and pager system
v. Fire suppression system
vi. PLC Data Communication through serial common modbus

vii Shutdown signals to various air-handling units relative to the zone of fire.
viii Siren
10.0 PANEL CONSTRUCTION
10.1 Equipment Mounting
10.1.1 All apparatus, display screen, instruments and indicating lamps mounted on the panel
front shall be flush mounting type. The external cabling shall not be terminated directly on
the base connector of PCBs but shall be terminated on separate terminal block. Further
connection to PCBs shall be as per manufacturer's standard. Routine calibration,
adjustments, programming and operation shall be accessible from the front of the panel
without opening the door. External cabling shall preferably be done from the rear.
10.1.2 Power supply system including battery bank shall be mounted inside the panel.
10.1.3 Doors shall be provided with pistol grip handle with lock. Lamps shall be provided inside
the panel to provide adequate light for maintenance of equipments.
10.1.4 Cable entry shall be from bottom unless otherwise specified in the data sheet. Terminal
strip shall be provided for incoming / outgoing cables.
10.2 Wiring and Terminals

0
10.2.1 Wiring within the panel shall be laid in slotted plastic raceways enclosed with cover.
Control connections shall be done with 660V grade PVC insulated wires having stranded
copper conductors. 1.5mm2 size of wire shall normally be used for circuits with control
fuse rating of lOA or less. Control wiring for electronic circuits shall be through ribbon
cable or through copper wire minimum of 0.5mm dia. Panels shall be supplied completely
pre-wired, such that only field termination shall be required at site before it is energized.
10.2.2 PCBs for identical functions shall be interchangeable. PCBs shall be plug in type having
pin/edge connectors. PCBs shall be suitable for use in tropical, humid and dusty
environment. These shall be protected with anti fungus treatment.
10.2.3 Cables shall be terminated on terminal blocks. Clamp type terminals shall be of spring-
loaded, stacking type, mounted on rails. Terminals shall be sized to accept, as a
minimum 2.5mm2 cross section conductors. Not more than one conductor shall be
terminated on the outgoing side of each terminal. At least 20 % spare terminals shall be
provided in each panel for termination of spare cores of cables.
10.3 Earthing
10.3.1 A common earth bar of minimum 25 x 3 mm. copper or equivalent aluminium shall be
provided throughout the length of the panel. All non-current carrying metallic parts of the
panel mounted equipment shall be earthed. Flexible jumpers shall connect all doors and
movable parts to the earth bus. Two numbers earth lugs shall be provided outside the
panel.
The FACPs shall be provided with triplicated earthing terminals on the either side. The
grounding terminal G1 shall be for safety grounding, G2 shall be for shield grounding and
G3 shall be for signal grounding
10.4 Name Plates / Warning plates
10.4.1 All nameplates for panel shall be engraved out of 3 ply (black-whiteblack) lamicoid
sheets or anodized aluminum. Back-engraved Perspex sheet nameplates will also be
acceptable. Engraving shall be done with square groove cutters. Hard paper or self-
adhesive plastic tape nameplates shall not be acceptable.
10.4.2 Labels shall be provided for every component on the cards, connecting wires as well as
for the terminals in the terminal strip inside the panel. Wiring diagram shall be pasted
inside the panel door as required for termination and maintenance.
10.4.3 Special warning plates shall be provided on all removable covers or doors giving access
to energized metallic parts above 24 volts.
10.5 Painting
10.5.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust,
grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any
trace of acid. The undersurface shall be made free from all imperfections before
undertaking the finishing coat.
10.5.2 After preparation of the undersurface, the panel shall be powder coated. The colour
shade of final paint shall be as approved by the purchaser. The finished panels shall be
dried in dust free atmosphere. Panel finish shall be free from imperfections like pinholes,
orange peels, fun-off paint etc.
10.5.3 All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust-
corrosion. Moving elements shall be greased.

0
11.0 AUTOMATIC FIRE DETECTORS AND ACCESSORIES

i) Detectors for microprocessor shall be addressable type. Detectors shall be plug-in
type and shall have twist lock action fitting. Multicolour LEDs provided on the detectors
shall indicate Normal and Alarm state. Essential features of detectors are indicated as
below.
ii) Detectors shall be supplied with mounting bases. Mounting base shall be identical for
all type of detectors. Detector housing (body and cover) shall be made up of damage
resistant, fire resistant polycarbonate and shall be suitable for either surface or recess
mounting. Detector base shall be mounted on Junction boxes having terminals for
cable termination. Installation equipment such as GI conduits, GI junction box/ conduit
box etc. shall also be included in vendor's scope.
iii) Detectors shall be suitable for storage at ambient condition specified in data sheet.
iv) All detectors shall be on the approved list of LPC, UL / FM/ equivalent international
approving agency as applicable.
11.1 Intelligent Addressable Dual Optical Smoke/Heat (Multi-sensor) Detector
i) The Intelligent Addressable Multi sensor Detector with 2 LED’s-Infrared & Blue used
and shall confine to the relevant standard shaving the following features.
ii) It shall be combination of Smoke detection and heat detection. The smoke detection
system shall work on Light scattering type principle using Infrared & Blue LED’s, and
the Heat detection system shall be of Rate of rise of temperature and Fixed
Temperature.
iii) The Intelligent Addressable Multi sensor Detector shall be of Spot type and
Addressable type.
iv) The Intelligent Addressable Multi-sensor Detector shall be addressed either by DIP
switches or through Programming from the Panel.
v) The Detector shall monitor EMC/EMI values in the surroundings on a continuous basis
and report the current & average values to the panel. The detector and the panel shall
together avoid the possibility of false alarm caused due to interferences from sources
such as Motors, power cables, Wi-Fi routers, fluorescent lamps, network switches,
mobile signals…etc.
vi) All the detectors shall have a visible multi-color LED to indicate the
healthiness/trouble/alarm condition of the detector. The LED shall be located in such
away that it shall be visible from all the 360 degree from below. In some cases where
the visibility of the detector is obstructed by cable trays, false ceiling etc. Facility for
connecting the detector to a response indicator has to be present. The response
indicator derives the power to glow from the loop.
vii) It shall possess False alarm immunity and a superior signal to noise ratio.
viii) It shall have drift compensation facility built-in.
ix) The detectors shall communicate the ambient reading to the FACP on time to time
basis, and the FACP shall make the decision about the current status of the
detector, whether it is in fire/pre-alarm/maintenance requirement etc.
x) The detector shall have different levels of sensitivity settings based on the
application and room where it is installed.
xi) The detector shall provide a chamber maid plug to blow out the dust/dirt using a
blower.
xii) In case of a failure, panel shall allow to replace the detector with the same type
without the need of additional programming

0
xiii) The detector shall be programmed to work as Optical only or Thermal only
detectors. It shall a provision to switch off any component (optical or thermal) of the
detector.
xiv) The detector shall work with 2 different sensitivity settings at any point of time and
the User shall have access to choose the desired settings without programming or
Laptop/PC for configuration.
xv) The detector shall change sensitivity settings based on day/night mode or with
schedules based on the programming.
xvi) The detector shall have Intermediate Alarm Storage, Dual Detector Dependency,
Dual group Dependency features that shall be programmed based on site
application.
xvii) The detector shall be capable of detecting both smoldering fires and open fires and
shall be EN54 /VdS approved
11.2 Heat Sensing Cables
Heat sensing cable shall be analogue type. It shall consist of four copper conductors,
each covered with a colour coded, negative temperature co-efficient material. The cores
shall be twisted together and protected by an outer sheath of high temperature, flame
retardant PVC insulation. External mechanical protection shall be provided over the
sensor cables. Vendor shall provide control unit for each 100 m length of the sensor
cable.
11.3 Manual Call Point (MCP)/Break Glass Unit (BGU)
i) Manual break glass unit shall be fabricated out of 14-gauge cold rolled sheet steel.
Alternately the break glass unit may be made of die cast aluminium alloy such as
LM6.
ii) It shall have IP-55 enclosure and weatherproof construction suitable for outdoor
installation. The break glass unit shall have a minimum dimension of
100x100x80mm.
iii) The box shall be fabricated in such a way it can be mounted flush to the wall or on
the surface without any modification. Two nos. 19 mm knockouts shall be provided
at the bottom of the box to facilitate cable / conduit entry. The glass shall cover at
least 30cm2 area and shall have a thickness not exceeding 2mm.
iv) The box shall have a push button element kept in pressed condition by a glass
sheet fitted in the front of the box.
v) The enclosure shall be painted with fire red colour (shade 536 of IS-5) epoxy
painting and an inscription" Break Glass in case of Fire", shall be painted in white
letters or riveted on the enclosure by a steel nameplate. A suitable nickel-plated
brass hammer, duly chained to the box with stainless steel chain shall be provided
with each box for breaking the glass. Each box shall have a distinct identification
number boldly painted on it.
vi) One no. blanking plug shall be provided for 5% of the total quantity of MCPs.
vii) Hazardous area Break Glass Units shall meet the requirement of clause 13 of this
specification.
11.4 Response Indicator

0
Response indicators shall be provided suitable for wall/ ceiling mounting as required.
Response indicator shall be provided where the detector is located either above false
ceiling or below false floor or where detectors are not directly visible. The response
indicators shall be connected to the detectors directly and shall be complete with terminal
blocks suitable to accept cables with up to 1.5mm2 copper conductor. In the normal state
of detector, the LEO shall flicker, but in the event the detector goes into alarm condition,
the LEO shall glow steadily. LEOs shall be red in colour with 5mm dia. as a minimum.
11.5 Exit signs
Exit signs shall be fabricated out of 1.6mm thick cold rolled sheet steel. This shall be
suitable for wall mounting or suspension from ceiling. Exit signs suspended from the
ceiling shall have text/ direction printed on both the side of exit sign.
Fire exit shall be displayed by means of 5mm dia LEDs or backlit text. It shall be powered
from the fire alarm panel. Exit sign shall operate on DC power supply.
The exit sign shall be either in red letter on white background or white letter on green
background.
Where specified in data sheet, self-luminous exit sign shall be provided.
11.6 Hooters
The unit shall consist of solid-state circuitry on a printed circuit board, a loudspeaker and a
flashing lamp housed in a weatherproof dust tight, wall mounting type enclosure. The
hooter shall, at least, have 102 db (A) output measured at I-meter distance. The unit shall
be powered from the fire alarm panel and operate on DC power. In the event of fire, the
hooter shall raise pulsating audio alarm and the lamp shall start flashing.
HAB shall be provided at exit doors of buildings to mute the hooters after evacuation.
11.7 Flashing Lights (Beacon)
The unit shall consist of solid-state circuitry on a printed circuit board and a red-capped
incandescent lamp and audio unit housed in a dust tight, wall/ ceiling mounting type
enclosure. It shall derive power from the Fire Alarm Panel and shall operate on DC supply.
Flashing lights shall be installed in the enclosed areas where clean agent/ CO2 to be
released. In the event a signal for clean agent/CO2, release is given, the lamp shall start
blinking with a warning sound enabling operating personnel to evacuate the area. The
audio unit (hooter) shall have 102 db (A) output measured at 1-meter distance.
11.8 Fault Isolator
Fault isolator shall be designed to provide short circuit protection to an addressable

detector loop. It shall be possible to wire the fault isolator at any point in the detector loop.
On occurrence of a fault (short circuit), the isolator shall cut power to all devices installed
between the two isolators minimizing the outage of all the detectors in a loop.
The fault isolator shall have the capability to continuously check the faulted side of the loop
to determine if the fault still exists. On rectification of the fault, the isolator shall
automatically reset itself.
Fault isolator modules shall be housed in a enclosure having IP-55 degree of protection as
a minimum. If located in hazardous area, it shall also be tested and approved for use in
area classification defined in the data sheet.
11.9 Sirens

0
Sirens shall be industrial type with minimum 2.5 km unidirectional range (i.e. 5km
diametrical range) against the wind direction.
The decibel level of the siren shall, at least be 132 db(A) at 1 meter, to meet the audibility
requirement for the above range. Unless otherwise specified, Sirens shall operate at 240
V, AC supply. Sirens shall be housed in weatherproof enclosure.
Starter shall be DOL and shall be housed in a separate IP55 enclosure suitable for
installation indoor/ outdoor.
The siren shall provided with five tones suitable for various conditions as follows:
i) SMALL FIRE: No siren.
ii) MAJOR FIRE: A wailing siren for two minutes.
iii) DISASTER: Same type of siren as in case of Major Fire but the same will be sounded
for three times at the interval of one minutes i.e.(wailing siren 2min + gap
1 min + wailing siren 2min + gap 1 min + wailing siren 2min) total duration
of Disaster siren to be eight minutes.
iv) ALL CLEAR (For fire): Straight run siren for two minutes.
v) TEST: Straight run siren for two minutes at frequency at least once a week.
The siren controller shall be as below:

a. The operation of siren shall be in Manual mode with single button operation through
Push Buttons - 5 Nos. mounted on the control desk for tone selection.
b. The siren shall be initiated with a single pulse from the Push Button. The logic shall be
such that first Push Button pressed shall be accepted till the completion of cycle of that
particular siren tone.
c. One no Push Button shall be provided for EMG STOP in case the siren tone is required
to be stopped mid way.
The operation of the siren shall also be possible in Auto mode. The arrangement for
the same shall be possible from the Fire Alarm panel
11.10 Clean Agent I CO2 Release and Inhibit Switches
This unit is required to be provided at the exit of the protected buildings/ rooms. If
specified, this unit is integrated with DGFAPI ZFAP. This shall consist of pull type release
and inhibit switches clean agent I CO2. The unit shall be fabricated out of 2mm thick cold
rolled sheet steel suitable for wall mounting. Switches shall be pulled to release or inhibit
clean agent I CO2. Release switches shall have inscription:
"PULL TO RELEASE CLEAN AGENT I CO2''
And inhibit switches shall have inscription:
"PULL TO INHIBIT CLEAN AGENT / CO2''
11.11 Zener Barrier

0
11.11.1 Preferably flameproof (Ex'd') equipment that does not require the use of Zener barrier
shall be used. When necessary, intrinsically safe (Ex 'i') detectors and MCPs, Zener
barriers shall be provided. These shall be located in unclassified/ non-hazardous areas.
11.11.2 Normally not more than 10 detectors shall be connected to one zener barrier. However
vendor shall indicate maximum number of detectors MCPs that can be connected to one
Zener barrier without compromising on working of loopl zone. Vendor shall also indicate
the maximum loop length from zener barrier considering 1.5 mm2 copper conductor,
screened cable.
11.11.3 In case loop length permits, zener barrier shall be located at DGFAP itself else it shall be
located in safe area nearest to the detector/ MCP.
11.11.4 Wherever zener barriers are provided in safe area outside the Zonal panel or DGFAP,
these shall be housed in their own enclosure with IP-55 degree of protection as a
minimum.
11.12 Fault Isolator
11.12.1 Fault isolator shall be installed, if specified in the data sheet.
11.12.2 Fault isolator shall be designed to provide short circuit protection to an addressable
detector loop. It shall be possible to wire the fault isolator at any point in the detector
loop.
11.12.3 On occurrence of a fault (short circuit), the isolator shall cut power to all devices installed
between the two isolators minimizing the outage of all the detectors in a loop.
11.12.4 The fault isolator shall have the capability to continuously check the faulted side of the
loop to determine if the fault still exists. On rectification of the fault, the isolator shall
automatically reset itself.
11.12.5 Fault isolator modules shall be housed in a enclosure having IP-55 degree of protection
as a minimum. If located in hazardous area, it shall also be tested and approved for use
in area classification defined in the data sheet.
12.0 FIELD DEVICES FOR HAZARDOUS AREA
12.1 Hazardous area is classified as Zone 1/ Zone 2, gas group IIA/ IIB or IIC, temperature
class T3 (200 DC) as specified in data sheet. The field devices shall be suitable for
installation in hazardous area as per specified area classification.
12.2 Field devices such as detectors, MCPs, fault isolators, Beacons, hooters etc for use in
hazardous area, if specified in the data sheet shall have flame proof enclosure
conforming to IS 2148. All equipment for hazardous area installation shall be complete
with flame proof, weather proof cable glands as specified in clause 11.5.
12.3 Equipment, which cannot have flameproof construction, shall be intrinsically safe in
design and shall be used with Zener barriers located in safe area.
12.4 Equipment that are tested / certified by a recognized test laboratory of country of origin
shall only be offered. The vendor shall possess valid test certificate issued by a
recognized independent test house such as CMRI/ BASEEFA/ UL/ FM or Equivalent for
the offered equipment.
12.5 All equipment (indigenous or imported) shall have valid statutory approval as applicable
for the specified hazardous location from CCE or any other applicable statutory authority.

0
All indigenous flameproof equipment shall also have valid BIS license and corresponding
marking as required by statutory authority.
12.6 A separate name plate shall also be provided on each equipment to indicate details of
testing agency, test certificate number with date, statutory approval number with date,
approval agency, BIS license number with date, applicable gas group, temperature class
etc. The nameplate shall be riveted/ fixed with screws and not pasted. In case above
information are embossed on the enclosure, the same need not be repeated.
13.0 CABLE AND CABLE ACCESSORIES
a) Supply and laying of FA cables shall be as per the requirement. Vendor shall provide
JBs for detectors, BGUs, exit signs, hooters etc as required.
b) Supply and installation and terminations of all cables at both ends shall be in bidder' s
scope.
c) Bidder, as a part of integration and selection of fire alarm equipment, shall furnish
detailed specifications for loop/zone cables, data highway cables, cables for
hooter/exit signs etc giving details such as type of cables, number of pairs, size of
cable, inductance and capacitance data, number of fibres/ connectors etc.
d) Data Cables
Unless specified otherwise, vendor shall supply Copper cable/ FO type data
communication cable to suit system design and equipment specification. Copper
cables, if supplied, shall be of adequate size, twisted pair, PVC insulated, overall
screened, PVC inner sheathed, armoured, FR type PVC outer sheathed as the
minimum requirement. Fibre Optic cables, if supplied, shall be armoured, overall FR
PVC outer sheathed and shall be as per ITU-T recommendation as a minimum.
Vendor shall supply and install all hardware and cabling accessories as per data high
way design including modems, repeaters etc as part of the FA system. Modems/
repeaters shall be powered by the supply provided for Fire Alarm panel.
e) Cable Glands / Accessories

All cable glands/ lugs/ connectors as required for the equipment shall be included in
bidder's scope and shall be supplied along with the system.
All the cable glands for outdoor application shall be weatherproof, nickel-plated brass
and double compression type, whereas those for indoor application shall be single
compression type.
Cable glands for hazardous area equipments shall be flameproof, weatherproof and
nickel plated brass double compression type.

14.1 All the equipment shall be tested to the defined specifications as per mutually agreed test
plan/ FAT procedure, which shall be submitted and got approved from Purchaser at least
one month before inspection. PMC/ Purchaser's inspectors shall witness all the tests.
14.2 During manufacture, the equipment shall be subject to inspection as per attached
inspection plan to assess the progress of work and to ascertain that the quality controls
are being maintained. Vendor shall provide all necessary assistance and information
concerning the supply to PDlL/Purchaser's inspectors.

0
14.3 Tests shall be carried out at the vendor's works under his care and expense and
Purchaser shall be informed at least 4 weeks in advance regarding this.
14.4 FAT shall include simulation of operational field conditions and test for functional
adequacy. Besides all routine, and acceptance tests specified by applicable codes and
standards, shall be performed on the complete system.
14.5 For bought out items, the routine and acceptance tests shall be conducted at the
respective equipment manufacturer's works.
14.6 At the time of inspection, vendor shall produce original of all the type test certificates, test
and approval certificates for hazardous area equipment from testing and approving
authority and any other certificates as required from statutory authority for the review of
inspectors.
14.7 Vendor shall submit a SAT procedure for PMC/ Purchaser's approval. All equipment and
systems shall be tested at site as per the approved SAT procedure.
14.8 SAT shall be conducted by vendor after the entire fire alarm system is installed and inter
connected by cables. These tests shall establish the operational correctness of the
system. Vendor shall rectify deficiencies noticed during SAT with no commercial
implication to Purchaser including replacement of system components and supply of new
component for making system successfully operational.
All the equipment shall be divided into several sections for protection and ease of
handling during transportation. The equipment shall be properly packed for selected
mode of transportation i.e. by ship/rail or trailer. The panels shall be wrapped in
polythene sheets before being placed in crates to prevent damage to finish. Crates shall
have skid bottom for handling. Special notations such as 'Fragile', 'This side up', 'Center
of gravity', 'Weight' etc., shall be clearly marked on the package together with Tag nos.,
Purchase order Nos. etc. The equipment may be stored outdoors for long periods before
erection. The packing shall be completely suitable for outdoor storage in areas with
heavy rains/ high ambient temperature.
16.0 INSTALLATION AND COMMISSIONING
As installation of the system is included in the scope of the vendor, vendor shall arrange
all necessary manpower and equipment required for the same. Commissioning of the
complete system is to be carried out by vendor in all cases irrespective of whether the
installation was performed by vendor or not. All tools, test equipment etc. for the
successful commissioning of the system shall be arranged by the vendor. Only the
cabling specifically excluded from vendor's scope shall be installed by others. However,
termination at panels for purchaser's cables shall be done by the vendor.
17.0 TRAINING
The vendor shall provide, free of cost, comprehensive training to Purchaser's personnel
on various operation and maintenance aspects of the Fire Alarm system as agreed
during ordering.

0
TECHNICAL SPECIFICATION - SOFT STARTER Document No. Rev
(PC150-TS-0828) Sheet 1 of 8
SOFT STARTER

0
(PC150-TS-0828) Sheet 2 of 8
CONTENTS
SECTION DESCRIPTION SHEET

NUMBER NUMBER
1.0 GENERAL 3
2.0 GENERAL TECHNICAL REQUIREMENTS 4
3.0 EQUIPMENT SPECIFICATIONS 5
4.0 EARTHING 6
5.0 NAME PLATES AND RATING PLATES 7
6.0 ACCESSORIES 7
7.0 PAINTING 7
8.0 INSPECTION AND TESTS 8

INFORMATION REQUIRED BY OWNER FROM THE
9.0 8
CONTRACTOR
10.0 MISCELLANEOUS 8
11.0 PACKING 8
12.0 DEVIATIONS 8

0
(PC150-TS-0828) Sheet 3 of 8
1.0 GENERAL
1.1 Scope
This specification covers the general requirements for design, manufacture, assembly,
inspection and testing at the Manufacturer’s works of high voltage indoor soft starters above
1100V grade.
1.2 Data sheet
Contractor shall submit the data sheet in the Bid .
1.3 Codes and standards
The design, manufacture, testing and performance of soft starter panel shall comply with all
current statutes, regulations and safety codes in the locality where the equipment will be
installed.
Unless otherwise specified, the soft starter shall confirm to the relevant Indian, IEC or British
Standards. Nothing in this specification shall be construed to relieve the Contractor of his
responsibility. The relevant Standards are:
1. IS: 2705 (1992) Current Transformers. (Part - I to IV)

2. IS: 3156 (1992) Voltage Transformers. (Part - I to IV)
3. IS: 1248 (1993) Direct acting indicating analogue electrical measuring
instruments and their accessories. (Part - I to IV)
4. IS: 13703 (1993) Low Voltage fuses for voltages not exceeding 1000V Ac.
(Part - I and II)
5. IS: 5578 (1985) Guide for marking of insulated conductors.
6. IS: 11353 (1985) Guide for uniform system of marking and identification of
7. IS: 694 (1990) PVC insulated cables for working voltage upto and
including 1100V.
8. IS: 6875 (1973) Control switches for voltages upto and
including1000VAC and 1200V DC. (Part - I to IV)
9. IS: 3700 (1972) Essential ratings and characteristics of semi-conductor
devices.
10. IS: 4411 (1967) Codes of designation of semi-conductor devices.
11. IS: 5469 (1969) Codes of practice for use of semi-conductor junction
devices.
12. IS: 10482 (1983) Connectors for printed wiring board.
13. IS: 12448 (1988) Basic testing procedures and measuring methods for
Electro-mechanical components for electronic
equipment.
14. IS:12970 (1990) Semi-conductor devices – Integrated circuits.
15. IS:13648 (1993) Power electronic capacitors.
16. IEC 297 Dimensions of panels and racks.
17. IEC352 Solderless wrapped connections.
18. IEC 446 Semi-conductor converters.
19. IEEE 444 Protection standards for Thyristor converters.
2.0 GENERAL TECHNICAL REQUIREMENTS

0
(PC150-TS-0828) Sheet 4 of 8
2.1 Design features
(1) The thyristorised starter shall be used for starting of large induction motors.
(2) The soft starter shall give an excellent voltage control during soft starts, smooth
steeples acceleration.
(3) The soft starter shall be used during starting for smooth and step-less acceleration
only. Once motor gains its full speed bypass vacuum contactor shall be operated to
bypass thyristors. The thyristor shall be short time rated (2 min.).
(4) The soft starter drive shall consist of the following.
- Isolation vacuum contactor.
- Bypass vacuum contactor.
- Thyristor unit.
- Motor protective devices.
- Indicating / Metering / Control circuits and accessories.
- Cooling / ventilation equipments / accessories.
(5) Soft starter shall have following minimum in built protection and alarm, but not limited
to,
- Electronic over load.
- Line fault.
- Under voltage.
- Over voltage.
- Stall.
- Phase reversal.
- Open gate for thyristor.
- Over temperature for thyristor.
- Over load for thyristor.
(6) Soft starter panel shall be provided with following indicating, metering and control
devices.
Motor starting / protection devices.
Selector switch – Auto / Manual.
Start / Stop push buttons for manual operation.
- Input voltmeter and ammeter.
- Meters to indicate power in MW.
- Current and potential transformers.
- Auxiliary relays.
- Audio-visual alarms / fault indicators.
- Alarm acknowledge / reset / test push buttons.
- Provision for wiring external sequential / process interlock / signals for starting
/ running / tripping.
- Terminals for remote control / indication.
- Space heater and ventilating fans / cooler, if required.
2.2 Performance requirement
Soft starter panel shall be designed for operation at design temperature of 50°C. Contractor
shall provide the necessary arrangement within the panel for satisfactory operation of soft
starter.
2.3 Construction
(1) Soft starter panel shall be industrial type (Non-hazardous), totally enclosed, dust and
vermin proof, floor mounted, free standing cubicle type of construction.
(2) The panel cubicle shall comprise rigidly welded structural frame enclosed completely
by sheet steel of minimum 14 SWG (cold rolled) thickness, smooth finished, leveled
and free from flaws. All doors and removable covers shall be provided with neoprene

0
(PC150-TS-0828) Sheet 5 of 8
gasket all around to make the cubical dust and vermin proof.
(3) The panel shall be provided with bottom sheet steel plates of minimum 2mm thick.
Panel shall be fitted with removable gland plates of sufficient thickness at the bottom
of the panel for fixing cable glands for power and control cable termination. Sufficient
space shall be provided for termination of power cable sizes, as specified in data
sheet.
(4) Louvers shall be provided at front, rear, top and bottom of the panel to dissipate heat
developed inside.
(5) Degree of protection shall not be less than IP 4X.
(6) Panel shall be fitted with a label and serial number on the front and rear. In addition,
panel shall be fitted with a label indicating panel designation and rating. All devices
shall be provided with separate labels to indicate the function and also device
numbers as marked in wiring diagrams.
(7) Main equipment of the panel shall be accessible for maintenance from the front and
rear. All insulating material shall be flame resistant, non-hygroscopic and antitracking.
(8) All hardware’s used inside the panel shall be zinc passivated or cadmium plated.
3.0 EQUIPMENT SPECIFICATIONS
3.1 HT Fuses
(1) High voltage fuses shall be of HRC link type and shall comply with the requirements of
relevant standards.
(2) The fuse link shall have a striker pin for indication and also for trip mechanism.
(3) It is Contractor’s responsibility to precisely co-ordinate these fuses with contactors and
upstream protective devices in the same system and shall be adequately rated for
short circuit capacity.
(4) The type of fuse chosen by Contractor shall subject to approval by the
Owner/Consultant. Contractor to furnish fuse pre-arcing time shall be furnished by
(5) Thyristor units shall be protected by fast acting semiconductor fuses
3.2 Vacuum contactors
(1) Vacuum contactors of adequate rating for the compressor motor starting at 11 kV
Voltage to match the bypass & isolation application and shall conform to relevant India
/ IEC standards.
(2) Vacuum contactor shall be provided with properly designed and co-ordinated HRC
fuses as mentioned in clause no. 3.1 above.
(3) DC operating coill shall be rated to operate satisfactorily between 80% and 110 % of
the rated voltage. The contactor shall not drop out, if the voltage drops to 70% of
rated voltage shall make arrangements to derive the auxiliary power, using necessary
control transformer, for operating the contactor.
(4) The vacuum contactors shall have exclusively for Owners use minimum 1 NO & 1 NC
auxiliary potential free contacts, rated for 10 amps, 240V AC and 0.5 Amp (inductive
breaking) 110V DC or as specified and shall be wired upto the terminal blocks.
3.3 Instrument transformers
(1) The current transformers and Voltage transformers shall conform to the requirements
stipulated in relevant standards. It shall Contractor’s responsibility to ensure adequate
size of CT & VT
(2) The CTs & VTs shall be of cast resin type (insulation class “E” or better) and shall be
able to withstand the thermal and mechanical stress resulting from the maximum short
circuit and momentary current ratings of the switchgear.
(3) CTs shall have polarity mrks on each transformer and at the associated terminal block

0
(PC150-TS-0828) Sheet 6 of 8
Facility shall be provided for short-circuit and earthing the CT secondary at the
terminal blocks.
(4) VTs shall be protected on the primary side by limiting fused and by MCBs on
secondary side with 9kA interrupting ratings.
(5) The MCBs shall have min 1 NO + NC auxiliary potential free contacts, for
annunication and interlocks.
(6) CTs shall withstand specified system fault current for 1 sec.
3.4 Measuring and recording instruments
(1) Microprocessor based measuring and recording instruments shall be provided. The
unit shall have RS-485 port at the output for serial communication.
(2) These instruments shall be standalone type, shall be configurable and shall be
compatible with higher level computer.
(3) The instrument shall be rectangular in shape and not greater than 150mm (W) x
150mm (H). The accuracy class shall be as per IS or international standards.
3.5 Control wiring and terminals
(1) Feeders for Control (DC) / Auxiliary supply shall be provided at one point of the panel
and voltage level shall be as specified in data sheet. Terminals to receive AC/DC
control and auxiliary power shall be provided in cubicle and the terminals shall
adequately rated (min. 20A).
(2) Adequate rated 2 pole MCBs shall be provided for each of the AC/DC control circuits.
(3) Internal wiring shall be done with 650V grade PVC insulated, stranded copper
conductor of minimum size 2.5mm2 size.
(4) Separate colour coding shall be used for AC / DC control and power circuits and earth
wire.
(5) All incoming and outgoing and control wire connection shall be wired to adequately
rated (min.20A), elmex type terminal blocks about 20% spare terminals shall be
provided in cubicle. All terminals shall be easily accessible.
(6) All wire shall be bunched together and routed through wire ways inside cubicle.
(7) Separate schematics, wiring diagrams and termination schedule for external and
internal cable/wire connections shall be furnished by the Contractor. External
connections shall include Owner’s remote equipment, which will be furnished by
Owner to the Contractor.
(8) Low watt consumption LED type indicating lamps shall be provided.
(9) All wires, terminals and all other devices shall be provided with appropriate ferrules to
correspond with wiring diagrams, for circuit identifications Termination lugs to be
provided wherever necessary.
4.0 EARTHING
(1) An earth bus having cross section as specified in data sheet A shall be provided and
extended through the length of the panel. All electrical equipment shall be connected
to this earth bus.
(2) Suitable clamp type terminals with hardware at each end of the panel shall be
provided to suit the size of the OWNER’s earthing conductor of size 75 x 10 mm GI
(3) Hinged doors shall be earthed through flexible copper brand of adequate size paint at
earthing points shall be removed for proper contact star washers for door earthing are
not acceptable.
(4) Bolted joints, splices, taps. etc to the earth bus shall be with at least two bolts
5.0 NAME PLATES AND RATING PLATES

0
(PC150-TS-0828) Sheet 7 of 8
5.1 Name plate
(1) Nameplate with engraved letters shall be provided for both front and rear side of panel
function of every instrument, relay fuse etc shall be indicated by labels fixed near each
device.
(2) Non-corrosive name plates shall be manufactured in anodized aluminium sheet and
the letters shall be engraved on black lettering on white background. The name
plates/labels shall be held in position by self-tapping screws.
(3) All devices mounted inside the cubicle and instruments etc., shall be identified by
marking the device numbers inside cubicle as per the wiring drawing.
5.2 Rating plates
(1) The panel shall have a rating plate fixed to the non-removable part of the enclosure.
(2) All electrical equipment like VTs, CTs, etc and all other electrical devices shall be
provided with rating plate made of stainless steel which can be easily seen.
(3) The rating plates shall give all the relevant information as specified in relevant
standards.
(4) Danger boards, caution boards, operating instruction plates, shall be fixed to panel as
per the standard engineering practice and regulations.
6.0 ACCESSORIES
6.1 Heater
Soft starter panel shall be equipped with space heaters to prevent moisture condensation
within the enclosure and shall be suitable for continuous operation on 240V, 1 phase, 50 Hz
AC supply. The space heaters shall be controlled through thermostats. Supply for motor
space heater shall be brought to separate terminals in respective cubicle.
6.2 Cooling
Soft starter panel shall be provided with necessary ventilation / cooling equipment’s for
smooth operation of soft starter at given design temperature.
6.3 Plug Point
A 240V, 1 phase, 50Hz AC plug point shall be provided in the interior of each cubicle with an
on-off switch.
7.0 PAINTING
(1) Oil grease, dirt and rust from the sheet steelwork shall be thoroughly Cleaned and
removed. Rust and scale shall be removes by picking process with dilute acid and
alkaline solution. Phospating and thorough rinsing with clear water followed by final
rinsing with dilute dichromate solution and oven drying shall follow this.
(2) The under surface shall he prepared by applying a coat of phosphate paint and coat of
yellow zinc chromate primer. The under surface shall be made free from all
imperfections before under taking the finishing coat.
(3) After application of Primer, two coats of finish epoxy paint shall be applied with each
coat followed be stowing. The colour shade for the finish paint shall be shade 631
(Light Gray) as per IS 5, unless otherwise specified.
8.0 INSPECTION AND TESTS

0
(PC150-TS-0828) Sheet 8 of 8
(1) Routine tests shall be carried out at works in the presence of OWNER/Consultant/
/Third party inspector as per relevant IS / IEC Standards.
(2) Contractor shall furnish type and routine test certificates for all bought out components
for the panel, as per relevant standards.
(3) Test certificates for type test carried out on similar equipment of identical design, if
available, shall be submitted along with the offer.
9.0 INFORMATION REQUIRED BY OWNER FROM THE CONTRACTOR
The Contractor shall submit following information in Bid: -

(1) Full technical description and performance details of the equipment accessories and
components offered including heat losses for all components in kW.
(2) Overall dimensions and shipping dimensions and weight.
(3) Deviation taken by the Contractor from the requirements of this specification.
(4) Guaranteed technical particulars.
(5) Man-day rates for commissioning supervision.
10.0 MISCELLANEOUS
Each panel shall be provided with the following

(1) Two sets of clearly identifiable key for all panel-locking devices.
(2) Complete set of special tools and equipment for installation maintenance and testing
of each panel.
11.0 PACKING
11.1 The switchboard shall be properly packed before dispatch to avoid damage during transport,
11.2 The packing box shall contain a copy of the installation, operation and maintenance manual.
11.3 A sign to indicate the upright position of the panels to be placed during transport and storage
shall be clearly marked. Also proper arrangement shall be provided to handle the equipment.
12.0 DEVIATIONS

0
TECHNICAL SPECIFICATION - AUXILIARY SERVICE Document No. Rev
TRANSFORMER (PC150-TS-0829) Sheet 1 of 8
AUXILIARY SERVICE TRANSFORMER

0
CONTENTS
SECTION DESCRIPTION SHEET

NUMBER NUMBER
1.0 SCOPE 3
2.0 STANDARDS TO BE FOLLOWED 3
3.0 SERVICE CONDITIONS 3
4.0 OPERATING REQUIREMENTS 3
5.0 GENERAL DESIGN FEATURES 3
6.0 CONSTRUCTIONAL FEATURES 5
7.0 FITTINGS 5
8.0 PAINTING 6
9.0 TESTS AND INSPECTION 6
10.0 DRAWINGS AND DOCUMENTS 6
11.0 SPARES 7
12.0 PACKING 7
13.0 DEVIATIONS 7
ANNEXURE - I DOCUMENTATION FOR AUXILIARY SERVICE 8

TRANSFORMERS

0
1.0 SCOPE
works and despatch in well packed condition of auxiliary service transformers.
1.2 This standard shall be applicable for 3 phase / single phase, separate winding
transformers of rating below 315 KVA used for Auxiliary services such as lighting,
control, Instrument supply etc.
1.3 This standard shall be read in conjunction with the relevant specification sheet.
comply with the latest issue of following Indian Standards. Equipment complying with
IS: 1180 Part -- Outdoor type 3 phase distribution transformers up to and
-1&2 including 100 KVA, 11 KV
IS: 2026 -- Power transformers
IS: 11171 -- Dry type power transformers
provisions of the latest issue of the Indian Electricity Rules and other relevant statutory
acts and regulations. The supplier shall, wherever necessary, make suitable
3.2 System Details
4.1 The transformer shall be suitable for operating at the rated capacity continuously at any
of the taps, under the ambient conditions and with the voltage and frequency variations
as indicated in specification sheet without exceeding the permissible temperature and
without any detrimental effect on any part.
5.1 Rated voltage and frequency

0
5.2 Phase connections
5.2.1 Three phase transformer

The primary winding shall be connected in delta and secondary winding in star with
neutral point earthed (Vector group Dyn-11)
5.2.2 Single phase transformer
Primary winding shall be connected between two phases of a 3 phase system or to the
three phases in open delta execution as specified in specification sheet and secondary
single phase winding shall have one terminal earthed with the tank through link inside
the secondary terminal box.
5.3 Tapping
5.3.1 The transformers shall be provided with off circuit tap changer with tapping of ± 2.5%
and ± 5%.
5.3.2 For transformers having primary 3.3 KV and above, tap changing shall be effected with
an externally operated handle, capable of being padlocked in any position on the
primary side.
5.3.3 For transformers having primary 415V and below, tap changing shall be effected by
means of links in the terminal chamber on the primary side.
5.4 Impedance voltage
The impedance voltage of the transformer at 75ºC shall be 4% unless indicated

otherwise in specification sheet.
5.4.1 Losses
The losses shall be indicated by the vendor and shall be guaranteed, within tolerable
limits specified in IS: 2026 at rated voltage and frequency.
5.4.2 Terminal Arrangement
The primary and secondary side terminals shall be brought outside the tank through
porcelain bushing in dust and weather proof terminal boxes, with links for tap changing
where required and suitable heavy duty double compression type aluminium cable
glands and cable lugs for receiving cables as indicated in specification sheet. The
neutral point of the secondary winding shall be brought out separately and earthed to
the transformer body through test link. Terminal board for the primary and the
secondary winding shall be amply sized and made of SRBP/ FRP materials.
5.4.3 Resistance to short circuit
The transformers shall be able to with stand electrodynamic stresses due to terminal
short circuit of the secondary assuming primary side fed from the infinite bus.
5.4.4 Cooling System
Transformers rated up to 50 KVA shall be natural air cooled type and above 50 KVA
shall be natural oil cooled / natural air cooled type as indicated in specification sheet.

0
6.1 Core
The transformer core shall be of high grade non ageing electrical silicon cold rolled
magnetic sheet steel of low hysteresis loss and high permeability. The maximum flux
density in any part of the core and yoke at rated voltage and frequency shall not exceed
1.7 Tesla for oil cooled transformers and 1.3 Tesla for air cooled transformers.
6.1.1 The tank for oil cooled transformer shall be made of mild steel plate of adequate
thickness. Cooling tubes, where necessary, shall be provided.
6.1.2 Air cooled transformer shall be sheet steel enclosed having minimum thickness of 2.0
mm and shall be provided with suitable reinforcement as required. The minimum degree
of protection for the enclosure shall be IP: 31. Ventilating louvers, if provided, shall be
covered by fine wire mesh.
6.1.3 All external hardware shall be cadmium plated.
6.2 Windings
6.2.1 Coil shall be made out of electrolytic grade copper conductor.

6.2.2 Class-F / class-H insulating material shall be used for air cooled transformers.
6.2.3 For oil cooled transformer class-A insulating material shall be used. Mineral oil shall
comply with IS: 325. 10% extra oil shall be supplied along with transformer in non-
returnable drums.
6.2.4 Winding assembly shall be dried and impregnated in vacuum with tested insulating oil /
varnish.
6.3 Bushing
The bushing insulators shall be rated for the maximum system voltage and shall comply
with the requirement laid down in IS: 2099 / IS: 7421. The minimum current rating shall
be 250A.
7.0 FITTINGS
7.1 Following fittings shall be provided for air cooled transformers.
i) Rating and diagram plate

ii) Lifting lug
iii) Primary and secondary cable boxes with heavy duty double compression type
aluminium cable glands and lugs.
iv) Earthing terminals
v) Rollers (for 25 KVA and above)
7.2 In addition to the above following fittings shall be provided for oil cooled transformer.
i) Oil conservator complete with drain plug, oil filling hole with cover and oil level
indicator with minimum marking.
ii) Silica gel breather
iii) Dial type thermometer
iv) Oil sampling cum drain valve

0
v) Explosion vent
vi) Air release plug
7.3 Any other fittings which may be necessary for satisfactory operation of the transformer
shall also be provided.
7.4 All fittings shall conform to relevant Indian Standards.
8.0 PAINTING
8.1 The surface shall be painted after removing all dust, scale and foreign adhering matter.
All traces of oil and greases should be removed by suitable treatment.
8.2 All steel surfaces in contact with insulating oil shall be painted with heat resistant oil
insoluble insulating varnish.
8.3 All steel surfaces exposed to outside shall be painted with suitable anti rust and anti
corrosive paints. Epoxy paints shall be used, if indicated in specification sheet.
8.5 Unless otherwise specified, the finishing shade shall be light grey shade no. 631 as per
IS: 5.
8.6 1 litre paint per air / oil cooled transformer shall be supplied for touch up at site.
9.1 All transformers shall be routine tested as per IS: 2026.
9.2 Additional tests, wherever specified, shall be carried out on one transformer of each
rating.
representative. In addition, the transformer shall be subjected to stage inspection at
9.4 These inspections shall, however, not absolve the vendor from his responsibility for
10.1 The drawings and documents as per Annexure-I shall be supplied, unless otherwise
specified.
- Name of client
- Name of Consultant
- Enquiry / Order No. with plant / project name
- Equipment Code no. and Description
11.0 SPARES

0

Commissioning Spares, as required, shall be supplied with the main equipment. Item
offer.
12.0 PACKING
12.1 The transformers shall be suitably packed in wooden crates to avoid damage in transit.
Oil cooled transformers shall be properly sealed so as to completely exclude oxygen
and moisture from coming in contact with oil.
manual.
13.0 DEVIATIONS
reasoning.
13.2 Deviations, if any, from the data furnished in specification sheet shall be indicated
therein beside the data by encircling it.

0
ANNEXURE – I
DOCUMENTATION FOR AUXILIARY SERVICE TRANSFORMERS
Sl.No. Description
1. Specification Sheet, duly completed N Y Y
2. Technical Particulars, duly filled-in N Y Y

Dimensional drawing with terminal
3. N Y Y
arrangement details
Installation, Operation and maintenance
5. N N Y
manual
Note:
the date of LOI.
coated folder.
Y - Yes, N - No

PC150 PDS: E113
PC009
PC150 0
PC150-
PC150 PDS: E116
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC150
PC009 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC009
PC150 0
PC150
PC009 0
OPENING
MAIN ALUMINIUM
CONDUCTOR (ROUND)
END VIEW OF THE ALUMINIUM CRIMPING SLEEVE

ALUMINIUM CRIMPING AFTER PUTTING THE
SLEEVE BEFORE CONDUCTOR
CRIMPING IN POSITION & CLOSING THE
OPENING
BRANCH ALUMINIUM
CONDUCTOR (ROUND)
PC009
PC150 0
PC009
PC150 0
PC150
PC009 0
PC009
PC150 0
PC009
PC150 0
PC150
PC009 0
PC009
PC150 0
PC150
PC009 0
PC009
PC150 0
PC150
PC009 0
PC150
PC009 0
2
3.0 (PART-A)-5.4
SHEET 1 OF 102

CONTRACTOR SCOPE OF WORK - INSTRUMENTATION



2 30.07.2020 30.07.2020 Issued for Tender SG VS RKR

1 17.03.2020 17.03.2020 Issued for Tender VS RKR SKT
0 16.01.2020 16.01.2020 Issued for Tender VS RKR SKT
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 2 of 102
CONTENTS
1.0 Instrumentation And Controls PHILOSOPHY

2.0 Documentation
3.0 Control Philosophy (General)
4.0 Instrumentation Code And Practices
5.0 Hazardous Area Classification & Electrical Execution
6.0 Electrical Supply
7.0 Field Instruments
8.0 Control system
9.0 Local Control Panel
10.0 Pneumatic transmission
11.0 Erection , installation & commissioning
12.0 Storage Tank
13.0 CCTV System
14.0 Telephone exchange and associated accessories
15.0 Local area network (LAN) for CR
16.0 Training
17.0 FAT/SAT
A. List of Annexure:
ANNEXURE DESCRIPTION
NUMBER
ANNEXURE-1 Instrumentation Accuracies
ANNEXURE-2 Instrument process connections
ANNEXURE-3 System Configuration
ANNEXURE-4 OS/ES/SOE specification
ANNEXURE-5 Cable Sizes
B. List General Specification
ATTACHMENT NUMBER DESCRIPTION

GSTD-0100 GENERAL SPECIFICATION FOR INSTRUMENT TUBE FITTING
GSTD-0101 GENERAL SPECIFICATION FOR INSTRUMENT TUBING
GSTD-0102 GENERAL SPECIFICATION FOR INSTRUMENT VALVES AND
MANIFOLD
GSTD-0103 GENERAL SPECIFICATION FOR JUNCTION BOXES AND
CABLE GLAND
GSTD-0201 GENERAL SPECIFICATION FOR DCS & PLC SYSTEM
GSTD-0202 GENERAL SPECIFICATION FOR PLC SYSTEM
GSTD-9998 INSPECTION AND TEST REQUIREMENTS

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 3 of 102
1.0 INSTRUMENT AND CONTROL PHILOSOPHY
SCOPE
The description and requirements contained in this specification are concise by necessity
and cannot include all details. However, it is the responsibility of the contractor to execute
the job on a turnkey basis in accordance with the specifications and internationally
recognized good engineering practices for smooth and successful operation of various
units of the plant.
Any activity specifically not listed in this document, does not absolve the contractor of their
responsibility to include such activities in their scope of work and supply, which otherwise
is necessary, to complete instrumentation work for the WTP/DM plant. Approval of
purchase specification does not absolve the contactor from supplying equipment of
proven design as per the tender requirement. All such activities shall be carried out by the
contractor without any implication.
This section outlines the general requirements and specifications for Instrumentation and
Control System for Design, Engineering, Manufacture, Shop test, third party Inspection,
Supply, erection and commissioning of Water Pre treatment, DM water treatment plant
along with associated facilities. The Instrumentation and Control System shall consist of
but not limited to the following:
 Water pre-treatment package plant shall be provided with DCS/PLC based control
system. This control system will accommodate all control/trip and monitoring
signal/functions for Raw water pre-treatment plant (RWPT), DM plan, Condensate
polishing unit and drinking water.
 Common DCS/PLC has been considered for complete package and bidder to
ensure segregation of individual plant level signals at AI/AO/DI/DO card level so as
to ensure the reliability of the system.
 The Complete DCS/PLC control system i.e. Marshalling panels, Cabinets (System,
I/O, PDB, IRP etc.) HMI/Consoles, printers, furniture etc. for the above package
shall be housed in the new air conditioned control room for this package.
Construction of CR with HVAC (Control room) shall be in bidder scope.
o 3 nos. OS, 1 no. ES cum OS with SOE, with dual LED monitors will be used
for controlling Water Pre-treatment package out of which 2 nos. OS will be
placed on the consoles of CR, 1 no. ES cum OS cum SOE will be placed
on the consoles of Engineering room.
o One no. Aux. Console with Ann. window, push buttons, switches for critical
trip and alarm shall also be provided.
o RIO shall not be considered anywhere in the package.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 4 of 102

 The control room shall have console area, engineering room, equipment/rack
room, 2 nos. Manager room, 1 no. supervisor room, UPS, battery, meeting room,
pantry room, ladies and gents toilet as minimum.
 Separate entry & exists with Air lock doors shall be considered for control room.
 2 Nos. Corrosion monitoring (copper & silver) with temperature and humidity
measurement of M/S PURAFIL make shall be mounted in control room. The
location of the monitors must be near the duct and cable entry. The four different AI
signals corresponding to above measurements from these two monitors shall be
connected to contractor control system with suitable soft alarms.
 Suitable Clean Agent System as per NFPA 2001 & hooking of the clean agent
system with fire alarm system for actuation on detection of smoke/fire,automatic
actuation and total flooding of clean agent in the required building area shall be
provided in control room.
 Packaged Air conditioning (HVAC) of control rooms. It shall be designed

considering the equipment heat loads, solar heat loads, heat gain into the room,
adequate no. of air changes etc. to maintain a uniform temperature and relative
humidity within the air conditioned areas.
 All the required protections & interlocks shall be carried out in DCS/PLC. All the
features such as graphics, alarms, and process parameters display diagnosis for
plant equipment shall be displayed in package’s operator station installed in the
CR.
 For important operating data and indications required for surveillance and
monitoring, a provision shall be made to repeat the signals in Client’s DCS/ ESD
from WTP package control PLC/DCS, wherever applicable. For this bidder to
provide communication redundant port, MODBUS TCP/IP. Bidder to provide
necessary interfacing cards in the CR and CCR. All the hardware & software
required for the same shall be in bidder scope.
 Network securities shall be provided by Vendor in all control rooms as per IEC
62443 for protection of the system from both internal and external threat. The
requirement includes all USB port blocking (including all monitors / CPU), provision
of sufficient firewalls, and antivirus update for one year, patch update;
unauthorized logging recording with events etc. must be addressed by Vendor.
 The Instruments in general shall be Electronic Micro processor based type with
latest revision of software. The field instrumentation i.e. Flowmeters, Transmitters,
Smart Positioner, etc. shall have latest HART protocol latest version as minimum.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 5 of 102

 All equipments/instruments/system oriented items (with all its sub-systems) shall
be of field proven quality both with respect to design and materials. Prototype
instruments or instruments of an experimental nature shall not be offered or
supplied. In general, all the supplied items by supplier shall have a well proven
performance record of operating satisfactorily in a Offsite/Acid Plants for minimum
of one year. No instrument requiring special maintenance or operating facilities
shall be offered or supplied as far as possible. PTR for field instruments shall be
considered min for 2 years.
 Preparation of engineering and construction documents like functional schematics,

I/O list, logic diagrams for interlocks as per ISA 5.2 with functional descriptions,
configuration diagram, electrical load list, cable schedule, cable tray/trench layout,
instrument air requirement, nameplate schedule, JB schedule, instrument location
layout, electrical instrument signal interface, instrument index, layout drawings,
loop diagrams, primary and secondary sketches and bill of materials, any other
drawing or documents which is required for package erection & commissioning and
SAT as well.
 Preparation of all engineering documents for DCS/PLC like graphic schemes,

instrument loop data base, log formats and any other documents necessary to
carry out the system engineering of DCS/PLC.
 Co-ordination with Control system vendor for system engineering, implementation,

software testing, supply and final commissioning and site acceptance tests.
 Co-ordination with all instrumentation vendors for obtaining sufficient information in

the form of documents, drawings for engineering and approval from OWNER.
 Preparation of specification for erection materials like cables (Signal, power,

control, Optical fiber etc), cable trays, pipe & pipe fittings, air tubing, junction
boxes, air distribution pots etc.
 All system cables/fiber optic cables in the field (including communication between
CCR and CR) shall be routed through separate tray and separate route. Fillings
shall be used for joining the HDPE pipe. HDPE pipes shall be ORANGE in colour
with BLACK fillings. All system cables/fiber optic cables shall be routed in the
middle 150mm portion of the tray. Wherever it is absolutely necessary to route
these cables underground, it should be routed in the RCC Trenches only.
Separate route should be followed for redundant system cables. Supply of Cable
trays and laying of cables through trenches upto CCR are in bidder scope.
 No copper or copper alloy shall be used for the parts coming either in contact with
process fluid or outside atmosphere.
 Package vendor shall be responsible for local instruments, controls, local panels,
installation & wiring, trays & cable laying & termination to junction boxes within the

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 6 of 102

battery limit. Bidder’s scope shall also supply, laying, termination of multi-core
cable in the junction boxes within battery limit as well as multi-core cable and other
inst. /power cables in package DCS/PLC located at Control Room.
 On line continuous monitoring analyzers system shall be provided to measure
Sodium, Silica and Chlorine to ensure that water is not contaminated.
 All instruments and equipments shall be suitable for use for specified site climatic
conditions and industrial environment in which corrosive gases and/or chemicals
may be present. As a minimum, all instruments and enclosures in field shall be
dust proof and weatherproof to IP-67 as per IEC-60529 or equivalent NEMA 4X
enclosure rating or better and secure against the ingress of fumes, dampness,
insects and vermin. All external surfaces shall be suitably treated to provide
protection against corrosive plant atmosphere.
 All Inst. JB’s shall be of FRP material with minimum 4 mm thickness with proper
support to protect against corrosive environment and cable entry shall be from
bottom only.
 The design of electronic instruments shall be in compliance with the

electromagnetic compatibility requirements as per IEC 61000-4 ''Electromagnetic
compatibility for Industrial Process measurement and Control equipment''.
 Process switches, shall be realized through field transmitters only. If for some
packages, process switches are unavoidable same shall be provided, with
Client/PMC approval, with sealed micro switch contacts rated for the specified
application. Contacts shall be 1 no. DPDT preferably. Otherwise 2 nos. SPDT can
be considered. All switch contacts except those used in intrinsically safe circuits
shall be silver plated. Contacts used in intrinsically safe circuits shall be suitable for
the applications. Switches shall be hermetically sealed type. Switches shall be
connected through interposing relays. The material of its construction shall be
resistant to acid environment.
 All Field transmitter supports should be properly clamped with SS304 accessories
to the pipe for pre-fabricated wherever required and closed couple installation. No
air gap shall be kept between support clamp and pipe.
 All Solenoid valves shall be Intrinsically Safe type (24 V DC), with details inside the
design basis. Solenoid valve body material shall be SS316. All critical loops must
have redundant SOV’s.
 All online/offline process analysers and gas detectors shall be supplied complete
with proper calibration apparatus / calibration gas cylinders, local indication etc.
Auto calibration facility need to be provided for the analysers and gas
chromatographs, if applicable. Wherever auto calibration features are not available
for any analysers from the approved manufacturers, manual calibration shall be
considered.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 7 of 102

 Other specification like panel earthing, instrument earthing, MCT material, temp
monitoring inside panels, inside CR the scope of vendor shall still be as per
contract, UPS monitoring alarms in control system, H2 detector in battery room etc.
shall be as specified elsewhere in this tender.
 Fire Detection & Alarm system including detectors (smoke, heat etc. ) of suitable
type to be considered for all buildings and hook up / interface with redundant
configuration with main fire alarm system located in central fire station. All
engineering, design, erection , commissioning , cable laying etc. Shall be done by
the bidder.
 In the event of any conflict between this specification, related standards and codes,
any other attachment to this package or process packages, the contractor shall
follow the following documents in the order of their priority:
General Standard specification attached
Licensor’s recommendation
Statutory requirements and codes & standards
WTP/DM plant shall be provide as per below mentioned Control System:
OPTION 1
DCS based control system for Control & ESD function also with applicable redundancy
as specified in this tender. This control system will accommodate all control/trip and
monitoring signal/ functions. One redundant controller with I/O cards (redundant cards
to be considered only for closed loops signals) for control & monitoring application and
one separate redundant controller with redundant I/O cards for trip/shutdown functions.
Scan time of the controllers shall not be more than 250 msec.
Control system for WTP/DM plant shall be placed in CR.
(Detail specification of DCS shall be share with the bidder on later stage.
OPTION 2
PLC based control system (TMR/DMR)
Scan time of the controllers shall not be more than 250 msec. (Other requirements for
PLC system shall be per NIT)
o 3 nos. OS, 1 no. ES cum OS with SOE, with dual LED monitors will be used for
controlling Water Pre-treatment package out of which 2 nos. OS will be placed on the

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 8 of 102

consoles of CR, 1 no. ES cum OS and 1 no. SOE station will be placed on the
consoles of Engineering room.
o One no. Aux. Console with Ann. window, push buttons, switches for critical trip and
alarm shall also be provided.
Dedicated SOE work station is not required. Engineering station shall have feature of
SOE.
Bidder to consider one no. Additional I/O card (16 channel) of each type i.e AI/AO/DI/DO
for raw water storage pumps package (pumps are not in bidder scope). As the I/O of these
packages are very less, it will be connected to additional I/O card and control system of
DM/RWTP, in the control room. Accordingly, execution of one or two small interlock and
development of 2-3 graphic pages in the bidder control system are in bidder scope.
2.00 DOCUMENTATION
SL Document Description Document to be submitted *

No
With Bid After order Final
for approval
1 List of Instruments (tag wise) Yes Yes Yes
indicating type of Instrument, make,
model no., quantity etc.
2 Instrument mounting and connection Yes Yes
details
3 Instrument layout drawings Yes Yes
4 Catalogue of Instruments & System Yes Yes
5 List of spares (item wise and Yes Yes Yes
quantity) for Commissioning and 2
years of operation
6 Specification of Instruments Yes Yes Yes
7 Detail wiring/ interconnection Yes Yes
diagram
8 P and I Diagram Yes Yes Yes
9 I/O list Yes Yes Yes
10 Loop Diagram Yes Yes
11 Logic Diagram for interlock & safety Yes Yes Yes
(if any)
12 J.B. termination drawings Yes Yes
13 Instrumentation, operating, Yes
maintenance manuals
14 Instrument Test Certificate Yes
15 Vendor to indicate power Yes Yes Yes
requirement (if any) for the control
system
16 Other documents necessary to have Yes Yes Yes
a clear understanding of the system
17 List of alarms Yes Yes Yes
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 9 of 102

18 Schematic drawings for controls Yes Yes Yes
19 Control Room Layout Yes Yes Yes
20 Field Operator Room layout Yes Yes Yes
21 System Architecture Yes Yes Yes
22 Instrument Air Consumption Yes Yes Yes
Requirement
23 UPS power & Heat Load Yes Yes Yes
Requirement
24 Bill of Material Yes Yes Yes
3.0 CONTROL PHILOSOPHY (GENERAL)
3.1 Design and installation of instrumentation shall comply with codes and recommendations
listed in item 4.0.
3.2 The instrumentation shall be designed to provide stable and accurate plant control ensure
safe plant operation and to facilitate plant maintenance, Control and Monitoring. The
operating interface to the process shall be colour dual (stacked monitors) screen 22” LED
TFT Colour (Minimum) display units with touch facility, presenting overview, group and
point displays as well as process graphics with live data. The operator will manipulate all
facilities through dedicated operator’s keyboard and using the touch panel.
3.3 I/O units, marshalling cabinets, power distribution cabinets shall be housed in Rack room
in the control room.
3.4 ES cum OS (dual stacked) with SOE shall be placed on the console of engineering room.
3.5 Package Unit PLCs :
Bidder to provide PLC with redundancy at all levels and with latest model. It shall have
provision to communicate with main DCS system through Modbus protocol and connected
by Serial cable in redundant mode. Main programmable Logic controller based system for
the package including marshalling cabinets, relay cabinets, MCC Interface cabinets,
power supply distribution cabinets, instrument isolator, alarm cards, terminals, relays with
accessories duly mounted, wired & tested to meet specified requirements.
3.6 DIs/DOs from MCC to control system or from control system to MCC shall be with relays
only (no fuse shall be considered). Separate panels for DI/DO and AI/AO. The details
will be discussed during detailed engineering.
3.7 Alarm and Annunciation System (LED type only):

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 10 of 102

Annunciation system is used to indicate and sound alarm for any process abnormality,
trip/status change of Electric drive. Annunciation system shall be of modular design &
programmable type. Electrical circuit is designed to read the change of state of discrete
signal and generate the output to illuminate the window and give the alarm. The alarm can
be silenced by acknowledge switch. Window light can be reset after acknowledgement
and, when the state of signal returns to the prior alarm state. Annunciation system can be
configured for any of sequences of ISA standard. There shall be a provision in circuit
design to change the state of signal required to generate alarm (from Open to Close or
vice versa) simply by changing the jumper position on circuit board. Lamps in window shall
be replaceable from the front.
Hooter in general, shall be solid state type with audibility of the order of 100 dB at the
distance of 3 meters. An interruption of power supply up to 20 msec shall not affect the
functioning of unit.
The minimum instrument accuracy shall be as defined in Annexure-1.
3.8 SIL certification rating for all the instruments shall be minimum as per following list :-
 All Smart Positioners - SIL 2

 All Transmitters - SIL 2
 All Solenoids - SIL 3
 All Gas Detectors - SIL 2
 All switches - SIL-3 or maximum SIL rating available
3.9 Universal HART Protocol with Latest Revision shall be used in all cases.
3.10 Card mounted Relays are acceptable but cards must have redundant power facility, with
its power healthiness indication in diagnostic graphics.
3.11 Cable entry to control room, analyser shelter, substations shall be through MCT blocks
with SS316 MOC only.
3.12 Entry into the Marshalling Panels in the control room shall be through bottom mounted
316SS MCT blocks.
3.13 General Earthing & Instrument Earthing shall be provided separately (Panel and power
earthing, PLC system earth and Instrument signal earth is minimum envisaged).
3.14 All wetted part materials for all instruments (sensing elements) for corrosion prone area
shall be min SS316L.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 11 of 102

3.15 The Instrument item like control valve, pressure relief valve, orifice flanges, level
instrument, thermowell etc., coming on pipe and vessel under IBR services shall be
certified by IBR or IBR authorised representative, even for SS metallurgy.
3.16 Turbine Flowmeter shall not be used.
3.17 All Contacts shall be 2 SPDT or 1DPDT.
3.18 No Switches (Pressure / Level/ Flow / Temp.) shall be used.
3.19 All Field transmitters for pressure, d/p, level and flow shall be microprocessor based (dual
compartment) SMART transmitters with “UNIVERSAL HART” protocol with latest revision.
The transmitter selection shall be such that the operating maximum upper limit shall be
around 70% of the total measurement range of the transmitter.
3.20 All Field transmitters for pressure, d/p, level and flow shall be provided with 10 years
stability (0.1%).
3.21 Package vendor shall provide a common laptop (latest configuration 8th Generation Intel
i7 8550U processor, Windows 10 Pro OS, 8GB RAM, 256 GB SSD+, 1TB HDD, Full HD
display (15"),3 yr warranty with anti-virus and other engineering software) for configuration
of dedicated vendor standard PLC/DCS.
3.22 All equipment/materials supply shall include spares required for 2 years operation and
separate consumable for commissioning.
3.23 Motor / electrical equipment control philosophy
a. Field :
 Ready to START (Lamp)
 START
 STOP
 L/R Switch
b. For Package PLC

 STOP Command
 Discrepancy Alarm
 Running Indication
 Motor Fault Alarm
 Current Indication ( All motor > 5KW)
 L/R Switch Indication
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 12 of 102

 Ready to START F/B
c. For start / stop of all electrical equipments, local/remote selector switch shall be
located in field, A/M (Auto/ Manual) and stop push buttons on consoles in CR.
d. Local stop push button on LCS (local control station) shall be always effective.
e. In remote mode, motor can be stopped from control system.
f. In LOCAL mode, both START and STOP shall be possible only from LOCAL. Only in
REMOTE, stopping is possible from control system.
g. Auto / manual selection shall be in PLC/Main Control System.
3.24 For all motors current indication shall be provided in control system for rating more than 5
KW.
3.25 Auto start for pumps must be designed using 1oo2 philosophy.
3.26 All Instruments including volume bottle must be painted with Corrosive resistant epoxy
paint.
3.27 Local indicators, start /stop switches, emergency stop switches shall also be provided near
package units/rotating machines where local start up of the equipment is advisable.
3.28 For instrumentation electrical interface, input and output contacts shall be in separate
multicables (should be signal cables).
3.29 Trip solenoids shall be dual redundant, and configured and hooked up properly in such a
way that failure of one solenoid doesn’t initiate a false trip. Trip solenoids shall be normally
in energised condition and shall be de-energised to initiate trip.
3.30 All trip interlocks must be designed on 2oo3 philosophy.
3.31 Emergency stop and critical stops must have transparent protective cover.
3.32 PB’s , Annunciator , EPB must be available on console placed in CR.
3.33 Air fail to open, Close or Hold of any control valve shall be as per Licensors document, to
take care of process, plant and human safety. For Piston actuators necessary air volume
chambers and lock up relay shall be provided to achieve the fail-safe condition.
3.34 All Analysers shall be Ex.proof irrespective of area of installation.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 13 of 102

3.35 All control valves / On–Off Valves / MOVs shall be flanged type.
3.36 Control valve / on-off valve, pneumatic valve shall be designed for minimum 4 Kg/cm2 air
pressure.
3.37 Actuator design shall be of 1.5 times of shut off pressure or design pressure, whichever is
higher.
3.38 Valve body MOC in steam service shall be of WCC or better irrespective of pipe class.
3.39 Air distribution pots shall be of stainless steel (SS304). Inst. Impulse pipes / tube for
process parameters shall be in accordance with piping specifications.
3.40 Hart Compatible gas-detectors to be provided. Electrochemical type gas detectors shall
not be considered. Bidder to submit suitable gas detectors as per OEM recommendation/
as per ITB as specified elsewhere. Bidder to submit gas detectors quantity calculation
along with layout. Bidder to provided hooters (electric type) & beacon ( rotating type with
light flash).
3.41 All line mounted instruments like in-line SOVs, Magnetic flow meter, Rotameter, Mass flow
meters etc shall be provided with block & bypass arrangement, with their indications in
system as per requirement, which will be discussed in detailed engineering.
3.42 Separate Sample handling system shall be used for each analyzer. Multi Channel with
stream selector can be used, provided the total system including sample handling system
shall be imported. Necessary sequence shall be inbuilt in the analyzer for draining the
condensate.
3.43 For double acting valve, air accumulator (with MOC as SS304) shall be used for achieving
fail safe operation.
3.44 FRP Canopies (UV stabilized 3 mm thick), 2” Pipe mountable, are required for Transmitter,
JBs, LCPs, Control Valve positioner, Temp Elements, Proximity level switch, remote
mounted electronics, mass flowmeter, ultrasonic flowmeter etc. FRP Canopy shall be
Prefabricated type. Canopy for transmitters shall cover top and 3 sides. SS canopy instead
of FRP, if offered by package vendor, shall also be acceptable. No separate canopy shall
be required for instruments located under shed like compressor shed etc.
3.45 System / Marshalling/ Packages cabinet size shall be 2100 (H) X 1200 / 800 (W) X 800 (D)
Rittal make.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 14 of 102

3.46 Separate Tapping shall be used for each instrument coming for trip, control & monitoring,
local display. Not more than 3 set of taps are allowed.
3.47 Smart positioner shall be considered for all Control Valves. For high temperature services
(Above 200 Deg C) remote mounting shall be used for the smart positioner.
3.48 Positioner shall be of valve OEM or as per approved vendor list.
3.49 For all Local panels rain cover to be provided. The gasket of local panels must be acid
resistant preferably Silicone/EPDM or better which will be discussed during detailed
engineering.
3.50 For Analysers separate feeders to be directly taken from UPS. No sub-branching is
allowed at any place.
3.51 No Switches to be used. If in pump seal plan, if level measurement is requirement, GWR
to be used.
3.52 Fibre optic cables shall be armoured, multicore type. All fibre optics cable must be laid
through HDPE conduit. The make of fibre optic cables shall be Belden / Leoni.
3.53 Fire Alarm system shall be interfaced with the Central fire station, all the necessary
communication up to the central fire system PLC shall be in bidder’s scope. Including
supply of OFC and network switches etc. Any alarm generated in DM/RWTP/CPU/ETP
units shall be displayed at Fire Control Room. Repeater panel at central fire control station
shall be in bidder scope.
3.54 All cables inside package battery limit shall be supplied and laid by Package vendor
through instrument cable trays supplied by Package vendor. All cables inside
skids/modules shall be supplied in pre-wired & pre-tested condition.
3.55 All Instrument Hookups shall be approved by owner/PMC.
3.56 All fittings shall be SS316 and in inch only.
3.57 All tubing shall be SS316 and must be made from hot extrusion process only.
3.58 The manifolds (3 valve/5-valve/2 valve) material shall be SS316L.
3.59 All the soft parts of Local panels/JB/SOVs etc shall be of acid resistance, preferably
silicone, EPDM or better which will be discussed during detailed engineering.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 15 of 102

3.60 Level measurement in the acids tanks shall be of Ultrasonic type with Instrument and
sensor material suitable for acid application.
3.61 For all Diaphragm Seal Type DP Transmitters/Gauges on Vessels, min size and rating
shall be 3” 300# RF. Isolation valve shall be BALL type.
3.62 Level measurement in the acids tanks shall be of ultrasonic type.
4.0 INSTRUMENTATION CODE AND PRACTICES

IEC 13 Diagrams, Charts and Tables, Preparation of Logic Diagrams
IEC 534 Industrial - Process Control Valves
IEC 584 Thermocouples
IEC 605 Equipment Reliability Testing elements
IEC 611-12 Part 12 Graphical Symbols for Diagrams. Binary Logic
IEC 654 Measurement and Control equipment
IEC 751 Industrial Platinum Resistance Thermometer Sensor
IEC 801 Electromagnetic Compatibility for Industrial Process measurement

and Control Eqpt.
IEC 848 Preparation of Function Charts for Control Systems
IEC 902 Industrial Measurement and Control Terms and Definitions
ISA S-5 .1 Instrumentation Symbols and Identification
ISA S-5.2 Binary Logic Diagrams for Process Operation
ISA S-5 3 Graphic Symbols for Distributed Control/Shared Display

Instrumentation, Logic and Computer Symbols
ISA-S20 Instrumentation specification formats
ANSI/ISA S 5.1 Process Instrumentation Terminology
ANSI/ ISA S71.04 Environmental conditions
ANSI/ ISA S75.01 Control Valve Equations
ANSI/ ISA S75.02 Control Valve Procedure Capacity Test
ANSI/ ISA S75.03 Face-to-Face Dimensions for Flanged Globe Style Control Valve
Bodies

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 16 of 102

ANSI/ Quality Control Standard for Control Valve Seat
FCI 70.02 Leakage
BS 6020 Instruments for the Detection of Combustible Gases
DIN 43760 Measurement Standard for RTD.
DIN 19243 Measurement and Control Electrical Sensors, Electrical Position

Sensors and Signal Converters used for Intrinsically safe two-wire DC
System.
EN-50-014/020 Electrical Apparatus for Potentially Explosive Atmospheres
EN 54 Part I Components of Automatic Fire Detection System Introduction.
EN 54 Part 5 Heat sensitive Detectors - Point Detectors containing a Static

Element.

Representation Part I: Basic requirements.

Representation Part 2: Extension of Basic Requirements.

Representation Part 4: BasicSymbol for Process Computer, Interface
and shared Display/Control Systems.
ISO 4200 Plain End Steel Tubes, Welded and Seamless - General Table of
Dimensions and Masses per Unit Length.
ISO 5167 Measurement of Fluid by Means of Orifice Plates, Nozzles and

Venturi Tubes Inserted in Circular cross-section Conduits Running Full.
API RP 520 Sizing, selection and Installation of Pressure relieving devices in

Refineries
API RP 521 Guide for Pressure Relieving and Depressuring System
API RP 2000 Venting Atmospheric and low-pressure storage tanks
API-RP-550 Manual on Installation of refinery Instruments Part I and Control

System
ANSI - B 16.104 Control Valve seat leakage
ISA-S 75.01 Control Valve sizing
ISA S 18.1 Specifications and guides for the use of general Annunciators.
IEC 529 Environmental Protection of equipment
ANSI B 2.1 Pipe threads

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 17 of 102

ANSI B 16.5 Steel pipe flanges, flanged valves and fittings
IEC 79.11/ Intrinsic safety code and practice
IEC-79.14 International Boiler Regulation
IS 2148 Flameproof enclosure of electrical apparatus
BS EN 62676 series Video surveillance systems for use in security applications
BS EN 62676-1-1 Video System Requirements
BS EN 62676-1-2 Video Transmission – General Video Transmission –

Requirements
BS EN 62676-2-1 Video Transmission Protocols – General Requirements

based on HTTP and REST services

based on web services
BS EN 62676-3 Analog and Digital Video Interfaces
BS EN 62676-4 Application guidelines
5.0 HAZARDOUUS AREA CLASSIFICATION & ELECTRICAL EXECUTION
5.1 Irrespective of area classification, the execution of instrumentation shall be as per area
Zone 2, group IIC, T6, EExib and Protection.
Electrical / Electronic instruments IP 67
Sensors; RTD, T/C, etc. IP 65
Local Gauges; PG, etc. IP 55
Pneumatic instruments IP 54
Solenoid valves IP 67
Local Panel / Skid Mounted Panels IP 55
EMC compatibility and electrical safety as per latest IEC standard.
5.2 Electrical instrument equipment shall be designed for and supplied as intrinsic safe
certified.
Analysers, solenoid valves and other equipment that cannot be classified intrinsic safe
shall be ex-proof in accordance with the above mentioned electrical specification.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 18 of 102

In general, Intrinsic philosophy shall be followed for all the instruments. Where ever
intrinsically safe philosophy is not available, Exproof/Flame proof philosophy shall be
followed.
Certification for installation in hazardous areas in accordance with IEC 60079 series is
shown below:
Transmitters, positioners, Limit Switches, etc.: EEx ib IIC T6
Field Switches: EEx de IIC T6
Analysers and Panels: Ex p IIC T6
Solenoid Valves: EEx ib IIC T6 (Ex md not allowed)
Junction Boxes and Cable Glands: Exe/Exd
6.0 ELECTRICAL SUPPLY
The electrical supply will be as follows:

S.No. Description 110 V 110 V 24V 110 240V AC 415 V Remarks
AC DC DC V AC 50Hz AC-3
50Hz Non (Non UPS phase
UPS UPS )
1 PLC/DCS YES
2 Package Units YES YES Non UPS for

Lighting
3 Alarm YES
Annunciator
5 Solenoid Valves YES
6 Smart YE S
Positioners, I/P,
Transmitters
7 I/P Interrogation YE S
Voltage
8 Gas Detectors YE S
9 Analyzers and YES

Analyzer
System
11 Level Gauge YES
Illumination
12 Cabinets Fan YES
13 Cabinets YES
Lighting
14 Control Room YES
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 19 of 102

15 Local Panel YES YES YES Non UPS for
Lighting
16 CCTV YES
17 Analyzer YES
Cabinet Air
Conditioning
18 Analyzer YES
Shelter HVAC
19 Normal AC for YES
Field Operator
Room
Where 24V DC is needed, it will be generated by local rectifier units (bulk power supply
with MOSFET O-ring), which are part of the instrumentation supply. The power supply to
these units shall be taken from the UPS.
Where 24V DC are used for Safety Circuits, the rectifier units shall be duplicated and with
high reliability and form a part of DCS/PLC vendor. The bulk power supply shall be with
MOSFET O-ring.
There shall be minimum 4 (two no. Of each type; total 8 nos.) separate earth pits for signal
(IS) , Non IS, Panel and chassis (system) grounding for DCS/PLC Earthing system at
Control Room with different cable colour codes. All earth shall be less than 2 Ohm or OEM
specific, if better. The size of Earthing Cable shall be 50 sq.mm minimum and should be
routed in proper HDPE conduit, outside the control room building. All above instrument
earth pits shall be separate from Electrical earth pits and must have separate colour
identification from electrical earths. Minimum 2 nos. Of earth pits of each type (total 8 nos)
shall be constructed by the bidder.
Supply of earth electrodes, grounding cables (separate for signal grounding and
instrument grounding) and other related accessories required for barrier earth, system
earth and installation shall also be in the scope of work Contractor. Copper conductor shall
be of 1Cx10 Sq mm as minimum. For surge protection devices separate earthing shall be
used.
Grounding requirement for other system to be taken care by Contractor
Earthing of all new equipments / instruments located at control room for New PLANT of
new earth pit at control room with all cables, electrode, pit shall be provided by contractor.
UPS supplies shall not be used for utilities supplies cooling fans, panel/cabinet lighting
etc. A separate non-UPS supply shall be used for the same.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 20 of 102

A summary of all critical UPS alarms, 24V DC supply, Panel supplies, diode o rings
healthiness shall necessarily provided in control system system and hardwired
annunciation in control room or any manned location
Only copper cables & tin-plated copper lugs shall be considered for instrumentation
power distribution system.
One no of redundant feeder for UPS supply be provided by the client. UPS shall be in
bidders scope. Further distribution to the bidder system in the CR, Field operator room
and in the field shall be in the bidder scope. Therefore necessary PDB shall be provided
by the bidder to distribute power supply.
Protection coordination with respect to fuse/MCB ratings from the supply source
ACDB/DCDB to downstream distribution panels shall be thoroughly studied by the system
designers/OEM and documented as a part of the system documentation and be
implemented accordingly.
MCB’s must have DI contact’s which must be wired to DCS/PLC and available in
diagnostic graphics.
7.0 FIELD INSTRUMENTS
7.1 Analyser
All liquid analysers (pH, conductivity, pH in Effluent) shall be of intrinsic safe design
suitable for execution class specified for the area. Liquid Analyser, sampling conditioning
unit and other accessories shall be mounted on a rack suitable for field mounting. pH,
conductivity shall be installed preferably in a bypass line to facilitate maintenance of the
analyser.
All Analysers shall be micro-processor based in general and shall be capable of providing
detail diagnostic alarms, messages to help maintenance personnel. Analysers shall have
manual/auto calibration facility.
Self diagnostic routines and calibration functions shall be provided as standard. The
Bidder shall supply details of self diagnostic routines and calibration functions including
calibration intervals. The Analysers shall use tried and field tested analysis technology.
Analysers shall generally be single stream. Multi stream Analyser applications shall be
supplied where process requirements specify.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 21 of 102

7.1.1 pH ANALYSER
Design Data and Construction
7.1.1.1 The bidder shall provide a complete pH Analyzer with electrodes mounting accessories,
sample handling system & indicating analyzer transmitter.
7.1.1.2 The pH of the solution shall be detected by a sensor assembly. This sensor shall provide
an output signal proportional to the concentration of free hydrogen ions. Unless otherwise
specified, measuring system shall be provided with automatic temperature compensation.
Temperature sensing shall be through temp sensor 3-wire platinum RTD.
7.1.1.3 In general, the selection of Analyzer shall be based on the type of installation e.g. Flow
thro’, insertion or submersion and the area classification.
7.1.1.4 When installed in electrically hazardous areas, the installation could be either intrinsically
safe. Specific preference, if not indicated, Intrinsic Safety shall be considered. In either
case, certification from statutory bodies such as ATEX, PTB or equivalent shall be
provided. Evidence of such approval shall be affixed to each and a copy of the certification
letter shall be provided.
7.1.1.5 DELETED
Sensor
7.1.1.6 Sensor shall consist of measuring electrode, reference electrode & 3-wire platinum RTD
temp sensor for automatic temperature compensation.
Electrodes
7.1.1.7 The type electrode and material of construction shall be decided based on the process
conditions furnished in data sheet. Bidder in his offer shall clearly demonstrate suitability
of selection of sensor.
7.1.1.8 Where required, bidder shall provide appropriate cleaning device for the electrodes.
7.1.1.9 For sanitary applications, provisions for sterilization shall be provided.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 22 of 102

Transmitter
7.1.1.10 Transmitter electronics shall be microprocessor based, two-wire transmitter with 4~20mA
DC linear output proportional to the pH with HART protocol. Transmitter electronics shall
be interchangeable with all other pH analysers.
7.1.1.11 Transmitter shall be provided with local LCD display and the range shall be user
configurable.
7.1.1.12 Transmitter housing shall be weatherproof to IP65 and shall have two number ½” NPT(F)
electrical entries for termination of cables.
7.1.1.13 Transmitter shall be suitable for 2” pipe mounting. Bidder shall provide mounting bracket &
other accessories of (SS304) .
7.1.1.14 In the event of transmitters being specified as ‘SMART’, following requirements shall be
met.
• All transmitters shall be high performance type microprocessor based ‘SMART’ type
with ‘HART’ protocol with latest version.
• Configuration shall be possible by locally and/or with handheld communicator. Bidder

shall optionally quote for hand held communicator.
• Multiple level of security shall be provided including elimination of zero and span
adjustments, software lockout of local adjustment and complete write protect
capabilities.
ACCESSORIES
7.1.1.15 Sensor Cable and Junction Box
• Bidder shall supply special cable for connecting sensor to the transmitter along with
SS316 double compression cable glands at both ends.
• Cable length shall be as specified. Where specified length is not available, bidder
shall supply junction box for connecting sensor cable and the extension cable.
• If applicable: Junction box shall be of SS316L & IP65. Bidder shall also supply
associated cable glands. Flameproof certification shall be provided if hazardous area
is specified in the specification. Spare entries of junction box shall be plugged (Ex
proof SS316).
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 23 of 102
Special Consideration
7.1.1.16 High Temperature
The problems of pH measurement at high temperatures are mainly associated with

electrode construction and assembly design. The performance of the glass electrode is
dependent on two factors, the composition of the glass bulb to withstand chemical attack,
and the performance of its inner reference electrode at high temperatures. Bidder shall
consider such application & suggest the electrode type.
7.1.1.17 Low Conductivity Water
The extremely low ionic strength of boiler feed or de-ionized water, demands the use of a
flowing sample, and the careful exclusion of air to prevent any ingress of carbon dioxide.
The glass electrode will tend to read high if the sample is not flowing past it. Some
response lag may occur because the low ionic concentration provides a very poor
diffusion gradient for hydrogen ion activity changes while a very high flow-rate could
evolve streaming potentials. Bidder shall consider & suggest the electrode & sampling
system for such application.
7.1.1.18 Installation
pH analyser shall be installed in field. Bidder shall provide analyser with Hazardous area
suitability, sample take off technique and inline installation drawing, Local LCD display on
analyser front.
and pressure to conditions suitable to the pH electrode. This shall consist of sample
7.1.1.20 Flushing: pH analyser with arrangement of flushing sequence with suitable time & SOVs
for slurry application shall be provided by bidders as per the requirement in the datasheet.
7.1.2 CONDUCTIVITY ANALYSER
7.1.2.1 The analyser shall perform the unattended analysis of the conductivity level of the stream.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 24 of 102

7.1.2.2 The bidder shall-provide a complete conductivity analyser system. The system shall
consist of the following:
• Conductivity cell with accessories.
7.1.2.3 Sample Conditioning System (If Required)
and pressure to conditions suitable to the conductivity cell. This shall consist of sample
7.1.2.5 Sample conditioning system components with the exception of the conductivity cell shall
be constructed of 316 SS.
7.1.2.6 The conductivity cell and the sample conditioning system shall be mounted on a steel
plate suitable for surface mounting.
7.1.2.7 Conductivity Cell
 Conductivity cells are to be suitable for the individual process streams as listed on the
data sheets.
 Line mounted insertion type conductivity cell, when specified on the Instrument Data
Sheets shall be retractable with suitable packing gland and isolation valve.
 Conductivity cells shall be provided with automatic temperature compensation.
 Electrodes shall be platinized, gold plated nickel or 316 SS with stainless steel
fittings.
 Conductivity cells shall be certified for installation in the electrical area classification
as specified on the data sheet.
Indicating Analyser Transmitter
7.1.2.8 Each analyser shall be suitable for pipe or wall mounting and shall be the indicating type.
7.1.2.9 Calibration check switches shall be provided on each analyser.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 25 of 102

7.1.2.10 Automatic temperature compensation shall be provided for each analyser.
7.1.2.11 The analyser shall have a weatherproof (IP 65 as minimum) housing and shall be certified
for installation in the electrical area classification specified on the Instrument Data Sheets.
7.1.2.12 Transmitter shall be the two wire type and provide an isolated 4-20 mA linear output wired
in control system and local indication.
7.1.2.13 Transmitter shall be suitable for field installation.
7.1.2.14. Transmitter shall be suitable to Hazardous area classification.
7.1.3 SILICA Analyzer
7.1.3.1 Silica Analyzer shall be HACH make. It shall be an on-line multi channel analyzer, designed
to provide continuous monitoring or programmed sampling of silica concentration, utilizing
a standard colorimetric analysis principle. Silica Analyzer shall be of 5 nos. of
Channels/streams and range shall be 0-0.02ppm (0-20ppb) (freely configurable) with
0.5ppb resolution for all range. Response time shall be <15 Min per sample. The Reagent
shall be supplied for at least Six (06) months operation backup post commissioning.
7.1.3.2 The bidder shall-provide a complete Silica analyser system. The system shall consist of the
following:
• Silica cell with accessories.
The analyser complete with sample conditioning system shall be housed in a cabinet.
7.1.3.4 The control unit shall be microprocessor based smart type with temperature controller, auto
calibration and zeroing facility, self diagnostic facility, with local indication and alarm for
operating parameters, Automatic shutoff on sample failure and automatic start up on
revival of sample etc.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 26 of 102

7.1.3.5 The control unit shall be weather proof to IP-65 ,intrinsically safe and shall be suitable for
7.1.3.6 Sample Inlet/Outlet Connections shall be ¼ inch OD .Tubing material shall be

Polypropylene or better.
7.1.3.7 Enclosure shall be constructed of SS.
7.1.3.8 Analyzer shall provide 2 isolated 4/20 mA outputs and 4 programmable alarm relays.
Relays shall be rated for 5 A @ 240 V AC
7.1.3.9 Analyzer shall be capable of auto ranging and auto calibration.
7.1.3.10 Display shall have digital graphics LCD with backlight.
vendor scope. However Reagent shall be supplied for at least Six (06) months operation
backup post commissioning
7.1.4 Sodium Analyzer
7.1.4.1 Sodium Analyzer shall be multichannel on-line analyzer, providing continuous sodium
measurement using ion selective electrode or vendor to specify. No of Channels/streams
shall be 3 nos. and range shall be 0-5ppm (Range shall be freely configurable)
7.,1.4.2 The control unit shall be microprocessor based smart type with temperature controller,
alarm for operating parameters, Automatic shutoff on sample failure and automatic start up
on revival of sample etc.
7.1.4.5 There shall be two 4-20 mA outputs, one dedicated to sodium and other one to
temperature.
7.1.4.6 Temperature compensation shall be provided

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 27 of 102

7.1.4.7 Sample conditioning system details shall be provided by vendor.
7.1.4.8 The vendor shall maintain sufficient stock for reagents/chemicals.
vendor scope.
7.1.4.10 Display shall be backlit LCD with temperature, concentration, mV, error codes etc.
7.1.5 Chlorine Analyzer

7.1.5.1 Chlorine analyzer shall be an on-line analyzer, designed to provide continuous monitoring
of chlorine, chlorine dioxide based on amperometric / colorometric method. The system
shall monitor and control free/ residual chlorine levels accurately. Range shall be 0-5ppm.
(Range shall be freely configurable)
7.1.5.2 The analyzer shall be complete with sample conditioning system.
7.1.5.4 The control unit shall be microprocessor based smart type with temperature controller,
alarm for operating parameters, Automatic shut off on sample failure and automatic start
up on revival of sample etc.
7.1.5.6 Analyzer shall be capable of automatic temperature compensation.
7.1.5.7 The sample shall drain into a non-metallic pipe due to the corrosive nature of chlorinated
water.
7.1.5.8 Self cleaning sensor assembly shall be considered to prolong sensor life and maintain
accuracy.
7.1.5.9 The sample tubing shall be kept as short as possible to minimize lag time.
7.1.5.10 Ph compensation shall be provided wherever necessary.
7.1.6 ORP Analyser
The bidder shall provide a complete ORP Analyser with electrodes mounting accessories,
The principle behind the ORP measurement is the use of an inert metal electrode
(platinum), which, due to its low resistance, will give up electrons to an oxidant or accept
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 28 of 102

electrons from a reductant. The ORP electrode will continue to accept or give up electrons
until it develops a potential, due to the build up charge, which is equal to the ORP of the
solution.
The analyser shall be stand alone panel mounted and protection class shall be IP67 .
Suitable canopy shall be provided for the enclosure. Analyser shall have 4-20mA for
indication in CR. Local display shall be digital LED type.
Sampling system shall be rugged construction and all tubing/ fittings shall be of SS 316
material (in inches only). Sample Flow Meter on Sampling Handling System shall be
provided. Vendor shall submit the details of sampling system along with offer.
Measurement of ORP shall be in mV. The accuracy shall be less than 1 mV.
Range shall be +/- 2000mV.
7.1.7 Turbidity Analyser

The bidder shall provide a complete Turbidity analyser along with mounting accessories,
sample handling system, calibration unit, and maintenance kit.
Turbidity is a measure of water suspended solids (SS) concentration. Turbidity

measurement shall be done based on 90º light scatter principle (Nephelometry). The
turbidity meter shall have following outputs:
 Analog 4-20mA output
 Self checking relay output
 Alarm Relay output
The sensor material shall be SS316L and shall have IP67 min, protection. The accuracy
shall be +/- 2 % of reading (NTU) and repeatability shall be +/- 1 % of reading (NTU).
Auto calibration shall be required for all analyser. Zero & span calibration gas cylinder to
be provided for the all analyser as applicable.
7.2 Flow Instruments
7.2.1 Flow Transmitters
D/P cells shall have measuring method on the floating capacitance technology. The signal
transmitter shall normally be a 2-wire system and shall be capable of delivering rated
current into external load of at least 600 ohms when powered with 24 V d.c. Protection
against short circuit and reverse voltage shall be provided. Bodies shall normally be in
stainless steel with SS316L internals. Integral 3- valve manifold similar to AGCO make
model 4A shall be used for mounting transmitters on manifold for ease of maintenance.
Material of manifold in general shall be SS316L but may vary depending upon service.
Digital output indication shall be preferable on the integral output meter with the
transmitter. All flow transmitters shall have sq.root extraction function.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 29 of 102

Pressure elements in austenitic stainless steel is a requirement. The transmitter shall be
furnished with an output meter or gauge with a sqrt scale. Smart type transmitters will be
used with Hart V protocol. Overall accuracy for SMART transmitters shall be +/- 0.050% or
better. Process connection size shall be 1/2” NPT.
shall be equipped with Local LCD type digital indicator. 2” pipe mounting, SS304 MOC
1:100, Local Display configurable, SS MOC, Double Compression SS 316 cable glands,
Aluminium Epoxy Painted, Universal Hart Protocol with Latest Revision is required.
7.2.2 Rotameter with Transmitters
Rotameters or variable area meters may be used in pipe sizes from 1 1/2” and smaller.
The meter shall be selected for normal flow at 50 to 60% of the span. In applications with
toxic or inflammable fluids, glass tubes must not be used except for low pressure analyser
sample flows. They may be used for severe corrosive services and of fluid of high
viscosity. The metal tube meters shall be of stainless steel, PTFE lined or any other
suitable lining for the service. The Indicator assembly shall be magnetically coupled and
mounted with Rotameter body. Transmitters or Indicators on float extension are not
recommended except for cryogenic services. The switch assembly shall be of proximity
type. All Rotametres shall be metal tube type with transmitter. The rotameter transmitters
shall have 4-20 mA output at 24V d.c. power on two wire system, which must wired to
control system.
7.2.3 PRIMARY DIFFERENTIAL PRODUCERS
7.2.3.1 Orifice Plates
Orifice plates of the square edged concentric type shall be specified except where
unsatisfactory for the application. Materials of orifice plate shall normally be AISI 316
unless special materials are required for the service. The maximum ratio of orifice to inside
pipe diameter of 0.70 and minimum ratio of 0.30.
Orifice plates dimensions and calculations shall be in accordance with ISO 5167-1980.
Minimum orifice plate thickness shall be 3.16mm.
The flow range shall be selected such that normal flow rates are between 50% and 70% of
the flow upper range value.
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 30 of 102

Material of construction of orifice plate shall be 316L SS except where this material is
unsuitable for the service because of corrosion or erosion considerations, in which case
an alloy shall be chosen whose corrosion allowance is equal to or better than line material.
Orifice plates dimensions, finishing, flatness, tolerances for dimensions and identification
information shall be in accordance with ISO standard. Orifice plate shall be provided with
tab handle, which is welded on the orifice plate and engraved with following information on
the upstream of the tab handle:
- UPSTREAM or UP
- Instrument tag number
- Orifice diameter
- NPS (Nominal Pipe Size) and ANSI flange class
- Material of the orifice plate
- DP range & Meter ( Flow) range
The tab shall also be in line with the Drain or Vent hole and shall indicate the direction of
flow.
BIDDER shall submit the sizing calculations for orifice plates for review.
Pressure drop for orifice sizing shall generally be selected among the following values:
125, 250, 500, 625, 1250, 2500, 5000 and 10000 mm H2O with standard selection at
2500 mmH2O.
Orifice plates shall be installed on horizontal lines when practical. Vertical meter runs may
be used for down flow of vapour and up flow of liquids.
Differential ranges for all liquid flow meters shall not exceed 5000 mm water. Typical
ranges for gas, steam or vapour meters are as follows:
Static Pressure Diff. Range
(in Kg/Cm2g) (in mmwc)
0.35 to 2.5 500-1200
2.6 to 6 1250-2500

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 31 of 102

Above 6 2500-5000
Orifice bore with diameter less than 0.125” shall be avoided.
a) Flange taps orifice shall generally be used for line sizes 2” to and including 18”. Above
18”line size, D and D/2 taps shall be used. Integral Orifice assembly with transmitter shall
be used for line size 1 1/2 “or below (as per standard BS-1042)
Orifice assembly shall be provided with two sets of “Flange Taps” located in accordance
with latest AGA standards. The orifice assembly shall be provided with jack screw for
removal of orifice plate. In case of 2 out of 3 logic requirement, three different transmitters
shall be used and no two transmitters shall share the common tapping. In such case six
set of taps (independent tapping from Flange Itself , NO TEE / Elbow shall be used ) shall
be provided in orifice assembly. Instrument tapping connections shall be 1/2”NPT
(F).ONE Set of spare flange ts required for 2oo3 configuration i.e. total FOUR Sets ( 8
Nos. ) Of flanges tapping.
b) Orifice flanges shall be in accordance with the ANSI B16.36, ANSI B16.36a and
applicable piping specification and shall generally be of weld-neck type only. The
minimum pressure rating of flanges shall be ANSI 300 lbs.
Flanges larger than 3" shall have a pair of jack-screws. The mating flanged shall be
aligned in such a way that jack-screws will be diametrically opposite.
Orifice flanges used at pressure ratings up to 600 Ib. shall be tapped ½” NPT(F) tap for
900 # above ¾” NPT(F). Orifice connections for Vena contracta taps or pipe taps ½”
socket with schedule/MOC as per piping specs
c) For line size below 2” Integral orifice with corner taps shall be supplied as an integral
assembly consisting of upstream and downstream straight pipes, integral orifice of 316L
SS (as a minimum) installed along with H type manifold and SMART, 2 wire 24 V DC, DP
transmitters with latest HART protocol (refer 7.2.1 for tx details). End flanges shall be as
per piping specifications. Upstream and downstream pipes shall be honed from inside to
achieve smooth surface. Integral orifice meters, when used, shall be installed with block
and bypass valves.
d) Upstream and downstream straight length shall be provided based on maximum d/D ratio
of 0.70, in general. Where it is difficult to meet this requirement, the actual d/D can be
considered for reducing the straight length as permitted by ' recommended practice shall
be as per API-MPMS Recommended Practices and AGA Report No.3. The piping layout,
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 32 of 102

where possible, shall be arranged such that straightening vanes are not required.
e) Orifice plates with RTJ flange connections above 2” shall be supplied with Carrier rings /
Plate holder. Holder MOC shall be same as Plate material as minimum.
f) Meter taps shall be horizontal for liquids, condensable vapors and steam. The tap shall
be on top for gas, non-condensable vapor, or liquids, which boils at maximum design
ambient temperature at operating pressure.
g) The Meter Range flow shall be equal to the 1.5 times of normal flow or 1.3 times of the
maximum flow and it shall be nearest higher multiple of 50/100/1000s of units of measure
(in Engg. Unit) in round figures. This meter max range criteria specified is applicable to all
other type of flow transmitters also.
7.2.3.2 Nozzles
ISA 1932 Nozzles may be used in high and medium pressure steam and BFW piping.
Materials for nozzle element shall normally be AISI 316L steel unless special materials
are required for the service. Dimensions and calculations shall be in accordance with ISO
5167-1980. Generally, branch pipe is required with the nozzle the same shall be
machined from higher schedule pipe than the one used for the service or forged branch
pipe shall be used if higher schedule pipe is not available. The branch pipe bore shall be
same as that of nozzle ID and shall have mirror finish.
7.2.3.3 Venturi Tubes
Venturi Tubes or nozzles as per ISO 5167-1980 or similar type elements may be used to
measure the flow of low pressure gases or liquids where loss of pressure is an important
consideration.
7.2.3.4 Averaging Pitot tube/Annubar (Not to be used)
7.2.3.5 Local Flow Indicator
Motion balance (Barton cell type) type differential pressure indicator shall be used for
local flow indication. Body and internals shall be of 316L SS. Process connection shall be
1/2” NPT(F) . SS316L 5-valve manifold with 1/2” NPT connection shall be used with the
meter.
7.2.4 OTHER FLOW METERS

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 33 of 102

7.2.4.1 Mass Flowmeter
Coriolis type mass flow meter with local digital display of flow shall be used to measure
the process flow where high accuracy is required. Normal accuracy for mass flowmeters
shall be 0.15% of span. The sensing element shall be straight/U-tube, matl. 316L in
general.
7.2.4.2 Vortex Meter
Vortex shedding meters may be used for wide range of flows for gases and liquids. The
measured flow shall be temperature compensated.
Insertion type vortex meter may be used in utility services for line size more than 6”
inplace of Pitot /Annubar/Pitot Venturi tubes.
7.2.4.3 Ultrasonic Flowmeter
Ultrasonic flow meters (non- insertion probes preferred) based on the “time-of-flight”
method shall be used. Meters based on the “Doppler” principle are less accurate and
shall not be used. Ultrasonic flow meters shall be considered for large turn downs and
where pressure drop is not permitted. Upstream and downstream straight lengths shall
be as per standard.
7.2.4.4 Electro-Magnetic Flowmeter
Electromagnetic Flowmeter with ceramic lining shall be used for the measurement of flow
with high accuracy for highly viscous and corrosive services. Instrument shall be suitable
for Acid and alkaline measurement.
7.3 LEVEL INSTRUMENTS
Level Instrument shall be suitable for Acid and alkaline measurement. Guided wave radar
type instruments (SMART) shall normally be used for level measurement up to 2400 mm,
wherever guided wave radar cannot be used then only external displacer type transmitter
to be used.. Differential pressure transmitter (Capillary type) shall be used for level
measurement above 2400 mm and for services requiring purge or where liquid might boil
in external portion. Capillary type DPTs shall not be used in vacuum services. Internal
displacer type of level transmitters shall be not be used. Remote Seal PT/DPT shall be
with min 5 mtr Capillary with SS armoured in PVC sheath of Protection with DRIP RING
and with Ball type Isolation Valve. For Vessel/Equipment requiring more than 5 m
capillary electronic remote seal shall be provided. Process connections shall normally be
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 34 of 102

3” flanged.
7.3.1 External Displacement
Displacer type level instrument shall be avoided and guided wave radar type or remote
diaphragm seal DP shall be used in their place if suitable to process condition.
If unavoidable External displacement type instruments shall generally be used (with

owner/PMC approval) for small spans only (The standard ranges shall be: 350 mm, 810
mm., 1200 mm). The cage material shall normally be forged material conforming to the
service requirements. Where the vessels are of alloy steel construction, the body material
shall be equivalent or of a better material. The displacer shall be in stainless steel
(SS316L) and the torque tube in inconel. If LVDT type transmitter in place of torque tube
is selected then the range spring of such transmitters shall be Inconel and cannot be
used for temp. more than 330 degree C. Process connections shall normally be 2”
For high temperature as well as low temperature and cryogenic services, torque tube
heat insulation extension or torque tube extensions shall be applied. Radiation fins or
extensions shall be used for temperature above 200 degree C or below 0 degree C.
7.3.2 LEVEL GAUGE GLASS
Gauge Glasses
Glass gauges shall be avoided and magnetic type level gauges shall be used if suitable
to process condition. If unavoidable Gauge Glasses shall normally be reflex type for all
process services, except for boiler drums bicolour types shall be used, and in corrosive
services. Where transparent gauges with glass protection and illuminators shall be used,
Illuminators shall be explosion-proof in hazardous areas. Gauge glass columns will not
exceed 1500 mm. Multiple level gauges shall be used for visible lengths more than 1500
mm.
Transparent type gauge glasses (double glass) will be used for services in which a level
may not be distinguishable, such as interface services, between different liquids, where
mica shields are required and fluids of high viscosity or high solid content.
For corrosive services, such as strong acids or alkalies, special devices such as magnetic
followers or plastic ("KelF") coated glasses shall be used.
Level gauges shall be supplied with a pair of off-set shut off valves with ball check with
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 35 of 102

SS304, or material suitable to process, as its MOC.
For cold services where temperature is below 0 deg C a non-frosting gauge will be used.
Glass tube level gauges shall be avoided.
Gauge glass columns will not exceed 1500 mm. Multiple level gauges shall be used for
visible lengths more than 1500 mm.
7.3.3 Non Contact Radar/Guided Wave Radar
Displacer type level instrument shall be avoided and guided wave radar type shall be
used in their place if suitable to process condition.
Ultrasonic / Radar type Instrument shall be used for large liquid storage tanks. Guided
Wave Radar type level instruments, where used, shall be external type with side / side
connections and rotatable transmitter head. Vent and drain valves shall be provided.
Non-Contact Radar type level shall be used on corrosive, congealing, slurry services
where diaphragm seal type transmitter cannot be used. Dip tube can be used in above
services where radar cannot be used. In case of heavy congealing service (sticky liquid)
rigid single lead type GWR shall be used. All guided wave radar will be coaxial type,
where high accuracy or interface level measurement is required. However single rod
design to be avoided to extent possible).
Guided Wave Radar Level transmitter shall be applicable for liquids or slurries,
hydrocarbons too water- based media. In absence of dielectric constant for the process
fluid, Bidder shall confirm the suitability of Guided Wave radar Level Transmitter for such
applications and Bidder shall suggest the suitable model for the same. Bidder shall
suggest the suitable model for Interface applications like oil on water, Hydrocarbon on
water, etc. Electronics shall be capable of measuring upper liquid and interface level
simultaneously. Selection shall be available for analog output signal from level transmitter
corresponding to upper liquid or Interface. Process connections shall normally be 2”
For sump levels, Guided wave radar for DCS and non- contact type radar level instrument
for interlock shall be used within accuracy ±3mm. For servo gauges where used,
calibration chamber with access for removing the displacer for maintenance purpose shall
be provided.
7.3.4 Magnetic Level Gauges

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 36 of 102

Magnetic type level gauges shall be considered for:
• Cryogenic services
• Fluids that attack glass (e.g., strong acids, alkalies, boiler feed water)
• Light ends services
• Toxic services
• Pressures above 500 psig (3450 kPa) special consideration must be given to the
design of float for high pressure
Magnetic- type level gauges shall consist of a liquid chamber enclosing a float which
is magnetically coupled to a rotary wafer-type indicator. It shall be top or side
mounted type. The liquid chamber shall be one- piece construction with a minimum
internal diameter of 50 mm, provided with a bottom flange for removal of the float,
vent and drain connections. Indicator shall be adjustable around the chamber with
provisions to indicate float failure.
The indication shall consist of bi-colour (red/white, silver/black) magnetic rollers

mounted on outside the magnet chamber. As the float rises or falls with the liquid
level each roller rotates 180 Deg and so presents a contrasting colour.
Floats shall be designed and manufactured for suitable to the process parameters. It
shall be designed to be adequate for hydrostatic test conditions. Floats shall be
hermetically sealed, no vented or pressure equalized construction shall be allowed.
7.4 PRESSURE INSTRUMENTS
7.4.1 Pressure Transmitters
Pressure Transmitters and differential pressure transmitters shall be modern inherent

motion-free type. Bodies shall normally be in stainless steel with pressure elements in
SS316L. Two valve integral manifold of SS316L material in general shall be used with
pressure transmitters.
The signal transmission should normally be a 2-wire system and shall be capable of
delivering rated current into external load of atleast 600 ohms when powered with 24 V.
Protection against short circuit and reverse voltage shall be provided. Pressure
transmitters shall normally be electronic type and shall have digital transmitter.. Smart
type transmitters will be used with Hart V protocol. Overall accuracy for SMART
transmitters shall be +/- 0.050% or better. Process connection size shall be 1/2” NPT.
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 37 of 102

shall be equipped with Local LED type digital indicator. 2” pipe mounting, SS304 MOC
1:100, Local Display configurable, SS MOC, Double Compression SS316 cable glands,
Aluminium .Epoxy Painted, Universal Hart Protocol with Latest Revision is required
7.4.2 Pressure Gauges
Gauges for process and utility services shall be industrial SS316L Bourdon
gauge/diaphragm or spring bellows type as per process requirement with the case in
316L stainless steel. The gauge for 60 kg/cm2 above pressure shall preferably be a
safety type with solid front where pointer and glass are partitioned off from the sensor by
a solid disc. Pulsation dampeners shall be installed with the gauges where pulsating
pressure occurs. Process connection shall be 1/2” NPT (M) bottom in general. Bezel
rings shall be screw on pattern. Dial Size minimum 150mm
Blow-out discs are required for all pressure gauges except for instrument air services.
Vibration proof gauges or remote seal type shall be used if the surrounding environment
is subject to vibration.
Minimum accuracy for pressure gauges shall be +/- 1%,
Pressure gauges for vibrating services shall be glycerine filled type or with pulsating
dampener device.
7.4.3 Pressure Switch (Not to be used)
7.4.4 Diaphragm seal
Diaphragms or liquid seals shall be inserted between the instrument and the process for
corrosive or highly viscous fluids. For all services element material shall be minimum
SS316L.
Pulsation dampeners shall be furnished with pressure transmitters on pulsating services.
All catalyst vessel’s dP measurement shall be with ERS (electronic remote seal).
Remote Seal PT/DPT shall be with min 5 mtr Capillary with SS armoured in PVC sheath
of Protection with DRIP RING and with SS304 Ball type Isolation Valve. For
Vessel/Equipment requiring more than 5 m capillary electronic remote seal shall be

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 38 of 102

provided.
DP transmitters with diaphragm seals are envisaged, where condensing leg required to
be filled in normal DP transmitters, at all those locations, remote seal type DP
transmitters are to be used. Also, wherever there is a control and interlock on level
measurement, one transmitter shall be remote diaphragm seal type and one will be
guided radar type with Material: Minimum Inconel. Guided Wave radar may be used for
non-critical applications. Process connection will be 3” flanged and sealing liquid must be
selected as per process requirement.
7.5 TEMPERATURE INSTRUMENTS (Duplex Type)
7.5.1 Thermocouples
Thermocouples shall normally be the sheathed type with high purity magnesium oxide
insulation. The hot junction shall be isolated from ground. Sheath diameter shall normally
be 6mm (1/4”) Inconel 600 sheath material shall be used for design temperatures above
400 degree C, whereas ordinary SS material can be used below 400 degree C. The
nominal wire diameter shall be approximately 0.19 x sheath OD. The casing material
must be SS316L.
Inputs from thermocouples shall be provided with cold junction compensation and
downscale burns out feature for high temperature shut downs and vice versa for low. A
passive alarms shall warn about the burn-out.
In general type K thermocouples shall be used according to IEC 584, class-1. All
temperature elements shall be duplex type, one connected and the second one shall be
used as spare.
Thermocouple head must be of die cast aluminium with epoxy paint to with stand the
corrosive environment.
Unless otherwise specified, thermocouples cable color coding shall be in accordance with
the latest edition of ANSI-MC 96.1.
The type of thermocouple shall be selected based on the following guidelines as

minimum:
Copper-Constantan (ISA-Type-T) (-) 200 to 200°C
Chromel-Constantan (ISA-Type-E) (-) 200 to 600°C

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 39 of 102

Iron-Constantan (ISA-Type-J) (-) 40 to 750°C
Chromel-Alumel (ISA-Type-K) (-) 180 to 800 °C
NiCrSil - NiSil (ISA-Type-N) 0 to 1200 °C
Platinum Rhodium-Platinum (ISA-Type-S or B) 600 to 1600°C
7.5.2 Resistance Temperature Probes
Resistance Temperature Probes shall be considered for applications where very narrow
spans and high accuracy are required as well as low temperature service. They shall be
6mm (1.4”) stainless steel sheath type similar to the thermocouples and with a Pt 100
ohms (0 degree C) element. The sensors shall be duplex type and shall be spring loaded
for vibration proof. The elements shall conform to DIN 43760 or IEC 751. The casing
material must be SS316L. RTD head must be of die cast aluminium with epoxy paint to
with stand the corrosive environment.
Class 'A' / Class '1’ tolerance as per IEC 751 / 584-2 shall be specified for all RTD and
thermocouple sensors in complete temperature measurements for all open/closed loops
and interlocks/Logic.
7.5.3 Temperature Transmitters
Temperature transmitters shall be Remote mounted type (on 2” Pipe), Smart with latest
HART protocol and integral digital output meter, dual compartment type.
Head mounted transmitters shall not be used.
Conventional transmitter shall have universal input for thermocouple / RTD and output 4-
20 mA DC for 2 wire system.
Transmitter output signal shall be linear and directly proportional to the measured
temperature with overall accuracy of +/- 0.1% FS. TT body must be of die cast aluminium
with epoxy paint to with stand the corrosive environment
Thermocouple transmitters shall have cold junction compensation and thermocouple

linear characterization. Resistance temperature transmitters shall have resistance
element linear characterization.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 40 of 102

Burnout protection (selectable Up Scale / Down Scale) must be provided for temperature
transmitters.
No temperature switches are to be used. The same is to be achieved through

transmitters which shall be directly connected as analog input to DCS / PLC.
Temperature transmitters are to be provided for all temperature measurement

(closed/open/interlock) loops. All process temperature measurements shall be done
through Temp. Transmitters. No temp. Input shall be connected directly to
ESD/PACKAGE UNITS. MUX is not allowed.
7.5.4 Thermometers
Thermometers shall normally be bi-metallic, heavy duty, weatherproof (IP 65), adjustable
angle connected type with 150 mm dial as a minimum, dials of smaller size may be used
for auxiliary services on machinery. Casing material shall be SS316L.
Liquid filled indicators will be used only where indication is required to be remote Case
and stem shall be in stainless steel. Dials shall be of white, non-rusting metal with black
figures.
For local temperature control upto a maximum scale range of 530 deg C, liquid filled
sensors with capillary extension shall be used.
Filled system instruments when used shall be fully compensated for ambient temperature
variations.
Capillary shall be SS armoured and length of which will not generally exceed 3 mtrs.
Range should be selected so that normal operating temperature is approximately 70% of

full scale, and the maximum expected temperature is approximately 90% of full scale.
7.5.5 Thermowells
Thermowells shall normally be made from bar stock material.
Flanged thermowell shall be used of 1 1/2” size, threaded thermowell shall not be used,
except where accepted by piping specifications, in such case they shall be 1” NPT(M)
and real welded. Flanges rating, facing and material shall be in accordance with the
equipment or piping standard. Thermowell flange rating shall be 11/2” 300# minimum.
Thermowell shall be used for thermocouples, bimetallic thermometers, filled system and
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 41 of 102

for temperature test points (TW).
Thermowells in vapor-liquid applications, inside columns, shall be located in the liquid

phase, unless otherwise dictate by process requirements.
Test wells shall be equipped with threaded plugs and chains.
The preferred mounting position of thermowells, in horizontal pipelines, shall be in the

upper half of the pipe.
For lines up to 3 inch size, the pipe shall be enlarged to 4 inches.
Thermowell material in general shall be of AISI 316L SS.
Immersion length of thermowells for different line sizes shall be as follows:-
Line Size Immersion length (U)
4" to 6" 280 mm
8" and above 320 mm
Vessels 400 mm
Immersion length is based on 200 mm length between flange face and inner well of pipe
and approx. 60% insertion in the pipeline. In vessels, where fouling with vessel internals
is expected, the immersion length shall be suitably modified. Other sizes and immersion
lengths may be considered based on special condition/actual requirements.
The design of the wells shall be verified by means of stress analysis, resulting from
stream velocity condition. The wake frequency shall not exceed 66% of the thermowell
natural frequency. Wake frequency calculation is required for all thermowells. Bidder has
to submit Wake frequency calculations for all thermowells as per latest PTC 19.3.
Velocity collars not to be used.
7.6 CONTROL VALVES
Valve types shall be selected, pneumatic diaphragm/piston operated globe, ball or

butterfly shall be selected taking into account such factors as piping, operating and
design conditions, fluid being handled, tangibility required, allowable leakage, noise and
other special requirements. The valves shall have smart electropneumatic positioners of
same OEM make as the valve. All control valves shall be provided with SMART valve
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 42 of 102

positioner with valve position signal feedback connected to DCS system by 4 to 20 mA
analog signal. It shall be HART compatible. Seat Leakage shall be chosen in accordance
with process demands and safe operation of the plant and in accordance with AISI
B16.104-1976. However, in general, the globe valves used shall be of class IV leakage
minimum as per ANSI B6.104 in general. Metal seated valves shall be preferred instead
of soft seated valves. Soft seat requirement shall be evaluated by PMC/Client on case to
case basis. However, in general, the globe valves used shall be of class IV leakage
minimum as per ANSI B6.104 in general. For vent services the leakage class shall be
class V or VI depending upon process requirement.
Safety shutoff valves must not be used in throttling service during normal operation.
Noise abating devices shall be provided with valves where noise level at the outlet of
valve at a distance of 1 metre all around is more than 85 DBA for valve which have
operating times of 5 minutes or more in general and which are only working during start
up and in upset conditions. For continuous operation the allowable sound level shall be
85 dBA. All noise abating plates, expanders, flanges, gaskets, studs & nuts shall be in
the scope of valve manufacturer. The noise abating plates shall be of wafer design for
easy removal for maintenance. Source treatment for noise shall be preferred over path
treatment and for high noise vent applications “DRAG” type trim shall be specified.
All valve bodies shall be cast or forged. Stainless steel bodies shall be acceptable inplace
of alloy steel bodies, if not available, for low temperature application.
The valve body, positioner and actuator body material shall be suitable to corrosive
environment. Suitable lining shall be provided inside wetted parts as per application.
Flanged bolted type gland packing boxes shall be used, unless other specified. Gland
packing shall normally be self-lubricating type. Packing shall be PTFE type up to 200”C.
For temperature above 200 “C, grafoil is to be used. Usage of asbestos is not allowed in
any part.
Bellows seals shall be used wherever gland leakage is not permissible like toxic /
hazardous product like carbon monoxide gas, etc.
As a minimum, trim MOC shall for all control/on-off valves shall be SS316L. By default, all
Guide MOC shall be hardened stainless steel like 440 C, 17.4 PH. For erosion service,
high pressure drop, cavitating service hard surfacing of plug and seat material, satellite
shall be used for all cases as specified in above point 22.1. Special cases valve may
require 17.4PH seat and 440C solid plugs or other material like Hastelloy, Monel,
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 43 of 102

Zirconia, duplex steel, etc. for severe services like steam, urea grade, carbamate
solution, acid, etc.
Mechanical stopper shall be provided as per process recommendations for Min/Max.

Flow condition.
On line replaceable trims shall be considered for all high pressure valves of butt-weld or
socket weld connections. Trim characteristics shall be equal percentage, unless
otherwise specified. For high erosion service or in steam service where, the delta P is
higher than 5 Kg/Cm2, hardened trim with stelliting shall be used. When this alone is not
sufficient, in such cases, special Anti-cavitating trim or shall be selected. In general, for all
trims, hardened full stelliting shall be used, as a minimum.
All on-off valves shall be ball type on-off valves only. The ball valves of up to 2” size shall
be floating ball design with full bore design, unless otherwise specified. Other ball valves
with higher size can be trunnion supported ball type design type.
For all shutdown valves on fire safe applications, air volume tank shall be supplied for the
storage of air volume for minimum 3 stroke operation.
Oxygen service valves shall be de-greased completely and certified for oxygen service
use. MOC for body shall be Monel and trim shall be Inconel 600 only.
Split body design for ball valves acceptable where top entry ball design has not been
considered for economical reasons. Mufflers shall be provided on ball valve vent air lines
for noise suppression. Spring loaded seat and hard chrome plated ball shall be a
standard feature for ball valves, in general. Wherever springs come into picture, vendor to
ensure corrosion resistant spring steels are provided.
All control valves/ Actuators (pneumatic & Motorised) shall be painted with corrosive
resistant epoxy paint. SS bug screen shall be provided for the exhaust ports.
All valve actuators shall be selected for a minimum operating air pressure of 4.0 kg/cm2g.
The actuators shall be diaphragm or piston actuators in general. Diaphragm actuators
with single or concentric multi-springs shall be used. volume tank with airlock relay ,
booster relays shall be avoided as far as possible.
Rotary rack and pinion pneumatic actuators may be used with ball and butterfly valves for
on-off services.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 44 of 102

In general, if otherwise not specified in the valve data sheet the time for full travel shall
not exceed 10 seconds.
Wherever handwheel is required with a valve the same shall be side mounted type.
All split range functions for valve operations shall be carried out in control system and
split range provision in valve positioners shall not be necessary.
Butterfly valve bodies shall be of wafer design. Lug type body shall be considered for size
above 12”. Face to face dimensions shall conform to ANSI B 16.10 and ANSI B 16.47
wherever applicable. Butterfly valves shall be used for high flow, low pressure drop below
10 kg/cm2g.
All instrumentation butterfly control valves shall be triple offset type only.
Non destructive test like radiography, ultrasonic, die penetration and magnetic particle
shall be carried out for cast and forged bodies conforming to procedures laid down in
ANSI B16.34. Radiography or ultrasonic test, if not specifically mentioned in the data
sheet, shall be carried out for cast or forged bodied of rating 900 lb. or above.
Valve bonnets shall be in general of bolted bonnet design as per ASME B 13.3 par 307.2
with minimum four bolts.
Smart E/P positioners with position transmitter along with valve signature software to be
provided for all control valves. It shall be HART compatible, The software shall be
provided for remote configuration and diagnostic analysis too.
Actuator sizing shall be done at 4 Kg/cm2.
Handwheel (Side-mounted) for All regulating control valves to be provided
By-pass valve provision shall be as per process licensor requirement.
The control valve % opening shall be at minimum flow 10-20%, for normal flow 50 to
70%, for maximum flow 75 to 85%.
All on – off application valve shall be fixed with necessary limit switches.
Valve Sizing shall be used on a maximum flow rate of approx. 1.5 time normal flow or 1.3
times the max. flow, whichever is greater, and the process conditions that exist at the
increased flow (Pressure and differential pressure). Valve lift shall be approximately 70 %
for equal percentage and 60 % for linear characteristic plug design at normal flow. It shall
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 45 of 102

be checked that the calculated and the selected valve also covers start-up and stop
conditions. In cases where over sizing shall not apply, it will be specifically mentioned in
the Instrument Data Sheets.
The fluid velocity at outlet flange shall not exceed 6 m/sec for liquids whereas the velocity
of gas or vapor shall not normally exceed 0.3 Mach under operating conditions. To meet
this, valves shall be selected having reduced trim, labyrinth plug or cage trim as
manufacturer standards.
Bidder shall submit the sizing calculations for all control valves.
Face to face dimensions of the control valves shall be as per ANSI/ISA-S75.03.
Direction of flow indication shall be engraved or embossed on the body.
Stroke time of the antisurge valves shall be 2-3 seconds and for critical services shall be
as defined by process licensor or as mentioned in individual data sheet.
7.6.1 Control Valve Test and Inspections
Valves shall be tested in accordance to individual specification which shall cover but not
limited to:
- Visual Inspection and dimensional check
- Liquid Penetrants examination on stellite coating as per ASME B16.34 ann D.
- Radiographic, ultrasonic, magnetic particle as per ASME B16.34
- Hydrostatic Body Test - Duration 3 min. (including all parts in assembled condition
like body, gland, all joints)
- Impact test
- Seat leakage test as per ANSI B16.104/FCI 70.2
- Performance tests and Functional tests
- Leakage test from actuators and seals and packings
- Diaphragm head test
- Complete actuator leak test

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 46 of 102

- Helium leak test for control valve with bellow seals
- Stroke calibration
- Stroke speed test
7.6.2 Limit switches / Position Switches:
7.6.2.1 All type of limit switches shall be 2 wire, proximity type sealed, intrinsically safe certified.
Limit switches shall be provided both for close and open positions for all shutdown
valves. The material of its construction shall be resistant to acid environment.
7.6.2.2 The make shall be P+F only. The sensor shall be generally cylindrical NAMUR sensor
type proximity switch. The diameter and sensing range shall be selected based on
application.
The MOC of sensor shall be SS316 or acid resistant body.
All limit switches sensor shall be adjustable with the threaded length and check nut
arrangement.
Flying lead type loose connections for NAMUR sensors are not acceptable. All these
NAMUR sensors installed on any instruments to sense the position shall be housed in a
closed box certified for weatherproof to IP65. The gland size shall be ½” NPT(F).
7.6.2.3 All ON-OFF type application valves taking in part in interlock/shutdown shall be provided
with Open and Close type NAMUR sensor as limit switches. The sensors along with
enclosure shall be installed in control valve in such a way that it can be removed with
ease for maintenance.
7.6.2.4 Limit switches shall not be used for Control Valves.
7.6.3 Actuators
7.6.3.1 Generally, control valve actuator shall be of the spring and diaphragm, pneumatically
actuated type. Standard air control signal to positioner shall be 0.2 to 1.0 kg/cm2g. For
larger dP shut offs, higher spring range/higher areas shall be considered.
7.6.3.2 Actuators shall be single acting type for all valves.
7.6.3.3 All valve actuators shall be designed with 1.5 times factor of safety.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 47 of 102

7.6.3.4 Piston type actuators (spring return type) with or without fail-safe capacity tanks (minimum
of 2 strokes to be possible in case of air failure) shall be considered for high-pressure drop
services or if actuator force requirements fall beyond the normal range of diaphragm
actuators. All actuators shall be adequate to fully stroke the valve under the
maximum differential pressure specified by the process requirements.
7.6.3.5 Air filter Regulator filter to be 5 micron. Miniature type, SS316L body & drain assembly etc
as parts of air filter regulator are not acceptable.
7.6.3.6 Actuators must be painted with corrosion resistant paints and all its springs must be
corrosion resistant spring steels. SS bug screen shall be provided for the exhaust ports.
7.7 DELETED
7.8 PRESSURE RELIEVING DEVICES
7.8.1 Pressure Relieving Devices

All Pressure Relieving Devices shall be sized in accordance with applicable local and
national code requirements. Formulas shall be in accordance with API RP 520, 1990 and
ASME Codes section I and VIII.
7.8.1.1 Percent Overpressure and Accumulation used in calculation of sizes of relieving devices
shall be :
Overpressure
3% - Steam services where ASME Power Boiler Code applies.

10% - Gas or Vapour service.
15% - For liquids and pump discharge lines with 6% system accumulation
(Power Boiler Code) and with 10% system accumulation (Pressure
Vessel Code)
21% - Fire exposure on unfired pressure vessels.
10% - Liquids for thermal relief of pipelines or vessels Accumulation
and the system is protected by means of multiple valves.
7.8.1.2 Nomenclature
Nomenclature used shall be in accordance with API RP 520.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 48 of 102

7.8.1.3 Safety and Relief Valves
Safety and Relief Valves shall normally be direct spring loaded type. Balanced bellows
valves shall normally be furnished for relief into closed flare and slowdown systems, if the
developed back-pressure exceeds 10% of the set pressure. Bellows shall also be
specified where leakage of gas from the seals are not permitted during normal plant
operation. Steam jacketing may be considered necessary to keep some valves and lines
warm at all the times to avoid the solidification of the lading fluid.
Full nozzle types of valves shall be specified for sizes 1” or above.
Test gags shall be furnished on all safety and relief valves. Test gags shall be removed
and transferred to Owners possession after testing, clearly labelled with the tag number
of the valve.
Lifting levers shall be furnished for exposed spring bonnets on valves on steam and hot
water services, on air valves and hot water service valves with closed bonnets.
Bonnet construction shall be plain closed bonnet for toxic and inflammable gases as well
as vapour and liquids. Exposed bonnet shall be specified for steam service and in Boiler
feed water service above 200°C. Bonnet extension shall be used above 400°C.
Springs shall be of carbon steel for normal process operating temperature of (-) 25°C to
200°C and tungsten alloy or high temp. alloy steel above 200°C. Stainless steel spring
may be used for services below (-) 25°C. Carbon steel is permitted above 200°C for open
bonnets.
Blowdown shall be between 5% to 7%. For steam services under Power Boiler Code as
per ASME the blowdown shall be 3% - 4%
All connections shall be flanged in general with facing and rating in accordance with the
piping specification or API 526 whichever is higher.
Centre to Centre dimensions shall be in accordance with API 526
7.8.2 Rupture Discs
Rupture discs may be used in lieu of or in combination with safety and relief valves,
where applicable or required. For disc rupture trip or alarm disc shall be with bursting
sensors.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 49 of 102

7.8.3 Pressure and Vacuum Relief Valves
Pressure and Vacuum Relief valves for storage tanks shall normally be of the weight
loaded or pilot operated type, and sized in accordance with API RP-2000 Tank Venting
Code, or Local Codes if they govern.
7.8.4 Thermal Relief Valves
For thermal relief of accumulated liquids in pipelines and vessels 1” x 2” size valves shall
be used in general.
7.8.5 Centre-to-Face
Centre-to-face dimensions shall be in accordance with API 526.
7.9 SWITCHES AND SOLENOID VALVES
7.9.1 Switches
Process switches, shall be realised through field transmitters only. If for some packages,
process switches are unavoidable same shall be provided with sealed micro switch
contacts rated for the specified application. Contacts shall be 1 no. DPDT preferably.
Otherwise 2 nos. SPDT can be considered. All switch contacts except those used in
intrinsically safe circuits shall be silver plated. Contacts used in intrinsically safe circuits
shall be suitable for the applications. Switches shall be hermetically sealed type.
Switches shall be connected through interposing relays.
7.9.2 Solenoid Valves
Solenoid valves shall normally be used to actuate other instruments/valves connected

directly to the process. The SOVs shall be SIL3, direct acting type (3/2 external pilot
operated, universal type, low power intrinsic safe type, with manual override and LED
indication). Protective enclosure shall be IP 67 and the coil insulation H class or better
suitable for continuous operation in 85 degree C ambient temperature (max. surface
temperature in sun) for outdoor service. Body materials shall normally be stainless steel
316. Solenoid valves will be powered by 24V DC or through barrier, insulation class ‘H’
and orifice size 9 mm. The D.C. solenoids shall not have in built rectifier to operate with
A.C voltage. The d.c. solenoids shall be used as an alternative to A/C solenoids only for
low current intrinsic safe operations.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 50 of 102

All solenoid valves shall be fitted with 1/2” NPT (F) SS 316 double compression cable
gland connection. The cable entry should be from bottom only and solenoid coils must be
hermetically sealed. SS bug screen shall be provided for the exhaust ports. The sealing
medium of the SOV’s will be EPDM or better (will be discussed during the detailed
engineering).
8.0 CONTROL SYSTEM (DCS/PLC)

DESIGN CRITERIA
EXPANDABILITY
Systems shall be designed with 20% installed pre-wired spare capacity for all I/O type
cards of each category for project development. The sparing supplied shall be for
“complete loop”; i.e. corresponding marshalling, power supply, terminals/barriers,
interposing relays, pre-fab cables other accessories, etc. and its space, and panel cut
outs where appropriate, etc.
To allow for future expansion 20% spare capacity shall be allowed & terminated in multi
core cables, junction boxes, marshalling racks, etc,
Communication networks and cables shall have a spare load capacity of 50% as a
minimum.
Plant wide networks shall have a node connection spare allowance of 50 % as a

minimum.
Local networks shall have a node connection spare allowance of 30% as a minimum.
including controller group display, trend, configuration display, alarm summary pages,
etc. There shall be both numeric and alphabet keys and dedicated function keys on
membrane type operator keyboard each of which must be freely programmable. There
shall be one no. of operator keyboard with each of the operator stations.
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 51 of 102

security levels.

Entry into the Marshalling Panels shall be through SS316 ET double compression cable
glands only.
PLC CONTROL SYSTEM
8.1 General
The operation and control of WTP/DM Plant shall be through Process PLC based Control
system.. The system shall be microprocessor based programmable logic control (PLC)
with fault tolerant redundant processors based on DMR/TMR/QUAD technology.
The PLC will be used to provide protection and controls for the entire plant.
Following minimum functions are provided on the OS (Operator station):
1. Area wise display of the plant.

2. Operation of the plant from the OS.
3. The schematics will be having dynamic parameters like valve open / close and motor
running/ fault indications
The Control system shall perform any of the following functions for safety of the plant from
control room.
- Total Shut Down
- Unit Shut Down
It will perform the following functions also:
Data Display
Process Control
Logging
Dynamic Graphics
System diagnostics
The following shall be adhered to while selecting the DMR system

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 52 of 102

a) Redundant CPU’s shall be applied.
b) If a CPU fails, the other(s) shall continue to operate. Single CPU operation system to
be certified to operate without any time limitation of faulty CPU repair.
c) Dual Redundant buses shall be applied.
d) All closed loop shall be Redundant
e) Redundant communication interfaces shall be supplied.
f) Redundant Power supplies (at least three in parallel) shall be supplied.
g) In the event of a failure of a fault tolerant component, power supply or other function, of
the system shall change over to "single mode" operation without causing nuisance trips
and also generate alarm on Operator and Engineering console.
h) In case of failure of complete processor system, i.e., system outputs shall take fail
safe state automatically unless otherwise specified.
Operator interface for critical trips shall be mosaic display with illuminated push button
for trip, reset, inactivation etc. and LED indication for each element of trip & actions.
The operator will be informed about a trip situation by a warning sound (to be different
from the audible signal from the alarm system), and a LED display will clearly inform
about the alarms in trip position. The first up alarm will flash.
Scan time shall be maximum 250 msec. CPU loading shall not exceed 50%, Bus
Communication modules, Power Supply and I/O cards shall have 100% redundancy
and fail safe certification.
System Redundancy
1. Controller 1:1
2. Communication Bus 1:1
3. I/O communication modules with CPU 1:1

4. Main data highway 1:1
5. Communication Cards 1:1

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 53 of 102
6. System Device 1:1
7. Power supply 1:3

8. History 1:1
9. Modbus/Serial interface 1:1
10. OPC server: OPC server, If applicable shall have RAID-5 configuration with firewall.
11. System server (for server based PLC): Redundant (1:1 redundancy)
However, lamp drive cards, supporting mosaic need not be redundant also. Active
isolator/barriers need not be certified for fail safe operation.
The operator can bypass trip alarm inputs, which may be necessary in abnormal situations.
A lamp shall indicate that the trip alarm is inactivated. The operator will be warned by
sound and fast flash if the inactivated circuit goes in alarm status.
The system shall include an event recording system, and it shall be considered to store
about 500 events. The system should have SOE backup facility for 30days. Sequence
event recorder (SOE) of 1 msec, resolution to be envisaged.

The mosaic panels shall be mounted on auxiliary consoles of PLC operating console.
Consumables like printer paper, cartridges, fuses etc shall be supplied along with the PLC
control system for a minimum period of one year duration.
Loading philosophy ( with 20% installed spares and 20% future expansion).


PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 54 of 102

8.2 PLC requirements
a) All systems' all cards shall be supplied with ISA G3 level or equivalent coating for
environmental protections.
b) ISOLATIONS
If individual channel to channel isolation is not available with system vendor, then only
Isolation shall be provided in a group of 4 channels as per system vendor design.
c) PANELS:
Electrical / Instrument panels, Third party device panels, etc.
d) All A/D converters of system I/O cards shall have resolution of min. 13 bits and all D/A
e) There shall be 20% installed spares minimum 1, installed and wired capacity for I/O
f) All marshalling and system panels shall have minimum 20 % wired spare capacity for
g) I/O cards’ Channel density shall not exceed the following limits:

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 55 of 102

Digital Output 16 Channels
h) Maintenance override switches (MOS) shall be soft type. One hardkey shall be
provided in Auxiliary console for the Activation of the MOS.
Process override switches (POS) shall be soft type.
i) Auxiliary Hardwired console
Auxiliary consoles shall be provided for high priority discrete hardwired safety
functions, which shall be manually operated. The console shall be installed adjacent
the operator station console, near 22” TFT/LED color monitors in the control room.
The console shall be equipped with, Mushroom top Emergency push buttons for
emergency shut-down action only. All Emergency stop and manual start/stop push
buttons shall drive an interposing relay located at IRC. For all critical electricals
drives (list will be discussed separately during detailed engineering), the spare
contact of final DO command from PLC going to MCC, must be connected as DI into
PLC and configured in SOE for confirmation of command to MCC from PLC.
All trip parameters shall have override switches and their output status lamp on
console.
j) All interlock and control transmitters shall be separate right from field junction box to
marshalling panels
k) Those parameters, which are directly or indirectly tripping the plant or may cause
production loss, shall be wired with 2 out of 3 transmitter trip voting interlock in PLC.
There shall be three separate analog input channels in three different cards. AI cards
shall be used for this purpose in system. Same thing is applicable to Digital inputs
also.
8.3 System Cabinets
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 56 of 102


8.3.2 Sequence of event (SOE)
and visualization operations to the dedicated SOE workstation, located on the consoles of
Engineering room in CR, to aid in diagnosis and recognise the first cause of plant or
equipment shut-down.
rate of 5000 events/day (shall be finalised during detail engineering ).
8.3.3 System Clock
The PLC control system clock shall have facility for synchronising with a Main plant DCS
through hardwire DI signal. Bidder shall consider Ethernet port/TCIP for synchronising to
PLC/DCS control system and Main plant DCS shall be consider by the bidder.
8.3.4 DELETED
8.3.5 Power Supply
An uninterrupted Supply to PLC system shall be provided to the power distribution cabinet
of PLC system at 115VAC +/- 10%, 50Hz +/- 3%. UPS feeders from ACDB to DCS/PLC

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 57 of 102

loads shall be redundant whereas UPS feeders for Non-Control system loads shall Non-
redundant, The Contractor shall prepare a list Non-Control system UPS load requirement.
110 VAC UPS Power supply feeder failure alarm before PDB shall be provided in PLC by
using double pole MCB in PDB. One contact of these MCBs shall be wired to PLC for alarm
purpose. Single point Power supply shall be provided at Main Control Room / SS, all cable
supply & laying, termination, any work related execution of this package shall be in bidder
scope.
24V DC power supply
DCS/PLC system.
same shall be wired to DCS/PLC for Power supply health monitoring and indication
from all BPS.
time on the system.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 58 of 102

cabinet.
connected to DCS/PLC as a separate DI signal. All Diode O rings Failures shall be
connected to DCS/PLC as a separate DI signal. All power feed Modules shall be connected
to DCS/PLC as a Separate DI signal. All MCB healthiness feedback shall be connected to
the DCS/PLC as a Separate DI signal. Silver/Cu/humidity/temperature monitoring shall be
with 2 nos. of C/R with indication in DCS/PLC.
8.3.6 Annunciator
The Annunciator display stations will consists of:

- LED Lamps
- Split type architecture with lamps and electronics separate

- All connections with interlock system cabinet and interlock marshalling cabinet shall
be through plug in connectors.
- About 20% spare capacity shall be there
- All switches and status lights indicated below shall be an integral part of Display
Modules.
- Supply shall include mounting accessories and about 20% of unassembled extra LED
lamps
8.3.7 Precision & Accuracy
8.3.8 PLC Spare Philosophy:

Marshalling 20%

Processor 50%
Marshalling 20%
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 59 of 102

8.3.9 DCS CONTROL SYSTEM
The control system shall be a modern Digital Distributed Control System (DCS) located in
the Control Room. The system shall be reliable, fault tolerant and build up in modules
from the suppliers’ standard components and software. The system shall have facilities
for plant control monitoring, alarm handling, shutdown & trip functions. It shall be self-
diagnostic, self documenting and contain all the functions necessary for advanced
regulatory control and trip functions.

The critical trip shall be displayed on a separate graphics available in control system.
All Emergency stop and manual start/stop push buttons shall drive an interposing relay
located at IRC. For all critical electrical drives (list will be discussed separately during
detailed engineering), the spare contact of final DO command from DCS going to MCC,
must be connected as DI into DCS and configured in SOE for confirmation of command
to MCC from DCS.
The control system shall comprise racks with I/O devices, control cards, CPU cards, hard
disk, system buses, and required number of operator stations with colour video display
units (VDU) with dynamic graphic generation capabilities to ensure complete access to
the process during normal operation, start-up, and upset conditions. The operator shall
use dedicated operator keyboards to manipulate the DCS.
The DCS shall have the following main components. Detailed specifications of each of
them are given in subsequent sections. The system shall be 100% fault tolerant and dual
redundant, except the redundancy at I/O cards levels. This means, all central control
processors, all communication processors and all other central rack and individual node’s
common cards, all the communication cards, networks and cables, etc. shall be 100%
fault tolerant and dual redundant, except individual IO cards of the system. All the system
hardware of DCS shall have ISA G3 level corrosion protection. All the hardware including
control/communication processors, networks, cables, all type of system cards, all type of

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 60 of 102

I/O cards shall be hot replaceable.
All operating consoles for control system shall be located inside the central control room
but their I/O units, marshalling cabinets, power distribution cabinets and engineering
station shall be housed in the adjacent room.
DCS Functions
The DCS will perform, as a minimum the following functions:
Data Display
Process Control & Trip/Interlock
Logging
Dynamic Graphics
System diagnostics
Trend: All the critical parameters (Temperature, flow, pressure, level, speed, vibration
etc) as well as the Closed loops (PV,LV, MV etc) the trend shall be recorded for every 1
second with the back up of minimum 4 days. Recording shall be on FIFO basis.
8.3.10 Data Storage and Retrieval
Data storage and retrieval will be provided on hard disc and on DVD or DAT. The trend
shall be recorded as follows:
Analogue signals
Last 3 days Every 1 second.
Last 7 days Every 1 minute.
Last 45 days Every 1 hour
Last 1 year Shift averages
Last 2 years Daily averages
Alarms Last 48 hours (Minimum)
8.3.11 DCS Operator Interface
For Details of OS/ES please refer Annexure -3 System configuration

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 61 of 102

One Emergency Stop push button station directly wired to MCC, should be provided for
all critical drives (if applicable). The spare contact of this emergency push button must be
mapped to DCS/PLC as a DI contact for SOE punching. All emergency push buttons and
stop push station must be provided with transparent safety covers.
8.3.12 Process Controller Cabinets
The process controllers will contain the microprocessor based system capable of
combining continuous, sequential and discrete functions in order to the requisition of
analog and discrete signals, sequential and continuous control.
The process controller cabinets shall/may have incoming and outgoing cable marshalling
facility. All field cables shall be terminated in marshalling cabinets in single tier WAGO
make cage clamp type terminals. Isolators shall be provided for all intrinsic safe input and
outputs. All thermocouple signal wiring from terminal to respective isolator/input card shall
be through extension wires corresponding to the type of thermocouple element used.
The signal I/O cards may also be installed in Process Controller Cabinets. Some
marshalling/I/O racks may be installed in remote safe areas by extending the system bus,
especially in MCC rooms where lot of inputs from drives shall directly be terminated in the
marshalling /I/O racks.
8.3.13 DCS Redundancy Philosophy
In order to increase the system availability and then the continuity of plant operation,
redundancy shall be provided as follows:
100% fault tolerance and dual redundancy in DCS shall be for Controller cards, all
communication cards and buses, all control buses, all type of common cards in the
system, all power supply modules, all I/O modules for closed loops and interlock I/Os,
buses, Ethernet modules. The failure of any single I/O module for open loop shall not
affect more than the channels being catered by that particular I/O card. Dual redundant
power supply modules for each dual redundant controller shall be dedicated.
8.3.14 Multiloop Controllers and Input/Output Cards

All multi loop shared controllers will be redundant with 1:1 redundancy. The control

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 62 of 102

processors shall be of fault tolerant type and both shall be active with cyclic changeovers.
All I/O cards for close loop applications shall be capable of holding the last value in case
of open condition of input. Input cards for specific open loop inputs used for calculation
functions must also be capable for holding the last value. As otherwise the same function
shall be built up in DCS software.
8.3.15 I/O Segregation:
The I/O card segregation for DCS shall be as per physical units of the plant.
8.3.16 Controller Loading
Each Controller loading shall not exceed more than 50% (hardware and software load of
each controller) in any case, after implementation of complete project and running at
peak load. In case more controllers are required to meet 50% loading criteria,
CONTRACTOR to include additional controllers without any cost implication.
8.3.17 DCS requirements
a) All DCS/ESD systems' all cards shall be supplied with ISA G3 level or equivalent
coating for environmental protections.
b) All digital output from DCS and ESD shall drive interposing relays of OMRON make, 4
Change over (4 NO/NC) with socket mounted relays with LED indicators and built in
surge suppressor. The contact rating shall be minimum 230 V AC/ 5 amps. Any DO
Channel from DCS/ESD shall not be directly connected to any devices without
interposing relays.
c) DCS shall be a large and expandable type system available with the vendor.
d) The system architecture shall be compliant to IEEE 802.XXX with dual redundant and
100% fault tolerant BUS/RING topology. System shall be fully open with
DDE/OPC&ODBC compliant. System availability shall be better than 99.95%.
e) DCS and ESDS I/O cards channel density shall be as per following:
I/O cards’ Channel density shall not exceed the following limits

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 63 of 102
RTD/T/C Inputs 16 channels
Digital Output DCS-32 Channels /ESDS-16 Channels
f) All I/O cards in individual category shall be of same type/model/revision only. No diff
bulk I/O cards or I/O cards with degraded features shall be accepted in any of the
category in a mix mode supply.
g) ISOLATIONS
If individual channel to channel isolation is not available with DCS / ESDS vendor,
then only Isolation shall be provided in a group of 4 channels as per DCS / ESDS
vendor design.
h) PANELS:
Electrical / Instrument panels, Third party device panels like wood word digital
governors, Bentley Nevada system hardware panels, etc.
i) All A/D converters of system I/O cards shall have resolution of min. 13 bits and all D/A
j) There shall be 20% installed spares minimum 1, installed and wired capacity for I/O
k) All marshalling and system panels shall have minimum 20 % wired spare capacity for

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 64 of 102
DCS System Redundancy
a. Controller 1:1
b. Input / output cards redundant

closed loops
c. Communication Bus 1:1
d. I/O communication modules with CPU 1:1

e. Main data highway 1:1
f. Communication Cards 1:1
g. System Device 1:1
h. Power supply 1:1

i. Serial (RS-485) Modbus (For Interlock PLC) 1:1
j. In case of client-server system, 1:1

server shall be redundant (Raid-6 Configuration)

I/O bus and I/O interface card at controller rack shall be redundant
Connectivity from Upstream redundant device to downstream redundant device shall be through
redundant device or cable.
Loading philosophy ( with 20% installed spares and 20% future expansion). Same philiosphy
applicable for PLC also.

8.3.18 Scanning Time
not more than 250 msec.
8.3.19 Other requirements
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 65 of 102

including controller group display, trend, configuration display, alarm summary pages, etc.
There shall be both numeric and alphabet keys and dedicated function keys on membrane
type operator keyboard each of which must be freely programmable. There shall be one no.
of operator keyboard with each of the operator stations.

security levels

Entry into the Marshalling Panels shall be through bottom mounted MCT blocks.
8.3.20 Consumables
One No. Spares like printer cartridges with each printer to be provided.
8.4 System Cabinets


PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 66 of 102

8.5 Sequence of event ,SOE (as feature of ES )
and visualization operations to the SOE which shall be feature of ES station. (I.e this feature
to be provided in Engineering station) located in the Engineering room in CR, to aid in
diagnosis and recognise the first cause of plant or equipment shut-down.
rate of 500 events/day (or shall be discussed during detail engineering).
The SOE package of the offered system must have facility to generate a separate SOE file
for critical event trips that is all important events just before and just after tripping event.
Time stamping of the SOE must be generated directly from the controller and it must be as
latest ISA standard.
8.6 System Clock

The PLC/DCS control system clock shall have facility for synchronising with a Main plant
GPS clock system through hardwire DI signal & Ethernet port/TCIP for synchronising to
PLC/DCS control system and Main plant DCS, if any shall be consider by the bidder.
8.7 Power Supply

An uninterrupted Supply to PLC/DCS system shall be provided to the power distribution
cabinet of PLC system at 115VAC +/- 10%, 50Hz +/- 3%. UPS feeders from ACDB to
DCS/PLC loads shall be redundant whereas UPS feeders for Non-Control system loads shall
Non-redundant, The Contractor shall prepare a list Non-Control system UPS load
requirement.
115 VAC UPS Power supply feeder failure alarm before PDB shall be provided in PLC/DCS
by using double pole MCB in PDB. One contact of these MCBs shall be wired to PLC/DCS
for alarm purpose
24V DC power supply

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 67 of 102

DCS/PLC system.
same shall be wired to DCS for Power supply health monitoring and indication from
all BPS.
time on the system.
cabinet.
connected to DCS/ PLC as a separate DI signal. All Diode O rings Failures shall be
connected to PLC/DCS as a separate DI signal. All power feed Modules shall be connected
to PLC/DCS as a Separate DI signal. All MCB healthiness feedback shall be connected to
the PLC/DCS as a Separate DI signal. Silver/Cu/humidity/temperature monitoring shall be
with 2 nos. of C/R with indication in PLC/DCS.
8.8 Precision & Accuracy
8.9 DCS Spare Philosophy:

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 68 of 102

Marshalling 20%

Processor 50%
Marshalling 20%
Rack
9.0 LOCAL CONTROL PANELS
All local panels under the scope of package vendor shall follow the minimum
specifications listed below:
9.1 Panels shall be suitable for acidic environment. All field mounted panels shall be of FRP
material only. Sealings of the panel will be Silicone/EPDM or better, which will be freezed
during detailed engineering.
9.2 Panel shall be free standing close cabinets, constructed in sections of min. 1000 mm
wide. The panel construction shall be welded or bolted frame construction with upright
and and additional framing in modular construction. The panel front sheet thickness shall
be min. 3 mm. The front of panel shall be stiffened where necessary with profiles tack
welded to the rear. Top, sides and doors can be made out of 1.6 mm thick plate.
9.3 The panels shall have environmental protection conforming to IP 55 min.
9.4 Instrument air shall be provided for purging of local panels.
9.5 Panel face, sides and doors shall be sand blasted and cleaned before primer and two
coats of paints are applied. The colour of paint shall be bright grey. The final surface shall
be semi mat, free from blemishes and paint runs.
9.6 115V A.C. +/- 10%, +/- 3% Hz power at one point to the local panel shall be provided by
the client. Any other voltage level if required preferably 24 V, DC, the same shall be
arranged by the vendor. Redundant rectifier units shall be provided for the generation of
d.c.by the vendor.
9.7 Earthing lugs for both power and system earthing shall be provided by the vendor.
9.8 The wiring shall preferably contained in polymer ducts. Instrument safe wiring shall be
laid separately from others. The colour of IS wiring shall be light blue.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 69 of 102

9.9 Wago/weidmuller/Phoniex /Klippon type cage clamp type terminals shall be used for
cable termination and wiring. 20% terminals shall be kept as spares in each terminal strip
and box. Terminals shall be spring loaded with screws, single tier in general.
9.10 Gland plates shall be provided alongwith cable glands (ex. proof wherever required) in
each panel for cable termination.
9.11 A miniature circuit breaker shall be provided for each power supply with DI contact wired
to system.
9.12 All panels shall be provided with vibration dampening pads.
9.13 Each panel section shall be provided with illumination level of 300 Lux min.
9.14 Each Control panel shall be provided with set of cooling fans to maintain and protect the
installed Control system.
9.15 Name plate/labels shall be provided for each panel mounted instruments, equipments
and accessories mounted in the front or rear of the panel.
9.16 Purged panels shall be provided with purge fail alarm. Purge fail trip shall be provided
with a bypass switch.
9.17 The local panel must have power segregation at all levels. There shall be clear
segregation and isolation of power supplies for all the local panels (115 VAC /240 VAC
/24 VDC ).
10.0 PNEUMATIC TRANSMISSION
10.1 Output Signal
Output signal from all pneumatic transmitters shall be 0.2-1kg/cm2g.
10.2 Pneumatic Receiver Instruments
Pneumatic receiver instruments shall have receiver elements design for 0.2-1 kg/cm2g
input signal.
10.3 Pneumatic Transmission Tubing
Pneumatic transmission tubing for local transmission shall be ½”or ¼” OD stainless steel
tubing with SS316 fittings (inch).
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 70 of 102

10.4 Instrument Air
Instrument air required is available at 6.5 kg/cm2g and max. 70 degree C. However, the
air pressure can be down to 4.5 kg/cm2g for remote consumers. Design pressure is 10
kg/cm2g. Dew point is -40 degree C at line pressure.
Air Distribution Headers shall be as SS 304.
11.0 ERECTION , INSTALLATION & COMMISSIOING
The bidder shall be responsible for the installation, calibration & testing, commissioning of
the complete instrumentation and controls as defined in this specification as minimum. All
the instruments & systems installed by the bidder as per scope subject to inspection,
checking, calibration & testing to prove their operational fitness. Testing & calibration
shall be done by the bidder, if required , all the required tools, tackles, calibration
instruments, qualified skilled manpower for conducting these tests shall be provided by
the bidder.
Testing & calibration may be witnessed by representative Client/PMC and/or

manufacturer's representative.
LETTER WRITING : LETTER WRITING FOR ALPHA-NUMERIC TAGGING ( WITH

SYNTHETIC ENAMEL). :- Letter writing of different sizes on Instrument Panels/misc.
Instruments/ Equipments with synthetic enamel paints (Asian/ Jonson & Nicolson/ Berger
/Nerolac Make) suitable for a temp. of 100 degree Celsius for writing of letters, figures
etc. Job includes cleaning of surface on panels/instruments/misc. instruments etc. All
complete with labour and materials as per drawings, specifications, Name plate schedule
and directions of Engineer-in-Charge. (Supply of paints is in contractor scope).
11.1 INSTRUMENT LOCATION
11.1.1 The location of instruments, control valves. Including junction boxes shall permit easy
access from grade, permanent platforms or stairways for operation, inspection and
maintenance.
11.1.2 The use of portable ladder or mobile platform shall be limited to access root valves,
thermowells and line mounted flowmeters.
11.1.3 Locations shall be decided to minimize the possibility of damage from passing or falling
objects and the possibility of tripping hazard or obstruct on walkway.
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 71 of 102
11.2 INSTRUMENT CABLE
11.2.1 Overhead Runs
Instrument main cable tray from field junction boxes to main control building or local
control room shall generally be laid in aboveground cable tray with protection cover. Tray
protection cover shall be provided only for the tray on top of tray layer.
Instrument branched cable runs from junction box or local panel to each instrument in the
field shall also be routed aboveground and supported with trays, steel angles and
channels.
FRP perforated cable trays/cable ducts shall generally be used for main cable trays.
Single pair cables from instrument to junction box and branch cable tray shall be through
perforated FRP cable trays.
The scope of supply includes FRP perforated type cable trays, FRP accessories such as
Bends, tees, crosses, reducers & connector plates and accessories like bolts, nuts etc.
FRP trays shall be vinyl ester resin based and all tray shall be manufactured using the
PULTRUSION process.
For Signal 900mm/ 600mm tray and for power 600mm/ 300 mm tray to be considered or
shall be discussed during detail Engineering.
Cable tray segregation shall be based on the voltage level. Cable tray shall be supported
at every 3M. 20% spare to be considered in the cable tray filling.
Instrumentation cables that form part of intrinsic safe (IS) circuits, if any, Shall be
segregated from other instrument signal cables.
Instrument power supply (AC) cables shall not run in the same tray of instrument signal
cables. Cable tray shall be dedicated for laying instrument power cables separately from
the signal cable tray.
Alternatively, cable ducts of suitable size shall also be considered for main cables. When
common cable ducts are used for running both power and signal cables, necessary air
gap partition shall be used to segregate the cables.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 72 of 102

11.3 CABLES
The primary insulation material shall be XLPE (cross linked polyethylene) for all types of
multi pair cables as per IEC-60502/60840/IS-7098 Part-1. Inner and outer jacket shall be
made of extruded flame retardant 90 deg C PVC to IS-5831
All cables shall be FRLS zero halogen as per standard IEC 332-3 Part 3 Cat. A. Fire
resistance cables whenever specified shall be as per me 331 Cat. A.
The insulation grade shall be 600 V/1100 V as a minimum arid shall meet insulation
resistance, voltage and spark test requirements as per BS-5308 Part-2
All cables shall be armoured. Armour over inner jacket shall be of galvanised steel
wire/flat as per IS-1554 part I I lEC 502. All the cores of single pair or multi-pair shall be
twisted and numbers of twist shall not be less than 10 per metre.
For signal and control cables, inner jacket colour shall be black. Outer jacket colour shall
be light blue, for intrinsically safe application and black for others. For thermocouple
extension cables the inner and outer jacket colour shall be as per IS-8784.
L/R ratio of adjacent cores shall not exceed 40 H/ohm for cables with 1.5 mm2
conductor Electrical Properties of Cables shall be in line with EN50288-7:2005
Contractor shall ensure a minimum of 20% of quantity of each type of cables supplied as
spare including any special cable and in each multipair cables 20% pairs shall be kept as
spare.
11.3.1 Instrument Signal Cable
a) Single pair shielded signal/alarm cables shall be used between all field instruments
including switches and junction boxes/local control panels.
b) Triad cable shall be used between GDs/RTDs to JB/Transmitter respectively.
b) Multipair individually and overall shielded signal/alarm cables shall be used between
junction boxes/local control panels and control room.
c) The single pair/triad cables shall be 1.5 mm2 conductor size made of annealed
electrolytic copper conductor of 7 strands with each strand of 0.53 mm diameter.
Multipair cables with 1.5 mm2 conductor size shall have 7 strands of annealed
electrolytic grade copper conductor with each strand of 0.3 mm diameter. Multi triad
cable or multi pair cable with 1.5 mm2 conductor shall have 7 strand with each
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 73 of 102

strand of 0.53 mm diameter. Colour of core insulation shall be black blue in pair and
black, blue and brown in a triad.
d) Shield shall be aluminium backed mylar/polyester tape bonded together with the
metallic side down helically applied with either side having 25% overlap and 100%
coverage. The minimum shield thickness shall be 0.05 mm in case of single pair/triad
and 0.075 mm in case of multipair/triad cable.
e) Drain wire shall be provided for individual pair and overall shield which shall be 0.5
mm2 multi stranded bare tinned annealed copper conductor. The drain wire shall be
in continuous contact with aluminium side of the shield.
f) All multi pair cables shall have 6 pair/12 pairs only while multitriad cable shall have 6
triads/8/12 triads only. Size for multipair cable will be 1.5mm2 with drain and overlap
as above.
11.3.2 Cables and Multicore Cables for Solenoids etc.
Cables and multicore cables for such items as solenoid valves and flame detectors shall
normally have a conductor size of 2.5 mm2. However, conductor sizes for power cables
shall be co-ordinated with the Electrical Group to avoid too many different cable types.
Signals (4-20 mA or switch 'contact): 6/12 pair individually and over all shielded
(screened) and armoured, twisted, 1.5 mm2 conductor.
11.3.3 Thermocouple Extension Wires
a) Single pair shielded thermocouple extension cables shall be used between

thermocouple head and junction boxes transmitters/ local control panel mounted
instruments.
b) Multipair individually and overall shielded thermocouple extension cables shall be

used between junction boxes and main control room mounted devices.
c) The type of thermocouple extension cables shall be compatible with thermocouple

used. In addition the colour coding of the primary insulation shall be as per ANSI.
d) The cable shall have 16 AWG and 18 AWG solid conductors for single and multipairs
respectively.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 74 of 102

e) All thermocouple extension cable shall be matched and calibrated in accordance with
MC-96.1.
f) Shield shall be aluminium backed by mylar/polyester tape bonded together helically

applied with the metallic side down with either side having 25% overlap and100 %
surface. Minimum shield thickness shall be 0.05 mm for single pair and0.075 mm for
multipair cable. Drain wire shall be 0.5-mm2 multi-strand bare tinned annealed copper
conductor. The drain wire shall be in continuous contact with the aluminium side of
the shield.
g) Inductance shall not exceed 4mH/Km.
h) All multi-pair cables shall have 6 pairs/12 pairs only.
11.3.4 Power supply Cables
All power supply cables shall be as per IS-1554 Part I and shall have copper conductors.
Minimum conductor size shall be 2.5 mm2. The cables shall be PVC insulated and
armoured. The higher size conductors shall be used incase of long distance power cable
where voltage drops more than 3 volts than required supply.
Any other special cable required for instruments that should also be supplied as per
requirements. CONTRACTOR shall ensure that these cables are armoured type and
shall meet all other requirements.
11.3.5 OPTICAL FIBER CABLE
The Optical Fiber Cable (OFC) used shall conform to the following specification as a
minimum:
a) The OFC shall be CSTA (corrugated steel tape armored, electrolytically chrome
plated low carbon steel) armored cable.
b) The OFC shall have FRP strength member, loose tubes for single mode optical fibers
filled with moisture resistant jelly, moisture barrier of polymer coated Aluminum tape
or water swellable tape, inner sheath of HDPE and outer sheath of PVC.
c) Optical fibers shall be single mode fibers compliant to ITU-TG.652 and fibers colours
shall correspond to IEC 793-2 and 304. Optical fibers shall be coated with UV cured
double acrylic resin. It should not have any reaction with cladding or core material.
The coating should provide maximum resistance to micro-bending & abrasion and
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 75 of 102

ensure mechanical & optical strength. The coating shall be easily stripped with
mechanical tools.
d) The number of fibers in the OFC shall be decided depending upon the requirement
with 8 fibers as a minimum.
e) The cabled fiber attenuation shall be -S 0.37 dB/km for 13] 0 nm wavelength range
and 0.22 dB/km for 1550 nm wavelength range.
f) The tensile performance shall be as per . IEC 60794-1-2 E1 and with tensile load of
9.81 x 2.5 W (Where W= mass of 1 km of cable in Kg)Newton Or 2670 N whichever
is higher.
11.4 JUNCTION BOX
a) JB MOC shall be FRP and 4 mm thick sheet. Junction boxes shall be for IEC Zone 2
& Gas group IIA/IIB EExe. with acid resistant gasket (will be freezed during detailed
engineering).
b) In all JBs, cable entries shall be from Bottom only. Further after commissioning, all
JB’s should be covered with Aluminum tapes at its periphery to prevent water
ingress.
In general a junction box shall contain only signal of same class. The signal class is
categorized as following type:
i) Signal Level
 Analog
 Digital
 T/C
 Solenoid Valve
 Instrument Power
 Gas Detectors
ii) Type of protection

 Non IS, Ex d
 IS
c) All JB extra entries shall be plugged with SS316 plug. Each junction box shall be
provided with 2 multi-cable entries from the bottom of the junction box with one
plugged. All Cable entry shall be at the bottom only, and not from side or top.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 76 of 102

d) All spare cable cores shall be terminated in the Junction box, at the marshalling panel
end and wired through spare barriers / isolators or relays (as the case may be) right
upto the corresponding spare channel of I/O module.
e) All spares hole of JBs, T/C head etc to be plugged with metallic plugs. The metallic
plugs, Junction box hinges, Handle, DIN rail, Allen screws shall be SS 316 material of
construction.
f) For ease of identification shutdown JB’s shall be colored should be marked with RED.
g) Cable glands shall be provided with Cables shrouds. 20% spare terminals shall be
supplied in each junction box.
11.5 CABLE GLANDS
a) Contractor shall supply all cable glands required for glanding the above mentioned
cables both at field instrument and local control panel side, junction boxes side and at
control room side.
b) All cables glands shall be of SS316 ex-proof and they shall be double compression
type suitable for armoured cables. Glands shall be in line with Area classification
c) Flame proof glands wherever required 'shall be supplied with EX'd' certification.
11.6 INSTRUMENT VALVES AND MANIFOLDS
a) Contractor shall supply instrument valves (miniature type) and valve manifolds
wherever required.
b) Body rating shall be as per piping class or better. All valves and manifolds shall be
forged type only.
c) Valve body and trim material shall be SS 316L unless otherwise specified. Superior
trim material shall be selected as requirement by process conditions. Packing material
in general shall be of PTFE
11.7 INSTRUMENT IMPULSE LINES
a) In general ½” OD annealed seamless SS 316 tubing shall be used in preference to

piping.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 77 of 102

b) Tubing standard shall be used upto 600 # only where the same is required as per job
specification. For rating above 600 # and hydrogen/lethal service, only piping
standard shall be used. The tubing shall be 1/2" OD tube with all fittings suitable for
the same. Valves used shall be threaded. At the first isolation / root valve end suitable
pipe tag to tubing conversion fittings shall be used. For remote installation suitable
unions / couplings shall be used.
c) Piping standard shall be used for all installation where specified in job specification.
For rating upto 600#, the connection to the transmitters shall be with a male
connector and tubing 1/2" OD. For rating higher than 600 #, no tubing shall be used.
The connection to the transmitters shall be with 1/2" piping with flanges in between
piping standard, all pipes shall be 1/2" NB unless higher sizes required to meet the
"requirements, with all fittings suitable for the piping. All the joints shall be welded or
flanged as required. For instrument end connection i.e root valve of orifices and other
items, level gauges vent and "drain connection, seal welding shall be provided. For
non diaphragm seal instruments and instruments where provided with threaded
connection, no welding is required at instrument end
d) All instruments shall be provided with isolation, drain and/ or vent valves with
vent/drain end duly capped. This isolation valve shall be SS304 GATE type. It shall be
in addition to the first isolation /root valve provided on the pipe or vessel at instrument
take off.
f) For diaphragm seal type instruments, spacer ring with vent and drain connection
along with vent / drain valve with end capped.
g) Contractor shall supply flareless compression type of tube fitting and of three piece
construction with design similar to Swagelok/Parker Hannifen etc.
h) Socket-weld type forged pipe fittings of suitable material and rating shall be supplied
for pipe fittings. The minimum rating shall be 3000 #. Weld neck fittings shall be used
where socket weld type are not allowed by piping class.
i) All pipe fittings shall be according to piping material specification as per piping class
of the pipe on which instrument is connected. In case of vessel/equipment / reactor,
PMS of equivalent piping class shall be considered.
11.8 INSTRUMENT AIR SUPPLY DISTRIBUTION

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 78 of 102

Instrument air headers, pipes and distributors shall be of S.S 304. Instrument air manifold
shall be used for supplying instrument air to control valves and other instruments. These
shall be with 10 nos. of tappings and be with ½” NPT (F), SS 304 valves. From the
nearby air manifold, instrument air shall be supplied to the control valves. For the
purpose, all tubing shall be used shall be of SS316, ¼”, 1/2” OD, seamless tubes, laid in
perforated aluminium trays. All intermediate fittings shall be double compression, SS316
MOC, Swaglok /Parker make only.
Instrument air shall be provided at one point at battery limit. Package vendor has to
develop air distribution scheme.
11.9 MCT Blocks
Cable entry to main control room shall be through MCT blocks.
Entry into the Panels in the control room shall be through bottom mounted MCT blocks.
Bidder shall provide minimum 8+8x6 MCT frame along with multi-dia blocks with peeling of
arrangement and centre plug, with wedge, lubricant, stay plate. Bidder shall provide at
least 20% installed spares with mult-dia blocks with peeling of arrangement and centre
plug. ( Qty of frame shall be submitted by the bidder during bidding stage with typical
cable arrangement).
11.10 PROTECTION AND PAINTING
All exposed carbon steel parts to be painted shall be thoroughly cleaned from inside and
outside to remove scale rust, dirt and other foreign materials by wire brushing / sand
blasting as applicable. Minimum acceptable standard in case of power tool cleaning shall
be St. 3 and in case of blast cleaning shall be SA 2. as per Swedish standard SIS 055900-
1967.
 Non – ferrous materials. Austenitic stainless steels, plastic or plastic coated materials.
 Insulated surfaces of equipment and pre-painted items shall need not be painted.
 Stainless steel surfaces, both inside and outside. Shall be pickled and passivated.
 Machined and bearing surfaces shall be protected with varnish or thick coat of grease.
Depending on the environment the following primer and finish coats shall be applied:
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 79 of 102

1 Normal – Industrial Primer 2 coats of Red oxide
Zinc phosphate each 30-35 microns thick

Finish Coat 2 coats of synthetic enamel, each 25 microns (min.)
thick.
2 Corrosive – Primer 2 coats of epoxy zinc chromate, Each 35 microns
Industrial (min.) thick.
Finish Coat 2 coats of epoxy high build paint, each 100 microns
(min.) thick.
3 Coastal and Primer 2 coats of high build chlorinated rubber. Zinc
Marine phosphate, each 50 microns (min.) thick.
Finish Coat 2 coats of chlorinated rubber coat paint. Each 35
microns (min.) thick.
(Any values refer to dry film thickness).

Colour Band shall be provided on loading arm as per Product colour code at site.
11.11 THIRD PARTY INSPECTION

Al instrumentation shall be inspected by TPIA as per approved QAP / ITP plan. General
specification for Inspection & Testing is attached herewith further bidder to submit detailed
QAP/ITP for each item for approval /review by Client/PMC. Client reserves the right to
review / inspect / witness the items at any stage of inspection.
The list of approved inspection agency Is:‐
a) Engineering India Limited
b) Lloyds Register of Shipping
c) Project & Development India Limited
d) Mecon Limited
e) SGS India Pvt. Ltd.
f) RITES Limited
g) Det Norske Veritas
h) TUV Rhineland (I) Pvt. Ltd.
i) TUV India Pvt. Ltd
11.12 PACKAGING AND IDENTIFICATION
All packaging shall be done in such a manner as to reduce the volume. The equipment
shall be dismantled into major components suitable for shipment. All assemblies shall be
properly match marked for site erection.
Attachments, spare parts of the equipment and small items shall be packed separately in
wooden cases. Each item shall be appropriately tagged with identification of main
equipment. Item denomination and reference number of the respective assembly drawing.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 80 of 102

Detailed packing list in waterproof envelope shall be inserted in the package together with
equipment Each equipment shall have an identification plate giving salient equipment
data, make, year of manufacture. Equipment number, name of manufacturer, etc.
12.0 Storage Tank
Instrument design Philosophy shall be same as per section above.
For each storage tank 2 Nos. of Level measurement of two different principles shall be
provided (One ultraonic & one DP Type level measurement.)
13.0 CCTV System
Bidder shall provide 6 (minimum) nos. (3 for DM and 3 for ETP) of (2MP minimum) PTZ,
picture IP based digital video camera with inbuilt IR to be installed at strategic location of
the DM/ETP plant. Provision shall be made in the CCTV system to connect total 10 nos.
Of camera.
13.1 Closed Circuit Television system for the PLANT units shall consist of the following
elements:
a) High resolution charge coupled device (CCD) day & night, tamperproof color
camera
b) Auto iris zoom lens, pan and tilt, near & far focus, screen wiper, ON/OFF control
equipment, color monitor and video recorder system
c) Automatic computer based switching device including Quad splitter.
d) Ceiling hung CCTV monitors such that these can be suitably matched with control
room aesthetics by dimensions appearance etc.
e) Coaxial cables, control cables, optical cables, connector etc. of required type &
size.
f) video recorder located in Control Room.
13.2 The complete hardware and software for PLANT shall be procured by Contractor.
Contractor scope shall include:
a) Identification of suitable location for mounting cameras in the field. Contractor shall
coordinate the locations, with PMC/ owner.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 81 of 102

b) Installation of cameras and their associated accessories in the field shall be in the
scope of contractor. This shall include any structure, support or stanchion required
for installation and their accessories.
c) Cabling from respective camera to control room and termination of cables in the
field, as per recommendations by CCTV manufacturer. This shall include any
additional support or tray/tray space provision by contractor.
d) Coordinate with CCTV manufacturer/supplier during testing, pre-commissioning

and commissioning of complete system.
e) Bidder to provide facility to connect FO cable from central control room CCTV
network to WTP/DM plant network. Laying of these FO cables will be in bidder
scope.
f) In order to have Server connectivity with state & CPCB portal along with CCTV
cameras at effluent outlet effluent outlet, Emergency power supply shall be
connected to the CCTV, Server and illumination for availability of power all the
time.
14.0 TELEPHONE EXCHANGE AND ASSOCIATED ACCESSORIES.
BASIS OF DESIGN
The system and all the equipment shall conform with all relevant and the latest
edition of Indian, International, OISD and CCITT/ ITU standards using field proven
microprocessor based design techniques for all processing and control functions.
The exchange shall be based on a robust, reliable, virus protected, IP based
platform for connecting IP phones, Digital phones as well as Analog extensions. As
a minimum, the following standards shall apply.
a. IS: 2148 Flameproof enclosures for electrical apparatus.
b. IS:13346 General requirements for electrical apparatus for explosive gas

atmospheres.
c. IS:5572 Classification of hazardous areas (other than mines) for electrical installation
areas having flammable gases & vapours.
d. IEC:79(Applicable parts) Electrical apparatus for explosive gas atmosphere.
e. IS: 13408 Code of practice for the selection, installation & maintenance of electrical
apparatus for use in potentially explosive atmospheres.
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 82 of 102

f. IS: 13408 Code of practice for the selection, installation & maintenance of electrical
apparatus for use in potentially explosive atmospheres.
g. IS: 5571 Selection of equipment for Hazardous areas.
The offered exchange should be capable and equipped with requisite software /
hardware for networking with different EPABX Systems of other makes for feature
transparency.
The VOIP Box shall comply with the ITU-T, IEC Standards with latest amendments (if
any). The system shall support fax messages via IP trunking
The telephony system shall be interconnected with the PA/GA systems such that
communications can be automatically established by authorized subscribers of any of the
systems without operator intervention
The telephony system shall also be connected to the Public Switched Telephone
Network (PSTN) through the PABX, and shall comply with all the telecommunication
carrier’s requirements; technical compatibility between the public and private networks
shall be ensured.
SERVICE CONDITIONS
All the equipment shall be suitable for the site conditions as specified in design basis.
Indoor equipment shall be installed in a HVAC controlled environment.
AREA CLASSIFICATION
All the out-door equipments shall be suitable for installation in hazardous area and shall
be Flameproof to Ex-d IIC/T6 and weatherproof to IP67 as per IEC529, irrespective of
plant’s hazardous area classification,.
All the outdoor equipments shall have certification for use in Zone-1, Gas group IIC/T6,
irrespective of plant’s hazardous area classifications and by the recognized testing and
certification authorities such as ‘CMRI’ Dhanbad, BASEEFA (UK), UL (USA) etc., or the
relevant authorities of the country of origin.
Indigenous equipment for hazardous areas shall be approved by CCEO and all
flameproof equipment shall be under a valid BIS license.
The exchange shall be fit operate on the following power supply.
a) UPS Supply voltage 115 A.C. ±10%
b) Supply frequency 50 Hz ±3%

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 83 of 102

DESIGN SPECIFICATIONS:
The system shall comprise of fully microprocessor based digital central exchange(s)
consisting of system control hardware, which shall be located at central control room. It
should be an expandable system. The system shall have capacity of 50 extensions .The
systems exchange shall be extending up to 100 telephone lines. It should support IP /
Digital / Analogue phones. A redundant interface for connecting any other Telephone
Exchange.
An Internet Protocol (IP) based telephony system shall be provided. The Exchange shall
have facility of connection to the LAN system with POE switches
The Telephone Exchange shall be interfaced with FGS system via 2 wire, RS-485 serial
interface over MODBUS. The Telephone Exchange system shall provide general failure
alarm signals for presentation on the DCS system in the Control Room (CR).
The telephony system shall be interconnected with the PA/GA systems such that
communications can be automatically established by authorized subscribers of any of the
systems without operator intervention
The EPABX and a Main Distribution Frame (MDF) shall be located at control room.CPU
and power supply shall be provided with 100% redundancy. Each office (or equivalent)
telephone set shall dispose of two connection possibility points as a minimum. The
additional connection points could be used either to change location inside the room or
to add further telephone subscribers
The cable supply and installation rules shall follow the same rules than the
instrumentation cables. The telephone JB supply and installation rules shall follow the
same rules than the instrumentation items.The system shall have automatic broad
casting of alarm when a fire or gas alarm signal is initiated from the fire and gas system.
Bidder has to provide complete layout of the Telephone network in its scope of the
building. Complete supply, erection of the exchange system shall be in bidder scope.
Bidder has to provide complete system in fully working condition.
The IP EPABX system must support IP TRUNK (SIP (mandatory) and should permit
management of communications between SIP terminals and the traditional telephony
devices (IP, analog, private or public lines). Central exchange and switches shall be
provided with Redundant FO port. FO cable laying and supply will be in scope of others.
The offered exchange should be capable and equipped with requisite software /
hardware for networking with different EPABX Systems of other makes via QSIG
protocol (QSIG-SIP, QSIG-PRI, QSIG-Analog etc.) for feature transparency as per
ECMA Standards (QSIG over ISDN & IP trunks).
The EPABX shall be suitable for up to minimum 5 digit extension numbering scheme.
This numbering scheme should be flexible. System shall also allow mixed numbering
scheme (open & closed numbering).
EXCHANGE

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 84 of 102

The central exchanges shall be fully digital, microprocessor based freely programmable
exchanges, working independent of each other. Programming shall be by means of user
friendly menu driven software via a dedicated lap top, which shall also be supplied by the
system vendor. The specification of laptop shall be latest Intel hardware, Microsoft OS
and MS Office software at the time of supply. it shall be possible to program / re-program
the exchange through external laptop PC, using text/graphic editor, via USB/RS 232 or
other suitable interface. This shall enable the user to carry out the following operations
without any additional software. It shall be possible to interface the system with Fire
Alarm system via RS485 serial interface over MODBUS protocol and with the central
EPABX system via EPABX digital lines .The exchange shall have conference module.
Complete hardware racks related to both these exchanges shall be accommodated
inside control room at central cabinet room in a common panel/cabinet. The cabinet shall
be fabricated out of minimum 16-gauge sheet steel, naturally ventilated, dust and vermin
proof with IP-41 enclosure as a minimum. The panel shall be with swing out assembly of
plug-in-card racks.. It shall be possible to locate faults by monitoring from the cabinet.
The central exchange shall have a processor module for the control of the central
exchange. The exchange shall have a completely non-blocking type switching system
and associated circuitry for call recognition and acknowledgement. The offered system
shall be flexible and modular in construction with the possibility of expanding to a bigger
system in the future. All hardware necessary for fault isolation and troubleshooting shall
be supplied as a part of the cabinet along with each exchange.
The system shall have capacity of 50IP extensions. Bidder has to supply the following
number of telephones as a minimum for all the plant area and closed buildings.
Flameproof to Ex-d IP Telephones with with Weatherproof to IP67

IIC/T6 and weatherproof caller id display for telephone sets with
to IP67 telephone sets indoor use acoustic hood (wall
with acoustic hood (wall mount),
mount),
WTP/DM/ETP 6 Nos.
Analyser 1 No for each

shelters, if
any
Control Room 20 Nos.
MCC/Sub 2 No for each

stations
Other facilities 4 Nos.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 85 of 102

15.0 LOCAL AREA NETWORK (LAN) FOR CR
The Bidder shall lay the LAN required for Main CR area.
BASIS OF DESIGN
The system shall have as a minimum the following for CR:
1. Manageable L2 switch with 1G/10G port, Jack panel and cable manager. 50%
spare port shall be kept in L2 switch.
2. Switch shall have with 4 redundant Fibre optic port. One redundant Fibre Optic
Port shall be used for connection to main Plant LAN switch/servers.
3. Cabling shall be CAT6A cabling. UTP CAT6A cabling shall be done with one
spare cable.
4. 24 Nos 6 m/Cat6a patch cords for end user
5. Cable and passive components shall be from AMP. I/O
16.0 Training
Supplier shall train Clients’ maintenance engineers as well as operations staff in his
works at Vendors Center of Excellence. The training imparted shall be by qualified and
experienced staff available. It shall be exhaustive and aimed at making clients’
maintenance & operations staff self reliant for most of the day to day applications. For
training, supplier shall make available as close a model of the system with all the
representative nodes, as the actual system to be installed. It is envisaged that following
be covered in the training:

Operating Staff Training
Operating courses include all aspects involved in operating the Control System from
operator interface. This shall include operation under normal and abnormal conditions as
may result from minor or major system malfunctions such that the trainee can take the
appropriate remedial actions. The training shall include but not be limited to the following:
• Overview of the system
• Control philosophy

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 86 of 102

• User interfaces
• Messages and alarms
• Operator commands
• Generation of reports
• Predictable events and expected operator action
Engineering staff training
Software Design courses shall be provided which would train the Employer's
Maintenance and Design staff to be able to identify and remedy software faults, upgrade
and implement data and software changes, generate/develop new software for the
purpose of improving the system and production of revised or new displays. The training
• Overview of the system architecture, hardware and software
• Software design and organisation
• Database structure, generation and modification
• Generation and modification of the VDU screen
• Customization of report/chart/graph format
• Assembly, compilation, linking, editing, debugging, distributing, testing and integration

of program modules
WARRANTY
Bidder shall be fully responsible for the manufacture in respect of proper design, quality,
workmanship and operation of all the equipment, accessories etc. related to control
system DCS/PLC supplied by the vendor for a period of 12 months from the preliminary
acceptance (date of commissioning) i.e. Warranty or Defects Liability period shall be 12
months from Preliminary acceptance

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 87 of 102

17.0 FAT/SAT
Bidder to consider FAT/SAT for the offered system in his scope of supply. FAT/SAT
procedure.
FAT – Factory Acceptance Test
FAT is inspection for verification that all equipment and devices function properly with
integrity.
Prior to notification of FAT to Client/Purchaser, all the involved contractual

documentation shall be completed and all the cabinets, equipment and components of
Control system shall be assembled and installed in one area at one time.
Bidder shall demonstrate all the functions of the PLC working properly in FAT. Each test
shall be carried out on the procedure reviewed and accepted by Client/PMC/Purchaser
after submitting Manufacturing Internal Test Certificate.
FAT certificate shall be issued by bidder at the successful end of the test activities. All
the hardware and software failures and problems shall be documented. All the failures
and problems shall be resolved before shipment to site, All series of actions shall be
taken in accordance with the FAT procedure.
FAT will start with Visual Inspection including the following activities as minimum;
 Quantity of all the cabinets, equipment and components.

 Installation of all the cabinets, equipment and components.
 Tagging of all the cabinets, equipment and components.
 Wiring of all the cabinets, equipment and components.
Once Visual Inspection has been successfully completed, Hardware Testing shall start
including the following activities as minimum;
Power-On
 Redundancy of Power Supply on failure

 Diagnostics of the main equipment
 Redundancy of the main equipment on failure
 Redundancy of network on failure

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 88 of 102

 100% I/O Accuracy Check at 5 point (0%, 50%,100%,50% and 0%) for all the
hardwired points (sample check may be allowed if 100% I/O Accuracy has been checked
Manufacturer Internal Test)
Once Hardware Testing has been successfully completed, Software Testing shall start
including the following activities as minimum;
 I/O Database implementation

 Graphic implementation
 Control implementation
 Logic and sequence implementation
 Historian implementation
 SER implementation
 AMS implementation
SITE ACCEPTANCE TEST (SAT)
SAT is inspection for checking that all the conditions are good after installation at site.
Prior to notice of SAT to Client/Purchaser, bidder shall submit all the "As-Shipped"
documentation incorporating all the FAT correction.
Prior to start SAT, all the cabinets, equipment and components of PLC shall be installed
in proper location as designed.
Bidder shall demonstrate all the function of PLC working properly in SAT. Each test shall
be carried out on the procedure and its criteria reviewed and accepted by
Client/Purchaser.
Test certificate shall be issued by bidder at the successful end of the test activities. All
the hardware and software failures and problems shall be documented.
SAT shall be identical to FAT but at reduced amount to check hardware without any
damage, installations completed properly and interface working properly. bidder shall
provide special tools and test equipments.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 89 of 102

ANNEXURE -1
INSTRUMENT ACCURACIES
The instrument reference accuracies shall be as per the table below. Accuracy of the
Instruments shall be minimum as follows. Custody Transfer accuracies shall be as defined in
the ITB in terms of rms.
Type of Instrument Accuracy

Process Gas Analyzer – All type +/- 2% FS
Conductivity , pH meters +/- 0.5 % of Reading
Belt weighers +/- 0.5 % of range
SILICA Analyzer +/-0.5 ppb or better
Sodium Analyzer ±5 % of reading or better
Chlorine Analyzer ± 2 % or better
Differential pressure & Pressure transmitter - SMART ± 0.050% of span within TD ratio of 1:
100 or better
Diaphragm seal transmitter & Pressure transmitter - ± 0.050% of span within TD ratio of 1:
SMART 100 or better
Variable area type flow meter with transmitter ± 2.0% FS Note (1)
Vortex flow meter ± 0.7 % FS
Positive displacement flow meter
- Others ± 0.5% FS
- Turbine meter or Mass flow meter
- Others ± 0.5% FS
- Magnetic type flow meter ± 0.5% FS
- Mass flow meter (Coriolis Type) ± 0.1% FS
- Ultrasonic type flow meter ± 0.5% FS
- Ultrasonic type flow meter( 5 – path) ± 0.1% FS
Orifice plate : Normal Application +/- 2% of flow rate
Orifice plate : Special Application +/- 1.5% of flow rate
Venturi +/- 1 % of flow rate
- Displacement type level indicator ± 1.0% FS
- Displacement type level transmitter ± 0.2% FS (Smart)
- Tank gauge (Custody Transfer) ± 1 mm with +/- 1 mm resolution
- Servo type tank gauge ± 2 mm (up to 20 m height)

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 90 of 102

- Radar type tank gauge ± 1 mm or better for custody transfer
± 5 mm or better for normal application
± 0.2% of span within TD ratio of 1: 100
- Pressure gauge ± 1.0% of span for Bourdon type , 1.5%
for diaphragm
- Temperature Transmitter ± 0.15 % of calibrated span for RTD &
T/C
- Filled system/Bimetallic ± 1.0% FS
- Small size pressure gauge ± 3.0% FS
- Draft gauge ± 3.0% FS
- Receiver gauge ± 1.5% FS
- Thermocouple & Resistance Bulb Applicable Codes/Standards
Note: 1. Vendor's standard accuracy is applied to local indicator type
Remarks: 1. Accuracy of instrument and special articles except for the above mentioned instrument
shall be in accordance with the applicable codes/standards, or Vendor's standards as
approved by Purchaser.
2. FS: Full scale.
3. Overall rangeability of transmitter except for draft range shall be 1: 100. Draft range
transmitter rangeability shall be 1: 30 for the accuracy indicated above.
4. Accuracy for the instruments shall be % of reading and shall be supplied with wet
calibration certification.


PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 91 of 102

ANNEXURE -2
Field instrument connections shall be as follows.
Instrument Type Process / Vessel Instrumentation

Connection Connections
DP Flow Instruments ½” NPT (M) ½” NPT
External Displacer on Vessel 2" Flanged 2" Flanged

Internal Displacer 4" Flanged 4" Flanged
External Ball Float on Vessel 2" Flanged 2" Flanged
Internal Ball Float 4” Flanged 4” flanged
Magnetic Level Gauge 2” Flanged 2" Flanged
D/P Level ½” NPT (M) ½” NPT
D/P Level with Remote Seal Diaphragm 3” Flanged 3” Flanged
D/P Level Direct Vessel Mounted 3” Flanged 3” Flanged
RADAR – Direct Mount on vessel 3" flanged 3" flanged
GW RADAR – Side/Side Chamber Mounted 2" flanged 2" flanged
on vessel (Min. Rating ANSI 300#)
Internal GWR on Equipment 4” Flanged 4” flanged
Special Level Instrument on Equipment 2" flanged 2" flanged
(Capacitance/ Ultrasonic/R.F.Probe)
Tank Level Instruments (Servo) on 6" flanged 6" flanged
Atmospheric tank/ Pressurized Equipment
Atmospheric tank clean service / Pressurized
Equipment
Atmospheric tank viscous service /
Tank Level Instruments (Capacitance/ 2" flanged 2" flanged
Ultrasonic/R.F.Probe) on Atmospheric tank /
Pressure Instruments ½” NPT (M) ½” NPT
Press.Gauge ½” NPT (M) ½” NPT
Pressure with diaphragm seal, 3" Flanged 3" Flanged
(Min. Rating ANSI 300#)
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 92 of 102

Pressure Instruments on Vessel 1 ½” Flanged ½” NPT
Pressure Instruments on Standpipe ¾” SW/BW/Flanged ½” NPT
Chemical Seal pressure Instrument gauge on 1 ½” Flanged ½” NPT

Vessel
Diaphragm Seal pressure Instrument gauge 1.5" Flanged 1.5" Flanged
on Vessel
Thermowell 1 ½” Flanged 1 ½” Flanged
Multipoint Temperature Element for Tanks 2" Flanged / 3" 2" Flanged / 3"
Flanged Flanged
Standpipe 3" Flanged -
Note:-
a. There shall be a separate tapping for each of the instruments on any pipeline/vessel. No
multiple instruments from one tapping is acceptable (for example PG and PT from single pipe
line tapping with single or double mechanical isolation valves are not acceptable). However,
as an exception to this, three transmitters on clean gas services from one orifice (with two
pairs of tapping) is acceptable, where multiple (2 out of 3, etc.) transmitters are to be
installed.
b. All type of instrument tapping flange rating shall be minimum ANSI 300#, irrespective of
minimum design pressure. However for pressure rating of 600# class and above, RTJ flange
shall be used. At few locations, double isolation valves shall be used as per table given
below.
PRESSURE LEVEL FLOW CONTROL

INSTALLATION TAPPINGS TAPPINGS ELEMENTS VALVE
RATING
300 # SINGLE SINGLE SINGLE SINGLE
600 # DOUBLE DOUBLE DOUBLE SINGLE
900 # / 1500 # / 2500
# DOUBLE DOUBLE DOUBLE SINGLE

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 93 of 102

Annexure ‐ 3
SYSTEM CONFIGURATION
PLC/DCS system package
in CR consoles
in CCR consoles .
1 Nos ES/OS (dual stacked) dual personality, 22” TFT, COLOR, LED type
1 no. of Membrane Operator’s Keyboard and 1 no. of QWERTY engineer’s
keyboards with mouse with each operator station
1 No. Annunciator with LED lamps with split type architecture
1 No Auxiliary Console
All USB ports must be blocked and the system must have latest anti-virus.
Printers
1 Nos A3 Heavy duty Colour HP make Laser printer
1 Nos A4 Black and White HP make Laser printer
(All printers shall have wireless facility)
Required furniture of GODREJ make shall be considered in the offer.
All the license required for OS,ES shall be in Bidder’s scope.

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 94 of 102

Annexure - 4
OPERATOR STATION SUB-SYSTEM
* Model No. _Note-1___
A. General Requirement
1 Number of Operator Consoles Three
2 Inter-changeability between operator consoles Required
3 On-line system diagnostics on Console Monitor Required at Module level
4 On-line configuration change Required
5 Console configuration Single
B. OPERATOR CONSOLE
1 Console's basic electronics Individual electronics for each monitor
μp Type 64 bit
μp Manufacturer/ model Note-1
Memory size /Cache size 16_GB (Vendor to check the suitability
of memory size)
2 Type of Database Functionally Separate
Database Storage Devices:
Sr. ITEM MODEL No. FUNCTION REDUNDANCY REMARK

No. (Refer Note)
1. HDD Note-1 REQUIRED 1 TB Min
2. Combo drive Note-1 REQUIRED
Vendor Note-1 REQUIRED
3.
recommended
4. REQUIRED
(Note: Full Redundancy is required if Centralized global database is provided)

STORAGE DEVICES ARE APPLICABLE IN EACH OPERATOR STATION.
3 Number of Devices (per console)

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 95 of 102

S. Description OF DEVICES NO. OF
TYPE OF DEVICE REMARKS
No REQUIRED DEVICES
22” TFT, COLOR, LED type dual

1. MONITOR stacked monitors 1 per console
(water package PLC architecture)
1 no. of Membrane Operator’s
2. KEYBOARD SETS Keyboard and 1 no. of QWERTY 1 per console
engineer’s keyboards with mouse.
ALARM & EVENT, 1 Nos A3 Heavy duty Colour –HP 1

3.
LOG A3 PRINTER make
7. DVD DRIVE 1 per console

1 No. Annunciator with LED lamps
ANNUNCIATOR
8. with split type architecture 1
KEYBOARD
4 Inter-changeability between Monitors Required
5 Spare memory requirement Min. 40%

6. Keyboard Set
a) Keyboard Security against unauthorized access Required with Key-lock
Note: Key-lock Password shall be provided for each operator console.
b) Maximum number of keystrokes for accessing views as per standard display

hierarchy:
S.No. TYPE OF VIEW REQUIRED OFFERED REMARKS
1. GROUP VIEW TWO
2. LOOP VIEW THREE
3. LOOP IN ALARM TWO
4. GRAPHICS VIEW TWO
c) Assignable function keys for single keystroke access Required

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 96 of 102

d) Number of Assignable function keys per Monitor 64
7 a) Number of devices for cursor control Two/Monitor
b) Devices for cursor control Keyboard [X] Mouse [X]
8 Monitors and Displays

a) Size of Monitor 22" diagonal
b) Type of Monitor TFT LED
c) Surface Treatment Hard Coating anti Glare
d) Length of tag number (characters) 16 alphanumeric
e) Length of description (characters) 24 alphanumeric
f) Display update rate 2s
g) Dynamic graphics Required
h) Multi Window Capability Required
i) Control through dynamic graphics Required
j) Screen displays and Call-up time
S.No. TYPE OF DISPLAY REQUIRED CALL-UP TIME(S)* REMARKS
1. OVERVIEW YES
2. GROUP DISPLAY YES
3. LOOP DISPLAY YES
DYNAMIC
4. YES
GRAPHICS
5. REAL-TIME TREND YES
6. HISTORIC TREND YES
7. ALARM SUMMARY YES
8. ALARM HISTORY YES
9. CONFIGURATION YES
10. DIAGNOSTIC YES
k) Display Hierarchy

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 97 of 102
S. SYSTEM
DESCRIPTION REQUIREMENT REMARKS
No. CAPABILITY
1. NO. OF OVERVIEW PAGES AS REQD.
2. NO. OF GROUPS/OVERVIEW AS REQD.
3. NO. OF LOOPS / GROUP 8
4. NO. OF GRAPHIC PAGES AS REQD.

NO. OF POINT IN ALARM AS REQD.
5.
SUMMARY
NO. OF POINTS IN ALARM AS REQD.
6.
HISTORY
7. NO. OF TRENDS PER DISPLAYS AS REQD.
8. NO. OF MULTI-TREND DISPLAYS AS REQD.
9. OTHERS AS REQD.
l) Multi Windowing facility Required

Note: Opening of more than four windows on the same Monitor shall be restricted by
the system .
m) Trending functions: Each Operator Console shall be capable of trending all analog
points.
n) Real-time trend
o) Historical trend
Time period 30 Days
9) Logging Function
a) Number of tags to be logged Required for ALL TAGS
b) Number of log reports:
Alarm History per shift
Event logging
Hourly logs
Shiftly logs
Daily logs
PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 98 of 102

Weekly logs
Shutdown report
Trip initiated log
Others (Note)
Note: Other log reports as required shall be furnished during execution stage.
c) Log formats User definable
10 System boot-up from Engineer console

11 Auto boot-up on power On Required
12 Storage disks
a) Type of storage disk HDD Optical (DVD)
b) Number of disks and capacity
Sl. NUMBER MEMORY CAPACITY PER

No. TYPE OF DISC (MINIMUM) DISK REMARKS
1 1 TB Min
HDD AS per latest configuration
One Per Monitor
2.
OPTICAL One Per Monitor AS per latest configuration
3. Other
13 Any other feature available as a standard:

a)______________________________________________________
b) ______________________________________________________
14 CPU Loading 60 %
15 Memory Utilization 60 %
16 Operating System Latest must have validation with the system
17 Antivirus/Network Security Required

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 99 of 102

ENGINEERING Cum OPERATOR STATION SUB-SYSTEM
 Model No. _______
1. Number of Engineering cum Operator Station One
2. Number of Monitors per Engg. Station One

3 Type of electronics Individual per Monitor
µP type 64 bit
Memory size NOTE-1
Model No. NOTE-1
4 Number of engineering keyboards One per Monitor
5 Number of Operation keyboards One per Monitor
6 Functional Capability Same as operator station subsystem
7 Basic functions of Engineering Console

a) System configuration and reconfiguration
b) Group & multi-groups alarm inhibiting
c) Plant views with/ without plant operation
d) Graphic page compilation
e) Setting/ resetting real-time clock
f) Loop tuning on selectable basis
g) System maintenance and diagnostics
8 Monitor specification As per operator station subsystem
9 Keyboard specification As per operator station subsystem

10 Data storage Devices and capacity
Sr. NUMBER MEMORY CAPACITY

TYPE OF DISC REMARKS
No. (MINIMUM) PER DISK
As per Latest
1 HDD One 1 TB Min
configuration
2. DVD writer One
As per Latest
3. OPTICAL(DVD) One
configuration
5. OTHER
11. Antivirus/Network Security Required

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 100 of 102
SEQUENCE OF EVENT (SOE)

*Model No.________
Offered System Details
1 Dedicated Sequence of Event Station Required
SPECIFICATIONS
1 Type Integrated with PLC system
2 Scan time Not more than system scan time
3 Resolution Required
Digital 1 msec [ X ] 10 msec [ ]
Analog 250 msec [ X] 100 msec [ ]
4 SOE PC Required
Function of PC:
Event Data Collection
Alarm Data collection

Diagnostics
History Data
SOE Printer Required
Alarm Data Storage Required
Storage Time 30 Days
5 Interfacing with:
PLC Yes

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 101 of 102
HARDWIRED CONSOLE
 Model No. ____By vendor
1. One no. of Hardwired/Aux. console:
2. Instrument Located on Hardwired consoles: (AS REQUIRED)
NUMBER REQUIRED ON HARDWIRED CONSOLE WITH

INSTRUMENT TYPE
CONSIDERED BY
VENDOR
ASSIGNABLE RECORDERS N.A.
HARDWIRED ANNUNCIATORS AS REQUIRED
INDICATING LAMPS AS REQUIRED
SWITCHES AS REQUIRED
PUSHBUTTONS AS REQUIRED
OTHERS AS REQUIRED
3 Power supply Alarm/Annunciator 110 V AC, 50 Hz [X]

4 Power supply for switches, lamps, pushbuttons etc. 24 V DC [X

PC150/E/4004/SEC-VI- 2
3.0 (PART-A)-5.4
RWTP-DMW-CPU-ETP
DOCUMENT NO REV
SHEET 102 of 102
ANNEXURE -5
Type of Inst to JB (1P,1T) JB to CR (6P/12P/6T/8T/12T) CR to MCC/MCC to CR

Signal (Multi‐conductor cable)
Size Type * Size Type Size (mm2) Signal
*(mm2) (mm2)
AI 1.5 Signal 1.5 Signal 1.5 Signal
AO 1.5 Signal 1.5 Signal 1.5 Signal
DI 1.5 Signal 1.5 Signal 1.5 Signal
DO 1.5 Signal 1.5 Signal 1.5 Signal
RTD 1.5 Signal 1.5 Signal 1.5 Signal
TC 1.5 Signal 1.5 Signal 1.5 Signal
GD 1.5 Signal 1.5 Signal ‐ ‐
SOV 2.5 Signal 2.5 Signal ‐ ‐
POWER 2.5 Power 2.5 Power 2.5 Power
TC Special compensation
Extension cable between
cable Element to
transmitter
RTD Triad cable between
Extension Element to
cable transmitter of
1.5mm2
Analysers 1.5 Signal 1.5 Signal or serial
communication
as the case
may be.
*Note : Above size is minimum. Further cable size may be increase based on voltage
drop calculation .

GSTD-0100 0
PROJECTS & DEVELOPMENT INDIA LTD Rev

SHEET 1 OF 5
GENERAL SPECIFICATION
FOR
INSTRUMENT TUBE FITTINGS


GSTD-0100 0
GENERAL SPECIFICATION FOR
INSTRUMENT TUBE FITTINGS Rev
SHEET 2 OF 5
1.0 GENERAL
1.1 Scope
1.1.1 This standard specification, together with the data sheets attached herewith, covers the
requirements for the design, materials, inspection, testing and shipping of instrument
tube fittings which includes the following type:
Stainless steel compression fittings (for stainless steel tube)
1.1.2 The related standards referred to herein and mentioned below shall be of the latest
Editions prior to the date of the purchaser's enquiry: -
ANSIIASME American National Standards Institute/American Society of Mechanical

Engineers
B 1.20.1 Pipe Threads General Purpose (Inch).
B 16.11 Forged Steel Fittings - Socket Welding and Threaded.
BS-4368 Carbon and Stainless Steel Compression Couplings for Tubes.
EN 10204 Inspection Documents For Metallic Products.
IS-319 Specification for free cutting Brass Bars, Rods and Sections.
ISA Instrumentation, Systems and Automation Society.
RP 42.1 Nomenclature for Instrument Tube Fittings.
1.1.3 In the event of any conflict between this standard specification, data sheets, statutory
regulations, related standards, codes etc., the following order of priority shall govern:
b) Data Sheets
c) Standard Specification
d) Codes and Standards
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to the vendor attached
along with the material requisition.
1.2.2 Whenever a detailed technical offer is required, vendor's quotation shall include the
Following;
a) Compliance to the specifications.
b) Whenever specifically indicated, detailed specification sheet for each item, which
shall provide the information regarding type, size, material of construction etc. of
GSTD-0100 0
SHEET 3 OF 5
the items. The material specifications and units of measurement for various items
in vendor's specification sheets shall be to the same standard as those indicated in
purchaser's data sheet.
c) Deviations on technical requirements shall not be entertained. In case vendor has

any valid technical reason to deviate, they must include a list of deviations item wise
summing up all the deviation from the purchaser’s data sheets and other technical
specification along with technical reasons for each of these deviations.
d) Catalogues giving detailed technical specifications, model decoding details and

other information for each type of instrument tube fitting covered in the bid.
1.2.3 All documentation submitted by vendor including their quotation, catalogues, drawings,
Installation, operation and maintenance manuals etc , shall be in English language only.
2.0 DESIGN AND CONSTRUCTION
2.1 Stainless Steel Tube Fittings
2.1.1 Nomenclature of all tube fittings shall be as per ISA RP 42.1.
2.1.2 Fittings shall be of flare less compression type having four-piece (for double compression
type) construction consisting of two ferrules, nut and body or three piece (compression
type construction consisting of single ferrule, nut and body suitable for use on tubes of
specified material for example stainless steel tubes conforming to ASTM A269 TP 316
with hardness in the range of HRB 70 to 79.
2.1.3 All parts of the tube fittings shall be of 316 Stainless Steel.
2.1.4 Hardness of the ferrules shall be in the range of HRB 85-90 so as to ensure a hardness
difference of the order of 5 to 10 between tube and fittings for better sealing.
2.1.5 Nuts and ferrules of a particular size shall be interchangeable for each type.
2.1.6 Spanner hold shall be metric.
2.1.7 Threaded ends of fittings shall be NPT as per ANSI B 1.20.1.
2.1.8 Specific techniques like silver plating shall be used over threading in order to avoid
jamming and galling.
2.1.9 Ferrule finish and fitting finish shall be such that there is no abrasion/galling when the nut
is tightened.
2.1.10 All instrument tube fittings in oxygen and chlorine service shall be thoroughly degreased
using reagents like trichloro-ethylene or carbon tetrachloride. End connection shall be
plugged after degreasing process in order to avoid entrance of grease or oil particles.
2.2 Copper Tube Fittings (Not applicable for this Project)
2.2.1 Nomenclature of all tube fittings shall be as per ISA RP 42.1.

GSTD-0100 0
SHEET 4 OF 5
Fittings shall be of flare less compression type and of three-piece construction consisting of
ferrule, nut and body Suitable for use on copper tubes conforming to ASTM B68 1B68M,
hardness not exceeding HRB 50.
2.2.2 All parts shall be manufactured from brass as per IS 319 bar stock and nickel plated.
2.2.3 For better grip, vendor shall maintain hardness difference between tube and ferrule and
indicate the same along with the offer.
2.2.4 Threaded ends of fittings shall be NPT as per ANSI B 1.20.1.
2.2.5 Spanner hold shall be metric.
3.0 NAMEPLATE
No separate nameplates are required on the fittings. However. manufacturer's name/trademark

should be punched on a visible place on the body of each fitting for easy identification.
4.0 THIRD PARTY INSPECTION AND TESTING
4.1 Unless otherwise specified, purchaser reserves the right to test and inspect all items at
vendor's works, inline with the inspection test plan for instrument tube fittings.
4.2 Vendor shall submit following test certificates and test reports for purchaser's review:
4.2.1 Type test reports for following tests in accordance with BS-4368ꞏPart IV:
a) Hydrostatic proof pressure test.

b) Minimum hydrostatic burst pressure test.
c) Disassembly and reassembly test.
d) Minimum static gas pressure (vacuum) test.
e) Maximum static gas pressure test.
f) Hydraulic impulse and vibration test.
4.2.2 Material test certificates as per clause 3.1 B of EN 10204.
4.2.3 Routine test reports for following tests:

a) Hydrostatic Test
Instrument tube fittings shall be hydrostatically tested at ambient temperature at
test pressures given in Annexure I of this specification. During and after the hydrostatic
test, the tube fittings shall not show any leakage or rupture.
b) Pneumatic pressure test
The fittings shall be tested at 7 kg/c mg of dry air. There shall not be any visible leakage
when immersed in water or coated with a leak detection solution.
c) Disassembly and reassembly test.
d) Hardness verification:
Hardness test shall be carried out on each rod used for machining ferrules. Vendor shall
ensure that after machining, the finished ferrules shall meet the required hardness given
in the specification.
d) Dimensional test report

GSTD-0100 0
SHEET 5 OF 5
4.3 Third Party Witness Inspection
4.3.1 All fittings shall be offered for pre-dispatch inspection for the following as a minimum:
a) Physical dimensional verification and workmanship on representative samples.
b) Hydrostatic and pneumatic tests as per clause 4.2.3 of this specification on
representative samples.
c) Hardness verification as per clause 4.2.3 of this specification.
d) Disassembly and reassembly test on representative samples.
e) Review of all certificates and test reports as indicated in clause 4.2 of this
specification.
4.3.2 In the event when no witness inspection is carried out by purchaser, vendor shall any way
complete the tests and test reports for the same shall be submitted to purchaser for scrutiny.
5.0 SHIPPING
5.1 All threads/ends shall be protected with plastic caps to prevent damage/entry of foreign matter.
5.2 All the fittings in oxygen and chlorine service shall be separately packed along with a
certificate indicating 'SUITABLE FOR OXYGEN/CHLORINE SERVICE', as applicable.
6.0 REJECTION
6.1 Vendor shall prepare their offer strictly as per clause 1.2 of this specification and shall attach
only those documents, which are specifically indicated in the material requisition.
6.2 Any offer not conforming to the above requirements, shall be summarily rejected.
Annexure- 1
Sr. No. Size of Tube Material Line Pressure Hydrostatic

Fittings No. Class Test Pressure
1 ¼”and ½” Stainless steel <600# 153 Kg/cm2 g

2 ¼” and ½” Stainless steel >=900# to 383 Kg/cm2 g
<=1500#
3 ¼” and 3/8” Brass 80Kg/cm2 g

GSTD-0101 0

SHEET 1 OF 9
FOR
INSTRUMENT TUBING


GSTD-0101 0
INSTRUMENT TUBING Rev
SHEET 2 OF 9
ABBRIVATIONS:
ID Inner Diameter
OD Outer Diameter
PVC Polyvinyl Chloride

GSTD-0101 0
SHEET 3 OF 9
CONTENTS
1.0 GENERAL
3.0 NAME PLATE
5.0 SHIPPING
6.0 REJECTION
ANNEXURES:
ANNEXURE - 1: MAXIMUM WORKING PRESSURE AND HYDROSTATIC

TEST PRESSURES FOR INSTRUMENT TUBING

GSTD-0101 0
SHEET 4 OF 9
1.0 GENERAL
1.1 Scope
requirements for the design, materials, inspection, testing and shipping of Instrument Tubing
which includes the following types: -
Stainless steel tubes
1.1.2 The related standards referred to herein and mentioned below shall be of the latest edition prior
to the date of purchaser's enquiry;
ASTM American Society for Testing and Materials.
A 269 Standard Specification for Seamless and Welded, Austenitic

Stainless Steel Tubing for General Services.
A632 Standard Specification for Seamless and Welded Austenitic

Stainless Steel Tubing (Small Diameter) for General Services.
B 251 Specification for general requirements for wrought seamless

copper and copper alloy tube.
B 251M Specification for general requirements for wrought seamless

copper and copper alloy tube (Metric)
B 68 Specification for seamless copper tube, bright annealed.
B 68 M Specification for seamless copper tube, bright annealed. (Metric)
E 243 Standard Practice for Electromagnetic (Eddy - Current)

Examination of Copper and Copper - Alloy Tubes
EN 10204 Inspection Documents for Metallic Products
1.1.3 In the event of any conflict between this standard specification, job specification/data sheets,
statutory regulations, related standards, codes etc. the following order of priority shall govern:
a) Statutory regulations
b) Job specification
c) Standard specification
d) Codes and standards,
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to vendor attached with the
material requisition.
1.2.2 Whenever a detailed technical offer is required, vendor's quotation shall include the following;

GSTD-0101 0
SHEET 5 OF 9
b) Whenever the requirement of a detailed specification sheet, is specifically

indicated, the specification sheet shall provide information regarding size, length,
construction, materials etc. of the Items. The material specifications and units of
measurement for various items in vendor's specification sheets shall be to the same
standards as those indicated in purchaser's data sheet.
c) Overall dimensions in mm/inch as per purchaser's specification.
d) Deviations on technical requirements shall not be entertained. In case vendor has any
valid technical reason to deviate, thc)! must include a list of deviations item wise.
summing up all the deviations from the purchaser's data sheet and other technical
specification along with the technical reasons for each of these deviations.
e) Catalogues giving detailed technical specifications; model decoding details and

other related information for each item covered in the bid,
1.2.3 All documentation submitted by the vendor including their quotation, catalogues, drawings,
installation and maintenance manuals shall be in English language only.
1.3 Drawings and Data
1.3.1 Detailed drawings, data, catalogues and manuals required from the vendor are indicated by the
purchaser in vendor data requirement sheets. The required number of reproducible, prints and
soft copies shall be dispatched to the address mentioned adhering to the time limits indicated.
1.3.2 Final documentation consisting of design data by the vendor or after placement of purchase order
shall include the following as a minimum;
a) Specification sheet for each type of tube.
b) Copy of test certificates of all tests indicated in clause 4.0 of this specification.
2.1 Stainless Steel Tubes
2.1.1 The tubes shall be 316 Stainless Steel fully annealed, and seamless and hot extrusion.
2.1.2 The hardness of the tubes shall be limited to HRB 70-79. Equivalent hardness as
Rockwell superficial scale (30T/15T) or Vicker's hardness scale shall also be acceptable.
2.1.3 Tubes shall have good surface finish and shall be free from scratches burrs etc. and
suitable for bending.
2.1.4 Maximum working pressure shall be as per Annexure - I attached with this specification.
2.1.5 Tubes shall preferably be supplied in length of 5 to 6 metres without welding in between.
Tube length less than 5 meters shall be rejected.
2.1.6 All tubes in oxygen and chlorine service shall be thoroughly degreased using reagents like
trichloro-ethylene or carbon tetrachloride and tube ends shall be plugged after degreasing
process in order to avoid entrance of grease or oil particles.

GSTD-0101 0
SHEET 6 OF 9
2.1.7 Stainless Steel Seamless Instrumentation Tubes should be Cold Finished and Bright Annealedas
per ASTM A 213 /A 269 / EN 10216-5.
2.1.8 Hot Extruded Mother Pipes must be used for manufacturing Seamless Tubes. It is not acceptable
to use Hot Pierced Mother Pipes. It should be followed by Cold Pilgering Process to ensure good
quality tubes from Hot Extruded Mother Pipes
2.1.9 With C <0.025% improves Corrosion resistance &Weldability with Special Chemistry
2.1.10 Nickel – 13% Minimum and Molybdenum – 2.50% Minimum
2.1.11 Hardness Controlled to < 80 HRB (It ensures easy Bending &Swaging)
2.1.12 Dual Certified Grades – 316 / 316L
2.1.13 IGC Practice as per ASTM A 262 Practice E
2.1.14 Complies to NACE MR 0175
2.1.15 100% Eddy Current Testing of Tubes as per ASTM A1016
2.1.16 Hydro Testing on Request
2.1.17 End Capped
2.1.18 Wooden Box Packing
2.1.19 Surface Finish Ra < 1.0 Microns on OD and 1.8 Microns on the ID Unpolished surface
2.2 Copper Tubes (Not applicable for this project)
2.2.1 Copper Tubes (PVC Jacketed)
a) The tube shall be soft annealed copper with 6mm OD and a wall thickness of
1.0mm as per ASTM B 68M copper No. C 12200.
b) The tube shall be jacketed with black PVC. The jacket thickness shall be 1.6mm.
The PVC jacket shall confirm to ASTM D-I047.
c) The tube ends shall be plugged prior to transportation.
d) The tube shall be continuous length without any brazing in between.
e) The length of single tube shall preferably be100 metres. However any tube length less
than 70 meters shall be rejected unless specifically required otherwise in job specification.
f) The dimensional tolerances shall be as per ASTM B 251M.
2.2.2 Bare Copper Tubes (For Steam Tracing)
a) The tube shall be soft annealed copper with 3/8" (10mm) OD with wall thickness
of 0.049" or 6mm OD with wall thickness of 1.Omm as per ASTM B6&.copper No.C12200.
b) The tube ends shall be plugged prior to transportation.
c) The tube shall be continuous length without any brazing in between.
d) The length of single tube shall preferably be 100 metres. However any tube length less
than 70 meters shall be rejected unless specifically required otherwise in job specification.
e) The dimensional tolerances shall be as per ASTM B 251.
f) Maximum working pressure shall be 53.0 kg/crrr'g at 38°C unless specified otherwise.
3.0 NAME PLATE
3.1 The following information shall he marked on the stainless steel tubes:
GSTD-0101 0
SHEET 7 OF 9
a) Name of manufacturer
b) Type and material grade of tube
c) Tube outer diameter and wall thickness.
4.1 Unless otherwise specified, purchaser reserves the right to test and inspect all the items at
vendor's works, in line with the inspection test plan for instrument tubing.
4.2 Vendor shall submit following test certificates and test reports for purchasers review:
a) Material test certificates as per clause 3.1B of EN 10204.
b) Hydrostatic test for stainless steel tube and bare copper tubes as per clause 4.3 of this
specification.
c) Pneumatic test for PVC jacketed copper tubes as per clause 4.4 of this specification.
d) Hardness / tension test for stainless steel tubes as per clause 4.5 of this specification.
e) Ball test for copper tubes as per clause 4.6 of this specification.
I) Eddy current examination of copper tubes as per ASTM E-243
g) Dimensional test report.
4.3 Hydrostatic test
4.3.1 Stainless steel and bare copper tube shall be hydrostatically tested at ambient temperature at
test pressures given in Annexure - 1 attached with this specification. During and after the
hydraulic test, the tubes shall not show any leaks or rupture.
4.4 Pneumatic test
PVC jacketed copper tubes shall be tested at 7.0 kg/crrr'g of dry air. During and after the test,
tubes shall not show any leak or rupture.
4.5 Hardness/Tension Test
All mother tubes shall be hardness tested for each heat prior to drawing for proper quality control.
The hardness of the drawn tubes shall be checked by Rockwell Hardness Test.
Following shall apply;
a) For tubing less than 0.6Sin (1.6Smm) in wall thickness, Rockwell superficial hardness test
on 30T / 1ST scale or Vicker's scale shall be equivalent to HRB 70 - 79.
b) Hardness test is not required for tubes smal1er than 1/4in (6.4mm) inside diameter or
tubes having a wall thickness thinner than 0.020in (O.Slmm). These tubes shall be
tension tested in accordance with ASTM A632.
4.6 Ball Test

GSTD-0101 0
SHEET 8 OF 9
4.6.1 Ball test shall be carried on all copper tubes to ensure clear opening of the tube. The OD of the
ball shall be minimum 1.0 mm for 6.0mm 00 tube and 2.0 mm for 3/8" (10mm) OD tube.
4.7 'Witness Inspection
4.7.1 All tubes shall be offered for pre-dispatch inspection for the following, as a minimum;
a) Physical dimensional verification and workmanship.
b) Hardness / tension test for stainless steel tubes.
c) Hydrostatic and pneumatic tests on representative samples.
d) Ball test on copper tubes on representative samples.
c) Eddy current examination of copper tubes on representative samples.
f) Review of all certificates and test reports as indicated in c1ause4.2 of this specification.
4.7.2 In the event that the witness inspection is not carried out by purchaser, vendor shall anyway
complete the tests and test reports for the same shall be submitted to purchaser for scrutiny.
5.0 SHIPPING
5.1 The tube shall be plugged at both ends to prevent entry of foreign matter.
5.2 The tubes shall be packed carefully so as to avoid damage during transport.
5.3 All tubes III oxygen and chlorine service shall be separately packed along with a certificate
indicating 'SUITABLE FOR OXYGEN! CHLORINE SERVICE', as applicable.
6.0 REJECTION
6.1 Vendor shall prepare their offer strictly as per clause 1.2 of this specification and shall attach only
those documents and information which is specifically indicated in the material requisition.
6.2 Any offer not conforming to above requirements, shall summarily be rejected.

GSTD-0101 0
SHEET 9 OF 9
ANNEXURE - 1 : MAXIMUM WORKING PRESSURE AND HYDROSTATIC

TEST PRESSURES FOR INSTRUMENT TUBING
Sr. Size of Tube (OD) Material Line Pressure Thickness Maximum Hydrostatic
No. Class Working Test
Pressure Pressure
1. ½” (12 mm) Stainless < 600 # 0.049” 102 Kg/cm2g 153 kg/cm2g
Steel
(1.2 mm)
2. ½” (12 mm) Stainless > 900 # to < 0.065” 253 Kg/cm2g 383 kg/cm2g
Steel 1500 #
(1.65 mm)
3. ¼” (6 mm) Stainless < 600 # 1.00 mm 102 Kg/cm2g 153 kg/cm2g

Steel
4. ¼” (6 mm) Stainless > 900 # to < 0.065” 253 Kg/cm2g 383 kg/cm2g
Steel 1500 #
(1.65 mm)
5. ¾” (10 mm) Copper - 0.049” 53 Kg/cm2g 80 kg/cm2g
6. ¼” (6 mm) Copper - 1.00 mm 53 Kg/cm2g 80 kg/cm2g

GSTD-0102 0

SHEET 1 OF 8
FOR
INSTRUMENT VALVES AND MANIFOLDS


GSTD-0102 0
INSTRUMENT VALVES AND MANIFOLDS Rev
SHEET 2 OF 8
Abbreviations
CWP Cold Working Pressure
NPT National Pipe Thread
PTFE Poly Tetra Fluoro Ethylene

GSTD-0102 0
SHEET 3 OF 8
CONTENTS
1.0 GENERAL
3.0 NAME PLATE
5.0 SHIPPING
6.0 REJECTION
ANNEXURE
ANNEXURE - 1: HYDROSTATIC TEST PRESSURES FOR INSTRUMENT
VALVES AND MANIFOLDS.
1.0 General

GSTD-0102 0
SHEET 4 OF 8
This standard specification shall be used for Instrument Valves and Manifolds.
2.0.1 The finishing and tolerances of parts like stem, piston, stem threading etc. of the offered
Valves and manifolds shall be properly machined to avoid problems like galling.
2.0.2 The hand wheel material for all valves and manifolds shall be zinc/nickel plated carbon steel.
Any other material, if provided as per standard vendor design, shall also be acceptable.
2.1 Instrument Valves (Miniature)
2.1.1 The instrument valves shall be of globe pattern needle valves forged bar stock with inside
screwed bonnet, with back-seated blowout proof system.
2.1.2 Body material shall be 316L Stainless Steel unless otherwise specified.
2.1.3 The minimum cold working pressure (CWP) rating of the valve shall be as per Annexure 1 of this
specification, unless otherwise specified.
2.1.4 The end connection shall be 1/2" NPTF to ANSI B1.20.1, unless otherwise specified.
2.1.5 Flow direction shall be marked on the body.
2.1.6 The valve dimensions shall be as follows:

a) End to end dimensions 76mm (approximately).
b) Height in fully open condition - 135mm maximum.
These dimensions are indicative only.
2.2 Valve Manifolds
2.2.1 3-Valve and 5-Valve manifolds:
2.2.1.1 3-Valve manifold

a) 3-Valve manifold shall be designed for direct coupling to differential pressure
Transmitters having 2 bolt flanges with 54mm (2-118") centre-to-centre connections and
41.3mm (1-5/8") bolt-to-bolt distance.
b) 3-Valve manifold shall contain two main line block valves and an equalizing by pass
valve. The valves shall be needle type. They shall use self-aligning 316LStainless Steel
ball seats, unless otherwise specified.
2.2.1.2 5-Valve manifold

a) 5-Valve manifold shall be designed for direct coupling to differential pressure
Transmitters having 2 bolt flanges with 54mm (2-1/8") centre-to-centre connections and
41.3mm (1-5/8") bolt-to-bolt distance.
b) 5-Valve manifold shall contain two main line block valves and a combination
Double block and bleed for the bypass line The valve shall of needle type or special ball
With bleed hole.
2.2.2 The flanges shall be integral part of manifold block.

GSTD-0102 0
SHEET 5 OF 8
2.2.3 The material of construction shall be 316L Stainless Steel, unless otherwise specified.
2.2.4 The minimum cold working pressure (CWP) rating of manifolds shall be as per Annexure
1 of this specification, unless otherwise specified.
2.2.5 The process connection shall be 1/2"NPTF to ANSI B 1.20.1.
2.2.6 Wherever the manifolds are specified for stanchion mounting, these shall be supplied
along with mounting accessories. The bolts and nuts MOC shall be ASTM A 193 Gr B7
and ASTM A194 Gr. 2H. Other accessories shall be zinc plated.
2.2.2 3 way 2 valve manifolds for pressure gauges
2.2.2.1 The manifold shall be designed for use with pressure gauges with block and bleed valves.
The manifold body shall be either straight or angle type as specified in the data sheet.
2.2.2.2 The valve shall be a needle type.
2.2.2.3 The body material shall be 316L Stainless Steel, unless otherwise-specified.
2.2.2.4 The minimum cold working pressure rating of the manifold shall be as per Annexure 1 of
this specification, unless otherwise specified.
2.2.2.5 The manifold shall have the following connections:
a) The inlet connection shall be %" plain ends with a minimum of 100mm nipple
Extension suitable for socket weld or butt weld as per B16.11/ B16.9 as
Specified in the job specifications
b) The gauge connection shall be with union nut and tail piece threaded to
½” NPTF.
c) The drain connection shall be ½” NPTF.
2.3 Instrument Air Valves
2.3.1 Instrument Air Isolation Valves (Miniature)
2.3.1.1 The valves shall be full-bore ball type with forged body.
2.3.1.2 Body material shall be 304 Stainless Steel
2.3.1.3 The minimum cold working pressure rating of instrument air isolation valves shall be as
Per Annexure 1 of this specification, unless specified otherwise.
2.3.1.4 The end connection shall be1/4'' NPTF to ANSI B 1.20.1, unless otherwise specified.
2.3.1.5 End to end dimensions shall be as per ASME B16.10.2000 (latest edition)
2.3.2 Instrument Air Needle Valves (Miniature)
2.3.2.1 The instrument valves shall be globe pattern-needle valves forged/bar stock with inside
Screwed bonnet.
2.3.2.2 Body material shall be 304 Stainless Steel.
2.3.2.3 The minimum cold working pressure of Instrument Air Needle valves shall be per
GSTD-0102 0
SHEET 6 OF 8
Annexure I of this specification. Unless otherwise specified.
2.3.2.4 The end connection shall be 1/4" NPTF to ANSI B1.20.1, unless otherwise specified.
2.3.2.5 Flow direction shall be marked on the body.
2.3.3 All instrument valves in oxygen and chloride service shall be thoroughly degreased using
reagents like trichloroethylene or carbon tetrachloride. End connection shall be plugged
after degreasing process in order to avoid entrance of grease or oil particles.
3.0 NAME PLATE
Following information shall be punched on the body of each of these items;
a) Material of construction to the same standards as in purchaser's data sheets.

b) Cold working pressure of each item to the same standards as in purchaser's data sheets.
c) Manufacturer's identification and model number.
d) Flow direction (if applicable)
e) Material of construction.
4.1 Unless otherwise specified, purchaser reserves the right to test and inspect all the items at
vendor's works, in line with the inspection test plan for instrument valve and manifolds.
a) Material test certificates as per clause 3.1B of EN 10204 for body and bonnet and as per
clause 2.2 for other parts.
b) Dimensional test report.
c) Pressure test report as per clause 4.3 of this specification.
d) Hydrostatic proof and burst tests as per MSS-SP-99 for each design and size of valve.
4.3 Pressure Test Requirements
4.3.1 Each valve and manifold shall be subjected to hydrostatic pressure test at ambient temperature
for both seat and shell leakage at test pressures given in Annexure-I of this specification. During
and after the hydrostatic test there shall not be any visible leakage.
4.3.2 Pneumatic Test
Each valve and manifold shall be subjected to pneumatic test for both shell and seat leakage at
7.0 kg/cm-g with testing medium as air at ambient temperature. There shall not be any visible
leakage when immersed in water or coated with a leak detection solution.
4.4 Witness Inspection
4.4.1 All valves and manifolds shall be offered for pre-dispatch inspection for following, as a
Minimum:
a) Physical dimensional verification and workmanship.

b) Pressure test as per clause 4.3 of this specification on representative samples.
c) Review of all certificates and test reports as indicated in clause4.2 of this specification.
4.4.2 In the event, when witness inspection is not carried out by purchaser, the tests shall anyway be
completed by the vendor and documents for the same shall be submitted to purchaser for
scrutiny.

GSTD-0102 0
SHEET 7 OF 8
5.0 SHIPPING
5.1 The threads/ends shall be protected with plastic caps to prevent damage/entry of foreign matter.
5.2 All instrument valves and manifolds in oxygen and chloride service shall be separately packed
along with a certificated indicating 'CERTIFED FOR OXYGEN/CHLORINE
SERVICE' as applicable
6.0 REJECTION
6.1 Vendor shall prepare their offer strictly as per this specification and shall attach only those
documents and information, which is specifically- indicated in the material requisition.
6.2 Any offer not conforming to above requirements, shall be summarily rejected.

GSTD-0102 0
SHEET 8 OF 8
Annexure-I
HYDROSTATIC TEST PRESSURES FOR INSTRUMENT VALVES AND MANIFOLDS
Sr. Item Line Pressure Minimum Cold Hydrostatic Test Pressure

No. Class working For
pressure(CWP)
Seat Shell Leakage

leakage Test
Test
1 Instrument valve ≤ 600# 102 kg/cm2 g 112 kg/cm2 153 kg/cm2 g

(Miniature) g
≥900# to ≤1500# 253 kg/ cm2 g 278 kg/cm2 383 kg/cm2 g
g
2 Instrument valve ≤ 600# 102 kg/cm2 g 112 kg/cm2 153 kg/cm2 g
(Manifolds) g
≥900# to ≤1500# 253 kg/ cm2 g 278 kg/cm2 383 kg/cm2 g
g
3 Instrument Air 27 kg/cm2 g 30 kg/cm2 g 41 kg/cm2 g
Isolation Valve
4 Instrument Air 27 kg/cm2 g 30 kg/cm2 g 41 kg/cm2 g
Needle Valves

GSTD-0103 0

SHEET 1 OF 8
FOR
JUNCTION BOXES AND CABLE GLANDS


GSTD-0103 0
JUNCTION BOXES AND CABLE Rev
GLANDS SHEET 2 OF 8
CONTENTS
1.0 GENERAL
2.0 DESIGNS AND CONSTRUCTION
3.0 NAME PLATE
5.0 SHIPPING
6.0 REJECTION

GSTD-0103 0
GLANDS SHEET 3 OF 8
1.0 GENERAL
1.1 Scope
requirements for design, materials, nameplate marking, testing and shipping of junction boxes
and cable glands which include the following types:
a) Electrical junction boxes

b) Pneumatic junction boxes
c) Cable glands (whenever specified)
1.1.2 The related standards referred to herein and mentioned below shall be of the latest editions prior to
the purchaser's enquiry;
ANSI/ASME American National Standards Institute I American Society.of Mechanical

Engineers.
B 1.20.1 Pipe Threads, General Purpose (Inch).
EN 10204 Inspection Documents for Metallic Products
IEC-60079 Electrical Apparatus for Explosive Gas Atmosphere
IEC-60529 Degrees of Protection Provided by Enclosures. (IP Code)
IS-5 Colours for ready mixed paints and enamels.
IS-13947 Specification for Low Voltage Switchgear and Control gear.
IS-2148 Electrical Apparatus for Explosive Gas Atmospheres – Increased safety
Enclosures ‘e'.
1.1.3 In the event of any conflict between this specification, data sheets, related standards, codes etc.,
the following order of priority shall govern:
b) Data Sheets
c) Standard Specification
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to vendor attached
along with the material requisition.
1.2.2 Deviation on technical requirements shall not be entertained.
1.2.3 Whenever a detailed technical offer is required, vendor's quotation shall include the following;
b) Whenever the requirement of a detailed specification sheet for each item is specifically
indicated, the specification sheet shall provide information regarding type, construction
material. Size and number of cable entries etc. The material specifications and unit of
measurement for various parts in vendor's specification sheets shall be to the same
standards as those indicated In purchaser's data sheets.
GSTD-0103 0
GLANDS SHEET 4 OF 8
c) Drawing for each type of junction box with dimensional details (in millimetres) showing the
terminal, entries arrangement, mounting details etc.
d) Proven references for each offered model in line with clause 1.2.4 of this specification
whenever specifically indicated in purchaser's specification.
e) Copy of certificate for approval of increased safety junction boxes, adapter, plug and
cable glands from local statutory authority as applicable such as Chief Controller of
Explosive (CCE), Nagpur or Director General Mines Safety in India along with:
i) Test certificate from recognised testing house like CMRl/ERTL etc. as per
relevant Indian Standard for all Indian manufactured items or items requiring
DGMS approval.
ii) Certificate of conformity from agencies like LICE, BASEEI:.A, PTB, CSA,
UL etc. for compliance to ATEX or any recognised standard for items
manufactured outside India.
f) Catalogues in English giving detailed technical specifications, model decoding details and
other related information for each type of junction box and cable gland covered in the bid.
1.2.4 All items, as offered, shall be field proven and should have been operating satisfactorily
individually for a period of minimum 4000 hours on the bid due date in the process conditions
similar to those as specified in the purchaser's data sheet. Items with proto-type design or items
not meeting provenness criteria specified above shall not be offered.
1.2.5 All documentation submitted by the vendor including their drawings, installation manual etc shall
be in English language only.
1.3 Drawings and Data
purchaser in vendor data requirement sheets. The required number of reproducible, prints and
soft copies, shall be sent to the address mentioned, adhering to the time limits indicated.
1.3.2 Final documentation consisting of design data and installation manual submitted by the vendor
after placement of purchase order shall include the following, as a minimum;
a) Specification sheet for each junction box and its accessories like cable glands etc.
b) Certified drawing sheets for each junction box and its accessories, which shall provide
dimensional details, internal constructional details (general arrangement details) and
material of construction.
c) Copy of type test certificates.
d) Copy of test certificates for all the tests indicated in clause 4.0 of this specification.
e) Installation procedure for junction boxes and its accessories
2.1 Junction Boxes

GSTD-0103 0
GLANDS SHEET 5 OF 8
2.1.1 Junction boxes shall be either of the following type as specified in data sheets.
a) Weather proof junction boxes.

b) Weather proof and increased safety junction boxes.
No other type of junction boxes shall be offered ,I supplied unless specifically indicated
otherwise.
2.1.2 Unless otherwise specified, the enclosure shall conform to the following standards:
Weatherproof housing : IP 65 to IEC-60529/IS-13947
Housing : EEx (e) as per IEC-60079/IS-2148.
2.1.3 Number of entries and their location shall be as per data sheets. Junction boxes with top entries
shall not be offered. The size of cable entries shall be as per the cable sizes indicated in the data
sheet.
2.1.4 Multi-pair junction boxes shall be provided with telephone sockets and plugs for connection of
hand-powered telephone set.
2.1.5 Electrical Junction Boxes
a) The material of construction of electrical junction boxes shall be SS316L of minimum 2

mm thick.
a) b) Weather proof junction box shall have hinged type door with Silicon/EPDM or
better gasket, which shall be fixed to the box by plated countersunk screws. JB’s should
be covered with Aluminum tapes at its periphery to prevent water ingress after final
commissioning.
c) Increased safety junction box shall have detachable cover, which shall be fixed to the box
by means of cadmium plated triangular head/hexagonal head screws.
d) Increased safety junction boxes for signal, alarm and control shall have the following
warning engraved/integrally cast on the cover; "Isolate power supply elsewhere before
opening"
e) Power junction boxes (junction boxes for power supply cable / distribution) shall have
either the warning cast or shall have warning plate with following marking;
"Isolate power supply elsewhere before opening".
Unless otherwise indicated in the job specification, power junction boxes shall be
suitable for incoming armoured power cable up to 150 sq.mm conductor size.
f) Terminals shall be spring loaded, vibration proof, clip-on type, mounted on nickel
plated steel rails complete with end cover and clamps for each row.
g) All terminals used In signal, alarm and control junction boxes shall be suitable for
accepting minimum 2.5sq.mm copper conductor, in general.
GSTD-0103 0
GLANDS SHEET 6 OF 8
h) Terminal used in power junction boxes / power supply distribution box shall be suitable
for accepting conductor size of 4 Sq. mm to up to 120 sq. mm. Exact requirement shall be
specified in job specification. Higher size of terminals shall be provided when indicated.
Bus bar terminals shall be provided for conductor size 50 sq.mm and above. Suitable size
of lugs shall be provided to suit conductor size specified.
i) Each junction shall have minimum of 30% spare terminal of those actually required to be
utilised. Unless higher number of terminal are specified in the purchaser's data sheet, the
number of terminals for various types of junction boxes shall be as follows;
24 Nos for 6 pair junction box.

48 Nos. for 12 pair junction box
36 Nos for 6 triad junction box.
48 Nos. for 8 triad junction box.
j) Terminals shall be identified as per the type of input signal indicated in data sheets e.g all
terminals for intrinsically safe inputs shall be blue while others shall be grey in colour.
k) Junction boxes shall be provided with external earthing lugs.
l) Sizing shall be done with due consideration for accessibility and maintenance in
accordance with the following guidelines;
i) 50 to 60 mm gap between terminals and sides of box parallel to terminal strip for
up to 50 terminals and additional 25 mm for each additional 25 terminals.
ii) 100 to 120 mm between two terminal strips for upto 50 terminals and additional 25
mm for each additional 25 terminals.
iii) Bottom/top of terminal shall not be less than 100 mm from bottom / top of the
junction box.
2.1.6 Pneumatic Junction Boxes
a) Pneumatic junction boxes shall be made of 3 mm thick hot rolled steel, They shall have
necessary Silicon/EPDM or better gasket between door and body. Door shall be flush with
the box and shall be hinged type and provided with wing nuts.
b) Single tube entries shall be suitable for 6 mm 0.0 copper tube with bulk head fittings. Multi
tube bundle entry shall be suitable for the data furnished in data sheets.
2.1.7 Painting (if applicable)
a) Surface shall be prepared for painting. It shall be smooth and devoid of rust and scale.
b) Two coats or lead-free base primer and two final coats of lead free epoxy based paint
shall be applied both for interior and exterior surfaces.
c) The colour shall be as specified in data sheets. However, following philosophy shall be
followed, in general:
(i) Light blue for all intrinsically safe junction boxes.

GSTD-0103 0
GLANDS SHEET 7 OF 8
(ii) Light grey for all others
2.2 Cable glands, Plugs and Reducers/Adaptors
2.2.1 Cable glands shall be supplied by vendor whenever specified.
2.2.2 Cable glands shall be double compression type for use with armoured cables.
2.2.3 The cable glands shall be of SS316, as a minimum.
2.2.4 The cable glands shall be weatherproof. Whenever specified they shall also be increased safety
and certificate for the specified electrical area classification specified in the data sheets.
2.2.5 Cable glands shall be supplied to suit the cable dimensions indicated along with tolerances in
data sheets. Various components like rubber ring, metallic ring, metallic cone and the outer /
inner nuts etc. shall be capable of adjusting to the indicated tolerances of cable dimensions.
2.2.6 Reducers / adapters shall be supplied as per details indicated in data sheets. They shall be
SS316 as a minimum. These shall also be weatherproof and I or increased safety wherever
specified and certified for the electrical area classification specified in the data sheets.
2.2.7 Plugs shall be provided as specified elsewhere.
2.2.8 Plugs shall be certified increased safety when used with increased safety junction boxes.
3.0 NAMEPLATE
3.1 Each junction box shall have an anodised aluminium nameplate permanently fixed to it at a
visible place furnishing the following information;
a) Tag number as per purchaser's data sheet.

b) Manufacturer's serial number and model number.
c) Manufacturer's name i trade mark.
d) Stamp of certifying agency with certificate number.
e) Electrical area classification.
4.1 Unless otherwise specified, purchaser reserves the right to test and inspect all the items at the
vendor's works in line with inspection test plan for junction boxes and cable glands.
a) Material test certificates as per clause 2.2 of EN 10204
b) Pressure test on castings for £1ameproofjunction boxes.
c) Dimensional test report.
d) High voltage and insulation resistance test report.
e) Air leak test report on pneumatic junction boxes.

GSTD-0103 0
GLANDS SHEET 8 OF 8
f) Certificate from statutory body for suitability to install in specified hazardous area.
4.3 Witness Inspection
4.3.1 All Junction boxes, cable glands and other accessories shall be offered for pre-dispatch
inspection for the following. as a minimum:
a) Physical dimensional verification and workmanship on representative samples.
b) High voltage and Insulation resistance test on representative samples.
c) Air leak test report on representative samples of pneumatic junction boxes.
d) Review of all certificates and test reports as indicated in clause 4.2 of this specification.
4.3.2 In the event when witness inspection is not carried out by purchaser, the tests shall anyway be
completed by the vendor and documents for the same shall be submitted for scrutiny of
purchaser.
5.0 SHIPPING
5.1 All threaded openings shall he suitably protected to prevent entry of foreign material.
5.2 All threaded components shall be protected with plastic caps to prevent damage of threads.
6.0 REJECTION
6.1 Vendor shall prepare their offer strictly as per clause 1.2 of this specification and shall attach only
those documents, which are specifically indicated in the material requisition.
6.2 Any offer not conforming to above requirements, shall be-summarily rejected.

STD-0201 0

SHEET 1 OF 146
STANDARD SPECIFICATION
FOR
DISTRIBUTED CONTROL SYSTEM & PLC SYSTEM
0 07.03.2011 07.03.2011 For Tender SKPradhan /HSaini SanjayKrTripathi SanjayKr Tripathi


STD-0201 0
STANDARD SPECIFICATION FOR
DISTRIBUTED CONTROL SYSTEM & PLC SYSTEM Rev
SHEET 2 OF 146
Abbreviations:
AC Alternating Current
APC Advanced Process Control
CFF Common File Format
CPU Central Processing System
CRT Cathode Ray Tube
DA Data Access
DC Direct Current
DD Device Description
DCS Distributed Control System
DVD Digital Versatile Disc
EDDL Enhanced Device Descriptive Language
EPROM Erasable Programmable Memory
EMI Electromagnetic Interference
ESD Emergency Shutdown System
FAT Factory Acceptance Test
FDT / DTM Field Device Tool / Device Tool Manager
FF Foundation Fieldbus
FMEDA Failure modes, Effects and Diagnostic Analysis
GPS Global Position System
HART Highly Addressable Remote Transducer
HDA Historical Data Access
HI Foundation Fieldbus low speed (31.25kbps) loop powered bus
HSE High Speed Ethernet
HVAC Heating, Ventilation and Air Conditioning
HW Hardware
HWC Hardware Console
I/O Input / Output
IAMS Instrument Asset Management System
LAN Local Area Network
LAS Link Active Scheduler
LCD Liquid Crystal Diode
MCC Motor Control Centre
MOV Motor Operated Valve
STD-0201 0
SHEET 3 OF 146
MTTF Mean Time to Failure
MTTR Mean Time to Repair
OIS Operator Interface System
OLE Object Linking and Embedding
OPC OLE for Process Control
PC Personnel Computer
P&ID Piping and Instrumentation Drawing
PID Proportional, Integral and Derivative
PLC Programmable Logic Controller
QUAD Quadruplet
RAID Redundant array of independent discs
RAM Random Access Memory
RDBMS Relational Database Management System
RFI Radio Frequency Interference
ROM Read Only Memory
SAT Site Acceptance Test
SCSI Small Computer System Interface
SER Sequence of Event Recorder
SIL Safety Integrity Level
SIS Safety Instrumented System
SPD Surge Protection Device
SQL Structured Query Language
TCP / IP Transmission Control Protocol / Internet Protocol
TFT Thin Film Transistor
UHF Ultra High Frequency
UPS Uninterrupted Power Supply
USB Universal Serial Bus
VDU Video Display Unit
VFD Vertical Field Device
VHF Very High Frequency
WAN Wide Area Network

STD-0201 0
SHEET 4 OF 146
CONTENTS
PART – I GENERAL SPECIFICATION OF DISTRIBUTED

CONTROL SYSTEM. page 05
PART – II TESTING, INSTALLATION, COMMISSIONING AND

ACCEPTANCE OF DISTRIBUTED CONTROL SYSTEM. page 115
PART - III GENERAL REQUIREMENTS OF

DISTRIBUTED CONTROL SYSTEM. page 133

STD-0201 0
SHEET 5 OF 146
PART – I
GENERAL SPECIFICATIONS
OF
DISTRIBUTED CONTROL SYSTEM

STD-0201 0
SHEET 6 OF 146
CONTENTS
SR.NO. TITLE PAGE NO.
1.0 GENERAL 7
2.0 DEFINITIONS 12
3.0 SPARES PHILOSOPHY 19
4.0 SYSTEM CONFIGURATION 22
5.0 DESIGN AND CONSTRUCTION 24

5.1 DESIGN REQUIREMENTS 24
5.2 FUNCTIONAL REQUIREMENTS 33
5.3 CONTROLLER AND DATA ACQUISITION SUB-SYSTEM 34
5.4 OPERATOR INTERFACE SUB-SYSTEM 44
5.4.1 GENERAL 44
5.4.2 OPERATOR CONSOLES 45
5.4.3 PROCESS DISPLAYS 48
5.4.4 LOGGING FUNCTION AND REPORT GENERATION FUNCTION 55
5.4.5 SELF DIAGNOSTICS 59
5.4.6 DATA STORAGE, ARCHIVAL AND RETRIEVAL 59
5.4.7 ASSIGNABLE TREND RECORDER 60
5.4.8 HARD COPY UNIT 60
5.4.9 SYSTEM SERVERS SIZING CRITERIA 60
5.4.10 SYSTEM OPERATIONAL RESPONSE TIME 62
5.5 ENGINEER INTERFACE SUB-SYSTEM 62
5.6 COMMUNICATION SUB-SYSTEM 66
5.7 OPEN SYSTEM CONNECTIVITY 69
5.8 TIME SYNCHRONISATION 72
5.9 SHUTDOWN SUB-SYSTEM -PLC 73
5.10 FOREIGN DEVICE INTERFACE 83
5.11 INTERFACE WITH SMART TRANSMITTERS 83
5.12 HARD WIRED INSTRUMENTATION 84
5.13 INSTRUMENT ASSET MANAGEMENT SYSTEM (IAMS) 85
5.14 ALARM INFORMATION MANAGEMENT SYSTEM (AIMS) 87
5.15 UNIT HISTORY NODE (UHN) 95
5.16 SEQUENCE OF EVENT RECORDER (SER) 99
5.17 LARGE SCREEN 100
STD-0201 0
SHEET 7 OF 146
6.0 MISCELLANEOUS REQUIREMENTS 101
6.1 SAFETY REQUIREMENTS 101
6.2 POWER SUPPLIES AND DISTRIBUTION 103
6.3 EQUIPMENT ASSEMBLY 105
6.4 EARTHING 112

STD-0201 0
SHEET 8 OF 146
GENERAL
1.1 SCOPE
1.1.1 This specification, together with the data sheets attached herewith defines the minimum functional
requirements for the design; hardware, software and firmware specifications, nameplate marking,
testing and shipping of Distributed Control System designed for reliable effective and optimum control
and monitoring of a process plant .
1.1.2 The related standards referred to herein and mentioned below shall be of the latest editions prior to the
date of the purchaser’s enquiry:-
AG-181 Foundation Fieldbus System Engineering Guidelines
EN 10204 Inspection Documents for Metallic Products.
EN 50039 Intrinsically Safe Electrical System
IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere.
IEC 60529 Degree of Production Provided by Enclosures.
IEC 60617 Graphic Symbols for Electronic Diagram
IEE 4 Guidelines for Documentation of Computer Software for Real time and Interactive
Systems
FF – 569 Foundation Fieldbus Host interoperability support test procedure
FF – 816 Foundation Fieldbus Specification 31.25 Kbits/s Physical Layer Profile
FF – 890~894 Foundation Fieldbus Specification Function Block Application process
ANSI / ISA Security Technologies for Manufacturing and control system

TR 99.00.01
ANSI / ISA Integrating Electronic Security into the manufacturing and control
TR 99.00.02 systems environment
EEMUA 191 Alarm System, a guide to design, management and procurement
IS-3043 Code of Practice for Earthing
IS 13947 Degree of Protection provided by Enclosures for low voltage switchgear and
control gear
IS 13948 Flameproof Enclosures of Electrical Apparatus
ISA S 71.01 Environmental Conditions for process Management
and Control System : Temperature and Humidity
S 71.04 Environmental Conditions for Process Measurement
and control System: Airborne Contaminants
S 5.2 Binary Logic Diagrams for Process Operations

STD-0201 0
SHEET 9 OF 146
S 5.3 Graphic Symbols for Distributed Control System Display
Instrumentation, Logic and Computer System.
S 5.4 Instrument Loop Diagram
S 5.5 Graphic Symbols for Process Display
S 18.1 Annunciator Sequences and Specifications
S 50.2 Fieldbus Standard for use in Industrial Control System
IEC 61000-4-3 Electromagnetic Compatibility (EMC) – Testing and Measurement
Techniques – Radiated Radio Frequency, Electromagnetic Field Immunity Test.
IEC-61000-4-4 Electromagnetic Capability (EMC) – Testing and measurement
techniques – Electrical fast transients / bust immunity test
IEC-61000-4-5 Electromagnetic Compatibility (EMC) – Testing and Measurement techniques –
Surge immunity test
IEC-61000-6-2 Electromagnetic Compatibility (EMC) – Generic Standards –
Immunity for Industrial Environments
IEEE 472 Electrical Surge protection
IEC-60584 Thermocouple (Tolerances)
IEC-60751 Industrial Platinum Resistance Temperature Sensors
ANSI MC 96.1 Temperature Measurement Thermocouples
IEEE 802.3 Telecommunication and Information exchange between Systems –
Local and Metropolitan Area networks – specific requirements –
Part 3 : Carrier Sense Multiple access with collisions Detection
(CSMA / CD) Access Method and Physical layer specification.
IEC 61508 Functional Safety of Electrical / Electronic / Programmable
Electronic Safety related Systems.
IEC 61131 Programmable Controllers
IEC 61511 Functional Safety – Instrumented System for Process Industry Sector IEC
61158 Fieldbus Standard for use in Industrial Control Systems.
1.1.3 In the event of any conflict existing between this specification, data sheets, statutory regulations, related
standards, codes etc., the following order of priority shall govern:
a) Design Basis / Statutory regulations
b) Data Sheets
c) Standard specifications
STD-0201 0
SHEET 10 OF 146
d) Codes and standards
1.1.4 In addition to meeting purchaser’s specifications in totality, vendor’s extent of responsibility shall also
include the following:
a) Purchaser’s data sheet specify the minimum acceptable functional requirements for the
control system. It shall be vendor’s responsibility to select proper hardware, software and
firmware to meet the specified functional requirements.
b) Purchaser’s data sheets specify the scan time / cycle time / response time / macro cycle
time and loading requirements. Vendor shall be responsible for sizing and selecting their
standard product i.e. hardware, software and firmware to meet the requirements specified
in the purchaser’s data sheets.
c) Selection of proper and adequate hardware, software and firmware to meet architectural
requirements specified in the purchaser’s specifications, keeping the integrity of functional
blocks specified in the configuration diagram attached with the material requisition.
d) Segment design based on requirements specified in the job specifications and its validation
during site testing and pre-commissioning.
e) Adequacy of Bill of material selected to meet purchaser’s requirements. Vendor to note
that bill of material shall not be verified by the purchaser during evaluation stage. Any
hardware, software and firmware required to meet the purchaser’s specified requirements
shall be provided by the vendor without any implication.
f) Providing adequate mandatory spares including consumable spares as specified in the
purchaser’s specifications. Vendor shall be responsible to meet mandatory spare
requirements specified by the purchaser.
1.2 Bids
1.2.1 Vendor’s quotation shall be strictly as per the bidding instructions to vendor attached with the material
requisition.
1.2.2 Whenever a detailed technical offer is required, vendor’s quotation shall include the following:
b) Detailed specification sheets for each sub-system. The specification sheet shall provide
information regarding hardware specifications, software specifications, redundancy
requirements, capacity, power consumption etc. of the distributed control system and its
accessories. The material specifications and unit of measurement for various items in
vendor’s specification sheets shall be to the same standards as those indicated in
purchaser’s data sheets.
c) System security features and design details
STD-0201 0
SHEET 11 OF 146
d) Proven references for each offered model in line with clause 1.2.4 of this specification
whenever specifically indicated in the purchaser’s specifications.
e) A copy of approval for flameproof enclosure, intrinsic safety etc whenever specified, from
local statutory authority, as applicable, like Petroleum and Explosive Safety Organisation
(PESO) / Chief Controller of Explosives (CCE), Nagpur or Director General of Mines
Safety (DGMS) in India along with;
i) Test certificate from recognised house CIMFR (Central Institute of Mines & Fuel
Research) / ERTL (Electronics Research and Test Laboratory) etc. for specified
protection class as per relevant Indian Standard for all Indian manufactured
equipments or for equipments requiring DGMS approval.
ii) Certificate of conformity from agencies like LCIE, BASEAFA, PTB, CSA, UL
etc., for compliance to ATEX or other recognised standards for all equipments
manufactured outside India.
f) Deviations on technical requirements shall not be entertained. In case vendor has any valid
technical reason to deviate from the specified requirement, they must include a list of
deviations item wise, summing up all the deviations from the purchaser’s data sheets and
other technical specification along with the technical reasons for each of these deviations.
g) FMEDA report and calculations for probability of failure on demand to meet specified SIL
requirements (e.g. SIL3).
h) Catalogues giving detailed technical specifications, model decoding details and other
related information for each item / sub-system covered in the bid.
1.2.3 Vendor shall offer only their standard proven product i.e. hardware, system software and firmware,
which shall be configured to meet the functional requirements specified in the material requisition.
Whenever any bought out item is offered to meet the configurational requirements specified in the
material requisition, it shall also meet the functional requirements. Moreover, the equipment being
offered / supplied shall be of latest proven version available in the current manufacturing range and
meeting the requirements specified in clause 1.2.4 of this standard specification.
1.2.4 The system hardware, software and firmware as offered, shall be field proven and should have been
operating satisfactorily for a period of minimum 4000 hours continuously on the bid due date in the
validly similar size and application specified in the purchaser’s data sheet. Items with prototype design
or items not meeting provenness criteria specified above shall not be offered or supplied.

STD-0201 0
SHEET 12 OF 146
1.2.5 The detailed scope of work, specific job requirements, exclusions, deviations, additions etc. shall be
indicated in the job specifications which shall be part of material requisition.
1.2.6 Whenever specified, vendor shall furnish tested values of failure rates, probability of failure on demand
and test intervals for safety integrity level analysis.
1.2.7 All documentation submitted by the vendor including their quotation, catalogues, drawings, installation,
operation and maintenance manuals shall be in English language only.
1.2.8 Vendor shall also quote for the following;
a) Two year’s operational spares for each sub-system and their accessories which shall include
the following as a minimum;
i) All type of electronic modules e.g I/O modules, processor modules, communication
modules, memory modules, disc controller module, power supply modules etc.
ii) All type of auxiliary items e.g. barriers / isolators, hardwired instruments, annunciator
modules, receiver switches, trip amplifiers, temperature element converters etc.
iii) Switches, lamps, fuses, connectors, terminals, pre-fabricated cables, circuit breaker,
relays etc.
iv) Video display units, keyboards, disc drives, PC’s, network items (e.g. switches, hubs etc.)
etc.
b) Any special tools and test equipments needed for the maintenance of DCS, PLC’s and other
items being offered by vendor. This shall also include test equipments for fieldbus testing and
configuration like fieldbus tester, fieldbus configurator etc. wherever specified in the data
sheets. Vendor must confirm in their offer if no special tools or test equipments are needed
for maintenance other than those specifically indicated in purchaser's data sheet.
1.3 Drawing and Data
purchaser in vendor data requirement sheets. The required number of producibles, prints and soft copies
shall be dispatched to the address mentioned, adhering to the time limits indicated.
1.3.2 Final documentation consisting of design manuals, installation manual, operation and maintenance
manual etc., submitted by the vendor after placement of purchase order shall include the following, as a
minimum:
STD-0201 0
SHEET 13 OF 146
a) Specification sheet for each sub-system, auxiliary instrument and bought out item.
b) Certified drawings for complete system including;
i) GA drawings for panels, cabinets, marshalling racks, hardwired consoles, operator /
engineering console etc with complete dimensions details, internal construction and
weight in kilograms.
ii) Control room e.g. console room, rack room and engineering room layout with all
dimensions in millimeters.
iii) Channel base drawing for console room, rack room and engineering room.
iv) Input / output assignment
v) Fieldbus segment drawing
vi) Loop wiring diagram
vii) Power supply distribution single line diagram
viii) Dynamic graphic diagrams
ix) System grounding drawing
c) Design manuals and functional design specifications which shall include hardware design
manual, software design manual and special software specifications.
d) Copy of type test certificates.
e) Copy of test certificates for all tests indicated in Part II of this specification.
f) Installation manual containing installation procedure for distributed control system and other
items covered in the material requisition.
g) Power-on, start-up and internal testing procedures.
h) Software debugging and system configuration procedures
i) Calibration and maintenance manual containing maintenance procedures including

replacement of parts, application modification etc.
j) Any other drawings and documents specifically indicated in job vendor data requirement
enclosed with the material requisition.
STD-0201 0
SHEET 14 OF 146
2.0 DEFINITIONS
The various terms used in this specification are defined as follows:
2.1 Distributed control system
The class of control systems which in addition to maintaining and managing data bases in distributed
fashion also executes the stated control functions and permits transmission of control, measurement
and operating information to and from a single or a plurality of user specified locations connected via a
communication sub-system.
2.2 Programmable Logic Controller
The class of control systems which can be programmed to execute plant shutdown and / or interlock /
sequence logics to the specified safety integrity levels.
2.3 Accessible
A system feature that is viewable by and interactive with the operator and allows the operator to perform
user permissible control action e.g. set point change, auto-manual transfers or on-off actions.
2.4 Assignable
A system feature that permits an operator to direct a signal from one device to another without the need
for change in wiring, either by means of switches or via other data entry devices like key board
commands to the system.
2.5 Configurable
A system feature that permits selection through entry of key board commands or commands from other
data entry devices of basic structure and characteristics of a device or system, such as control
algorithm, display format or I/O termination.
2.6 I/O
Input / Output with respect to process / operator.
2.7 Fieldbus
Fieldbus is a digital two-way multi drop communications link among intelligent measurement and
control devices.
2.8 System Size

STD-0201 0
SHEET 15 OF 146
System size shall be defined as maximum number of process inputs or tags those can be connected to
the system and viewable from any one of the VDUs of an operating console in all hierarchical displays
without changing the configuration or without operator interaction considering;
a) all inputs as close loops
b) all inputs as open loops
2.9 Operator console
Operator console is the operator’s main plant interface device via which operator can view, monitor and
control the plant and can give instructions to peripherals to execute commands, and shall have
protective access to configure and maintain the system.
2.10 Engineering console
Engineering console shall be the engineer’s main interface device via which engineer can configure
and maintain the system, and shall have protective access to monitor and control the plant, give
instructions to peripherals to execute commands,.
2.11 Local Level
All those sub-systems, which directly interface with field devices shall be referred to as local level.
2.12 Central Level

Operator consoles and Engineering Console, which present data acquired from local level devices shall
be referred as Central Level.
2.13 Data base

Database shall be defined as the information stored temporarily or permanently in the system which
can be accessed by various programs to meet all its functional requirements.
2.14 Global Database
Global database is defined as the database that can be accessed by two or more non-nested modules of
a program without being explicitly passed as parameters between the modules.
2.15 Loop integrity
A system shall be said to have loop integrity if the failure of one component in the system/ sub-system
does not affect more than one loop.
2.16 Interchangeability
System/sub-systems shall be said to have full interchangeability if the functions and information
available on one system/sub-system shall also be available on the other in totality.
2.17 System Loading

STD-0201 0
SHEET 16 OF 146
System loading for a sub-station is defined as the percentage of time a sub-system spends in carrying out
various activities referred to the use of memory, CPU time and communication capacity in the worst
case of high sub-system operation out of the designed / designated cycle time of the sub-system.
2.18 Bus-degradation
Bus-degradation shall be defined as a change in the system performance from the specified one
measured in terms of display update rate while loading the communication sub-system from 10 through
100 percent.
2.19 Redundancy
A system component shall be termed as redundant if it takes over automatically the operation in the
event of the failure of the main component without causing any interruption in the system and upsetting
the process. The repaired or replaced device shall be brought in-line only through operator action
without upsetting system operation.
2.20 Switchover Time
Time required for a back up instrument / system to come on-line automatically in case of the failure of
the main instrument / system.
2.21 Processor Cycle Time (Tpc)

Processor cycle time is the measure of the processing speed of a processor and is user selectable from
the pre-defined discrete values. Processor cycle time for a sub-systems shall be defined as follows:-
a) Controller Sub-system
Processor cycle time for controller sub-system shall be defined as the total time taken by the
control processor to read inputs supplied by input module, execute control algorithm and write the
outputs for the output module.
b) Data acquisition sub-system

Processor cycle time for data acquisition sub system shall be defined as the total time taken by the
processor to read inputs supplied by input processor, perform calculations for all the open loops
configured within the data acquisition sub-system and make data available to the communication
sub-system.
c) Programmable logic controller

STD-0201 0
SHEET 17 OF 146
Processor cycle time for programmable logic controller shall be defined as the total time taken by
the processor to read input supplied by input module, execute all computations (analog as well as
logic as configured) and write the outputs for the output module.
2.22 Scan time (ts)

Scan time is the end-to-end response time of a sub-system and shall be defined as follows:
For fieldbus based system refer clause 2.25 for close loop response time.
a) Close-Loops
Scan time for a close-loop shall be defined as the total time taken by a sub-system e.g. controller
and data acquisition sub-system to read inputs from the input terminal, process input, perform
control algorithms, update control output and write output at the output terminal for all the loops
configured within the sub-system.
b) Open-Loops
Scan time for an open loop shall be defined as the total time taken by a sub-system e.g controller
and data acquisition sub-system to read input from input terminal, process input, perform
calculations and write output for communication sub-system to pick-up the same for all the open
loops configured within the sub-system e.g. controller and data acquisition sub system.
c) Logic Loops
The scan time for a logic loop shall be defined as the total time taken by a sub-system e.g.
programmable logic controller to read input from the input terminal, process input, execute logic,
updating logic output and write output at the output terminal for all the logics configured within
the subsystem.
2.23 Control Cycle time

Control cycle time is defined as the total cycle time taken by the supervisory computer to read data
from control system, perform calculations and update the set point of a regulatory loop configured in
the control system e.g. controller and data acquisition sub-system.
2.24 Macro Cycle

Macro cycle is defined as a single iteration of a schedule within a fieldbus device.
2.25 Macro Cycle Time
Macro Cycle time or execution time is defined as the amount of time taken by a fieldbus device to
complete the macro cycle. Macro cycle time can refer to a single field device, the LAS or a complete
segment made up of multiple devices.

STD-0201 0
SHEET 18 OF 146
2.26 Loop Response Time
Loop response time for fieldbus based system shall be defined as the total time required to perform the
following functions in each of the specified loop configuration;
a) Control function in transmitter

Execute the analog input and control (PID) function block in transmitter, publish the output on the
fieldbus, receive the controller out value and perform analog output function block in final control
element.
b) Control function in final control element

Execute the analog input function block in the transmitter, publish the process variable on the
fieldbus, receive the process variable and execute the control algorithm (PID) and analog output
function block in the final control element.
c) Control Function in DCS

Execute the analog input function block in the transmitter, publish the process variable at DCS,
execute the control algorithm (PID) in DCS, publish the controller output value on the fieldbus and
execute the analog output function block in the final control element.
2.27 Display update rate

Display update rate shall be defined as the time taken by the system to display the information present
at the system input terminals updated on the current display on the VDU of an operator console
2.28 Call-up time

Call up time shall be defined as the time taken by the system to display a particular display/data on the
VDU after getting the corresponding command from the operator.
2.29 User’s memory
Free memory space available after utilisation of memory required for system operation, configuration
and implementation of application and other system related functions for implementation of user
defined specific programs such as plant calculations, process optimization or MIS (like free formatting
of certain logs). The programs shall either be written in high level language or system specific
language.
2.30 Event

STD-0201 0
SHEET 19 OF 146
An event shall be defined as any action taken by the operator via operator keyboard or switches on
hardwired console like change of set point, change of control mode, start/stop of motor, open/close of
shut down valves, alarm acknowledge etc.
2.31 Sequence of Event (SOE)

Arranging events in the sequence of their occurrence in time with a specified time resolution by a
program is defined as sequence of event.
2.32 Sequence of Event Recorder (SOR)
System of sub-system which presents and / or records the events in the sequence of their occurrence in
time with a specified time resolution utilizing its hardware and software capabilities is termed as
sequence of event recorder.
2.33 Real time trend
Real time trend shall be defined as a continuously progressing graphical record showing continuously
updated parameter with most recent value and a past record of minimum of 10 minutes without
depressing any additional key for moving backward in time.
2.34 Windowing
Ability of software program to break the console screen i.e. video display unit into simultaneous or
overlapping zones with separate presentations at the same time.
2.35 Interoperability
Interoperability is the capability to substitute a device from one manufacturer with that of another
manufacturer as a fieldbus network without loss of any functionality or degree of integration.
2.36 Acyclic Period
Acyclic period is defined as the portion of communication cycle time during which information other
than publish / subscribe data is transmitted.
2.37 Capabilities File
A capabilities file describes the communication objects in a fieldbus device. A configuration file can
use DD files and capabilities files to configure a fieldbus system without having the fieldbus device
active.
2.38 Link Active Scheduler (LAS)

LAS is defined as a deterministic centralised bus scheduler that maintains a list of transmission times
for all data buffers in all devices that need to be cyclically transmitted.

STD-0201 0
SHEET 20 OF 146
2.39 Link Master
Any device containing the link active scheduler personality that can control communication of a H1
fieldbus segment is designated as link master.
2.40 Segment
Segment is defined as a network or part of network that serves as the primary communication highway for
the connected field-bus devices.
2.41 Resource Block (RB)
Resource block describes the characteristics of a fieldbus device such as device name, manufacturer
and its serial number. Resource block is unique for a device.
2.42 Vertical Communication Relationship (VCR)
VCR is defined as the pre-configured application layer channels which provide the data transfer
between applications. Publisher – subscriber, client – server and report distribution are three VCRs in
foundation fieldbus.
2.43 Link Objects
Link object contains information to link function block input / output parameters in the same device
and between different devices.
2.44 Plant Control Network
Communication network within a plant that has control information circulating between various plant
units or processing locations.
2.45 Plant Information Network
High-level communication network which serves various user’s within a plant and transfer information
for the purpose of unit / plant monitoring. This network is different than control network and is
generally realised using open communication protocol network e.g. OPC etc.
2.46 OPC node
OPC node is any node in the network that provides OPC interfaces consistent with OPC data access,
OPC alarm and event and OPC historical data access interface specifications certified against OPC
compliance and interoperability test specification.
2.47 Computer Integrated Manufacturing (CIM)
Computer integrated manufacturing shall be defined as the integration of process, plant and business
operations made possible through information network.
3.0 SPARES PHILOSOPHY
3.1 The system including programmable logic controller, alarm information management system, sequence
of event recorder, hardwired instruments etc. shall meet the following spare philosophy. This
STD-0201 0
SHEET 21 OF 146
philosophy shall also be applicable for items like field-bus accessories, barriers, relays, terminals,
lamps, push buttons etc.
3.1.1 Mandatory Spares

Vendor shall include following mandatory spares in their scope of supply;
3.1.1.1 Installed Engineering Spares
Installed engineering spares shall be provided in each sub-system for each type of module to enhance
the specified system functional requirements by 20%. The basic of offering installed engineering
spares shall include;
a) For a system with conventional and / or smart input / output, 20% spare input / output of each
type shall be considered for calculating I/O modules and all other related accessories.
b) For a system with fieldbus input / output, 20% spare segments of each type of field-bus type
(foundation fieldbus, profibus etc.) shall be considered for calculating I/O modules, power
supply modules and all other related accessories. When only input / outputs are indicated
instead of field-bus segments, the installed spare philosophy as specified in 3.1.1.1 (a) shall be
followed.
c) For all serial input / outputs to the system 20% spare serial I/O channels of each
type of serial input / output shall be provided.
d) A minimum of one spare I/O module of each type as offered to meet type of inputs / outputs
specified in the material requisition.
e) 20% spare accessories like relays, switches, lamps, fuses, circuit breakers,
barriers, isolators, terminals etc.
f) A minimum of one number of input / output module and accessories of, each type such as
analog input / output, discrete (contact) input / output, pulse input, serial input / output,
foundation fieldbus / profibus PA input / output modules (in case of fieldbus based system)
temperature input shall be provided irrespective of those required as per 3.1.1.1(d) as
engineering spare.
g) The engineering spares shall be wired up to the field cable interface and shall be in
ready-to-operate condition when field cable is connected to spare assigned terminals.
h) Spare pairs of the incoming cables shall be terminated on spare terminals in the
marshalling / barrier cabinets as applicable.
i) The system shall be fully engineered considering 20% installed engineering spares
STD-0201 0
SHEET 22 OF 146
including processor loading.
3.1.1.2 Spare Space Requirement

In addition to installed engineering spares specified in Clause 3.1.1.1 of this specification, the system
shall be provided with following spare space;
a) The controller and data acquisition racks shall have 10% usable spare space for installing
additional I/O and field-bus segment modules in future. However, the control and data
acquisition processor shall have additional 10% capacity to handle these I/O’s and field-bus
segment. In addition, internal wiring for the same shall be completed up to I/O terminals.
b) Each operator console shall contain 10% usable spare group and related display capability in
addition to as specified in para 3.1.1.1 of this specification.
c) The system shall have capability to extend its historical trending, logging and user’s memory
by 20% to meet future expansion with/without adding additional memory modules.
d) I/O racks of programmable logic controller shall have 10% usable spare space for installing
additional I/O cards of each type in future. However internal wiring for the same shall be
connected up to the I/O terminals.
e) Processor system of programmable logic controller shall have capability to execute additional
20% logics.
f) The communication sub-system shall have sufficient capacity to handle additional data
contributed by addition of 20% I/O / segments over and above installed engineering spares
g) Usable spare space in panels and cabinets to install 10% spare hardwired items like barriers,
trip amplifiers, receiver switches, panel mounted instrument, relays etc. in future.
3.1.1.3 Spare Memory Requirement

a) The system shall be provided with a minimum of 40% spare memory capacity, as
required for application program and data base to meet specified functional requirements.
b) For field-bus based system, spare memory capacity (and CPU loading) shall be
calculated considering all control algorithms being configured in the system and executed at
the scan time equal to the specified control loop response time.
c) It shall be possible to extend the memory by at least 20% over and above the
actual requirement at a later date.

3.1.1.4 Spare Software Capability
STD-0201 0
SHEET 23 OF 146
a) Sufficient additional software capacity shall be available in the system to take care of spares
requirement as specified in para 3.1.1.1 and 3.1.1.2(a) to (f) of this specification to meet all
functional requirements as per para 5.0 of this specification.
b) Unless specifically indicated otherwise, the offered system shall have software
licenses to cover all the tag numbers indicated in the material requisition, including installed
engineering spares and spare space indicated in clause 3.1.1.1 and 3.1.1.2 of this specification.
3.1.1.5 Predefined Mandatory Spares

a) Mandatory spares shall be ware-house spares and shall be supplied as loose items.
b) Mandatory spare module of 5% or one module of each type, whichever is higher, must be
supplied for each type of modules being used including in consoles.
c) For items like hardwired instruments, assignable recorders, Personnel computers, VDU / video
screens, keyboards, disc drives, RAID controller, lamps, network components, barriers, fuses
and circuit breakers complete item limited to 5% or minimum one of each type shall be
supplied as predefined mandatory spare. But this shall not include hardware like discs,
terminals, switches, telephone sets etc.
d) Items like personnel computers, operator consoles servers, engineering consoles etc. where
complete item needs replacement instead of individual modules, complete unit shall be
supplied as mandatory spares in line with clause 3.1.1.5(b).
e) Software which need to be separately loaded in the items specified in clause 3.1.1.5(d) above
to define the items personality and can't be uploaded from engineering console or any other
network device shall be supplied along with additional software.
3.1.1.6 Consumable Spares

Any paper, ribbon, printer heads and ink required for printers, assignable recorders, video copier or any
other consumable item shall be supplied along with system required for minimum of six months
duration after system acceptance.
3.1.1.7 Commissioning Spares
Unless otherwise specified, vendor shall be responsible to supply all spares which are found necessary to
replace failed modules, failed sub-systems, or corrupted / faulty softwares while performing pre-
commissioning and commissioning activities.
3.1.2 Two years operational spares

STD-0201 0
SHEET 24 OF 146
Two years operational spares shall be as per Clause 1.2.8(a) of this specification and shall be quoted
separately.
4.0 SYSTEM CONFIGURATION

The system configuration shall consist of the following major sub-systems:-
4.1 Controller and Data acquisition sub-system

Controller and data acquisition sub-system is the main field interface sub-system and is capable of
performing control and data acquisition functions as one integrated sub-system.
Controller and data acquisition sub-system shall interface with field instrumentation like transmitters,
process switches and final control elements to monitor and / or control process parameters like flow,
temperature, level etc. The sub-system shall include a comprehensive set of control algorithms and
auxiliaries to provide close loop control and data monitoring capability of the system.
4.2 Operator interface sub-system

Operator interface sub-system shall consist of one or more operator consoles for monitoring and
controlling process parameters and performing other process related functions.
4.3 Communication sub-system

Communication sub-system interconnects various sub-systems over which they can communicate with
each other to meet all functional requirements.
4.4 Engineer interface sub-system

Engineer interface sub-system shall consist of an engineering console primarily for tuning, configuring
and maintaining the system.
4.5 Supervisory computer sub-system

Supervisory computer, when specified, shall be employed for providing supervisory level plant control,
plant and unit optimization and other computer based plant management capabilities. For the Integrated
network , each node where history resides should be minimum RAID-5 configuration to ensure
maximum availability of history or otherwise separate redundant Servers in RAID-5 configuration and
redundant power supply configuration should be provided

Plant start up and safety shutdowns shall be performed by separate programmable logic controller
which shall communicate with other sub-systems over the communication sub-system.
STD-0201 0
SHEET 25 OF 146
4.7 Foreign Device Interface

Foreign Device like programmable logic controllers, gas chromatographs, analyzer systems, gas
turbine systems etc. when specified shall communicate with other subsystems over the communication
sub system for plant monitoring and control using foreign device interface. The foreign device
interface shall be either dedicated or shall be part of controller data acquisition sub-system as specified
in the job requirements.
4.8 OPC Server
OPC Server when specified in this specification is used as synonymous with any server entity on the
communication sub-system network which shall allow the user to implement applications, within or
outside the system, without providing any special drivers or custom interfaces. OPC server, when
specified, shall be used to transfer / receive data to / from applications run in other systems.
4.9 Unit History Node
4.9.1 Unit history node, when specified, shall store the long term historical data of the complete unit and
shall interact with central computer system over plant wide network. In addition every history residing
node should be minimum RAID-5 configuration.
4.9.2 Unit history modem, when specified shall be a dedicated node and shall be in addition to historical data
required for normal plant operation (specified as part of operating interface sub-system).
4.10 Sequence of Event Recorder (SER)
Sequence of event recorder, when specified, shall be a dedicated equipment which shall identify, store
and print alarms with the specified time resolution. SER may also transfer data to operator sub-system
over communication sub-system.
4.11 Documentation node (DON)

Documentation node, when specified, shall be a node on the information network sub-system and shall
store unit documentation.
4.12 Alarm Information and Management Sub-system (AIMS)

STD-0201 0
SHEET 26 OF 146
Alarm information and management sub-system when specified, shall be a alarm management package
which shall gather alarm information from various sub-systems and shall present the desired
meaningful analysed data for information and further analysis.
4.13 Instrument Asset Management System (IAMS)

Instrument asset management sub-system shall acquire store, analysed and present meaningful
diagnostic and maintenance related data of field devices for efficient plant maintenance.
4.14 Large Display System (LDS)

Large Display System, when specified, shall consist of one or more large video screens which shall
display either operator selected operator console screen or any pre-selected screen on a back projected
large video screens as real time basis.
4.15 Hardwired Instrumentation

Hardwired instrumentation shall be provided as a back up to the distributed control system for critical
process parameters when specified in the job specification.
4.16 Information Network Sub-system

4.16.1 Information network when specified shall interconnect with various plant wide systems like distributed
control system/systems, mainframe computers, personal computers, laboratory information and
management system (LIMS) etc over which any information can be exchanged without affecting and
disturbing the plant control and operations.

5.1 Design Requirements
5.1.1 The system shall be microprocessor based having functional distribution and data base distribution
sub-system wise. The system design shall ensure that;
a) All the functions defined in this specifications are performed in
an integrated manner
b) The access to the distributed data base is available system-wide.
This system shall also have networking capability with other systems distributed geographically in the
various units of a plant, over a plant wide information network such as Ethernet or other industrially
recognised open networks.
5.1.2 The system shall be of modular construction and expandable in future by adding additional modules.
The type of modules shall be kept to the minimum possible in order to have interchangeability and low
inventory.

STD-0201 0
SHEET 27 OF 146
5.1.3 System Availability

a) The system shall be designed ‘fault avoidant’ as a minimum by selecting high grade
components of proven quality and proper design of system electronics.
Redundancy shall be provided, as per this specification as a minimum, to improve the system
availability and reliability. Due considerations shall be given to the environmental conditions
particularly for field mounted sub- system, if specified in job specifications, during system
design.
b) The system shall have a high MTBF value and shall have well proven record of
operating in hydrocarbon plants.
c) The system shall be designed with 99.995% or greater availability. The
availability shall be defined as follows;
Availability = Meantime Between Failure (MTTF)

MTTF + Mean time to repair (MTTR)
For the purpose of calculations, consider mean time between repairs as four (4) hours unless
the manufacturer recommends higher value for MTTR. It is therefore necessary that;
i) Vendor covers all necessary spare parts in 2 years recommended operational spares which
shall be necessary to meet specified MTTR time.
ii) Vendor provides adequate training to owner's personnel and cover all necessary
maintenance related topics in their training programmes to ensure specified MTTR time.
5.1.4 Operating Environmental Conditions

5.1.4.1 Environmentally controlled location installation
a) All subsystem of Distributed Control System located in control room, Local Control Room or
in Satellite Rack room shall be able to operate satisfactorily from 15°c to 30°c and 20% to 80%
non condensing humidity.
b) In addition to above, all such sub-systems shall also be able to operate
satisfactorily in case of air conditioning failure with ambient temperature of 50°c and 90%
non-condensing humidity until the system safe operating limits are exceeded. The minimum
period of continuous operation shall be 48 hours at least once in a month without any damage
or degradation of system performance. Vendor, therefore, shall provide continuous
temperature monitoring for each enclosed cabinet housing items / equipments generating heat,
such as system cabinets, barrier cabinets, relay cabinets etc and also provide alarm for operator
STD-0201 0
SHEET 28 OF 146
alert in case the safe operating temperature limits are exceeded. Alarm in the operator consoles
shall be available for each cabinet while group alarms shall be provided on hardwired
annunciator located on hardware console.
c) Chemical filters have been provided in the incoming air conditioning air to limit the
concentration of contaminants below following limits
Contaminants Concentration
(Corrosive Gases)
SOx <10ppb
Nox <5ppb
H2S <5ppb
Cl2 <10ppb
SPM <0.2gm/m3
All sub-systems and system components shall be suitable for operating continuously in the above
mentioned corrosive environments.
d) Vendor shall provide continuous corrosion monitoring system consisting of transmitter with 4
– 20mA output and switch unit with setting as per contaminant level exceeding limits specified
in clause 5.1.4.1(c) of this specification. Unless otherwise specified the number of corrosion
monitors shall be as follows;
Equipment Type Room Type Quantity

Corrosion Transmitter Rack Room / Satellite
Rack Room 1 No.
Corrosion Switch Unit Rack Room / Satellite
Rack Room 3 Nos.
Console Room 1 No.
Engineering Room 1 No.
Continuous corrosion monitoring trend and alarms shall be provided on the operator console while
one group alarm shall be provided on the hardwired annunciator located on the hardwired console.
5.1.4.2 Outdoor Installations

a) Sub-systems or system components which are installed outdoor shall be able to continuously
operate at ambient temperature of 50°c and non-condensing humidity of 90%.

STD-0201 0
SHEET 29 OF 146
b) Unless otherwise specified, all sub-systems or system components installed outdoor shall have
corrosive environmental protection coating meeting the environmental classification class G3
as per ISA-S71.04.
5.1.5 Transient, Static and EMI / RFI Protection

5.1.5.1 The system shall be internally protected against system errors and hard ware damage resulting from:
a) Electrical transients on power wiring

b) Electrical transients on signal wiring
c) Connecting and disconnecting devices or removing or inserting printed circuit boards in the
Distributed Control System(DCS) and Programmable Logic Controller (PLC) .
5.1.5.2 All sub-systems and system components shall be capable of accepting various signal inputs for its direct
use while preventing noise errors due to electromagnetic interference (EMI) or radio frequency
interference (RFI) including nearby radio stations, hand held two way radios, electrical storms,
solenoids, relays or contactors carrying heavy currents as per levels of Environmental electromagnetic
phenomenon defined in IEC-61000-6-2. The system shall have total noise immunity from UHF / VHF
radio communication equipments (RFI) and (EMI) noise generating equipments as per IEC-61000-4.
The surge withstand capability for input/output modules shall be as per IEEE standard 472.
5.1.5.3 System cables for interplant, inter unit, and others routed in the field, the level of surge immunity
required for equipment signal ports shall be increased to level 4 as defined in IEC-61000-4-5 and the
system shall operate according to performance criterion B as defined in IEC-61000-6-2.
5.1.6 On-line replacement
5.1.6.1 On-line replacement of electronic module shall be possible in such a way that removal and addition of
an I/O module shall be possible and safe without de-energising the system. Furthermore, there shall not
be any interruption of the system while replacing a faulty module wherever redundant modules are
provided.
5.1.6.2 Apart from system modules, power supply units shall be replaceable on-line without disrupting the
process and without effecting the system redundancies.
5.1.7 Electrical Isolation

Galvanic or optical isolation shall be provided for all field signals. The isolation levels shall be as
follows;
Analog I/o channel to system ground : 1500 VAC
Discrete I/o channel to system ground : 500 VAC

STD-0201 0
SHEET 30 OF 146
Isolation shall also be provided between Engineering / operator console/PLC programming terminal and
related sub-systems connected to it if there is any possibility of high voltage being transmitted to the
sub-systems.
5.1.8 Design Requirements of Equipments in Hazardous Area

5.1.8.1 Unless specifically indicated, the field devices are beyond the scope of this specification. However
vendor shall be fully responsible for integrating these devices with their system including compiling
and maintaining the engineering data base of these devices and incorporating the data base into the
Asset Management System.
5.1.8.2 General Requirements
a) Unless otherwise specified, all instruments in hazardous area shall be intrinsically safe type. Other
concepts shall be used when specified.
b) For conventional instrumentation, entity concept shall be used for selecting proper barriers /
isolators.
c) Fieldbus segment in classified area may consist only of the type and number of devices which will
not cause the segment current draw to exceed the rated barrier / isolator parameters.
5.1.8.3 Fieldbus design in Hazardous Area
The segment design and equipment solution shall be based on the classified area concept used. The
functions and entity / safety parameters of power conditioner, safety barriers / isolator, terminators and
field devices shall be considered to verify the compliance to the requirements applicable for the
specified concept. Following concepts shall be used depending upon the one specified in the job
specifications;
a) Entity Concept
Certified entity / safety parameters of each device shall be used to match the entity parameters on
entity concept.
b) FISCO
Certified FISCO parameters shall be used and shall be matched like entity parameters. All
elements in the hazardous area and their interface module shall be certified FISCO.
c) FNICO
Certified FNICO parameters and equipment shall be used to design loop on the basis of FNICO.
d) Multi barriers
The safety barriers / isolators shall be installed in the field in an increased safety enclosure. The
enclosure shall be metallic either of SS or of anodised alluminium. The entity / safety parameters
shall be matched as in case of entity concept. Vendor's scope shall include barriers duly installed
in the box / junction box.
STD-0201 0
SHEET 31 OF 146
5.1.9 Repeat Signals

5.1.9.1 Unless otherwise specified in the job specifications, following philosophy shall be followed for repeat
signals;
a) Whenever repeat contact outputs are required as per job specifications following philosophy shall
be followed;
i) For intrinsically safe input contacts, isolating barrier with dual contact output shall be
utilized.
ii) For all other contact inputs, repeat contact shall be provided using electro magnetic relays.
b) Whenever repeat analogue outputs are required as per job specifications, following philosophy
shall be followed;
i) For intrinsically safe analogue inputs, isolating barrier with dual analogue outputs shall be
utilized.
ii) For all other analogue inputs, repeat analogue outputs shall be provided using signal
isolators with dual output.
5.1.10 System Integration
The distributed control system shall be a fully integrated control system , also the Shut Down System
(Safety Instrument system(ESD)) and the Fire and Gas system should be fully integrated with the
control system . Shut Down system and Fire and Gas system should not be integrated with the control
system as or with serial/Foreign/third party device card , however engineering database and
engineering tool of all the above three system should be separate, dedicated and independent of each
other Foreign devices like analyser system, third party equipment, (like compressors etc) etc. shall
be functionally integrated with the distributed control system. Functionally integrated system shall
meet the following requirements, as a minimum;
a) The foreign devices shall either be configurable from DCS engineering consoles or from the
dedicated engineering consoles of each foreign device.
b) Unless specifically indicated otherwise, each foreign device shall be integrated with DCS through
MODBUS (RTU) protocol using redundant interface unit.
c) Operator console shall display information in the similar fashion irrespective of source of
information. Source of information shall be transparent to the operator.

STD-0201 0
SHEET 32 OF 146
d) The process alarms and diagnostic alarms shall be presented on the operator console in the similar
fashion as DCS alarms.
e) Whenever specifically indicated, the time of all foreign devices shall be synchronized with DCS
clock or GPS, as specified in the job specification.
f) The data transfer to and fro from other distributed control systems or supervisory computers
through information network shall utilize OPC protocol with adequate security.
5.1.11 Surge Protection
5.1.11.1 Surge protection devices (SPD's) shall be provided on the system to limit the surge voltages reaching
beyond the safe limits, under normal, abnormal or lightening strike condition. Unless otherwise
specified, SPD's shall be provided at least at the following locations;
a) All serial signal cables (UTP / STP / coaxial and not fibre optical) going from or to control system
and from one location to another out side the control building at both ends.
b) All fieldbus segments at control system end.
c) All power incoming cable (220 V AC ) UPS or non UPS, at the power supply distribution cabinet.
5.1.11.2 The selection of type and rating of SPD shall be selected such that the introduction of this device shall
not change the characteristics or reliability of an application, whether it is for the protection of power
system, signal such as fieldbus or analog or communication signal, as applicable.
In case of fieldbus system, the SPR shall be selected such that its inclusion in the segment shall not
degrade the fieldbus signal, maximum length of the segment and / or number of devices on a segment
significantly.
5.1.12 System Securities
5.1.12.1 The system shall have incorporated a fool proof system security feature in its design which would
protect its data base and functioning against viruses, trojans and works through integrated anti virus,
fire wall and intrusion detection for the system.
5.1.12.2 All devices and / or servers which interface and interact with external application must be supplied
with hardware and software firewalls.
5.1.12.3 All the security protections, hardware or software, as offered shall provide protection against all sort of
threats and vulnerabilities which include;
a) Positive user authentication and login privileges.
b) Prevention of importation of viruses.
c) Packet filtering, content filtering, URL filtering protocol filtering and application level filtering to
accept only intended data.
d) Strict Access controls like password hash files, cryptographic material used in confidentiality etc.
STD-0201 0
SHEET 33 OF 146
e) Hardening of operating system.
f) Firewall proxy.
g) Network sniffers and file integrity checkers
h) Scanning, enumeration and vulnerability scanning tools.
i) Log file analysis tools.
The functionalities indicated above are the indicative security features and shall be provided within and
where data import / export utilities apply.
5.1.13 System Software

5.1.13.1 The system software shall be governed by the operating system running in a real time mode and shall
be able to meet all functional requirements specified in clause 5.2 of this specification as a minimum.
Any other standard/special software package, if available, shall also be offered describing the full
capabilities.
5.1.13.2 The operating system and other standard softwares (e.g. OPC foundation fieldbus etc.) shall be of latest
version.
5.1.14 The system shall have the capability of detecting the open sensors and short sensor. The sensor status
reading on failure either upscale or downscale shall be field configurable.
5.1.15 Emergency Switches (ESD Switches)
5.1.15.1 All Emergency (ESD) switches shall he hardwired and shall preferably pull type with red coloured
knob. Control room mounted ESD switches shall be installed on hardwired console.
5.1.15.2 ESD switches shall directly trip the final ESD element without any intermediate device. Where
multiplication of ESD switch contacts is necessary fail safe relays shall be utilized (SIL3).
5.1.15.3 In addition to utilizing contacts for direct shutdown, the contacts shall also be used in ESD system
(PLC etc) for logic implementation and event history.
5.1.16 Alarm by-pass Switches
5.1.16.1 Startup by-pass (SBS) switches
a) Unless otherwise specified, all SBS's shall be configured in the ESD system (i.e. PLC) and shall be
operable from DCS operator console and PLC operator console when specified. All such by-pass
switches shall be alarmed and shall have audit trail.
5.1.16.2 Maintenance by-pass switches (MBS's)
Unless otherwise specified, following philosophy shall be utilized for MBS's;
STD-0201 0
SHEET 34 OF 146
a) All process inputs shall have miniature back lighted MBS (else shall have LED to show by-pass
status).
b) MBS shall be installed in a cabinet which can be physically lockable. The by-pass status shall also
be available in operator console with a common flashing message always appearing on operator
server whenever an MBS is operated. All MBS's shall have audit trail.
c) Logic-wise common alarm shall also be available on the hardwired console.
5.1.17 Interface with Electrical Input / Outputs

5.1.17.1 All contact input and output contacts from electrical switch gear panels (MCC / PCC etc.) shall be
terminated in a dedicated 'Electrical Interface marshalling cabinet' located in control room. All such
I/O's shall have intermediate relays.
5.1.17.2 Remote I/O rack shall be provided in sub-station for non-shutdown related data, when specifically
indicated in the material requisition.
5.1.17.3 All serial I/O cables from sub-station to control room shall be redundant including remote I/O cable.
5.1.18 Automatic Loop Tuning Software Package
5.1.18.1 It shall be possible to tune a control loop or group of control loops on selective basis at a time
automatically unless otherwise specified. Tuning parameters computed by the system shall either be
loaded automatically or manually by operator.
5.1.18.2 The automatic loop tuning software shall be used to tune PID control loops. The auto tuning
technology used shall utilize principles like Ziegler – Nichols, Cohen – coon or Internal Model Control
(IMC).
5.1.18.3 The software package for loop tuning may reside / run on any system hardware including controller
sub system, console sub system, engineering sub system, supervisory computer etc. The tuning
software must ensure that the process is not disturbed whenever a loop is being tuned.
5.1.18.4 Automatic look tuning package shall be able to study the dynamics of control loops and shall be able to
compute response time, dead time, lead or lag time etc. directly from Engineering / operator console.
5.1.19 The system shall be suitable for power supply as specified in para 6.2 of this specification. Suitable
battery back-up shall be provided for volatile memory protection only.
5.1.20 System Upgrade Capability
5.1.20.1 System shall be scalable and upgradeable by adding additional hardware, over and above the spares
specified, without rendering the initial hardware and software investment obsolete within the capability
of the system.
5.1.20.2 This is in addition to the system upgrades, hardware and software, available from vendor as standard
from time to time.
STD-0201 0
SHEET 35 OF 146
5.1.21 Noise Level
5.1.21.1 Noise level generated by any equipment shall not exceed the following limits;
a) Noise level shall not exceed 55dBA for equipments installed in console room,
engineering room and computer room.
b) Noise level shall not exceed 65dBA for equipments installed in rack room and satellite rack room
(SRR).
c) For control rooms where consoles and cabinets are installed in the same room, the noise level
generated by any equipment shall not exceed 55dBA.
5.1.21.2 The noise level shall be measured in dBA at a distance of 1 metre from the equipment generating noise.
5.1.22 Equipment Identification
Unless otherwise specified, all equipments shall be identified by tag numbers indicated in the data
sheet / summary sheet attached with the material requisition. The tag number shall be inscribed on a
nameplate which shall be fixed with screws.
The nameplate shall be black laminated plastic with core i.e. black with white characters. The size and
description shall be subject to purchaser's approval.
5.1.23 System Furniture

All system furniture required for mounting and operation of the system including mounting of tabletop
equipments shall be supplied. Furniture for operating personnel shall be as defined in job
specifications.
5.2 Functional requirements

5.2.1 The system, as a minimum, shall meet the following requirements without the supervisory computer:
a) Control
b) Data acquisition & monitoring
c) Alarming
d) Logging & report generation
e) Historical data storage
f) Trending
g) System shall have some free memory space available for the user and CPU shall have the
additional capability to perform advance control functions, process optimization programs or
STD-0201 0
SHEET 36 OF 146
generate management reports as specified in job specification in addition to space requirements as
per para 3.0 of this specification. The availability of process control language shall be preferred.
h) System shall support functionalities like remote calibration, remote diagnostics and asset
management in case of smart or field-bus based instruments.
5.2.2 In addition to above, following functional requirements shall also be complied, when specifically
indicated in the job specifications;
a) Sequence of event function.

b) Alarm management
c) Long term historisation
d) Open system connectivity
5.2.3 The system when specified with Programmable Logic Controller (PLC) either as integral part of
system or as separate third party device it shall perform follow functions;
a) Process interlocks
b) Plant safety shutdown
c) Monitoring the sequence control units, when specified
Plant process and safety shutdown shall be independently performed by programmable logic controller.
(PLC shall be communicating with other sub-systems via communication sub-system).
5.2.4 The system when specified along with a supervisory computer, shall meet the following requirements
in addition to as specified in para 5.2.1 of this specification.
a) Advanced Control
b) Unit and plant optimization
c) Management information service reports.
5.2.5 Whenever information network alongwith plant wide interconnectivity is specified, the system shall meet
any or all of the following requirements in addition to those specified in para 5.2.1 of this
specification as specified in the material requisition:-
a) Centralised information system
b) Statistical process control/statistical quality control.
c) Plant optimization, data reconciliation, overall mass balance, etc.
d) Plant planning and scheduling.
e) Computer integrated manufacturing with information transfer to achieve functions like production
and preventive maintenance scheduling and plant wide coordination etc.

STD-0201 0
SHEET 37 OF 146
5.2.6 The system as offered shall be fully and functionally integrated meeting the requirements specified
above. In addition, the system shall also have capability and capacity to interact with smart and field-
bus instrumentation simultaneously. The system shall also be capable of accepting signals from
different type of field-buses in the same controller and data acquisition sub-system.
5.3 Controller and data acquisition sub-system (CDAS)

5.3.1 Controller and data acquisition sub-system shall primarily be used for plant control and data
acquisition and shall interface with physical inputs and outputs from the plant and third party devices.
5.3.2 CDAS shall be microprocessor based and fully programmable sub-system which shall be capable of
processing the acquired data from input / output devices utilizing a set of algorithms within its defined
processing cycle. The microprocessors utilized in controller and data acquisition sub-system shall
generally be of latest generation.
5.3.3 CDAS shall have a multi-processor architecture with each processor responsible to carryout predefined
functions like Input / Output processing, control processing, internal communication, external
interfaces etc.
5.3.4 The hardware and software capability of this sub-system shall primarily be exploited for processing
regulatory close loop and open loop control functions only. Sequencing and interlocking capability
shall be utilized whenever specified in job specifications.
5.3.5 CDAS shall be capable of accepting signals from various process sensors and devices with linear, non-
linear and serial outputs preferably without requiring external or auxiliary signal conditioning devices
and processing signals. Typically the inputs shall include 4-20mA DC (both conventional and HART),
1-5VDC, milli volt signal from thermocouples, resistance from resistance temperature detectors
(RTD's), pulse input, field-bus (foundation field-bus, profibus PA etc.), serial inputs (MODBUS) and
discrete contacts (powered or potential free), as a minimum. System shall also accept other inputs
when specified in job specifications.
System shall be able to accept 2-wire, 3-wire and 4-wire signal inputs without any change in the I/O
module.
5.3.6 The system shall have capability to generate analog 4-20mA DC (conventional or HART) current
signal, 1-5VDC voltage signal, field-bus output signal, potential free contacts for discrete outputs and
serial (MODBUS) outputs, as a minimum, apart from others specified in the job specifications.
5.3.7 The output from the system shall be capable of driving following loads;

STD-0201 0
SHEET 38 OF 146
a) Analog outputs shall be able to drive loads of output devices such as I/P converters, smart
positioners, recorders / indicators etc. In general, it should have load driving capabilities up to
750 ohms.
b) Contact outputs suitable for driving alarm annunications, status lamps, relays, converters,
solenoid valves, contactors / breakers of motor control etc. In general, contacts rating shall as
follows;
Intrinsically safe load : 30V 0.5 Ampere
AC powered loads : 230 V 5 Ampere
DC powered loads : 110V 0.5 Ampere
DC powered loads : 220V 0.2 Ampere
5.3.8 The system shall be capable of differentiating between out of range measurement (Bad process value)
and a failed transmitter signal. In conventional 4-20mA output transmitter this shall be identified by
setting bad quality data flags while for smart (HART) and field-bus transmitters data quality indicator
from the device shall be utilized.
The detection of device failure alarm and driving output to a pre-defined value shall be configurable
within this sub-system.
5.3.9 It shall be possible to override or force an input measurement or an output in the system while testing
or on failure of an input.
5.3.10 Controller and data acquisition sub-system shall have a non-volatile memory for storing
configurational data. In case vendor's standard product supports only volatile memory, battery back-up
shall be provided to store the data for a period of 72 hours, as a minimum. A battery drain indication
along with a potential free contact shall be provided to alert the operator.
5.3.11 The sub-system shall have sufficient memory to store the program instructions, CDAS data base, data
required for real time trending and point trend and any other data required to be stored to meet
specified functional requirements.
5.3.12 The sub-system shall incorporate a hardware or software based watch dog timer to monitor the
healthiness of the CDAS processor-health.
5.3.13 Each controller and data acquisition unit shall have its own dual redundant power supply which can be
replaced online. Separate dual redundant power supply unit shall be provided for powering field
devices.

STD-0201 0
SHEET 39 OF 146
5.3.14 Controller and data acquisition sub-system shall be modular in construction with rack mounted
modules in general. Input / Output modules shall be either rack mounted or DIN Rail mounted type.
5.3.15 Input / Output Modules

5.3.15.1 General
a) I/O modules shall communicate with processor modules serially either through back-plane or
through I/O communication network. I/O network shall always be redundant. Data transferring
through hardwired connections shall not be acceptable.
b) Analog to digit converters for analog 4-20MA / 1-5VDC modules shall meet the following
requirements;
A/D Resolution 12 bits

Repeatability ± ½ LSB
Accuracy ± 0.1% of full scale
Common mode Rejection 60dB at 50Hz
Normal mode Rejection 55dB at 50Hz
c) Digital to analog converters for output module shall meet the following requirements;
D/A Resolution 10 bits (min.)
Repeatability ± 1 LSB
Accuracy ± 0.25% of full scale
d) Each output channel must maintain its own – failure mode value, which is automatically executed
upon detection of a communication failure between process and output module.
e) Unless I/O module has universal design it shall have unique keyed facility to prevent faulty
operation and termination.
In addition I/O modules shall also meet the specific requirements specified in clause 5.3.15.2 through
5.3.15.7.
5.3.15.2 Analogue Input / Output modules (conventional / smart)
The input module shall meet the following requirements;

a) It shall accept 4-20mA isolated input with maximum input resistance of 250 ohms or 1-5VDC
isolated input with input resistance more than 500k ohms.
b) The input module shall support field powered transmitter i.e 2-wir, 3-wire or 4 wire system.

STD-0201 0
SHEET 40 OF 146
c) Input faults such as open circuit, short circuit and earth fault shall be detected by I/O module.
d) The output module shall provide 4-20mA output driving up to 600ohms of total loop resistance at
24V DC.
e) The system shall provide 24V DC for loop powered 2-wire transmitter and shall also loop power
the 2-wire outputs.
f) Input / Output module shall not have more than 16 inputs or outputs.
5.3.15.3 Analogue Input / Output module with HART
a) The Analogue Input / output modules for HART signal shall meet all requirements specified in
clause 5.3.15.2 above.
b) Input / Output shall fully support the HART communication signal i.e. the American Bell 202
standard frequency shift keeping signal superimposed at a low level on analogue measurement
signal.
5.3.15.4 Foundation Fieldbus (H1) Interface Module
a) Foundation fieldbus HI interface module shall be capable of supporting multiple segments and able
to operate in full redundancy mode.
b) Foundation fieldbus H1 interface module shall always be provided in redundant configuration with
Link Active Schedulers (LAS) configured in primary and back-up HI interface modules
respectively to ensure that failure of primary LAS shall not cause failure of H1 bus
communication. Power for H1 segment shall be provided by power conditioner module which
shall be separate from H1 interface module to ensure that failure or removal of H1 interface
module does not affect the supply of power to the segment.
c) HI interface module shall be supplied with link active scheduler (LAS) capability and running
foundation fieldbus (FF) function blocks which include PID, PD, Bias, Gain, calculations etc.
These function blocks shall be code identical to FB code provided in the field devices. The
manufacturer shall guarantee the interoperability of HI interface module with any function box
residing in the field device.

STD-0201 0
SHEET 41 OF 146
d) Foundation fieldbus HI interface card shall utilize a fieldbus Foundation Registered mark.
e) The sub-system shall accept all the dynamic variables transmitted by the field-bus-device.
5.3.15.5 Temperature Input Module
a) The thermocouple input module shall accept grounded or ungrounded inputs from various
thermocouple types i.e. T, E, J, K, R, S and B. The module shall be capable of linearising the
thermocouple inputs and provide cold junction compensation.
b) The module shall have 12 bit resolution with digital accuracy of ±1°c
c) The RTD input module shall accept 100ohm platinum resistance temperature detector (Pt 100) in
3-wire or 4-wire configuration.
d) The module shall be capable of linearising the RTD input.
e) The module shall have 12 bit resolution with digital accuracy of ±0.28°c
5.3.15.6 Serial Interface Modules
a) Serial Interface modules shall be capable of communicating with RS232C, RS422 or RS485
signals.
b) Unless otherwise specified, all serial interface modules shall be configured in redundant
configuration.
5.3.15.7 Discrete Digital Input / Output Module
a) Digital input module shall be capable of detecting close or open status of powered or potential free
contacts. The interrogation voltage of the contacts shall be 24VDC or as per selected barrier for
barrier powered contacts.
b) The input module shall also be suitable to accept inputs from proximity switches or from open
collector output from proximity input barrier.
c) The digital output module shall provide output contact rated for 220V AC 10 Ampere 110V AC 5
Ampere or 110V DC 0.3 Ampere.
d) The type of contact output ie. normally open or normally closed shall be user selectable.
e) Maximum number of inputs or outputs shall not exceed 32.

STD-0201 0
SHEET 42 OF 146
5.3.16 Fieldbus Segment Power supply and terminators
5.3.16.1 The power supply used for powering fieldbus segment shall have a impedance matching network,
preferably part of power supply unit.
5.3.16.2 Short-circuit at spur level shall not lead to failure of any fieldbus segment except the short-circuited
spur.
5.3.16.3 Unless otherwise specified, fieldbus power supply / conditioner shall meet the requirement of type
selected instruments and shall be as per;
a) Foundation fieldbus power supply Type 131 non – IS power supply intended for feeding IS
barriers.
b) Foundation fieldbus type 133 IS power supply compliant with IS parameters.
c) For Non-Intrinsically safe segment, the power conditioner shall be capable of each drawing 20mA
current supplying power to at least sixteen field devices including a segment terminator.
d) For intrinsically safe segment, the power conditioner shall comply with FISCO or entity concept
requirements as specified in purchaser's specifications.
e) For a segment designed with Non-insendive concept, the power conditioner shall meet the
requirements of FNICO.
5.3.16.4 Each foundation fieldbus power supply shall have redundant power conditioners (unless limited by
concept design), current limited outputs to all foundation fieldbus segment and surge protection as
applicable.
5.3.16.5 Individual power conditioners and input power supplies can be replaced without interrupting power or
communication fieldbus segment.
5.3.16.6 Terminators
Terminators shall be provided by vendor at both ends of a foundation fieldbus segment. The
terminator at DCS side shall be incorporated into the foundation fieldbus power supply / conditioner
while field side terminator shall be installed in the junction box.
5.3.17 Control functions and algorithms

Controller and data acquisition sub-system shall have capability to perform conventional and advanced
control algorithms for implementation of regulatory and advanced control strategies. This sub-system
shall have real time computational capability and shall be able to perform following algorithms and
computations in addition to those specified in job specifications;
a) Control algorithms
Proportional (P), Proportional – Integral (PI), Proportional – integral – derivative (PID), adaptive
gain, feed forward, cascade, split-range etc.

STD-0201 0
SHEET 43 OF 146
b) Dynamic Functions
Lead-lag, dead time, timers, counters etc.
c) Signal Selector
High selector, low selector, high-low selector.
d) Calculation Blocks
Linearisation, pressure-temperature compensation, polynomial, multiplication / division / addition /
subtraction etc.
e) Signal Limiters
Low limiter, high limiter, high-low limiter etc.
f) Logic Blocks
Logic 'GATES' (OR, AND, NOR, NOT NAND etc), Flip-flops etc.
5.3.18 Controller shall be able to operate in either manual, auto, cascade or computer mode. Mode changeover
in either direction shall be procedure-less and bump-less. Following functional capability shall
necessarily be possible;
a) In cascade loops, the primary controller shall be able to track the set point of the secondary
controller when the secondary controller is not operating in cascade mode.
b) In computer mode, controller shall be able to track computer generated set point and shall hold the
last generated value in case of computer failure. In such case, controller shall fall back on auto-
mode and continue to operate at the last received set point, in general. Other options like
pre-defined set point operation and fail safe condition shall also be possible. On the resumption of
computer set point again, the controller shall not return to the computer mode automatically.
Computer failure indicator shall be provided at central and local level.
5.3.19 Controller shall accept the change in set point command from central level (as operator interface
function) and take action accordingly. It shall have facility for slow and fast ramping of set point as
well as output. In addition, it shall have anti-reset wind-up feature as standard.
In addition to above, it shall also be possible to change set point, tuning constant, operating mode,
controller configuration from the central level i.e. operator’s interface keyboard and engineer’s
interface keyboard.
5.3.20 Loop Integrity

STD-0201 0
SHEET 44 OF 146
5.3.20.1 Loop integrity shall be maintained in controller functionality in such a way that the single component
failure in the sub-system shall not effect more than one control loop (single loop integrity). This shall
be achieved in offered sub-system architecture in one of the following ways;
a) By providing one to one controller back-up. In case failure is detected in the active controller all
the loops of the failed controller shall be transferred to the back-up controller.
b) Where single loop controller is specified in the purchase specifications, no controller back-up
shall be necessary provided no input other than that required for the specified loop is connected
to the controller.
5.3.20.2 Loop integrity shall be maintained for the data acquisition functionality i.e openloop processing
including processor such that a single component failure shall not effect more than 16 analog inputs or
32 discrete inputs.
5.3.20.3 Loop integrity shall also be applicable to I/O modules, power supply modules, communication modules
and other associated devices as per the philosophy explained in clause 5.3.20.1 and 5.3.20.2 of this
specification.
5.3.21 Sub-system Redundancy

5.3.21.1 In case of redundant configuration (where back-up components are provided), the design shall
incorporate a fail-safe automatic control transfer switching mechanism which shall transfer the entire
configuration, data base and loop control of the failed controller to the back-up controller. Design
must also ensure that data integrity is maintained during switchover and no portion of data to be
transferred is corrupted or lost before and during switch over to the redundant (back-up) controller.
The indication of the failed controller / component shall be displayed at the level as well as on the
central level.
5.3.21.2 The switchover from primary to back-up component / device shall be bumpless and transparent to the
operator i.e. the outputs shall be held at the last value during switchover to avoid any process upset.
The switchover time shall be of the order of one (1) second.
In case of redundant HI modules, the back-up module shall maintain connectivity with all publishers
and shall subscribe to all publishers to minimise switchover time.
5.3.22 Sub-system configuration and on-line modifications

5.3.22.1 Controller and data acquisition sub-system shall be configured from the central level i.e. through
engineers interface sub-system under password or hardwired key lock protection. Single loop
controller when specified shall be configured from the local level.

STD-0201 0
SHEET 45 OF 146
5.3.22.2 Sub-system shall allow following configurational functions to be performed for each loop;
a) Control function parameters
b) Processor cycle time for each loop tagwise.
d) Macro-cycle time for foundation fieldbus HI segment as per segment loading.
d) Output status of each control loop in case of processor failure.

5.3.22.3 It shall be possible to carryout online modifications or perform back-up without interrupting the central
software of preventing the operator commands. Such modifications shall be possible without any plant
upset or process interruption.
5.3.22.4 Downloading of modifications to the respective controller and data acquisition sub-system shall be
possible in running condition.
5.3.22.5 Sub-system shall perform saving and back-up of data base as per changes made automatically.
5.3.23 System Diagnostics
5.3.23.1 Each module shall have a board diagnostic with on board LED for indicating status of the module at
local level.
5.3.23.2 All diagnostic subroutines shall carryout various diagnostic tests to check the healthiness. The test
shall include memory test (RAM and ROM), on-board processor test and back-up module
communication healthiness test etc. Failure of any of the tests shall be alarmed as module failure.
5.3.24 Sub-System Performance
The sub-system response time shall be the indicator for the performance of the sub-system. The
control system shall be able to perform control algorithm, calculation function etc. for each loop within
the specified response time unless specified otherwise in the purchaser's data sheets, the system
response time (scan time) and loop response time as defined in clause 2.22 and clause 2.26 (for
fieldbus based system) respectively of this specification shall be as follows;
° For flow and pressure close-loops - 500mS
° For temperature and level close-loops - 1000mS
° For analyser close-loops - 1000mS
° For all open loops - 1000mS
° For Interlock related inputs - 500mS

STD-0201 0
SHEET 46 OF 146
The processor cycle time shall be set to achieve the scan time and loop response time values specified
above.
Scan time of multi-variable advanced control loops when implemented in controller and data
acquisition sub-system shall be specified in purchaser's data sheets.
5.3.25 Controller & data acquisition subsystem loading
The system loading for controller and data acquisition subsystem shall not exceed 60%. The loading as
indicated here is the worst case of high system activity referred to the use of memory, CPU time and
communication capacity for this sub-system.
5.3.26 Sub-system Sizing

5.3.26.1 Sizing of controller and data acquisition sub-system shall be carried out considering the following
parameters, as a minimum;
a) Unit-wise segregation of CADS as specified in the job specification.
b) Number and type of inputs / outputs specified in each unit in the job specifications e.g. analogue
I/Os (conventional / smart (HART), Fieldbus I/Os, discrete I/Os etc.
c) Intrinsically safe and non-intrinsically safe I/Os.
d) Spares philosophy.
e) Distribution of spare I/O's in I/O modules
f) Scan time (Response time) and loop response time specified for each type of I/O.
g) Segment design criteria
h) Worst-case processor loading specified in the specifications.
i) Calculation blocks specified in the job specification. Following philosophy shall be followed for
computing calculation blocks in addition to those indicated;
PID Blocks - No of outputs
Calculation Blocks - 50% of PID Blocks or 130% of specified calculation

Blocks whichever is higher.
Logic Blocks - 150% of specified blocks or 100% of specified

Discrete outputs whichever is higher.
Advanced blocks - 150% of actual numbers specified.
For the purpose of block calculation, consider actual I/O's along with installed engineering spares.
Also consider clause 5.3.26.2 (e) for fieldbus based system.
j) Serial interface modules in redundant and single configuration as specified.

STD-0201 0
SHEET 47 OF 146
k) Any parameter not specified above but required to be considered for size because of vendors
standard sizing methodology.
Processor loading factor / calculation available in standard product guide for sizing shall be utilised else
vendor shall reduce the sub-system block handling capability by a factor of loading.
5.3.26.2 In addition to relevant requirements specified in Clause No.5.3.26.1, following process control
functionalities and requirement must be considered for fieldbus segment design;
a) The sensor device and the corresponding actuator in a control loop shall be on the same fieldbus
segment.
b) Control loop that include a cascade type controller, the primary and secondary loop measurement
as well as final control element shall be on the same fieldbus segment.
c) Split range measurement and final control element shall be on the same fieldbus segment.
d) Discrete fieldbus device used in an interlock alongwith a control loop, discrete device shall
preferably be on the same fieldbus segment. Discrete device here means fieldbus converter.
e) The default configuration shall be for control (except high level calculations) to reside in fieldbus
device. System shall be configured for control to fail over to CDAS
f) Type of hazardous area philosophy i.e entity concept, FISCO, FNICO or high power trunk.
g) Length of each segment with respect to the physical distance between control system (host) and
field devices.
h) Loop response time or macro cycle time as specified.
i) Sufficient unscheduled time must be kept in each cycle to transmit a cycle information within
defined loop response time. This shall be 50% of the specified loop response time.
5.4 Operator interface sub-system
5.4.1 General
5.4.1.1 The operator interface sub-system shall provide the centralized information to the plant
operator/Engineer in the following fields:
a) Indication of all analog and digital process variables of control loops, open loops and all loop
related parameters

STD-0201 0
SHEET 48 OF 146
b) Manipulation of control loops including changing set point, mode, output, configuration, tuning,
and computational constants.
c) Alarm displays and annunciation.
d) Graphic displays and status indication.
e) Logging and trending including historical trend recording.
f) Trend recording on assignable trend recorders.
g) Self diagnostic messages.
5.4.1.2 The operator interface sub-system shall consist of a single or multiple operator consoles (VDU's driven
by console electronics) and hardwired consoles. The number of consoles for a unit shall depend upon
the size and operating philosophy of the plant. The number of console shall be specified in the job
specifications.
5.4.1.3 The operator interface subsystem shall have either single tier construction or stacked construction. The
type of construction shall be specified in the material requisition.
5.4.1.4 The operator station shall comply with ISO 9241-5 'Workstation layout and postural requirements' and
ISO 9241-7 'Display requirements with reflections'. The layout of the operator interface sub-system
shall be as indicated in the material requisition. The consoles required to meet the shape and symmetry
indicated shall be supplied by the vendor.
5.4.1.5 Unless otherwise specified in job specifications, each VDU shall be a 459.7mm active matrix TFT type
LCD display unit and shall have native resolution of 1280 x 1060 pixels, as a minimum, with a 160°
wide viewing angle.
5.4.2 Operator Consoles
5.4.2.1 Each operator console shall consist of the following;
a) Single tier construction shall have three (3) VDU screens with its own dedicated keyboards (a total
of three keyboards) each driven by an independent electronics.
b) Stacked construction shall have the two stacks of VDU's with four VDU's (2VDU's / stack) and
two sets of keyboards (one keyboard / stack) each stack driven by an independent electronics.
c) Each operator video screen or 2 VDUs of stacked construction shall be driven by a dedicated driver
electronics which also keeps the desired data base for various functions defined and termed as

STD-0201 0
SHEET 49 OF 146
workstation. All the three operator workstations shall be operationally interchangeable in such a
way that all the three workstations have similar data base and functionalities.
d) The operator console shall also have a logging printer, a alarm and event printer and a hard copy
unit, unless otherwise specified in job specifications.
5.4.2.2 Hardware Configuration
The operator console shall meet any one of the following configuration options;
5.4.2.2.1 Option I
Each operator video screen shall be driven by a dedicated driver electronics which also keeps the desired data base
for various functions defined and termed as workstation in this case each as has data stored in it should
be minimum RAID-5 configuration to ensure maximum availability of history/data . All the three
operator workstations shall be operationally interchangeable in such a way that all the three
workstations have similar data base and functionalities.
5.4.2.2.2 Option II
One or more number of operator console (consisting of three video screens and dedicated keyboards)
are driven by a common redundant server machine storing a common database for all the three video
screens (three video screens may work like clients to this server).
Server shall be a multifunction higher end server grade machine which may support functionalities
such as;
a) Data connectivity between CDAS and other sub-systems (i.e. operator sub-system, engineering
sub-system, IAMS etc.)
b) Database storage and engineering functionality as per Clause 5.4.2.3 of this specification.
c) Historisation of data related to associated operator consoles.
This server can also be used for functions like;
a) Plant history (UHN)
b) Connectivity to information network or OPC node.
c) Running specific applications like generating advance controls, MIS reports, IAMS, AIMS etc.
5.4.2.2.3 Option III
a) Two parallel servers (each containing same data base, each driving), two of the operator console
VDU's are driven by a server which stores complete data base for the units being assigned. In this
case, operator console shall have four operator console VDU's (instead of three specified as
operator console). Similar philosophy shall apply in case of stacked VDUs operator console.
b) In case, multiple servers are used to support different functions like data connectivity, data base
storage and historian function, similar philosophy as 5.4.2.2.3(a) may be followed.

STD-0201 0
SHEET 50 OF 146
5.4.2.3 The system shall have global data available at each operator console electronics and all the functions
explained in Clause 5.4 shall be available / executed at operator console. However, in case
functionalities are distributed in various intelligent hardwares / softwares or in case of distributed
database / console functions is supported by the standard system architecture, each data base
electronics / functionality shall be RAID 5 configuration dual redundant. Further any change made in
the data base of one operator console shall automatically update the data base of other operator
consoles if configured identically. Following shall apply;
a) history function, for the units monitored and controlled from the operator console, shall be RAID 5
configuration dual redundant with each node have dual disc drives dedicated for history storage.
b) Data base storage function for the units being monitored and controlled by the unit shall be RAID
5 dual redundant and shall have dual disc drive configuration.
c) All stations used for data storage and such functionalities shall have RAID5 configuration.
5.4.2.4 The operator, as a minimum, shall have access to the following through the operator key board at all
times:
a) Selection of all the displays including the direct selection of loop in alarm, page turning facility,
overview, group view and loop view selection etc.
b) Selection of loop for operation.
c) To acknowledge alarms as and when they are annunciated on the operator console.
d) Facility to enter any changed parameter like setpoint, manipulated variable, digital commands and
to cancel any wrong entry while making such change.
f) Facility for easy positioning of cursor for the selection of any parameter.
g) Selection of hardcopy printout, logging printout, alarm history printout and assignable trend
recorder points.
h) Auto/manual/cascade/computer mode changeover of each controller.
5.4.2.5 In addition the Engineering keyboard shall have the following capabilities for restricted user/engineer
through a key-lock or with password protection;
a) Data base configuration including overview, group, loop, multi-loop and multi-variable control
configuration.
b) Group or multi-group alarm inhibit from a plant under maintenance.

STD-0201 0
SHEET 51 OF 146
c) Reconfiguration of alarm settings and their values, addition and deletion of components in a loop.
d) Tuning of control loops including change of P, I, D and dead-time contacts
e) On-line compilation of graphic displays using standard user defined symbols.
f) Changing of parameters to be logged.
g) Setting of real time clock.
h) Assigning of parameters for historical trending.
i) To call detailed self-diagnostic for maintenance.
Any change made for any parameter for an input from any display shall be automatically updated on all
displays configured for that input.
5.4.2.6 Operational Protection
A key-lock switch or software password shall be provided for operational protection. Following
minimum level of access and authorisation shall be available;
Operator Level - Authorises all commands for plant operation.
Engineers level - Authorises all commands for plant operation and

system engineering.
Management Level - Authorises all operational data and reports to be

viewed.
Other levels of key-lock / password protections if available as standard with the system shall also be
offered.
5.4.2.7 It shall not be possible to override any process variable or digital status from operator keyboard.
5.4.2.8 Each keyboard either integral or as a separate attachment shall have a set of dual function user
configurable keys. These keys shall be configured to access important pages in single keystroke. These
keys shall have LEDs which flash on pre-configured alarm conditions. A minimum of 32 number of
such keys shall be offered with each keyboard. Systems, which do not support dual function keys with
their standard keyboard shall offer either;
i) a dedicated VDU and keyboard with each operator console configured with an intelligent graphic
which would replicate the functionality of dual function keys.
ii) a dedicated keyboard with dual function keys alongwith each standard keyboard.
5.4.3 Process displays

STD-0201 0
SHEET 52 OF 146
5.4.3.1 Process information and operational aids shall be presented to the operator in the form of display.
These displays shall cover all points related to tag numbers built within the system. The process
displays shall include different type of displays and the functionalities associated with each of these
displays. Various types of process displays, as envisaged, are detailed out in the clauses to follow.
The details provided herein are typical and explain only the functional requirements. The systems as
offered must provide displays which meet these functional requirements.
5.4.3.2 Overview display
5.4.3.2.1 Overview display shall present the overall status of a unit or large segment of the process plant. The
analysed data and alarm conditions are displayed with colour changes.
5.4.3.2.2 Overview display shall incorporate a minimum of 128 analog or discrete inputs which can be
monitored simultaneously on the VDU screen (Referred as page). Each page shall be organized into a
suitable number of groups. Each group shall be identified separately. Each group shall further
incorporate suitable number of inputs (Referred as tags). Suitable identification and description shall be
shown for each group on the overview display to relate it to a group or loop display.
5.4.3.2.3 All analog points in the overview shall be represented as variable lengths indicating deviation above or
below the normal operating value or set point.
5.4.3.2.4 Alarms shall be displayed in change of colour against each variable if the variable crosses a set value.
Control loops operating in manual mode shall be indicated.
5.4.3.2.5 An input in alarm condition shall be identified by flashing.
5.4.3.2.6 In case, any hard wired instrumentation backup is provided, overview pages shall be assigned
indicating the tag number and type of hardwired instrument.
5.4.3.2.7 The operator shall be able to call directly any group display or loop display or any predetermined
displays covered in the overview display.
5.4.3.2.8 It shall not be possible to acknowledge alarms directly from the overview display.
5.4.3.3 Group Display
5.4.3.3.1 Group display shall be limited to the group of inputs as displayed in the overview display. Each group
shall preferably include eight (8) number of inputs.
5.4.3.3.2 Each input in the group shall be identified by the tag number, unit of measurement and process
description which shall be displayed on the VDU screen.
STD-0201 0
SHEET 53 OF 146
5.4.3.3.3 Display, as a minimum, shall show following degree of details:
a) Process variable in analog form shall show, as a percentage of the transmitter span on a linear scale
bar graph of 0- 100% or engineering units and in digital form as alphanumeric display in
engineering units.
b) Set point value in analog form as a percentage of the transmitter span on linear scale bar graph of
0-100% engineering units and in digital form as alpha-numeric display in engineering units.
c) Output value in analog form as a percentage of linear scale bar graph of 0-100% and digital form
as percentage.
d) Controller mode i.e. auto, manual, cascade, computer.
e) Process alarm on process variable, deviation or velocity.
f) Selected loop within the group shall be identified by cursor marking or similar identification.
g) Control valve failure position.
h) The contact input / output shall be represented by simulated graphic lamps and configurable
alphanumeric status description.
5.4.3.3.4 It shall be possible to control the process from group views. Following control actions shall be
possible;
a) Increase / decrease of set point value either slow or fast.
b) Change of controller mode i.e. Auto/manual transfer.
c) Changing output to the final control element.
d) For digital points, start/stop or open/close command.
5.4.3.3.5 It shall be possible to repeat any tag number in more than one group/console. However it shall be
possible to control or change configuration from only pre-assigned group/console.
5.4.3.4 Loop Display
5.4.3.4.1 Loop display shall provide a separate detailed display for each of the process inputs. The graphic
representation of analog and digital points shall be similar to group display. However in addition
following information shall also be presented in alphanumeric form as a minimum
a) Controller tuning constants.

b) Process variable zero and span values.
STD-0201 0
SHEET 54 OF 146
c) Alarm set point on various parameters.
d) Limits on set point, output, velocity etc.
e) Controller action (direction/reverse).
f) Failure position of final control element.
g) Computational constants like ratio or bias.
h) Integrated value.
i) Output to the final control element.
j) Engineering units.
5.4.3.4.2 It shall be possible to change the following through the keyboard of operator console:
a) Tuning constants.
b) Scale, zero and span.
c) Limits on set point, output, velocity etc.
d) Configuration of any loop.
e) Alarm set points.
f) Control mode.
g) Output to the final control element.
h) For digital points, it shall be possible to issue start/stop or open/close command.
5.4.3.4.3 Loop control parameters changes as specified in para 5.4.3.4.2 (a) to (e) shall be restricted by a key
lock control or password.
5.4.3.4.4 The loop display shall also contain a trend displaying process variable, set point and output with a
sample interval time of maximum 1 second and full scale time base of minimum 60 seconds for tuning
the process control loops.
5.4.3.5 Graphic display
5.4.3.5.1 It shall be possible to display dynamic graphic of different sections of plant on the operator console
VDU screens. Graphic displays shall be field configurable only through engineering key-board with
standard / user defined graphic symbols. Dynamic graphic displays if different sections of the plant
shall be displayed on different pages.
5.4.3.5.2 The system shall have graphic symbol library as per ISA-5.1 and 5.3. In addition standard industrial
symbols like distillation columns, heat exchangers, pumps, compressors, tanks etc. shall also be
provided as a standard.

STD-0201 0
SHEET 55 OF 146
5.4.3.5.3 Graphic displays shall be interactive type through which it shall be possible to control the process. It
shall also be possible to send motor start/stop and shutdown valve open/close commands, as specified
in job specifications, from this display.
5.4.3.5.4 It shall be possible to view the process variable and alarm points and view and change set point value,
manipulated variable, controller mode etc. from the graphic display. Also rotating machinery (i.e.
compressor / pump) status and valve status shall be displayed on the graphic display with different
colours.
5.4.3.5.5 Various colours used in the generation of graphics like colour of the process lines, utility lines,
Instrument signal lines and event modifier conditions shall be finalised during detailed engineering.
The colours used to identify event modified conditions shall generally be as follows unless otherwise
indicated during detailed engineering.
Red : All points alarm
Blue : Valve open, pump running.
Green : Valve closed, pump stopped.
Flashing green : Shut down valve transition state.
5.4.3.5.6 It shall be possible to go from any graphic page to related graphic pages or any group view or alarm
summary in single key stroke using soft key function.
5.4.3.6 Trend Display
5.4.3.6.1 The system shall be capable of displaying the following trends:
a) Real time trends for the parameters specified in job specifications displaying current data for a
period of minimum one (1) hour as defined in clause 2.33 of this specification. However it shall be
possible to assign any parameter for real time trend.
b) Historical trend for number of parameters as specified in the job specification for a period of 30
days with sampling rate of 10 minutes. However, it shall be possible to assign any parameter for
historical trending.
5.4.3.6.2 Historical data shall be stored on the nonvolatile memory device like hard disc in such a way that such
historical data can be utilized for archival storage and subsequent recall.
5.4.3.6.3 Real time and historical trend shall be possible on any parameter or variable like measured variable, set
point, output, calculated variable etc.

STD-0201 0
SHEET 56 OF 146
5.4.3.6.4 It shall be possible to sample and store data of instantaneous and average value at the intervals
mentioned below. However it shall be possible to display by scrolling or expanding the time base for
all the trends.
a) At intervals 1 second or higher for the real time trend.
b) At 1 minute, 10 minute & 1 hour interval for historical trend.

Historical data trends shall be displayed for a period of minimum up to 72 hours for a data
sampling rate of 1 minute.
5.4.3.6.5 The requirement of fast trend (trends with sample time faster than Real time trend) if any, shall be
specified in the job specification. This shall be in addition to tuning trend requirement specified in this
specification.
5.4.3.6.6 Selection of the tag number and sampling time for real time and historical trending shall be possible
from operator keyboard.
5.4.3.6.7 The system shall also have a multi trend capability in such a way that it shall be able to display set
point, measured variable and output on the same display, the trend of either the same process variable
or any other process variable.
5.4.3.6.8 Trend display shall be single line type or bar graph type with additional information like loop tag
number, engineering units, span, present value of the trended point, alarm status etc displayed.
5.4.3.7 Closed Circuit Television Window display
It shall be possible to display close circuit television (CCTV) video monitor image on the operator
console as a CCTV window. A function key on the operator keyboard shall be assigned to select the
desired CCTV monitor window. The CCTV window on the operator console video shall always be on-
top.
5.4.3.8 Alarm Monitoring and display
5.4.3.8.1 Alarm Management
a) It shall be possible to display process as well as system alarms on the operator console for
operator’s attention and action. Alarms shall appear immediately on the operator console as and
when they occur on priority basis.
b) It shall be possible to set process alarm limits from the engineering keyboard i.e. alarm limits on
absolute value of measured variable; rate of change of measured variable; high and low deviation
set points; high, extra-high, low and extra-low points on process variable and output etc. In
STD-0201 0
SHEET 57 OF 146
addition, it shall be possible to derive alarm conditions on the basis of few calculations performed
by the system.
c) Alarm messages shall be displayed by flashing the page and group number of the input under alarm
irrespective of type of display. It shall be possible to access the group or tag in alarm condition
with a maximum of two key-strokes of operator’s console keyboard. The plant overview display, in
addition to display alarm message, shall also be able to provide warning by changing colour of
excessive deviation of process variable from their set value.
d) All alarms shall be displayed as and when they occur or generated with change in the colour of
display in the following sequence, activating an audio signal:
Continuous flashing : Un-acknowledged alarm

Steady display : Acknowledged alarm
e) The system shall not put off the audio alarm and visual flashing even after the condition returns to
normal unless it is acknowledged by the operator.
f) In order to provide immediate attention to critical alarms, alarms shall be classified in the priority
of their criticality.
g) In addition to alarms appearing on the different displays as mentioned in para 5.4.3.1 to 5.4.3.5 of
this specification, the system shall also be able to display alarm summary and alarm history as per
para 5.4.3.8.2 and 5.4.3.8.3 of this specification.
5.4.3.8.2 Alarm summary display
a) It shall be possible to display summary of all alarms in the sequence of their occurrence and shall
disappear from display only when they are acknowledged and cleared. The alarm display shall list
the following for each alarm as a minimum:-
i) The date and time of occurrence.
ii) Point identification (i.e.Tag number)
iii) Point description.
iv) Type of alarm (absolute value or deviation.)
v) Serial number of alarm in the sequence of its occurrence.
b) The system shall be able to display on alarm summary a minimum of 100 alarms.
c) Alarms shall preferably be listed in the form of alarm list like current, List I, List II etc. The
minimum number of alarms per list shall be 25. Alternately system may provide a common list of
alarms in the sequence of their occurrence (with respect to time).
5.4.3.8.3 Alarm history
STD-0201 0
SHEET 58 OF 146
a) The history of alarm conditions shall be maintained in the database for alarm history display and
printed on shift-wise basis for the parameters specified in the job specifications. The alarm display
and print out shall list the following for each alarm as a minimum:-
i) The data and time of occurrence.
ii) Point identification (i.e. Tag number)
iii) Point description.
iv) Type of alarm (absolute value or deviation.)
v) Time of acknowledgement.
vi) Time of return to normal.
vii) Serial number of alarm in the sequence of occurrence.
b) The system shall be able to display and print out the alarm history of minimum of 300 alarms.
c) Alarms shall be listed in the form of alarm lists like List I, List II, List III etc. The minimum
number of alarm points per list shall be 25. Alternately system may provide a common list of
alarm in the sequence of their occurrence.
5.4.3.8.4 System alarm
a) System shall have capability of on-line self diagnostics as mentioned in para 5.4.5 of this
specification.
b) Any abnormal conditions in and sub- system or any other functional device shall be displayed as
system alarm message on the operator console irrespective of the display selected.
5.4.3.9 Configuration display
5.4.3.9.1 Configuration display shall provide a separate detailed display for each loop indicating the
configuration of that loop. When control requires more than one loop, all interrelated loops shall also
be displayed. Following information is required to be available on configuration display.
a) Loop configuration giving designation of each block.
b) Control block interconnection showing soft-wiring or hardwiring.
c) Value of each block parameter like P.I.D., ratio, bias, dead-time, lead- time etc.
5.4.3.9.2 It shall be possible to configure & reconfigure the loops from this view using user friendly software.
5.4.4 Logging and Report Generation function
5.4.4.1 It shall be possible to log all real time data, historical data, computed parameters, operator actions,
alarms and events etc from operator consoles irrespective of data source connected to communication
sub-system. In general, the data type shall include;
a) All measured and manipulated variables (inputs as well as output data)
STD-0201 0
SHEET 59 OF 146
b) System calculated variables
c) Historical data values
d) Alarm and event data
e) Operator data entry and operator actions
f) Equipment status data
g) Data through serial links
h) Data through OPC server
i) Batch related data
j) System clock time
k) System diagnostic data
5.4.4.2 The system shall have a report builder and report scheduler which shall have following capabilities;
a) The system shall be able to generate reports on hourly basis, shiftly basis (8 hourly), daily basis and
in some cases weekly or monthly basis, as specified in job specifications.
b) The system shall be able to generate reports as per operator command either on-demand or on
predefined time.
c) In general, the type of reports shall be;
° On demand report initiated by operator action
° Predefined time initiated report e.g. hourly, shiftly, daily etc.
° Event driven report
° Shutdown driven report

° Equipment runtime status report
d) The generation of on demand report shall not affect any scheduled report.
e) These reports shall be stored in separate files independent from historical and trend data files.
5.4.4.3 All parameters required for logging shall be stored in the system memory as per data base update rate.
The system shall be able to perform following functions on all such stored data prior to logging as per
the requirement of the report;

STD-0201 0
SHEET 60 OF 146
a) Basic arithmetic calculations such as averaging, summing, multiplication, division etc.
b) Advanced calculations like efficiency calculations, conditional calculations etc.
c) Extended log reports such as weekly and monthly reports.
d) Batch Reports
5.4.4.4 The formats used to generate log reports shall be user definable, in general. Typical log formats for
hourly, shiftly and daily reports have been attached alongwith (Refer Annexure 1) for reference.
System shall have a user friendly structured programming language suitable to generate and access
various reports. System may utilize high level language for generating reports with advanced
calculations. High level language compiler software shall be supplied as part of standard system
function.
5.4.4.5 Number of log reports generated for a project shall be governed by the number and type of log formats
defined for a project like hourly report format, daily report format, shutdown report format etc.
Number of pages in each log report shall be sufficient to accommodate all the parameters defined in the
job specifications.
5.4.4.6 In addition to the real time and historical data, the report builder programme shall incorporate report
title, sub-headings, notes and messages.
5.4.4.7 Hourly report shall be printed only as and when initiated on demand by the operator and shall not be
printed automatically after the end of the hour. All other reports shall be printed automatically at the
end of the pre-defined time as well as on demand by the operator. The maximum storage time for a log
information shall be 15 minutes after the pre-defined print out time for a format, within which time log
report must be printed. In case report could not be printed within the scheduled defined time, data shall
remain stored till the report is finally printed.
5.4.4.8 Logging hardware
Data required to be logged shall be finalised during log report finalisation stage. However, typically
following shall apply;
a) All tag numbers, analogs as well as digitals, shall be available for hourly log.
b) All flow tag numbers and other selective tag numbers shall be available for daily log
report.
c) Only selective tag numbers shall be available for weekly and monthly report.

STD-0201 0
SHEET 61 OF 146
d) Average (over the defined period) for flow and instantaneous shall be used for log printing with
maximum and minimum value as defined in log formats.
5.4.4.9 Logging Hardware and Software
5.4.4.9.1 The system shall be supplied with all hardware and software necessary to meet functional requirements
specified in Clause 5.4.4.7 of this specification. Log reports shall be generated, compiled and printed
using system standard hardware and software. No separate computer / server shall be used.
Separate server, if necessary, may be utilised, to generate extended logs or reports requiring advanced
calculation.
5.4.4.9.2 It shall be possible to archive log reports on an external computer. Facility shall also be available to
retrieve these reports as a magnetic tape or a disc for future reference.
5.4.4.9.3 In the event of printer failure, the system shall maintain the data in the point buffer memory of the
report originating device buffer with a printer failure alarm.
It shall also be possible to print the report at an alternate printer without any data loss, whenever
necessary.
5.4.4.9.4 System Printers
a) In addition to configuration and maintenance (C&M) printing, printers shall be used for printing
reports like log reports and alarm and event reports.
C&M printers shall be dedicated for each machine whenever such a function is required.
b) All printers shall be low noise industrial type and shall be suitable for continuous duty.
c) Logging printer
Logging printer shall be A3 size colour laser printer and shall be able to meet the following
requirements;
i) Logging printer shall be able to print the following reports;
- Printing of hourly, shift-wise, daily and weekly log.

- Shut down report printing.
- Any other report defined in the job specification.

STD-0201 0
SHEET 62 OF 146
ii) In addition to above, logging printer shall also be used for printing hard copy of any video
screen, whenever necessary.
d) Alarm and event printer
Alarm and event printer shall be low speed dot matrix printers capable of meeting the following
requirements;
i) Alarm and Event printer shall be able to print out following reports;
- Log the process and system alarm messages with a time stamp as and
when they occur
- Print the alarm history for every shift of operation or on demand from operator
console.
- Log events such as operator actions as defined in para 2.30 of this

specification, as and when they are initiated.
- System alarms as per self-diagnostic reported alarms.
ii) Alarms and Events shall be clearly distinguishable on the report, preferably by colour.
iii) Print out shall show as a minimum the tag number, description, date and time of
occurrence, time of acknowledgement and time of return to normal.
iv) The time stamp shall include month, day, hour and minute.
e) Multifunction printer
Multifunction printer be a colour laser printer which shall be able to print out log reports as well as
alarm and event reports. Multifunction shall be specified either common for a unit or a group of
units. The functionality of multifunction printer shall be same as (a) through (d) specified in clause
5.4.4.9.4 of this specification.
The command for printing of any report shall be generated from any operator and / or engineering
console. The reports shall be generated in the priority of which shall be as per request time for
printing report.
f) Hard-copier
i) Hard-copier shall preferably be a coloured heavy duty laser printer. The command for
copying shall be initiated from any operator console.
STD-0201 0
SHEET 63 OF 146
ii) The screen display may be changed on the console after the copy command is initiated for
any screen. This video copier shall have buffer memory storage for at-least two screen
pages.
5.4.5 Self diagnostics
5.4.5.1 The self diagnostic message for a subsystem failure shall appear on the operator console irrespective of
display selected. The choice of the detailed self diagnostic displays shall be made by a key-lock switch.
5.4.5.2 The system shall have an extensive set of self-diagnostic routines which shall locate and identify the
system failure at least up to module level including redundant components.
5.4.5.3 At the local level, failure of a module in a sub-system shall be identified by an individual LED display.
5.4.5.4 Failure of a subsystem shall be annunciated with the change in colour. To aid system maintenance and
for effective fault location, following displays shall be provided as a minimum.
5.4.5.4.1 Communication system status display.
The display shall show an over view of different sub-systems connected over the communication
sub-system showing status of each sub-system. When a failure is detected by the system self diagnostic
routine, the display shall indicate the location and nature of malfunction. Display shall as a minimum
have
- Type of sub-system.
- Failure of communication bus/link with the sub-system.
5.4.5.4.2 Sub-system diagnostic display
One display page shall be available for each sub-system on the communication sub-system which can
be called on demand.
The display as a minimum shall contain:

- Sub-system number and type
- Error code and description
- Details of failed module
5.4.6 Data Storage, Archival and Retrieval
5.4.6.1 Historical data shall be stored on a non-volatile memory device like hard disc which can be
subsequently recalled by operator on any screen. System must support multiple historical data
discs in order to avoid data loss in case of disc crash.
STD-0201 0
SHEET 64 OF 146
5.4.6.2 It shall also be possible to store and retrieve this data on removable mass storage media like floppy
disc, cartridge or tape etc.
5.4.7 Assignable Trend Recorder
5.4.7.1 It shall be possible to provide real-time trend on the assignable recorders for any process or calculated
variable. The variable shall be assigned through the keyboard of operator console on any point and any
recorder connected to that console.
5.4.7.2 Assignable trend recorders shall be located on the hard wired console. Each recorder shall have four
pens.
5.4.8 Hard copy unit
5.4.8.1 Hard copy unit shall be used to make permanent copy of any VDU page when demanded through the
operator console/Engineer console.
5.4.8.2 VDU page shall not be locked for more than 5 seconds while taking the video-copy.
5.4.8.3 Copies of display shall be in full colour.
5.4.9 System Servers sizing criteria

5.4.9.1 The servers provided as part of standard system architecture shall have fault tolerant architecture with a
minimum availability of 99.999%. The design requirements of each server shall be dependent on its
functional requirements such as;
a) Guaranteed throughput performance.
b) Continuous and consistent data connectivity even during fault.
c) Continuous and consistent processing of data even during fault.
d) Fault tolerant operating system.
The fault tolerant configuration of server shall include synchronised redundant processors such that
failure, if any, is transparent to the user and server applications.
Transparent to the user implies that the data display on the graphic of any VDU shall not be lost for
more than three (3) seconds in case of failure of the main server.
5.4.9.2 In case if redundant server configuration, the maximum switchover time shall not exceed ten (20)
seconds.
System servers which have switchover time exceed 3 seconds, shall ensure that real time data is
available on at least two of the three operator console VDU's even during switch over.

STD-0201 0
SHEET 65 OF 146
5.4.9.3 All machines that are used for data is storage shall be high end server garde machine with minimum
RAID – 5 configuration. General purpose servers( below RAID 5 Configuration) shall not be
acceptable.
5.4.9.4 Server Sizing
5.4.9.4.1 Unless otherwise specified, following criteria shall be considered while sizing the server / servers used
for driving operator console( for configurations where data is not stored in the operator station);
a) Number of operator workstation (clients)
Consider 1.2 times the specified number of operator workstations rounded to next higher whole
number for each type.
b) Number of Engineering workstations (clients)
Consider 1.2 times the specified number of engineering stations round to next higher whole
number.
c) Number of Controller and data acquisition nodes
Consider 1.4 times the specified number of CDAS nodes.

d) Maximum number of nodes / sub-systems on the network should be less than 60% of the system
capacity specified in the standard printed catalogues of manufacturers.
e) Maximum history storage tag numbers per second
Consider 1.4 times the specified number of tag points in the material requisition with storage rate
of 1 second.
f) Maximum number of trends
Consider 1.4 times the specified number of trend points. Where no separate trend points are
indicated consider all analog inputs and outputs as required trend points.
g) Maximum number of Reports
Maximum number of log reports (formats) shall be 50 with 1000 points in each log report.
h) Maximum number of Tag data
Consider 1.4 times the total number of tags and associated parameters i.e. process variable, set
point, manipulated variable, auto-manual-computer status, alarm values, diagnostic data from field
devices, serial data (process and diagnostics) from third party devices SOE data etc.
i) Maximum number of process alarms, operator events and operator messages
Consider 1.4 times the maximum specified parameters. Where no operator-events or operator
messages are indicated in material requisition, consider a total of 1000 points for sizing.
STD-0201 0
SHEET 66 OF 146
j) Number of Peripheral devices
Consider 1.4 times the maximum number of peripheral devices specified in the configuration
diagram.
k) Maximum number of fieldbus segments
Consider 1.4 times the maximum number of fieldbus segments specified or computed by the
vendor, as applicable.
l) Maximum number of data for UHN and OPC node ( If applicable )
Consider 1.4 times the maximum number of tag data specified in the job specification. Where no
separate data is given in the job specification consider through put requirements specified for UHN
and OPC node sizing in this specification. The polling rate shall be considered as 1000 tags per
second.
m) Maximum amount of Asset Management data
Consider 1.4 times the maximum data available from field devices for asset management.
5.4.9.4.2 While sizing the server / system consider the following operational features;
a) Number of Operator Console VDU (WS) : 33% of 'A'
with over view display.
b) Number of operator console VDU's (WS) with : 33% of 'A'
trend displays.
c) Number of operator console VDU's (WS) with graphic : 33% of 'A'
displays.
Consider 'A' as number of workstations specified in clause 5.4.9.4.1(a) of this specification.
5.4.10 System Operational Response Time
The system shall meet the following response times beyond which the delay may have detrimental
effect on the operator's performance;
System activation or Logging-on of a terminal : 1 sec.
Display call-up time
- Simple pages like menu display : 0.5 sec.
- Graphic page : 1 sec.
Command execution response : 4 sec
Data entry error reporting : 1 sec.
Response to mouse / keyboard commands : 0.5 sec.
5.5 Engineer interface sub-system

STD-0201 0
SHEET 67 OF 146
5.5.1 Engineer interface sub-system shall be primarily an engineer's interface which shall normally be used
for configuring, tuning and maintenance of the Distributed Control System. This sub-system shall also
be used as operator console whenever necessary (e.g. during start-up etc).
5.5.2 It shall consist of an Engineering console which shall be able to perform all engineering functions
related to each operator console and other sub-systems e.g. controller and data acquisition sub-system,
interface devices etc (except PLC for which dedicated engineering console shall be provided). It shall
also be possible to configure field-bus function blocks on any segment from engineering console.
5.5.3 Each Engineering console shall consist of single or multiple colour 459.7mm active matrix TFT LCD
video screens with full integrated audio capability and shall have an integral USB hub. The video
screen shall have a native resolution of 1280 x 1024 pixels with wide viewing angle. Each engineering
video screen shall be provided with one operator key-board and one engineering keyboard. This, as a
minimum shall also have one configuration and maintenance printer.
5.5.4 Engineering console shall also have, the capability of an operator console. However, the operation of
the plant shall be restricted from this console. All the operator console displays as specified under
clause 5.4.3 of this specification shall also be available on Engineering console.
5.5.5 Engineering console like any other sub-system shall be capable of communicating with all other
sub-systems over the communication sub-system.
5.5.6 Engineering console shall have individual dedicated electronics with RAID 5 disk configuration.
5.5.7 It shall be possible to perform all system configuration functions and configuration modification
functions from the Engineering console typically;
a) Data base configuration including overview, group view, loop view, trend view, sequential
programming, multi-loop multi-variable control configuration for connection, smart and field-bus
based inputs.
b) Group or multi group alarm inhibit from the plant under maintenance.
c) Configuration or re-configuration of alarm settings, their values, addition or deletion of any control
block or component in a loop.
d) Compilation of graphic displays.
e) Setting of real time clock.
f) Compilation of logs/reports/historical trend points.

STD-0201 0
SHEET 68 OF 146
g) To call detailed self diagnostic displays for maintenance aid.
5.5.8 Configuration Requirements

5.5.8.1 It shall be possible to configure conventional, smart (HART) and fieldbus I/O's and control strategies
the same way. The device configuration application for HART and fieldbus devices shall utilize
EDDL or FDT / DTM as specified in data sheet. It shall include the following;
a) Capability to display all device parameters directly from the device itself.
b) Modify and download device configuration directly to device.
c) Separate display of process values and device alarms.
d) Capability to modify multi-device and download all at the same time.
5.5.8.2 Fieldbus HI interface configuration
a) The configuration software shall have capability to configure all HI fieldbus interfaces such as;
- LAS assignment and management
- LAS scheduling
- Macro cycle time calculations / optimisation
b) Interface configuration software shall support multiple LAS as a segment. Graphical tool shall be
provided which shall provide sequence of execution, execution time of each fieldbus device and
overall macro-cycle time.
5.5.8.3 Fieldbus Function blocks
a) The configuration software shall be able to configure all fieldbus functional blocks available in
fieldbus devices.
b) Function block configuration shall be downloaded from engineering console to field devices on
line.
c) Downloads that will result in change in segment macro-cycle shall proceed with a positive
confirmation before the download is allowed.
5.5.8.4 Segment Scheduling
a) The engineering software shall have capability to carryout segment scheduling against the
scheduling constraints such as number of parameters which LAS can transmit during the single
cycle.
b) Response time for an HI segment shall be from 32μ seconds to 2.2milliseconds.
5.5.8.5 Automation configuration tool
5.5.8.5.1 The configuration software shall be capable of auto-detection of following I/O devices;
a) Identification of I/O ports and all types of I/O modules with software configuration defined. If
mismatch is detected, an alarm message shall be generated.

STD-0201 0
SHEET 69 OF 146
b) Function block configuration tool shall be capable of identifying the installed field devices. An
alarm message shall be generated in case of mismatch.
c) Automatic address and tag name assignment for fieldbus devices. These capabilities shall also
include handling of any foundation fieldbus registered device using the device DD and CFF files.
5.5.8.5.2 The system shall be pre-configured to identify the attributes of all I/O interface ports and general
characteristics of any connected field device, which comply with FDDL (of latest version) or FDT /
DTM as specified.
5.5.9 Tuning of a control loop shall be possible from Engineering as well as from operator console, the
location for tuning shall be selected by the operator.
5.5.10 On-line Configuration

The system shall have the capability to copy, store, modify and restore the configuration data on-line
without shutting the system partly or completely. The system shall be capable of downloading
controller configuration from engineering console without taking controller off-line.
5.5.11 Off-line Configuration
5.5.11.1 It shall be possible to generate system configuration i.e. controller and data acquisition sub-system and
display configuration including graphics from an independent PC with windows software loaded.
System engineering features like continuous control, advanced controls, displays, alarm, historical
functions, logging functions etc. shall be configurable from above station. The configuration shall be
possible without the availability of actual engineering station. Configuration generated off-line shall
be loaded on to engineering station without any limitation.
5.5.11.2 Fieldbus engineering software tool shall be able to perform offline fieldbus engineering by accessing
CFF and DD files of field devices without connecting the field devices.
5.5.12 During the normal operation, the Engineering console, in no case, shall interfere with the process
operation or system software. However any change in the configuration shall be down loaded into the
system with proper knowledge of the operator.
5.5.13 All detailed diagnostics of the system shall appear on the Engineering console with a print out on the
Configuration and Maintenance (C & M) printer. A common diagnostic message on the operator
console shall indicate the need of the maintenance.
5.5.14 To aid the system maintenance and effective fault identification, following displays shall appear on the
engineering console;
a) Communication system status display

STD-0201 0
SHEET 70 OF 146
b) Device diagnostic display and System diagnostics upto module level should be possible from the
diagnostic software. The details of system diagnostics are described under para 5.4.5 of this
specification.
5.5.15 Any special diagnostic package, in addition to as mentioned under para 5.4.5 of this specification, if
available with the system shall also be offered. Detailed description and capability of this package shall
be supplied.
5.5.16 C&M Printer shall be used for printing the configuration or configuration changes, printing system
alarms as and when they appear and to print out any engineers command from Engineering console.
Hard copy unit, when specified, shall be used to take hard copy of the engineers console screen.
5.5.17 The system shall have adequate security features to secure plant operation and DCS data base.
Engineering console shall have the following security features, as a minimum;
a) Key-lock or password protection for accessing operator functions and engineering functions.
b) Redundant disc and RAID-5 controller configuration
c) Disc interface to enable 'disc down loading' / database or configuration data back-up.
d) Defuncting / inhibiting all functions other than those functions which are required for engineering
and operation as defined above.
5.5.18 System Back-up and Re-initialization
a) The entire control software including control database (application program), system software,
source code, schematics etc shall be backed up on system hard disc automatically at a regular
interval.
b) It shall be possible to have a complete back-up of system including the historical data on-demand
without interrupting the system normal function.
c) It shall be possible to have back-ups on remarkable media like CD-RW, DVD-RAM or DVD-RW.
d) The maximum time acceptable for reloading a device like console is five (5) minutes.
5.5.19 Global database Management and Configuration
5.5.19.1 System configuration software shall provide a common database configuration environment and shall
support the following data management facilities, as a minimum;
a) System design shall follow the data centric approach and shall manage entire system data in global
manner. Paths and connections between data objects shall be automatically maintained when
configuration is changed.

STD-0201 0
SHEET 71 OF 146
b) Whenever the offered system maintains multiple data bases, the design must ensure a close
coordination between these data bases such as management of cross reference table and data
reconciliation algorithms.
c) Configuration of operator graphics including management of change tools so that the changes
made in graphics are updated uniformly throughout the system.
d) All control historical trend function configuration and interconnection between data elements in the
system without any need to maintain user based cross references.
5.6 Communication sub-system
5.6.1 The communication shall be a digital communication network bus, that provides a high speed data
transfer rapidly and reliably between the operator consoles, process I/O devices, process computer and
other devices connected to it. Each network node shall be capable of communicating with other nodes
over the communication network.
5.6.2 The Communication network topology shall preferably be bus structure. Other vendor standard
topologies shall also be acceptable provided these meet all the functional requirements specified in this
specifications and in the material requisition.
5.6.3 The communication over the communication network shall not be affected even if a node connected to
network is powered down or fails to respond. It shall be possible to connect or disconnect a device
from the system without disturbing the operation.
5.6.4 The communication sub-system shall be dual redundant, consisting of two separate communication
networks and two separate communication system interfaces for each device. The systems requiring
traffic directors shall be avoided. However, if unavoidable, dual redundant traffic directors shall be
provided
5.6.5 Design shall ensure that there is no cause of common mode failure in communication sub-system.
In general, both the communication networks / devices shall be active at all the times in such a way that
either they shall take the communication data load or switch the communication path at regular interval
whenever vendor standard data transfer technique allows data transfer to one network while redundant
network takes control on the failure of the main network fails. Vendor shall ensure that there shall not
be any system degradation or data loss before, during and after the changeover.
Redundant communication network and communication components / modules shall be continuously

checked for their availability and healthiness. In case of main bus failure or any communication device
failure, the transfer to the back-up device or bus shall be automatic without interrupting the system
STD-0201 0
SHEET 72 OF 146
operation and without any operator's intervention. Information about the failed device / bus shall be
displayed on the operator console.
5.6.6 Communication network protocol used within the system shall safeguard against false date transfer and
allow error detection, recovery failure detection and initiatives of switchover to the redundant network
/ network component / module.
5.6.7 In addition to automatic switchover of communication network on detection of failure of active / one of
the network / network device, it shall be possible to switch over the communication from main bus to
the redundant bus manually without disturbing the system operation. Manual switchover shall be
effected whenever the network integrity and switchover is to be verified during testing.
5.6.8 The mechanism used by the communication system for error check, parity error, over-run error etc and
other advanced codes.
5.6.9 In general, the transmitting message shall identify the transmitting the receiving device. The
transmitting device shall receive a reply from the receiving device on the receipt of correct message.
Lack of response shall be considered as a receiver failure. These shall be positive acknowledgement of
all messages transmitted over the communication network.
5.6.10 Communication speed on the communication bus shall be sufficient to update the operator console data
base once in every second. The overall system performance shall not be degraded whether
communication sub-system is 10% loaded or 100% loaded. Degradation of communication bus shall
be as defined under para 2.18 of this specification. Failure of one or more nodes shall not degrade the
communication performance in any way.
5.6.11 Network Diagnostics
5.6.11.1 Network management software shall be resident on all the network modules in order to ensure
reporting of node status to other network nodes and reporting node failure alarm within one second.
5.6.11.2 Communication network diagnostics shall run continuously so that the failure of any network / network
component / communication module is alarmed without any delay.
The diagnostics sub-routines shall detect and isolate faulty network component and noisy network
cables. Communication shall automatically transfer to the redundant component/ module / network
whenever the failure is detailed without interruption of system operation and loss of data.
5.6.11.3 Diagnostic sub routines shall be available to monitor the network performance and generate an on-
demand report of all the accumulated number of errors over a specified time period.
STD-0201 0
SHEET 73 OF 146
5.6.12 Network Components and their Requirements
5.6.12.1 All hardware like network cables, connectors, media converters, network switches and hubs and fibre-
optic patch-cards required for completing communication network shall be supplied by the vendor.
5.6.12.2 Network can be either screened twisted pair copper and / or fibre optic cable. All network cables shall
be armoured type. Fibre optic cable in addition shall be jelly filled for protection against ingress of
moisture.
5.6.12.3 Communication network if routed outside the control room shall be fibre optic type only and shall
support the use of media converters for fibre optic network. The system design shall allow the use of
unequal network lengths in case of redundant network configuration to make-up for the difference in
routing lengths.
5.6.12.4 Type and specifications of the fibre-optic cable shall be decided by vendor based on the distance, band-
width required for data transfer and allowable signal attention. Minimum two number of spare fibres
shall be provided in fibre optic cable.
5.6.12.5 Fibre optic cable shall always be routed in enclosed HDPE conduit with matching fittings. HDPE
conduit shall be as per IS-4984 or as per equivalent IEC code. The outer sheath colour of HDPE
conduits shall be orange with black for the fittings throughout the fibre optic cable run.
5.6.12.6 The network devices such as network switches, media converters, connectors etc, utilized in
communication sub-system shall be of industrial grade type and of rugged design. These components
shall be selected as per the make and model number listed in the vendor standard product guide.
5.6.12.7 The network switches used shall have multiple speed ports (10/100/1000 MBPS) and shall have;
a) Multi-processor design for high performance operation.
b) Routine diagnostics to detect and isolate noisy cables and jabbering nodes.
5.6.13 Network Loading and OPC Server
Worst-case network loading for the systems supporting determinable protocol shall not exceed 50%
while for non-determinable protocol shall not exceed 15%.
5.7 Open System Connectivity
5.7.1 The system shall be capable of interacting with other plant systems and computers over a well
established communication network like ethernet (HSE) conforming to IEEE 802.3. This connectivity
with the other systems shall always be made via a firewall.
STD-0201 0
SHEET 74 OF 146
5.7.2 The system software shall be support industry standards like Windows, OSF/ MOTIF, TCP/IP etc. as
applicable.
5.7.3 The method of data access by any user on this network shall be by I/O Tag name and not by any
physical or logical address.
5.7.4 Whenever the communication network is required to connect to any other system network or to plant
information network, fire-wall (hardware and software) and routers shall be used.
5.7.5 The system shall be capable of acting as a Dynamic data Exchange (DDE) or OPC client or server to
exchange real time data with DDC or OPC compliant application.
5.7.6 When OPC is used for interfacing, system shall exchange the data with any client's application in the
standard OPC format. Design shall ensure that OPC connectivity tools are fully integrated within the
standard product providing seamless integration. Following shall be ensured;
a) System shall provide alarm and event information with no point building from other OPC alarm
and event server directly into DCS system alarm summary.
b) Allows OPC data access clients to view DCS system data, hierarchical area, point and parameter
structure.
e) Allows access to historical data from DCS.
f) Allows third party OPC server information to be mapped, displayed, alarmed, get historical data
and controller data into the system server.
g) Integrates supervisory monitoring, alarming and control data between two or more OPC servers.
h) All graphic applications and all control function blocks supported by operator console software
shall have direct access to data integrated with DCS via OPC.
i) OPC data groups, items and tags shall be viewable in any browser function provided in graphics,
devices or control configuration tools as if it were data native to the controller sub-system.
5.7.7 OPC Server

5.7.7.1 Vendor shall offer integrated or dedicated OPC server in a high grade minimum RAID 5
Configuration only This node in no way restricts the data transfer. In any case, the device shall be
intelligent with adequate memory and software capabilities.

STD-0201 0
SHEET 75 OF 146
5.7.7.2 OPC Data Access (DA) Server
a) OPC data access server functionality shall allow bi-directional data transfer between multiple OPC
data access servers for monitoring, alarming and control. DA server shall read and write process
data using item ID is identifier.
b) Rate of data transfer in case of DA server is typically 1000 tags per second.
5.7.7.2.2 OPC Historical data access (HDA) Server
a) OPC client shall access DCS data by connecting to HDA server. It shall also automatically save
instantaneous data acquired from DA server and A&E server to be a historical database in HDA
server.
b) HDA server shall be able to receive and publish data timely and efficiently whether online or from
archived source. System shall be able to read raw data at the rate of 1000 tags per second and read
manipulated data at the rate of 100 data per second.
5.7.7.2.3 OPC Alarm and Event (A&E) Server
a) OPC A&E server shall publish DCS alarm and events to OPC clients. The server shall support
event types such as conditions, tracking and simple events (e.g. component failure). It shall also
publish DCS alarm and event such as process alarms, alerts, messages, event, sequence of events
and operator changes.
b) OPC A&E server shall write the following messages to DCS, as a minimum;
i) System and process alarm messages
ii) Mode change and status change message
iii) Sequence message
iv) Operator guide message
v) OPC server alarms and errors
vi) Engineering maintenance messages
c) The maximum number of alarms and events received by OPC A&E server shall be of the order of 1
A&E per second.
5.7.7.2.4 OPC Batch Server
OPC batch server shall read and write the batch related data and information of DCS.
5.7.7.3 The OPC server software shall have the following features, as a minimum;
a) It shall meet support standard OPC standard interface functions such as DA, A&E, HDA, Batch
and security as specified by OPC foundation.
b) The software shall be able to interact with another OPC compliant software loaded in another Third
party server machine associated with different make of DCS or control system without the need of
any additional hardware or / and software.

STD-0201 0
SHEET 76 OF 146
c) The software shall support automatic data back-up in such a way that process data acquired by DA
/ A&E server are automatically saved as back-up data on a disc without client having requested to
save the data by server.
d) The software shall allow viewing of contents of OPC server from OPC client.
e) The software shall have capability to restrict the access of OPC server to its client to avoid
exceeding the maximum accessible data to avoid load concentration which may slow down the
data access.
5.7.7.4 System Sizing
Following criteria shall be followed for sizing OPC notes;
a) Number of third party OPC servers / nodes (This shall include UHN connected to other DCS
systems) shall be minimum 10. Ten (10) concurrent licenses shall be supplied as part of OPC
node.
b) In addition to third party servers, consider the following;
Number of client per OPC node : 10
Number of third party OPC devices : 10 (when specified)
Such as RTU's
c) Follow up rate of data read / write shall be considered for sizing;
OPC client data read (cache read) : 1000 per second
OPC client data read access (Device) : 500 per second

OPC client write : 500 per second
d) Maximum number read and write data for OPC node : 2000 data points
(unless otherwise
specified)
One data point shall include PV, MV, SP for analog control loop.
5.7.7.5 System performance
OPC node shall meet the following performance requirements;
Data read and write on client machine : max. 5 seconds
(This includes data display update for real time data)
Data read and write on server machine : max. 5 seconds
Maximum server loading : 50%
5.7.7.6 OPC node configuration shall be minimul RAID -5
5.7.7.6.2 OPC node shall be supplied with operating system and other softwares to meet functional requirements
specified herein.

STD-0201 0
SHEET 77 OF 146
5.7.7.6.3 Whenever OPC node is provided with historisation or dedicated , it shall have RAID 5 configuration.
5.7.7.6.4 The system when specified, shall offer a standalone software application that provides OPC server
redundancy by transparently redirecting client requests to secondary OPC server when primary OPC
server is unavailable or fails.
5.8 Time Synchronization
5.8.1 The system shall have capability to synchronize the time of all the sub-systems within the system either
by internal or external clock as specified in the job specification.
5.8.2 Time Synchronization with Internal clock
Unless specified otherwise, all the sub-system node clocks shall be synchronized with designated
system master clock. Master clock shall either be assigned automatically by system or assigned
manually during system configuration. In both the above cases, whenever the master clock node fails,
an alternate sub-system clock assumes the charge of time synchronization. In no case, the system shall
operate without time synchronization.
5.8.3 Time Synchronisation with External Clock
a) When specifically indicated, the time shall be synchronised with external time reference eg GPS.
This shall ensure that data acquired by all sub-systems will have the same and common global time
reference. All hardware and / or software required to meet this requirement shall be supplied by
the vendor.
b) In general, the system shall be provided with an external GPS antenna connected to a master clock
server. This server shall synchronise all DCS clocks and also provide time synchronising outputs to
synchronise all non DCS sub-system clocks. The node shall not exceed 30 millisecond time
difference between GPS and any node clock come.
c) In case of failure of master clock server the time synchronisation shall be carried by the designated
DCS master clock.
5.9 Shutdown Sub-system - Programmable logic controller (PLC)
5.9.1 Programmable logic controller shall be microprocessor based system which shall be used to execute all
the process and safety shut-down logic of the plant when specified, it shall also execute plant interlock
logics as well. Programmable logic controller shall be an independent unit and shall not depend on any
of its functionality on any other system including Distributed Control System.
5.9.2 The system shall be designed fault tolerant and shall utilize high quality components of proven quality.
Any single system fault shall not degrade the system safety or functionality of effect operation. The
STD-0201 0
SHEET 78 OF 146
system shall have certified Safety Integrity Level as per IEC-61508 / 61511 as applicable and specified
in job specification. Unless otherwise specified it meet the availability requirement specified in Clause
5.1.3 of this specification.
5.9.3 The system shall have a very high noise immunity in order to ensure safe and reliable operation when
subjected to electrical radio frequency interference and Electro-magnetic disturbances expected in a
plant.
5.9.4 Unless otherwise specified, the scan time of programmable controller shall be of the order of 250
milliseconds. Scan time for a PLC shall be as defined under para 2.21(c) of this specification.
5.9.5 Operation of PLC shall be completely unaffected by a momentary loss of power of the order of 20
milliseconds.
5.9.6 On line replacement of any module of programmable logic controller shall be governed by Clause 5.1.6
of this specification in general. However, in case of Triple redundant, Quadruple Modular Redundant
(QMR)configuration, there shall not be any process upset while replacement of failed module.
5.9.7 It shall be possible to Hot swap any faulty system module without degrading the system safety or
operation or freezing the output status. The switchover to the healthy module shall be bumpless. The
swaped module shall take over the function of the failed module without any manual programming.
5.9.8 The system shall be programmed in principle as per the logic diagrams furnished during detail
engineering. Vendor shall prepare their own Logic/Ladder diagrams depending upon the capability of
the programmable logic controller offered by them. Owner / Consultant reserves the right to revise or
review the logic diagrams even after acceptance of any offer. The programming language of offered
PLC shall be as per IEC 61131.
5.9.9 Whenever the requirement of SIL is specified for the, it shall meet the requirements of SIL level
specified and shall be certified by an indepedent body (e.g. TUV) for complying requirements of IEC-
61508 / 61511 as specified. For shutdown application requiring SIL certification, PLC shall always
meet SIL 3 requirements.
5.9.8 Power supplies in the system shall be provided as follows:
5.9.8.1 Each I/O rack shall have a separate independent power supply system. Each power supply shall be
sized to take full load of the I/O rack/signal conditioning panel/rack and shall be provided with dual
redundant power supply.

STD-0201 0
SHEET 79 OF 146
5.9.8.2 Each processor shall be provided with separate power supply. Failure of one power supply shall not
affect the system operation in case of dual processor system. Wherever triple redundant system is
specified each processor shall preferably be provided with a separate power supply. Also separate
power supply must be provided for each multiplied process I/O channel.
5.9.9 System Architecture
5.9.9.1 General
a) PLC system configuration / architecture shall be as specified in the job specification. For
emergency shutdown system application specified with SIL 3 classifiction, the system
configuration shall be TMR or QMR
b) Regardless the action feature selected (except for single architecture), the failure of single
component shall not result in a failure of correctly executed safety function. The degradation mode
for the selected configuration e.g. 3-2-0 or 4-2-0 or 3-2-1-0 etc. shall be documented in SIL
certification report.
c) In general, the PLC system shall comprise of various sub-systems as described in the subsequent
clauses of 5.9.9.
5.9.9.2 Input/Output system
5.9.9.2.1 Each I/O module shall have its own processor working asynchronocally w.r.t control processor and
other I/O processors. However, I/O modules configured in redundant configuration, shall have their
processors properly synchronised.
5.9.9.2.2 Unless otherwise specified, system shall accept analog 4 – 20mA inputs and contact inputs. The
maximum number of Input/Output per I/O module shall be limited as per the following table.
Maximum
Sl. No. Type of Configuration
No. of I/Os
1 Single I/O system 8
2 Dual I/O system 16
Triple Modular Redundant
3 40
system (TMR)
Quadruplicate Modular
4 16
redundant System (QMR)
In case of PLC certified for SIL requirements, the maximum number of I/O's shall governed by the SIL
certification applicable for specified SIL level.

STD-0201 0
SHEET 80 OF 146
5.9.9.2.3 Each I/O shall be galvanically isolated from external control circuit by suitable means. The minimum
isolation level between I/O and logic circuit shall be 1000 volts DC.
5.9.9.2.4 Each I/O shall be protected against the reversal of polarity of the power voltage to I/O.
5.9.9.2.5 Each input shall be provided with filters to filter out any noise in the input line and contact bouncing
noise, as applicable.
5.9.9.2.6 All the inputs shall be double ended i.e. two wires per input and not with common return for all inputs.
5.9.9.2.7 The interrogation voltage to the inputs and power supply for 2-wise instruments shall be powered from
separate redundant power supply / supplies and shall not be a part of PLC, unless otherwise specified.
This power supply shall be supplied at one point and shall be distributed by the vendor.
5.9.9.2.8 a) Each I/O module shall have a LED per channel to indicate the status of each
Input/Output.
b) When specified, input module shall be capable of monitoring the input contacts for any wire open
fault (i.e. 4 – 20mA).
5.9.9.2.9 Analog input module
a) Input module shall be capable to accept input from transmitters (.e.g. 4 – 20mA ).
b) The module shall have 12 bit A/D resolution accuracy of ±0.25% of full scale over the entire range,
5.9.9.2.10 a) Output contacts from the PLC shall be potential free dry contacts with contact rating
as per para 5.9.9.2.10 b) of this specification. Wet contacts/ powered contacts / TTL outputs etc.
shall not be acceptable. Vendor must provide arc suppression device for each output contact.
b) The output contact rating shall be as follows:
VOLTAGE CURRENT
Sl. No. APPLICABLE FOR
RATING RATING
All output cards driving solenoid
1. valve and alarm annunciator system 110 V DC 0.5 A
All motors/pumps/compressor output
cards unless otherwise specified.
2 240 V AC 5.0 A
Category – I
220 V DC 0.2 A
Category - II
The category of contacts shall be specified in the material requisition.
c) Each output shall be short circuit proof and protected by fuse. Visual indication of fuse blown must
be provided for each module.
STD-0201 0
SHEET 81 OF 146
d) When specified contact output module shall have monitored output features like 5.9.9.2.8(b).
5.9.9.2.11 The communication of I/O system with central processor shall be carried out redundant with complete
error checking.
5.9.9.2.12 Where inputs or outputs have multiple field devices for the same measurement or device, the outputs
shall be configured in separate I/O modules.
2.9.9.2.13 Where single input signal is available for QMR or TMR configuration, inputs shall be multiplied to
feed independent inputs to each input modules.
5.9.9.3 Processor system
5.9.9.3.1 The processor shall have capability to implement all the control functions required to implement the
logic scheme attached alongwith, as logic/ladder diagram.
5.9.9.3.2 The size of the memory shall be sufficient for storage of the program instructions required by the logic
schemes and other functional requirements. Offer shall indicate the amount of memory capacity
occupied by the actual program and spare capacity available for later program modifications or
additions.
5.9.9.3.3 Memory shall be non-volatile. However in case volatile memory is provided, battery back up shall be
provided with a minimum of 3 months lifetime to keep the program storage intact. A battery drain
indication shall be provided at least one week before the battery gets drained. A potential free contact
shall be provided for hardwired annunciation in the central control room.
5.9.9.3.4 Watchdog timer shall be a software device. The healthiness of processors shall be continuously
monitored by watchdog timer. Any hardware or software problem in the processor system, which shall
include, CPU, memory, power supply, communication interface etc. shall cause the watch dog timer to
report processor failure.
5.9.9.3.5 Wherever Qurd redundant processor is specified, redundancy, shall be provided in such a way that in
case of failure of the main processor, the standby shall take over automatically. The changeover, shall
be bumpless and the system shall be fail proof, unless any other requirement is specified in the job
specifications. Redundancy shall be provided for complete processor system including CPU, memory,
power supply and communication sub system.
5.9.9.3.6 In case of triple redundant system all the three processors shall execute the same instructions /
programs and check their results and majority vote to correct any faulty result. The faulty processor
diagnostic shall be made available.
STD-0201 0
SHEET 82 OF 146
5.9.9.3.7 In case of QMR system, individual processors shall execute the same instructions / programs and check
their results within same CPU module and vote to correct any faulty result. The faulty processor
diagnostic shall be made available.
5.9.9.3.8 Failure of a single processor in triple redundant system and two processors in quad system shall not
affect the system. In case of failure of complete processor system i.e. both processors in case of dual
configuration, two or more in case of triple redundant system and more than two in case of quad
system, outputs shall take failsafe state automatically unless otherwise specified in the data sheets.
5.9.9.3.9 In case multiprocessor configuration is offered, the processors must be able to communicate with each
other over the interconnecting data link. Vendor must ensure that system performance shall not be
degraded by any means when such a system is offered.
5.9.9.3.10 It shall be possible to generate the first out alarm contact by the PLC in case where a group of
parameters are likely to trip a system.
5.9.9.4 PLC console (Programming)
5.9.9.4.1 The PLC console shall be used for programming, program storing, fault diagnostics and alarm
monitoring and should be completely independent of control system(DCS) network
/functionality/hardware/software. Whenever specified, it shall also be possible to use this for plant
operation. The functionality to operate as engineering terminal or operator terminal or both shall be
specified in the material requisition.
5.9.9.4.2 It shall consist of a at least one coloured 21" size TFT screen and one programming / operating
keyboard and printer unless specified otherwise.
5.9.9.4.11 PLC console when used for plant operation shall also meet the following functional requirements.
5.9.9.4.3 The keyboard shall preferably be touch sensitive sealed type, easy to operate with each key clearly
identified.
5.9.9.4.4 All illegal entries shall be rejected by the terminal and shall be identified by warning signal on VDU.
5.9.9.4.5 Manual forcing of any input or output contact connected to PLC shall be possible from keyboard.
Forced functions shall have an associated audit trail.
5.9.9.4.6 It shall be possible to modify, add or delete the application program on line without affecting the
outputs.

STD-0201 0
SHEET 83 OF 146
5.9.9.4.7 PLC Console shall display logic and/or ladder diagram indicating power flow and shall show
description and status of each contact. It shall also be possible to display process alarms and diagnostic
messages as and when they appear. Further it shall also be able to display I/O map in a user defined
format.
5.9.9.4.8 It shall be possible to print out the ladder/logic diagram on the dedicated PLC printer. The printer in
addition shall also print out;
a) The diagnostic messages as and when generated and diagnostic reports, when called for.
b) Process alarms connected to the programmable logic controller as and when they appear and alarm
report whenever initiated. The choice of printing alarms on this printer shall be operator selectable
from a key lock switch on PLC console.
c) The I/O maps showing status of all inputs and corresponding outputs in a user defined format.
5.9.9.4.9 The PLC console shall be provided with self diagnostics feature which shall display error messages and
initiate an audible alarm if the fault is detected. A potential free contact for diagnostic group alarm
shall be provided which shall be connected to the hardwired alarm and annunciator system.
5.9.9.4.10 The system shall be able to identify the failure at least up to the module level including I/O system and
redundant processor and report print out.
a) When PLC console is specified, it shall have complete graphic capacity and shall be used for plant
operation, process monitoring and control, fault diagnostics, alarm monitoring and report
generation.
b) At least three number cursor control devices shall be provided in addition to keyboard which may
include touch screen, mouse, track ball etc.
c) PLC operator console shall have complete graphic capability and shall be able to display process
dynamic graphics, overview and group view displays. It shall be possible to operate the plant i.e.
start and stop of rotating machinery, opening and closing of valves etc. from dynamic graphics and
group displays available on PLC operator console.
d) It shall be possible to monitor, historise and print out all process alarms, diagnostic alarms and
alarm reports.
e) The time stamping of all alarms shall be as per PLC processor time stamping .

STD-0201 0
SHEET 84 OF 146
f) The system shall be able to store and display stored data wherever required. The minimum storage
capacity shall be for 30 days at 1 minute sample rate for all the inputs specified, diagnostic alarms,
process and first out alarms, manipulation data etc.
g) The system shall be able to generate shiftily, hourly, daily, weekly and monthly reports. The log
format shall be furnished during configuration.
h) The system shall be supplied with first out alarm generation capability. The resolution of alarm
shall be as per processor cycle time.
5.9.9.5 PLC Communication Subsystem
5.9.9.5.1 The PLC communication subsystem shall be a digital communication bus that provides a high speed
data transfer rapidly and reliably between the processor, I/O sub-system, PLC console and other
devices connected in the PLC system.
5.9.9.5.2 Redundancy in PLC communication subsystem shall be provided as follows unless otherwise specified.
a) The communication subsystem between PLC processor and I/O subsystem shall be single unless
otherwise specified. This shall include single communication bus and single interfaces/buffers.
b) For the triple redundant system, each processor shall have a separate set of PLC communication
subsystem.
c) For the QMR systems each I/O subset shall have separate communication interface and bus for
connecting to respective CPU module.
d) The communication subsystem between processor subsystem and PLC console shall be dual
redundant, consisting of two separate communication interfaces and two buses, each one
configured in redundant mode, unless this is only used as programming aid.
.
5.9.9.5.3 The mechanism used by the system for error checks and control shall be transparent to the application
information / program. Error checking shall be done on all data transfers by suitable codes.
5.9.9.6 Interface with Distributed Digital Control System
5.9.9.6.1 The PLC shall be required to be interfaced to the offered Distributed Digital Control System bus. A
suitable interface shall be offered in order to achieve the following functions:
a) Display of all input points under alarm/first out alarm connected to PLC or generated by PLC on
the main operator console.
STD-0201 0
SHEET 85 OF 146
b) Generate shutdown reports on the logging printer of Distributed Digital Control System.
c) To receive certain operational commands from the operator console for the operation of certain
output devices connected to PLC.
d) To display diagnostic messages of PLC.

5.9.9.6.2 In general, PLC shall provide data in a well established protocol format preferably MODBUS protocol.
5.9.9.6.3 The interface shall be dual redundant unless otherwise specified meeting all requirements as specified
under para 5.9.9.5.3 and 5.9.9.5.4 of this specification.
5.9.10 System software

5.9.10.1 The system software shall include all programs for the PLC and PLC console which are required to
perform all PLC functions including communication and self-diagnostics.
Whenever PLC is specified for shutdown application with SIL classification, the system shall be
designed and engineered in full compliance with the requirement of IEC-61511.
Whenever different functional logics are combined within a common PLC, the safety related I/O's of
each functionality shall be kept segregated within the system.
5.9.10.2 Logic program shall be recorded on the CD which shall be delivered in duplicate together with the
system.
5.9.10.3 The PLC programming language for implementation of logic operations shall be based on the
following representations:
a) Logic diagrams - Binary logic symbols such as AND, OR, NOT Gates, Timers
and Flip-Flops.
b) Ladder diagram - Series parallel connection of relay contacts.
c) Combination of (a) & (b) above.
5.9.10.4 It shall be possible to print out the ladder/logic diagram on a dedicated printer. The printer shall also
print out all diagnostic reports. Vendor must supply the off line software package to enable the owner
to modify/add/delete any part of program and for documentation.
5.9.10.5 Software for the generation of various displays including dynamic graphics, whenever specified, to be
provided as per para 5.4.3.5 of this specification.

STD-0201 0
SHEET 86 OF 146
5.9.10.6 The software for printing alarms, system as well as process and events on the PLC printer must be
provided. All alarms must be printed as and when they appear.
5.9.10.7 Software package for displaying I/O map showing status of inputs and corresponding output as per
logic shall be offered. The I/O map format shall be users definable.
5.9.10.8 The system shall have an extensive set of self diagnostic routines which shall be able to identify all
permanent and transient system faults / failures at least up to module level including redundant
components and power supplies through detailed VDU displays and report print out. Diagnostic
software shall have the capability to provide information about the failed module/system either in the
form of a system configuration display or provide information in the form of a statement.
5.9.10.9 System for the following functionalities shall be supplied when specified;
a) Long storage historisation
b) Log report generation
c) First out alarm generation
5.9.10.10 System diagnostics shall be capable of identifying, locating and reporting the following faults, as a
minimum;
a) Processor fault
b) Communication fault
c) I/O module fault
d) Power supply fault
e) Over temperature monitoring
f) Permanently close / open (stuck on or off) fault
g) Scan time failure
h) Memory fault
i) Signal redundancy fault
Any other additional diagnostic alarm if available as standard shall also be provided by vendor.
5.9.10.11 Self diagnostic software shall have capability to detect faults which make the system permanently
close/open in the I/O modules or I/O signal conditioning modules (incase of triple redundant system,
whenever specified in the job specifications, this may be achieved by automatically running the testing
software at cyclic intervals) The automatic cyclic testing feature shall also be provided for dual I/O
configuration and dual I/O signal conditioning for triple redundant system. The testing software cycle
time may be considered one in 30 minutes however this shall be field adjustable by engineer. However,
system performance shall not be degraded whenever testing feature is specified.

STD-0201 0
SHEET 87 OF 146
5.9.10.12 In case of triple redundant system or quadruplicate system, whenever output module testing software
detects any faulty channel, the power supply to that particular module in that particular bank is
removed automatically and further testing on the corresponding module in the other mirror image bank
is stopped. However, the testing continues uninterruptedly in other output modules.
5.9.10.13 Feedback must be provided in case of triple redundant system and quadruplicate system from the
output voter system to detect any latest faults of the system in addition to other diagnostic software as
per para 5.9.10.9 through 5.9.10.10 of this specification.
5.9.10.14 Diagnostic package and its related equipment and software shall be supplied. A list of additional
diagnostic packages available and the packages provided, including the description and capabilities,
shall be provided with separate quote.
5.9.11 Sequence of Event (SOE) Function Requirement

Sequence of Event for analog and digital inputs shall be generated and time stamped in PLC. The
maximum resolution between two events shall not exceed specified PLC scan time unless specified
otherwise. A separate SOE PC with 21" size TFT screen and laser printer shall be provided for each
PLC sub-system unless specified otherwise.
5.10 Foreign Device Interface

5.10.1 Foreign device interface shall be capable to transfer data from the foreign devices like analyser
systems, gas chromatographs, gas turbine system etc. to other sub-systems connected to
communication sub-system and vice-versa wherever specified in the job specifications.
5.10.2 Each device interface shall be redundant unless otherwise specified in job specifications.
5.10.3 Interface hardware and software shall be suitable to match the foreign device communication
requirements like hardware interface, communication protocols etc.
5.10.4 While writing software or mapping the input/output in the interface device it must be ensured that
integrity of the data to be transferred like resolution, correctness etc. shall be maintained.
5.10.5 Redundant interface switchover shall be designed based on the type of redundancy available in the
foreign devices.
5.10.6 The total responsibility of selection of hardware, writing of software, switchover of redundant interface
etc. shall be of distributed control system vendor only. All necessary information, assistance and help
shall be rendered by the Foreign device vendor.

STD-0201 0
SHEET 88 OF 146
5.10.7 The exact requirements of Input/outputs to be transferred shall be as per job specifications.
5.11 Interface with Smart Transmitters
5.11.1 System shall be provided with suitable hardware and software to interface with the communication
protocol of specified smart transmitters.
5.11.2 In case, smart transmitters are specified with 'HART PROTOCOL', the maintenance data related to
these transmitters shall be made available on a separate Personnel Computer. The system shall meet the
following requirements as a minimum :-
a) The system shall allow the maintenance functions like configuration, calibration and monitoring of
transmitter's data from the associated personnel computer in addition to Hand held terminal,
whenever used.
b) The hardware used shall allow unrestricted transfer of digital signal without degrading the analog
data i.e process variable.
c) The software supplied shall be 'CORNER STONE' OR EQUIVALENT compatible with the
specified transmitter protocol. The software shall allow the following data to be displayed on the
PC:-
(i) Complete configurational data base of all transmitters including data of commissioning,
last calibration, next due calibration etc.
(ii) Historical data for calibrations and configuration changes.
(iii) Event and log reports.
(iv) Multiple authorisation levels for carrying out Configuration changes and Calibration
adjustments.
(v) Manual editing of data base with Password and /or keylock protection.
5.12 Hard-wired Instrumentation
5.12.1 Hardwired instruments shall be stand-alone type and shall meet their functional requirements fully
without depending on DCS system. Even power supply and input/output circuits of hardwired
instruments shall be totally independent of DCS system.
5.12.2 Hard wired instruments shall be microprocessor based. Each instrument shall have as a minimum the
necessary firm-ware to meet its functional and operational requirements.
5.12.3 Each device shall have its own analog to digital/digital to analog converter.
5.12.4 The display of each device shall preferably be bar graph type.
STD-0201 0
SHEET 89 OF 146
5.12.5 Controller shall be digital type capable of performing automatic control based on the set points given
locally or from a remote device like another controller or Distributed Control System or Supervisory
computer. The controller as an instrument shall also have provision for manually controlling the
process by means of a manual loader and cascade-computer auto-manual transfer switch. The operation
of the transfer switch shall be procedure-less and bumpless while changing mode from computer to
cascade to manual and from manual to auto to cascade to computer. During such a change the output
shall not change by more than 1% of span. Controller shall have a facia giving continuous indication of
process variable, set value, controller output, and controller mode. It shall be possible to remove an
instrument for maintenance without upsetting the process by use of device like service station.
Operation of the controller like set point change, manual control, controller mode change shall be
possible from the front of the controller. Controller shall be flush panel mounting type on the
panel/hard wired console. Configuration and tuning of controller shall be possible through a portable
and pluggable configurator.
5.12.6 Recorder shall have independent circuit and pen drive assembly for each channel. Recorder shall have
capability of continuous line marking or digitized marking of input value with high resolution.
Recorder chart drives shall be of multi-speed type and shall be operator selectable. Recorders shall be
flush panel mounting type on the panel/hard wired console.
5.12.7 Manual loader unit shall have continuous display of process variable and manual loader output. It shall
be possible to manually change the output to control valve. Manual loaders shall be flush panel
mounting type on the panel/hardwired console.
5.12.8 Temperature transducers and trip amplifiers shall accept inputs from standard industrial thermocouple
and resistance temperature detector (RTD). Linearization of the thermocouple and RTDs shall be done
inside each instrument. Transducers and amplifiers shall be suitable for rack mounting.
5.12.9 Alarm cards shall accept standard outputs and shall produce changeover contact output. Each alarm
card shall have one continuously adjustable blind setting device. Alarm cards shall be suitable for rack
mounting.
5.12.10 Alarm and annunciator system
5.12.10.1 The alarm logic shall be executed in single input plug-in type logic modules. Where integral logic has
been indicated, the logic module shall be accessible from the front of the annunciator after opening the
swing door. The design of each module shall be such that by simply jumpering suitable point, it may be
changed from normally open mode of operation to a normally closed mode of operation and vice versa.
STD-0201 0
SHEET 90 OF 146
5.12.10.2 Lamps shall be replaceable from the front. The power consumption of each lamp shall be
approximately 10 watts.
5.12.10.3 The initiation of alarm condition in the annunciator shall take place approximately 330 millisecond
after the condition sensing contact have assumed the off- normal state.
5.12.10.4 Hooter, in general, shall be solid state type with audibility of the order of 100 dB at a distance of 3
metres.
5.12.10.5 An interruption of power supply for a duration of 20 milliseconds or less shall not affect the
functioning of the annunciator.
5.13 Instrument Asset Management System (IAMS)
5.13.1 Instrument Asset Management System shall facilitate the maintenance management of all smart, field-
bus based and conventional field instruments. Unless otherwise specified, the system shall manage the
maintenance of following;
a) All smart and field-bus based instruments connected to Distributed Control System or
Programmable Logic Controller.
b) Conventional (non-smart / non field-bus) instruments connected to DCS or PLC or any other
dedicated instruments.
c) Field Instruments other than (a) and (b) above eg. local gauges etc.
5.13.2 The system shall include all hardware and software to meet specified functional requirements. In
general, IAMS shall be an integral part of Distributed Control System and shall acquire the data from
the controller and data acquisition sub-system. Inputs, which are connected to programmable logic
controller, shall be parallely connected to DCS in such a way that the hardware used shall allow
unrestricted transfer of digital signal without degrading the analog signal.
5.13.3 A dedicated IAM console consisting of one video display unit along with a printer shall be provided;
a) Display all data related to device diagnostics.
b) Provide historical data for calibration and device configuration / reconfiguration etc.
c) Generate event and other device reports.
d) Manual data entry with password / key lock.
The VDU shall be 21" colour TFT monitor along with a keyboard and a printer.
5.13.4 The system shall support multiple authorisation levels for carrying out configuration charges and
calibration adjustment.

STD-0201 0
SHEET 91 OF 146
5.13.5 The Instrument Asset Management System shall meet the following requirements:
a) Instrument Configuration
It shall be possible to configure, verify the configured parameters, reconfigure, re-range and
calibrate / recalibrate the smart and field-bus devices from IAM console.
b) Device Status Monitoring
The system shall monitor the status of all field devices and shall report any maintenance alarm
generated by these devices. In general, following shall apply;
- Diagnostic alarms from smart and fieldbus devices shall be classified into device failure
and device diagnostic categories.
- Out of limit alarm shall be generated to indicate device failure alarm for conventional
devices.
The system shall be capable of displaying and generating maintenance report listing all devices
currently under alarm. The report may be generated unit-wise / area-wise or for complete plant.
c) Maintenance database
The system shall be able to maintain maintenance database for all the instruments which shall
include date of commissioning, last calibration date, next due calibration. The system software
shall have capability to manage and track scheduling of all such maintenance related activities.
The software shall also provide data as predictive maintenance such as list of transmitters
experiences excessive drift, list of control valves loosing on shipping characteristics etc.
d) Audit Trail
The system shall have capability to provide an audit trail for a complete historical record of all
configuration, calibration and device alert data. This shall include tracking of maintenance history
for all instruments in the plant, typically recording the type of maintenance work done, smart and
compilation times of activity, person responsible for the activity etc.
e) Advanced diagnostics
The system shall be able to provide advanced diagnostics such as device step response, device
signature, dynamic error band etc. special device diagnostic software whenever required (like for
smart / field-bus position) shall run in the system.
f) Documentation
System shall generate documentation like trend reports, diagnostic reports, pre-detective
maintenance report, audit report, historical data and device specification sheet etc. Definition,
STD-0201 0
SHEET 92 OF 146
engineering, configuration, loading and completion of all reports whether specifically indicated are
available as standard and shall be supplied as part of vendor scope of supply.
5.14 Alarm Information Management System (AIMS)
5.14.1 The purpose of Alarm Information Management System (AIMS) is to provide a centralised Alarm
information over and above the requirements specified in Clause 5.4.3.8 of this specification and shall
be used for acquiring, sorting, add value and provide redistribution platform, so as to streamline and
transform the raw alarm data into intelligent, add actionable information for plant operation personnel.
5.14.2 The system shall acquire inputs from various systems such as;
- Distributed Control System / Systems and Programmable Logic Controllers.
- ESD and F&G Systems
- Package unit control systems
- Machine monitoring and Analyser system
- Electrical control system / systems
- Electrical numerical relays
- Any other system defined specifically in the job specifications.
5.14.3 Unless otherwise indicated, the AIMS shall have a high speed data transfer OPC link connectivity with
the systems. Where OPC link is not available, the data transfer shall be through dedicated serial links.
In addition, AIMS shall also have capability to accept hardwired inputs.
5.14.4 Unless otherwise specified, the following type of data shall be acquired by the AIMS software for
further analysis;
- Process and utility alarms
- System diagnostic alarm
- Sub system status alarms
- Operator activities
- Maintenance alarms
The AIMS shall offer a variety of alarm handling feature for processing, and presenting alarms in most
efficient way. The package shall be a comprehensive tool with capabilities of;
a) Logical filtration of alarms during normal and special operating conditions such as
start-up, process upset and turndown conditions.

STD-0201 0
SHEET 93 OF 146
b) Logical processing of events and sequence of events for facilitating quick assessment
of normal or emergency situation based on pre-defined rule-sets.
c) Generation of different levels of alerts, based on type of alarms, sequence of alarms,

logical processing of alarms etc. and propagation of the same to different groups and categories of
personnel's, based on pre-defined alarm distribution matrix.
5.14.5 AIMS shall meet the following functional requirements, as a minimum;
5.14.5.1 Data Acquisition
The data acquired from the various sub-systems and other control systems shall be stored in a dedicated
AIMS server. The data shall be stored in a structured format and shall contain tag number, time of
occurrence, text information like service description, event type, alarm priority, alarm group priority
etc.
5.14.5.2 Alarm Computing
The package shall have capability to generate / compute alarms based on a logical combination of
states, conditions and events.
5.14.5.3 Information Analysis
The package shall have capability to analyse and present only the meaningful information. This shall
include the following;
a) Analyse the alarm frequency within the predefined period and its repetition period.
b) Analysis of various alarms to identify nuisance, chattering and redundant alarms and eliminate
them, if necessary.
c) Analysis of various alarms to identify serious alarms and monitor their frequency of occurrence.
d) Monitoring Operator actions.
5.14.5.4 Expert Alarming
i) The system shall be able to carry out statistical analysis on the alarms data gathered
and perform;
- Real-time frequency analysis

- Alarm frequency break-up
- Alarm frequency monitoring
- Standing alarms
STD-0201 0
SHEET 94 OF 146
- Time elapsed between two alarms / events
ii) The system shall have capability of implementing rule sets to analyse various alarms / data and
inform plant operator the probable reason, make recommendations for the action to be taken and
provide operational alternatives.
iii) System shall also be capable of analysing and recommending maintenance requirements based on
preset rules.
iv) The system shall have advanced search and sort features to provide quick access of alarm data to
operator.
5.14.5.5 Alarm Prioritisation
The system shall have the capability to segregate the alarms as per their criticality and operational
importance, which may be defined as per the severity with respect to its;
- Production losses
- Human and equipment safety
- Environmental safety
- Process reaction time like run-down reactions
The alarms shall be differentiated in different displays by allocating different colour codes.
The system shall be able to be configured with different priority levels which shall be defined based on
the process criticality and operational requirements. As a minimum following priority levels shall be
definable;
Level 1 - Alarms directly related to human safety – leading to heavy casualties
Level 2 - Alarms directly leading to total plant shutdown – personnel,

environmental and equipment safety hazard.
Level 3 - Alarms leading to partial plant trip conditions.
Level 4 - Maintenance alarms not leading to immediate plant trip.
Level 5 - Status or low priority alarms for operator information.
Other priorities shall also be user definable. It shall also be possible to set priority for each and every
alarm point. Assignment or change of level of priority shall be possible only under password
protection.

STD-0201 0
SHEET 95 OF 146
Number of alarms under each level of priority shall be user definable. However, for the purpose of
internal assignment, following numbers may be considered
Priority No. of Alarms

Level
Level 1 10 Nos.
Level 2 70 Nos.
Level 3 5% of Total
Level 4 20% of Total
Level 5 75% of Total
5.14.5.6 Alarm Display
a) AIMS shall display alarms gathered from all Nodes / subsystems seamlessly and shall
be displayed on any display irrespective of source or location.
b) Alarm display shall be sorted out in the form of alarms groups in the following categories;
- Priority level sorting

- Sorting as per type, frequency, unit-wise, area wise and operating area wise.
c) AIMS displays shall be in graphic form with user friendly displays, color modifiers etc.
d) The system shall process alarms using well proven analysis techniques, directly related to specific
alarms, which are trendable.
The system shall have advanced Rule-based and latest abnormal condition management tool which
shall provide prediction and anticipation of plant deterioration with sufficient lead time for
operation action. The system shall also have real time root cause analysis.
5.14.5.7 Operator Actions
The system shall be able to acquire and analyse operation action required during plant operation such
as;
° Time to alarm acknowledge
° Controller mode changes

° Controller set point changes
° Analogue output changes (in manual mode)
° Discrete output changes (in manual mode)
° Alarm level of priority changes

STD-0201 0
SHEET 96 OF 146
° Range changes
° Tuning constant changes
° System configuration changes e.g. control algorithm, cycle time changes etc.
° Manual time adjustment
° Alarm acknowledgement
° ESD switch actuation (full or partial)
° Any other operator action not specifically indicated above but required during operation. The
operator actions shall also be categorised based on their criticality in various levels.
Level – 1 - Most critical operator actions leading to plant shutdown in full eg.
ESD switch action.
Level – 2 - Configuration changes or set point changes which may lead to mal
Operation or partial plant shutdown eg. set point changes, range
Changes, time adjustment etc.
Level – 3 - Changes which may effect control but rarely could lead to plant
Shutdown full or partial eg. controller mode change, range changes,
tuning constant changes etc.
Level – 4 - Actions which are mere operation but does not lead to plant
operation.
The system shall also able to provide information like;
i) Time to acknowledge alarms
ii) Alarm acknowledge time exceeding a pre-set value.
5.14.5.8 Report Generation Printing
The package shall have capability to;
a) Store alarm messages for a period of minimum one year and shall have facility for data
archival on portable media.
b) AIMS shall be capable of generating and printing reports in user defined formats. The data
in each report shall be either raw, manipulated, calculated, compressed or analysed.
c) The alarm shall be possible to be printed as and when required, as a user

defined formats. These formats shall be defined during engineering.
STD-0201 0
SHEET 97 OF 146
5.14.5.9 System Diagnostics
The AIMS shall have extensive set of diagnostic subroutines running in real time basis and shall
provide at least the following diagnostic alarms;
- System software failure

- Disc / Disc drive failure
- Application software failure
- Network failure
- Communication software failure
- Disc full
- Power supply failure
These diagnostic alarms shall also be made available at DCS operator and engineering consoles.
5.14.5.10 Data Storage and Archival
AIMS shall store alarms and events indicated in Clause 5.4.6 for a period of minimum 1 (one) year in
the hard disc. Multiple disc configuration, if required, shall be provided for the purpose of calculating
data storage capacity consider occurrence of 30% of alarm and events per day apart from other system
defined functionalities.
5.14.5.11 Alarm Notification and Audio Messaging
The system shall be capable of performing following alarm notification and messaging functions;
a) Dial Telephone
In case of predefined alarm or alert condition the system shall automatically dial a telephone
number and plays a pre-recorded message. All hardware and software for auto-dialing shall be
included.
b) Dial a Cell phone
The system shall have facility to dial up mobile pager or mobile cell phone. When an alarm
occurs, the system shall be able to send a test (SMS) message also.
c) E-mail
When a predefined alarm occurs, the system shall be able to send message through an e-mail to the
predefined user. This facility shall also be utilised to send e-mails to the manufacturers of various
system oriented items like DCS, PLC etc in case of occurrence of a critical system diagnostic
alarm.
STD-0201 0
SHEET 98 OF 146
d) Audio Messages
The system shall be capable to play a pre-recorded message in case of predefined critical alarms on
the plant public address system. For example, this shall be useful for alerting plant personnel's on
gas / fire alarm in a particular area.
e) Emergency Hooters
The system shall be capable of generating input such that in case of an emergency condition
emergency hooters can be initiated along with audio messages on the public address system.
5.14.6 System Hardware & Software
5.14.6.1 AIMS shall have all the hardware and software to meet the following major functional requirements;
a) Efficient storage and archiving of acquired and manipulated data to allow
retrieval of reports or alarm analysis information.
b) Retrieval of important information on-line to a network drive disc or
dedicated device.
c) Remote access to more than one clients on the network.
d) Export alarm, events or other information to other applications, Excel or

Access.
e) Advanced diagnostic techniques for analysis of acquired data.
f) Log the time between specified alarms / messages.
g) Assignment of various level of pass-ports.
h) Multiple client's displaying different data or data screens simultaneously.
i) Disc mirroring for data storage over the network.
j) Automatic Triggering of alarm reports and messages on devices like mobiles,

telephones, computer networks etc.
k) Data search facilities with efficient search engines like SQL.
l) Data sorting facility as per defined rule-set.
m) Time stamping of data as per AIMS clock wherever required.
5.14.6.2 AIMS can be reealised on either the DCS platform or as a stand along system. In either case the
offered solution shall meet all the requirements specified in MR without exception.

STD-0201 0
SHEET 99 OF 146
5.14.6.3 In case AIMS functionality realised on DCS platform a separate dedicated AIMS station shall be
provided. This station shall have same hardware and software configuration as operator console and
shall have redundant storage disks for bulk data storage.
5.14.6.4 In case stand-alone system is considered, the same shall meet the following requirements;
a) The system shall be capable of interaction with DCS via a serial port or by OPC
connectivity.
b) The system shall have a minimum of one dedicated server with monitor and cursor control
devices capable of meeting all functional requirements for AIMS. If the system demands
more than one server to meet job requirements, the same shall be supported and provided.
c) The AIMS console shall be server based machine and shall have 21" LCD display screen
with keyboard, mouse and read / write DVD drive.
d) The system shall support client server architecture with minimum of 4 clients. Detailed
functionalities of these clients shall be finalised during engineering. The clients shall also
meet hardware and software requirement specified in Clause 5.14.6.4(c).
e) AIMS server shall have redundancy in storage discs for bulk-data storage.
5.14.6.5 In general, all alarms and events shall be transferred to AIMS with time stamped by the originating
devices. AIMS shall maintain this time for further analysis. AIMS shall time stamp the acquired data
only when this data is not transferred by the originating device with time stamp.
5.14.6.6 The AIMS connectivity to third party devices and systems shall be either from the control network (i.e.
communication sub system) or from the serial ports available in these devices. For third party systems
direct connectivity from the station having master database is preferred.
5.14.6.7 When multi drop serial link connectivity, not more than four (4) devices shall be multi-dropped on one
serial link to server.
5.14.6.8 AIMS shall have sufficient flexibility in hardware and software to interface a variety of peripheral
devices, these include but shall not be limited to;
- Printer to be provided and attached to the server or client for printing reports and
alarms.
- Public Address system for automatic broadcasting of alert messages in pre-designated

STD-0201 0
SHEET 100 OF 146
areas. (The package shall be supplied with a voice package, which shall automatically broadcast
the message as the occurrences of the particular alarm).
- Fixed line EPBAXs and Mobile telephones
- Horn and / or beacons for Audio / Visual alarming.
5.14.6.9 AIMS server memory shall be sized suitably to display and printout the alarm history of all the tags of
all the systems and sub-systems connected to it.
5.15 Unit History Node (UHN)
5.15.1 UHN shall primarily used to carryout the following activities;
a) Store automatically gathered data from control system (DCS, PLC, etc), other DCS systems over
OPC and manually entered data.
b) Present data in a meaningful manner for performance enhancements and fault analysis.
c) Long term historisation of data for future reference and decision making.
d) Carryout calculations on the real time and stored data, as necessary.
5.15.2 The UHN shall be a high capacity data storage device where data from various process units shall be
stored in a fast access database. The node shall support standard open system interfaces like OPC,
SQL, OLE, DDE and shall provide active X facility.
5.15.3 UHN shall collect data from;
a) Distributed Control system of which this UHN is a node.
b) UHN's of other control systems
c) Nodes other than UHN's connected on information network.
d) Manually entered data.
The data collected shall be of various types like process variable, set point, computed variable,
manipulated data, outputs, alarms, events, which shall be used for long term storage, trending and
report generation.
5.15.4 UHN shall have capability of storing real time data in real time database and shall perform functions
like;
a) Identification of bad data (algorithm to run in UHN when necessary)
b) Specify dead band and data sampling rate (or collection rate) as user definable parameter.
c) Calculate maximum, minimum, average, summission, and, integrated values of collected data. The
time period of calculating average shall be user definable.
d) Specify high / low, high – high / low – low alarm limits for triggering an event or message or alarm
as applicable.

STD-0201 0
SHEET 101 OF 146
e) Specify damping parameter, delay parameter etc. to reject unwanted data.
f) Specify data storage / sampling rate and period of storage necessary for historical storage of data.
g) Mathematical functions and application program as specified in material requisition which are
necessary for report generation. (This does not include advanced control functions but do include
MIS reports)
All the parameters indicated or functions performed shall be definable tag number wise.
5.15.5 Data Management and data presentation
5.15.5.1 UHN shall act as a network server and shall support two way data communication between;
a) DCS and UHN for real time data transfer. UHN shall acquire real time data from DCS and provide
derived and calculated data to DCS.
b) UHN and information network to transfer data from other systems on information network to UHN
and vice versa.
5.15.5.2 UHN provides the user with current raw and calculated / manipulated data on predefined graphic
screens or pre-defined report formats. The graphic screens and report formats are user configurable.
5.15.5.3 UHN perform long-term historization of raw and calculated / manipulated data.
5.15.5.4 The data received or sent from the UHN shall have time stamp associated with it from the originator of
the data. The data update is effected in case the data value has changed by more than the configured
dead band since the last update.
For manually entered data, the time stamp shall be time of entering data (by default) or the time entered
with the data as applicable.
5.15.5.5 UHN time shall be synchronized with DCS time clock. For time synchronization refer clause 5.8 of
this specification.
5.15.5.6 UHN shall maintain relational database and shall support oracle ROBMS tool.
5.15.5.7 All data raw, manipulated or manually entered acquired or calculated by UHN shall be stored, as unit-
wide historian. Historian can be accessed to retrieve the data from specified period in the past.
Historian should have capability to store data for a period of one year (365 days) with a sampling rate
of 30 seconds, as a minimum. Other sampling rates such as 1 minute, 5 minutes, 10 minutes and 1
hour shall also be possible. The duration of on-line storage shall be controlled by the archiving
facilities which in turn shall be dependent on specified sampling rate.
5.15.5.8 The data shall be presented to the user in a well structured hierarchically configured user displays.
User shall be able to navigate down to any detailed data displays without any system configuration
knowledge.
The display structure may include;

STD-0201 0
SHEET 102 OF 146
a) Overview display or main menu display, displaying key process parameters and performance
indicators like real time data, swap-shot, calculated variables, real time trend, historical trends,
manual data entry, function block, alarm and events, reports etc.
b) The reports generated shall include both tabular and graphical type (i.e. trend and bar graph). The
reports as a minimum, shall include shiftily, daily, weekly, monthly and yearly reports. The report
formats and specific data shall be finalised during system configuration stage.
5.15.6 System Administration and Security functions
5.15.6.1 The system shall perform the following administration functions;
a) System start-up and shutdown
b) System configuration and configuration changes
c) System diagnostic alarm management
d) Archiving and storing history data.
e) System back-up and system restoration from back-up.
f) Manning user and security files.
g) Maintenance sub-routines and manipulation of data in the database with Audit.
5.15.6.2 UHN shall provide a full data security guarantee and shall be equipped with proper fire wall security
features. For details refer clause 5.1.12 of this specification. Typically firewall shall be CISCO system
appliance firewall (PIX) and software (IOS) or equivalent.
5.15.7 System Configuration
5.15.7.1 UHN shall be higher grade RAID 5 server machine with preferably Xeon CPU. The selected UHN
hardware platform shall meet system throughput and capacity requirements. As a minimum, the
system hardware shall meet the following requirements;
a) VDU shall be 459.7 mm active matrix TFT type coloured LCD screen.
b) QWERTY keyboard with SCSI interfaces
c) Mouse or track-ball control
d) Memory as 1GB RAM and 80GB hard disc (HDD) and shall support DAT and DVD / CD ROM.
e) Clock speed as 2.4 GHZ
f) Coloured laser printer
5.15.7.2 The system shall be supplied with a robust operating system and all supporting softwares necessary to
meet functional requirements specified here in including RDBMS such as oracle or SQL with TCP / IP
as network protocol.
5.15.8 System Sizing
Following criteria shall be followed for sizing UHN;

STD-0201 0
SHEET 103 OF 146
a) UHN shall interact concurrently with minimum 10 number of users in addition to DCS (of which
UHN is the node) and clients main computer. Unless otherwise specified, ten concurrent user
licenses shall be supplied along with UHN node. For the purpose of sizing consider at least 20
concurrent users.
b) The data shall be accessed from remotely located data sources through information network or
through auto-dialing with proper ID address and password protection. The rate of data access
from / to this network shall be considered as 1000 tags per second.
c) The data access from DCS shall be all 1.4 times the all analog (PV, MV, SV) and digital tags
accessed at the rate of 1000 tags per second.
d) UHN historian shall be sized considering following factors;
Storage data : 2 times the total analog (PV, MV, SV) and digital
data of all DCS connected tag number (through hardwiring, serial
ports, fieldbus etc.
Storage time : 1 year (365 days)
Storage rate : 30 seconds for all data
Storage interval on RAM: 20 minutes
5.15.9 System Performance
5.15.9.1 The response to all online enquiries and actions from any user shall be complied with 95% confidence
level from any client with a maximum of 20 concurrent users as defined in clause 5.15.8(a) of this
specification shall be as follows;
a) A data query to display on graphic or report : 5 second
b) Pre-defined trends up to 1hour data : 5 seconds
c) A data query to present a 24 hours report : 10 seconds
5.15.9.2 Average loading shall not exceed 50% when averaged over 15 minutes with peak loading at any time
not to exceed 70%.
5.15.9.3 All securities shall be positioned while evaluating system performance.
5.16.1 Sequence of event recorder shall be provided for recording sequence of alarms / events for shutdown
inputs.
5.16.2 The inputs for sequence of event recording shall be handled as follows;
a) The maximum number of inputs for I/P module shall be 32.

STD-0201 0
SHEET 104 OF 146
b) The contact inputs (either open or close on alarm) shall be multiplied using dual output contact
barrier one of which contact shall be connected to PLC while the other contact is routed to SER.
Wherever necessary, fast response multiplying relays may be used (certified by SER manufacturer)
c) For analog input, the signal shall be connected in parallel across the conditioning resistance to PLC
or dual output barrier and to a dedicated alarm card, the contact of which shall be routed to SER.
In case analog input are to be routed to different physical locations or more than two devices, analog
isolators shall be used.
5.16.3 SER shall be capable of providing demonstrable alarm resolution of 1millisecond between the events
and shall also be able to print out the same with similar resolution.
5.16.4 The contacts or alarm may be close or open on failure and must be configurable for close / open on
failure.
5.16.5 The SER system shall be capable of providing alarm monitoring, printing and inputs for management
packages. The configuration of inputs and other functions mentioned above shall be carried out using
a dedicated terminal, which is also provided with a printer. Once configured, the access to
configuration shall be denied except with 3 level of password protection.
5.16.6 All the trip / alarm settings should be same as that of PLC in all respects. The accuracy and resolution
of measurements and settings are to be equal or greater than that of PLC.
5.16.6.7 Vendor shall make a provision to connect PLC outputs to SER recorder whenever necessary and
decided during engineering with proper isolation.
5.16.8 There must be 20% installed and wired spare input channels up to the marshalling cabinet for each type
of input / output of DCS, PLC and other systems.
5.16.9 The system must have facility of keeping at least 96 hours of record at the time with last in and first out
facility.
5.16.10 It shall be possible to configure / modify / reconfigure the system online through a dedicated
programming unit. Engineering shall be possible to engineer the system using menu driven fashion.
Any addition and deletion of inputs should be menu driven only and should be possible to be done
during running condition.
5.16.11 It shall be possible to archive data from the SOE recorder on tape drive / CD drivt. CD driver and CD
writer along with all necessary software shall be part of system supply by the vendor. The CD driver
and CD writer must be with latest hardware and latest software.
5.16.12 The system shall have an extensive set of diagnostic package, which shall be able to provide the fault
alarms up to the module level. The same shall be also printable on the laser printer.
The system shall be able to generate an audit report, which can be printed on demand. The audit report
shall be able to provide shutdown area, time of shutdown and reason for shutdown.

STD-0201 0
SHEET 105 OF 146
5.16.13 Sequence of events shall also record PLC shutdown outputs.
5.17 Large Screen
5.17.1 The Giant Screen (Large screen) in the control room, is primarily used for:
a) Display important operational data of the plant /unit for ready reference like daily production,
shutdown required /requested etc.
b) Display operational situations like start up or shutdown to enable mangers / operators to discuss
without disturbing the unit operator.
c) Display any operator screen on the large screen.
d) To provide real time clear luminous view of the unit to share information’s between operators, unit
managers and refinery manager.
e) To hold demonstrations to visitors for ready impressive and effective plant overview and plant
highlights.
5.17.2 The giant screen shall be installed in the control room wall. The size of the screen shall be
approximately 3200mm(L) X 1300mm(H) as a minimum.
5.17.3 The giant screen system shall have the following specifications:
i) The screen design shall be based on single chip DLP

technology.
ii) Optical system shall have a resolution of 1024 pixels X

768 pixels Colour pixels per cubic. Each cube shall have a screen diagonal of 70 inches
with 16.7 million colours
The lamp shall be pre-adjusted in lamp module, which shall not require any readjustment
after replacement. The minimum operational time of lamp shall be 8000Hrs.
They shall be able to provide uniform brightness of 95% with a contrast 250:1, which shall
be able to provide high contrast even in bright ambient light.
iii) The display screen shall be seamless and flicker less. It shall be black or grey in colour.
The brightness and contrast shall remain uniform irrespective of the number of cubes used.
iv) The control of screen displays shall be carried out either from
the operator console. The signal transfer shall provide
guaranteed disturbance free operation, which shall not effect sharpness and colour quality.

STD-0201 0
SHEET 106 OF 146
v) The giant screen shall be lightweight and low thickness type, which can be supported from
the control room wall. Only the front access shall be provided for any maintenance.
vi) The system shall perform satisfactorily in ambient conditions with maximum temperature
of +40 degree Celsius and 80% non-condensing humidity.
vii) Provision of automatic switch off of Giant screen if temperature in the console room
increases above the maximum permissible limit for Giant screen is required.
viii) VDU shall be provided with the Giant screen Control station.
Ethernet card shall be provided in Giant Screen to connect it with Ethernet port for
necessary functionality.
5.17.5 The Giant screen system shall be interfaced with the system such that any operator display of any screen
could be displayed on the Giant screen suitably. It shall meet the following requirements;
i) Any operator console display or all operator console displays shall be
able to be displayed or switched as desired.
ii) Screen areas should be protected for each console group.
iii) Priority of displays should be assignable.
iv) The system shall be supplied complete with all hardware and software as necessary for the
specified application including interface software for DCS.
6.0 MISCELLANEOUS REQUIREMENTS
6.1 Safety requirements
6.1.1 Unless otherwise specifically indicated in job specification, all the equipment covered in this
specification shall be located in general purpose non hazardous area, normally in control room or / and
satellite rack room. However, transmitters, process switches and final control elements including smart
positioners, solenoid valves etc. I/P converters (not forming part of this specification) shall be located
in the field and shall be specified as per the electrical area classifications.
6.1.2 Unless otherwise specified, intrinsically safe certified transmitters, smart positioners, field-bus devices,
and I/P converters shall be used when located in hazardous area.
6.1.3 Intrinsic Safety Protection
6.1.3.1 I/O modules of Distributed system shall have either built in intrinsic safety or shall use external barriers
for intrinsic safety. Safety barriers shall also be used whenever intrinsic safety is specified for contact
inputs and solenoid valves. Barriers shall not be required when protection other than intrinsic safety
are specified.
STD-0201 0
SHEET 107 OF 146
6.1.3.2 The system as a whole shall be intrinsically safe based on entity concept. It may be noted that the field
instruments are being bought separately and can be of different make and models by different
recognised statutory body. These details shall be furnished during detailed engineering. Safety barriers
selection shall be carried out based on the entity (safety) parameters which shall be properly matched.
Field-bus segment terminator shall be considered for evaluating intrinsic safety of a segment. Any
limitation or special requirements for cables to meet the intrinsic safety requirements shall be brought
out in the offer.
6.1.3.3 Conventional or smart Instrumentation
a) Whenever intrinsic safety is specified for conventional and smart instrumentation entity parameters
of the elements in loop shall be matched with the barrier safety description parameters (i.e. loop
design as per entity concept).
b) In case of smart transmitter, the entity parameters of the hand held terminals shall also be
considered while selecting proper barriers.
c) Unless otherwise specified all intrinsically safe barriers shall be isolating type only providing
isolation between;
i) Input and output (non-hazardous to hazardous side of barriers)
ii) Power supply and input
iii) Power supply and output
The minimum isolation level shall be 250V. In case of I/O modules have built in barriers, I/O
modules shall also meet the requirements specified in Clause 6.1.3 of this specification.
d) Unless specifically indicated, only single channel barriers shall be selected. Following shall apply;
i) Dual input barriers shall not be selected

ii) Single input and single output barriers shall be selected.
iii) Single input dual output shall be selected when specifically indicated.
6.1.3.4 Field-bus instrumentation
a) Whenever intrinsically safe field-bus system is specified with Entity concept, safety parameters of
various items in the segment shall be matched with the selected barrier.

STD-0201 0
SHEET 108 OF 146
b) Whenever FISCO system is specified, all components in the segment is FISCO complied, segment
power supply selected shall also meet FISCO compliance. Segment design shall also meet FISCO
requirements.
c) Whenever non-incendive is specified, all components in the segment shall be FINICO complied
including segment power supply.
6.1.4 All intrinsically safe barriers shall be of the isolating type only, shunt diode type of safety barriers
shall not be used. Only single channel type of barriers shall be used.
6.2 Power supplies and distribution
6.2.1 System Power Supply
6.2.1.1 Unless specified otherwise, the system shall operate on uninterrupted power supply (UPS). However
the system shall be capable of operating satisfactorily at the following power supply specifications :
Voltage : 220 V AC ±10%

Frequency : 50 Hz ±3 Hz
Harmonic contents : Less than 5%
Power interruption : 10 millisecond
Various main load centres of distributed control system may be sequentially started whenever
the starting current are high. The requirement of sequential starting shall be specified in job
specification. The sequential starting circuit shall be designed using hardware timers and contactors of
adequate rating.
6.2.1.2 The system shall be supplied with dual DCS feeders each capable of handling 100% of the total power
supply load requirements. The system shall be engineered such that;
a) The redundant systems / sub-systems shall be powered such that main and redundant
components are powered from separate UPS feeders.
b) The non-redundant components / items shall be powered from either of the

feeders, unless otherwise specified in the job specification.
c) In case of failure of one feeders, redundant feeder shall supply the total load.
6.2.1.3 Each power feeder shall be monitored for its voltage and current in DCS, the transducers required for
the measurement shall be located in power supply distribution cabinet/cabinets.
In addition to above, following indication / alarms shall also be provided for each feeder;

STD-0201 0
SHEET 109 OF 146
a) Voltmeter, ammeter and power-on-lamp on the cabinet front of respective power supply
distribution cabinet.
b) Power failure Alarm contacts for such feeder for DCS monitoring.
c) One common power failure alarm contact for alarm on hardwired console.
6.2.2 DC Power Supply
6.2.2.1 DC supply shall be generally used for ESD devices and shall be 24V DC as specified in job
specifications. In general, DC supply shall have the following specifications;
Voltage : 24V ±10%
Harmonic Contacts : ...
6.2.2.2 Each DC power supply feeder shall be monitored for its voltage. The voltage transducer shall be
installed in the DC supply distribution cabinet.
6.2.2.3 In addition to above, following indications and alarms shall also be provided for each DC supply
feeder;
a) Voltmeter installed on the respective DC power supply distribution cabinet.
b) Power failure alarm contacts for each feeder for DCS monitoring.
c) One common power failure contact for alarm as hardwired console.
6.2.3 Non-UPS Power Supply
6.2.3.1 Non-UPS power supply shall be generally used for panel / cabinet / console lighting, power sockets.
The voltage shall be 240V 50Hz power supply. In general, 240V 50Hz Non-UPS power supply shall
follow the following specifications;
Voltage : 240V ± 10%
Frequency : 50Hz ± 3%
6.2.3 All cubicles lighting shall be on 240 V, 50 Hz normal power supply.
6.2.4 Power supply shall be made available at one point. Further power distribution network shall be
designed such that a single power fault in any instrument branch system shall not cause a trip of the
entire system. Each consumer shall be provided with a separate switch and fuse for isolation and
protection of the system.

STD-0201 0
SHEET 110 OF 146
6.2.5 Each transmitter shall preferably be powered with individual power supply. However when several
transmitters are powered by a common DC source, each power supply branch shall have a separate
switch and fuse. The distribution network shall be designed in such a way that overload in any branch
shall not trip the main power supply. Enough redundant power supplies/battery banks shall be provided
which shall take over automatically in case of main common power source failure. All power supplies
shall have one to one redundancy and shall be sized for full load.
6.3 Equipment assembly
6.3.1 General
6.3.1.1 All system equipment like instruments, electronic modules, power supplies, barriers, relays etc shall be
installed in either of the following enclosures / cubicles as specified in purchaser's job specifications.
The layout of these enclosures shall be prepared considering proper accessibility and maintainability;
a) Control Panels
All indicating types of dedicated instruments like single loop controllers, indicators, recorders, alarm
annunciators, manual loading station manual switches etc shall be installed on control panel when
control panel is the operator interface or when specifically indicated in the job specifications.
b) Hardwired Console
All indicating type of dedicated instruments like single loop controllers, indicators, recorders,
alarm annunicators manual switches shall be installed on hardwired console when hardwired
cosole is the operator interface or whenever specifically indicated in the job specifications.
Hardwired consoles form the part of main operator console and shall have same design,
dimensions, colour, and shape as operator consoles.
c) System cabinets
All system hardware (excluding consoles) shall be installed in system cabinets. This shall include
system racks, system modules, communication modules, power supply modules etc.
System cabinets shall be pre-standing type and shall be freely accessible from front and / or back as
required. Following system cabinets shall be required, in general;
i) Power distribution cabinet (for AC and DC distribution).
ii) Safety barrier mounting cabinet (when field instrument is intrinsically safe).
iii) Controller and data acquisition sub-system cabinet.

STD-0201 0
SHEET 111 OF 146
iv) Temperature converter trip amplifier and other auxiliary card mounting cabinet.
v) Shutdown system cabinets (PLC processor and I/O cabinets)
vi) SER Cabinet
vii) Marshalling cabinets
Free issue items mounting cabinet (for mounting items which are free issued to vendor)
6.3.1.2 In general, control panels and hardwired consoles supplement the operator consoles for plant operation.
Those instruments which provide direct operating interface to the plant operator are installed on these
enclosures / cubicles.
In contrast, system cabinets generally house back and items / equipments / instruments which are not
required by the plant operator for direct operation.
6.3.1.3 Mechanical Design
6.3.1.3.1 As far as possible, panels / cabinets / consoles shall be manufactured using standard modular design
and standard equipment. Vendor may follow their standard manufacturing procedures, however
following points must be ensured;
a) All nuts, bolts, screws, washers (lock or flat) and hinges shall be of stainless steel. All fastening
links shall also be of stainless steel.
b) Document pocket / wallet shall be provided on the inner side of front and rear doors of each
cabinet and on the inner side of the door of each panel. Similar arrangement shall also be made on
the inner side of doors of console.
6.3.1.3.2 Control Panels
a) Control panels shall have self-supporting free standing cubical construction with back doors made
up of sectional steel panels. Two doors shall be provided for each panel, as standard.
b) Each panel section shall have the following dimensional details;
Height : 2000mm
Width : 1200mm
Depth : 1000mm
Panel shall be rigidly mounted on 100mm high channel base.

STD-0201 0
SHEET 112 OF 146
c) The panel shall be fabricated using angle iron frame section of minimum 50mm x 50mm x 4.0mm
size. The control panel front shall be fabricated preferable from 3.0mm cold rolled carbon steel
sheet.
d) Unless otherwise specified the panel shall be straight face type. Desk type panel shall be supplied
where specified. Case shall be taken to ensure that the face of the panel is truly float and smooth.
e) Panel painting procedure shall include sand blasting, grinding, chemical cleaning, surface finishing
by suitable filler and two coats of high grade lacquer with wet sand blasting between coats. Two
coats of paint in the panel colour shall be provided. Final coat shall be given after assembly at site
of non-glossy high satin finish when specified in the job specifications. Colour of the panels shall
be as per job specifications.
f) Normal mounting heights of instruments (centre lines of instruments to floor) on panel shall
conform to the following, with minor adjustments depending upon instruments selected.
1 Miniature and sub-miniature Bottom Row 1100 mm

instruments. (3 rows) Middle Row 1350 mm
Top Row 1600 mm
2 Annunciators 1950 mm
3 Electrical push buttons 700 mm
d) Door locking arrangement
All doors of cabinets / panels / consoles shall have flush mounted handles with key operated
mechanical door locking arrangement. The locking arrangement shall be interchangeable and
shall have common key for locking / unlocking all locks (master keying arrangement).
e) Internal lighting arrangement
Internal illumination shall be provided for all panels / cabinets / consoles to ensure proper
illumination level of 250 lux for performing maintenance activities.
Fluorescent lamps shall be provided in each cabinet / console / panel which shall be activated
individually by door operated magnetic switches. The lamps shall activate when door is opened
and deactivate when the door is closed. The magnetic switches selected shall have undergone life
cycle cyclic test of at lest 10,00000 operations. A manual over-ride switch shall be provided inside
the panel / cabinet / console which shall keep the lamp deactivated even when the door is open.

STD-0201 0
SHEET 113 OF 146
Panels / cabinets / consoles housing memories, which are likely to be effected by fluorescent light,
shall have incandescent lamps.
The cabinet / panel / console lighting shall operate on 240V AC emergency power supply.
f) Utility Sockets
Each cabinet / panel / console shall have at least one number each of 240V AC (emergency power) and
220V AC, (UPS) power socket. The sockets shall be rated for 10A as a minimum.
g) Ventilation
In order to effectively remove dissipated heat from the cabinets / panels / consoles, ventilation fans
along with vent louvers backed by wire fly screen shall be provided as required. Ventilation fans
shall be provided in all cabinets / panels / consoles where the temperature rise with all doors closed
and all internal and external loads energised shall exceed 10°c above the ambient temperature. A
temperature element (resistance temperature detector) shall be provided in each cubicle for
temperature measurement. Ventilation fans shall be provided in dual configuration, as a minimum.
Each fan shall have a separate dedicated assembly and shall be replaceable on-line without shutting
down any equipment / panel / cabinet / console in part or in complete.
Ventilation fan assembly shall operate at 240V AC emergency power supply. Each fan shall have
its own dedicated circuit breaker.
Each ventilation fan shall be fitted with a protection type finger guard. Whenever, the number of
panels / cabinets / consoles are compacted (supplied in mechanical joined conditions), each panel /
cabinet / console shall be provided with separate ventilation fan assembly.
The maximum noise level with all fans operating and cubicle doors open shall not exceed 85dBA.
Following signals and alarms shall be provided for each panel, cabinet and console separately;
i) Fan failure alarm for each cubicle in DCS.
ii) Temperature indication of each cabinet or compacted combination, as applicable in DCS.
iii) A common alarm each for high temperature and fan-failure on hardwired console.
h) Earthing
Each cubical (panel / cabinet / console) shall be provided with earth bus bars of at least 15 x 5
square mm cross-section for the following;

STD-0201 0
SHEET 114 OF 146
i) Electrical earthing (non-isolated earth) where all metal components like all cabinet panels,
doors etc shall be connected.
ii) System earthing (isolated earth) where cable shielding of all cables shall be earthed.
System earth bus bar shall be isolated from electrical earth and also from metallic doors,
panels etc.
iii) DC earth (isolated earth) where cable shielding of all 110V DC shall be earthed. DC earth
shall be isolated from electrical earth, system earth and also from metallic doors, panels
etc.
i) Lifting lugs
All control panels and system cabinets shall be provided with removable lifting lugs to permit
lifting of panels / cabinets. The panel structure / frame shall be designed to permit panel / cabinet
lifting without deformation. The normal working load of the lifting lugs shall be more than 1.5
time the panel / cabinet load. The eye bolts shall be certified for their normal working load.
Panels / cabinets shall also be supplied with plugs which can be fitted after the lifting lugs are
removed after their placement.
j) Name Plates
All panels / consoles / cabinets shall have name plates fixed on the front, back and inside with
following details;
Front and Back : Tag number and description
Inside : Manufacturer's name, purchase order number and year of
manufacture, port number of manufacture.
All other details shall be as per clause 5.1.22 of this specification.
6.3.1.3.3 System cabinets
a) All the cabinets shall be free standing, enclosed type and shall be designed for bottom entry for
cable connection. Cabinets structure shall be sound and rigid.
b) Cabinets shall be equipped with front and rear access doors. Doors shall be equipped with lockable
handles and concealed hinges with pull pins for each door removal.
c) Each cabinet shall have the following dimensional details;
Height : 2000mm
Width : 600mm / 1200mm
Depth : 800mm

STD-0201 0
SHEET 115 OF 146
Cabinets shall be rigidly mounted on 100mm high channel base. Construction shall be modular
preferably to accommodate 19" standard electrical racks. All racks shall be of same height.
Maximum swing out for doors and drawers shall be limited to 600 mm.
d) Cabinets shall be fabricated from cold rolled steel sheet of minimum 2 mm thickness suitably
reinforced to prevent warping and buckling. Doors shall be fabricated from cold rolled steel sheet
of minimum 1.6 mm thickness. Cabinets shall be thoroughly deburred and all sharp edges shall be
grounded smooth after fabrication.
e) Equipment, within the cabinet, shall be laid out in an accessible and logically segregated manner.
All metal parts of the cabinet including doors shall be electrically continuous and shall be provided
with a common grounding lug.
f) Cabinet painting procedure shall include sand blasting, grinding, chemical clearing, surface finish
by suitable filler and two coats of high grade lacquer with wet sand blasting between the coats.
Two coats of paint shall be provided. Colour of the cabinet shall be as per job specifications.
6.3.1.3.4 Electrical Wiring

All the cabinets, consoles and panels shall be completely wired and/or tubed, as required.
Interconnections shall preferably be done with the help of pre-tracked cables. Vebdir may follow their
standard wiring practices, however the requirements specified herein must be complied.
6.3.1.4.1 Terminals and Terminal Blocks
a) All terminal / terminal blocks shall be DIN Rail mounted type and shall be easily removable. The
size of the terminal blocks / terminals of different types shall be consistent and identical.
b) All terminal blocks shall be mounted on suitable anodised metallic or plastic stand-off.
c) Terminal strips shall be arranged group-wise for incoming and outgoing cables separately.
Terminal blocks for intrinsically safe wiring shall be separate. 20% spare terminals shall be
provided, as a minimum, preferably in each terminal strip.
d) Terminal housing shall be strictly sized with considerations for accessibility and maintenance.
Minimum distance required between various components are listed below. These distances are
clear distances, and are excluding the width of the raceways or any other component / item
mentioned herein. Following clearances should be considered;
i) Distance between terminal strip and side of the cabinet parallel to the strip, up to 50
terminals, shall be minimum 50mm.
ii) Distance between terminal strip and, top and bottom of the cabinet shall be minimum
75mm.

STD-0201 0
SHEET 116 OF 146
iii) Distance between two adjacent terminal strips shall be minimum 100mm.
iv) Additional distance for each additional 25 terminals shall be minimum 25mm.
v) Distance between cable gland plate and the bottom of the strip shall be minimum 300mm.
6.3.1.4.2 Terminals
a) Terminals shall be non-hygroscopic type made up of unbreakable fire-retardant, safe
extinguishable, halogen free polyamide compound of VO grade of 960°c. These shall be
manufactured as per IEC-60947-7-1.
b) Terminals shall be suitable for wires up to 2.5 sq. mm base solid or standard conductor in general.
For power cables, higher size terminals shall be used.
c) The metal parts of terminals shall be of high quality (pure electrolytic) copper and shall be tin or
nickel plated (of thickness up to 15 micron). The contact terminal resistance shall be of the order
of 0.3 multi ohm.
d) The spring material for all terminals shall be chrome nickel spring steel of high tensile strength and
of excellent corrosion resistance.
e) Voltage withstand capacity of the terminals shall be up to 4KV for 60 seconds as per IEC/EN-
60664-1.
f) Field side terminal blocks in marshalling cabinet shall be cage clamp interruptable (i.e. disconnect)
terminals providing necessary polarity distribution, protection, test point and earthing.
6.3.1.4.3 Wiring Requirements
a) All wiring shall conform to SPI RP 550 Part-I, Sections 7 and 12. Different signal level cables
shall be routed under false flooring with separation distances as recommended by API RP 550
Section 7.
b) All wiring inside racks, cabinets, and back of the panels shall be housed in covered, non-flammable
plastic raceways arranged to permit easy assembly to various instruments for maintenance,
adjustments, repair and removal.
c) All wiring in the raceways shall be properly clamped. All incoming cable shall be terminated by
vendor at marshalling rack with cable glanding including supply of cable glands. Total wiring
cross-sectional area shall not exceed 50% of the raceway cross sectional area.

STD-0201 0
SHEET 117 OF 146
d) Separate wiring raceways shall be used for power supply wiring, DC and low level signal wiring,
and intrinsically safe wiring. Parallel runs of AC and DC wiring closer than 300mm shall be
avoided.
e) Vendor can alternately offer prefabricated cables for interconnection between different cabinets
and panels.
f) Wire termination shall be done using self-insulating crimping lugs. More than two wires shall not
be terminated on one side of single terminal. The use of shorting links for looping shall be
avoided.
g) No splicing is allowed in between wire / cable straight run.

6.3.1.3.5 Hardwired console
a) Hardwired console shall be non-graphic self supporting, free standing cubicle with back doors and
shall be designed for batter cable entry for connections. Console structure shall be sound and rigid.
b) The design and dimensions of hardwired console shall strictly match with the operator consoles.
For designing hardwired console, following points must be ensured;
- No instrument or switch shall be installed on the horizontal portion of console.
- Horizontal portion of console shall be spill proof, as well as scratch proof. Materials other
than metallics can also be accepted for horizontal portion provided this can provide rigid,
hard, flat and smooth surface. This shall require the purchaser's approval prior to deciding
the material.
- In order to reduce number of hardwired consoles, vendor may utilize back-lighted switches
and miniature instrumentation and annunciator windows.
c) Whenever the operator consoles are specified with table top design instead of console type of
design, the hardwired console shall be identical and symmetrical to the operator console design.
d) Panels/hard wired console shall be fabricated preferably from 3 mm thick cold rolled steel sheet.
Angle iron frame shall use a minimum section of 50 x 50 x 4 mm angle.
e) Cabinet paint procedure shall include sand blasting, grinding, chemical cleaning, surface finish by
suitable filler and two coats of high quality lacquer with wet sand blasting between two coats. Two
coats of paint shall be provided. Colour of hardwired console shall be as specified in job
specification.
6.4 Earthing
6.4.1 All system equipments such as panels, marshalling cabinets, system cabinets and other powered
equipments shall be provided with following type grounding system;
STD-0201 0
SHEET 118 OF 146
a) Protective Earth / Electrical Earth
b) System earth / signal earth
c) Safety earth / ZB earth (when required)
d) SPD Earth
Both system earth and safety earth shall be totally separate from protective earth.
6.4.2 Protective earth / Electrical earth
a) Earth metallic enclosure / cabinet / panel / console etc shall be provided with electrical
earth lug, as a minimum. Door hinges, flexible conduits or self-detachable connectors
shall not be considered path for earth connectivity/earth return paths. Separate earth lug or
permanent connectivity shall be considered.
b) Unless recommended otherwise by vendor, all earthing lugs of metallic equipments

indicated in Clause 6.4.2(a) above shall be connected individually to electrical protective
earthing system bus-bar / earthing station using a maximum of 10sq mm solid copper
conductor PVC installed wires.
c) Where multiple cabinets are multiplexed together, earth looping with permanent shorting
link cables shall be acceptable. Two earthing connection wires as indicated in Clause
No.6.4.2(b) above shall be used for connecting multiplexed cabinets to protective earth
station / bus-bar.
6.4.3 System Earth
a) System earth shall be totally noise free dedicated earthing system and shall be fully
isolated from electrical protective earth. This earth must be very high integrity system and
shall be used to ground zero volt references and signal cable grounds.
b) System earth shall be less than one (1) ohm grounding system with its own
dedicated earthing pits. These earth pits shall be away from any heavy noise plant
equipment. Outside the control room building is the most appropriate location.
c) The earth pit design shall be as per IS-3043 code of practice for earthing. A minimum of
four (4) number of earth pits shall be provided for grounding system integrity. In case
number of pits required to meet 1 ohm resistance are more than (2), the number of earth
pits shall be two times the actual number of pits required to meet resistance criteria. All

STD-0201 0
SHEET 119 OF 146
these pits shall be security connected with each other to form a one homogeneous system
earth grid.
d) Each marshalling / system cabinet / panels etc shall be provided with system earth bus-bar
which shall be insulated from the metallic body frame. This bus-bar shall be used to earth
also signal zero volt references and signal cable screens. Terminals used for termination of
spare conductor pairs / cores of multi-pair signal / control cables shall be connected to
system earth bus-bar. Shorting links shall be used for spare terminal looping.
e) System bus-bars in the multiplexed cabinets can be joined together by permanent shorting
links. System bus-bars of other cabinets can also be connected together provided they are
permanently joined using 35 sq mm stranded copper conductor cable in a looped both ends
except for the following exceptions;
6.4.4 Safety earth / Zener barrier earth
a) Whenever Zener barriers are selected or used to meet intrinsically safe requirements, the earthing
terminal of the zener barriers shall be connected to a separate earth bus bar.
b) This earth shall meet all the requirements specified in Clause 6.4.3 of this specification.
c) Safety earth bus bar shall be directly connected to earth pits using dual insulated cable. Cable
conductor size shall be minimum 95 sq. mm (copper).
6.4.5 SPD Earth
a) SPD earthing terminals are connected to separate earthing bus bar in the cabinets.
b) This earth shall meet all the requirements specified in Clause 6.4.3 and 6.4.4(c) of this
specification.

STD-0201 0
SHEET 120 OF 146
PART - II
TESTING, INSTALLATION, COMMISSIONING
AND ACCEPTANCE OF

STD-0201 0
SHEET 121 OF 146
CONTENTS
Sr.NO. TITLE PAGE NO.
1.0 SCOPE 117
2.0 FACTORY TESTING AND ACCEPTANCE 118
2.1 General 118

2.2 Testing details 118
2.2.1 Phase - I 118
2.2.2 Phase - II 120
3.0 INSTALLATION, TESTING AND COMMISSIONING 127
4.0 SYSTEM ACCEPTANCE 131
5.0 FINAL ACCEPTANCE TEST 132
6.0 TESTING / CALIBRATION EQUIPMENTS 132

STD-0201 0
SHEET 122 OF 146
1.0 SCOPE
1.1 This specification defines the basic guidelines to Distributed Control System vendor for factory testing
and acceptance, installation, commissioning and field acceptance of the fully integrated system.
1.2 These guidelines shall also be applicable to all sub-systems and hardware bought by DCS vendor.
1.3 On the basis of this specification, vendor shall submit detailed testing and acceptance procedures
specifically applicable for their system. The procedure shall include both hardware as well as software
testing and acceptance methodology covering following details;
a) Hardware Testing;
The procedure shall include;
i) Test name
ii) Purpose of Test
iii) Test equipment
iv) Test set-up (Block diagram)
v) Input definition
vi) Test procedure
vii) Results expected
viii) Acceptance criteria.
b) Software Testing;
The procedure shall include;
i) Test name
ii) Purpose of Test
iii) Test equipment
iv) Test set-up
v) Sequence of Execution
vi) Results expected
vii) Acceptance criteria
The procedure shall not omit any column as indicated above in the procedure submitted. Indicate 'NA'
whenever any column is not applicable. Additional requirement, if any may be include, as applicable.
1.4 The testing and acceptance of the system shall be carried out on the approved testing procedures and
criterion based on this specification and vendor’s standard testing requirements and procedures.
2.0 FACTORY TESTING AND ACCEPTANCE

2.1 General
STD-0201 0
SHEET 123 OF 146
2.1.1 Vendor shall test and demonstrate the functional integrity of the system hardware and software. No
material or equipment shall be transported until all required tests are successfully completed and
certified “Ready for Shipment” by the owner/consultant.
2.1.2 The purchaser reserves the right to be involved and satisfy himself at each and every stage of
inspection. The purchaser shall be free to request any specific test on any equipment considered
necessary by him although not listed in this specification, as a part of approval of factory testing
procedure. The cost of performing all tests shall be borne by the vendor.
2.1.3 Vendor to note that acceptance of any equipment or the exemption of inspection or testing shall in no
way absolve the vendor of the responsibility for delivering the equipment meeting all the requirements
specified in Material Requisition.
2.1.4 It shall be vendor’s responsibility to modify and/or replace any hardware and modify the software if
the specified functions are not completely achieved satisfactorily during testing and factory acceptance.
2.1.5 Failure of components/ modules/ sub-systems during Testing
2.1.5.1 Vendor shall not replace any system component/module/sub-system unless it is failed. A log of all
failed components/modules in a sub- system shall be maintained which shall give description of the
failed component/module, effect of failure on the sub-system, cause of failure and number of hours of
operation before it failed.
2.1.5.2 If malfunction of a component/module in a sub-system repeat, the test shall terminate and vendor shall
replace the faulty component/module. Thereafter the test shall commence all over again. If even after
this replacement, the sub-system fails to meet the requirements, vendor shall replace the full
sub-system to the one meeting the requirements and the system shall be tested all over again.
2.1.5.3 If a sub-system fails during the test and is not repaired and made operational within four hours of active
repair time after the failure, the test shall be suspended and restarted all over again only after the
vendor has replaced the device in the acceptable operation.
2.2 The factory testing and acceptance shall be carried out in two phases i.e. Phase I and Phase II. The
schedule for the testing shall be submitted by the vendor for both Phase I and Phase II separately. The
minimum requirements for testing during these two phases are as follows:
2.2.1 Phase-I
2.2.1.1 Vendor shall perform tests at his works to ensure that all components function in accordance with their
respective specifications. A test report shall be submitted to the owner/consultant for review within one
week of completion of testing giving details. Phase II testing (witness inspection) shall start only after.
2.2.1.2 All sub-systems shall undergo a minimum of 30 days (720 hours) burn-in period. The system shall be
offered for factory acceptance only after it has completed the specified burn-in period. The
requirements shall be as follows;

STD-0201 0
SHEET 124 OF 146
a) The burn-in time shall start after the sub-system is fully assembled and is powered up. It may
include any such time for which the system has been kept powered on even for system generation
and Phase I testing.
b) Burn-in period log report shall be maintained by the vendor clearly recording sub-system (Tag No.
/ Identification No.), date and time of power-on, date and time of power-off, failed component (if
any) with identification, communicative power-on time and sign-off. In case power to the sub-
system is switched off because of any reason, the same shall be recorded in this log report.
c) Vendor shall submit burn-in period log report as part of Phase I test report for purchaser's review.
2.2.1.3 All the test results shall be recorded in the test log report. The test logbook shall contain the following
information about the tests:
a) Date/time
b) Assembly /loop tag number
c) Test input
d) Test results and sign off with personnel name
e) Action required (if deficiency is detected)
f) Action taken, date of completion and sign off
g) Special test methods (including special equipment requirement, bypasses used etc.)
2.2.1.4 Test details

Following tests shall be performed by the vendor and report shall be forwarded to the owner/consult-
ant.
2.2.1.4.1 Quality control test
a) Quality control tests shall be carried out to assure quality of all components and modules in
accordance with vendor’s quality control and assurance procedures. QA / QC test methodology
shall be in accordance with relevant international standards and practices. Vendor shall forward the
details of these procedures for purchaser’s review.
b) The sampling procedures for all purchased components or components manufactured by the vendor
shall be in accordance with the vendor standard quality assurance / quality control procedures.
c) All assemblies shall be aligned and adjusted before conducting tests. All tests shall be carried out
as per manufacture's published / established testing methods and shall be recorded in a test
logbook. The test logbook shall be duly signed by the QA / QC manager.
2.2.1.4.2 System power-up tests

STD-0201 0
SHEET 125 OF 146
All sub-systems shall undergo complete functional testing as part of Phase I power-up testing. Testing
shall include, but not limited to, the following;
a) System hardware functional testing including redundancy, wherever applicable, as per vendor
standard testing procedures
b) System software testing as per vendor standard testing procedure including builder functionality.
c) System performance on power supply variations as per vendor standard procedures.
d) Application, Software testing;
Complete application programme generated by the vendor specific to the job shall be tested by
simulating inputs. This shall include the following, as a minimum;
° Database verification including loop configuration as per approved functional schematics.
° Display verification including dynamic graphics and hierarchical displays.
° Trending, real time and historical, functionality and assignment.
° Logging and report generation
° Serial port assignment and its proving
° Security functionalities, as applicable e.g. password functionalities, fire-wall protection
° Testing of third party equipments (if applicable)
° Verification of logic diagrams
° Alarm management verification
° Any other software verification necessary for the offered system, as per vendor standard.
e) System Diagnostic verification
All the test results shall be recorded as per Clause 2.2.1.3 of this specification.
2.2.2 Phase II (Witness Inspection)
2.2.2.1 During Phase II testing, all the hardware and software shall be systematically, fully and functionally
tested in the presence of purchaser representative.
All the sub- systems shall be interconnected to simulate, the totally integrated system as close as
possible. Vendor purchased items (third party equipment) e.g. programmable logic controller, sequence
of event recorder, alarm information management system etc shall also be integrated with the system.
Free issue item, if any supplied by purchaser to the vendor for integrated factory acceptance test, shall
also be integrated with the system. Barrier cabinets shall be used as the connecting points for the test
inputs and outputs.

STD-0201 0
SHEET 126 OF 146
2.2.2.2 The duration of Phase II testing shall be communicated by the vendor along with day wise testing
schedule to the purchaser. System shall be shipped to site only after the successful completion of this
testing and the system is certified 'ready for shipment' by purchaser.
2.2.2.3 Data review:
Purchaser shall review the following documents before starting the witness Inspection (Phase II));
a) The latest document revisions, based on which vendor has generated the system, to the current
data. Any revision or changes required shall be informed to the vendor before starting the witness
inspection.
b) Test reports of all bought-out items by their respective manufacturers.
c) The test report/log book forwarded by vendor after Phase-I testing. Owner / consultant has right to
witness any test performed in Phase I, if found necessary.
2.2.2.4 Testing record
a) During testing of Phase II, each test carried out shall be recorded. Any deficiency or problem
observed during testing shall be clearly recorded and corrected thereafter.
b) Vendor shall prepare a punch list report listing out all the action points. All punch list actions must
be completed before system dispatch.
c) Any change in the data or configuration etc informed to the vendor during testing by purchaser
shall be recorded and modifications required shall be carried out by the vendor.
2.2.2.5 Visual and mechanical testing.
Visual and mechanical testing shall be carried out in principle to assure correct, proper, good and neat
workmanship by the vendor. This testing shall include the following, as a minimum;
i) Dimensional verification
ii) Sheet thickness
iii) Layout verification as per approved GA drawings
iv) Quality of painting (outer and inner)
v) Nameplates, identifiers and tag plates
vi) Adherence to ferruling philosophy.
vii) Dressing of wires / prefabricated cables and clearances
viii) Locks and handles
2.2.2.6 Verification of Bill of Material (BOM)
Hardware and software including bought-out items shall be available for verification with the bill of
material (BOM) document submitted by the vendor during engineering. Vendor must obtain
STD-0201 0
SHEET 127 OF 146
purchaser's prior approval if any sub-system or bought-out equipment / item can't be made available
during Phase II testing i.e. witness inspection. The verification of BOM shall include the following;
a) Hardware verification
The verification shall include verification of all hardware including mandatory spares as per the
model numbers and quantities indicated in bill of material document. Items which can't be
identified with model numbers, shall be verified with manufacturer's serial numbers. In all such
cases, vendor must ensure that the serial number has been indicated against all such items in the
BOM document.
b) Software verification
The verification shall include verification of licenses and their numbers for all softwares as listed in
bill of material document. All licenses shall be in the client's name. Number of copies of as built
application programmes shall be verified at the time of site acceptance test and not during factory
acceptance test.
All system hardware including network interfaces and all software including operating system, console
software, network software, complete application software etc. shall be installed and tested as part of
function testing.
2.2.2.7 Functional testing
All system hardware including network interfaces and all software including operating system, console
software, network software, complete application software etc. shall be installed and tested as part of
function testing.
Functional testing shall include the simulation of inputs and outputs to verify proper system response
for both analog and discrete signals. Unless otherwise specified, at least 20% of I/O's shall be simulated
in controller and data acquisition sub-system while all I/O's shall be simulated and corresponding logics
shall be verified in case of Programmable logic controllers. The I/O sampling shall be at random and
shall be selected by the purchaser during testing. The testing, as a minimum, shall include the
following:-
a) Complete system configuration loading.
b) Controller and Data acquisition Sub-system
Demonstration of all controller functionalities verification and data acquisition sub-system
functions from local as well as from central level including;
- Changing control algorithms
- Changing control mode and controller action
- Changing alarm limits
- Controller tuning using tuning trend.

STD-0201 0
SHEET 128 OF 146
- Controller tuning using auto-tuning package and change in tuning package and change in
tuning parameters either automatically or manually.
- Output status on controller failure.
- Setting of macro-cycle time for fieldbus segment.
c) Scan time verification of scan time values for controllers and data acquisition sub-system and PLC
testing shall be carried out by simulating the inputs as follows;
i) Open or close the contact input as per logic execution requirements.

ii) Step input or slow ramp input (typical frequency of 4 cycles / second) with amplitude
corresponding to 16mA (4mA to 20mA or vice versa) for all conventional analog and
smart (HART) inputs from a signal generated.
The processor cycle time setting and the processor loading shall not exceed the specified limits
while verifying scan time.
Checking of scan time values for controllers and data acquisition sub-system and PLC;
The inputs to the system shall be;
- Step input i.e. 0 or 1 for all contact inputs.
- Step input or ramp input for all analog inputs
The processor cycle time setting and the processor loading shall not exceed the specified limits
while verifying scan time.
Control cycle time shall be measured by simulating a segment with transmitters and positioners in
the worst case fieldbus segment (w.r.t number of transmitters and positioners) and scheduled
activities.
d) Checking of correct change-over of the back-up units in case of main unit failure. This shall
include the following:-
i) Uninterrupted controller operation shall be verified even during and after switchover of
back-up device. The failed controller Database, point records, inputs and outputs of the
failed main controller shall be transferred to the back up controller without any
interruption. The same shall be repeated for transfer back from back up controller to the
main controller. Maximum transfer time shall not exceed the specified value. The test shall
be repeated for controller all redundant devices including input /output modules.
ii) Uninterrupted data transfer from main communication network and communication
interfaces to the redundant ones shall be checked. The transfer back from back-up device
or back-up communication network to main network or interface shall not be automatic
(automatic transfer from back-up device / network to main device / network shall also be
STD-0201 0
SHEET 129 OF 146
acceptable in case the changeover procedure is flawless and smooth). This test shall be
repeated for all interface units in the system including foreign device interfaces.
iii) Uninterrupted operation of system shall be checked on failure and resumption of any of the
power supplies where redundant power supplies are provided.
iv) Uninterrupted operation of the system incase of redundant H1 module, power supply
conditioners and LAS functionality.
e) Checking of controller loading

Controller loading shall be verified as displayed by the system by simulating as many as inputs to
simulate worst case data transfer condition.
f) Simulation of fieldbus segment

At least one fieldbus segment of each type (e.g. foundation fieldbus, profibus etc) shall be
simulated as applicable. The segment shall include at least one device of each make and model
number being used in the project (purchaser shall identify and provide the device to vendor for
segment simulation). Following minimum tests shall be carried out;
i) Inter operability test to ensure correct data transfer between devices of different makes and
host (i.e. DCS).
ii) Control cycle time verification as per specifications.
iii) Control loop functionality when control algorithm is configured in DCS and in a field
device i.e. positioner and in transmitter.
iv) Verification of functionality of control input data transfer along with fieldbus converter by
simulating inputs.
g) Functional verification of cursor movement devices
Verification of correct functioning of all keyboards, mouse, touch screens, light pen etc shall be
carried which shall include;
i) Smooth functioning of all devices.
ii) Functional commands verification
iii) Dual function key configuration.
The devices shall include those attached to operator console, engineering console, PLC console,
personal computers, other sub-systems / accessories.
h) Verification of loop configuration
Data base and the configuration of all the loops shall be verified for their correctness with respect
to range, limits, engineering units, alarm set points, software configuration, output status of

STD-0201 0
SHEET 130 OF 146
controller / control block failure etc with respect to latest revisions of instrument details and
functional schematics / P&ID's supplied by purchaser.
i) Verification of Displays
All types of displays, process as well as system, configured on operator console, engineering
console and PLC console shall be verified with respect to correct display configuration, colour
scheme, colour modifiers, engineering units, windowing feature, alarms, flags, restricted operation
etc.
j) Verification of functionality of accessories
All the accessories like printers and hard copiers shall be verified for their proper operation by
printing either test data or actual data.
k) System Diagnostics
System diagnostics shall be thoroughly checked for all sub-systems on local level as well as on
operator/engineering console. These shall include diagnostics of failure of main as well as
redundant items such as a sub-system, sub-system module, HI module, LAS functionality, power
supply, interface unit, network and network module, consoles, third party device interfaced with
DCS, printers, hard copier, server failures, key-board / cursor movement devices, disc and disc
drives, field-bus devices, field-bus segment, network devices etc. and other detailed diagnostics
and their corresponding displays. Diagnostic alarms for any ventilation fan failure, cabinet
temperature high and corrosion monitor shall also be verified.
l) Verification of Application programme
Following application programming shall also be verified thoroughly in addition to the complete
loop operation by simulation;
i) Verification of trending and trend displays.
ii) Verification of historisation functionalities
iii) Verification of alarm management
iv) Verification of data retrieval functionalities.
v) Verification of all dynamic graphics.
vi) Verification of interchangeability between various video screens of a console.
vii) Synchronisation of system clocks.
viii) Verification of various log formats and log reports including MIS reports as applicable.
ix) Complete (100%) verification of interlock and shutdown logic by simulating inputs and
verifying outputs preferably using simulator, other related functions like forcing, first out
shall also be verified.
STD-0201 0
SHEET 131 OF 146
x) Verification of third party device (like PLC, analyser system, computers, MMS, F&G
systems etc) interfaces for complete data transfer between device and DCS and vice versa.
Where third party devices are not supplied by vendor (and cannot be provided by
purchaser for conducting factory testing), the complete address mapping shall be verified
and the link shall be proved using third party device simulation.
xii) Verification of data and reports related to instrument asset management system.
m) Verification of other specific requirements when specified like;
i) Large screen functionality and display solution shall be verified along with large screen
controller. Where large screen is not available during factory acceptance test, vendor may
utilize a PC in place of display unit for application verification.
ii) Verification of all functionalities of alarm information and management system including
report generation.
iii) Verification of functionalities of unit history node and its verification. The verification
shall include configuration verification, sample rate versus storage time verification (by
extrapolated method for extended time period), throughput, report formats and report
generation.
iv) OPC node verification with respect to its configuration, data structure and throughput.
v) Sequence of Event Recorder functionalities verification by verifying identification of
events with the specified resolution. The input shall be generated using pulse generator of
suitable frequency.
vi) Functionalities of other items when specified shall also be verified.
n) Verification of hardwired console and its functionality. All functions shall be 100% verified such
as operation of hardwired instruments, hardwired annunciator, switches, ramps, pushbuttons,
instruments like controllers, indicators, recorders etc. Hardwired consoles must be present during
factory acceptance test and shall be interconnected for functional verification. All hardwired
instruments like alarm cards, barriers and relay shall also be verified for their proper operation.
o) Verification of all system builder functions and engineering console functionalities.
p) Verification of fieldbus simulator functionalities when specified and purchased along with the
system.
q) Verification of display update rate and call-up time under worst loading conditions. Network
performance shall also be verified by verifying display update rate of an analog tag number when all
other inputs in the system are under varying conditions.

STD-0201 0
SHEET 132 OF 146
2.2.2.8 The vendor shall notify the owner/consultant at least three weeks prior to final system testing. In the
event that representatives arrive and the system is not ready for testing, the vendor will be liable for
back charges for any extra time and expenses incurred.

STD-0201 0
SHEET 133 OF 146
2.2.2.6.4 Checking of loop configuration for correctness with respect to ranges, limits, alarm points, engineering
units etc.
2.2.2.6.5 Checking of all types of VDU displays including process and system displays on operator Engineering
and PLC console.
2.2.2.6.6 Checking of correct functioning of key-board operation for operator, Engineering and PLC console.
2.2.2.6.9 Testing of proper functioning of all printers and hard copy units.
2.2.2.6.10 Testing of system features like interchangeability between VDUs of a console, synchronisation of
system clocks, selective tuning from Engineering console, key-lock functions etc.
2.2.2.6.11 Checking of various log formats, shut down reports, I/O mapping and other MIS formats printing.
2.2.2.6.12 Checking of shutdown and interlock configuration and proper operation thoroughly.
2.2.2.6.13 Proper system operation at power supply specifications specified in the Material Requisition.
2.2.2.6.14 Checking of proper operation of all interfaces with the system like interface with PLC, computer,
analyzer system etc as specified in Material Requisition.
2.2.2.6.15 Checking of bus-degradation while loading the bus from 10% to 100%.
2.2.2.6.16 Simulation of power failure and restarts.
2.2.2.6.17 Checking of all hardwired instrumentation including all alarm cards, alarm annunciator system,
switches and other indicating instruments.
3.1 Vendor shall offer the services of the installation team which would install the equipment in the control
room, lay the interconnecting cabling inside the control room, check out, test and commission the
system.
All technical personnel assigned to the site by the vendor shall be fully conversant with the supplied
system and software package, and shall have both hardware and software capability to bring the system
on line quickly and efficiently with a minimum of interference with other concurrent construction and
commissioning activities.

STD-0201 0
SHEET 134 OF 146
3.2 Vendor’s responsibility at site shall include all activities necessary to be performed to complete the job
as per material Requisition including:
a) Receipt of hardware/software and checking for completeness of supplies.
b) Installation of the system including free supply equipment and field cable termination in the
system.
c) Check out of the equipment installation.
d) Checking of interconnection, hardware & software configuration, overall system functioning etc.
e) Loop checking.
f) Liaison with vendor’s home office.
g) Field tests
h) Commissioning and on-line debugging of the system.
i) Performance of final acceptance test.
3.3 The only exclusion from vendor’s responsibility shall include the following:
a) All civil works in the control room including false flooring, control room lighting and air
conditioning ducting.
b) Laying and identification of field cables.
c) Field instrument installation and calibration.
3.4 Field Inspection
3.4.1 All equipments shall be inspected thoroughly by vendor after its receipt at site. The tests, as a
minimum, shall include;
(a) Hardware verification as per packing list.
(b) Visual and mechanical checking.
(c) Complete System Configuration loading.
(d) Functioning of all VDUs, keyboards, disc drives, printers, hardcopy units etc.
STD-0201 0
SHEET 135 OF 146
(e) Checking of correct change-over of redundant devices.
(f) Checking of hardwired instruments.
(g) Any other checking.
3.4.2 The testing defined in para 3.4.1 shall be carried out to ensure functional integrity of all hardware being
supplied. Vendor must initiate the remedial action in case unsatisfactory operation of any equipment or
item is observed during this testing with an intimation to Engineer-in charge.
3.4.3 Vendor must document all observations including details of malfunctions observed, if any. Items/
equipments requiring total replacement must document reasons for the same.
3.5 Loop Checking
3.5.1 Vendor shall be responsible for loop checking which shall also include checking of the interconnection,
at control room end, configuration and ensuring over all system functioning.
3.5.2 Calibration and installation of field instruments, installation of junction boxes, interconnection between
instruments and junction boxes, laying of single, multi pair cables upto control room, tagging all field
cables, performing continuity/ insulation test of cable, core identification of field cables etc. shall not
be in the vendor scope. This work shall be carried out by the field contractor.
3.5.3 Vendor's scope of work, as a part of system installation and loop checking shall include termination of
all field cables in control room, checking of interconnection between instrument glanding and
equipment, ferruling and tagging of interconnecting cables in control room, ferruling of field cables in
control room and performing overall loop performance check.
3.5.4 Loop checking shall be carried out to check the functional performance of all elements comprising the
loop and thereby ensuring proper configuration, functioning and interconnection.
For fieldbus devices the loop checking shall include the checking of complete fieldbus segment
connectivity with its devices including noise, device configuration, waveform checking. The complete
device configuration shall be downloaded to all field devices from DCS prior to the start of loop
checking.
3.5.5 Vendor shall co-ordinate with the field contractor for smooth and proper loop checking. Any
discrepancy found during checking shall be brought to the notice of Engineer-in-Charge. Complete
loop checking shall be performed in the presence of Engineer-in Charge or his authorised repre-
STD-0201 0
SHEET 136 OF 146
sentative. All readings shall be recorded on a suitable format which shall be handed over to the vendor
by the field contractor after completing calibration record of each field device. On the completion of
loop checking, remaining information related to loop checking shall be filled by the vendor.
Completely filled format duly signed shall be submitted for approval, to Engineer-in Charge.
3.5.6 a) All the components of the loop shall be checked for proper functioning. All field
instruments connected to control room shall be loop checked at 0%, 50% & 100% of FS (for both
increasing and decreasing signals). The mode of generating signal from the field by field contractor
shall be as follows for different instruments types:-
Type of Instrument Mode of Signal Generation
a) Differential pressure/ flow By applying impulse to the primary by squeeze

instruments/ DP type level bulb or regulator at field
instruments
b) Pressure instruments By applying impulse to the instrument using
instrument air, regulator & standard gage or
using portable hydraulic pump and standard
gage.
c) External Displacer Cage shall be filled with water for different
levels and specific gravity correction shall be
applied
d) Other type of tank level By lifting the float of the level instruments for
instruments 0% and 100% of range
e) Temperature loops with Appropriate mV signals shall be fed from
thermocouple thermocouple head
f) Temperature loops with RTD Appropriate resistance shall be fed from RTD
head
g) Field switches for Alarm & Abnormality shall be simulated by
Shutdown disconnecting and connecting the wires at field
instruments end
h) Owner supplied items As per Engineer-in-Charge’s Instructions
i) Special instruments & any As per Engineer-in-Charge’s Instructions

other type of instruments
b) Receiver alarm cards shall be checked by the vendor for different settings on both increasing and
decreasing signals.
c) Shutdown schemes shall be checked for proper functioning, configuration and actuation.
d) Performance of individual loops may be accepted for an overall accuracy of ± 1.0% unless
otherwise specified. Where deviation exists, re-calibration of instruments, based on the scope of
work, shall be carried out either by field contractor or by vendor.
e) Signal from controllers/shutdown schemes to control valves/shutdown valves shall be checked at
the respective valves. The stroke checking including checking of time of operation of control

STD-0201 0
SHEET 137 OF 146
valves/shutdown valves also forms a part of loop checking. Vendor shall coordinate this activity
with field contractor and record the same in the loop checking format.
f) For the loop checking of loops connected to substation, vendor shall be responsible to coordinate
with the Electrical Contractor.
g) After loop checking is completed, vendor shall connect back any terminals and connections
removed for loop checking.
4.0 SYSTEM ACCEPTANCE
4.1 The owner shall provisionally takeover the system from vendor after System acceptance test. System
acceptance test shall be started only after the satisfactory performance of loop checking and
verification of all loop checking records by Engineer-in-charge.
4.2 The system acceptance test shall be carried out in the presence of owner's representative and Engineer-
in-charge or his authorised representative. The tests carried out in System acceptance test shall be fully
recorded and duly signed by all representatives participating in the System Acceptance Testing.
4.3 Vendor shall carry out the following functional tests on the fully integrated system as a part of System
acceptance test, as a minimum;
a) Hardware verification as per final Bill-of-material.
b) Visual and mechanical checking for proper workmanship, identification, ferruling, nameplates, etc.
c) System configuration as per approved configuration diagram.
d) Checking of correct functioning of all keyboards and dual function keys.
e) Checking of proper operation of hardcopy unit and all printers including printing of Alarms and
Events on the Alarm & Event (A&E) printer.
f) Demonstration of all system diagnostics.
g) Checking of correct changeover of redundant devices.
h) Checking of redundancy for LAS functionality for fieldbus segments.
i) Checking of communication between DCS, PLC and other foreign devices.
j) Checking of proper functioning of all disc drives, historical trend-points, alarm summary and alarm
history.
STD-0201 0
SHEET 138 OF 146
k) Verification of proper functioning of assignable trend recorder
l) Printing of Configuration and Configuration changes on C&M printer.
m) Proper information transfer on the information network by verifying system displays and printouts.
5.0 FINAL ACCEPTANCE TEST
5.1 The owner will take over the system from the vendor after the final acceptance test, which is defined as
successful uninterrupted operation of the integrated system for three weeks for all units of the plant.
Vendor’s personnel shall be present during the test.Any malfunctioning of the system components shall
be replaced/repaired as required. Para 2.1.6 of this specification shall be applied for failure of
components & readjustments.Once the system failure is detected, the acceptance test shall start all over
again from the beginning. The warranty period commences from the day owner takes over the system.
6.0 TESTING/CALIBRATION EQUIPMENTS
6.1 Vendor shall make available all consumable, instruments, and equipments necessary for testing,
calibration, maintenance etc. as required by the defined scope of works. All instruments and equip-
ments used for the above purpose shall be of standard make with accuracy better than the accuracy
expected from the calibrated/tested instruments, and certified by National Physical Laboratory or other
equivalent agencies. These instruments/equipments are necessary only during
testing/calibration/maintenance.

STD-0201 0
SHEET 139 OF 146
PART - III
GENERAL REQUIREMENTS
OF

STD-0201 0
SHEET 140 OF 146
CONTENTS
SR.NO. TITLE PAGE NO.
1.0 SCOPE 135

2.0 LOGISTIC SUPPORT SERVICES 135
3.0 DOCUMENTATION 137
4.0 WARRANTY 139
5.0 MAINTENANCE CONTRACT 139
6.0 PACKING AND SHIPPING INSTRUCTIONS 140

STD-0201 0
SHEET 141 OF 146
1.0 SCOPE
1.1 This specification defines the general requirements expected to be fully complied by Distributed
Control System vendor including logistic sup ports, documentation, warranty, maintenance contract
and shipping instructions etc.
1.2 The requirements defined in this specification shall also be applicable for all sub-system and hardware
bought and supplied by vendor from manufactures other than his own.
2.0 LOGISTIC SUPPORT SERVICES
2.1 The hardware maintenance engineers shall be trained for module level nd optionally component level
diagnostics of the system. Vendor is required to quote separately for these training facilities. It is also
necessary to include in the proposal the details of diagnostic software package for isolating the fault at
module level for all the sub- system of Distributed Control System.
2.2 Training
2.2.1 The requirements of training for owner/consultant personnel (one group consisting of operators and
other group consisting of hardware/software maintenance engineers) in the operational software and
diagnostic programs, are set forth herein.
2.2.2 Vendor shall be responsible for furnishing details of course outlines, manuals of training, equipment
necessary to conduct the training, exercises to evaluate trainees’ progress. Vendor shall also be
responsible for any other requirements necessary to train the engineers deputed by owner within a time
limit so that they acquire the necessary expertise to operate and maintain the programs and the
equipments supplied.
2.2.3 Owner/ consultant or his authorised representatives shall select personnel for training on the basis of
his requirements and will review all materials furnished for adequacy of teaching aids and time tables.
2.2.4 Training Personnel.
Each instructor-designate shall have the following minimum qualifications for his area of instructions:
a) Six months of formal class-room instructor experience.
b) Complete and thorough technical knowledge of the equipment and system supplied under the
contract and skilled experience in their programming, maintenance and operation.
c) Complete and thorough knowledge of the test and laboratory equipment maintaining, diagnosing,
programming, operating and trouble shooting the hardware software system.
2.2.5 Course contents
2.2.5.1 The outline of each course shall give the subject matter, a short resume of the pre-requisite subjects (if
applicable), the position of the course in the training programme, the aim and yardsticks for evaluation
and other topics which will add to the usefulness of the program. In order that the selected trainees
shall have time to participate in the course, sufficient advance notice of minimum 8 weeks shall be
given by the vendor. The course outlines shall be submitted 10 weeks ahead for review.

STD-0201 0
SHEET 142 OF 146
2.2.5.2 The training exercise shall be designed to be objective in nature and shall include trouble shooting
exercises on similar equipments.
2.2.6 Training manuals
2.2.6.1 All training manuals shall be prepared by the vendor and submitted for review 10 weeks ahead of the
commencement of the course. After course completion, these manuals shall become the property of the
owner. Any change in equipment, manuals and other material shall be informed to the owner during the
guarantee period. In addition to vendor documentation, the following minimum requirements shall be
adhered to for the training manuals:
a) Functional flow-charts, descriptive material, program source listings applicable to all operating
and application software and diagnostics programs.
b) Schematic drawings of each assembly of the hardware for the course on maintenance.
c) All manuals pertaining to procedures, specifications and operation for each equipment.
2.2.7 DCS hardware and software maintenance training
2.2.7.1 Vendor shall conduct a course in hardware (module level and optional component level) maintenance,
software maintenance and diagnostic of the system for owner at vendor’s facility. The course shall be
conducted prior to the factory system performance tests so that trained personnel can participate
effectively in the final testing.
2.2.7.2 The hardware maintenance training course shall cover every equipment item supplied as part of the
Distributed Control System. This course shall include:
a) Actual operation, detection and correction of faults in equipments.

b) Familiarisation with maintenance procedures for the system offered.
2.2.7.3 Some of the topics covered in the course shall include:

a) Fundamentals of the system
b) Equipment logic diagrams
c) Diagnostic procedures
d) Peripherals maintenance
e) Preventive maintenance procedures
2.2.7.4 Software maintenance training shall cover all software supplied with the system. The trained personnel
shall be able to write and debug the application and system software.
2.2.7.5 The vendor is required to quote for in-house and on-site training separately and manhour rate for
additional training, if required by the owner.
2.2.8 Site training facility and training kit
2.2.8.1 The training kit shall essentially be used for refresher and training courses for process engineers,
operating and instrument maintenance staff. The training kit shall be simple control system with
process simulator for a group of loops and shall include:
a) An operator console with a VDU, operator key board and engineering keyboard.
STD-0201 0
SHEET 143 OF 146
b) Controller with auto backup facility.
c) One each of the varieties of PCBs used in data acquisition.
d) Signal simulator.
2.2.8.2 Vendor to provide the details of the kit offered alongwith the proposal.
2.2.8.3 Training kit system shall be stand alone with respect to hardware and software and in no way be lined
with the main system.
2.3 Spare parts
2.3.1 Vendor shall include in the proposal, provisions for special tools, test equipments and initial stock of
maintenance spares for a period of two years after commissioning as are essential for proper
maintenance and operation of the equipment. In addition, estimated requirements of spares
consumption per annum should also be indicated. Full particulars of the tools, test equipments and
spare parts shall be provided separately. The list should also include the item wise price.
2.3.2 The successful vendor shall warrant that spare parts for the system would be available for a minimum
of fifteen years. After this period, if vendor discontinues the production of spare parts, vendor shall
give at least twenty four (24) months notice prior to such discontinuation so that the owner may order
his requirements of spares in one lot.
3.0 DOCUMENTATION
Vendor shall furnish all the manuals necessary to test, operate and maintain Distributed Control System
hardware and software.
3.1 Hardware documentation
3.1.1 The following documentation for all hardware supplied and as built under this contract shall be
submitted for review two months before the start of factory acceptance testing.
a) The specifications for all off-the-shelf hardware manufactured by vendor, his sub-contractors or
suppliers.
Supplier’s name and identification of ordered hardware and expected delivery data to vendor’s
premises shall also be supplied along with this.
b) Documentation relating to off-the-shelf hard ware and hardware developed by vendor including
description, specifications, theory of operation, maintenance procedures, installation information
and drawings. This information shall exclude all non-applicable information.
c) Where more than one size, rating or type of construction appears on the submitted catalogue data,
those characteristics applicable shall be identified. Non applicable information shall be suppressed.
d) Test plans and test reports as specified in Part II of this specification for each item of hardware, to
be supplied.
e) Bill of material listing all hardware to be supplied including manufactures part numbers, name
plates data, approximate volume, weight and overall dimensions.
f) Spare parts catalogue for all items (at component level) to be supplied.
STD-0201 0
SHEET 144 OF 146
g) Recommended spare parts for two years.
3.2 Software documentation

The following documents shall be submitted for review before 90 days of the shipment of the system,
for the software packages included in the supply:
a) The specifications for all software to be obtained in-house or from subcontractors or suppliers. The
details supplied shall also include the name of the suppliers, software identification including latest
modification data.
b) Reference manuals, operating manuals, programming manuals and other software manuals (if any).
c) Description of the function of each program. This shall include the logic, configuration
requirements and constraints and sub-programs used,, memory map and special characteristics.
d) Input and output details for each program.
e) Listing of assembled programs with label and symbol tables in assembler/compiler language.
3.3 System manuals
3.3.1 Manuals shall be submitted for assuring satisfactory operation and maintenance of the system. Detailed
literature for installation and maintenance of all hardware should be provided to the owner.
3.3.2 All system manuals shall be supplied in hard cover loose ring folders in A size i.e. 216 x 279 mm. All
drawings and sketches shall be in multiple of ‘A’ size like ‘B’ (279 mm x 432 mm) or ‘C’ type (406
mm x 518 mm) etc. but folded to ‘A’ size.
3.3.3 Instruction Manual
The information submitted shall preferably be in three parts.
I Part
First part shall give the following information:
a) A general functional description of the whole system.
b) General software description.
c) General Instructions and start up procedures.
II Part
Second part shall describe the system software in detail including its interaction with application
programs and other programs used as supporting software.
III Part
The third part shall include detailed maintenance information including all data pertaining to
equipment required for maintenance of the system.
3.3.4 Maintenance manuals
3.3.4.1 The maintenance manual shall include details of

STD-0201 0
SHEET 145 OF 146
a) Preventive maintenance procedures.
b) Trouble shooting procedures including failure analysis.
3.3.4.2 A section on repairs shall provide enough information on repairs including removal, repairs, adjust-
ment and replacement.
3.3.4.3 The maintenance manuals shall contain a list of all maintenance parts to facilitate quick identification
of the parts for replacement and ordering. Standard hardware structural parts, or other parts not
requiring maintenance shall not be included here. At the end of the list of parts requiring maintenance,
a list of special tools required for the maintenance of each unit shall be given. List of manufacturers of
each part shall also be included.
3.3.5 The final system manuals shall be furnished to owner within a month of completion of final
satisfactory field testing. All field modifications shall be incorporated and system as built drawings and
documents shall be included. Fifteen copies of each manuals shall be submitted to the owner/con-
sultant.
3.3.6 Engineering drawings
3.3.6.1 The vendor shall provide a complete set of drawings covering each art of the supply for the
owner/consultant record. The vendor is required to include owner’s project number on each of his
drawings in order to ease owner/consultant’s record keeping.
3.3.6.2 Functional schematics and logic diagrams are furnished by owner/consultant to provide an idea of
system hardware and software requirements to the vendor. Functional schematics shall be furnished in
two parts.
a) Part-I, containing all system hardware and software requirements is furnished along with Material
Requisition.
b) Part-II, containing the field devices details like transmitter, junction box details, final actuating
device single and multi cable/core details, shall be furnished later.
Vendor shall develop loop wiring diagrams, containing full information of each loop (one drawing
per loop) including field termination, junction box details, cables numbering, rack number, bus
address code, device address code, power supply connections, final actuating device details
including positioner and air supply etc and furnish these before the installation of system.
3.3.6.3 All field modifications shall be carefully recorded by the vendor’s commissioning personnel and
change shall be incorporated into final drawings. Fifteen copies of each drawing shall be submitted
with one reproducible.
4.0 WARRANTY
4.1 Vendor shall be fully responsible for the manufacture in respect of proper design, quality, workman-
ship and operation of all the equipment, accessories etc. supplied by the vendor for a period of 18
months from the date of taking over by the owner at the site as mentioned in this specification or 24
months from the shipment date whichever is later.
4.2 It shall be obligatory on the part of vendor to modify and/or replace any hardware and modify the
operating, application and diagnostic software free of cost, in case any malfunction is revealed even
during on line operation after taking over within the warranty period.

STD-0201 0
SHEET 146 OF 146
4.3 Vendor shall also provide the total maintenance of the system during warranty period. The cost for
warranty maintenance, if any, shall be included in the proposal separately in ‘vendor proposal outline
and pricing details’.
5.0 MAINTENANCE CONTRACT
5.1 Vendor shall quote separately for maintenance contract after warranty period for two years based on
per day rate for each category of personnel required. The personnel deployed shall have thorough
knowledge of the system and atleast two years of experience on the maintenance of similar system.
Any other conditions of contract required by vendor shall be explained in the offer.
6.0 PACKING AND SHIPPING INSTRUCTIONS
6.1 All the material used for packing, wrapping, sealers, moisture resistant barriers and corrosion
preventers shall be of recognised brands and shall conform to the best standards in the areas for the
articles which are packaged.
6.2 Workmanship shall be in accordance with best commercial practice with the requirement of applicable
specifications. There shall be no defects, imperfections or omissions which would tend to impair the
protection offered by the package as a whole.
6.3 The package shall be suitable for storing in tropicalised climate, the ambient conditions being specified
in the job specifications.
6.4 Shipment shall be thoroughly checked for completeness before final packing and shipment.

GSTD-0202 0

SHEET 1 OF 39
FOR
PROGRAMMABLE LOGIC CONTOROLLER (PLC)

0 05.12.2016 05.12.2016 For Tender Ritu Agarwal Sanjay Kr Tripathi Sanjay Kr Tripathi


GSTD-0202 0
Rev
SHEET 2 OF 39
AC : Alternating Current
API : American Petroleum Institute
BIS : Bureau of Indian Standards
CCOE : Chief Controller of Explosives
CPU : Central Processing System
DC : Direct Current
DCS : Distributed Control System
DGMS : Director General of Mines Safety
DMR : Dual Modular Redundant
DVD : Digital Versatile Disc
EMI : Electromagnetic Interference
ERTL : Electronic Regional Testing Laboratory
ESD : Emergency Shutdown System
FAT : Factory Acceptance Test
FMEDA : Failure Modes, Effects and Diagnostic Analysis
HART : Highway Addressable Remote Transducer
HW : Hardware
HWC : Hardwired Console
I/O : Input / Output
IEC : International Electrotechnical Commission
IEEE : Institute of Electrical and Electronic Engineers
IS : Indian Standards
ISA : International Society of Automation
ISO : International Organization for Standardization
LAN : Local Area Network
LCD : Liquid Crystal Display
LCIE : Laboratorie Central Industries Electriques
LED : Light Emitting Diode
MTBF : Mean Time Between Failure
MTTR : Mean Time to Repair
OLE for Process Control(Open Platform
OPC : Communication)
P&ID : Piping and Instrumentation Diagram
PC : Personal Computer
PESO : Petroleum and Explosives Safety Organisation
PID : Proportional, Integral and Derivative
PLC : Programmable Logic Controller
PTB : Physlkalisch Technische Bundersanstalt
QMR : Quadruple Modular Redundant
RFI : Radio Frequency Interference
SAT : Site Acceptance Test
SER : Sequence of Event Recorder
SIL : Safety Integrity Level
SIS : Safety Instrumented System
TCP / IP : Transmission Control Protocol /Internet Protocol
TFT : Thin Film Transistor
TMR : Triple Modular Redundant
TUV : Technische Uberwachungsvereine

GSTD-0202 0
Rev
SHEET 3 OF 39
UHF : Ultra High Frequency
UL : Underwriter's Laboratories
UPS : Uninterrupted Power Supply
VDU : Video Display Unit
VHF : Very High Frequency
Triple Modular redundant (TMR), Quadruple Modular Redundant (QMR)configuration, Flexible Modular
Redundant (FMR) configuration, Virtual Modular Redundant (VMR)

GSTD-0202 0
Rev
SHEET 4 OF 39
1.0 GENERAL 5
2.0 DEFINITIONS 11
3.0 SPARES PHILOSOPHY 14
4.0 DESIGN AND CONSTRUCTION 16
5.0 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE 36
6.0 GENERAL REQUIREMENTS 42
7.0 SHIPPING 42

GSTD-0202 0
Rev
SHEET 5 OF 39
1.0 GENERAL
1.1 Scope
1.1.1 This specification, together with the Material Requisition defines the minimum functional
requirements for the design, hardware, software and firmware specifications, nameplate
marking, testing and shipping of Programmable Logic Controllers (PLC) designed for reliable
effective and optimum control and monitoring of a process plant .
1.1.2 The related standards referred to herein and mentioned below shall be of the latest editions
prior to the date of the purchaser's enquiry:
APIRP 552 Transmission Systems
EEMUA 191 Alarm System -A Guide to Design, Management and Procurement
EN 10204 Metallic Products -Types of Inspection Documents
EN 50039 Electrical Apparatus for Potentially Explosive Atmospheres: Intrinsically
Safe Electrical System 'I'
IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere
IEC 60529 Degree of Protection Provided by Enclosures
IEC-60584 Thermocouple Part 2: Tolerances
IEC 60617 Graphical Symbols for Diagram
IEC-60751 Industrial Platinum Resistance Thermometers and Platinum Temperature Sensors
IEC 61000-4-3 Electromagnetic Compatibility (EMC) -Testing and Measurement Techniques -

Radiated, Radio Frequency, Electromagnetic Field Immunity
IEC-61000-4-4 Electromagnetic Compatibility (EMC) -Testing and Measurement Techniques -

Electrical Fast Transients / Bust Immunity Test
IEC-61000-4-5 Electromagnetic Compatibility (EMC) -Testing and Measurement Techniques –

Surge Immunity Test
IEC-61000-6-2 Electromagnetic Compatibility (EMC) -Generic Standards -Susceptibility -

Industrial
IEC 61508 Functional Safety of Electrical/Electronic / Programmable Electronic Safety-related

Systems
IEC 61131 Programmable Logic Controllers
IEC 61511 Functional Safety -Safety Instrumented Systems for the Process Industry Sector

GSTD-0202 0
Rev
SHEET 6 OF 39
IEEE 802.3 Telecommunication and Information Exchange between Systems -Local and
Metropolitan Area Networks -Specific Requirements -Part 3: Carrier Sense
Multiple Access with Collisions Detection (CSMA / CD) Access Method and
Physical Layer Specifications
IS 2148 Flameproof Enclosures of Electrical Apparatus
IS-3043 Code of Practice for Earthing
IS 13947 Specifications for Low Voltage Switchgears and Control Gears
ISA 5.1 Instrumentation Symbols and Identification
ISA 5.2 Binary Logic Diagrams for Process Operations
ISA 5.3 Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic
and Computer System.
ISA 5.4 Instrument Loop Diagrams
ISA 5.5 Graphic Symbols for Process Displays
ISA 18.1 Annunciator Sequences and Specifications
ISA 71.01 Environmental Conditions for Process Management and Control Systems:
Temperature and Humidity
ISA 71.04 Environmental Conditions for Process Measurement and control Systems:
Airborne Contaminants
ANSI/ISA Security Technologies for Industrial Automation and Control Systems TR 99.00.01
Manufacturing and Control System
ISO 216 Writing Paper and Certain Classes of Printer matter-Trimmed Sizes-A & B Series
ISO 9241-5 Workstation Layout and Postural Requirements
ISO 9241-7 Display Requirements with Reflections
1.1.3 In the event of any conflict between this specification, data sheets, statutory regulations,
related standards, codes etc., the following order of priority shall govern:
a) Design Philosophy / Statutory regulations
b) Data Sheets
c) Standard Specifications
1.1.4 In addition to meeting purchaser's specifications in totality, vendor's extent of responsibility

shall also include the following:
GSTD-0202 0
Rev
SHEET 7 OF 39
a) Purchaser's data sheets specify the minimum acceptable functional requirements
for the programmable logic controllers. It shall be vendor's responsibility to select
proper hardware, software and firmware to meet the specified functional
requirements.
b) Purchaser's data sheets specify the scan time / cycle time / response time and
loading requirements. Vendor shall be responsible for sizing and selecting their
standard product i.e. hardware, software and firmware to meet the requirements
specified in the purchaser's data sheets.
c) Selection of proper and adequate hardware, software and firmware to meet

system requirements specified in the purchaser's specifications, keeping the
integrity of functional blocks specified in the configuration 'diagram attached with
the material requisition.
d) Adequacy of Bill of Material selected to meet purchaser's requirements. Vendor to

note that bill of material shall not be verified by the purchaser during evaluation
stage. Any hardware, software and firmware required to meet the purchaser's
specified requirements shall be provided by the vendor without any implication.
e) Providing adequate mandatory spares including consumable spares as specified

in the purchaser's specifications. Vendor shall be responsible to meet mandatory
spare requirements specified by the purchaser.
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to vendor attached with the
material requisition. Vendor's quotation shall enumerate and include the detailed specification
of each subsystem and each module of programmable logic controller, detailed system
configuration, hardware and software capabilities, programming aids, display facilities and
other relevant information.
1.2.2 Whenever a detailed technical offer is required, vendor's quotation shall include the following:
b) Detailed specification sheets for each sub-system. The specification sheet shall
provide information regarding hardware specifications, software specifications,
redundancy requirements, capacity, power consumption etc. of the programmable
logic controllers and its accessories. The material specifications and unit of
measurement for various items in vendor's specification sheets shall be to the
same standards as those indicated in purchaser's data sheets.
c) System security features and design details.
d) Proven references for each offered model in line with clause 1.2.4 of this
specification whenever specifically indicated in the purchaser's specifications.
e) A copy of approval for flameproof enclosure, intrinsic safety etc whenever

specified, from local statutory authority, as applicable, like Petroleum and

GSTD-0202 0
Rev
SHEET 8 OF 39
Explosive Safety Organization (PESO) / Chief Controller of Explosives (CCOE),
Nagpur or Director General of Mines Safety (DGMS) in India along with:
i) Test certificate from recognized house CIMFR (Central Institute of Mines &
Fuel Research) / ERTL (Electronics Research and Test Laboratory) etc. for
specified protection class as per relevant Indian Standard for all Indian
manufactured equipments or for equipments requiring DGMS approval.
ii) Certificate of conformity from agencies like LCIE, Baseefa, PTB, CSA, UL
etc., for compliance to ATEX or other recognized standards for all
equipments manufactured outside India.
f) Deviations on technical requirements shall not be entertained. In case vendor has

any valid technical reason to deviate from the specified requirement, they must
include a list of deviations item wise, summing up all the deviations from the
purchaser's data sheets and other technical specification along with the technical
reasons for each of these deviations.
g) Certificate for specified SIL requirement (e.g. SIL-3) from Independent Testing
Agency.
h) Catalogues giving detailed technical specifications, model decoding details and

other related information for each item / sub-system covered in the bid.
1.2.3 Vendor shall offer only their standard proven product i.e. system hardware, system software
and firmware, which shall be configured to meet the functional requirements specified in the
material requisition. Moreover, the equipment being offered / supplied shall be of latest
proven version available in the current manufacturing range and meeting the requirements
specified in clause 1.2.4 of this standard specification.
1.2.4 The system hardware, software and firmware as offered, shall be field proven and should
have been completed trouble free satisfactory operation for a period of minimum 4000 hours
on the bid due date in the similar application with equal or higher than the proposed system
size with respect to number of inputs and outputs specified in the purchaser's data sheet.
Items with prototype design or items not meeting proneness criteria specified above shall not
be offered or supplied.
1.2.5 The detailed scope of work, specific job requirements, exclusions, deviations, additions etc.
shall be indicated in the job specifications which shall be part of material requisition.
1.2.6 Whenever specified, vendor shall furnish tested values of failure rates, probability of failure on
demand and test intervals for safety integrity level analysis.
1.2.7 All documentation submitted by the vendor including their quotation, catalogues, drawings,
installation, operation and maintenance manuals shall be in English language only.
1.2.8 Vendor shall also quote for the following:
a) Two year's operational spares for each sub-system and their accessories which
shall include the following as a minimum:

GSTD-0202 0
Rev
SHEET 9 OF 39
i) All type of electronic modules e.g. I/O modules, processor modules,
communication modules, memory modules, disc controller module, power
supply modules etc.
ii) All type of auxiliary items e.g. barriers / isolators, hardwired instruments,
annunciator modules, receiver switches, trip amplifiers, temperature
element converters etc.
iii) Switches, lamps, fuses, connectors, terminals, pre-fabricated cables,

circuit breakers, relays etc.
iv) Video display units, keyboards, disc drives, PC's, network items (e.g.
switches, hubs etc.) etc. \
b) Any special tools and test equipments needed for the maintenance of PLCs and
other items being offered by vendor. Vendor must confirm in their offer if no
special tools or test equipments are needed for maintenance other than those
specifically indicated in purchaser's data sheet.
1.3 Drawing and Data
1.3.1 Detailed drawings, data, catalogues and manuals required from thy vendor are indicated by
the purchaser in vendor data requirement sheets. The required number of prints and soft
copies shall be dispatched to the address mentioned, adhering to the time limits indicated.
1.3.2 Final documentation consisting of design manuals, installation manual, operation and
maintenance manual etc., submitted by the vendor after placement of purchase order shall
include the following, as a minimum:
a) Specification sheet for each sub-system, auxiliary instrument and bought out item.
b) Certified drawings for complete system including the following:
i) GA drawings for panels, cabinets, marshalling racks, hardwired consoles,

operator console, programming terminal etc with complete dimensional
details, internal construction and weight in kilograms.
ii) Control room layouts e.g. console room, rack room and engineering room
layout with all dimensions in millimetres.
iii) Channel base frame drawing for console room, rack room and engineering
room.
iv) Input / output assignment.
v) Logic / Ladder diagrams.
vi) Loop wiring diagram.
vii) Power supply distribution diagram.

GSTD-0202 0
Rev
SHEET 10 OF 39
viii) Memory loading calculations/Scan time calculation.
ix) Protocol/Pin Details.
x) Dynamic graphic diagrams.
xi) System grounding drawing.
c) Design manuals and functional design specifications which shall include hardware
design manual, software design manual and special software specifications.
d) Copy of type test certificates.
e) Copy of test certificates for all tests indicated in this specification.
f) Installation manual containing installation procedure for programmable logic

controllers and other items covered in the material requisition.
g) Power-on, start-up and internal testing procedures.
h) Software debugging and system configuration procedures.
i) Calibration and maintenance manual containing maintenance procedures

including replacement of parts, application modification etc.
j) Any other drawings and documents specifically indicated in job vendor data
requirement enclosed with the material requisition.
All system manuals and documentation shall be supplied in hard dover loose ring folders in
'A4' size as per ISO 216 i.e. of size 210mm x 297mm. All drawings and sketches shall be in
multiple of'A4' size like 'A3' (297mm x 420mm) or 'A2' type (420mm x 594mm) etc. but folded
to 'A4' size.
2.0 DEFINITIONS
The various terms used in this specification are defined as follows:
The class of control systems which can be programmed to execute plant shutdown and / or
interlock / sequence logics to the specified safety integrity levels.
2.2 Accessible
A system feature that is viewable by and interactive with the operator and allows the operator
to perform user permissible control action e.g. set point change, auto-manual transfers or on-
off actions.
2.3 Assignable
A system feature that permits an operator to direct a signal from one device to another
without the need for change in wiring, either by means of switches or via other data entry
GSTD-0202 0
Rev
SHEET 11 OF 39
devices like keyboard commands to the system.
2.4 Configurable
The capability to select and connect standard hardware modules to create a system or the
capability to change functionality or sizing of software functions by changing parameters
without having to modify or regenerate software.
2.5 I/O
Input / Output with respect to process / operator
2.6 PLC Console (Operator)
PLC console (Operator) is the operator's main plant interface device through which operator
can view, monitor and control the plant and can give instructions to peripherals to execute
commands, and shall have protective access to configure and maintain the system.
2.7 PLC Console (Programming Terminal)
PLC console (Programming Terminal) shall be the engineer's main interface device through
which engineer can configure / program and maintain the system, and shall have protective
access to monitor and control the plant, give instructions to peripherals to execute
commands.
2.8 Local Level
All those sub-systems;' which directly interface with field devices shall be referred to as local
level.
2.9 Central Level
Operator Console and Programming Terminal, which present data acquired from local level
devices shall be referred as Central Level.
2.10 Database
Database shall be defined as the information stored temporarily or permanently in the system
which can be accessed by various programs to meet all its functional requirements.
2.11 Loop Integrity
A system shall be said to have loop integrity if the failure of one component in the system/
sub-system does not affect more than one loop.
2.12 System Loading
System loading for a sub-system is defined as the percentage of time a sub-system spends in
carrying out various activities referred to the use of memory, CPU time and communication
capacity in the worst case of high sub-system operation out of the designed / designated
cycle time of the sub-system.

GSTD-0202 0
Rev
SHEET 12 OF 39
2.13 Redundancy
A system component shall be termed as redundant if it takes over automatically the operation
in the event of the failure of the main component without causing any interruption in the
system and upsetting the process. The repaired or replaced device shall be brought in-line
only through operator action without upsetting system operation.
2.14 Switchover Time
Time required for a back up instrument / system to come on-line automatically in case of the
failure of the main instrument / system.
2.15 Processor Cycle Time (tpc)
Processor cycle time is the measure of the processing speed of a processor. Processor cycle
time for a sub-system ofthe programmable logic controller shall be defined as follows:
Processor cycle time for programmable logic controller shall be defined as the total time
taken by the processor to read input supplied by input module, execute all computations
(analog as well as logic as configured) and write the outputs for the output module.
2.16 Scan Time (ts)
Scan time of a logic loops is the end-to-end response time of a sub-system and shall be
defined as follows:
The scan time for a logic loop shall be defined as the total time taken by a sub-system e.g.
programmable logic controller to read input from the input terminal, process input, execute
logic, updating logic output and write output at the output terminal for all the logics configured
within the subsystem.
2.17 User's Memory
Free memory space available after utilization of memory required for system operation,
configuration and implementation of application and other system related functions for
implementation of user defined specific programs such as plant calculations, process
optimization or MIS (like free formatting of certain logs). The programs shall either be written
in high level language or system specific language.
2.18 Event
An event shall be defined as any action taken by the operator via operator keyboard or
switches on hardwired console like change of set point, change of control mode, start/stop of
motor, open/close of shut down valves, alarm acknowledge etc.
2.19 Sequence of Event (SOE)
Arranging events in the sequence of their occurrence in time with a specified time resolution
by a program is defined as sequence of event.

GSTD-0202 0
Rev
SHEET 13 OF 39
System or sub-system which presents and / or records the events in the sequence of their
occurrence in time with a specified time resolution utilizing its hardware and software
capabilities is termed as sequence of event recorder.
2.21 Real Time Trend
Real time trend shall be defined as a continuously progressing graphical record showing
updated parameter with most recent value and a past record of minimum of 10 minutes
without pressing any additional key for moving backward in time.
2.22 Plant Information Network
High-level communication network which serves various users within a plant and transfer
information for the purpose of unit / plant monitoring. This network is different than control
network and is generally realised using open communication protocol network e.g. OPC etc.
2.23 Tag
A Tag is a collection of attributes that specify either a control loop or a process variable, or a
measured input, or a calculated value, or some combination of these, and all associated
control and output algorithms. Each tag is unique.
3.0 SPARES PHILOSOPHY
3.1 The system including sequence of event recorder, hardwired instruments etc. shall meet the
following spare philosophy. This philosophy shall also be applicable for items like barriers,
relays, terminals, lamps, push buttons etc.
3.1.1 Mandatory Spares
Vendor shall include following mandatory spares in their scope of supply:
3.1.1.1 Installed Engineering Spares
Installed engineering spares shall be provided in each sub-system for each type of module to
enhance the specified" system functional requirements by 20%. The basis of offering installed
engineering spares shall include:
a) For a system with conventional and / or smart analog input / output, discrete
(contact) input / output, 20% spare input / output of each type shall be considered
for calculating I/O modules and all other related accessories.
b) For all serial input / outputs to the system, 20% spare serial\I/O ports ofeach type
of serial input / output shall be provided.
c) 20% spare accessories like relays, switches, lamps, fuses, circuit breakers,
barriers, isolators, terminals etc.
d) The engineering spares shall be wired up to the field cable interface and shall be
in ready-to-operate condition when field cable is connected to spare assigned
terminals.
GSTD-0202 0
Rev
SHEET 14 OF 39
e) Spare pairs of the incoming cables shall be terminated on spare terminals in the
marshalling / barrier cabinets as applicable.
f) The system shall be fully engineered considering 20% installed engineering

spares including processor loading.
3.1.1.2 Spare Space Requirement
In addition to installed engineering spares specified in Clause 3.1.1.1 of this specification, the
system shall be provided with following spare space:
a) I/O racks of programmable logic controller shall have 10% usable spare space for
installing additional I/O cards of each type in future. However internal wiring for the
same shall be connected up to the I/O terminals.
b) Processor system of programmable logic controller shall have capability to

execute additional 20% logics.
c) Each operator console shall contain 20% usable spare group and related display
capability in addition to as specified in para 3.1.1.1 of this specification.
d) The system shall have capability to extend its historical trending, logging and
user's memory by 20% to meet future expansion with/without adding additional
memory modules.
e) The communication sub-system shall have sufficient capacity to handle additional

data contributed by addition of 20% I/O over and above installed engineering
spares.
f) Usable spare space in panels and cabinets to install 10% spare hardwired items
like relays, switches, lamps, fuses, circuit breakers, barriers, isolators, terminals,
panel mounted instrument etc. in future.
3.1.1.3 Spare Memory Requirement
a) The system shall be provided with a minimum of 40% spare memory capacity, as
required for application program and data base to meet specified functional
requirements.
b) It shall be possible to extend the memory by at least 20% over and above the
actual requirement at a later date.
3.1.1.4 Spare Software Capability
a) Sufficient additional software capacity shall be available in the system to take care
of spares requirement as specified in para 3.1.1.1 and 3.1.1.2 of this specification
to meet all functional requirements as per para 4.0 of this specification.
b) Unless specifically indicated otherwise, the offered system shall have software
licenses to cover all the tag numbers indicated in the material requisition, including
installed engineering spares and spare space indicated in clause 3.1.1.1 and
GSTD-0202 0
Rev
SHEET 15 OF 39
3.1.1.2 of this specification.
3.1.1.5 Predefined Mandatory Spares
a) Mandatory spares shall be ware-house spares and shall be supplied as loose

items.
b) Mandatory spare module of 5% or one module of each type, whichever is higher,

must be supplied for each type of modules being used excluding modules used in
consoles, servers, Personal Computers.
c) For items like, Video Display Units, keyboards, disc drives, network components,
hardwired instruments like barriers, lamps, fuses and circuit breakers, complete
item limited to 5% or minimum one of each type shall be supplied' as predefined
mandatory spare. But this shall not include hardware like hard discs, terminals.
3.1.1.6 Consumable Spares
Any paper, ribbon, printer heads, toner and ink required for printers, video copier or any other
consumable item shall be supplied along with system required for minimum of six months
duration after system acceptance.
3.1.1.7 Commissioning Spares
Unless otherwise specified, vendor shall be responsible to supply all spares which are found
necessary to replace failed modules, failed sub-systems, or corrupted / faulty softwares while
performing pre-commissioning and commissioning activities.
3.1.2 Two Years Operational Spares
Two years operational spares shall be as per Clause 1.2.8(a) of this specification and shall be
quoted separately.
4.1 Design Requirements
4.1.1 Programmable logic controller shall be microprocessor based system which shall be used to
execute all the process and safety shut-down logic of the plant. When specified, it shall also
execute plant interlock logics and sequence operation. Programmable logic controller shall be
an independent unit and shall not depend on any of its functionality on any other system
including Distributed Control System.
4.1.2 The system shall be of modular construction and expandable in future by adding additional
modules which shall be easily accessible for maintenance and repair. The type of modules
shall be kept to the minimum possible in order to have interchangeability and low inventory.
4.1.3 System Availability
a) The system shall be designed 'fault avoidant' as a minimum by selecting high

grade components of proven quality and proper design of system electronics.
GSTD-0202 0
Rev
SHEET 16 OF 39
Redundancy shall be provided, as a minimum, as per this specification to improve
system availability and reliability. Due considerations shall be given to the
environmental conditions particularly for field mounted sub-system, if specified in
job specifications, during system design.
b) The system shall have a high MTBF value and shall have well proven record of
operating in hydrocarbon plants.
c) The system shall be designed with 99.995% or greater availability. The availability
shall be defined as follows:
Availability = Mean Time Between Failure (MTBF)
MTBF + Mean time to repair (MTTR)
For the purpose of calculations, consider mean time to repairs as four (4) hours
unless the manufacturer recommends higher value for MTTR. It is therefore
necessary that:
i) Vendor covers all necessary spare parts in 2 years recommended

operational spares which shall be necessary to meet specified MTTR time.
ii) Vendor provides adequate training to owner's personnel and cover all
necessary maintenance related topics in their training programmes to
ensure specified MTTR time.
4.1.4 Operating Environmental Conditions
4.1.4.1 Environmentally Controlled Location Installation
a) All subsystem of Programmable Logic Controllers located in Control Room, Local

Control Room or in Satellite Rack Room shall be able to operate satisfactorily from
15°C to 30°C and 20% to 80% non condensing humidity.
b) In addition to above, all such sub-systems shall also be able to operate

satisfactorily in case of air conditioning failure with ambient temperature of 50°C
and 90% no condensing humidity until the system safe operating limits are
exceeded. The minimum period of continuous operation in such condition shall be
48 hours at least once in a month without any damage or degradation of system
performance. Vendor, therefore, shall provide continuous temperature monitoring
for each enclosed cabinet housing items / equipments generating heat, such as
system cabinets, barrier cabinets, relay cabinets etc and also provide alarm for
operator alert in case the safe operating temperature limits are exceeded.
c) Chemical filters have been provided in the incoming air conditioning air to limit the
concentration of contaminants below following limits:
Contaminants Concentration
(Corrosive Gases)
SOx < 0.01 ppm by volume
NOx < 0.05 ppm by volume

GSTD-0202 0
Rev
SHEET 17 OF 39
H2S < 0.003 ppm by volume
Cb < O.OOlppm by volume
NH3 < 0.5 ppm by volume
SPM < 200 ugm/m'
RSPM < 100 ugm/nr'
All sub-systems and system components shall be suitable for operating continuously in the above
mentioned corrosive environments
4.1.4.2 Outdoor Installations
a) Sub-systems or system components which are installed outdoor shall be suitable

to continuously operate at ambient temperature and humidity specified under
ambient conditions. The heat generation effect of current carrying for the
electronic modules shall also be considered. For this purpose the system shall
be\rated for minimum 5 deg C more than the maximum ambient temperature
specified. In case the system is not suitable for the above conditions, necessary
cooling arrangement shall be provided.
b) Unless otherwise specified, all PLC sub-systems or system components installed

outdoor shall have corrosive environmental protection coating meeting the
environmental classification class G3 as per ISA-S71.04.
4.1.5 Transient, Static and EMI / RFI Protection
4.1.5.1 The system shall be internally protected against system errors and hardware damage
resulting from:
a) Electrical transients on power wiring.
b) Electrical transients on signal wiring.
c) Connecting and disconnecting devices or removing or inserting printed circuit

boards in the Programmable Logic Controller (PLC).
4.1.5.2 All sub-systems and system components shall be capable of accepting various signal inputs
for its direct use while preventing noise errors due to electromagnetic interference (EMI) or
radio frequency interference (RFI) including nearby radio stations, hand held two way radios,
solenoids, relays or contactors carrying heavy currents as per levels of Environmental
electromagnetic phenomenon defined in IEC-61000-6-2. The system shall have total noise
immunity from UHF / VHF radio communication equipments, (RFI) and (EMI) noise
generating equipments as per IEC-61000-4.
4.1.5.3 For interplant, inter unit and other system cables routed in the field, the level of surge
immunity required for equipment signal ports shall be increased to level 4 as defined in IEC-
61000-4-5 and the system shall operate according to performance criterion B as defined in

GSTD-0202 0
Rev
SHEET 18 OF 39
IEC-61000-6-2.
4.1.6 On-line Replacement
4.1.6.1 On-line replacement of any module of programmable logic controller shall be possible in such
a way that removal and addition of the module shall be possible and safe without de-
energising the system. Furthermore, there shall not be any interruption of the system while
replacing a faulty module wherever redundant modules are provided.
4.1.6.2 Apart from system modules, power supply units shall be replaceable on-line without
disrupting the process and without affecting the system redundancies. It shall be possible to
hot swap any faulty system module without degrading the system safety or operation or
freezing the output status. The switchover to the healthy module shall be bumpless. The
swapped module shall take over the function of the failed module without any manual
programming.
4.1.7 Electrical Isolation
Galvanic or optical isolation shall be provided for all field signals. The isolation levels shall be
as follows:
Analog I/O channel to system ground 1500V AC
Discrete I/O channel to system ground 500V AC
External isolator shall be provided, if necessary to meet the above.
Isolation shall also be provided between Engineering / operator cbnsole/PLC programming

terminal and related sub-systems connected to it if there is any possibility of high voltage
being transmitted to the sub-systems.
4.1.8 Design Requirements of Equipments in Hazardous Area
4.1.8.1 Unless specifically indicated, the field devices are beyond the scope of this specification.
However vendor shall be fully responsible for integrating these devices with their system.
4.1.8.2 General requirements
a) Unless otherwise specified, all instruments in hazardous area shall be intrinsically

safe type. Other concepts shall be used when specified.
b) For conventional instrumentation, entity concept shall be used for selecting proper
barriers / isolators.
4.1.9 Repeat Signals
4.1.9.1 Unless otherwise specified in the job specifications, following philosophy shall be followed for
repeat signals:
a) Whenever repeat contact outputs are required as per job specifications following
philosophy shall be followed:

GSTD-0202 0
Rev
SHEET 19 OF 39
i) For intrinsically safe input contacts, isolating barrier with dual contact
output shall be utilized.
ii) For all other contact inputs, repeat contact shall be provided using electro-
magnetic relays.
4.1.10 The system shall be designed fault tolerant and shall utilize high quality components of
proven quality. Any single system fault shall not degrade the system safety or functionality or
affect operation. The system shall have certified Safety Integrity Level as per IEC61508/
61511 as applicable and specified in job specification. Unless otherwise specified, it shall
meet the availability requirement specified in Clause 4.1.3 ofthis specification.
4.1.11 Unless otherwise specified, the scan time of programmable controller shall be of the order of
250 milliseconds for SIL certified PLCs. Scan time for a PLC shall be as defined under para
2.16 of this specification.
4.1.12 Operation of the PLC shall be completely unaffected by a momentary power loss of the order
of 20 milliseconds.
1.1.13 The system shall be programmed in principle as per the logic diagrams furnished during
detailed engineering. Vendor shall prepare their own Logic/Ladder diagrams depending upon
the capability of the programmable logic controller offered by them. Owner / Consultant
reserve the right to revise or review the logic diagrams even after acceptance of any offer.
The programming language of offered PLC shall be as per IEC 61131.
1.1.14 Whenever the requirement of SIL is specified for the PLC, it shall meet the requirements of
SIL level specified and shall be certified by an independent body (e.g. TUV) for complying
requirements of IEC-61508 / 61511 as specified. For shutdown application requiring SIL
certification, PLC shall always meet SIL 3 requirements.
1.1.15 The system shall have extensive set of self diagnostics hardware and software for easy and
fast maintenance of PLC. Routine checks should run automatically at frequent intervals for
identifying any fault in software or hardware. Diagnostics shall be required at local as well as
console level. \
1.1.16 Safety barriers shall be provided by the vendor for intrinsically safe input/output circuits
wherever specified. In such cases, the system shall be designed intrinsically safe based on
entity concept. The barriers shall be certified by a statutory authority like Baseefa, LCIE, CSA,
UL, PTB, CIMFR etc., for the use in the area classification as specified elsewhere in the job
specifications. The proper selection of the safety barriers shall be the vendor's total
responsibility. In case of smart transmitter, the entity parameters of the hand held terminals
shall also be considered while selecting proper barriers.
1.1.17 Unless otherwise specified all intrinsically safe barriers shall be 3 port isolating type only
providing isolation between;
i) Input and output (non-hazardous to hazardous side of barriers)
ii) Power supply and input

GSTD-0202 0
Rev
SHEET 20 OF 39
iii) Power supply and output
The minimum isolation level shall be 250V.
4.2 System Configuration
4.2.1 General
a) PLC system configuration / architecture shall be as specified in the job

specification. For emergency shutdown system application specified with SIL
classification, the system configuration shall be TMR or QMR or DMR or VMR as
per the job specification and shall be certified by independent agency e.g. TUV.
b) Regardless of the action feature selected (except for single architecture), the
failure of single component shall not result in a failure of correctly executed safety
function. The degradation mode for the selected configuration e.g. 4-2-0 or 3-2-0
or 3-2-1-0, etc. shall be documented in SIL certification report.
c) In general, the PLC system shall comprise of various sub-systems as described in

the subsequent clauses of 4.2.
4.2.2 Input/ Output Subsystem
4.2.2.1 Each I/O module shall have its own processor. I/O modules configured m redundant
configuration, shall have their processors properly synchronised.
4.2.2.2 Unless otherwise specified, system shall accept analog 4 -20mA inputs and contact inputs.
The maximum number of Input/Output per I/O module shall be limited as per the following
table.
Sl No. Type of Configuration Maximum No. I/O s
1 Single I/O system 8
2 Dual I/O system 16
3 Triple Modular Redundant 32

system (TMR)
4 Quadruple Modular redundant 16

System (QMR), Flexible Modular
Redundant (FMR) configuration,
Virtual Modular Redundant
(VMR)
4.2.2.3 Each I/O shall be galvanically isolated from external control circuit by suitable means. The
minimum isolation level between I/O and logic circuit shall be 1000 volts DC.
4.2.2.4 Each I/O shall be protected against the reversal of polarity of the power voltage to I/O.
4.2.2.5 Each input shall be provided with filters to filter out any noise in the input line and contact
GSTD-0202 0
Rev
SHEET 21 OF 39
bouncing noise, as applicable.
2.2.2.6 All the inputs / outputs shall be double ended i.e. two wires per input / output and not with
common return for all inputs.
4.2.2.7 The interrogation voltage to the inputs and power supply for 2-wire instruments shall be
powered from separate redundant power supply / supplies and shall not be a part of PLC,
unless otherwise specified. This power supply shall be supplied at one point and shall be
distributed by the vendor.
4.2.2.8
a) Each module shall have a LED per channel to indicate the status of each input
output.
b) When specified, input module shall be capable of monitoring the input contacts for
any wire open fault and short circuit.
4.2.2.9 Analog Input Module
a) Input module shall be able to accept 4~20 rnA DC input from smart transmitters
(e.g. 4 -20mA HART).
b) The module shall have 12 bit Analog to Digital resolution accuracy of ±0.2S% of
full scale over the entire range, unless otherwise specified.
4.2.2.10
a) Output contacts from the PLC shall be potential free dry contacts with contact
rating as per para 4.2.2.10 b) of this specification. Vendor must provide arc
suppression device for each output contact.
b) The output contact rating shall be as follows:
SL.No. APPLICABLE FOR VOLTAGE RATING CURRENT

RATING
1 All output cards driving solenoid valve
and alarm annunciator system unless
otherwise specified
Category -I 110 V DC 0.5 A
Category -II 24VDC 2A
2 All motors/pumps/compressor output
cards unless otherwise specified.
Category –I 240 V AC 5.0A
Category -II 220 V DC 0.2 A
c) The category of contacts shall be specified in the material requisition. Each output
shall be short circuit proof and protected by fuse. Visual indication of fuse blown
must be provided for each module.
d) When specified contact output module shall have monitored\ output features like
wire open and short circuit.
GSTD-0202 0
Rev
SHEET 22 OF 39
4.2.2.11 Where inputs or outputs have multiple field devices for the same measurement or device, the
corresponding inputs / outputs shall be configured in separate I/O modules.
4.2.2.12 Where single input signal is available for QMR or TMR or FMR or VMR configuration, inputs
shall be multiplied to feed inputs to each input modules / channels.
4.2.2.13 PLC shall be provided with Auto I/O testing facility as a standard diagnostics features. PLCs
which do not have auto I/O testing facility, manual testing facility shall be provided to detect
any system fault. For manual testing, manual switches shall be provided to bypass each input
at a time and its effect on the output shall be monitored.
4.2.3 Processor System
4.2.3.1 The processor shall have capability to implement all the control functions required to
implement the logic scheme as logic/ladder diagram.
4.2.3.2 The size of the memory shall be sufficient for storage of the program instructions required by
the logic schemes and other functional requirements. Offer shall indicate the amount of
memory capacity occupied by the actual program and spare capacity available for future
program modifications or additions.
4.2.3.3 Memory shall be non-volatile. However in case volatile memory is provided, battery backup
shall be provided with a minimum of 3 months lifetime to keep the program storage intact. A
battery drain indication shall be provided at least one week before the battery gets drained.
4.2.3.4 Watchdog timer shall be a software device. The healthiness of processors shall be
continuously monitored by watchdog timer. Any hardware or software problem in the
processor system, which shall include, CPU, memory, power supply, communication interface
etc. shall cause the watch dog timer to report processor failure.
4.2.3.5 Wherever dual redundant processor is specified, redundancy shall be provided in such a way
that in case of failure of the main processor, the standby shall take over automatically. The
changeover shall be bump less. Redundancy shall be provided for complete processor
system including processor, power supply and communication sub system.
4.2.3.6 In case of triple modular redundant system all the three processors shall execute the same
instructions/program and check their results and vote to correct any faulty result. The faulty
processor diagnostic shall be made available.
4.2.3.7 In case of QMR system, individual processor shall execute the same instructions/ programs
and check their results within same CPU module and majority vote to correct any faulty result.
The faulty processor diagnostic shall be made available.
4.2.3.8 Failure of a single processor in dual redundant, triple redundant system and two processors
in QMR system shall not affect the system. In case of failure of complete processor system
i.e. both processors in case of dual configuration, two or more in case of triple redundant
system and more thah two in case of QMR system, outputs shall take failsafe state
automatically unless otherwise specified in the data sheets.
4.2.3.10 It shall be possible to generate the first out alarm contact by the PLC in case where a group
GSTD-0202 0
Rev
SHEET 23 OF 39
of parameters are likely to trip a system.
4.2.4 PLC Console (Programming Terminal)
4.2.4.10 The PLC console (Programming Terminal) shall be used for programming, program storing,
fault diagnostics and alarm monitoring. Whenever specified, it shall also be possible to use
this console for plant operation. The functionality to operate as engineering / programming
terminal or operator terminal or both shall be as specified in the job specification.
4.2.4.2 It shall consist of at least one coloured 22" LED monitor with TFT technology and one
programming / operating keyboard, mouse and printer unless specified otherwise.
4.2.4.3 PLC console when used for plant operation shall also meet the functional requirements as
per clause 4.2.5 of this specification
4.2.4.4 The keyboard shall preferably be touch sensitive sealed type, easy to operate with each key
clearly identified.
4.2.4.5 All illegal entries shall be rejected by the terminal and shall be identified by warning signal on
VDU.
4.2.4.6 Manual forcing of any input or output contact connected to PLC shall be possible from
keyboard. Forced functions shall have an associated audit trail.
4.2.4.7 It shall be possible to modify, add or delete the application program on line without affecting
the outputs.
4.2.4.8 PLC Console shall display logic and/or ladder diagram indicating power flow and shall show
description and status of each contact. It shall also be possible to display process alarms and
diagnostic messages as and when they appear. Further it shall also be able to display I/O
map in a user defined format.
4.2.4.9 I t shall be possible to print out the ladder/logic diagram on the dedicated PLC printer. The
printer in addition shall also print out:
a) The diagnostic messages as and when generated and diagnostic reports, when
called for.
b) Process alarms connected to the programmable logic controller as and when they
appear and alarm report whenever initiated. The choice of printing alarms on this
printer shall be operator selectable from a key lock / password protected switch on
PLC console.
c) The I/O maps showing status of all inputs and corresponding outputs in a user
defined format.
4.2.4.10 The PLC console shall be provided with self diagnostics feature which shall display error
messages and initiate an audible alarm if the fault is detected. Wherever specified, a potential
free contact for diagnostic group alarm shall be provided which shall be connected to the
hardwired alarm 'annunciator system.

GSTD-0202 0
Rev
SHEET 24 OF 39
4.2.4.11 The system shall be able to identify the failure at least up to the module level including I/O
system and redundant processor and report print out.
4.2.5 PLC Console (Operator)
4.2.5.1 Where dedicated PLC operator console is specified, it shall be used for operation of plant,
fault diagnostics, alarm monitoring and report generation.
4.2.5.2 It shall consist of colored 22" LED monitor with TFT technology, operator keyboard and
printer unless specified otherwise.
4.2.5.3 At least two number cursor control devices shall be provided in addition to keyboard which
may include touch screen, mouse, track ball etc.
4.2.5.4 PLC operator console shall have complete graphic capability and shall be able to display
process dynamic graphics, overview and group view displays. It shall be possible to operate
the plant i.e. start and stop of rotating machinery, opening and closing of valves, Pill function
etc. from dynamic graphics and group displays available on PLC operator console.
4.2.5.5 It shall be possible to monitor, historise and print out all process alarms, diagnostic alarms
and alarm reports.
4.2.5.6 Unless otherwise specified, the time stamping of all alarms shall be as per PLC processor
time stamping.
4.2.5.7 The system shall be able to store and display stored data wherever required. The minimum
storage capacity shall be for 30 days at 1 minute sample rate for all the inputs specified,
diagnostic alarms, process and first out alarms, manipulation data etc.
4.2.5.8 The system shall be able to generate shiftly, hourly, daily, weekly and monthly reports. The
log format shall be furnished during detailed engineering.
4.2.5.9 The system shall be supplied with first out alarm generation capability. The resolution of
alarm shall be as per processor cycle time, as a minimum.
4.2.6 Communication Subsystem
4.2.6.1 The PLC communication subsystem shall be a digital communication bus that provides a high
speed data transfer rapidly and reliably between the processor, I/O sub-system, PLC console
and other devices connected in the PLC system.
4.2.6.2 Redundancy in PLC communication subsystem shall be provided as follows unless otherwise
specified:
a) For single architecture, the communication subsystem between PLC processor

and I/O subsystem shall be single unless otherwise specified. This shall include
single communication bus and single interfaces/buffers.
b) For dual I/O configuration, each I/O sub set shall have separate communication
interface and bus for connecting to PLC processors.

GSTD-0202 0
Rev
SHEET 25 OF 39
c) For the triple redundant system, each processor shall have a separate set of PLC
communication subsystem.
d) For the QMR systems each I/O subset shall have separate communication
interface and bus for connecting to respective CPU module.
e) The communication subsystem between processor subsystem and PLC console

shall be dual redundant, consisting of two separate communication interfaces and
two buses, each one configured in redundant mode, unless this is only used as
programming aid.
4.2.6.3 In case of redundant PLC communication sub system, on the failure of the active device, the
redundant device shall take over automatically without interrupting the system operation.
Information about the failed device shall be displayed at local as well as on PLC console. It
shall be possible to manually switch over the communication from main bus / device to
redundant bus / device without interrupting any system function.
4.2.6.4 The mechanism used by the system for error checks and control shall be transparent to the
application information / program. Error checking shall be done on all data transfers by
suitable codes.
4.2.6.5 In general, PLC shall provide data m a well established protocol format preferably MODBUS
protocol.
4.2.7 System Power Supplies
4.2.7.1 Unless specified otherwise, the programmable logic controller shall operate on uninterrupted
power supply (UPS). However the system shall be capable of operating satisfactorily at the
following power supply specifications:
Voltage 220 V ±10%
Frequency 50 Hz±3 Hz
Harmonic contents less than 5%
Power interruption 10 millisec
4.2.7.2 The power supply system shall be supplied with dual PLC feeders each capable of handling
100% of the total power supply load requirements. In case of failure of one feeder, redundant
feeder shall supply the total load.
4.2.7.3 Each I/O rack shall be provided with separate power supply unless otherwise specified in job
specifications. Each power supply shall be sized to take full load of the I/O rack/signal
conditioning panel. Each rack shall be provided with dual redundant power supply.
4.2.7.4 Processor subsystem shall be provided with separate power supply, as a minimum, unless
otherwise specified in job specification. Failure of one power supply shall not affect the
system operation/processor switchover in case of dual processor system. Wherever triple
redundant system is specified each processor shall preferably be provided with a separate
power supply. Also separate power supply must be provided for each multiplied process I/O
GSTD-0202 0
Rev
SHEET 26 OF 39
channel.
4.2.8 Self Diagnostics
4.2.8.1 The system shall have an extensive set of self diagnostic routines which shall be able to
identify all permanent and transient system faults / failures at least up to module level
including redundant components and power supplies through detailed VDU displays and
report print out.
4.2.8.2 At the local level, failure of a module in any subsystem shall be identified by an individual
LED.
4.2.8.3 Diagnostic software shall have the capability to provide information about the failed
module/system either in the form of a system configuration display or provide information in
the form of a "statement".
4.2.8.4 Self diagnostic software shall have capability to detect faults which make the system
permanently close/open in the I/O modules or I/O signal conditioning modules (in case of
triple redundant system, whenever specified in the job specifications, this may be achieved by
automatically running the testing software at cyclic intervals), The automatic cyclic testing
feature shall also be provided for dual I/O configuration and dual I/O signal conditioning for
triple redundant system. The testing software cycle time may be considered once in 30
minutes however this shall be field adjustable by engineer. However, system performance
shall not be degraded whenever testing feature is specified.
4.2.8.5 System for the following functionalities shall be supplied when specified:
a) Long storage historisation
b) Log report generation
c) First out alarm generation
4.2.8.6 System diagnostics shall be capable of identifying, locating and reporting the following faults,
as a minimum:
a) Processor fault
b) Communication fault
c) I/O module fault
d) Power supply fault
e) Over temperature monitoring
f) Permanently close / open (stuck on or off) fault
g) Memory fault
h) Signal redundancy fault

GSTD-0202 0
Rev
SHEET 27 OF 39
Any other additional diagnostic alarm if available as a standard shall also be provided by
vendor.
4.2.8.7 Testing software shall be capable of detecting faults in case of normally closed system as
well as in normally open system.
4.2.8.8 Feedback must be provided in case of triple redundant system and QMR system from the
output voter system to detect any latest faults of the system in addition to other diagnostic
software.
4.2.9 System Software
4.2.9.1 The system software shall include all programs for the PLC and PLC console which are
required to perform all the PLC functions including communication and self-diagnostics.
Whenever PLC is specified for shutdown application with SIL classification, the system shall
be designed and engineered in full compliance with the requirement of IEC-61511. Whenever
different functional logics are combined within a common PLC, the safety related I/O's of each
functionality shall be kept segregated within the system.
4.2.9.2 Logic program shall also be recorded on the external most reliable electronic media like DVD
which shall be delivered in triplicate together with the system.
4.2.9.3 The PLC programming language for implementation of logic operations shall be based on the
following representations:
a) Logic diagrams -Binary logic symbols such as AND, OR, NOT Gates, Timers and
Flip-Flops.
b) Ladder diagram -Series / parallel connection of relay contacts.
c) Combination of (a) & (b) above.
4.2.9.4 Diagnostic package and its related equipment and software shall be supplied. A list of
additional diagnostic packages available and the packages provided, including the description
and capabilities, shall be provided with separate quote, wherever asked.
4.2.9.5 It shall be possible to print out the ladder/logic diagram on a dedicated printer. The printer
shall also print out all diagnostic reports. Vendor must supply the off line software package to
enable the owner to modify/add/delete any part of program and for documentation.
4.2.9.6 Software for the generation of various displays including dynamic graphics wherever specified
to be provided as per given below:
4.2.9.6.1 It shall be possible to display dynamic graphic of plant on the operator console VDU screens.
Graphic displays shall be field configurable only through PLC Console (Programming
terminal) with standard / user defined graphic symbols. Dynamic graphic displays of different
sections of the plant shall be displayed on different pages.
4.2.9.6.2 The system shall have graphic symbol library as per ISA-5.! and 5.3. In addition standard
industrial symbols like distillation columns, heat exchangers, pumps, compressors, tanks etc.
shall also provided as a standard.
GSTD-0202 0
Rev
SHEET 28 OF 39
4.2.9.6.3 Graphic displays shall be interactive type through which it shall be possible to control the
process. It shall also be possible to send motor start/stop and shutdown valve open/close
commands, as specified in job specifications, from this display
4.2.9.6.4 It shall be possible to view the process variable and alarm points and view and change set
point value, manipulated variable, controller mode etc. from the graphic display. Also rotating
machinery (i.e. compressor / pump) status and valve status shall be displayed on the graphic
display with different colours
4.2.9.6.5 Various colours used in the generation of graphics like colour of the process lines, utility lines,
Instrument signal lines and event modifier conditions shall be finalised during detailed
engineering. The colours used to identify event modified conditions shall generally be as
follows unless otherwise indicated during detailed engineering
Red - All points alarm
Blue- Valve open, pump running
Green - Valve closed, pump stopped
Flashing green - Shut down valve transition state
4.2.9.6.6 It shall be possible to go from any graphic page to related graphic pages or any group view or
alarm summary in single key stroke using soft key function.
4.2.9.7 The software for printing alarms, system as well as process, and events on the PLC printer
must be provided. All alarms must be printed as and when they appear.
4.2.9.8 Software package for displaying I/O map showing status of inputs and corresponding output
providing tag numbers as per logic diagram shall be offered. The I/O map format shall be user
definable.
4.2.10 Power Supply Distribution
4.2.10.1 All type of power supplies shall be made available at one point. Further distribution of power
supply shall be in vendor's scope.
4.2.10.2 In general, all output contacts and solenoids shall be powered with 1l0V±10% DC/ 24V±10%
DC power supply. However, the actual interrogation voltages shall be as per job
specifications and logic diagrams.
4.2.10.3 The distribution network for interrogation voltage shall be designed such that a single fault in
any branch shall not cause trip of the logic other than where the fault has occurred.
4.2.10.4 Sequential starting of various load centers shall be provided whenever specified.
4.2.10.5 Power distribution network must use bus bars of adequate capacity with DPDT (Double Pole
Double Throw) switches and HRC (High Rupture Capacity) fuses in each branch network.
Vendor may select circuit breaker if short circuit characteristics do not match the HRC fuse.

GSTD-0202 0
Rev
SHEET 29 OF 39
4.2.10.6 All cubicles lighting shall be on 240 V, 50 Hz AC normal power supply.
4.2.11 PLC System Cabinets
4.2.11.1 All PLC system cabinets shall be completely wired with all modules in place. Inside cabinet
wiring shall preferably be done using ribbon type pre-fabricated cables.
4.2.11.2 All the cabinets shall be free standing, enclosed type and shall be designed for bottom entry
of cables. Cabinet structure shall be sound and rigid. Cabinet shall be provided with
removable lifting lugs to permit lifting of the cabinets.
4.2.11.3 Cabinet shall be fabricated from cold rolled steel sheet of minimum 2 mm thickness suitably
reinforced to prevent warping and buckling. Doors shall be fabricated from cold rolled steel
sheet of minimum 1.6 mm thickness. Cabinets shall be thoroughly deburred and all sharp
edges shall be grounded smooth after fabrication.
4.2.11.4 Cabinet finish shall include sand blasting, grinding, chemical cleaning, surface finishing by
suitable filter and two coats of high grade lacquer with wet sanding between two coats. Two
coats of paint in the cabinet colour shall be given for non-glossy high satin finish. Colour of
the cabinets shall be as per job specification. Final coat shall be given after assembly at site
when specified in the job specifications.
4.2.11.5 Each cabinet shall be maximum 2100 mm high (excluding 100 mm channel base), 800 mm
wide and 800 mm deep, in general. Construction shall be modular preferably to
accommodate 19" standard electrical racks. All cabinets shall be of same height.
4.2.11.6 Cabinets shall be equipped with front and rear access doors. Doors shall be equipped with
lockable handles and concealed hinges with pull pins for easy door removal.
4.2.11.7 In order to effectively remove dissipated heat from the cabinets, ventilation fans along with
vent louvers backed by wire fly screen shall be provided as required. Ventilation fans shall be
provided in all cabinets where the temperature rise with all doors closed and all internal and
external loads ertergised shall exceed 10° C above the ambient temperature. A temperature
element (resistance temperature detector) shall be provided in each cubicle for temperature
measurement. Ventilation fans shall be provided in dual configuration, as a mmimum.
Each fan shall have a separate dedicated assembly and shall be replaceable on-line without
shutting down any equipment / panel/cabinet / console in part or in complete. \
Ventilation fan assembly shall operate at 240V AC power supply. Each fan shall have its own
dedicated circuit breaker.
Each ventilation fan shall be fitted with a protection type finger guard. Whenever, the numbers
of cabinets are compacted (supplied in mechanical joined conditions), each cabinet shall be
provided with separate ventilation fan assembly.
The maximum noise level with all fans operating and cubicle doors open shall not exceed
85dBA.
Following signals and alarms shall be provided for each cabinet:

GSTD-0202 0
Rev
SHEET 30 OF 39
i) Fan failure alarm for each cubicle in PLC.
ii) Temperature indication of each cabinet or compacted combination, as applicable

in PLC.
iii) A common alarm each for high temperature and fan-failure shall be made
available.
4.2.11.8 Internal illumination shall be provided for cabinets to ensure proper illumination level of250
lux for performing maintenance activities. Illumination shall be provided for all cabinets by
incandescent lamps, which shall be activated individually by door operated magnetic
switches. The lamps shall activate when door is opened and deactivate when the door is
closed. The magnetic switches selected shall have undergone life cycle cyclic test of at least
1000000 operations. A manual over-ride switch shall be provided inside the cabinet which
shall keep the lamp deactivated even when the door is open.
4.2.11.9 Equipment within the cabinet shall be laid out in an accessible and logically segregated
manner. Cable glands shall be provided and supplied by vendor for incoming and outgoing
cables to prevent excessive stress on the individual terminals. All metal parts of the cabinet
shall be electrically continuous and shall be provided with a common grounding lug.
4.2.12 Control Panels/ Hardwired Console
4.2.12.1 Control panels, if required, shall be non-graphic self supporting, free standing cubicle with
back doors made up of sectional steel panels. Each section shall be maximum 2100 mm
high, 1200 mm wide and 1000 mm deep and shall be mounted on 100 mm high channel
base. Care shall be taken to ensure that the face of the panel is truly flat and smooth.
4.2.12.2 Panels / hardwired console shall be fabricated from 3.0 mm thick cold rolled steel sheet.
Angle iron frame shall use a minimum section of 50x50x4mm angle.
4.2.12.3 Front of panel/console instrument nameplates shall be black laminated plastic with white
core. Nameplate shall be provided on the rear of the panel also for each instrument.
4.2.12.4 Document pocket / wallet shall be provided on the inner side of front and rear doors of each
cabinet and on the inner side of the door of each panel. Similar arrangement shall also be
made on the inner side of doors of console.
4.2.13 Wiring Requirements'!
4.2.13.1 All wiring shall conform to API RP 552-Transmission Systems. Different signal level cables
shall be routed with separation distances as recommended by this code.
4.2.13.2 All wiring inside racks, cabinets, and back of the panels shall be housed in covered, non-
flammable plastic raceways arranged to permit easy assembly to various instruments for
maintenance, adjustments, repair and removal. \
4.2.13.3 All wiring in the raceways shall be properly clamped. All incoming cable and outgoing cables
shall be terminated by vendor at marshalling rack. Total wiring cross-sectional area shall not
exceed 50% of the raceway cross sectional area.

GSTD-0202 0
Rev
SHEET 31 OF 39
4.2.13.4 Separate wiring raceways shall be used for power supply wiring, DC and low level signal
wiring, and intrinsically safe wifing. Parallel runs of AC and DC wiring closer than 300mm
shall be avoided.
4.2.13.5 Vendor can alternately offer prefabricated cables for interconnection between different
cabinets and panels.
4.2.13.6 Wire termination shall be done using self insulating crimping lugs. More than two wires shall
not be terminated on one side of single terminal. The use of shorting links for looping shall be
avoided.
4.2.13.7 Terminal housing shall be strictly sized with considerations for accessibility and maintenance.
Minimum distance required between various components is listed below. These distances are
clear distances and are excluding the width of the raceways or any other component / item
mentioned herein. Following clearances should be considered:
a) Distance between terminal strip and side of the cabinet parallel to the strip, up to
50 terminals, shall be minimum 50 mm.
b) Distance between terminal strip and, top and bottom of the cabinet shall be
minimum 75mm.
c) Distance between two adjacent terminal strips shall be minimum 100 mm.
d) Additional distance for each additional 25 terminals shall be minimum 25 mm.
e) Distance between cable gland plate and the bottom of the strip shall be minimum
300 mm.
4.2.13.8 All terminal/terminal blocks shall be DIN Rail mounted type and shall be easily removable.
The size of the terminal blocks / terminals of different types shall be consistent and identical.
All terminal blocks shall be mounted on suitable anodised metallic or plastic stand-off.
4.2.13.9 No splicing is allowed in between wire/ cable straight run.
4.2.13.10 Terminal strips shall be arranged group-wise for incoming and outgoing cables separately.
Terminal blocks for intrinsically safe wiring shall be separate. 20% spare terminals shall be
provided, as a minimum, preferably in each terminal strip. Terminals shall be suitable for
wires up to 2.5 sq. mm base solid or stranded conductor in general. For power cables, higher
size terminals shall be used.
4.2.13.11 Cabinet and rack layout shall be made considering proper accessibility and maintenance.
4.3 Earthing
4.3.1 All system equipments such as panels, marshalling cabinets, system cabinets and other
powered equipments shall be provided with following type grounding system:
a) Protective Earth/ Electrical Earth
b) System Earth! Signal Earth

GSTD-0202 0
Rev
SHEET 32 OF 39
c) Safety Earth! Barrier Earth (when required)
Both system earth and safety earth shall be totally separate from protective earth.
4.3.2 Protective Earth / Electrical Earth
a) Each metallic enclosure / cabinet / panel/console etc. shall be provided with

electrical earth lug, as a minimum.
b) Unless recommended otherwise by vendor, all earthing lugs of metallic

equipments indicated in Clause 4.3.2 (a) above shall be connected individually to
electrical protective earthing system bus-bar / earthing station using ,a maximum
of 10sq mm solid copper conductor PVC insulated wires.
c) Where multiple cabinets are multiplexed together, earth looping with permanent
shorting link cables shall be acceptable. Two earthing connection wires as
indicated in Clause NoA.3.2 (b) above shall be used for connecting multiplexed
cabinets to protective earth station / bus-bar.
4.3.3 System Earth
a) System earth shall be totally noise free dedicated earthing system and shall be
fully isolated from electrical protective earth. This earth must be very high integrity
system and shall be used to ground zero volt references and signal cable grounds.
b) System earth shall be less than one (l) ohm grounding system with its own
dedicated earthing pits. These earth pits shall be away from any heavy noise plant
equipment. Outside the control room building is the most appropriate location.
c) Wherever supply of earth pit is kept in vendor's scope in the Material Requisition,
the earth pit design shall be as per IS-3043 code of practice for earthing. A
minimum of four (4) number of earth pits shall be provided for grounding system
integrity. In case number of pits required to meet 1 ohm resistance are more than
(2), the number of earth pits shall be two times the actual number of pits required
to meet resistance criteria. All these pits shall be securely connected with each
other to form a one homogeneous system earth grid.
d) Each marshalling / system cabinet / panels etc shall be provided with system earth
bus-bar which shall be insulated from the metallic body frame. This bus-bar shall
be used to earth also signal zero volt references and signal cable screens.
Terminals used for termination of spare conductor pairs / cores of multi-pair
signal/control cables shall be connected to system earth bus-bar. Shorting links
shall be used for spare terminal looping.
e) System bus-bars in the multiplexed cabinets can be joined together by permanent

shorting links. System bus-bars of other cabinets can also be connected together
provided they are permanently joined using 35 sq mm stranded copper conductor
cable.

GSTD-0202 0
Rev
SHEET 33 OF 39
4.3.4 Safety Earth / Zener Barrier Earth
a) Whenever Zener barriers are selected or used to meet intrinsically safe

requirements, the earthing terni'inal of the zener barriers shall be connected to a
separate earth bus bar.
b) This earth shall meet all the requirements specified in Clause 4.3.3 of this
specification.
c) Safety earth bus bar shall be directly connected to earth pits using dual insulated
cable. Cable conductor size shall be minimum 95 sq. mm (c~pper).
4.4 Interface with DCS
The PLC shall be required to be interfaced to the Distributed Control System bus whenever
specified. A suitable interface shall be offered in order to achieve the following functions:
a) Display of all input points under alarm/first out alarm connected to PLC or
generated by PLC, continuous indication for analog signal on the main DCS
operator console.
b) Generate shutdown reports on the logging printer of Distributed Control system.
c) To receive certain operational commands from the operator console for the
operation of certain output devices connected to PLC
d) To display diagnostic message of PLC.
In general, PLC shall provide data in a well established MODBUS protocol format.
The interface shall be dual redundant unless otherwise specified.
The speed of data transfer shall be such that any change in I/O which is to be updated on the
operator console shall not exceed 3 second from the time event to update on the operator
console screen considering one second standard update rate in DCS operator console.
4.5 Sequence of Event (SOE) Function Requirement
Sequence of Event, whenever specified, for analog and digital inputs shall be generated and
time stamped in PLC. The maximum resolution between two events shall not exceed
specified PLC scan time unless specified otherwise. A separate SOE PC with 21" size TFT
screen and printer shall be provided for PLC sub-system unless specified otherwise.
5.0 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE
5.1 General
5.1.1 This specification defines the basic guidelines to vendor for factory testing and acceptance,
installation, commissioning and field acceptance of the complete PLC system. On the basis of
GSTD-0202 0
Rev
SHEET 34 OF 39
this specification, vendor shall submit their own detailed testing, installation, commissioning
and acceptance procedure. For hardware, the procedure shall include test name, purpose of
test, test equipment / set up, definition of input, test procedure, results expected and
acceptance criteria. Similarly for software, it shall include test name, details of the method, list
of tests, sequence of execution, results expected and acceptance criteria. For PLC system
with SIL 3 requirement, certificate for hardware & software (Like TUV etc.) shall be verified.
5.1.2 The testing and acceptance of the system shall be carried out on the approved testing
procedures and criteria based on this specification and vendor's standard testing
requirements and procedures.
5.2 Factory Acceptance Tests (FAT)
5.2.1 Vendor shall test and demonstrate the functional integrity of the system hardware and
software. No material or equipment shall be transported until all required tests are
successfully completed and certified "Ready for Shipment" by the owner/consultant.
5.2.2 The purchaser reserves the right to be involved and satisfy himself at each and every stage of
inspection. The purchaser shall be free to request any specific test on any equipment
considered necessary by him although not listed in this specification, as a part of approval of
factory testing procedure. The cost of performing all tests shall be borne by the vendor.
5.2.3 Vendor to note that acceptance of any equipment or the exemption of inspection or testing
shall in no way absolve the vendor of the responsibility for delivering the equipment meeting
all the requirements specified in Material Requisition.
5.2.4 It shall be vendor's responsibility to modify and/or replace any hardware and modify the
software if the specified functions are not completely achieved satisfactorily during testing
and factory acceptance.
5.2.5 Schedule of FAT shall be included in the Vendor's proposal.
5.2.6 Vendor shall not replace any system component/module/sub-system unless it is failed. A log
of all failed components/modules in a sub-system shall be maintained which shall give
description of the failed component/module, effect of failure on the sub-system, cause of
failure and number of hours of operation before it failed. If malfunction of a component/
module in a sub-system repeats, the test shall terminate and vendor shall replace the faulty
component/ module. Thereafter the test shall commence all over again. If even after this
replacement, the sub-system fails to meet the requirements, vendor shall replace the full sub-
system by the one meeting the requirements and the system shall be tested all over again. If
a sub-system fails during the test, which is not repaired and made operational within four
hours of active repair time after the failure, the test shall be suspended and restarted all over
again only after the vendor has replaced the device in the acceptable operation.
5.2.7 Testing and FAT shall be carried out in two phases. The minimum requirements for testing
during these two phases shall be as follows:
5.2.7.1 Under the first phase, vendor shall perform tests at his works to ensure that all components
function in accordance with the specification for each type of test. A test report shall be
submitted for purchaser review within one week of completion of this test. Phase II testing
GSTD-0202 0
Rev
SHEET 35 OF 39
(witness inspection) shall start only after this.
All subsystem shall undergo a minimum of 30 days burn in period. The burn-in time shall start
after the sub-system is fully assembled and is powered up. It may include any such time for
which the system has been kept powered on even for system generation and Phase I testing.
Following tests shall be performed by the vendor and reports shall be forwarded to purchaser:
a) Quality control test which shall be carried out to assure quality of all components
and modules in accordance with vendor's quality control and assurance
procedures.
b) System pre-test which shall be physical check of all modules, racks, cabinets etc.
c) System power-up test which shall test functionally all hardware and software. This
shall include testing of redundancy, System performance on power supply
variations, application software testing and system diagnostic verification.
5.2.7.2 The second phase of testing shall systematically, fully and functionally test all hardware and
software in the pre~ence of purchaser representatives. All subsystems shall be
interconnected to simulate, as close as possible, the total integrated system. Following
minimum tests shall be carried out:
a) Visual and mechanical testing, which shall be carried out in principle to assure
correct, proper, good and neat workmanship by the vendor This testing shall
include dimensional verification, Layout verification as per approved GA drawings,
Verification of Sheet thickness / Quality of painting (outer and inner) / N~meplates,
identifiers and tag plates / Adherence to ferruling philosophy / Dressing of wires /
prefabricated cables and clearances / Locks and handles as a minimum.
b) Verification of Bill of Material. The Bill of material verification shall include both
hardware and software.
c) Functional testing:
This shall include the simulation of each input and output to verify proper system
response. The testing as a minimum shall include:
i) Complete system configuration loading.
ii) Demonstration of all PLC system builder functions including

addition/deletion of an input/output, addition/ deletion of a rung or an
element in a rung, generation of dynamic graphics and other views, report
generation etc.
iii) 100% checking of logics configured in the PLC by connecting switch/lamp

at input/output, by simulating inputs and verifying outputs preferably using
simulator, other related functions like forcing, first out shall also be verified.

GSTD-0202 0
Rev
SHEET 36 OF 39
iv) Checking of scan time. Scan time verification shall be carried out using
high resolution storage oscilloscope during Factory Acceptance Test based
on the specified requirements considering discrete input by given step
change. The scan time values so observed shall be within 90% confidence
level. Incase of analog inputs, input shall be ramp or minimal step,
however such reading for analog inputs should be noted only for reference.
v) Checking of all PLC console displays, keyboard and touch-screen

operation (wherever specified), printer/hard copier functions etc.
vi) System redundancy check including correct change over of the back-up
unit in case of failure of main unit.
vii) System diagnostic checking for all subsystems on local level as well as on
console, including checking of the testing software for I/O modules/signal
conditioning modules, when specified.
viii) Checking of output status on processor failure.
ix) Checking of first-out alarm generation.
x) Simulation of power failure and system restart auto boot-up of system

configuration and program after power restoration.
5.2.8 Vendor shall notify the purchaser at least three (3) weeks prior to factory acceptance test. In
the event that representative arrives and the system is not ready for testing, vendor shall be
liable for back charges for any extra time and expenses incurred.
5.3 Installation, Testing and Commissioning
5.3.1 Vendor shall offer the services of an installation team which would install the equipment in the
control room, lay the interconnecting cables inside control room, check-out, test and
commission the system.
All technical personnel assigned to the site by the vendor shall be fully conversant with the
supplied system and software package, and shall have both hardware and software capability
to bring the system on line quickly and efficiently with a minimum of interference with other
concurrent construction and commissioning activities
5.3.2 Vendor's responsibility at site shall include all activities necessary to be performed to
complete the job as per material requisition including:
a) Receipt of hardware/software and checking for completeness of supplies.
b) Installation of the system including for free supply equipment, if any.
c) Field cable termination and inter-cabinet cabling and termination.
d) Check out equipment installation.
e) Checking of interconnections, hardware and software configuration, overall system

GSTD-0202 0
Rev
SHEET 37 OF 39
f) Loop checking.
g) Field tests.
h) Commissioning and on-line debugging of the system.
i) Involvement during plant commissioning and performance of final acceptance test.
j) Co ordination for integration with DCS / other third party system.
5.3.3 Field Inspection
5.3.3.1 All equipments shall be inspected thoroughly by vendor after its receipt at site for
completeness and proper functioning. Vendor must initiate the remedial action, in case
unsatisfactory operation of any item is observed, with intimation to Engineer-in-charge.
5.3.3.2 Vendor must document all observations including details of any malfunction observed. Items/
equipments requiring total replacement must document the reasons for the same.
5.3.4 Loop Checking
5.3.4.1 Loop checking shall be carried out by vendor including checking the interconnections,
configuration and overall system functioning.
5.3.4.2 Vendor's scope of work as a part of system installation and loop checking shall include
termination of field cables in the control room, checking of interconnection between
instrument/equipment, glanding, ferruling/tagging of interconnecting cables in control room,
ferruling of field cables in control room and performing overall loop performance check.
5.3.4.4 The input signals shall be simulated by disconnecting/connecting the field wires for all field
switches connected to 'PLC. All field transmitters connected to control room shall be loop
checked at 0%, 50% & 100% of full scale (for both increasing and decreasing signals).
Wherever receiver cards are used, the set point shall be generated by giving the input signal
to receiver card. All outputs shall be checked in field, either for actual operation of solenoid
valve or actual pick-up of electrical contractor for rotary equipments. Shutdown schemes shall
be checked for proper functioning, configuration and actuation.
5.3.4.5 After loop checking is completed, vendor shall connect back any ~erminals and connections
removed for loop checking.
5.4 System Acceptance
5.4.1 The owner shall provisionally takeover the system from vendor after System acceptance test.
System acceptance test shall be started only after the satisfactory performance of loop
checking and verification of all loop checking records by Engineer-in-charge.
5.4.2 The system acceptance test shall be carried out in the presence of owner's representative
and Engineer-in-charge or his authorised representative. The tests carried out in System
acceptance test shall be fully recorded and duly signed by all representatives participating in
the System Acceptance Testing. .

GSTD-0202 0
Rev
SHEET 38 OF 39
5.4.3 Vendor shall carry out the following functional tests, as a part of system acceptance test, as a
minimum.
a) Hardware verification as per final Bill of Material.
b) Visual and mechanical check-up for proper workmanship, identification, ferruling,

nameplates etc.
c) System configuration as per approved configuration diagram.
d) Demonstration of all system function, display and diagnostics.
e) Checking of correct change-over of redundant devices.
f) Checking of various peripheral devices like printers and printing of all reports.
g) Complete checking of logic system, loading of user's program and checkout of

results.
h) Checking of proper functioning of all disc drives, alarm summary, alarm history
etc.
i) Proper information transfer on the information network by verifying system

displays and printout.
5.5 Final Acceptance Test
The owner will take over the system from the vendor after the final acceptance test, which is
defined as successful uninterrupted operation of the integrated system for three weeks.
Vendor's personnel shall be present during the test. Any malfunctioning of the system
components shall be replaced / repaired as required. Once the system failure is detected, the
acceptance test shall start all over again from the beginning. The warranty period commences
from the day owner takes over the system.
6.1 Vendor shall comply fully with the general requirements of PLC system including logistic
support services, documentation, warranty, maintenance contract and shipping instructions.
Post Warranty Maintenance Contract
Vendor shall quote separately for post warranty maintenance contract after warranty period
for five years for the complete system as per commercial terms and condition of the
requisition and the type (i.e. comprehensive or non-comprehensive) of post warranty
maintenance shall be as specified in job specification. The personnel deployed during post-
warranty maintenance shall have thorough knowledge of the system and at least two years of
experience on the maintenance of similar system. Any other conditions of contract required
by vendor shall be explained in the offer.
7.0 SHIPPING

GSTD-0202 0
Rev
SHEET 39 OF 39
7.1 All the materials used for packing, wrapping, sealers, moisture resistant barriers and
corrosion preventers shall be of recognised brands and shall conform to the best standards in
the areas for the articles which are packed
7.2 Workmanship shall be in accordance with best commercial practices and requirements of
applicable specification. There shall be no defects, imperfections or omissions which would
tend to impair the protection offered by the package as a whole.
7.3 The packing shall be suitable for storing in tropicalised climate, the ambient conditions, being
specified injob specifications.
7.4 Shipment shall be thoroughly checked for completeness before final packing and shipment.
Vendor shall be responsible for any delay in installation or commissioning schedule because
of incomplete supply of equipments.

GSTD-9998 0
PROJECTS & DEVELOPMENT INDIA LTD Re

SHEET 1 OF 13
INSPECTION AND
TEST REQUIREMENTS
FOR INSTRUMENTATION

GSTD-9998 0
INSPECTION AND TEST REQUIREMENTS FOR
INSTRUMENTATION Rev
SHEET 2 OF 13
CONTENT
Sl. No. DESCRIPTION
1.0 Inspection and Tests
1.1 General
1.2 Visual Inspection
1.3 Dimensional Inspection
1.4 Material Inspection
1.5 Non-Destructive Examination
1.6 Pressure Test
1.7 Pneumatic Test
1.8 Seat Leakage Test
1.9 Performance Test
1.10 Steam Test
1.11 Insulation Resistance Test
1.12 High-voltage Test
ATTACHMENT
Sl. No. DESCRIPTION
Table-A Table-A- Table of Inspection and Test Items

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 3 OF 13
1. INSPECTION AND TESTS
1.1 General
1.1.1 All instruments and system-oriented items shall undergo factory testing and inspection by
authorized Third party representatives / Owner and PMC unless specified otherwise.
1.1.2 Wherever inspection at manufacturer’s shop is waived because of any reason, the sub vendor’s
own testing reports shall be verified before despatch. In no case items shall be released without
proper inspection verification.
1.1.3 The inspection and testing shall be carried out as per related specifications, international codes
and practices/standards, approved documents and/or any other documents attached along with
specifically suggesting testing to be carried out at manufacturer’ works.
1.1.4 Items, for which ‘Witness Inspection’ is specifically exempted, manufacturer shall forward the test
certificates as desired for review. The material shall be despatched only after obtaining written
despatch clearance.
1.1.5 No system or system oriented item shall be despatched without integrated factory testing
witnessed by representatives of / Third party inspector / Owner /PMC. The testing procedures
shall be detailed out, based on testing requirements indicated in individual system specifications
and shall be approved by Owner/ PMC. It must certify that the system is actually ready before
calling the Owner/PMC for FAT. Also all the necessary documents and literature are to be
submitted before calling for FAT.
1.1.6 Testing and inspection for all items shall be carried out as per approved factory testing
procedures.
1.1.7 Performance specifications must be detailed out on each time which shall be verified by third
party agency / by Owner / PMC during factory testing.
1.1.8 Acceptable criteria for Radiography and other NDT requirements for the instruments / instrument
castings shall be inline with those specified in ‘Piping Specifications’ have been attached
elsewhere in this package.
1.1.9 IBR certifications shall be provided by in the appropriate format duly signed by IBR authority or
their authorised agency.
1.1.10 Verification of setpoint of rupture disc shall be part of witness inspection. Testing shall be carried
out on the rupture disc, which are part of the actual rupture disc batch of manufacturer. This shall
be in addition to the 3 numbers of spare rupture discs already indicated in the requirements. The
testing, in general, shall be as per ASME section VIII.
1.1.11 Inspection and test items, witness inspection items for each kind of instrument at FAT (Factory
acceptance test) shall be as shown in Table A.
1.1.12 Inspection and acceptance standards
Inspection and acceptance standards shall be as follows.
1.2 Visual Inspection
1.2.1 Conformation items

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 4 OF 13
1. Type and model

2. Tag no.
3. Rating
4. Range, Scale and symbol of unit
5. Set pressure and capacity of safety valves
6. Valve characteristics and CV value of control valves
7. Name of materials
8. Nameplate
9. Colour of painting
10. Die Marking (nominal size, material of flange and direction of flow)
11. Accessories
12. Quantity
1.2.2 Harmful defects
 Defect such as cracks, deformation and flaws shall not be found in the casting, forging and
machined surface of the pressure rating part.
 Defect such as inside surface weld protrusion; lack of fusion and incomplete penetration shall
not be found in welded places of pressure retaining part.
1.2.3 The instrument shall be in rugged design and assembly of all components within the enclosure
fixed firmly to avoid loosening or falling-off of any parts.
1.2.4 Painting of instrument's surface shall be such that there is no defect or lack of uniformity.
1.3 Dimensional Inspection
[X] Main parts

[ ]
[ ]
Check and conform to the requirement of Purchaser's Spec, approved drawings or applicable
code and standards.
1.4 Material Inspection
1.4.1 Mill test certificates
Manufacturer shall submit the mill test certificates for the following parts.
1. ANSI class 900 or above (ALL material used at the P.T. ratings)
2. The following parts made of steel for :

 High temperature service (Alloy steel above C-Mo steel used at temperature of 400ºC
or over)
 Low temperature service (Iron and steel material of design temperature bellow minus
11ºC containing Al-killed steel)
 Corrosion-resistant materials
I. Temperature detective parts : [X] Flange and Thermowell

II. Orifice assembly : [X] Flange
III. Venturi tube, Flow nozzle and : [X] Body
Low-loss tube
IV. Positive displacement flow meter and : [X] Body, Strainer and

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 5 OF 13
Turbine meter Straightner
V. Area type flow meter : [X]
Body and Flange
VI. Displacement type liquid level meter : [X]
Chamber and Flange
VII. Glass Gauge : [X]
Body and Flange
VIII. Control valve : [X]
Valve body, Bonnet,
Plug, Seat and Vane
IX. Safety valve : [X] Valve body, Nozzle and
Disc
X. Condensate pot : [X] Body
XI. Gas eliminator : [X] Body
1.4.2 Material grade 316SS or 316L SS of stainless steel, Purchaser may require Vendor to carry out
the qualitative analysis for molybdenum.
1.5 Non-Destructive Examination
1. Control valve and safety valve

Following Par. 1.5.2 and 1.5.3
2. Other instruments
Shall be carried out in accordance with manufacture's standards approved by Purchaser
1.5.1 Ultrasonic Examination
1. Forging material on Orifice flange and Flow nozzle

[X] ANSI class 900 or above
1.5.2 Radiography Examination
[ ] The pressure retaining casting parts
1. Applicable material and quantity (refer table VI)

 Welded parts : [ ] JIS Z 3104, Z 3106
[X] ASME VIII Division 1 uw-51 "Radiographic
& Radioscopic Examination of Welded Joints"
2. Acceptant standards and grade

 Casting : [ ] JIS G 0581
[X] ASTEM E 446-9 or 186-93

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 6 OF 13
Table VI Radiography Examination
Materials Quantity
class 1500 or over C-steel
class 900 or over C-Mo steel One out of total

quantity of the same
Casting class 600 or over Cr-Mo steel type, size and rating
Stainless steel for pressure retaining
critical parts(a)
class 300 or over Al-killed steel
2.5 Ni steel
3.5 Ni steel
C-Mo steel
One spot on each
class 300 or over Cr-Mo steel welded parts per same
Pressure retaining
Stainless steel material and same
welded parts
welder. All welded
class 150 or over Al-killed steel
crossing parts
2.5 Ni steel
3.5 Ni steel
a. Following parts are Critical parts.

 Groove-welded parts of cast body
 Flange neck and valve seat's vicinity of cast body
 Other welded parts included in pressure retaining parts
Note: 1. In case of practical difficulty to perform Radiography Test, Manufacture

shall notify Purchaser in advance, and for such case, magnetic particle or liquid
penetrant examination may be used in accordance with Par. 1.5.3 with
Purchaser's approval.
2. For the welded parts having nominal size of 1-1/2 in. or below, magnetic particle or
liquid penetrant examination in Par. 1.5.3 may be used.
1.5.3 Magnetic Particle or Liquid Penetrant Examination
[X] For the pressure retaining parts

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 7 OF 13
Table VII Magnetic particle / Liquid penetrant examination
Materials Quantity
20% of total quantity of

class 600 or over Cr-Mo steel
the same type, size
Cr-Mo steel
Casting and rating for pressure
Stainless steel
retaining critical parts
class 150 or over Al-killed steel (a)
2.5 Ni steel
3.5 Ni steel
Pressure retaining class 150 or over All materials 20% of total welded
welded parts (b) parts
a. Refer to Par. 1.5.2(1).

b. Including butt groove-welded parts at site.
1.6 Pressure Test
1.6.1 Control Valve
1. Body and Bonnets
[X] Hydrostatic test with Applicable codes and standards
2. Body of special type
[X] Hydrostatic test
Test pressure and Hold time
[X] 1.5 times of max. Operating pressure / min. 2 kgcm2g

[X] Minimum 5 minutes.
3. Permanent distortion or Leakage
[X] shall not be found
1.6.2 Safety Valve or Safety Relief Valve
1. Pressure retaining parts
[X] Hydrostatic test before assembling
i. Test pressure and Hold time
[ ] 1.5 times of Max. Operating pressure / min. 2 kgf/cm2g.

[X] 2.2 times of Max. Operating pressure.
GSTD-9998 0
INSTRUMENTATION Rev
SHEET 8 OF 13
ii Distortion or leakage
[X] shall not be found
2. The out side parts of enclosed type

[X] Hydrostatic test after assembling
i. Test pressure and Hold time

[X] 1.5 times. Nominal pressure of flange
[ ] 2.2 times. Nominal pressure of flange
ii. Defects
[X] Shall not be found
3. Special type valves
[X] Hydrostatic test with the manufacturer's standards approved by purchaser, where
Par. 1.6.2(1) and (2) are not applicable
1.6.3 The pressure retaining parts of instrument
[X] Hydrostatic test or Pneumatic test as per applicable codes and standard
I Test pressure and Hold time

[X] 1.5 time of Max. Operating pressure / Min. 2 kg/cm2g
[X] Min. 5 minutes
ii Permanent distortion or Leakage

If the above mentioned test is technically difficult, the test shall be carried out in accordance
with the manufacturer's standards approved by purchaser.
1.7 Pneumatic Test
1.7.1 The pneumatic test for instrument
I Test pressure & Hold time
[X] Max. Operating Pressure. (Design press.)

[X] Minimum 5 minutes
ii Permanent distortion or Leakage
1.8 Seat Leakage Test
1.8.1 Control Valve
Allowable leakage valve / (code):
[X] ANSI B16.104 (FCI 70-2)

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 9 OF 13
Unless other wise specified, butterfly valves shall not require the seat leakage test.
1.8.2 Safety valve
Seat leakage test (closing property) as follows.
1. Safety valve for Steam
i. Test pressure
[X] 90% of set pressure
ii. Leakage
2. Safety valve for Gas
i. Test pressure
[X] 90% of set pressure
ii. Allowable leakage value (Refer Table – VIII)
Table VIII - Allowable leakage value of Safety valve
Type Orifice Area Number of Bubbles Leakage Value

(mm) (min) (cm3/min)
General 16.0 and less 40 11.80
20.5 and over 20 5.90
Balance bellows 16.0 and less 50 14.75
20.5 and over 30 8.85
3. Relief safety valves, Vacuum breakers and atmospheric valve

[X] Manufacture's standard (approved by Purchaser)
1.9 Performance Test
For each instruments, the performance test shall be carried out in accordance with procedure
approved by Client / PMC.
Acceptance standard shall be in accordance with applicable codes & standard, All specification, and
manufacture's standard shall be approved by Client / PMC.
1.10 Steam Test
Steam test shall be performed as follows:
[ ] Valves used for steam service Temperature of 450°C or more, and the body ratings of class
600 and above.
[ ] After attaining the steady surface temperature same as temperature of the service with the
pressure of service condition.

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 10 OF 13
In the case, when steam test has been performed and the report is submitted for the valve of
same type, same bore size and material from the same lot, the steam test for the other valves
may be omitted.
1. Leakage
i. Body : [ ] Shall not be found

ii. Seat : [ ] As per specified leakage value
2. Operation
[ ] To be smooth
After the steam test, the test of Par. 1.6 and Par. 1.8 shall be carried out.
1.11 Insulation Resistance Test
1. Power supply circuit : 10M  or over (instrument panel: 3 M or

& alarm circuit over/each panel)
2. Signal circuit : 5M  or more (instrument panel: 3 M or

More per panel)
The test shall be carried out in accordance with the applicable codes & Standards. Due to any
technical constraint to measure, this test can be omitted
1.12 High-voltage Test
1. A-C power supply and alarm circuits
i. Voltage level less than 250 V : [X] A-C 1500 V
ii. Voltage level 250 V and above : [X] A-C 2E + 1000V
‘E’ is the rated voltage.
2. D-C power supply circuits : [X] A-C 500V
Test can be omitted in case of any technical constraint.

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 11 OF 13
Table A : Table of Inspection and Test Items

Inspection and Test Items
Visual Dime Materi Non- Press Pneu Seat Perfor Insula High Steam
Kind of Instrument insp. nsion al destru ure matic Leaka mance tion voltage test
al insp. ctive test test ge test resist test
insp. exam test ance
test
1 Thermocouple  T T      T T T 
2 Resistance T T T
   
thermometer bulb      T T
3 Compensating lead wire T T      T T T 

4 Bimetallic thermometer T T      T   
5 Gas or liquid-filled T
       
thermometer T T 
6 Thermowell T T         
T T T
7 Orifice plate T  T        
T
8 Orifice flange T T         
T T
9 Restriction orifice T  T        
T
10 Flow nozzle low-loss tube T T         
T T T
11 Venturi tube T T         
T T T
12 Positive displacement T T T T T S T T
  
flow meter              
13 Area type flow meter T T     T   T 
 
T T T T
14 Thermal mass flow meter T T T T S T T
   
          
15 Turbine meter T T T T T S T T
  
             
16 Differential pressure T T T T T T
    
flow meter          
17 Differential pressure T T T T T T
    
transmitter          
18 Magnetic flow meter T T T T T S T T
  
            
19 Bourdon gauge T T       T   
T
20 Draft gauge T T       T   
21 Differential pressure gauge T T       T   
T
22 Pressure transmitter T T       T   T 
T T
23 Displacement type level T S T T S S S T
  
indicator, controller             
24 Chamber for displacement
type level meter T          
T T T T
25 Glass gauge T     
     
T T T

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 12 OF 13
test
26 Float type level meter, T S T T S S S T
  
             
27 Differential pressure type T T T T T T
   
level meter T          
28 Purge type level meter T T       T   
29 Capacitance type T T T T T
    
level meter T         
30 Conductivity type level T T T T T
    
meter T        
31 Conductivity type level T S S S T
     
meter        
32 Weight sounding type level T S S S T
     
meter        
33 Radiation type level meter T S S S T
     
       
34 Pneumatic type control T S T S S S T T
valve                
T
35 Hydraulic type control valve T S T T S S S T T

               
36 Motor-operated control T S T T S S S S S

valve                
37 Self-acting control valve T T      T  
 
T T T
38 Indicator T T      T   T
 
T
39 Recorder unit T T       T   T

T
40 Controller unit T T       T   T

T
41 Integrator unit T T       T   T

T
42 Alarm setting unit T T       T   T

T
43 Computing unit T T       T   T

T
44 Converter unit T T       T   T

T
45 Limiter unit T T       T   T

T
46 Power source unit T T       T   T

T
47 Instrument panel T S T S S T T
   
           
48 Instrument desk T S S T T
     
       
49 Gauge board T S T S S T T
   
           
50 Safety valve T S T T T S S
   
            
51 Pilot operated safety relief T S T T T  S S   

GSTD-9998 0
INSTRUMENTATION Rev
SHEET 13 OF 13
test
valve             
52 Vacuum breaker T S T T T S S
   
            
53 Atmospheric valve T S T T T S S
   
            
54 Gas chromato-graph T T T S S T
    
         
55 Mass spectro-meter T T T S S T
    
         
56 Infrared type gas analyzer T T T S S T
    
         
57 Magnetic type gas analyzer T T T S S T
__ __ __ __
         
58 Thermal conductivity type T T T S S T
    
analyzer          
59 Combustion type gas T T T S S T
    
analyzer           
60 Density type gas analyzer T T S S T
     
       
61 Photo-electric type analyzer T T T T T
     
       
62 Moisture analyzer T T T T
     
T       
63 pH meter T T  T   T
     
T
64 Turbidity analyzer Water T T T T T T
    
quality analyzer          
65 Density meter T T    T   T 
  
T T
66 Electric conductivity meter T T     T
    
T T T
67 Flame detector T T S S T
     
       
68. Mass Flow meter T T T T T S T T
  
             
69. Vortex Flow Meter T T T T T S T T
  
             
70 Gas detector T T S S T
     
       
 : Tested by Manufacturer.
rd
 : Tested by manufacturer & witnessed by 3 party inspector(TPI).
 : Manufacturer will submit Inspection & test records.
T : Total Inspection by TPI.
S : Sample inspection by TPI.(10% of total quantity of the same type & rating.
Notes: PMC/OWNER may witness any or all testing in stages during manufacturer or at final stage before shipment.

PC150/E/4004/SEC VI-
0
5.5 (PART A & B)
Sheet 1 of 202
DESIGN PHILOSOPHY FOR CIVIL & STRUCTURAL

WORK (PART-A & B)



PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
DESIGN PHILOSOPHY FOR CIVIL &
STRUCTURAL WORK R
Document No.
ev
SHEET 2 OF 202
CONTENTS
SL.NO. DESCRIPTION DOCUMENT NO. PAGE NO.
1 DESIGN PHILOSOPHY FOR CIVIL & PC150/E/4004/SEC VI-5.5 6-14

STRUCTURAL WORK (PART A & B)
ANNEXURES
2 DESIGN PHILOSOPHY - (Annexure-I) 15-44

ARCHITECTURAL
3 DESIGN PHILOSOPHY - GENERAL (Annexure-II) 45-64
CIVIL
4 CIVIL ENGINEERING DESIGN BASIS (Annexure-III) 65-110
( STRUCTURAL)
5 ES -2516 : TECHNICAL SPECIFICATION (Annexure-IV) 111-143
FOR CIVIL, STRUCTURAL & ALLIED
WORKS
6 ES-2517 : TECHNICAL SPECIFICATION (Annexure-V) 144-158
FOR WATER SUPPLY, DRAINAGE &
SANITATION
7 ES: 2518 TECHNICAL SPECIFICATIONS (Annexure-VI) 159-191
FOR BORED CAST-IN-SITU CONCRETE
VERTICAL PILES
8 QUALITY ASSURANCE PLAN (Annexure-VII) 192-196
9 VENDOR LIST (Annexure-VIII) 197-204
10 TOPOGRAPHICAL SURVEY REPORT (Annexure-IX)

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 3 OF 202
INDEX
Sl.No. DESCRIPTION
General Description Of Scope
1.0 DETAILED SCOPE OF WORK
1.1 Soil Investigation
1.2 Topographical / Contour Survey
1.3 Grading
1.4 Disposal of Surplus Earth
1.5 Site Cleaning
1.6 Roads
1.7 Surface Drainage
1.8 Contaminated Rain Water Sewer (CRWS) System and oily
water sewer system (OWS)
1.9 Sewage Disposal Scheme
1.10 Paving
1.11 Structures, Buildings etc.
1.12 Surface Finishing
1.13 Acid / Alkali Proof Lining
1.14 Anti-termite Treatment / Damp Proof Course / Water
Proofing
1.15 Miscellaneous
1.16 Engineering and Construction
1.17 Existing Facilities
1.18 Transfer of Benchmark
1.19 Sizing of Various Facilities
1.20 Rules and Regulations
2.0 DETAILED ENGINEERING

2.1 General

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 4 OF 202
Sl.No. DESCRIPTION
2.2 Design Calculations
2.3 Drawings
3.0 CONSTRUCTION
3.1 General
4.0 QUALITY ASSURANCE PLAN
5.0 COMPLETENESS OF WORK CONTRACT

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 5 OF 202
GENERAL DESCRIPTION OF SCOPE
This section of the Tender Documents deals mainly with the Scope and Technical
Specifications needed for the Detail design, preparation of detailed Drawings and getting
the design/ drawings approved by Owner/Consultant, execution and construction of
complete Civil, Structural and other Allied Works on turnkey basis.
The scope of Civil Structural and Architectural Works under this Contract shall include
carrying out Basic Design, Detailed Engineering, development of Drawings, Supply of
materials, Procurement of materials, Construction, Demolitions, Supervision of all relevant
Civil and Structural Works including providing all labour, supervision, material, scaffolding,
construction equipment, tools, tackles and plants, supplies, transportation, statutory
approvals, all incidental items though not indicated or specified but reasonably implied or
necessary for successful completion of the project.
Further description of Scope of the CONTRACTOR shall include but not limited to the
following:-
a) Engineering related to site preparation, micro-grading etc.

b) Soil Investigation
c) Preparation of concept notes for design, engineering & construction.
d) Structural Analysis and design calculations as per specifications laid down in Civil
Engineering Design Basis, enclosed in the tender. for all Civil works including but
not limited to footings, pile, pile-cap, foundation, plinth beam, RC superstructure,
steel super structure, trenches, drains, pits etc.
e) Architectural design and drawings including details for doors, windows, partitions,
false floor, false ceiling, toilet, finishes etc.
f) General Arrangement and detail design drawings for all types of foundations, pile,
pile-cap, foundations, plinth beams etc, based on the soil investigation carried out
by the bidder for the proposed site.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 6 OF 202
g) General Arrangement and structural drawings at grade level showing foundations,

extent of paving, trenches, drains, pits etc.
h) General Arrangement and detail design drawings for superstructure (RCC and
structural steel) at all levels.
i) RCC drawings showing all necessary details for all foundations and structures.
j) Structural steel detail drawings for all steel structures.
k) General Arrangement and detail drawings for storm water drains, effluent drains,
cable trenches, sewerage, manholes, pits, sumps with all necessary details.
l) Bar Bending Schedules for all RCC works.
m) Fabrication drawings with all details for steel structures.
n) Coordination with OWNER / PMC for various activities including approvals of design
basis, concept note, drawings, material samples, laboratory test results etc.
o) Procurement of all items necessary for completion of scope of work.
p) Construction of all units / structures, items of work included in scope of work.
q) Preparation of as built drawings & final documentation.
r) Obtaining Statutory Approvals.
s) Adherence to Quality Assurance Plan
1. DETAILED SCOPE OF WORK
1.1. Soil Investigation
1.1.1 The Contractor is advised to conduct preliminary soil investigations for the bidding
purpose. However, the CONTRACTOR shall carryout detailed soil investigation for
the proposed plant afresh for detail engineering.
1.1.2 The CONTRACTOR shall adopt pile foundation, open type isolated, raft foundations
as per foundation requirements of structure, loads, settlement & other design
criteria.
1.1.3 The CONTRACTOR shall design and construct all foundations as per requirements
with no extra cost to OWNER / Project Management Consultant (PMC).
1.2 Topographical / Contour Survey


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 7 OF 202
The Topographical Survey report of plant area is attached with the Tender purely
for reference.
1.2.1 Site Conditions
At bidding stage, the CONTRACTOR shall visit the site and study the existing site
conditions & existing structures if any.
1.3 Grading
Graded land shall be provided to the Bidder. However, micro-grading as required

shall be done by the bidders in their respective areas
1.4 Disposal of surplus earth
The CONTRACTOR shall dispose-off all surplus and unserviceable earth (if any),
outside the plant in dumping grounds in accordance to rules and regulations of local
Governing authority, at his own cost.
1.5 Site cleaning
During construction and on completion of construction (inclusive all internal and

external finishes), cleaning all the debris, waste materials scattered in and around
the site and disposal of the same shall be in the scope of the CONTRACTOR with
the consent of the OWNER.
1.6 Roads
External roads shall be taken care through separate Tender. Roads within Battery
limit is in contractor’s scope.
1.7 Surface Drainage
The scope of work includes also providing all internal services such as water
supply, sanitary sewerage, drainage and storm water drains etc. and connection to
external prevailing facilities complete in all respects. All the above work shall be
carried out strictly in accordance with the "Technical Specifications (ES- 2517)"
enclosed with the tender.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 8 OF 202
The CONTRACTOR shall ensure proper drainage of all components of the Plant.
For the purpose of drainage the Contractor’s scope is not limited only up to the Unit
Battery Limit but shall extend up to the adjacent drainage network around the unit.
1.8 Contaminated Rain Water System and Oily Water Sewer (OWS) System
The CONTRACTOR shall provide proper underground drainage system for

contaminated rain-water and OWS. These shall be as per the philosophy mentioned
in this tender document or in consultation with PMC/OWNER. The treated oily water
shall be pumped to Owner’s Guard Pond. Details of Tie-in points at battery limit
shall be provided during detail design stage.
1.9 Sewage Disposal Scheme
The CONTRACTOR scope is to provide proper underground drainage system for

sewage disposal and its connection to Common Sewage treatment plant for whole
complex.
1.10 Paving
The CONTRACTOR shall provide RCC pavement for the complete area of the plant
as job specific requirement. For the purpose of paving the Contractor’s scope is not
limited only up to Battery Limit, but shall extend up to the adjacent roads around the
unit.
1.11 Structures buildings etc.
Contractor’s scope shall include various technological structures steel & R.C.C.
structures, pipe rack, buildings, equipment foundations, pits, cable trench, sheds,
etc. as per the approved Plot Plan or mentioned in this tender document, required
for the complete execution and commissioning of the plant.
1.12 Surface Finishing’s
The CONTRACTOR shall be responsible for complete planning and detailing of all
surfaces finishes viz. painting, flooring etc as per specifications given in the Tender.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 9 OF 202
1.13 Acid / Alkali Proof Lining
The CONTRACTOR shall be responsible for surface treatment of floors, exposed

portion of foundations, pits and basins against acid / alkali as per process
requirement.
1.14 Anti-termite Treatment / Damp proof course / Water proofing
The CONTRACTOR shall provide anti-termite treatment, damp proof course and
water proofing as per design basis.
1.15 Miscellaneous
These shall include local platforms, pipe sleepers, local foundations, local supports,
etc. as per requirement.
1.16 Engineering and construction
Preparation of detailed design, drawings, supply and construction of all civil,

structural, architectural, plumbing & sanitary and building works shall be in the
scope of contractors work.
1.17 Transfer of benchmark
The Benchmark will be made available inside plant premises. However, it may be
verified by CONTRACTOR.
1.18 Sizing of various facilities
Sizing, nos., location etc. of various facilities viz. buildings, pipe rack, structures,
equipments, etc. shall be in the scope of the bidder.
Any change of sizing, addition of any structure / facility, indicated by Owner/PMC

during design stage, based on functional requirements and as well as local rules
and regulations, etc, shall be in the Contractor’s scope, at no extra cost to OWNER
/ PMC.
1.19 Rules and regulations

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 10 OF 202
All the facilities shall conform to all Local Rules and Regulations, Factory Inspector,
Rules, TAC rules etc. whichever is more stringent.
Getting the approval of the various documents through the various authorities shall
be in the Contractor’s scope at no extra cost to OWNER / PMC.
2.0 DETAILED ENGINEERING
2.1 General
2.1.1 The CONTRACTOR shall carryout Analysis and Design of the structures required for
this document and shall prepare all the required Architectural, Civil and Structural
drawings needed for correct and accurate construction as per the Design
Specifications given in this document.
2.1.2 The CONTRACTOR shall submit a Detailed Schedule for release of documents and
drawings for review / approval to PMC/CLIENT, within 2 weeks/or mutually period of
date of award of the Contract. Such a schedule shall be made in line with the
overall Project Schedule given in the document. The CONTRACTOR shall strictly
adhere to the approved schedule.
The Format of Submission of the above mentioned schedule shall be mutually

discussed and finalized after award of the job.
2.1.3 Construction of various structures / facilities, whose designs and / or drawings are
specially identified in the document submission requirements for approval by PMC,
shall not be taken up for construction at site till they are approved by PMC and
comments given by PMC are incorporated.
For other structures / facilities, the CONTRACTOR shall directly submit the
Approved for Construction (AFC) drawings to PMC for information before, taking up
construction.
2.1.4 It shall be the responsibility of the CONTRACTOR to accommodate all the

functional requirements such as access, cutouts, clearances, interference etc. while
designing / detailing of various structures / facilities.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 11 OF 202
2.1.5 Complete analysis, design and all drawings of each independent structure / facility
shall be submitted in one lot so as to facilitate overall systematic review by PMC.
2.1.6 Only after the necessary architectural drawings are approved by the OWNER /
PMC to their satisfaction, then the design drawings shall be reviewed and approved
by PMC.
2.1.7 The CONTRACTOR shall keep the OWNER / PMC informed of any major design
revisions simultaneously in progress.
2.2 Design calculations
The CONTRACTOR shall prepare the design calculations based on the standard
accepted practice and guidelines from PMC / OWNER.
All design calculations shall be written systematically, legibly and submitted for
approval as per standard accepted practice.
For structures, analysis and design shall be done on latest version of STAADPRO
SOFTWARE.
For other miscellaneous works Excel and Word shall be used. Design calculations
shall be done on A4 size sheet only.
2.3 Drawings
The CONTRACTOR shall prepare
- Civil & structural design & construction drawings, architectural drawings

based on the standard accepted practice and guidelines from PMC /
OWNER.
- Bar bending schedules.
- Fabrication drawings.
- As-built drawings.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 12 OF 202
- Detailing / drafting shall be done on AUTOCAD Latest Version only. Drawing

size used shall be preferably of A1 size only. For foundation layout, drainage
plans and paving plans, A0 size drawings can be used if necessary.
3.0 CONSTRUCTION
3.1 General
3.1.1 Construction of all civil and structural works including all material, labour,
Supervision, tools and tackles etc. shall be carried out by the CONTRACTOR
3.1.2 Procurement and supply of all materials viz. cement, reinforcement, structural steel
etc. shall be in the scope of CONTRACTOR.
3.1.3 All materials shall be procured in consultation with the Owner or as per the
approved vendor list given elsewhere in this document. All materials of construction
must be of ISI approved brand.
3.1.4 All materials and construction shall confirm to the specification given elsewhere in
this document.
3.1.5 Materials of construction, construction methodology etc. shall be such, so as to

protect the structures and foundations against the harmful effect of chemical, fumes
etc. present in the plant, its vicinity, in ground and / or subsoil water.
3.1.6 The CONTRACTOR shall be responsible for obtaining the statutory approval from
local authorities such as Inspector of Factories, Development Authorities, Municipal
Corporation and other concerned authorities before starting the work.
3.1.7 The CONTRACTOR shall ensure that the facilities are constructed in accordance
with the APPROVED FOR CONSTRUCTION drawings and specifications.
3.1.8 The CONTRACTOR shall maintain and operate an adequate system of control of
availability of latest drawings and specifications, at all the places where work is
performed.
3.1.9 Construction shall include excavation in all types of soils / rock inclusive of
necessary dewatering as applicable.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 13 OF 202
3.1.10 The CONTRACTOR shall redo / repair all the existing facilities viz. roads, paving,
drainage etc. which are damaged during transportation, construction and erection
activities performed by him.
3.1.11 Rain water harvesting is mandatory for building like control room, operator room,
view room, change room &check room, administration building, security building,
maintenance building, canteen, laboratory building etc.
4.0 Quality Assurance Plan
Contractor shall ensure the quality of civil works by engaging a third party
supervision /inspection and provide test results to Owner/PMC for information. The
Quality Assurance Plan is attached for reference as Annexure VIII and the
contractor is obliged to follow it.
5.0 COMPLETENESS OF WORK/CONTRACT
5.1 The scope of work mentioned in the contract/NIT is not the comprehensive one, but
gives total idea/outline of the scope of work; however contractor shall be responsible
for completeness of the job for the purpose indicated elsewhere to make the system
fully functional and operational.
5.2 In case there is any conflict in the specifications appearing in different contractual
documents then the specification whichever is stringent shall be applicable without
any technical or commercial implications.
5.3 The work furnished shall be complete in every respect with all mounting, fittings,
fixtures and standard accessories etc. normally provided for such item/equipment
and or needed/required for erection, completion and safe operation of the
item/equipment/system as required by applicable codes though they may not have
been specifically detailed in the respective specifications, unless included in the list
of exclusions.
5.4 Any additional items and materials which are not specifically mentioned but are
required to complete the system offered, in every respect in accordance with the
technical specifications and required for safe operation and guaranteed performance

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 14 OF 202
shall also be deemed as included in the scope of work of this tender. Contractor
shall not be eligible for any extra payment in respect of such
mountings,fittings,fixtures,accessories etc.which are needed/required for safe
operation of the item/ equipment/system, as required by applicable codes of the
country though they may not have been explicitly spelt out in the NIT/Contract.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 15 OF 202
ANNEXURE - I
DESIGN PHILOSOPHY – ARCHITECTURAL

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 16 OF 202
CONTENTS
1.0 GENERAL
1.1 SCOPE
1.2 UNITS OF MEASUREMENT
1.3 DEFINITION
1.4 CODES & STANDARDS
2.0 DESIGN PHILOSOPHY / CRITERIA - GENERAL
2.1 ARCHICHITECTURAL DESIGN
2.2 BUILDING REQUIREMENT
2.3 BUILDING SERVICES
2.4 AESTHETICS
2.5 BUILDING ELEMENTS
3.0 BUILDING STRUCTURE
4.0 ARCHITECTURAL TRADES
4.1 EXTERNAL FINISHES
4.2 INTERNAL FINISHES
4.3 DOORS, WINDOWS & VENTILATORS
4.4 SANITARY FITTINGS & FIXTURES
5.0 MISCELLANEOUS
5.1 DRAWING
5.2 DESIGN
5.3 BUILDING REQUIREMENTS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 17 OF 202
1.0 GENERAL
1.1 SCOPE
The design philosophy defines the minimum design requirements and procedures
for carrying out architectural design and engineering of buildings covered under this
project. Relevant criteria shall be taken into consideration to achieve satisfactory
and trouble free performance of the facilities.

Units of measurement in design shall be in metric system.
1.3 DEFINITIONS
Owner Talcher Fertlizer Limited (TFL)

PMC Projects & Development India Limited (PDIL)
LSTK Contractor Successful LSTK bidder of the tender (To be selected)
NFPA National Fire Protection Association
IS Bureau of Indian Standards
The design shall be in accordance with established codes, sound engineering

practices and shall conform to the applicable statutory regulations.
The main codes, standards and statutory regulations considered as minimum
requirements are as follows. Latest revision of these shall be followed.
1.0 National Building Code of India

2.0 Factories Act of State

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 18 OF 202
3.0 Local Municipality or any other Authority’s Bye-laws as applicable.

4.0 Bye-Laws applicable of Town & Country Planning Organization.
5.0 Code of practice for building bye-laws IS : 1256
6.0 TAC (Tariff Advisory Committee) Rules
7.0 Indian Electricity Rules
8.0 Bureau of Indian Standards
Note: The above list is suggestive and not exhaustive. Apart from the basic codes
any other related codes shall also be followed wherever required.
1.4.1 Order of Precedence
In case of any conflict / deviations amongst various documents, the order of

precedence shall be as follows:
- Statutory Regulations
- Job Specifications
- Engineering Design Basis
- Standard Specifications
2.0 DESIGN PHILOSOPHY / CRITERIA – GENERAL
2.1 ARCHITECTURAL DESIGN
Architectural design of buildings / sheds shall be in accordance with this design

basis and references as stated herein, to facilitate the intended functions. The
various types of requirements to be considered are described further. In Plant Area
no underground/ basement shall be provided in the building.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 19 OF 202
2.2.1 Spatial Requirements
Spatial requirements inside a building / shed shall be decided based on activities to

be performed in the building and consequent occupancy pattern, equipment layout
etc. Spaces can be generally classified as functional spaces, circulation spaces,
amenity spaces, utility spaces. They are elaborated further.
2.2.1.1 Functional Spaces
Functional areas of any building / shed are constituted by the main activity for which
the building is required. Various spaces/rooms shall be judiciously sized and shall
be integrated logically to generate the total building plan taking into account the
following parameters :-
a) Activities, group of activities and consequent work-flow pattern.

b) Site conditions i.e., dimensions, contours etc.
c) Climatic conditions vis-à-vis orientation.
d) Safety regulations.
e) Lighting and ventilation.
f) Green building Concept as per Govt. Guidelines for the state (applicable to non
plant buildings only)
g) Acoustics
h) Services
i) Security
j) Economy
k) Aesthetics
l) Specific requirement pertaining to particular buildings,if any
m) All other established architectural design parameters in practice.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 20 OF 202
The objective of spatial arrangement shall be to satisfy functional requirements and

physical comfort and safety regulations as well as aesthetics which has significant
role in creating a favourable working environment.
2.2.1.2 Circulation Spaces

Following spaces are classified as circulation spaces. These spaces shall be
provided as per required building services, for integrating various types of spaces
and as means of access / exit / escape.
a) Corridors & passages.
b) Staircases
c) Elevator
d) Entrance lobby / Foyer including Reception & waiting.
e) Gangway / walkways.
f) Equipment loading / unloading platforms
g) Emergency Exits
2.2.1.3 Amenity Spaces

Following spaces are classified as amenity spaces :
a) Toilet (Gents & Ladies).
b) Drinking Water Facility.
c) Locker & Change Room.
d) Rest room / Lunch Room.
e) First-Aid Room
Out of the above mentioned areas, a) Toilet, b) Drinking water, c) First Aid
enclosures shall be mandatory requirement for occupied buildings / sheds. Other
facilities shall be provided as required.
2.2.1.4 Utility Spaces

Utility spaces are space requirements which materialize due to provision of services
like air-conditioning, pressurization, fire fighting, electrical, telephone, LAN etc.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 21 OF 202
Following are examples. These spaces shall be provided as per required building
services.
i) Air-conditioning plant room.
ii) Air handling rooms.
iii) Pressurization blower plant room.
iv) Electrical distribution panels rooms.
v) Service ducts
vi) Firefighting equipment room.
vii) Telephone exchange equipment room.
viii) UPS room.
ix) Battery room.
2.2.1.5 Sizes of Spaces
Sizes of various type of spaces shall be decided based on occupancy / equipment /

Panel / furniture layout, clearance, maintenance & safety requirements & ventilation
requirements.
However, following are the limiting sizes / dimensions for various purposes, which
shall be adhered to :
a) Minimum area of any habitable = 9.5 m² with minimum dimension

room restricted to 2.5 m
b) Minimum ht of any habitable = 3 m which may be reduced to 2.75

room m for air-conditioned areas. Due
provision / clearance may be made
for AC ducts above false ceiling if
any. Headroom below beams
should be min. 2.4 m.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 22 OF 202
c) Maximum ht of habitable rooms = As stipulated by the local bye-laws

d) Scale of accommodation for = @ 14 m³ per occupants. Minimum
industrial work spaces clear height of such workspaces
shall be 3.6 m. Heights above 4.25
m shall not be taken into account.
2.2.2 Day Lighting and Ventilation
2.2.2.1 Day Lighting
Established level of illumination shall be maintained for all parts of the buildings by
means of windows, ventilators, skylights, etc. Following references shall be
adhered to in this regard.
a) National Building Code of India, Part-VIII, Section-1

b) IS:2440: IS 3646 (Part-II) : IS:7662 (Part-I)
c) State Factories Rules
d) Any other relevant rules / code etc.
Following architectural norms shall be adopted:
a) Direct solar illumination shall not be considered and only sky radiation shall be
taken as contributing to illumination of the building.
b) Openings shall be provided with shading devices to avoid glare.
For the purpose of illumination, day lighting shall also be supplemented by artificial
illumination.
2.2.2.2 Ventilation
A) Natural Ventilation

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 23 OF 202
Established level of ventilation in terms of air changes per hour shall be

maintained for all spaces. Following references shall be adhered to for the
purpose.
a) National Building Code of India, Part-III, Section-1

b) IS:3101 (industrial buildings), IS:3362 (residential buildings); IS:7662(Part-
I)
c) State Factories Rules
d) Any other relevant rules / Codes etc.
Natural ventilation shall also be supplemented by mechanical or electrical

means of ventilation in all areas of habitation. Sufficient no of Glazed /
Louvered windows / ventilators shall be provided and supplemented by
exhaust fans.
B) Mechanical Ventilation
In addition to natural ventilation, if required mechanical or electrical ventilation
shall be provided depending on the type of building and its use. Other relevant
design basis shall be referred for its requirement and applications.
2.2.3 Acoustics And Sound Insulation
Specified acceptable noise level and reverberation time shall be maintained inside
a building / shed. Following references shall be referred to for the purpose.
a) National Building Code of India.

b) State Factory Rules.
c) Limitations on decibel level stated elsewhere, if any, in the bid document

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 24 OF 202
Required noise level in any space shall be maintained by means of
a) Segregating noise sources by buffer zones

b) Dampening of noise levels by damping devices
c) Providing Acoustic treatment with acoustic material (on walls, ceilings, floors,
as required).
2.2.4 Safety Requirements
Safety from fire and like emergencies shall be taken into account in building / shed
design. Buildings / sheds meant for human occupancy shall be provided with exits
sufficient to permit safe escape of occupants in case of an emergency. The exits
shall be in terms of doorway, corridors, and passage ways to internal / external
staircase or to areas having access to the outside. Following references shall be
adhered to this regard. Max distance to an exit from any point in a building shall
not exceed 30 m. Control Room building shall be provided with emergency exit on
the other side of entrance.
A minimum of two staircases and two exits per floor shall be provided in each
building. Width of passage / corridor shall not be less than 1500 mm. Following
references shall be referred to for the purpose design of Control Room building.
a) National Building Code of India, Part-IV

b) State Factories Rules.
c) Any other relevant rules / codes.
2.2.5 Site Planning & Landscaping
Site planning of building shall take into account aspects like inter-relationship of
the buildings with the whole system, movement pattern, traffic and road net-work,
safety regulations, service network, fire safety, climatic and environmental
aspects.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 25 OF 202
Main and service / maintenance entrances of buildings shall be provided with

vehicular access. All exit points shall also be provided with footpath / vehicular
access. Truck movement space in accordance with traffic pattern shall be
provided for the building as per the location of hoisting bay / loading, unloading
platform. Road network and open space around the buildings shall be designed
considering movement and functioning of fire tenders and cranes, etc.
Suitable landscaping treatment shall also be done around Control Room. Such
treatment shall generally consist of lawns, road side plantation and beautification
of building entrance areas. Standard landscape elements such as earth contours,
paving, flower beds, hedges, shrubs, ground cover and ornamental trees shall be
incorporated in landscape treatment. Necessary water supply / sprinklers shall
also be provided.
2.3 BUILDING SERVICES
Following services shall be provided for all building / sheds as essential services.
2.3.1 Water supply, Distribution and Drainage, Sanitary Services.
The service is essential for all habitable buildings / sheds. All buildings with human
occupancy shall have toilet and drinking water facility and accordingly water
supply, distribution and drainage, sanitary services as per following references.
a) National Building Code of India, Part-IX, Section 1 & 2

b) State Factories Rules.
Drinking water provisions, including one number water cooler per area (of approx
20 m x 20 m) shall be provided within an enclosure separated from the toilets.
Space for janitor shall be provided in the toilets. All service pipes showing on the
external wall shall be suitably concealed or shall be provided within a shaft.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 26 OF 202
Each building shall be equipped with approved PVC overhead water tanks of
capacity not less than 2000 litres.
2.3.2 Electrical Services
This service shall be provided as essential service for all building / sheds.
Electrical services for buildings shall consist of electrical supply and distributions,
electrical lighting installations, telephone network, fans, exhaust fans, lighting
protection system etc. including all accessories, cabling etc. including emergency
power supply, all as per requirement. All electrical switches / sockets shall be of
modular type as per the approved makes given separately.
Air conditioning and Heating

Areas of control room, spaces housing equipment / machinery / panels etc. which
required conditioned environment and certain specified areas like offices, specific
office accommodation shall be suitably air-conditioned by window / split / package
/ centrally air-conditioned type units, as per requirement with respect to other
relevant Design Basis.
Accordingly, AC Plant / AHU etc. of the required capacity, whenever required,
shall be provided and housed, suitably.
2.4 AESTHETICS
Apart from the fulfillment of functional & safety requirement, aesthetic requirement
of the buildings / sheds shall be taken care of in the design. As specific guidelines
for achieving required aesthetics are difficult to establish, following guidelines shall
be followed:
a) Preliminary Drawings including perspective views indicating architectural

treatment minimum three different alternative proposals shall be submitted for
Owner’s approval.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 27 OF 202
b) Following elements shall be considered as contributory elements to aesthetics

and their design etc. shall be subjected to the Owner’s approval. Any change /
modifications sought for aesthetics improvements with regards to these
elements shall be carried out. Any incidental elements like brickwork, RCC work
etc. required for such changes / modifications shall also be added.
i) Building / shed shape and features
ii) Canopies, overhangs & shading devices
iii) Gutters
iv) Entrance / exit steps, door
v) Window / Ventilator composition
vi) External wall location with respect to columns
vii) Colour scheme, grooves in plaster
viii) Spatial arrangement
ix) Aesthetic of the buildings should match with the surrounding existing
facilities at the site.
2.5 BUILDING ELEMENTS
2.5.1 Plinth protection

All the buildings & sheds shall be provided with minimum 1000 mm wide plinth
protection around the building / shed. Level wise, it shall be 100 mm high above top
of approach road level. In order to avoid accumulation of water outside the
buildings, requirement of surface drains shall be examined on case to case basis
for individual building and provided if necessary.
2.5.2 Finished Floor Level (Plinth FFL)

In general, Plinth FFL of the buildings, sheds shall be determined with respect to
top of approach road or pavement. Unless noted otherwise on the reference

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 28 OF 202
drawings, following schedule shall be adhered to for FFL of various buildings &
sheds.
a) Sub Station Building

> Cable cellar floor - Top level of approach road + 450 mm/or as
specified in Electrical section of NIT
> Transformer bay with pebbles - Top level of approach road + 150 mm /or as
> Single storey substation with trenches - F.G.L. (+) approx. 1000 mm high from top
of road /or as specified in Electrical section
of NIT
b) Transformer bay - Top level of approach road + 150 mm/ or as
c) Vehicle, scooter, cycle shed including - Top level of approach road + 300 mm
fire tender bays, repair shop
d) False floor areas (Control Room) - As specified in the Instrumentation section
of NIT
e) Loading, Unloading bays, platforms - Top level of approach road + 1100 mm
f) Electrical rooms - As specified in the Electrical section of NIT
g) Other Buildings / Shed (Process - Top level of approach road + 450 mm from
Operator’s Cabin) surrounding ground level.
Notes:
a) In case of approaches with different top levels, the highest top level of approach
road / pavement shall be considered.
b) FFL shall be same throughout in a building / shed. Split levels any be
considered in exceptional cases due to ground terrain etc.
c) FFL of external loading / unloading bays / platforms, toilet, pantry, kitchen shall
be 6 – 12 mm lower than that of the building / shed’s FFL to check ingress /
spillage of rainwater.
d) FFL of Warehouses, stores may be kept lower than loading / unloading bays /
platforms where forklifts etc. are used for internal movement of items. Adequate
arrangement for negotiating the level difference shall be provided in that case.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 29 OF 202
e) Where applicable, existing levels of building / sheds shall be followed.
2.5.3 Steps / Ramps
Steps / ramps shall be provided for access to the buildings / sheds for pedestrian
/vehicular movement, equipment entry, etc. Minimum 1500 mm wide platform shall
be provided in between entrance door and steps / ramps. Following dimensions of
the steps / ramps shall be adhered to:
a) Tread : 300 mm minimum

b) Riser : 175 mm maximum
c) Slope of ram : Not steeper than 1:10 slope
d) Ratio of tread & riser : 2 Riser + Tread = 600 to 650 mm
e) Landing width : 1500 mm minimum
f) Flight width : 1500 mm minimum
Edge of treads shall be provided with friction grip strips
2.5.4 Wall
Following schedule shall be adhered to for wall material and thickness
1 Blast Proof/resistant Min 230 mm thk.RCC wall

Wall
2 Rain water duct / shaft Min. 230 mm thk. hollow/ solid concrete block work
3 External walls 230 mm thk. hollow/ solid concrete block work
4 Fire wall 240 thk RCC or 355 mm (including plastering) thick

(Around hollow/ solid concrete block work wall / OR as per
transformers) Electrical requirements. (IER/TAC)
5 Internal partition wall 230 / 115 mm thk. hollow/ solid concrete block work wall
depending on the overall length and height of the wall

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 30 OF 202
(refer notes below)
Notes:
a) 115 mm thick partition walls shall be provided with RCC transoms and mullions
for suitability.
b) Wherever conduits or pipes are required to be concealed within partition wall,
the local wall thickness shall be increased suitably.
2.5.5 Doors
Doors shall be provided for access, security and safety to all rooms, functional
areas in a building. Air tight door shall be provided in pressurized area and in
gaseous protection area. Emergency door shall be opened outwards. Sizes of the
doors shall be determined on the basis of the following schedule:
a) Equipment, Panel area : Maximum size of equipment including packing

b) Other areas : Volume of movement through door
c) Minimum door size at entrance : 1500 mm x 2500 mm (masonry opening size)
d) W.C. bath Cubicle door : 800 mm x 2100 mm (masonry opening size)
e) Minimum size of other doors : 1000 mm x 2100 mm (masonry opening size)
Notes:
a) Entrance doors shall be provided covering full width of the entrance lobby. In
that case the door shall be of composite type consisting of openable shutters &
fixed panels. Entrance lobby shall be provided with elaborate canopy.
b) Rolling shutters min 2500 mm wide shall be provided for equipment entry for
Switchgear room, Electrical room, A.C. Plant room etc. and also wherever size
of opening exceeds 2500 mm x 2500 mm.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 31 OF 202
c) Mechanically operated rolling shutters shall be provided for main equipment

entry opening, and also where opening size exceeds 8 m².
d) Fireproof door shall be with two hours fire rating as per statutory requirements.
e) Blast resistant Control room entry door shall be provided with blast resistant
baffle wall in front of entry door and shall have 45 degree / 90 degree overlap on
both sides as per relevant standard/codes.
2.5.6 Windows / Ventilators
Windows / ventilators shall be provided in all areas for natural lighting, ventilation,
and visibility of working level. For the purpose of ventilation, total openable area of
the windows / ventilators shall be as per Factories Act subject to a minimum of 15%
of the floor area to be ventilated. However, for control room and in office areas, etc.
where visibility from inside is also important, increased window area (as per
discussion with Owner/PMC) shall be provided. Areas accommodating panels /
equipment shall be normally provided with ventilators at high level for uniformity
distributed lighting.
Notes :
a) Requirements of window / ventilation area as stipulated above is for maximum
room height of 4000 mm. For heights more than 4000 mm, additional window /
ventilator shall be provided in the same manner at every work area / platforms
at all levels.
b) Wherever due to limitation of external wall area or other reasons, stipulated
area of window / ventilator cannot be provided, suitable mechanical / electrical
system shall be employed.
c) Fly mesh shutters shall be provided for windows / ventilators in Kitchen, Pantry,
Dining hall etc.
d) Ventilator shall be able to serve as smoke vents in the event of fire.
e) For structures like workshop / warehouse / compressor shed with pre-coated or
G.I. roof sheeting, suitable monitor may be added to provide proper ventilation.
f) Fireproof windows shall be provided as per TAC, electrical, process, etc.
statutory requirements.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 32 OF 202
g) External windows shall have P.C.C. (1:3:6) sills, 100 thk.

h) All glasses in windows & doors shall be toughened glass. Outside glasses shall
be tinted toughened.
2.5.7 Canopy / Overhang
RCC Canopy / Overhangs shall be provided at all entrances for rain / sun
protection, accentuation of the entrances, and pedestrian movement as per the
following schedule:
a) For all offices, control rooms, composite buildings / sheds accommodating

offices, canopy shall be provided at all entrances. Size of the canopy shall be
decided based on vehicle parking & pedestrian movement in addition to
aesthetics of the building / shed. Bottom of canopy shall be minimum 2800 from
top of drive way.
b) Overhangs shall be provided over all exits. Size of the overhang shall be
decided on the aesthetics of the building / shed subjected to minimum of 1000
mm.
Blast proof Control rooms shall not have any projections on outer face of its
walls except with false treatment for aesthetics of the building.
2.5.8 Shading Devices

RCC Shading devices shall be provided over all windows, openable ventilators for
rain & sun protection. These devices shall be in form of horizontal projections,
vertical projected fins or combination of both as per building façade treatment.
Minimum projection shall be 600 mm.
2.5.9 Parapet
Parapets shall be of RCC for all buildings with minimum 500 mm high for non-
approachable roof and 1100 mm high for approachable roof.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 33 OF 202
2.5.10 Roof Gutter
Gutter with rainwater pipes shall be provided for all the buildings / sheds for roof
water drainage. Sizing of the gutter shall be based on areas to be drained and
number of outlets. Gutters shall be of RCC or sheet metal depending on
type of structure.
2.5.11 Rain Water Pipes Spouts
PVC rain water pipes shall be provided for roof water drainage. Number of rain
water pipes shall be decided on the basis of roof area, slope and rainfall intensity as
per NBC-IX, Section-2. Rain water pipes shall be concealed as far as possible.
RCC or GI spouts may be used for drainage of chajja / small canopies of ground
floor. Dia of rain water pipe shall be 150 mm minimum.
2.5.12 Entrance Lobby

Entrance lobby shall be provided as a common entrance for all buildings / sheds
accommodating separate functional spaces integrated together. Individual entries to
such functional spaces shall be from this lobby by means of passages / corridors.
Apart from common entry lobby, separate independent entries to these functional
spaces shall also be provided if functionally required. Size of the entrance lobby
shall be decided on the basis of volume of movement. Air lock lobby shall be
provided for all entries with centrally air-conditioned spaces, and pressurized.
2.5.13 Passage / corridors

Passage / corridors shall be provided to integrate various spaces. Width of the
passage / corridors shall be as per statutory requirement, subject to a minimum
width of 1500 mm.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 34 OF 202
2.5.14 Service Entry

Separate service entry shall be provided for service areas such as kitchen, air-
condition / pressurization plant room, electrical rooms. A common service entry may
be provided depending on spatial arrangement.
2.5.15 Emergency Exits
Emergency exits shall be provided for all the building / sheds as per statutory
requirements. Emergency exits for individual function spaces such as console area,
cable cellar, and switchgear hall shall also be provided. Emergency exits shall be
located in such a manner that escape route is unobstructed & without passing
through any other function areas. Corridors / staircases shall be provided as escape
route.
2.5.16 Staircases
Staircases shall be provided in multi floor buildings for vertical circulation &
emergency exits. Number of staircases shall be based on building / shed sizes,
emergency exit requirements, and travel distances to exit points as per statutory
regulations. More than 500 sq m ground covered area shall have at least two stairs
in line with NBC-Part-IV. Emergency exit requirements shall be as per safety
distance requirement. At least one staircase shall be provided for access to the flat
roof tops for maintenance. Following dimensions for staircases shall be adhered to.
a) Stairs width : 1500 mm minimum, (1000 mm minimum for

emergency exit)
b) Tread : 300 mm minimum
c) Riser : 150 mm maximum
d) Ratio of tread & riser : 2 Riser + Tread = 600 to 650 mm
2.5.17 Railings

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 35 OF 202
Railings shall be provided in roofs, stairs and in all unprotected openings in slabs as
a safety device. Railings in high level loading / unloading bay of substations shall be
of removable type. Parapets shall be given precedence over railings in roofs.
2.5.18 Toilets
Toilets shall be provided for all habitable buildings / sheds. Gents & ladies Toilet,
drinking water enclosure & janitor space, all shall be provided as required. The
fittings / fixtures provided for bath / toilet shall be of luxury / colored type.
2.5.19 Partitions
If required partitions shall be provided for flexible space arrangement in office
spaces, Control room etc. The partitions shall be modular, dismantleable type of
Godrej or approved equivalent make.
2.5.20 False Ceiling

False ceilings shall be provided for following purposes:-
a) To reduce room volume and hide ducting etc. for air conditioned spaces.
b) To maintain acoustic level inside any space.
c) To reduce habitable room, corridor, lobby, toilet heights located in high ceiling
building / shed to a reasonable and satisfactory height of minimum 3000 mm.
d) In fire rated areas where walls and doors are required to be fire rated, false
ceiling shall also have complementing fire rating. It is appreciated that false
ceiling have limitations in their fire performance due to openings in them for
lighting and air conditioning. Therefore alternative systems to prevent puncturing
the ceiling must be employed.
2.5.21 Under deck Insulation

Under deck insulation below RCC roof and over false ceiling (both locations) shall
be provided for air-conditioned office / space.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 36 OF 202
2.5.22 False / Cavity flooring

False / cavity flooring, consisting of cement filled flooring sheets with antistatic
lamination on the top, of approved make / as directed by Engineer in charge, shall
be provided to accommodate under floor cabling in all areas. Extent of false / cavity
flooring shall be as per functional requirements.
False flooring shall be fire rated to the level of fire rating of the walls, doors and
suspended ceiling in the compartment.
Cavity flooring for Control Room buildings, specifications given in Instrumentation
section is to be followed.
2.5.23 Waterproofing on roofs
Waterproofing on non plant buildings’ roofs shall be of Brickbat-coba.
For plant buildings, water proofing shall be as follows:
Water proofing treatment using High solid content, liquid applied Elastomeric
Polyurethane Waterproofing Membrane. The two component Solvent free
Polyurethane coat shall have the following properties -
1. Solid content ASTM D 2369- ≥ 90%
2. Mixing ratio - 8:1
3. Elongation ASTM D 638 - 700-900%
4. Tensile strangth ASTM D 638- 1-2 MPa
The coating shall be applied to a minimum thickness of 600 microns (300µX2)
thickness with separate wearing course ( as per ASTM C 898 & 836) over
application of 2 component, solvent free Epoxy Primer of 200 microns with tensile of
20-30 MPa and elongation of 4-5% for smooth surface and act as primer coat at all
elevations in vertical and horizontal surface etc including labour, material,
equipment handling, preparation of surface, transportation, placing, leveling, curing,
testing, etc complete as per specifications, drawing and instruction of the Engineer
2.5.24 Dash fasteners, if used, shall be of approved make or as directed.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 37 OF 202
3.0 BUILDING STRUCTURE

The layout of the buildings shall be finalized within 3 months after the effective date
of contract.
The design considerations, type of buildings and specifications of various buildings
shall be as generally defined under this clause, unless stated otherwise as per plant
Requirements:
S. No. Building Design Type of Building

Consideration
1 Operators & Rack layout, RCC blast resistance structure
Maintenance/ occupancy as per specifications/ relevant
Control Room standard/codal requirements including
building Hollow /Solid Concrete Block work
infill walls
2 Sub station Equipment layout, RCC frame, hollow/solid concrete
occupancy block work/ masonry infill walls
3 Technological Equipment layout, Structural steel Framed Structure
structures occupancy
4.0 ARCHITECTURAL TRADES (To be finalized in consultation of OWNER/PMC)
All the buildings shall be provided with Architectural finishes such as floor finishes,
plastering & painting on walls & ceilings, doors / windows / ventilators, roof
treatment, plinth protection, etc. pertaining to approved make/brand and best quality
for industrial usage.
4.1 EXTERNAL FINISHES (To be finalized in consultation of OWNER/PMC)
4.1.1 External Wall

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 38 OF 202
a) Substation Room, Operator & Maintenance building - Cement Based water

proof paint of approved Quality.
b) Control Room – Sand Stone Cladding
4.2 INTERNAL FINISHES (To be finalized in consultation of OWNER/PMC)

4.2.1 Floor Finishes
a) Office area, & Sub station
Vitrified tiles in glazed or matt finish / Marbo-granite tiles
b) Toilet, Drinking Water area
Granite flooring
c) Circulation area (Corridor / Passage etc. except Entrance Lobby) of Substation
& Control room - Kota stone flooring
d) Switch Gear, Cable Cellar, A.C. Plant Room, storage area
Switch gear Room for substation will have Kota Stone Flooring. Rest of the
buildings wil has heavy Duty Decorative Ceramic Tiles. / Hardcrete Floor, as
directed by E.I.C
e) Battery Room
Acid resistant epoxy coating over IPS-flooring & 2100 high dado.
f) Entrance lobby, corridor lobby of main building- granite flooring
Note:
Skirting shall be provided in all areas, which shall be of same material as that of
flooring. Glass strip panel shall be provided in cement concrete flooring.
4.2.2 Internal Wall Finishes

a) Entrance lobby, Corridor lobby:
Granite stone cladding and plastic emulsion paint.
b) Office areas of Buildings:
Cement plaster, POP punning & plastic emulsion paint

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 39 OF 202
c) Circulation areas (Corridor / Passage etc. excepting Entrance lobby) of

Buildings
d) Rack Room, Office Rooms, Operators Room
e) Switchgear Room / Electrical Room
Cement plaster & Plastic Emulsion paint (Switchgear Room)
f) Battery Room
Acid resistant epoxy coating over cement plaster up to 2100 height. Plastic
emulsion paint above 2100 height.
g) Toilet, Drinking water area
Granite stone cladding / Marble / Ceramic tiles (up to lintel level)as directed by
E.I.C
4.2.3 Internal Ceiling Finishes

a) Toilet Electric Operator, Rack room, MCC panel room, UPS
As described in Instrumentation and Electrical specifications
b) Other areas which do not have false ceiling
Cement plaster & white / color wash, plastic emulsion paint etc., as in the case
of wall finish.
4.3 DOORS, WINDOWS & VENTILATORS
4.3.1 DOORS
All frame works shall be in Sal/chap wood in size 125 x 65 mm.
a) All doors in Toilet / WC / Bath

35 mm flush door laminated with 01mm laminate from both sides.
b) All doors of Electrical Room, A.C. Plant Room, Battery Room
Pressed steel frame with pressed steel shutter (or as specified in Electrical
section).
c) Inside Control Room

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 40 OF 202
Fire check door with 2 hours rating as required in perfect partition wall
separating various fire zones (or as specified in Instrumentation section)
d) All other door of Control Room / Satellite Rack Room / Sub station
Glazed, powder coated Aluminum door with decorative etching (or as specified
in Instrumentation section).
4.3.2 WINDOWS & VENTILATORS

a) Windows / ventilators
Glazed, powder coated aluminum window / ventilator.
4.4 SANITARY FITTINGS (Make: Jaquar/Cera/Hindware/Perryware or equivalent)

a) Water Closet for Control Room
Wall hung type colored European designer type WC.
b) Water Closet for Sub Station.
Pedestal type white European designer type W.
c) Water Closet (Indian).
Orissa type (Indian) pan white WC.
d) Wash basins for Control Room.
Round wash basin white / colored housed in granite counter with electronic
sensors for water control, approved quality mirror. Front portion below the
counter shall be covered with shutters of laminated boards.
e) Wash basins for Sub Station / Satellite Control Room.
Wall hung wash basin with pedestal.
f) Plumbing fixtures.
Stainless steel bib cock, stop cock etc. fittings.
5.0 MISCELLANEOUS
5.1 ARCHITECHTURAL DRAWING

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 41 OF 202
5.1.1 Plant datum shall always be 100.00 meters and its correspondence to the reduced
level with respect to the mean sea level shall be indicated in the “NOTES” (Unless it
is already established).
5.1.2 Location co-ordinates shall be indicated on grids.
5.1.3 Reference drawings, notes, holds list, schedule of finishes including painting, door
and window schedules, area statement, notes on plastering, key plan, were
necessary, shall appear in the first drawing sheet of a building. Subsequent sheets
can cover them by a reference to the first sheet.
5.1.4 Elevations shall show siography to highlight features, human figures for scale,
automobiles for headroom, trees and foliage for appearance.
5.1.5 False ceiling area shall be shown by hatching suitably.
5.1.6 False flooring area shall be shown by hatching suitably.
5.1.7 Air-conditioned rooms shall be identified suitably.
5.2 DESIGN
5.2.1 Entrances shall be elaborate and well sheltered to accommodate pedestrians and
vehicles.
5.2.2 Provision for future extension, vertical and horizontal shall reflect in the work.
5.2.3 Toilet, kitchen and pantry floors with waterproofing and sloped for drainage. The
finished floor level shall be 25 mm below the general finished floor level. Tile drops
shall be indicated were required. For example from general floor to toilet floor, toilet
floor to WC / Shower floor, general floor to pantry, general floor to entrance
platforms and so on.
5.2.4 Plumbing works, external drainage, schematic, flow, shall be indicated.


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 42 OF 202
5.2.5 Water tanks, AC plant, cooling tower, Chiller units etc., where required, shall be
located on building roof as far as possible and it shall be positioned and supported
to transfer its load on to beams and columns and not to the slab. Such facilities
should not be visible from outside. Suitable side cladding shall be provided for this
purpose.
5.2.6 Access to all roofs via steel ladder. In case of accessible roofs at least one
staircase shall go up to the roof.
5.2.7 Plinth beams level shall clear trenches if any.
5.2.8 Vertical ducts for running services must be examined.
5.2.9 Ventilator arrangement shall be provided unless situations strongly prevent or make
it unnecessary. In addition to ventilation requirements, ventilators shall have the
capacity to vent smoke in the event of fire.
5.2.10 Layout shall take into account the type of air-conditioning and built-in provisions
shall be made to accommodate the equipment.
5.2.11 Walls on steel beams shall be constructed after wall below and up to the steel beam
is constructed. This shall appear in the ‘Notes’ if applicable.
5.2.12 Gaps in floor cut outs shall be sealed with fireproof material for fire safety.
5.2.13 Openings in wall / cladding for pipes and cables from pipe rack / trays shall be
made water tight primarily by means of design features.
5.3.1 All free edges of chajjas and slab projections shall have drip mould in plaster 50
mm wide and 20 mm drop, unless the need is resolved in some other manner.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 43 OF 202
5.3.2 Floor slab in WC areas shall be sunk by 500 mm and toilet, pantry, kitchen floor
slabs shall be sunk by 200 mm at all levels (including terrace, where future
extension is envisaged).
5.3.3 All partition walls within toilet kitchen areas shall be 115 mm thick and 2200 mm
high.
5.3.4 All supporting framework members of partition walls within false ceiling areas shall
go up to roof level, partitions shall go up to false ceiling level except where there are
fire compartment wall where it shall be from floor to ceiling.
5.3.5 All windows and ventilators opening periphery shall have granite embedded in
cement mortar 1:3.
5.3.6 Preferably all cut out in slab shall be provided with 200 high kerb.
5.3.7 Groove in plaster, 20 wide x 10 deep shall be provided aesthetically to break

extensive areas of plaster.
5.3.8 Flooring shall be done in panels, preferably in 3000X3000 size with expansion joints
provided at 25000 c/c.
5.3.9 Flooring contraction joint shall be provided as per design.
5.3.10 Parapet walls shall be at least 1100 mm high.
5.3.11 Roofs of RCC buildings should have mild slope towards rain water gutters.
5.3.12 All Instrument / Electrical cables at the junction of the building (outside) shall be
covered with pre-cast RCC slab. Sleeve pipes should be provided for the cable in
the masonry wall including its sealing.
5.3.13 All new buildings shall be having provision of one additional storey in design for
vertical extension in future.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 44 OF 202
ANNEXURE II
DESIGN PHILOSOPHY – GENERAL CIVIL & DESIGN BASIS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 45 OF 202
TABLE OF CONTENTS
1.0 GENERAL
1.1 SCOPE
1.3 DEFINITIONS
2.0 DESIGN CRITERIA – GENERAL
2.1 SURFACE TREATMENT
2.2 ROADS
2.3 CONCRETE PAVING (WITHIN PLANT AREAS)
2.5 STORM WATER DRAINAGE
2.6 WATER SUPPLY
2.7 SANITARY SEWERS
2.8 CONTAMINATED RAIN WATER SEWERS
2.9 OTHER PROCESS DRAINS
2.10 STORAGE TANK FOUNDATION AND DYKE WALLS
2.11 BARRICADE
2.12 TRENCHES
2.13 HARD SURFACES
3.1 REMOVAL / REROUTING OF CONSTRUCTIONS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 46 OF 202
1.0 GENERAL
1.1 SCOPE
This engineering design basis defines the design criteria that shall form the basis
for carrying out design and engineering of items under general civil, viz. roads,
paving, drainage, etc.
1.2 UNITS OF MEASURMENTS
Units of measurement in design shall be metric system.
1.3 DEFINITIONS
Owner Talcher Fertlizer Limited (TFL)
Consultant To be selected
LSTK Contractor Successful bidder of the tender
IS Indian Standards

practices and shall conform to the statutory regulations applicable to the country.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 47 OF 202
1.4.1 The main codes, standards and statutory regulations considered as minimum
requirements are as follows. Latest revision of these shall be followed.
IS: 456 Code of practice for plain and reinforced concrete

IS: 800 Code of practice for general construction in steel
IS: 875 Code of practice for design loads (Other than earthquake for
buildings &
Structures
IS: 1172 Code of basic requirements for water supply, drainage & sanitation
IS: 1742 Code of practice for building drainage
IS: 1905 Code of practice for structural use of unreinforced masonry
IS: 2065 Code of practice for water supply in buildings

IS: 2212 Code of practice for brick work
IS: 8835 Guidelines for design of surface drains.
IRC: 6 Code of practice for road bridges, Section-II Loads and stresses
IRC: 19 Standard Specifications and Code of Practice for Water Bound
Macadam
IRC: 37 Design of flexible pavements
IRC: 58 Design of rigid pavements
Factory Rules for State
Note: The above list is suggestive and not exhaustive. Apart from these basic
codes
any other related codes shall be followed wherever required.
1.4.2 In case of any conflict / deviations amongst various documents, the order of
precedence shall as follows –

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 48 OF 202
- Job specifications
- Engineering design basis
- Standard specification
2.0 DESIGN CRITERIA –GENERAL
2.1 SITE GRADING
2.1.1 The work area shall be cleared and stripped completely of all bushes, roots, trees,
Shrubs and other vegetation, organic matter and other objectionable materials. All
these should be completely uprooted and removed, and not merely scraped at the
surface.
2.1.2 The grading of the area, if required, shall be done by cutting and filling with the
following:
a. Cutting Area : Thoroughly rolled and compacted.

b. Filling Area : Compacted in layers not exceeding 20cm to
Achieve minimum 95% of maximum dry density.
2.1.3 Site grading philosophy shall be based on following:
FFL of the adjacent paved area is ........m above Mean Sea Level (To be
decided later).
However, levels like Finished Ground Levels (FGL) and Highest Point of Paving
(HPP) shall be finalised by the CONTRACTOR, in consultation with OWNER /
PMC, based on contour survey of the Unit, levels of adjacent units and levels of
adjacent Roads.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 49 OF 202
2.1.4 Slope in Graded Areas
a. General Site Grading 1 in 500 to 1 in 1000

b. Micro grading, after completion of
major construction (for road corridors) 1 in 200
c. Tanks Farms 1 in 200 to 1 in 300
2.2 ROADS
Contractor shall design cross section of roads, including roads for crane access, as
per IRC 37. However, the minimum section to be adopted shall be as given in
clause 2.2.7 Ruling gradient shall not exceed 1 in 20. If existing roads are to be
used for erection purposes, the same should be strengthened to cater for erection
loads. It should be ensured that use of existing roads does not hinder normal
activities in existing plants.
2.2.1 ROAD WIDTH
Category Width* Carriageway Width

I. Road around unit and its 12.5 10.5 m (three lane road or width to suit
Primary access m crane type)
ii. Roads for high lifts crane 2.0 3 m + outer width of crawlers of required
m+ Capacity crane.
c.w.
width
iii. Plant approach road 9. 0m 7.0 m (two lane)
iv. Roads around tank farm 7.5 m 5.5 m
v. Patrolling roads (along 6.0 m 4.0 m
boundary wall)
vi. Access to building 5.5 m 3.5 m

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 50 OF 202
vii. Foot path 1.0 m …….
* Width of the road to be finalised as per site condition in consultation with client /
PMC.
2.2.2 Camber 1 in 50
2.2.3 Radius of curve: 12 m for 8 m wide carriage way roads, 8 m for 5.5 m wide
Carriage way width & 15 m for roads of higher carriageway width.
2.2.4 Pavement Type: Concrete pavement at all roads to be used for crane movement
(Requirement of crane movement route and its specification to be finalised in
consultation with client /PMC)
2.2.5 Extents: As per Plot Plan / Equipment Layout drawing / scope drawing.
2.2.6 Clearance: Minimum 9.0 m to underside of pipe racks or Refer Design basis –
Piping.
2.2.7 Minimum Cross Section
i. Sub base: The sub base shall be 300 mm layer of crushed / broken size
stones on well compacted earth or approved fill.
ii. Base course: The base course shall be 225 mm stone size thick water
bound Macadam consisting of 3 layers of 75 mm each.
iii. Bituminous wearing course / RCC: The wearing course shall be 75 mm thick
for roads with crane duty and 50 mm thick for roads without crane duty.
However, roads for crane movement, concrete pavements shall be provided.
2.2.8 Crossings

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 51 OF 202
a. Pipe Ways under roads & rails RCC Box Culverts

b. Storm Water Culverts Under road / rail. RCC Box Culverts
c. Electric / Instruments Cable RCC duct bank with PVC Pipe
Class – 1 (IS 4985)
2.2.9 Finished Road Top Levels Above FGL
When box culverts for pipe ways 1.05 m (minimum)

are provided
Ways are provided 1.6 m at box culvert location with a slope from 1.05 m to 1.6
m above FGL
When overhead bridges are 1.05 m around hazardous units
Provided for pipe ways 0.40 m to 0.60 m for others areas
Other areas 0.40 m to 0.60 m
2.3 CONCRETE PAVING (WITHIN PLANT AREAS)
2.3.1 General
RCC paving to be done for entire battery limit and extend up to the adjacent roads
around the unit. The contractor’s scope is limited to all round the peripherical roads.
Heavy duty paving shall be designed for heavy vehicular traffic movement as per
IRC Loading.
Concrete paving shall be laid in cast-in-situ panels of 3.0 meter X 3.0 meter size,
with expansion joints spaced approximately 15.0 m c/c, each panel being cast in a
single pour.
Hard stands should be designed and provided by contractor, based on required

crane capacity, here called for by Owner, the same shall be demolished after
erection, and surface made good.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 52 OF 202
Provision of trenches, drains, sealing of trench covers, inserts, thickening for pipe /
equipment supports etc. shall be made while construction pavements, as detailed in
drawings.
Acid / alkali / chemical resistant coating as required shall be applied in areas where
such corrosive materials are likely to come in contact with concrete.
Suitable drainage arrangements will be provided within curbed areas around

pumps, for drainage leaks. Similarly, suitable drainage arrangement shall be
provided at streaming points also.
2.3.2 Joints
Expansion joint of 20 mm shall consist of 20 thick impregnated fibre boards. Filled
at top with joint sealing compound 20 x 25.
Equipment / column pedestals will be separated from paving with 20 thick sand fill
and Sealing compound 20 x 25.
Contraction joints will be sealed by sealing compound 10 x 40.
2.3.3 Slope: 1 in 100 (minimum)
2.3.4 Minimum requirements of paving in various areas
a. Paving within Process & Utility : Type – 1 (200 mm thk. RCC)

areas for maintenance compatible
to crane movements / dropout
/ Loading / Unloading areas /
Vehicular movement areas
b. Non vehicular movement areas

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 53 OF 202
i. Unit : Type –II (150 mm thick RCC)

II. Offsite pump station : Type –II (100 mm thick RCC)
II. Bullet Area : Type –II (100 mm thick RCC)
II. Utilities : Type –II (150 mm thick RCC)
c. Pipe rack : PCC 1:3:6 (100 mm thick)
Paving and trenches including covers in process units shall be suitable for Hydra
crane movement. Where movement of bigger cranes for maintenance is envisage
paving and trenches including covers shall be designed for the loads arising from
the same.

The surface treatment for the various areas shall be provided as enumerated in the
table below.
AREA RCC PAVING ASPHALT 50 thick PCC GRAVEL 100 THK ACID /
PAVING 1:3:6 ON 115 PCC 1:3:6 ALKALI
thick brick PROOF
soling COATING
Operating
Areas of
Process units
X
(including
(Type I /II
Roads for
Paving as per
crane
cl. 2.3.4)
movement)
Around
Transformers
In substation
Roads
(excluding
X
roads having
crane

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 54 OF 202
movement )
Approaches to
X
units
Tank farms X
Acid / alkali /
storage / X
handling area
Parking X
Hardstands X
Pathways X
Pipe ways X
‘ X ’ Indicating applicable option
Notes:
1. Existing services where interfering with the new construction should be located and rerouted
as instructed by Owner / Consultant.
2. Micro-grading shall be carried out by the Contractor over graded areas to bring the FGL
to indicated levels including provision of required slopes and finishes.
2.5 STORM WATER DRAINAGE

2.5.1 Storm water drains shall be sized for the higher discharge arising out of either rain
water or fire fighting water.
2.5.2 Rain water run-off shall be computed by the formula:-
Q = KIA / 360
K is run-off coefficient given below.
A is area (hectares) contributing to the drain
I is rain fall intensity (mm / hr.)
Q is the discharge.
2.5.3 Design of drains shall be based on Manning’s formula:-

V=R 2/3 S 1/2 / n
V is velocity of flow m/s,
R is hydraulic radius,
S is slope,
n is roughness coefficient taken as 0.013 for plaster surface, 0.015 for cast-in-situ
concrete, 0.017 for brick lined.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 55 OF 202
The following parameters are to be ensured to be within limits specified while sizing
Minimum velocity of drains : 0.6 m/s

Maximum velocity of drains : 2.4 m/s
Minimum depth of drains : 300 mm
Minimum width of rectangular drains : 300mm (for depth<500mm)
Minimum width of drains : 500 mm (depth > 500mm)
Run off coefficient ‘K’
a. paved area concrete - 1.0

Bituminous - 0.9
b. unpaved areas - 0.7
c. unusable areas like Green belt - 0.4
2.5.4 Drains within Process Units
Rain water falling on such portion of paved areas of process unit where it is not
likely to get contaminated, shall be collected in open rectangular RCC drains. These
drains shall be covered by gratings, and shall be generally connected to periphery
drains, which at battery limit shall have a double valve chamber. This will permit
discharging the rain water either to storm water network, or to the battery limit
CRWS manhole. Drains shall be designed for the maximum of rainwater / firewater
on same principles as storm water drains.
2.5.5 Culverts and Road/Rail Crossings

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 56 OF 202
Road / Rail and storm water drain crossing shall by RCC box culverts, designed for
the Relevant IRC loads for roads, and track loads for rail. The relevant lateral loads
due to wheel / track loads on the soil adjacent to wall on crossing shall be
considered on the walls. Approval from the rail authorities on culvert design shall be
in the scope of LSTK contractor.
Drain to adjacent to roads / pavement where heavy crane movement is anticipated

shall be Concrete drains, designed to resist the lateral thrust due to wheel loads.
Pipe culverts, if instructed to use by Owner/PMC, shall comprise of R.C.C. pipes

(class NP-3, IS: 458) under roads; and R.C.C. pipes (class NP-4, IS: 458) under rail
lines.
2.5.6 Tank Farm Drainage
Tank farm drainage system should be provided in such a way that the storm water
discharge shall be either sent to storm water open ditch or to the oily water sewer
by providing valve pit outside the dyke wall depending on its contamination.
2.5.7 Disposal of Storm Water

Storm water drains shall not be combined with oily waste sewer / CRWS/combined
sewer system, etc. For disposal of storm water references shall be made to the
‘scope’ document.
2.5.8 Oil Catcher

An oil catcher with baffle wall type arrangement shall be provided a storm water
ditch before it leaves the battery limit of the unit, & tank farm.
2.6 WATER SUPPLY

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 57 OF 202
Existing drinking water piping shall be extended to new facilities. Adequacy of

header branch line etc. shall be ensured; else additional lines shall be run.
2.7 SANITARY SEWERS
2.7.1 General
Sanitary sewerage will not be combined with storm water.

Building drainage shall be designed as a dual pipe system with separate soil &
waste pipe.
Sewers shall be designed for discharging 3 times average flow flowing half full in
case of lateral sewer, and flowing 2/3 full in case of Main sewer. The minimum and
maximum clearing velocities shall be 0.75 m/s and velocity 2.4 m/s respectively.
Velocity shall be calculated by Manning’s formula with n=0.015
Minimum pipe size shall be 100 mm and all pipes shall preferably be salt glazed
stoneware unless abnormal soil conditions or high velocity dictates otherwise.
2.7.2 Sanitary sewer shall be led into the sewerage system leading to waste water
treatment plant (WWTP). Where system is not available, septic tank/soak pit shall
be provided.
2.7.3 Cover for Sewer Line shall be minimum 600 mm.
Under road, sewer shall be protected by concrete encasement or minimum cushion

shall be 1200 mm.
Under railway, the sewer shall be protected as per railway standards.
2.7.4 Material of Construction

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 58 OF 202
a. Material of Construction for Manholes shall R.C.C. M30.

b. Material of Construction for Sewer
Sanitary Sewer
i. Toilet block to inspection - CI pipes as per IS: 3486/1729)
chamber or UPVC, as directed.
ii. Gravity main & lateral - Salt glazed stoneware / C.I./ R.C.C. Class
P1 (as per IS:458)
iii. Pressure main - C.I. pipes (as per IS: 1536 an IS: 1537)
iv. Offsite Pumping, if any - CPVC pipes/GI as per PMS J2A(as directed )
v. Manholes - R.C.C. M30
2.8 CONTAMINATED RAIN WATER SEWERS
2.8.1 Process Unit
Contaminated rain water / floor wash / fine water shall be collected through catch
basins located in the contaminated areas of the process unit and shall be send to
the oil catcher / CRWS pit / CRWS header. The continuously contaminated area of
all pumps shall be segregated by kerb wall; discharge from such kerbed areas shall
be collected in OWS network and not in CRWS network.
CRWS shall be designed for contaminated water due to rain water or Fire water,
whichever is more.
The quantities of contaminated rain water shall be worked out based on the
contaminated process area in the unit block.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 59 OF 202
Sewer shall be sized flowing full with peak flows taking future requirements or 2/3
full without future requirements.
CRWS manholes shall be R.C.C. (M30) construction. For trapping of gas or

prevention of spread of fire through CRWS from one area to another, a liquid seal
of minimum 150 mm shall be provided in manhole along with suitable vents.
Location of sealed manholes should be decided accordingly. The vents on the
manholes should extend minimum 2.0 m above the pipe rack or 1.0 m above
buildings, or if in open areas extending min 3.0 m above FGL with frame arresters.
CRW sewers in process units and tankage areas shall be of mild steel /Carbon
steel conforming to IS: 3589
2.8.2 Tank Farm Area
Tank farm areas, not containing tanks for corrosive materials, shall be drained by
surface drains. Waste water shall be led to a sand trap and then to a valve chamber
which shall either drain the water to storm water drain or oily water drain. Waste
water from tank farm areas containing corrosive / hazardous materials shall be
drained by chemical sewers to neutralization tank / ETP.
2.9 OTHER PROCESS DRAINS
Other process drains shall be oily water sewers, closed blow down sewers or
chemical Sewers. Sizing, layout, material specification, corrosion protection etc will
be as per u/g piping design Basis.
Oily water sewer convey water contaminated with oil, e.g. from reflux drums,
separators, Cooling / quench water for compressor / pump, process wash water,
floor and paving Drains in oily areas etc. These are conveyed either to WWTP or oil
separator by means Of U/G steel pipes through sealed manholes.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 60 OF 202
Blow down are liquid streams containing water / oil / chemicals that are required to
be drained from process equipment under different operating situations like start-
up, shutdown etc. Blow down systems are closed piped systems in which streams
are collected in underground blow down drums and then pumped to respective slop
/ field tanks.
Chemical sewers carry effluents containing chemicals which require separate

treatment from oily water streams. These are generally corrosive and require pipe
of materials resistant to corrosion or lined pipes.
Closed blow down sewers shall be closed piping systems as shown in piping
drawings. These will lead to underground blow down drum / drums which shall be
protected by a concrete pit as detailed in drawings. Before entering the blow down
drum, a valve chamber shall be provided for the sewer .Sewer cleanouts will be
provided at start / end charges in direction and at 45 m intervals on straight length.
Other aqueous blow downs within process areas will be collected by funnels and
routed through oily water sewers to sealed manholes. A common oily water header
will route these streams to the plant oily water sewer network leading to waste
water treatment plant.
Small neutralization pits hall be provided near battery rooms to treat floor wash in
battery rooms. Water from these pits will further be routed to storm water drains.
Dyked areas around emergency booths shall drain into a gully trap which shall be
connected to the chemical sewer network.
Oily water & contaminated rain water catch pits / manholes shall be of reinforced
concrete to the chemical sewer network with internal coal tar epoxy lining.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 61 OF 202
Manhole for acid / alkali sewer shall be of reinforced concrete (M30). Exposed steel
work shall be provided with coal tar epoxy coating.
2.10 STORAGE TANK FOUNDATION AND DYKE WALLS
2.10.1 The storage tank foundations shall be designed to sustain the forces at the tank
bottom within permissible settlement, under operating and hydro-test conditions.
Tanks less than 2.5m dia. may rest directly on a concrete pedestal with anti
corrosive layer.
Tanks greater than 2.5m dia. but less than 10.0 m dia. may be supported on RCC
ring Wall with sand / murrum fill.
For tanks greater than 10m dia, Tank Pad Foundations shall be provided as per
relevant design Codes.
2.10.2 Anticorrosive layer shall be provided as per specifications for tank pads of 50 thick
premix Carpet over 50 thick bitumen sand mixed with additions of kerosene / oil as
required.
2.10.3 Storage tank Dyke Walls / Fire Walls

Dyke walls / Fire walls shall be provided. Walls shall be plastered brick work
conforming to standard relevant Codes. DYKE walls shall be designed for retaining
liquid in case of rupture of the largest tank in the farm. It shall be minimum 600mm
thick to enable persons to walk on the wall top. If space permits, Dyke walls shall be
provided with ramps on both sides at suitable places, for movement of vehicles for
tank cleaning purpose. Fire walls shall only be 600 mm high (min.) or as shown in
drawings / as instructed. They shall only retain spillages, to prevent fire spread.
2.11 BARRICADE

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 62 OF 202
Contractor shall design a suitable barricading system for protection of existing

facilities if required. Barricade shall be of G.I. sheet cladding with suitable
supporting system of height and extent shown in drawings or as instructed by
Owner / Consultant. Water spray system shall be incorporated where felt necessary
by Owner / Consultant. Localized G.I. sheet barricading shall be provided from
operational constraint requirements as directed by Owner / consultant.
2.12 TRENCHES
Trenches shall be of RCC with inserts or other suitable arrangement required to

support Cables pipes etc. Pre-cast concrete covers with lifting arrangement shall be
provided on top. In paved areas, the top will be flush with finished floor level.
Covers shall overlap walls and joints with paving shall be sealed to prevent water
entry. In unpaved areas, walls shall be raised above ground level by 100 mm.
Trench floors shall be provided with a nominal slope to drain pits, where any water
entering trenches can collect and be detained to the nearest contaminated rain
water sewer / storm water sewer. Trench covers shall be designed for the vehicle
load relevant to the area where the trench is located. Cable trench shall be of leak
proof construction.
2.13 HARD SURFACES
Hard surface of PCC 1:3:6, (100 mm thick) over suitable bedding (brick / stone
soling) Shall be provided below all new pipe tracks and / or extended potion of
existing pipe Tracks(if any). This shall extend 600 mm on one side for track width
less than 6 m, and 900mm On either side for pipe track having width 6 m or more,
end it shall have approach @ 500 M c/c from nearest road.
Hard surface of PCC 1:3:6 (100 mm thick) over suitable bedding (brick / stone
soling) of approximate size 1 m x 1 m shall be provided with proper approach near
drain point of offsite piping, near drinking water installations, at washing facilities,

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 63 OF 202
etc., with suitable curbing and drainage arrangements as required for the fluid being
handled.
2.14 REMOVAL / REROUTING OF OBSTRUCTIONS
All underground or above ground structures / foundations which will cause

obstruction to new structures / foundations, and which can be removed without
disturbing any functions of the existing structures if any, shall be removed by the
Contractor.
All existing underground or above ground facilities requiring rerouting due to fouling
with new facilities shall be rerouted by the Contractor in such a manner that
rerouted facilities keep on functioning as before.
NOTE:
Before finalizing the route connection to existing system, adequacies of existing

system shall be checked by the contactor.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 64 OF 202
ANNEXURE- III
CIVIL ENGINEERING DESIGN BASIS
(STRUCTURAL)

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 65 OF 202
TABLE OF CONTENTS
1.0 GENERAL
1.1 SCOPE
1.3 DEFINITIONS
2.0 MATERIALS OF CONSTRUCTION
3.0 DESIGN LOADS

3.1 DEAD LOADS
3.2 EQUIPMENT LOADS
3.3 LIVE LOADS
3.4 WIND LOADS
3.5 SEISMIC LOADS
3.6 IMPACT & VIBRATORY LOADS
3.7 BLAST FORCES
3.8 CONTINGENCY LOADS
3.9 MISCELLANEOUS LOADS
3.10 LOAD COMBINATIONS
4.0 DESIGN CRITERIA FOR FOUNDATIONS

4.1 GENERAL
4.2 TYPES OF FOUNDATIONS
4.3 SHALLOW FOUNDATIONS
4.4 PILED FOUNDATIONS
4.5 MACHINE FOUNDATIONS
4.6 CONCRETE GRADE
4.7 FOUNDATION BOLTS
4.8 PEDESTAL HEIGHTS
4.9 GROUTING
5.0 DESIGN CRITERIA FOR REINFORCED CONCRETE
STRUCTURES
25.1 GENERAL
5.2 LIQUID RETAINING R.C.C. STRUCTURES AND BASEMENTS
5.3 STAIRCASE
5.4 CONCRETE GRADE
5.5 REINFORCEMENT BARS
5.6 MINIMUM THICKNESS OF STRUCTURAL CONCRETE ELEMENTS
5.7 MINIMUM COVER TO REINFORCEMENT
5.8 EXPANSION JOINT
5.9 DEFLECTIONS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 66 OF 202
5.10 MISCELLANEOUS APPLICATIONS
6.0 DESIGN CRITERIA FOR STEEL STRUCTURES

6.1 GENERAL / DESIGN METHOD
6.2 EXPANSION JOINTS
6.3 STEEL GRADE
6.4 FIRE PROOFING OF STEEL STRUCTURES
6.5 LIMITING PERMISSIBLE STRESSES
6.6 LIMITING DEFLECTION
6.7 MINIMUM THICKNESS
6.8 ELECTRICAL SWTCHYARD STRUCTURES AND TRANSMISSION
TOWERS
6.9 PAINTING
6.10 GROUTING
6.11 CLADDING / RAINWATER FUTTERS
7.0 CRITERIA FOR MASONRY WORKS

7.1 GENERAL
7.2 CEMENT MORTAR
7.3 FIRE WALLS
8.0 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS

8.1 PIPERACK
8.2 RCC AND STEEL CHIMNEYS
8.3 CULVERTS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 67 OF 202
1.0 GENERAL
1.1 SCOPE
This engineering design basis defines the minimum design criteria that shall form
the basis for carrying out detailed structural design and engineering of all plant
and non-plant structures and buildings. All data required in this regard shall be
taken into consideration for acceptable, satisfactory and trouble-free engineering of
the structures.
Compliance with this design basis and / or review of any of the contractor
documents shall in no case relieve the contractor at the contractual obligations. All
structures shall be designed for the satisfactory performance of the functions for
which they are being constructed.
Units of measurement in design shall be in metric system.
1.3 DEFINITIONS
Owner Talcher Fertilizer Limited (TFL)
Consultant Projects & Development India Limited (PDIL
LSTK Contractor Successful LSTK bidder of the tender

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 68 OF 202
IS Indian Standards

practices and shall conform to the statutory regulations applicable to the country.
1.4.1 The main codes and standards and statutory regulations considered as minimum
requirements are as follows Latest revision of these shall be followed.
1) National Building Code of India : 2005

2) IS: 875 (Part 1) – Code of Practice for Design Loads (Other than Earthquake)
for Buildings and Structures (Part 1 – Dead Loads).
3) IS: 875 (Part 2) - Code of Practice for Design Loads (Other than Earthquake)
for Buildings and Structures (Part 2 – Imposed Loads).
4) IS: 875 (Part 3) - Code of Practice for Design Loads (Other than Earthquake)
for Buildings and Structures (Part 3 – Wind Loads).
5) IS: 1893 (Part 1):2002 –Criteria for Earthquake Resistant Design of Structures
(Part 1 – General Provisions and Building).
6) IS: 1893 (Part 4):2005 –Criteria for Earthquake Resistant Design of Structures
(Part 4 – Industrial Structures including Stack-Like Structures).
1.4.2 STRUCTURAL STEEL
1) IS: 800 – Code of Practice for General Construction in Steel

2) IS: 802 – Code of Practice for use of structural steel in overhead transmission
line towers.
3) IS: 1161 – Code of Practice for Circular hollow sections/pipes.
4) IS: 4923 – RHS & SHS sections.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 69 OF 202
5) IS: 2629 – Recommended practice for hot dipped galvanizing on iron and
steel.
6) IS: 2633 – Methods for testing uniformity of coating of zinc coated articles.
7) IS: 6533 – Code of Practice for design and construction of steel chimney.
8) IS: 6745 – Method for Determination of mass of zinc coating.
9) IS: 814 – Covered Electrodes for manual metal arc welding of Carbon and
carbon manganese steel.
10) IS: 816 – Code of Practice for use of Metal arc welding for General
Construction in mild steel.
11) SP-06 – (Part 1 to Part 7)- Handbook for Structural Engineers.
1.4.3 REINFORCED CONCRETE AND MASONRY WORK
1) IS: 456 – Plain and Reinforced Concrete – Code of Practice

2) SP:16 - Design Aids for Reinforced Concrete to IS: 456
3) SP: 34 – Handbook of Concrete Reinforcement and Detailing.
4) SP:24 – Explanatory Handbook on Indian Standard Code of Practice for Plain
and Reinforced
5) SP: 20(S & T) – Explanatory Handbook on Masonry Design and Construction.
6) IS: 2911 (Part 1 to Part 4) – Code of Practice for Design and Construction of
Pile Foundation.
7) IS: 2950 (Part 1) – Code of Practice for design and construction of Raft
foundation.
8) IS: 2974 (Part 1 to Part 5) – Code of Practice for design and construction of
Pile Foundations.
9) IS: 3370 - Code of Practice for Concrete Structures for storage of liquids.
10) IS:4326 – Code of Practice for earthquake resistant design & construction of
buildings
11) IS: 13920 – Code of Practice for ductile detailing of reinforced concrete
structures subjected to seismic forces.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 70 OF 202
12) IS:1172 - Code of basic requirements for water supply, drainage & sanitation
13) IS:1742 - Code of practice for building drainage
14) IS:1905 - Code of practice for structural use of unreinforced masonry
15) IS: 2212 - Code of practice for brick work
1.4.4 ROADS AND SANITARY WORKS

1) IS: 2065 - Code of practice for water supply in buildings
2) IS: 8835 - Guidelines for design of surface drains.
3) IRC: 6 - Code of practice for road bridges, Section-II Loads and stresses
4) IRC: 19 - Standard Specifications And Code of Practice for Water Bound
Macadam
5) IRC: 37 - Design of flexible pavements
6) IRC: 58 - Design of rigid pavements
Note: The above list is suggestive and not exhaustive. Apart from these basic
codes any other related codes shall also be followed wherever required.
In case of any difference between Codes provision and this design basis, the
stringent one should govern the design.
1.4.5 In case of any conflict / deviations amongst various documents, the order of
precedence shall be as follows.
- Statutory Regulations
- Job Specifications
- Engineering Design Basis
- Standard Specifications

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 71 OF 202
2.0 MATERIALS OF CONSTRUCTION
Type of Structure Materials of Construction
Piperacks Structural Steel (unless required

otherwise from process requirement or
operation considerations)
Technological Structures/Platforms -do-

Shed type structures (e.g. compressor -do-
shed, Pump shed)
Opening Platforms in steel structures Steel gratings
Blast Resistant Control Room RCC
Control Room RCC framed structure with Hollow/solid
concrete block work
Substation RCC framed with hollow/solid concrete
blocks walls
3.0 DESIGN LOADS (DL)

The following design loadings shall be considered
1)Dead loads including self weight
2)Live load
3)Wind load
4)Seismic load
5)Equipment load
6)Dynamic load
7)Load from lifting appliances
8)Erection loads / maintenance loads
9)Thermal load

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 72 OF 202
10) Earth pressure / Hydrostatic Loads

11) Any other load not mentioned above, but applicable
These loadings shall be applicable to all structures irrespective of the material
employed for construction.
3.1 DEAD LOADS
Dead load shall comprise of the weight of all permanent construction including
walls, fire proofing, floors, roofs, partitions, stairways and fixed services.
Unless noted otherwise following unit weights shall be adopted.
Reinforce Concrete : 2500 kg/m³
Plain Concrete : 2400 kg/m³
Structural steel : 7850 kg/m³
Backfill Soil : 1800 kg/m³
Operating floor with grating : 100 kg/m²
Staircase (steel) : 140 kg/m²
Ladder : 40 kg/m²
False ceiling : 60 kg/m²
Heavy duty tar felting : 30 kg/m²
3.2 EQUIPMENT LOADS
 EQUIPMENT CATEGORY I
The weight of equipment category I such as pumps, compressors, motors etc.,
shall be derived as far as possible from Manufacturer’s data and shall include
controls, auxiliary machinery, piping etc. The equipment load shall be categorized
if required for use in various loading combinations as empty and operating.
 EQUIPMENT CATEGORY II
This category consists of loads from equipments such as vessels, columns, heat
exchangers, condensers, settlers, filters and the like, complete with their piping.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 73 OF 202
In accordance with the various load combinations for the category of equipment,
the following weights/loads shall be included in the calculations.
a) EMPTY WEIGHT (ELe)
This is the dead weight of vessels, columns, etc. completely installed) including
platforms and ladders, piping, insulation and fireproofing) and ready for operation,
however, without liquid filling. Weights will be derived from manufacturer’s data.
b) OPERATING LOAD (ELo)
This is the empty weight plus the maximum weight of contents of vessels,
columns, etc. during normal operation of the plant, Weight of pipes full of product
(liquid/gases) plus the weight of insulation and anchor loads if any.
c) HYDROSTATIC TEST LOAD (ELt)
When Hydrostatic pressure testing of equipment is required at site and is done
after installation, the weight of equipment, completely filled with water shall be
incorporated in the design of the supporting structure. Only one biggest system
shall be considered to be tested at a given time.
The empty / operating / test weight of process equipment including contents and
all fixtures, platforms, ladders and attached piping etc, shall be considered. If
piping weight is not indicated separately or not included in the weight of the
equipment, the same shall be taken as 10% of the weight of the equipment.
3.2.1 Exchangers / Fabricated equipments

When exchangers are supported on structures, the supports shall be designed for
vertical and horizontal forces (bundle pulling force or friction forces). The vertical
loads shall be categorized into empty weight, operating weight and test weight.
Weight distribution over two (2) saddles of an exchanger shall normally be as
follows:
Exchanger Type Channel Side Shell Side

Floating head type 60% 40%
Fixed tube sheet type 50% 50%
Kettle type 45% 55%

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 74 OF 202
U-tube and other type 67% 33%
3.2.1.1 Special Considerations
a. Bundle Pull
Bundle pull forces for different types of exchangers shall be taken as under :-
Fixed type - Nil

Kettle type - 0.30 x Bundle weight
All other types - 0.86 x Bundle weight or 30 N/mm of diameter
whichever is greater.
Total Bundles Pull shall be considered on fixed pedestal alone
b. Thermal Expansion
Horizontal force due to thermal expansion of horizontal vessels / exchangers
shall be relieved by using slotted holes and slide plates and remaining force
derived from the product of the sliding saddle ‘gravity load’ and the coefficient
of friction shall be applied to each support. The coefficient of friction shall be as
under:
a. Teflon to Teflon : 0.08
b. stainless steel to Teflon : 0.10
c. steel to steel : 0.30
d. steel to concrete : 0.45
c. Non-Static Loading
Foundations and structures supporting vessels subject to surge loading, such
as De-aerators shall be designed with sufficient stiffness and rigidity to resist a
notional horizontal forces of 10% of those derived from the Vessel’s operating
weight or the given surge load whichever is the greater. The forces shall be
applied at the vessel’s centre of gravity and act longitudinally OR transversely.
Consideration shall be given to bracing these structures.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 75 OF 202
The design of foundations and structures supporting agitated vessels,

centrifuges, reactors and other variable load equipment shall take full account
of all the loading data provided by the equipment vendors. Where no loads are
available, consideration shall be given to applying force at 10% of operating
weight. In addition, for dynamic effect loads will be increased by 50% of steam
agitated equipment and 25% for mechanical agitated vessels.
Where two or more similar items of such equipment are supported on a

common foundation or structure, the design must be based on the assumption
that these items will resonate in phase.
3.3.2 Rotating Equipment

Comprehensive loading data of mechanical equipment, such as, fans, blowers,
pumps, compressors, D.G. Sets, turbines, motors engines etc., as furnished by
the equipment vendor shall be considered.
3.3 LIVE LOADS (LL)

Live loads shall, in general, be as per IS: 875. However, the following minimum
live loads shall be considered in the design of structures to account for
maintenance and erection phases; if equipment layout / vendor drawings indicate
loads of greater magnitude, the same shall be adopted.
i. Process Building / Technological Structure (Open / Enclosed type)

Operating area - 5.0 kN/m²
Maintenance area - 7.5 kN/m²
Ground floor - 10.0 kN/m²
ii. Compressor House/TG House

Operating area - 10.0 kN/m²

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 76 OF 202
Maintenance area - 10.0 kN/m²

iii. Service Platform

Vessel / Tower - 3.0 kN/m²
Isolated platform - 2.5 kN/m²
(For valve operation)
Access way - 2.5 kN/m²
Cross over - 2.0 kN/m²
Piperack walkways - 2.5 kN/m²
Gantry girder walkway - 3.0 kN/m²
iv. Substation / Control Room

Panel floor - 10.0 kN/m²
Miscellaneous partition - 1.0 kN/m²
Other areas - 5.0 kN/m²
v. Office building
Office area - 3.0 kN/m²
Entrance lobby - 5.0 kN/m²
Exit way - 5.0 kN/m²
Miscellaneous partition - 1.0 kN/m²
Document Storage area - 10.0 kN/m²
vi. Laboratory
Upper floors - 4.0 kN/m²
vii. Cooling Tower

Operating platform /cover - 3.0 kN/m²

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 77 OF 202
Slab of hot water basin &

Sump
viii. GT Building / DM Plant /ETP

Operating platforms - 3.0 kN/m²
ix. Staircase
Process Building - 5.0 kN/m²
Technological structure - 5.0 kN/m²
Office - 5.0 kN/m²
Substation/Control Room - 3.0 kN/m²
Laboratory - 4.0 kN/m²
Service platform - 2.5 kN/m²
Loads on account of equipment and incidental loads shall be taken over and
above the loads indicated in the table.
For all other buildings not covered in above Table as well as roofs of various
structures, the imposed loads shall be taken as specified in IS: 875 (Part II)
1 KN/m² allowance shall be made for services supported from below the floor.
Live load on various types of roofs shall be as per the requirements given in IS:
875.
3.4 WIND LOADS (WL)

Wind loads shall generally be as per IS-875 (Part-3) except for switchyard
structures and transmission towers for which IS: 802 shall be applicable. Basic
wind speed shall be as per the Code. As per IS:875 (Part-3), definition of basic
wind speed shall be peak gust velocity averaged over 3 second time interval at 10
m height above mean ground level with 50 years mean return period . The design
life span of all structures, except temporary structures, and boundary wall shall be

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 78 OF 202
taken as per IS 875. Life span of temporary structures and boundary wall can be
lesser and shall be as per IS: 875.
Design wind speed and pressure shall be worked as per the latest revision of IS
875 Part-3.
To account for surface area of piping, platforms and other attachments fixed to the
equipment, the surface area of the equipment (vessel/column) exposed to wind
shall be increased by 20% or as specified in the mechanical data sheets of the
equipment.
Wind force on structural elements shall be calculated using design wind pressure
multiplied by elements frontal area, normal to wind direction multiplied by force
coefficient as per Table 5, IS 875 Part-3-2015.
In calculation of wind force frictional drag shall be considered where applicable.
3.5 SEISMIC LOADS(SL)

Seismic loads shall be as per IS: 1893 (latest version).
3.6 IMPACT AND VIBRATORY LOADS
Structures subjected to impact or vibratory loads shall be designed as per the

provision of IS: 875 & IS: 2974. Requirements for monorails and overhead cranes
shall be as per IS: 800, IS: 875 or manufacturer’s data, whichever is more
stringent.
3.7 BLAST FORCES

Blast resistant Control Room or any other specified structure, subjected to blast
forces generated due to accidental blast from hydrocarbon ignitions should be
designed to withstand all such forces. Unless specifically mentioned by the
process licensor, design blast loads and blast resistant construction shall be as
specified below and shall conform to relevant IS codes and good engineering
practices.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 79 OF 202
Buildings located within 30 m from a potential blast source, shall be designed to

withstand the maximum combination of loads resulting from any one of the
following:
1)Blast pressure equivalent to static pressure 21KPa acting on all exterior

surfaces.
2)Suction blast pressure equivalent to static pressure 7 KPa acting on all
extreme surfaces.
Design of blast resistant control building shall be according to the following

minimum blast-loading conditions:
Condition 1:
Any of the following combinations:
1A, 1B, 1C whichever is the most critical
21 KPa on walls and roof.
1A 1B 1C
Condition 2:
7KPa on interior wall and roof surfaces.
2
Control buildings located more than 30 m from a blast source shall be designed to
resist maximum combination of loads in accordance with the following table:

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 80 OF 202
Distance versus Design Pressure

Distance from Blast Pressure Suction Blast Wind Velocity
Process Equipment (KPa) Pressure (KPa) Pressure
(meter) (KPa)
30 to 45 21 7 4
45 to 60 10 3 2
60 to 75 7 2 1
75 to 150 3 1 *
Over 150 * * *
Structural Design Criteria

- Design the structure as a shear wall structure with the roof acting as a
horizontal diaphragm that transfers the transverse loads to the side shear
walls. External shear walls shall be continued up to 1.5 m below GL or up to
founding level whichever is less.
- Design of walls and roof shall be based on the “Yield Line Theory”.
- Provide cast-in-situ reinforced concrete walls and roof of load-bearing type,
designed to resist bending and transmit horizontal shear. Precast concrete
panels may be used but shall be either mechanically bonded to cast-in-situ
reinforced concrete columns or provided with built-in load transmitting steel
plates or angles so that the panels can be welded in place.
- Anchor walls to foundations and concrete roof slabs with steel reinforcing
bars to provide full moment connections.
Provide roof framing with adequate bearing and good anchorage to the supporting
walls. Weld roof form decking if used to the top member of the roof frame.
- Distribute loads on roofs and walls in two directions where possible.
- Consider stress reversals at each member and provide a minimum 20%
stress reversal.
- Design reinforced concrete members with good ductile properties. Limit
tension steel to 1% of the concrete area and 2% of the concrete area for
tension plus compression steel. To allow for stress reversal provides
reinforcing steel in both concrete faces and set shear bars perpendicular, not
inclined.
- Provide local strengthening of concrete at opening by additional reinforcing
without local thickening where possible.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 81 OF 202
Load combinations with blast loads

- For Flexure
1.0 (Dead load + Blast load)
- For shear
1.2 (Dead load + Blast load)
Live load shall not be considered on the roof during blast.
Soil Bearing Capacity

Design bearing pressure shall be taken as equal to twice the allowable static
bearing pressure for load combinations with blast load.
Stability Ratio
Factor of Safety in case of load combinations with blast load shall be as follows:
Overturning - 1.2
Sliding - 1.3
Openings:
- Minimize openings in the building enclosure and locate openings to avoid or
be shielded from direct blast pressures.
- Windows, if unavoidable shall be limited in size and provided with special
glazing.
- Select external doors, louvers and similar items, together with their frames,
capable of withstanding the pressures. Do not use glass panels in these
doors. Provide for personnel at least for two access doors, located remote
from each other and where possible not in opposite walls. The size of
equipment doors for maneuvering factory-fabricated control boards into or
out of the control room.
3.8 CONTINGENCY LOADS

3.8.1 RCC Structures
All floor slabs and beams shall be designed for a concentrated load of 10 KN
acting simultaneously with the uniform live load, but not with actual concentrated
loads from equipment, piping etc. This load shall be placed to result in maximum
moment and / or maximum shear.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 82 OF 202
This load shall not be considered for the design of columns, foundations and in
overall frame analysis. For floor slabs, the load shall be considered to be
distributed over an area of 0.75 m x 0.75 m.
3.8.2 Structural Steel

For process plants, the following contingency additional loading shall be applied to
individual beam elements, these shall be applied as point loads to produce worst
shear and bending stresses:
Platform Walkways 3 KN
Secondary Floor Trimmers 5 KN
Primary / Grid beams 10 KN
3.9 MISCELLANEOUS LOADS

Apart from the specified live loads, possible overloading during construction /
hydro-test maintenance / erection shall also be considered in the design Job
specifications shall also be referred to, for any specific loading.
Hydrostatic pressure shall be adequately accounted for, in the design of

structures, below ground water table.
All the handrails, parapets, parapet walls, balustrades shall be designed for
horizontal load mentioned in Table 3 of IS-875 (Part-2).
3.10 LOAD COMBINATIONS

Structural analysis and design shall take into consideration, worst combination of
the above loads under different phases, such as, Erection, Operation, Hydro-test,
Shutdown, Maintenance, and Blast for control room, as applicable.
The design shall be governed by worst load combinations as per the procedures of
relevant BIS codes.
4.0 DESIGN CRITERIA FOR FOUNDATIONS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 83 OF 202
4.1 GENERAL
Foundation sizing shall be based on working loads, not on loads which may have
been increased by factors for the purpose of concrete design.
4.2 TYPE OF FOUNDATIONS

Type of foundations to be adopted and the pertinent details there of shall be as
per provisions of scope and job specifications documents.
Following clauses describe the general guidelines to be followed while designing
the foundations; these clauses do not per se stipulate the type of foundations to be
followed.
4.3 SHALLOW FOUNDATIONS
4.3.1 For gravity loading, allowable net bearing capacity of soil shall be based on the
following settlement criteria:
Foundation Type Allowable Settlement(mm)
Foundations in unit areas, utility areas and 25

Foundations for plant buildings including substation,
Compressor house, control room, technological
structures
Machine foundations and critical equipment with 25
interconnected piping
Foundations supporting non-plant buildings 40
4.3.2 For transient loadings, such as wind / seismic, allowable net bearing capacity
based on shear criteria may be considered.
4.3.3 For load combinations including wind, the Safe Soil Bearing Pressure may be
increased by 25%.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 84 OF 202
4.3.4 For load combinations including earthquake, the Safe Bearing Pressure of Soil
may be increased as permitted in IS: 1893.
4.3.5 Under blast (due to hydrocarbon explosion) load combinations if any, the design
bearing pressure of soil shall not exceed twice the allowable static bearing
pressure of soil.
4.3.6 Allowable Loss of contact area between underside of foundation and soil (due to
resultant Overturning Moment) under different loading conditions shall be as given
below.
Load Combination description Allowable % Loss of Contact Area
A Operating Load case ( Plant 0 % to 10%
operating, with or without Live Loads,
for worst cases)
Operating Load Case with Wind or up to 25%
Earthquake (with or without Live
Loads, for worst cases)
B Operating Load case (Plant 0 % to 20%
operating, with or without Live Loads,
for worst cases)
Operating Load Case with Wind or up to 30%
Earthquake (with or without Live
Loads, for worst cases)
Where
A = Foundations on Soil
B = Foundations on Rock
4.3.7 Soil and hydrostatic pressure on walls below grade.
In the design of walls below grade, provision shall be made for the lateral pressure
of adjacent soil. Due allowance shall be made for possible surcharge from fixed or

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 85 OF 202
moving loads. When a portion or whole of the adjacent soil is below a free water
surface, computations shall be based on the weight of the soil, diminished by
buoyancy, plus full hydrostatic lateral pressure.
The lateral pressure from surcharge loads shall be taken in addition the lateral
earth pressure loads.
4.3.8 Stability of foundations
Foundations shall be checked for stability against overturning, sliding & uplift.
While checking against uplift, the following shall be considered.
FOUNDATION DESIGN – FACTORS OF SAFETY
Type of Structures Minimum factor of Minimum factor of % Weight of
safety against safety against Overburden
overturning Sliding over

projected
With wind Without With wind Withou
plan area of
or wind or or seismic t wind
footing
seismic seismic or
seismi
c
All Buildings/ 1.5 1.5 1.5 1.5 100
Structures / Eqpt. In
Units
Pipe Rack (Offsite) 1.5 1.5 1.5 1.5 50
Flood Light Mast 1.5 - 1.5 1.5 50**
Retaining Wall 1.5 1.5 1.5 1.75 100
Over Head water 1.5(empt - 1.5 - 50**
tank y)
2.0(full)

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 86 OF 202
Blast Resistant 1.5 2.0 1.5 1.5 100

Structures
Flare supporting 1.5 - 1.5 - 50**
Structures
** In case area is paved, overburden shall be based on NGL (for area under filling)
or 600 mm below HPP, whichever is lower. In case of unpaved area, it shall be
w.r.t. FGL.
Minimum factor of safety against uplift shall be 1.2 for all structure. (Note: In case
of sumps, lining weight shall not be included). Beneficial load of backfill can be
included on in circumstances where it will never be removed.
Buoyancy from high ground water levels shall be taken into account in
investigating stability against uplift.
4.4 PILED FOUNDATIONS
Piles shall be designed as per IS: 2911. However, pile capacity shall be proven by
a sufficient number of initial load tests before preparing piling plans.
The increase in Safe Working Load permitted as per codal provisions, under load
combinations including wind / earthquake shall apply equally to uplift and sheer
conditions, subject to confirmations by the piling Contractor with respect to the
particular piling system. Pile capacity may be similarly increased in blast condition
to 1.5 times the permissible capacity under compression, tension and shear
modes.
When any major machinery is to be supported on piles, behavior of the piles under
dynamic, loading conditions, as established by necessary field test, shall be
considered.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 87 OF 202
The capacity of pile groups shall be obtained by applying appropriate group

efficiency factors. Where piles pass through filed ground, the available pile safe
working load shall be suitably reduced to account for negative skin friction caused
by settlement of fill. Where suitable, consideration shall be given to reducing
drawdown effects by slip coating the piles
While computing horizontal capacity, piles shall be treated as fixed head or free
head depending on the degree of fixity at the top.
4.5 MACHINE/EQUIPMENT FOUNDATIONS:
Machine / Mechanical equipment foundations shall satisfy the requirements of IS:

2974 and any other parameters as per machine vendors.
Generally, foundations and structures supporting rotating machinery shall be so

proportioned that their natural frequency shall not fall within the range of 0.8 to 1.2
of normal operating speed of the equipment. Further for major rotating machinery
such as main compressor, the amplitude of foundation of structure during normal
operation shall not exceed the allowable amplitude specified by the equipment
manufacturer. The above consideration may be omitted for centrifugal pumps and
fans and other minor rotating equipment weighing less than 1 ton or if the mass of
the rotating parts are less than 1/100th of the mass of foundation installed directly
on concrete provided that the weight of foundation is not less than 3 times of the
equipment weight. In such cases, dynamic analysis is not necessary.
When dynamic analysis is called for, the combined centre of gravity of the
machine and foundation system shall, as far as possible, pass through the centre
of area of the foundation raft or centroid of the pile group. Wherever unavoidable,
eccentricity shall be less than 5% for block foundations and 3% for frame

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 88 OF 202
foundations. However, in highly compressible soils, no eccentricity shall be

permitted.
Foundations shall be so designed that natural frequency of the foundation system

shall not resonate with the following:
a) Operating speed of the motor / turbine

b) Operating speed of the machine
c) 2 x Operating speed of the machine
d) Critical speed of the machine (for centrifugal machines)
It shall be ensured that there is no transfer of vibrations from machine foundations

to any part of the adjoining structures. In case such machines are sitting on
building floors, approved damping pads shall be used with prior approval of the
Owner / Consultant.
Where deviations (resulting from inaccuracies in soil parameter measurements,

approximations in design method, etc.) from calculated natural frequencies,
leading to amplitudes in excess of specified limits are foreseen, provision for
increasing the foundation mass without removal of the machine and without
affecting surrounding space availability or connected piping shall be made, if
possible.
4.6 CONCRETE GRADE
Grade of concrete to be used in foundation shall in general be as per the

philosophy adopted for the entire structure. However, minimum cement content,
type of cement and any remedial actions, if required for foundations due to
aggressiveness of subsoil water, shall be as stated elsewhere in this document.
For underground structures, such as, foundations, manholes etc. M30 grade
reinforced concrete shall be used.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 89 OF 202
4.5 FOUNDATION BOLTS

All holding down bolts or threaded rods for non-post tensioned applications shall be
out of Mild Carbon steel conforming to IS: 2062 with Fy = 250 MPa unless Noted
Otherwise. For scrubbing section /acid storage section/highly corrosive
environment, holding down bolts should conform to SS 316.
4.7.1 Minimum cover to Foundation Bolts
Minimum distance between a Standard Holding down Bolt or Anchor Sleeve and
the face of Foundation/pedestal shall not be less than 6 x (dia of bolt) mm.
4.7.2 All equipment foundation bolts / templates shall be designed and supplied by
equipment vendor. Foundation bolts for steel structures shall be designed and
supplied by contractor as per standard drawings or approved equivalent.
4.7.3 Other Inserted And Embedded Items

Unless otherwise specified, all structural steel shall be weldable structural steel
“Standard Quality” (Fe 410 WA), in accordance with code IS: 2062.
All embedded steel items (exposed to atmosphere) shall be hot-dip galvanized in

accordance with IS: 2629, except if noted otherwise on the design drawings.
All inserted and embedded items shall be accurately placed or template in and be
securely anchored prior to placing concrete.
At sliding ends of vessels and horizontal exchangers, sets of plain steel plates shall
be provided. In order to reduce the horizontal force due to friction at sliding ends
sets to PTFE bonded steel plates may be provided.
4.8 PEDESTAL HEIGHTS
Building plinth : 600 mm above FGL or as per requirement

Pedestals for structural columns : As per design requirement
Open paved area : 300 mm (min.) OR as indicated in Equipment

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 90 OF 202
Layout drawing
Open unpaved area : 300 mm
Covered area(building etc.) : 300 mm (min.) OR as indicated in drawing
Storage tank foundation : As per equipment layout
All equipment supporting foundations / pedestals
Open area : As required but not less than 300 mm

Covered area : As required but not less than 150 mm
Stair Pedestals : 300 mm (min.) OR as indicated in equipment
Layout drawing.
Ladder pedestals : 300 mm
4.9 GROUTING
The minimum thickness of grout shall be 25 mm.
All anchor bolts sleeves / pockets and spaces under column bases, shoe plates
etc. shall be grouted with free flow, non shrink (premix type) grout, with 28 days
minimum cube crushing strength of 40 N/mm². Ordinary grout consisting of 1 part
of OPC and 2 parts of clean, dry well graded sand mixed with water to obtain the
required consistency shall only be used under the base plates of cross-overs,
short pipe supports (not exceeding 1.5 m height) and small operating platforms
(not exceeding 2 m height) not supporting any equipment.
For rotating equipment bases, (above 300 kw rating), grout shall be as per
requirements of equipment vendor, as per the approved list / as per the decision of
EIC.
5.0 DESIGN CRITERIA FOR REINFORCED CONCRETE STRUCTURES
5.1 GENERAL

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 91 OF 202
a) All buildings, structures, foundations, machine equipment foundations, liquid

retaining storage structures, trenches, pits etc. shall be of RCC and designed
based on the following IS codes (latest revision with all amendments, issued
there to) in general, and other relevant IS codes applicable : IS:456, 875, 1893,
1904, 2911, 2950, 2974, 3370, 4326, 4991, 4998, 5249, 6403, 8009, 13920.
b) Only limit state method as per IS: 456 shall be followed for the design unless
otherwise specified elsewhere in this document for special structures.
c) All skeletal structures shall be of frame type construction, and detailing shall be
as per provision of IS: 13920.
d) Where the specified design depth of groundwater table so warrants, all
underground pits, tunnels, basements, etc. shall be leak-proof R.C.C.
construction using water proofing compounds.
5.2 LIQUID RETAINING R.C.C. STRUCTURES AND BASEMENTS
5.2.1 All liquid retaining / storage R.C.C. structures shall be leakpoof and designed as
uncracked section in working stress method as per IS:3370. However, the parts of
such structures not coming in contact with the liquid, shall be designed according
to IS:456 except ribs of beams of suspended floor slabs and counterforts of walls
(located on the side remote from liquid) and roof of liquid retaining structures
which shall be designed as uncracked section. Hot/cold water basin, and other
primary framing members of Cooling Towers and similar liquid retaining structures,
which remain constantly in contact with water (stored / sprayed) shall be designed
as uncracked sections. No increase in permissible stresses in concrete and
reinforcement shall be made under wind or seismic conditions for such structures.
5.2.2 All liquid retaining / storage structures shall be designed assuming liquid up to the
full height of wall, irrespective of provision of any overflow arrangement. Pressure
relief valves or similar pressure relieving devices shall not be considered in

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 92 OF 202
underground water retaining RCC structures. Hot water basin in cooling tower
shall be designed for the weight of water up to top of parapet wall.
5.2.3 Following conditions shall be also considered for design of liquid retaining
structures, basement, trenches and other underground structure:-
a) Only water pressure from inside and no earth pressure, groundwater pressure
or surcharge from outside wherever such a condition is likely to exist either in
operation or during installation / testing.
b) Earth pressure, surcharge pressure or ground water pressure from outside and
no water pressure from inside.
c) Base slab shall also be designed for the empty condition during construction
and maintenance stages with maximum ground water table. Pressure Relief
Valves shall not be used.
d) Intermediate dividing walls of pump sumps shall be designed considering water
in one pump only and the other sump being empty for maintenance.
5.2.4 The walls and base slabs of liquid retaining storage structures shall be provided
with reinforcement on both faces for thicknesses greater than 150 mm.
5.2.5 In all liquid retaining structures, PVC water bars (230 mm wide, 6 mm thick) shall
be provided at each construction joint. PVC water bars shall be of minimum
150/230 mm width and 6 mm thickness, and generally shall be riffed/serrated type
with a central bulb Kicker type PVC water bars shall be used for the base slab and
in other areas where it is required to facilitate concreting. Material quality of PVC
water stops shall confirm to IS 12200.
5.3 CONCRETE GRADE
All cast-in-situ structural concrete shall be Reinforced Concrete conforming to IS:
456. Minimum grade M30 shall be used for all sub-structures (foundations/ Pile
foundations etc) except for grade slabs / paving for which M20 may be used. M25

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 93 OF 202
grade shall be used for all super-structures. For major foundations such as
compressor etc., M30 grade concrete shall be used.
Pre-cast concrete shall be of minimum grade M35.
From durability consideration the minimum cement content and maximum water-
cement ratio shall be as pr the relevant standard IS codes.
If soil investigation report recommends high cement content and / or specified type
of cement, the same shall have precedence.
75 mm thick PCC of grade M15 (nominal mix) shall be provided under all RCC
foundations except under base slab of liquid retaining structures where 100 mm
thick concrete of mix M15 (nominal mix) shall be used.
Concrete for encasing shall be M20 with 10 mm down aggregate.
Plain cement concrete (PCC) of grade M15 (nominal mix) of minimum 150 mm
thickness shall be provided under all masonry wall foundations. Plain cement
concrete of grade M20 of minimum 40 mm thickness shall be provided as damp
proof course, at plinth level of all masonry walls and to be coated with 3 mm thick
bitumen emulsion.
Lean concrete of grade 1:5:10 shall be used as filler material wherever loose sub-
grade exists by removing the loose soil/fill.
Any specific requirement regarding grade and thickness of PCC to be provided
shall be incorporated in the drawing.
5.4 REINFORCEMENT BARS
High yield strength deformed TMT steel bars of grade Fe500D conforming to IS:
1786 shall be used. The Minimum dia. used shall be 8mm. All steel reinforcements
shall be procured from SAIL / TISCO /RINL/SHYAM STEEL INDUSTRIES LTD or
Owner’s approved Vendor List. HYSD Fe500 corrosion resistant bars confirming
to IS: 1786 shall be used in foundations, piles and pile caps.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 94 OF 202
Binding wire of 16 Gauge GI shall be used for tying the reinforcement conforming
to IS: 280 unless specifically mentioned herein or in engineering drawings or other
engineering design basis prepared for the individual units/structures.
5.5 MINIMUM THICKNESS OF STRUCTURAL CONCRETE ELEMENTS
For structural concrete elements, the following minimum thickness shall be

followed:-
Footings (All types with or without beams) 300 mm

Note: Tapered footings shall not have thickness less than 150
mm at the edges. Minimum average thickness shall not
be less than 300 mm
Pile Cap 500 mm
Basement walls 150 mm
Basement slab with beams / without beams 200/300 mm
Slab thickness in raft foundations with beam & slab construction 150 mm
Floor / roof slab, walkway, canopy slab 150 mm
Cable / Pipe Trench, Launder Walls & Base Slab 125 mm
Parapet 100 mm
Louvre/Fin (not in contact with liquid) 100 mm
Louvre (in contact with liquid) 100 mm
Precast Trench Cover / Precast Floor Slab 125 mm
Liquid retaining / Leak proof structures, Underground Pits
Walls 150 mm
Base slab with beams 200 mm
Base slab without beams 300 mm
5.6 MINIMUM COVER TO REINFORCEMENT

The following minimum clear cover shall be provided to all steel reinforcement
including links.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 95 OF 202
Slab (roof & floors, canopy, cantilever, 30 mm

waist slab)
Beam (roof, floor tie, & lintel) 30 mm or dia. of bar whichever is greater
Column, Pedestal 40 mm above FGL, 50 mm below FGL
Retaining wall, Basement and Pit Wall
a. Face in contact with earth 50 mm
b. Free face 30 mm or dia.of bar whichever is greater
Liquid retaining structure
a. Face in contact with liquid 30 mm or dia.of bar whichever is greater
b. Face away from liquid but in contact 50 mm
with earth
c. Free face 30 mm or dia.of bar whichever is greater
Foundation slab, base slab, plinth beam 50 mm
Pile Cap
a. Bottom face 100 mm
b. Top face 50 mm

Expansion points in concrete structures shall be provided at 30-35 m centers. The
expansion joint shall be provided preferably by way of twin columns on a common
foundation. Sliding joints shall be avoided as far as possible.
5.8 DEFLECTIONS
5.8.1 Deflections in concrete structures shall in general be limited by adherence to the

limits on span by depth ratio for beams and slabs and length to lateral dimension
ratios for columns as prescribed in IS: 456. Where special functional /
serviceability requirements or large spans demand actual deflections and / or
crack widths shall be calculated and the following limits adhered to:
Total vertical deflection due to all loads including the Span/250

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 96 OF 202
Effects of temperature creep and shrinkage

Crack width (for non-liquid retaining structure) 0.3 mm
Crack width (for liquid retaining structure) As per design requirement
Total horizontal deflection between two floors Storey height/200
5.9 MISCELLANEOUS APPLICATIONS

5.10.1 Admixtures
Admixtures shall conform to IS: 9103 and to be mixed with concrete (if required)
strictly as per manufacturer’s recommendations.
5.10.2 Water for Construction
Water used for mixing and curing shall be clean and free from injurious amounts of
soils, acids, alkalis, salts, sugar, organic materials or other substances that may
be deleterious to concrete or steel. Portable water is generally considered
satisfactory for mixing concrete. It should meet the requirement of IS: 456-2000.
5.10.3 Aggregates
These shall conform to IS: 383, specification for Coarse and Fine Aggregates
from Natural resources.
5.10.4 Plinth protection
Each building shall be provided with 1.0 m wide concrete M10, 100 thick laid on
75 mm thick M7.5 concrete with 8 Tor @ 250 c/c both ways Reinforcement bars
all round as plinth protection. A surface drain to be provided along-with plinth
protection which shall be connected to the drainage system.
5.10.5 Ramps
Ramps for building entrance shall be cast in situ R.C.C. designed as a grade slab
and the slope of ramps shall not be less than 1 in 10. Minimum thickness of the
slab shall be 150 mm.
5.10.6 Hot Bitumen Paint


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 97 OF 202
All underground structures including top surface of foundations shall be painted

with two coats of hot bitumen paint of grade 20/30 with quantity of bitumen at least
1.2 kg/m² per coat.
5.10.7 Masonry Wall
a. All masonry walls from ground floor shall be placed on R.C.C. grade beams.
However, light internal partitions may be placed on ground floor slab.
b. All brick masonry (M 7.5 MPa) grade walls shall be considered as 230 mm
thick, except for partition walls which will be 115 mm thick. However, for fire
barrier walls minimum thickness shall be considered as 350 mm.
c. All in-filled brick (M 7.5 MPa grade) panels shall be designed to transfer
horizontal loads from wind and seismic to the structural frameworks without
damage and the extent of brick panel dimensions shall be as per the
recommendations in IS. All brickworks shall be provided with reinforcement
consisting of 2 Nos. of 6 mm diameter bars at every fourth layer.
5.10.8 Anti-termite treatment

Anti-termite treatment shall be provided under all buildings as per IS:6313.
Materials shall be as per IS:8944.
5.10.9 Building Slabs on Grade
The specifications given in Table below shall be followed.
Sl. DESCRIPTION FLOORING TYPE

No. I II III

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 98 OF 202
1.a Earth fill base compacted Yes Yes Yes

to 95% dry density
Sub Grade
1.b Rubble soling 230 Thick 230 Thick 150 Thick
2.a Lean concrete 1:5:10 50 Thick 50 Thick 50 Thick

over 1.b layer
2.b Stable in Grade M20 150 Thick 150 Thick 100 Thick
Structural concrete (Reinforced with R/F placed R/F placed No

8 mm dia bars @ 200 c/c centrally in two layers reinforceme
Grade Slab
both ways) over lean at top & nt required
concrete bottom
3 Finish Floor finish As/Architectur As/Architect As/Architect

al detail ural detail ural detail
TYPE I: Plant buildings such as Sub-stations, Control Rooms, Process Operators’

Room, Pump Houses, Utility Compressor Houses, D.M. Plant, E.T.P., Parking
Areas, Stores, Porches.
TYPE-II: Warehouses, Workshops, Cement Godowns, Fire Stations, Process Compressor
House.
TYPE III: Non Plant Buildings (viz. Administration, Laboratory, Canteen, Time Office,
Gate House, Training Centre, Guest House, Residential Building)
Note: 1. Reinforcement steel shall be as per clause 5.5
5.10.10 Insulation
For equipment with temperatures over 200º C, or sub zero temperatures,
insulation shall be provided between equipment base / lugs and concrete / steel
structure.
6.0 DESIGN CRITERIA FOR STEEL STRUCTURES

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 99 OF 202
6.1 GENERAL / DESIGN METHODS

6.1.1 Design fabrication and erection of the above work shall be carried out in
accordance with the following IS Codes as applicable to the specific structures,
viz, IS: 800, 801, 802, 806, 814, 816, 875, 1893, 6533, 9595, etc. Basic
consideration of structural frame work shall
primarily be stability, ease of fabrication/erection and overall economy, satisfying
relevant Indian Standard Codes of Practice. Steel structures adequately braced in
vertical and horizontal planes, consistent with functional requirements, shall be
preferred over structure having moment connections. Moment connections, if
adopted, shall be fully rigid as per IS:800. Where fully rigid joints are adopted they
shall generally be confined to the major axis of the column member. Flare stack
supporting structure shall be adequately braced on all four faces.
Structural elements, continuously exposed to temperatures above 200º C, shall be

designed for reduced stress as per Table-4 of IS: 6533 (Part-2). The expected
temperature of steel components shall not be allowed to exceed 400 º C. The
structures connected to column, heater vessels working at high temperatures shall
not be rigidly connected with staircase and adjoining structures, which are on
ambient temperatures.
6.1.2 Crane gantry girders shall generally be of welded construction and of single span
length. Chequered plate shall be used for gantry girder walkway flooring.
6.1.3 Monorails shall be provided for all pumps and motors located in buildings, sheds
and in open areas having rating more than 55 45 KW. For pumps and motors of
smaller ratings, monorails shall be provided if directed by Owner / PMC.
6.1.4 Steel staircases shall have channels provided as stringers with minimum clear
width of 750 mm and maximum slope of 41 degree. The vertical height between
successive landings shall not exceed 4.0 meters. Treads shall be minimum 230 m

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 100 OF 202
wide made of grating (with curved chequered plate nosing) spaced equally so as
to restrict the rise to maximum 200 mm. If relevant local by-laws or applicable
Factory Act Rules stipulates more stringent requirements in this regard, the same
shall be adhered to.
6.1.5 Hand rails, 1000 mm high, shall be provided to all walkways, platforms, staircases.
Toe plate (100 mm x 5 mm) shall be provided for all hand railing (except for
staircases). Spacing of uprights shall be 1500 mm (maximum). Two types of hand
railing shall be provided.
a. For walkways, platforms (except platform around/on circular & horizontal vessels),
and staircases: Top rail, mid rail and upright shall be 32 mm dia. (NB) galvanized MS
tubes.
b. For platforms around circular vessels : Top rail shall be 32 mm dia. (NB) galvanized
MS tubes, but mid rail and upright shall be of structural steel.
6.1.6 Electro-forged/Welded hot dip galvanized MS gratings shall be minimum 25 mm
deep. The maximum size of voids in the grating shall be limited to 30 mm x 55
mm. The minimum thickness of galvanizing shall be 120 microns. Gratings shall
be suitable for the operation and maintenance loads for the floors
6.1.7 Welded connections shall be adopted during shop fabrication, except where only
bolted connections are required (viz. removable members, galvanized electrical
switchyard structures
and transmission towers). Field/ site connections may be bolted or welded as per
requirement. Minimum no. /size of erection bolts shall be 2-16mm dia in case of
site welding.
6.1.8 Lock nuts shall be provided for anchor bolts of tall structures, tall process columns,
vibrating equipment, etc.
6.1.9 Minimum two nuts shall used for all anchor bolts except for ladder, stair and hand
rail.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 101 OF 202
Expansion joints shall be provided at 80 – 100 m centres, where possible, column

bracing shall be provided at the center of a longitudinal frame, rather than at the
ends so as to avoid constraints on free expansion.
6.3 STEEL GRADE

Structural steel shall be of yield stress of 250 Mpa conforming to grade A of IS:
2062.
Tubular steel shall conform to Yst 310 of IS: 1161 & IS: 4923. Structural pipes
shall be either seamless or mild welded. Spiral welded pipe is not acceptable.
Structural Steel shall be procured from approved Vendor List attached with the
NIT or Owner’s approved list.
6.5 LIMITING PERMISSIBLE STRESSES
- Permissible stresses in structural members shall be as specified in:

IS: 800 - Hot rolled sections (excluding transmission towers and
Switchyard structures).
- IS: 801 - Cold formed light gauge sections
- IS: 802 - Transmission towers & switchyard structures
- IS: 806 - Tubular Structures
- Permissible stresses in bolts shall be as specified in :-
- IS: 800 - Hot rolled sections
- IS: 801 - Cold formed light gauge sections
- IS: 802 - Transmission towers & switchyard structures
- IS: 806 - Tubular Structures
- Permissible stresses in welds shall be as specified in :-
- IS:801 - Cold formed light gauge sections
- IS: 806 - Metal Arc Welding

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 102 OF 202
6.6 LIMITING DEFLECTION
a. The limiting permissible vertical deflection for structural steel members shall be
as specified below :- (Where “L” represents the span)
Gantry girder for electric overhead crane(Capacity up to 50T) : L/750

Gantry girder for electric overhead crane((Capacity over 50T) : L/1000
Gantry girder for manually operated crane : L/500
Girder beam for supporting dynamic equipment/hoist : L/450
Grating / Chequered plate : L/200 or 6mm
Whichever Is less
Purlins supporting any type of roofing material under (dead load + live : L/200
load) or (dead load + wind Load ) conditions
- Other structural components : As specified in
relevant IS Code
b. The limiting permissible horizontal deflection for multistoried steel structure/

building including flare stack shall be Height/325.
6.7 MINIMUM THICKNESS

6.7.1 Structural Components
The minimum thickness of various structural components (Rolled Steel sections)
shall be as given:-
a. GENERAL CONSTRUCTION
Trusses, Purlins, Side Girts, Bracings 6 mm

Columns, beams 7 mm
Gussets in trusses & girders
i. Upto and including 12 m span 8 mm
ii. Above 12 m span 10 mm
Flare Trestles, Stiffeners 8 mm

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 103 OF 202
Base plates 10 mm
Chequered plate 6 mm (on plain)
Grating 5 mm
b. The minimum thickness of various structural components Transmission tower

and Switch yard structure shall be as per IS: 802.
b. The minimum thickness for rolled beams and channels shall be mean flange
thickness regardless of the web thickness.
c. The minimum thickness of tubes shall be as specified in IS: 806.
d. For structural members exposed to marked corrosive action, corrosion
allowance shall be added as specified elsewhere, or otherwise suitably
protected against corrosion.
e. The minimum thickness of structural components (except gratings &
chequered plates) which are directly exposed to weather and inaccessible for
repainting shall be 8 mm.
f. Cold formed light gauge sections can be used for purlin and side girts.
Minimum thickness criteria shall also not applicable for very light structures like
sheds etc.
6.8 ELECTRICAL SWITCHYARD STRUCTURES AND TRANSMISSION TOWERS
All electrical switchyard structures and transmission towers shall have bolted
connections, and designed on the basis of IS: 802.
6.9 PAINTING
Painting including shop primer to structural steel shall be as per the painting
specification for this project, included elsewhere in Technical Specification.
6.10 GROUTING
For structural columns : As required but not less than 25 mm
For equipment : As required but not less than 25 mm
6.11 CLADDING AND RAINWATER GUTTERS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 104 OF 202
All roof and cladding sheets should be galvalume sheet of 0.5 mm total coated
thickness with 550 MPA grade steel confirming to AS 1397 with AZ150 grade
coating.
Translucent sheets shall be provided, in non-process areas only, intermittently
where day lighting is required. Rainwater gutters of Galvanized / Zinc coated
sheets and UPVC rainwater pipes shall be provided for proper roof drainage.
7.0 CRITERIA FOR MASONRY WORKS
7.1 GENERAL
All masonry works shall be designed in accordance with IS: 1905, IS: 1597, IS:
2185, IS: 4326 and other relevant IS Codes as applicable. All external brick, stone
and hollow concrete block masonry walls shall be of minimum 230, 350 and 250
mm thickness respectively. Hollow concrete blocks shall conform to IS: 2185.
Masonry shall be plastered with CM 1:6, 12 mm thick on inside surfaces and 20
mm thick on outside surfaces.
7.2 CEMENT MORTAR
All masonry work shall be constructed in 1:6 cement sand mortar except half brick
partition walls which shall be constructed in 1:4 cement sand mortar with two
numbers of 6 mm diameter MS bars provided a every fourth course properly
anchored with cross walls or pillars.
7.3 FIRE WALLS

Thickness of all masonry firewalls shall be as per Electricity Rules but not less
than 345 mm.
8.0 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 105 OF 202
8.1 PIPERACK
For designing the pipe rack superstructure and foundation the following loads shall
be considered:
8.1.1 Vertical Loading

Actual weights of pipes coming at each tier shall be calculated. In calculating the
actual weight of pipe, the class of pipe, material content and insulation, if any,
shall be taken into consideration. Insulation density shall be taken as 2600 N/m³
minimum. In case of gas / steam carrying pipes, the material content shall be
taken as one-third volume of pipe filled with water. The total actual weight thus
calculated, shall then be divided by the actual extent of the span covered by the
pipes to get the uniformly distributed load per unit length of the span. To obtain the
design uniformly distributed load, over the entire span, the u.d.l. obtained as
above, shall be assumed to be spread over the entire span. However, minimum
loading for any piperack shall not be less than 1.25 kN/m². In case, the calculated
loading is higher than 1.25 kN/m², this shall be rounded off to the nearest multiple
of 0.25 (i.e., 1.50, 1.75 kN/m²)
Vertical loads of flare pipe shall be taken as one third full of water for piping within
units & one sixth full for outside unit battery line. All flare line independent support
shall be of four legged braced open lower type construction.
In addition to piping load, gravity loads due to encasement, if any, shall be
considered.
8.1.2 Friction Force (Longitudinal & Transverse)
Where the pipes are of similar diameter and service conditions, the friction force at
each tier on every portal both in longitudinal and transverse directions, shall be
10% of the design vertical loading of the pipes for four or more pipes supported on
a tier and 30% of the design vertical loading of the pipes, for single to three pipes
supported on a tier. Longitudinal friction force shall be considered as uniformly

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 106 OF 202
distributed over the entire span of the beam at each tier and transverse friction
force shall be considered as a concentrated load at each tier level. Friction forces
on T-supports and trestles shall be taken as 30% of the vertical loading. Both
longitudinal and transverse friction forces shall be considered to be acting
simultaneously.
For two-phase fluid flow/transfer lines frictional force shall be minimum 50% of the
weight of pipe including contents & insulation, acting simultaneously in transverse
& longitudinal direction.
8.1.3 Anchor and Guide Force (Thermal Load)

Anchor and guide force (thermal load) in transverse and longitudinal direction shall
be as per piping data.
8.1.4 Loading on intermediate Beam at Tier Level

Intermediate beam at tier level shall be designed for 25% of load on main portal
beams in transverse direction. A reduction of 10% in vertical loading shall be
considered for main portal beams, if intermediate beams are provided.
8.1.5 Loading on Longitudinal beams
Longitudinal beams connecting portal columns shall be sufficiently strong to

sustain 25% of the load on the transverse beams. The total load shall be assumed
as two equal concentrated loads acting at 1/3rd span. Other longitudinal axial
forces coming on it from
the design of the supporting system shall also be simultaneously taken into
account in the design of the longitudinal beam. Friction & anchor forces, if
specifically given by the Piping Specialist, shall also be catered for in the design.
Loads from monorails, when supported from these beams, shall also be
considered to be acting simultaneously along with all other loads mentioned
above.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 107 OF 202
8.1.6 Cable Tray and Walkway Loads
The estimated actual load from electrical, instrumentation trays shall be considered
at the specified locations, together with walkways, platforms for valve operation,
wherever provided.
8.1.7 Wind Force
Transverse wind loading shall be calculated depending on the width of the

piperack as per the following table. This force shall be considered irrespective of
the height between two tiers.
Width of Piperack Wind Force at each Tier level(N)
Upto 4 m 1.25 x p x s
Above 4 m but upto 6 m 1.50 x p x s
Above 6 m but upto 10 m 2.00 x p x s
Above 10 m projected height x p x s
Where p = Horizontal wind pressure as per IS:875 (N/m²)

s = Spacing of portals (m)
For pipe racks of width greater than 10 m, the projected height shall be lesser of
the following two:
i) 0.8 x (diameter of largest pipe including insulation (m) + tan 10º x (width of
rack (m).
ii) height between consecutive tiers

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 108 OF 202
8.1.8 For flare header or any other line supported on extended leg of piperack, the wind
force shall be considered separately.
8.1.9 Seismic Loads
8.1.10 Seismic loads shall be as per IS: 1893 (latest version).Pipe racks should be
adequately braced in all possible directions, consistent with function requirements.
8.1.11 Limiting permissible horizontal deflection for piperack shall be height / 325.
8.1.12 PLATFORMS BELOW AIR COOLERS
If handling pumps or other equipment is located below air coolers located on

piperack or technological structures, blind floors shall be provided below air
coolers, else, 2 m wide center platform with 3m wide local extension below motors
shall be provided.
8.2 RCC AND STEEL CHIMENY
RCC and steel chimneys shall be designed as per IS: 4998 and IS: 6533
respectively.
8.3 CULVERTS
Culverts shall be designed as per the following IRC codes of practices and
manual. Where crane access is specified, the culverts shall be designed for the
crane loads.
1. Standard specifications and code of practice for Road Bridges IRC 5

(Section – I - General features of design)
2. Standard specifications and code of practice for Road Bridges IRC 6
(Section-II – Load and Stresses)

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 109 OF 202
3. Guidelines for Evaluation of Load Carrying Capacity of Bridges SP 37
Note: The above list is suggestive and not exhaustive. Apart from these basic codes
any other related codes shall also be followed wherever required. This list is to be
read in conjunction with the list of codes given in Civil Structural job specifications.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 110 OF 202
ANNEXURE-IV
ES-2516
TECHNICAL SPECIFICATIONS
FOR
CIVIL, STRUCTURAL
AND
OTHER ALLIED WORKS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 111 OF 202
CONTENTS
SL. NO.
Specifications DESCRIPTION
of materials and workmanship shall be as described in the Central Public W
1. GENERAL
2. REFERENCE CODES AND STANDARDS
3. EARTH WORK
4. PLAIN AND REINFORCED CONCRETE WORK
5. STEEL REINFORCEMENT
6. FORM WORK
7. HOLLOW BLOCK MASONRY
8. STRUCTURAL STEEL WORK
9. PAINTING ON STRUCTURAL STEEL
10. STEEL/ALUMINIUM DOORS,WINDOWS AND VENTILATORS
11. ROOFING & CLADDING
12. FLOORING AND PAVING
13. PLASTERING
14. EXTERIOR PAINTING
15. GLAZING
16. PROTECTIVE COATING AND LINING SYSTEM
17. CULVERT WORK

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 112 OF 202
1.1 CONTRACTOR shall procure and maintain copies of the latest CPWD
Specifications at site for reference.
1.2 These technical Specifications shall be supplementary to the specifications

contained in the CPWD specifications, wherever at variance, these Particular
Specifications shall take precedence over the provisions in the CPWD
Specifications.
2.0 Reference Codes & Standards
2.1 Wherever reference of IS Specifications/ or IS Codes of Practice are made in the

Specifications/ Schedule of Rates or Preambles, reference shall be to the latest
edition of IS (Bureau of Indian Standards).
IS - 383 Coarse & Fine aggregates from natural sources for concrete.
IS - 427 Distemper, dry, colour as required.
IS - 432 Mild Steel & Medium tensile steel bars.
IS - 456 Code of Practice for Plain and Reinforced Concrete.
IS - 515 Natural and Manufactured aggregates for use in mass

concrete
IS - 730 Hook bolts for corrugated sheet roofing
IS - 800 Code of Practice for General Construction in Steel
IS - 1079 Hot rolled carbon steel sheets & strips
IS - 1081 Code of practice for fixing and glazing of metal (steel &
aluminium) doors, windows and ventilators.
IS - 1161 Steel tubes for structural purposes.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 113 OF 202
IS - 1285 Wrought aluminium & aluminium alloy extruded round tube and
hollow sections
IS - 1361 Steel windows for Industrial Buildings.
IS - 1363 Hexagon head bolts, screws & nuts of product grade C : Part -
I Hexagon head bolts ( size range M5 to M64)
IS - 1367 Technical supply conditions for threaded steel fasteners
IS - 1566 Hard - Drawn steel wire fabric for concrete reinforcement.
IS - 1786 High strength deformed steel bars & wires for concrete
reinforcement.
IS - 2062 Steel for general structural purposes.
IS - 2116 Sand for masonry mortars.
IS - 2212 Code of practice for brickwork.
IS - 2386 Methods of test for aggregates.
IS - 2835 Flat transparent sheet glass
IS - 4021 Timber door, window and ventilator frames
IS - 4923 Hollow Steel sections for structural use.
IS - 4925 Concrete batching and mixing plant.
IS - 5410 Cement Paint
IS - 6477 Dimensions for wrought aluminium & aluminium alloys,

extruded hollow sections.
IS - 7318 Fusion welding of steel.
IS - 10262 Recommended guidelines for concrete mix design.
IS - 14871 Products in Fibre Reinforced Cement – Long Corrugated or

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 114 OF 202
Asymmetrical Section Sheets and Fittings for Roofing and

Cladding - Specification
3.0 Earthwork
3.1 Excavation
3.1.1 Excavation shall be carried out in soil of any nature and consistency, in the
presence of water or in the dry, met on the site to the lines, levels and contours
shown on the detailed drawings and CONTRACTOR shall remove all excavated
materials to soil heaps on site or transport for use in filling on the site or stack
them for reuse as directed by the Engineer-in-Charge.
3.1.2 Surface dressing shall be carried out on the entire area occupied by the buildings
including plinth protection as directed without any extra cost. The depths of
excavation shown on the drawings are the depths after surface dressing.
3.1.3 The site around all buildings and structures to a width of 3 metres beyond the
edge of plinth protection, ramps, steps, etc. shall be dressed and sloped away
from the buildings.
3.1.4 Black cotton soil, and other expansive or unsuitable soils excavated shall not be
used for filling in foundations, and plinths of buildings or in other structures
including manholes, septic tanks etc. and shall be disposed off within the
contract area marked on the drawings, as directed, levelled and neatly dressed.
3.1.5 In case of trenches exceeding 2 metres depth or where soil is soft or slushy, the
sides of trenches shall be protected by timbering and shoring. The
CONTRACTOR shall be responsible to take all necessary steps to prevent the
sides of trenches from caving in or collapsing. The extent and type of timbering
and shoring shall be as directed by the Engineer-in-Charge.
3.1.6 Where the excavation is to be carried out below the foundation level of adjacent

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 115 OF 202
structure, the precautions to be taken such as under pinning, shoring and strutting
etc. shall be determined by Engineer-in-Charge. No excavation shall be done
unless such precautionary measures are carried out as per directions of
Engineer-in-Charge.
3.1.7 Specification for Earth work shall also apply to excavation in rock in general. The
excavation in rock shall be done such that extra excavation beyond the required
width and depth as shown in drawings is not made. If the excavation done in
depth greater than required /ordered. The CONTRACTOR shall fill the extra
excavation with concrete of mix 1:5:10 as the foundation concrete at his own
cost.
3.1.8 CONTRACTOR shall make all necessary arrangements for dewatering / defiling
as required to carry out proper excavation work by bailing or pumping out water,
which may accumulate in the excavation pit from any cause/ source whatsoever.
3.1.9 CONTRACTOR shall provide suitable draining arrangements at his own cost to
prevent surface water entering the foundation pits from any source.
3.1.10 The CONTRACTOR is forbidden to commence the construction of structures

or to carry out concreting before Engineer-in-Charge has inspected, accepted
and permitted the excavation bottom.
3.1.11 Excavation in disintegrated rock means rock or Boulders including brickbats

which may be quarried or split with crow bars. This will also include laterite and
hard conglomerate.
3.1.12 Excavations in hard rock - meant excavation made in hard rock to be done
manually, or by blasting using only explosives and / or pneumatic hammers. In
case of blasting, control blasting should be adopted depending on site
conditions. For using explosives CONTRACTOR shall follow all provisions of
Indian Explosives Act / Rules 1983, corrected / revised up to date.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 116 OF 202
3.1.13 In case of hard rock excavation to be carried out using explosives the,
CONTRACTOR shall obtain the written approval in advance.
3.1.14 The measurements for excavations shall be restricted and limited to minimum
excavation line as per drawing for payment purposes.
3.1.15 Adequate protective measures shall be taken to see that the excavation does
not affect or damage adjoining structures. The CONTRACTOR shall take all
measures required for ensuring stability of the excavation and safety of
property and people in the vicinity. The CONTRACTOR shall erect and
maintain during progress of work, temporary fences around dangerous
excavations at no extra cost.
3.1.16 Excavation in ordinary soil means excavation in ordinary hard soil including
stiff heavy clay, hard shale, or compact moorum, or any materials, which can
be removed by the ordinary application of spades, shovels, picks and pick
axes. This shall also include removal of isolated boulders each having a
volume not more than 0.50m³.
3.1.17 Excavation in soft rock includes limestone, sandstone, laterite, hard

conglomerates, etc. or other rock which can be quarried or split with
crowbars or wedges. This shall also include excavation of tarred pavements,
masonry work and rock boulders each having a volume of not more than
0.25m³.
3.1.18 Excavation in hard rock includes any rock bound in ledges or masses in its
original form or cement concrete for which in the opinion of the Engineer-in-
Charge, requires the use of compressed air, equipment, sledge hammer and
blasting or non-explosive materials viz. Acconex manufactured by A.C.C. Ltd.
Specifications and instructions for use shall be as per manufacturer.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 117 OF 202
3.1.19 In case of any difficulty concerning the interpretation of type of soil as

mentioned above, the Engineer-in-Charge shall decide whether the
excavation in a particular material is in ordinary soil, soft rock or hard rock
and his decision in this matter shall be final and binding on the
CONTRACTOR and without appeal.
3.2 Filling
3.2.1 Back filling of excavations in trenches, foundations and elsewhere shall consist
of one of the following materials approved by Engineer-in-Charge.
Soil
Sand
Moorum
Hard-core
Stone/gravel
All back filling material shall be approved by the Engineer-in-Charge.
3.2.2 Soil filling - Soil material shall be free from rubbish, roots, hard lumps and any
other foreign organic material. Filling shall be done in regular horizontal layers
each not exceeding 20 cm. depth.
3.2.3 Back filling around completed foundations, structures, trenches and in plinth shall
be done to the lines and levels shown on the drawings.
3.2.4 Back filling around pipes in the trench shall be done after hydro testing is done.
3.2.5 Back filling around liquid retaining structures shall be done only after leakage
testing is completed and approval of Engineer-in-Charge is obtained.
3.2.6 Sand used for filling under foundation concrete, around foundation and in plinth
etc. shall be fine/ coarse, strong, clean, free from dust, organic and deleterious

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 118 OF 202
matter. The sand filling under foundation shall be rammed with Mech. compactor.
Sand material shall be approved by Engineer-in-Charge.
3.2.7 Moorum for filling, where ordered, shall be obtained from approved pits and
quarries which contain siliceous material and natural mixture of clay. Moorum
shall not contain any admixture of ordinary earth. Size of moorum shall vary from
dust to 10 mm.
3.2.8 Hard-core shall be of broken stone of 90 mm to 10 mm size suitable for providing

a dense and compact sub grade. Stones shall be sound, free from flakes, dust
and other impurities. Hard core filling shall be spread and levelled in layers, 15
cm thick, watered and well compacted with ramming or with mechanical / hand
compacts including hand packing wherever required.
3.2.9 If any selected fill material is required to be borrowed, CONTRACTOR shall

make arrangements and procure such material from outside borrow pits. The
material of source shall be subject to prior approval of Engineer-in-Charge.
CONTRACTOR shall make necessary access roads to borrow areas and
maintain the same, if such access roads do not exist, at no extra cost.
3.2.10 Plinth filling shall be carried out with approved material as described earlier, in
layers not exceeding 150mm, watered and compacted with mechanical
compaction machines. Engineer-in-Charge may however permit manual
compaction by hand tampers in case he is satisfied that mechanical
compaction is not possible. When filling reaches the finished level, the surface
shall be flooded with water, unless otherwise directed, for at least 24 hours,
allowed to dry and then the surface again compacted as specified above to
avoid settlements at later stage. The finished level of the filling shall be
trimmed to the level specified. Compacted surface shall have at least 95% of
laboratory maximum dry density. A minimum of one test per 250 sq. meters of
compacted area shall be done.
3.2.11 Whenever the fill material (earth or soil) is purchased, CONTRACTOR shall

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 119 OF 202
get the approval of Engineer-in-Charge. The CONTRACTOR shall arrange to

determine the following properties of the soil and shall get the approval of
Engineer-in-Charge.
1. Clay content : 15% to 20%
2. Laboratory dry : Not less than 1600 kg/m³

density
3. Plasticity Index : Not more than 20
3.2.12 The fill shall be compacted using a vibrating compactor of not less than 1.5
tonne. The fill shall be thoroughly compacted in layers as directed but not
more than 200 mm thick. Adequate water shall be used for compaction and
the density after compaction shall be not less than maximum dry density
obtained in test of IS: 2720 Part-8. Compacted surface shall have at least 90%
of laboratory maximum dry density. A minimum of one test per 250 sq. meters
of compacted area shall be done.
3.2.13 The Gravel fill shall be non plastic granular material, well graded, strong, with
maximum particle size of 50 mm, with not more than 15% passing a 4.75 mm
IS sieve, free of all debris, vegetable matter and chemical impurities.
3.2.14 All clods, lumps etc. shall be broken before compaction.
3.2.15 In case of grading/banking successive layers of filling shall not be placed, until
the layer below has been thoroughly compacted to satisfy the requirements
laid down in this specification.
Prior to rolling, the moisture content of material shall be brought to within +/-
2% of the optimum moisture content as described in IS 2720 Part-7. The
moisture content shall preferably be on the wet side for potentially expansive
soil.
After adjusting the moisture content as described, the layers shall be

thoroughly compacted by means approved by Engineer-in-Charge, till the

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 120 OF 202
specified maximum laboratory dry density is obtained.
General, fill shall be placed in layers not exceeding 300 mm thickness and
shall be thoroughly compacted to achieve a compaction of at least 90% of
laboratory maximum dry density up to a depth of 600 mm below finished
grade. Final fill of 600 mm thickness shall consist of preferably natural material
in, as dug condition except that stones larger than 100 mm shall be removed.
It shall be placed in layers not exceeding 150 mm thickness and compacted to
achieve of at least 95% of laboratory maximum dry density. Each layer shall
be tested in field for density and accepted by Engineer-in-Charge, subject to
achieving the required density before laying the next layer. A minimum of one
test per 250 sq meters for each layer shall be conducted.
If the layer fails to meet the required density, it shall be reworked or the
material shall be replaced and method of construction altered as directed by
Engineer-in-Charge to obtain the required density.
The filling shall be finished in conformity with the alignment, levels, cross-
section and dimensions as shown in the drawing.
Extra material shall be removed and disposed off as directed by the Engineer-
in-Charge.
4.0 Plain and Reinforced Concrete Work
This specifications deals with cement concrete, plain or reinforced, for general
use, and covers the requirements for concrete materials, their storage, grading,
mix design, strength & quality requirements, pouring at all levels, reinforcements,
protection, curing, form work, finishing, painting, admixtures, inserts and other
miscellaneous works.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 121 OF 202
4.1 Materials
4.1.1 Cement: Any of the following cements may be used as required. If soil
investigation report recommends any specified type of cement then same shall
have precedence.
IS - 269 Ordinary Portland cement, 33 grade
IS - 8112 43 Grade ordinary Portland cement
IS - 12269 53 Grade ordinary port land cement
4.1.2 Water: Water used for mixing and curing concrete and mortar shall conform to
the requirements as laid down in IS: 456. Sea water shall not be used for
concrete work.
4.1.3 Aggregates: Coarse and fine aggregates for cement concrete plain and
reinforced shall conform to the requirements of IS 383 and / or IS 515.
Before using, the aggregates shall be tested as per IS: 2386.
Coarse aggregate: Coarse aggregate for all cement concrete work shall be
broken or crushed hard stone, black trap stone obtained from approved Quarries
or gravel.
Sand: Fine aggregate shall consist of natural or crushed sand conforming to BIS
383 and conforming to test as per BIS 2386 parts I to IV.f. Grading of coarse
sand shall be within grading zones I, II or III as laid down in IS: 383, table 4. If
required the aggregates (both fine and coarse) shall have to be thoroughly
washed and graded as per direction of Engineer-in-Charge.
4.2 Mixing
All cement concrete plain or reinforced shall be machine mixed. Mixing by hand
may be employed where quantity of concrete involved is small, with the specific

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 122 OF 202
prior permission of the Engineer-in-Charge. 10% extra cement shall be added in

case of hand mixing as stipulated in IS-456.
For large and medium project sites the concrete shall be sourced from ready-
mixed concrete plants or from on site or off site batching and mixing plants (IS
4926)
4.3 Water Cement Ratio, Laying & Curing
Water Cement Ratio, Laying & Curing shall be done as per IS: 456.
4.4 Grades of Concrete
4.4.1 Grades lower than M 25 shall not be used in reinforced concrete.
4.4.2 A sieve analysis test of aggregates shall be carried out as and when the source
of supply is changed without extra charge notwithstanding the mandatory test
required to be carried out as per CPWD specification.
4.4.5 All tests in support of mix design shall be maintained as a part of records of the
contract. Test cubes for mix design shall be prepared by the CONTRACTOR
under his own arrangements and at his costs, but under the supervision of the
Engineer-in-Charge.
4.5 Design Mix Concrete
4.5.1 Design mix shall be allowed for major works where it is contemplated to be used
by installing weigh batch mixing plant as per IS 4925. At the time of tendering,
the CONTRACTOR, after taking into account the type of aggregates, plant and
method of laying he intends to use, shall allow in his tender for the design mix
i.e., aggregate/cement and water/cement ratios which he considers will achieve
the strength requirements specified, and workability for concrete to be properly
finished.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 123 OF 202
4.5.2 Before commencement of concreting, CONTRACTOR shall carry out preliminary

tests for design mix on trial mixes proposed by him in design of mix to satisfy the
Engineer-in-Charge that the characteristic strength is obtained. In this regard,
CONTRACTOR may consult govt. approved/reputed institute to get design mix
done as per IS 10262 at his own cost. The concrete mix to be actually used shall
be approved by the Engineer-in-Charge.
4.5.3 Notwithstanding the above, the following shall be the maximum combined weight
of coarse and fine aggregate per 50 kg of cement.
Grade of Concrete Maximum weight of fine & coarse

aggregates together per 50 kg of cement
(for nominal mix only)
1. M - 10 480 kg
2. M - 15 350 kg
3. M - 20 250 kg
4.5.4 The workability of concrete produced shall be adequate, so that the concrete can
be properly placed and compacted. The slump shall be as per IS 456.
4.5.5 The minimum consumption of the cement irrespective of design mix shall not be
less than the following:
M 7.5 (1:4:8) 170 kg/cu m

M 10 (1:3:6) 240 kg/cu m
M 15 300 kg/cu m
M 20 330 kg/cu m
M 25 350 kg/cu m
M 30 400 kg/cu m

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 124 OF 202
4.6 Testing of Concrete
4.6.1 Testing of concrete, sampling and acceptance criteria shall be in accordance

with IS 456.
4.7 Proportioning
Mixes of cement concrete shall be as ordered. Where the concrete is specified

by grade, it shall be prepared by mixing cement, sand and coarse aggregate by
weight as per mix design. In case the concrete is specified as volumetric mix,
then dry volume batching shall be done, making proper allowances for dampness
in aggregates and bulking in sand. Equivalent volume batching for concrete
specified by grade may however be allowed by the Engineer-in-Charge at his
discretion.
4.8 Pre Cast Concrete
The specifications for pre cast concrete will be similar as for the cast in situ
concrete. All pre cast work shall be carried out in a yard made for the purpose.
This yard shall be dry, properly levelled and having a hard and even surface. If
the ground is to be used as a soft former of the units, shall be paved with
concrete or masonry and provided with a layer of plaster (1:2 proportion) with
smooth neat cement finish or a layer of MS sheeting. The casting shall be over
suitable vibrating tables or by using form vibrators as per directions of Engineer-
in-Charge.
The yard, lifting equipment, curing tank, finished material storage space etc. shall
be designed such that the units are not lifted from the mould before 7 (seven)
days of curing and can be removed for erection after 28 (Twenty Eight) days of
curing. The moulds shall preferably be of steel or of timber lined with G.I .sheet
metal. The yard shall preferably be fenced.
Lifting hooks, wherever necessary or as directed by Engineer-in-Charge shall

be embedded in correct position of the units to facilitate erection, even though

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 125 OF 202
they may not be shown on the drgs. and shall be burnt off and finished after
erection.
Pre cast concrete units, when ready shall be transported to site by suitable
means approved by Engineer-in-Charge. Care shall be taken to ensure that no
damage occurs during transportation. All adjustments, levelling and plumbing
shall be done as per the instructions of the Engineer-in-Charge. The
CONTRACTOR shall render all help with instruments, materials and staff to the
Engineer-in-Charge for checking the proper erection of the pre cast units.
After erection and alignment the joints shall be filled with grout or concrete as
directed by Engineer-in-Charge. If shuttering has to be used for supporting the
pre cast unit they shall not be removed until the joints has attained sufficient
strength and in no case before 14 (fourteen) days. The joint between pre cast
roof planks shall be pointed with 1:2 (1 cement : 2 sand) mortar.
5.0 STEEL REINFORCEMENT
5.1 Steel reinforcement shall comprise:
1) CRS bars
2) TMT bars
5.2 All joints in reinforcement shall be lapped adequately to develop the full strength
of the reinforcement as per provision of IS: 456 or as per instruction of Engineer-
in-Charge.
6.0 Form Work
6.1 The shuttering or form work shall conform to the shape, lines and dimensions as
shown on the drawings and be so constructed as to remain sufficiently rigid
during placing and compacting of the concrete and shall be sufficiently tight to
prevent loss of liquid from the concrete. The surface that becomes exposed on
the removal of forms shall be examined by Engineer-in-Charge or his

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 126 OF 202
authorized representative before any defects are made good. Work that has
sagged or bulged out, or contains honey combing, shall be rejected. All
shuttering shall be plywood or steel shuttering.
6.2 The CONTRACTOR shall be responsible for sufficiency and adequacy of all form
work. Centering and form work shall be designed & detailed in accordance with
IS 14687 and approved by the Engineer-in-Charge, before placing of
reinforcement and concreting.
6.3 Stripping Time
Forms shall not be struck until the concrete has reached strength at least twice
the stress to which the concrete may be subjected at the time of removal of form
work. The strength referred to shall be that of concrete using the same cement
and aggregates, with the same proportions and cured under conditions of
temperature and moisture similar to those existing on the work. Where possible,
the form work shall be left longer as it would assist the curing.
Note 1: In normal circumstances and where ordinary Portland Cement is used,

forms may generally be removed after the expiry of the following periods:
1. Walls, columns and vertical faces of 24 to 48 hours as may be

all structural members decided by the Engineer-in-
Charge
2. Slabs (props left under) 3 days
3. Beam soffits (Props left under) 7 days
4. Removal of props under slabs
1. Spanning up to 4.5 m 7 days
2. Spanning over 4.5 m 14 days
5. Removal of props under beams &

arches:

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 127 OF 202
1. Spanning up to 6 m 14 days
2. Spanning over 6m 21 days
For other types of cements, the stripling time recommended for ordinary Portland
Cement may be suitably modified.
Note 2: The number of props left under, their sizes and disposition shall be such
as to be able to safely carry the full dead load of the slab, beam or arch as the
case may be together with any live load likely to occur during curing or further
construction.
7.0 Cement Concrete Block
Cement concrete block shall be machined made in the proportion of such that
mix shall not be leaner than one cement to twelve combined aggregates (by
volume) but having minimum strength of 7.5 MPa. Combined aggregate shall be
graded as near as possible to IS: 383. The fineness modules of combined
aggregate shall be between 3.6 and 4. The concrete block shall be properly
cured as per IS-456. The surface of conc. block shall have even face without any
honeycomb and free from cracks.
7.7.1 Mortar
Cement and water shall confirm to the requirements laid down for cement
concrete work.
7.7.2 Sand for concrete block masonry mortars shall be coarse sand generally
conforming to IS: 2116. Maximum quantities of clay, fine dust, shall not be more
than 5% by weight. Organic impurities shall not exceed the limits laid down in
IS: 2116.
7.7.3 Mix of mortar for building concrete block shall be as specified in the item of work.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 128 OF 202
7.7.4 Mixing of the mortar shall be done in a mechanical mixer. When quantity involved
is small hand mixing may be permitted by Engineer-in-Charge. Any mortar
remaining unused for more than 30 minutes after mixing shall be rejected.
7.8 Concrete Block Masonry
The thickness of joints shall be 10 mm +- 3mm. Thickness of joints shall be kept

uniform. In case of foundation and manholes etc. joints up to 15 mm may be
accepted.
7.9 Half Concrete Block
All courses shall be laid with stretchers. Reinforcement comprising 2 nos. 6 mm

dia MS bars shall be provided over the top of the first course and thereafter at
every fourth course.
7.10 Fixtures
All iron fixtures, pipes spouts, hold fasts of doors and windows which are
required to be built into the wall shall be embedded in cement concrete blocks
1:2:4 mix (1 cement :2 coarse sand :4 graded stone aggregate. 20 mm nominal
size) of size indicated in the item.
7.11 Curing
Concrete block masonry shall be protected from rain by suitable covering when
mortar is green. Masonry work shall be kept constantly moist on all faces for a
minimum period of seven days.
8.0 STRUCTURAL STEEL WORK
This specification covers the technical requirements for the preparation of shop
drawings, supply, fabrication, protective coating, painting and erection of all
structural steel rolled sections, built up sections, plates and miscellaneous steel
required for the completion of the work.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 129 OF 202
Steel
All structural steel used in construction within the purview of this contract shall,
comply with one of the following Bureau of Indian Standard Specifications,
whichever, is appropriate or as specified.
IS – 2062 Hot rolled sections and plates
IS – 1079 Cold formed light gauge sections
IS – 1161 Tubular sections
IS – 4923 Hollow sections (rectangular or square)
Fabrication
Fabrication of steel structure shall be carried out in conformity with the best
modern practices and with due regard to speed with economy in fabrication and
erection and shall conform to IS-800. All members shall be so fabricated as to
assemble the members accurately on site and erect them in correct positions.
Before dispatch to site the components shall be assembled at shop and any
defect found rectified. All members shall be free from kink, twist, buckle, bend,
open joints etc. and shall be rectified before erecting in position. Failure in this
respect will subject the defective members to rejection.
Fabrication Drawings:
Connections, splices and other details shall be suitably designed based on good
Engineering practice.
Electrodes:
Electrodes used for welding shall comply with IS-814 or IS - 815.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 130 OF 202
8.1 MS Black/High Strength Bolts and Nuts
M.S.Black or high strength bolts, nuts and washers etc. shall be as per IS-800,
IS-1363 and IS-1367. Manufacturer's test certificate shall be made available to
the Engineer-in-Charge. For bolted joints, shanks and threaded bolts are to be
used to ensure that threaded length do not encroach within the thickness of
connected members of dimension beyond the following limit:-
1. 1.5 mm for connected members of thickness below 12 mm and
2. 2.5 mm for connected member of thickness 12 mm and above and that

adequate shearing and bearing values required as per design are achieved.
Every portion work shall have its erection mark or numbers stencilled on the member
for guidance in erection and bear all necessary marks of erections as directed by the
Owner / Consultant.
7.13 No part of the work is to be oiled, painted (except contact surfaces ) packed,
bundled, crated or dispatched until it has been finally inspected and approved by
the Owner / Consultant or his authorized representative. The whole steel work
before being dispatched from the Contractor’s shop shall be dry and after being
thoroughly cleaned from dust, mills scale, rust etc., and shall be given two coats of
primer and one coat of final paint as per painting specification attached in this
enquiry. Unless otherwise specified, all surfaces inaccessible after welding shall be
given two coats of primer and two coats of paints as per painting specification
attached in this enquiry.
7.14 The Owner / Consultant or his authorized representative shall have free access at all
reasonable time to all places where the work is being carried out, and shall be
provided by the Contractor at his own expenses all necessary facilities for inspection
during fabrication and erection. The Owner / Consultant or his authorized
representative shall be at liberty to reject the work in whole or in part if the
workmanship or materials do not conform to the terms of the specifications

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 131 OF 202
mentioned herein. The Contractor shall remove, replace or alter any part of the work
as ordered by the Owner / Consultant or his authorized representative.
9.0 Painting on Structural Steel
Painting shall be as Painting Specification given elsewhere in the Tender

document.
10.0 Steel / Aluminium Doors, Windows and Ventilators
10.1 The Steel doors, windows and ventilators shall be of the size and type as per IS-
1361 and IS-1038. Fixing and glazing shall be done as per IS-1081 and as per
manufacturer’s instructions. The putty of approved make such as special gold
size or equivalent conforming to IS-419 shall be used.
10.2 Aluminium doors, windows and ventilators shall be manufactured from wrought
aluminium and aluminium alloy extruded round tube and / or hollow rectangular /
square sections conforming to IS: 1285 & IS : 6477 or equivalent as approved
by Engineer-in-Charge.
11.0 ROOFING & CLADDING
All roof and cladding sheets should be galvalume sheet of 0.5 mm total coated
thickness with 550 MPA grade steel confirming to AS 1397 with AZ150 grade
coating.
Translucent sheets shall be provided, in non-process areas only, intermittently

where day lighting is required.
12.0 FLOORING AND PAVING
12.1 Sub Base of floor
12.1.1 The area to be paved shall be divided into suitable panels. Form work shall be
provided. The boarding / battens shall be fixed in position with their toe at proper

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 132 OF 202
level, giving slope where required. Alternatively base concrete may be deposited
in the whole area at a stretch.
12.1.2 Before placing the base concrete the sub-base shall be properly wetted and
rammed. The concrete of the specified mix shall then be deposited between the
forms where provided, thoroughly tamped and the surface finished level with the
top edge of the forms. The surface of base concrete shall be spreader uniformly.
The surface shall be finished rough to provide adequate bond for the topping.
Two or three hours after concrete has been laid the surface shall be brushed with
wire brush to remove any scum or Latinate and swept clean so that coarse
aggregate is exposed.
12.2 Cement Concrete Floor Finishes
12.2.1 The surface of base concrete shall be thoroughly cleaned by scrubbing with coir
or steel wire brush. Before laying the toping, the surface shall be soaked with
water at least for 12 hours and surplus water mopped up immediately before the
toping is laid.
12.2.2 The forms shall be fixed over the base concrete dividing into suitable panels.
Where glass dividing strips are provided, thickness of glass dividing strips shall
be 4 or as indicated. Before placing the concrete toping, neat cement slurry at
the rate of 2 kg/sq.m shall be then thoroughly brushed into the base concrete just
ahead of the finish. The topping shall then be laid, thoroughly compacted by
using screed board/plate vibrator. The surface floated with a wooden float to a
fair and even surface shall be left for some time till moisture disappears from it.
Junctions with skirting / dado or wall surfaces shall be rounded off using cement
mortar 1:2 curing shall be carried out for a minimum of 7 days.
13.0 PLASTERING
13.1 Sand for plastering shall be 50% fine sand and 50% coarse sand from approved
sources.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 133 OF 202
13.2 Preparation of surface shall be done as per CPWD specifications.
13.3 Cement mortar shall be of the mix as indicated in the items and shall be mixed
as specified in the CPWD specifications.
13.4 Joints in walls etc. shall be raked to a depth of 12 mm, brushed clean with wire
brushes dusted and thoroughly washed before starting the plaster work.
13.5 The surface shall be thoroughly washed with water cleaned and kept wet to
saturation point before plastering is commenced.
13.6 Cement mortar as indicated, shall be firmly applied to the masonry walls in a
uniform layer to the thickness specified and will be pressed into the joints. On
concrete surfaces rendering shall be dashed to the roughened surface to ensure
adequate bond. The surface shall be finished even and smooth. Hectoring
wherever required shall be done as per directions of Engineer-in-Charge.
Nothing extra shall be paid on this account.
13.7 All plaster work shall be cured for at least 7 days.
13.8 Integral water proofing compound shall be mixed with cement in the proportion
recommended by the manufacturer. Care shall be taken to ensure that the water
proofing material gets well and integrally mixed with cement. All other operations
are the same as for general plaster work.
13.9 For sand face plaster undercoat of cement plaster 1:4 (1 cement : 4 sand) of
thickness not less than 12 mm shall be applied similar to one coat plaster work.
Before the under coat hardens the surface shall be scared to provide for the top
coat. The top coat also of cement mortar 1:4 shall be applied to a thickness not
less than 8 mm and brought to an even surface with a wooden float. The surface
shall then be tapped gently with a wooden float lined with cork to retain a coarse
surface texture, care being taken that the tapping is even and uniform.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 134 OF 202
14.0 Exterior Painting or Apex
14.1 Exterior painting shall be Apex.
14.2 Where shown on drawings for external surfaces of sand faced plaster, or any
other surface, two coats of cement paint shall be applied of tint and shade as
approved by the Engineer-in-Charge.
14.3 The surfaces shall be prepared as specified for white washing. Before applying
cement paint the surface shall be thoroughly wetted to control surface suction.
The surface shall be moist but not dripping wet, when the paint is applied. Not
less than 24 hours shall be allowed between the two coats. In hot weather the
first coat shall be slightly moistened before applying the second coat.
14.4 On external plastered surfaces (one coat primer + minimum 3 coat of paints),
sand faced or plain plastered and concrete surfaces, apex weather proof paint
shall be vigorously scrubbed on to work the paint into the voids and provide a
continuous paint film free from pin holes and other openings.
15.0 GLAZING
15.1 Sheet glass glazing of doors, windows etc. shall be of selected quality glass
conforming to IS: 2835. Toughened splinter proof industrial safety glass shall
confirm to IS: 2553. No cracked chipped or disfigured glass shall be accepted
Glass shall be in one piece for each pan.
15.2 Glazing shall be fixed with timber or steel / aluminium beading as called for.
Glass shall be back puttied and fixed with beading for a water tight and rattle free
installation. Sizes of timber/ steel / aluminium beading shall be as directed.
16. PROTECTIVE COATING AND LINING SYSTEM
16.1 ACID PROOF TILES:

MATERIAL

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 135 OF 202
1) TILES
These tiles shall be made of clays, feldspar, quartz, talc and vitrified at high
temperature in ceramic kilns and kept unglazed so as to prevent from slipperiness.
Tiles shall not absorb more than 2% of their own dry weight when soaked in water.
Compression strength: 700 Kg/cm2 Min. & Flexural strength: 200 Kg/cm2 Min. It
shall not lose more than 1.5% of it weight when soaked in acid.
Chemical compositions of tiles:
 Al2O3 : 22-24%
 SiO2 : 60-65%
 Fe2 O3 : 1.0-2.0%
 Alkalise : 10-12%
2) K-BASED SILICATE MORTAR
Acid Proof cement KSC is a potassium silicate based corrosion cement. Acid
tile linings carried out with KSC cement are not subject to crystal formation in
the pores of cement. Besides Bitumastic surface is joint-less, hence there is no
danger of Acids percolating through the surface.
Characteristics of K-based Silicate mortar:
 Colour : White
 Density (lbs/Cub. ft.) : 130
 Water Absorption : 2-5 %
 Tensile Strength (Psi) : 400
 Compressive strength (Psi) : 2800
 Bond Strength (Psi) : 180
 Coefficient of thermal expansion : 6.0 x 10-6
3) BITUMASTIC MORTAR

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 136 OF 202
It shall consist of an acid proof inorganic filler and blended bitumen. It shall be
trowelled to concrete having total thickness of 10 mm.
Characteristics of Bituminous compounds:
 Density (Kg/m3) : 2200
 Water content by mass percent (max) : 0.5
 Flash point °C ,min. : 35
Consistency
a) Before setting (test after 1 hr) min. : 100
b) After setting (test after 24 hr) min. : 80
Mastic shall be heated to 150-300oC and shall be applied in 5 mm layers after

surface is cleaned and dried.
4) BITUMINOUS PAINT
This is generally of heavy grade bituminous corrosion resisting paint. 2 coats

of the paint shall be given, and drying time between the 2 coats shall not be
less than 5 hours. Also, its drying time after second coat shall not be more
than 8 hours. Its finish shall be smooth, glossy and elastic.
The primer shall confirm to the following requirements:
 Viscosity by standard tar viscometer, 4mm orifice at 25°C: 4 to 24
 Penetration at 25°C, 100g, 5sec in 1/100 cm : 20 to 50
 Water content percent (max) : 0.2
APPLICATION
SL.
DESCRIPTION ITEM OR AREA
NO.
1. Bituminous Paint (Primer) Concrete surface

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 137 OF 202
SL.
NO.
10mm Bitumastic Laying in two layers each Over Bituminous

2.
shall not be more than 5mm thick Paint
One layer, 5mm Acid, K-based Silicate Type

3. #
mortar
Over K-based
4. 10 mm thick Acid proof tiling
Silicate
# - Tiles should be fixed on bitumastic surface with the help of 5mm K-

based silicate mortar.
16.2 EPOXY COATING
A. MATERIAL
1) EPOXY COATING
Characteristics of coated surfaces (after application)
• Compressive strength : min. 90 N/mm2
• Tensile strength : min. 10 N/mm2
• Abrasion resistance : as per Amsler 1.5 mm after 3000 revol.
• Bonding (joining) factor :1
APPLICATION:
SL.
DESCRIPTION APPLICATION
NO
One coat of two pack Primer coat on Concrete surface

1. interpenetration polymer (Epoxy
Phenolic)

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 138 OF 202
SL.
DESCRIPTION APPLICATION
NO
Thickness 60 micron per coat
One coat of two pack Intermediate Coat over Primer

interpenetration polymer (Epoxy Coat
2.
Phenolic)
One coat of two pack Final Coat over Intermediate Coat

interpenetration polymer
3.
(Polyurethane)
Sealing by polysulphide compound This will be provided at all joints

4.
with foundation, pits & wall etc
16.3 ACID RESISTANT BRICK LINING
A. MATERIAL
These bricks are made of raw materials such as clay or shale of suitable
composition with low lime and iron content, feldspar, flint or sand and vitrified at high
temperature in ceramic kilns. Bricks shall not absorb more than 2% of their own wt.
when soaked in water. Compression strength: > 700 Kg/cm2. Bricks shall not lose
more than 1.5% at their own weight when tested for acid resistance.
Chemical compositions of bricks are
a) Al2O3 22-24%
b) SiO2 60-65%
c) Fe2 O3 1.0-2.0%
d) Alkalies 10-12%

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 139 OF 202
1) K-BASED SILICATE MORTAR
Acid Proof cement KSC is a potassium silicate based corrosion cement. Acid
brick linings carried out with KSC cement are not subject to crystal formation in
the pores of cement. Besides Bitumastic surface is joint-less, hence there is no
danger of Acids percolating through the surface.
Characteristics of K-based Silicate mortar:
Colour : White
Density (lbs/Cub. ft.) : 130
Water Absorption : 2-5 %
Tensile Strength (Psi) : 400
Compressive strength (Psi) : 2800
Bond Strength (Psi) : 180
Coefficient of thermal expansion : 6.0 x 10-6
2) BITUMASTIC MORTAR
It shall consist of an acid proof inorganic filler and blended bitumen. It shall be
trowelled to concrete having total thickness of 10 mm.
Characteristics of Bituminous compounds:
Density (Kg/m3) : 2200
Water content by mass percent (max) : 0.5
Flash point °C ,min. : 35
Consistency
c) Before setting (test after 1 hr) min. : 100
d) After setting (test after 24 hr) min. : 80

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 140 OF 202
Mastic shall be heated to 150-300oC and shall be applied in 5 mm layers after

surface is cleaned & dried.
3) BITUMINOUS PAINT(PRIMER)
This is generally of heavy grade bituminous corrosion resisting paint. 2 coats

of the paint shall be given, and drying time between the 2 coats shall not be
less than 5 hours. Also, its drying time after second coat shall not be more
than 8 hours. Its finish shall be smooth, glossy and elastic.
The primer shall confirm to the following requirements:
Viscosity by standard tar viscometer, 4mm orifice at 25°C : 4 to 24
Penetration at 25°C, 100g, 5sec in 1/100 cm : 20 to 50
Water content percent (max) : 0.2
APPLICATION
SL.
NO.
Bituminous Paint (Primer) Concrete surface

.
10mm Bitumastic Laying in two layers each Over Bituminous

. shall not be more than 5 mm thick Paint
One layer, 5mm Acid, K-based Silicate

3. #
Type mortar
Over K-based
4. One layer, 40mm Acid resistant Brick lining
Silicate
#:- K-based Silicate mortar should be buttered on all sides of acid-resistant

brick except the side facing the surface to be exposed to corrosives

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 141 OF 202
17.0 CULVERT WORK
17.1 Pipe Culverts
17.1.1 Reinforced concrete pipes shall be provided between the drain pits of storm
water drains to cross the roads. These pipes shall be non-pressure type
conforming to IS: 458 and class as specified in the nomenclature of the item. The
pipes shall be laid between the drain pits with a uniform slope and with proper
bedding, if required, as per approved drawings. The reinforced concrete pipes
shall be manufactured by centrifugal process. All pipes shall be true to shape,
perfectly straight, sound and free from cracks. The pipes shall be free from
defects resulting from imperfect grading of the aggregate mixing or moulding.
17.1.2 Reinforced concrete pipes shall be laid, jointed and tested as per IS: 783. Pipes
shall be laid true to alignment and gradients over cement concrete bed of 1:2:4
mix and / or encased, if required, as per approved drawings or as directed by
Engineer-in-Charge. No deviations from the lines, depths of cuttings or gradients
shall be permitted without approval in writing by Engineer-in-Charge. The joint
between concrete drain pit wall and concrete pipe shall be done properly to make
it water-tight. The pipe joints shall be spigot and socket joint (rigid type) for pipes
of 600 mm. diameter and below and collar joint (rigid type) for pipes over 600
mm. diameter. For both types of joints, the annular space shall be filled up with
cement and sand mortar 1:2 mix which shall be rammed with caulking tools. After
the day's work, any extraneous matter shall be removed from inside of the pipes.
Joints shall be cured properly as per IS: 783. Reinforced concrete pipes shall be
tested hydraulically as per IS: 783. Refilling of trenches shall not be commenced
until the entire length of the pipe has been tested and approved. The excavation
of earth in trenches for laying the concrete pipes and refilling shall be done as
per IS: 783.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 142 OF 202
17.2 Box Culverts
17.2.1 The box-culverts are to be provided across the roads joining the storm water
drains on both sides of the road. These box-culverts shall be of either complete
reinforced cement concrete construction or brick masonry and reinforced cement
concrete construction as specified in the schedule of items. The box-culvert
construction shall be carried out as per the approved drawings.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 143 OF 202
ANNEXURE-V
ES-2517
FOR
WATER SUPPLY, DRAINAGE & SANITATION

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 144 OF 202
CONTENTS
SL.NO. DESCRIPTION Page No.
1.0 SCOPE 162
2.0 GENERAL REQUIREMENTS 162
3.0 CODES & STANDARDS 163
4.0 MATERIALS 166
5.0 MANHOLES 173
1.0 Scope
This Specification Covers The supply, laying and installation of pipes / open
surface drains for draining off rain / surface water, fire water, sewage, plant

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 145 OF 202
effluent / blow down / floor washings etc., with all fittings and fixtures including
jointing.
The supply, laying and installation of pipes for supply of water with all fittings and
fixtures including jointing.
The supply and installation of sanitary fixtures like water closets, urinals, wash
basins, sinks etc., with all fittings and fixtures.
The supply and installation of toilet accessories like mirrors, shelves, towel rails,
liquid soap containers etc., with all fittings and fixtures.
The supply and installation of overhead water tanks with all fittings and fixtures.
The supply and construction of ancillary works like manholes, drop connections,
gully chambers, oil traps, soak pits etc., with all fittings and fixtures.
2.1 The Contractor shall furnish all skilled and unskilled labour, plant, equipments,
scaffolding, men, materials, etc., required for complete execution of the work in
accordance with the drawings and as described herein and / or as directed by
the Engineer.
2.2 The Contractor shall make his own arrangements for locating the coordinates
and positions of all works and reduced levels (RL) at these locations based on
two reference grid lines and one bench mark which will be furnished by the
owner. The Contractor has to provide at site all the required survey instruments
etc., to the satisfaction of the Engineer so that the work can be carried out
accurately according to the specification and drawing.
2.3 The Contractor shall make good to the satisfaction of the Engineer all cuttings /
damages resulting from his operations during the installation.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 146 OF 202
2.4 Only tentative Plant layout shall be furnished by the Owner. Detailed working
drawings showing the layout, installation and other details will be prepared by the
Contractor and got approved from the Engineer.
2.5 The Contractor shall dispose of all unserviceable materials at least 50 m away
from the plant boundary, unless otherwise directed by the Engineer. All
serviceable material shall be stacked within a lead of 500 m as directed by the
Engineer.
2.5 In case of any contradiction between the provisions stipulated in this module of
technical specification and those of other modules like Excavation and Filling,
Cast-in-situ Concrete and Allied works etc., the former shall govern.
All works shall be carried out by qualified / licensed plumbers.
3.1 All standards, specifications, acts, and Codes of practice referred to herein shall
be the latest edition including all applicable official amendments and revisions.
3.2 In case of conflict between this specification and those (IS Standards, codes etc.)
Referred to herein (in para 3.3) the former shall prevail.
3.3 Some of the relevant Indian Standards, Acts and Codes referred to herein are
given below:
IS : 458 : Precast concrete pipes.
IS : 554 : Dimensions for pipe threads, where pressure tight

joints are made on threads.
IS : 651 : Salt glazed stoneware pipes and fittings.
IS : 771 : Glazed fire clay sanitary appliances.


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 147 OF 202
(Part-1 to 7)
IS : 774 : Flushing cisterns for water closets and urinals.
IS : 775 : Cast iron brackets and supports for wash basins and
sinks.
IS : 778 : Copper alloy gate, globe and check valves for water
works purposes.
IS : 781 : Cast copper alloy screw down bib taps and stop
valves for water services.
IS : 782 : Caulking lead.
IS : 783 : Code of practice for laying of concrete pipes.
IS : 805 : Code of practice for use of steel in gravity water tanks.
IS : 1172 : Code of basic requirements for water supply, drainage

and sanitation.
IS : 1239 : Mild steel tubes, tubular and other wrought steel

fittings.
IS : 1536 : Centrifugally cast (Spun) iron pressure pipes for water,

gas and sewage.
IS : 1703 : Copper alloy float valves.
IS : 1726 : Cast iron manhole covers and frames.
IS : 1729 : Sand cast iron spigot and socket, soil waste and
ventilating pipes, fittings and accessories.
IS : 1742 : Code of practice for building drainage.
IS : 1795 : Pillar taps for water supply purposes.
IS : 2065 : Code of practice for water supply in buildings.
IS : 2326 : Automatic flushing cisterns for urinals.
IS : 2501 : Solid drawn copper tubes for general engineering

purposes.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 148 OF 202
IS : 2548 : Plastic seats and covers for water closets.
IS : 2692 : Ferrules for water services.
IS : 2963 : Copper alloy waste fittings for wash basins and sinks.
IS : 3311 : Waste plug and its accessories for sinks and wash
basins.
IS : 3438 : Silvered glass mirrors for general purposes.
IS : 3486 : Cast iron spigot and socket drain pipes.
IS : 3989 : Centrifugally cast (spun) iron spigot and socket soil,

waste and ventilating pipes, fittings and accessories.
IS : 4111 (Part- : Code of practice for ancillary structure in sewerage

1 to 5) system.
IS : 4127 : Code of practice for laying of glazed stone-ware pipes.
IS : 4764 : Tolerance limits for sewage effluent discharged into

inland- surface waters.
IS : 4827 : Electro plated coatings of nickel and chromium on

copper and copper alloys.
IS : 5219 : Cast copper alloys traps.
IS : 5329 : Code of practice for sanitary pipe work above ground

for buildings.
IS : 5382 : Rubber sealing rings for gas mains, water mains and
sewers.
IS : 5822 : Code of practice for laying of welded steel pipes for

water supply.
IS : 6163 : Centrifugally cast (spun) iron low pressure pipes for

water, gas and sewage.
IS : 7231 : Plastic flushing cisterns for water closets and urinals.
IS : 7740 : Code of practice for construction and maintenance of


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 149 OF 202
road gullies.
IS : 8931 : Copper alloy fancy single taps combination tap

assembly and stop valves for water services.
IS : 8934 : Cast copper alloy fancy pillar taps for water services.
IS : 9762 : Polyethylene floats for float valves.
IS : 10446 : Glossary of terms for water supply and sanitation.
IS : 10592 : Industrial emergency showers, eye and face fountains

and combination units.
IS : 12592 : Specification for precast concrete manhole covers and

frames.
SP : 35 : Hand book on water supply and drainage.
4.0 MATERIAL
4.1 All pipes, fittings, fixtures, appliances and accessories shall conform to the
relevant Indian Standards as listed under Clause No. 3.0. These shall be
obtained from an approved reputed manufacturer, and shall be approved, the
Engineer. Wherever indicated by the Engineer, the Contractor shall submit
samples of materials. These may be retained by him for subsequent comparison
when bulk supplies are received at site. Ultimate choice of type lies completely
with the Engineer.
4.2 The material brought to the site shall be stored in a separate secured enclosure,
away from the building materials. Pipe threads, sockets and similar items shall
be specially protected till final installation. Brass and other expensive items shall
be kept under lock and key. Fragile items shall be checked thoroughly when
received at the site and item found damaged shall not be retained at site.
4.3 Chromium plating fittings and appliances shall be of grade-2. (10 micron
thickness), conforming to IS: 4827.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 150 OF 202
4.4 Pipes
Unless otherwise specified, following types of pipes shall be used:
For water supply to buildings, fittings CPVC pipes conforming to IS 15778 shall
be used.
For inlet connecting pipes to appliances / fittings, C.P. brass pipe of 15 mm N.B.
with union of approved make shall be used. Standard length of 300 mm to 450
mm pipe shall be used to suit the site requirements.
For building sanitary work above ground, UPVC pipes, fittings and accessories
conforming to IS: 13592/relevant IS Codes shall be used. Pipes shall be coated
with coal-tar by hot dipping process for both inner and outer surfaces.
Glazed stoneware pipes used for sewer and drain shall conform to Grade A of IS:
651. RCC pipe used for sewer and drain shall conform to IS: 458. Class NP2
pipe shall generally be used. However, for road or railway crossing higher class
of pipe or concrete encashment shall be provided to take care of higher load.
For drain and sewer line work in bad or unstable ground condition and under
building, centrifugally cast (Spun) iron pressure pipes conforming to IS: 1536
shall be used. Class LA pipe with spigot and socket ends shall be used. Pipes
shall be coated with coal tar.
PVC rain water pipes shall be used for roof drainage.
4.5 Above Ground Level
1) Galvanised mild steel pipes for water supply
For work above ground level, the galvanised mild steel pipes and fittings
shall run on the surface of the walls, ceiling or in chase as specified or shown
on the drawing. The fixing shall be done by means of standard pattern holder
bat clamps, provided at no more than 90 cm and keeping the pipes about 1.5

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 151 OF 202
cm clear of the wall. To conceal the pipes, chasing may be adopted or pipes
fixed in the ducts or recess etc. Provided there is sufficient space to work on
the pipes with the common tools. The pipes shall not ordinarily be buried in
walls or solid floors. Under unavoidable situations, pipes may be buried for
short stretch after providing adequate protection against damage. Union
joints shall be provided for all required locations to facilitate maintenance.
Where directed by the Engineer, a M.S. tube sleeve shall be fixed at a place
the pipe is passing through. In case the pipe is embedded, it should be
painted with anti-corrosive bitumastic paints conforming to IS: 158. The pipes
shall be oiled and rubbed over the white lead and a few turns of spun yarn
wrapped round the screwed end of the pipe. The end shall then be screwed
in the socket, tee etc., with the pipe wrench. All pipes and fittings shall be
properly jointed and made complete water tight. Burr from the joint shall be
removed after screwing.
The pipes and fittings shall be checked under working pressure. Any joint
found leaking, shall be rectified and all leaking pipes removed and replaced.
The pipes and fittings shall be tested to a hydraulic pressure of 6 kg/sq.cm.
All pipes used for water supply should be thoroughly and efficiently
disinfected before being taken into use. The method of disinfection shall be
subject to the approval of the Engineer.
The storage tanks and downtake distribution pipes shall be disinfected

together as specified under clause no. 13.2 of IS: 2065-1983, using
disinfecting chemical.
2) UPVC pipe above ground for Buildings Sanitary work
For sanitary pipe work above ground for Buildings, 1S:5329 shall be followed
for general guidance. Proper ventilation shall be provided in the piping
system. The single stack system shall not generally be provided.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 152 OF 202
Plain pipes shall be secured to the walls at all joints with M.S. holder bat
clamps. The clamp shall be made from 1.6 mm thick M.S. sheet of 30 mm
width, bent to the required shape and size so as to fit tightly on the socket of
the pipe, when tightened with screw bolts. It shall be formed out of two
semicircular pieces, hinged with 6 mm dia M.S. pin on one side and provided
with flanged ends on the other side with holes to fit in the screw holt and nut,
40 mm long. The clamp shall be provided with a hook made out of 27.5 cm
long, 10mm diameter M.S. bar, riveted to the ring at the centre of one
semicircular piece. C.I. brackets can also be used. The clamps shall be fixed
to the wall by embedding their hooks in cement concrete block 10 x 10 x 10
cm (1:2:4 mix) for which necessary holes shall be made in the wall at proper
places. The clamps shall be kept about 25 mm clear of finished face of wall.
All soil pipes shall be carried up above the roof and shall have sand PVC
terminal guard. The pipes above parapet shall be secured to the wall by
means of clamps.
The pipes shall be fixed perfectly vertical or to the lines as directed. The
spigot of the upper pipes shall be properly fitted in the socket of the lower
pipe such that here is a uniform annular space for filling with the jointing
material. The interior of the socket and exterior of the spigots shall be
thoroughly cleaned and dried. The spigot end shall be inserted into the
socket right up to the back of the socket and carefully jointed using solvent
as per recommendation of manufacturer.
Floor trap shall be 'Nahni' or ordinary type and shall conform to IS:1729. The
floor shall be suitably lowered to accommodate the trap and the top of the
floor shall be properly sloped towards the trap for effective drainage. A
chromium plated/galvanised grating shall be provided on the trap. The
sunken floor slab shall be filled with light weight materials like cinder mixed
with cement. Sunken slab shall be made watertight by means of Sika water
proofing compound as recommended by the manufacturer.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 153 OF 202
Rain Water Downcomers
Rain water downcomers and fittings shall be standard PVC rainwater

downcomers shall run along and be secured to walls, columns etc. Where
desired by the Engineer, these may have to be installed in chases cut out in
the structure. All pipes shall be well secured to the walls and supported by
adequately strong brackets. The brackets may be wrought iron clevis type,
lip-ring type or perforated strap iron type, as approved by the Engineer.
Suitable spacer blocks shall be provided against the vertical surface on
which the pipe is fixed.
All bends and junctions shall be supplied with water tight cleaning eyes. For
improving the aesthetic appearance of the portion of building carrying rain
water downcomers, the pipes may have to be concealed by encasing them
with brick masonry, concrete, etc.
Galvanised M.S. pipes shall be joined by using standard sockets or by

welding. For welding of pipes, IS:11906 shall be followed. After welding, the
welded area shall be coated with zinc rich paint after proper cleaning and
preparation of the surface. Joints between successive lengths of pipe can be
by collars according to provision of IS:1742-1983. All rainwater downcomers
shall be provided with roof drain head of the shape and type as shown on the
drawing. Unless otherwise specified, dome type drain head shall be used.
3) Khurras
The khurras shall be constructed before the brick masonry work in parapet
wall is taken up, and it shall be 45x45cm in size, unless otherwise specified
and be formed of cement concrete 1 :2:4 (1 cement: 2 sand: 4 graded stone
aggregate of 20 mm nominal size).
A PVC sheet 1 mx1 mx400 micron shall be laid under khurras and then
cement concrete shall be laid over it to a minimum thickness of 3cm with its

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 154 OF 202
top surface lower than the level of adjoining roof surface by not less than
50mm.
The concrete shall be laid to a size greater than the stipulated size of khurra
in such a way that the adjoining terracing of brick tile overlaps the concrete
on its 3 edges by not less than 7.5 cm. The concrete shall slope uniformly
from the edges to the rainwater outlet. The concrete shall be continued at the
same slope through the width of the wall into outlet opening to ensure a
water tight joint.
The khurras and the sides of outlet shall then be rendered with 12 mm coat
of cement plaster 1:3 (1 cement: 3 sand). This shall be done when the
concrete is still green and shall be finished with a floating coat of neat
cement. The sides of khurras and the sides of openings shall be well
rounded. The size of finished outlet opening shall be 10cm wide by 20cm
high or as directed by the Engineer.
Iron grating shall be provided at the outlet to prevent chocking. The grating
shall be 20×25cm with an outer frame of 15mm x 3mm MS flat, to which 4
nos. - 10mm dia MS bars shall be welded in vertical direction, keeping an
equal clear spacing of 2.5cm.
4) Rainwater Spout
No spout shall be less than 80 mm in diameter. The spacing of spouts shall

be arranged to suit the position of openings in the wall.
The spouts shall be of PVC, 60 cm long. These shall be perfectly sound, free
from cracks, imperfections of glazing etc. These must be straight, cylindrical
and of Standard nominal diameter, length and depth of socket. Full length of
pipes shall be used on the work. These must be salt glazed and shall
generally conform to IS: 651.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 155 OF 202
These shall be provided at the mouths of khurras and shall be fixed in

cement mortar 1: 4 (1 cement: 4 sand) with the socket embedded in the
masonry and the spigot end projecting outside. The masonry around the pipe
and socket shall be thoroughly wetted and the hole shall be given a coat of
cement mortar around. The pipe shall then be inserted and fixed with a
surround of mortar. In case the hole is made much larger than the size of the
pipe. Cement concrete 1: 2: 4I (1 cement: .2 sand: 4 graded. stone
aggregate of 12.5 mm nominal size) shall be used to fill in the annular space.
The spouts shall slope downward at a slope of 1 in 6. The projection outside
the wall shall be uniform and not less than 40 cm. The entrance with the pipe
shall be smoothly rounded to meet the internal bore of the pipe to facilitate
easy flow. Care shall be taken to ensure that the vertical plane through the
centre line of the spouts in a row shall be true to line.
4.6 Below Ground Level:
1) Trenches and other Excavation:
Except as mentioned hereunder, all work for earthwork shall be done as

specified in relevant chapter of Excavation and Filling. The trenches shall be
so dug that the pipe may be laid to the required alignment and at required
depth. The cover shall be measured from top soil or other surface of the
ground. Turf, top soil or other surface material shall be set aside, turf being
carefully removed and stacked for use in reinstatement. The bed of the
trench, if in soft or made up earth, shall be well watered and rammed before
laying the pipes and the depressions, if any, shall be properly filled with earth
and consolidated in 20 cm layers.
If the trench is extremely hard or rocky or loose stony soil, the trench shall be
excavated at least 150 mm below the trench grade. Rocks, stone or other
hard substances from the bottom of the trench shall be removed and the

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 156 OF 202
trench brought back to the required grade by filling with selected earth and
compacted so as to provide smooth bedding for the pipe.
The last 7.5 cm. of excavation shall be trimmed and removed as separate
operation immediately prior to the laying of the pipe on their foundations. The
width of the trench shall be such as to provide not less than 20 cm clearance
on either side of the pipe. Excavation in road shall be so arranged as to
cause minimum obstruction to traffic.
2) Laying of Pipes:
In no case, pipes shall be rolled and dropped into the trench. After lowering,
the pipes shall be arranged so that the spigot of one pipe is carefully
centered into the socket of the next pipe and pushed to the distance that it
can go.
The pipe shall be laid with socket facing the direction of flow of water. The
connection to an existing sewer shall as far as possible be done at the
manhole.
3) Filling of Trench
Filling of the trench shall not be commenced until the length of pipes therein
has been tested and passed. Special care shall be taken to pack under and
sides of the pipes thoroughly with selected material. At least 300 mm over
the pipe shall also be filled with selected earth.
5.0 MANHOLES
5.1 Wherever applicable manhole should be suitably designed & constructed.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 157 OF 202
ANNEXURE-VI
ES-2509
TECHNICAL SPECIFICATIONS
FOR
BORED CAST-IN-SITU CONCRETE VERTICAL PILES

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 158 OF 202
CONTENTS
SL. NO. DESCRIPTION
1.0 SCOPE
2.0 GENERAL REQUIRMENTS
4.0 MATERIALS
5.0 CONCRETE
6.0 REINFORCEMENT
7.0 PILE INSTALLATION
8.0 SAMPLING, TESTING & QUALITY

ASSURANCE
9.0 LOAD TEST ON PILES
10.0 RECORDING OF DATA & PRESENTATION
ANNEXURE - A PILE DATA
TABLE - 1 FREQUENCY OF SAMPLING AND TESTING
ANNEXURE - B PILE LOAD TEST DATA

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 159 OF 202
1.0 SCOPE
1.1 The specifications cover the installation of bored cast-in-situ reinforced

concrete Vertical Piles.
1.2 This specification also covers the technical requirements for load test (Initial
and Routine tests) on reinforced concrete single vertical piles of specified
diameter to assess their vertical, horizontal and pull-out load carrying
capacity.
1.2.1 Load tests on piles shall conform to IS : 2911 ( Part – IV ).
2.1 The work shall include mobilisation of all necessary equipment, kentiledge,
reaction piles, or combination of reaction piles, providing necessary
engineering supervision through qualified and technical personnel, skilled and
unskilled labour, etc. as required carrying out the complete piling work, load
tests and submission of records/ reports as per schedule.
2.2 The Bidder shall guarantee the “safe load” capacity of piles for various modes
i.e., vertical, lateral and pull-out tests for piles installed by him.
2.3 Consequent upon award of work and prior to installation of piles, the Bidder
shall submit design of piles in terms of allowable capacity, length, diameter,
termination criteria, reinforcement, etc. for OWNER’S/CONSULTANT’S
approval. OWNER’S/CONSULTANT’S approval on pile design in no way
absolves the Bidder for his responsibility to carry out all the initial (vertical,
lateral and pull-out) load test of piles prior to installation of the job piles. The
pile capacity to be used in design shall be arrived at from the initial load test
of piles.
2.4 The Bidder shall make his own arrangement for locating the co-ordinates and
position of piles shown in approved drawings and for determining the

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 160 OF 202
Reduced Levels (R.L) of these locations with respect to the single Bench
Mark indicated by the Engineer-in-Charge. Two established reference lines
in mutually perpendicular direction shall be indicated to the Bidder. The
Bidder shall provide at site all the required survey instruments to the
satisfaction of the Engineering–in–Charge so that the work can be carried out
accurately according to specifications and drawings.
2.5 In case of working piles, if the pile is rejected due to any other reasons, the
Bidder shall install extra piles at no extra cost to OWNER/CONSULTANT.
Further, the extra cost due to the increase in the pile cape size, if any, on
account of extra piles shall be borne by the Bidder.
2.6 It is essential that all equipment and instruments are properly calibrated both
at commencement and immediately after the tests so that they represent true
values. Certificates to this effect from an approved institution shall be
furnished to the Engineer-in-Charge. If the Engineer-in-Charge so desires the
Bidder shall arrange for having the instruments tested at an approved
laboratory at his own cost and the test report shall be submitted to the
Engineer-in-Charge. If the Engineer-in-charge desires to witness such tests
Bidder shall arrange to conduct the test in his presence.
2.7 The complete jacking system including the hydraulic jack, hydraulic pump and
pressure gauge shall be calibrated as unit. The complete unit shall be
calibrated over its complete range of travel for increasing and decreasing load
same as that of test loads. The calibration certificate shall be submitted to the
Engineer-in-Charge.
2.8 The reaction load to be made available for the test shall be at least 25%
greater than the maximum jacking force. The reaction system as relevant
shall be designed for the total reaction load. All reaction loads shall be stable

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 161 OF 202
and balanced during all operations of testing. During testing, stability of

reaction system shall be ensured.
2.9 The load applied on the pile shall be measured by a calibrated pressure
gauge mounted on the jack.
2.10 The displacement of the pile (in vertical, horizontal and uplift) shall be
measured using dial gauges having a least count of 0.01 mm.
2.11 Load test shall be conducted at pile Cut of Level (COL). If the water table is
above the COL the test pit shall be kept dry throughout the test period by
suitable dewatering methods.
2.11.1 In case initial vertical load test where the water table is higher than the COL
BIDDER may use reaction piles for testing purpose in each case. Engineer-
in-charge may at his discretion to decide to raise the COL above water table.
2.12 Full details of the equipment proposed to be used and the test set-up with
detail sketches shall be submitted to the engineer-in-charge, before making
arrangement to carry out the tests, for his approval. Approval of Engineer-in-
charge shall also be obtained after the test set up is complete prior to
commencement of loading.
2.13 All operations in connection with pile load test shall be carried out in a safe
manner so as to prevent the exposure of people to hazard.
2.14 If any test has to be discontinued, which in the opinion of the Engineer
interferes with the load test results, and he decides to abandon the test,
BIDDER shall install another pile for the purpose and repeat the test after

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 162 OF 202
correcting the fault and the cost of all such operations, including the cost of
test pile, shall be at the BIDDER’S expenses..
2.15 After completion of piling work Bidder shall submit four copies of the following
documents for OWNER’s record and future reference:
a. Initial load test data for all tests done along with the pile data and the
analysis of the Initial load test results.
b. Pile data along with concrete mix design detail ( Note : pile data shall
contain details as per requirement of Annexure – A )
c. Routine load test data for all tests done.
d. A full record giving all details of test in the performa shown in

Annexure–B shall be submitted in triplicate to the Engineer-in-charge
immediately on completion of each test. The record shall also include
the plots of:
i. Load vs. Settlement

ii. Time vs. Settlement
iii. Characteristic of the piles and the interpretation of the pile load test
curve as per the criteria for safe loads as mentioned in the
specification.
2.16 Before commencement of the work, the bidder shall submit Quality
Assurance Plan to OWNER / CONSULTANT for their approval.
3.0 CODES AND STANDARDS.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 163 OF 202
3.1 All standards and code of practice referred to herein shall be the latest
editions including all applicable revisions issued.
3.2 All works shall be carried out as per the relevant latest Indian Standard
Codes. In case of conflict between the specification and the IS codes referred
to herein, the former shall prevail. Some of the applicable Indian Standards
and codes are referred to here below. :
IS : 432(part-I&II) Specifications for mild steel and medium tensile steel bars
and hard drawn steel wire for concrete reinforcement.
IS : 456 Code of practice for plain and reinforced concrete.
IS : 1786 Code of practice for twisted steel high strength deformed

bars for concrete reinforcement.
IS: 2911(part I &II) Code of practice for design and construction of pile
foundation - Bored cast in situ concrete piles.
IS : 2911 (part-IV) Code of practice for design and construction of pile

foundations – Load test on piles.
SP-34 Handbook on concrete reinforcement and detailing
IS : 5121 Safety code for piling and other deep foundations.
IS: 10262 Recommended guidelines for concrete mix design.
IS: 12330 Code of practice for Sulphate resistant Cement.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 164 OF 202
4.0 MATERIALS
4.1 GENERAL
All materials viz. cement, steel, aggregate, water etc., which are to be used
for pile construction shall conform to relevant IS codes specifications for
properties, storage and handling of common building materials. However,
aggregate more than 20 mm shall not be used.
5.0 CONCRETE
5.1 Enclosed Technical Specification for cast-in-situ concrete and allied works
along with IS: 2911 (Part-I/Sec.2) – Code of Practice for Design and
construction of pile foundations (Bored cast- in- situ piles) shall be applicable
to concrete works for piles. Use of plasticizer to control the water- cement
ratio shall be permitted on specific approval from Engineer-in-charge.
5.2 GRADE AND MINIMUM CEMENT CONCRETE
5.2.1 Cement concrete of M-30 as per IS 456 shall be used. Cement content shall
be as per mix design conforming to IS : 10262. However, the minimum
cement content shall be 400 kg. per cubic metre of concrete. In case of piles
subsequently exposed to free water or in case of piles where concreting is
done under water or drilling mud using methods other than the tremie, 10%
extra cement over that required for the design grade of concrete at the
specified slump shall be used subject to minimum cement specified above.
5.2.2 For the concrete, water, aggregate, cement, reinforcement etc., specification
laid down in 9338-PSCV-0000-946 & IS: 456 shall be followed in general.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 165 OF 202
Natural rounded shingle of appropriate size may also be used as coarse

aggregate. It helps to give high slump with less water cement ratio.
5.2.3 The concrete for piles in aggressive surroundings due to presence of

Sulphates, etc, should have a concrete mix of appropriate type of cement in
suitable proportion.
a. If the concentration of sulphates ( measured as SO3) exceeds one

percent in soil or 2500 parts per million ( ppm. ) in water, a mix using 400
kg/Cu.M. of super sulphated cement conforming to IS: 6909 or Sulphate
resisting Portland Cement conforming to IS : 12330 shall be used. For
soils with 0.5 to 1 percent of sulphates or ground water with 1200 to 2500
ppm, the mix should be minimum 400 kg/Cu.m. of supersulphated or
sulphate resisting Portland cement . For concentrations less than above,
concrete mix with 400 kg/cu.m. Pozzolona/ blast furnace slag cement
shall be used.
b. For bored compaction piles rapid hardening cement shall not be used. To
facilitate construction, admixtures for retarding the setting of concrete
may be used in consultation with the Engineer-in-charge.
5.3 SLUMP OF CONCRETE
The slump of concrete shall vary between 150 mm to 180 mm for concreting
in water–free unlined boreholes. For concreting by tremie, a slump of 150 mm
to 200 mm shall be used.
6.0 REINFORCEMENTS

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 166 OF 202
6.1 For Longitudinal and lateral reinforcement in piles, high yield strength deformed
CRS steel bars of grade Fe500D conforming to IS: 1786 shall be used. The
Minimum dia. used shall be 8mm. All steel reinforcements shall be procured from
SAIL / TISCO /RINL/SHYAM STEEL INDUSTRIES LTD or Owner’s approved
Vendor List.
. The provision of reinforcement will depend on nature and magnitude of loads,
nature of strata and method of installation. It should be adequate for vertical load,
lateral load and moments, acting individually or in combination.
6.2 The minimum area of longitudinal reinforcement shall be 0.4 percent of the
sectional area calculated on the basis of outside area of casing or pile shaft
where casing Is not used, whichever is more. The minimum number of
longitudinal reinforcement shall be 6 (Six) and its minimum diameter shall be
12 mm. The stipulated minimum reinforcement shall be provided for full
length of pile. Adequate reinforcement shall be provided to take full uplift
loads.
6.3 Longitudinal reinforcement shall project 50 times its diameter above cut off
level unless otherwise indicated.
6.4 The minimum diameter of the links or spirals bar shall be 8.0 mm and the
spacing of the links or spiral shall not be more than 150 mm The laterals shall
be tied to the longitudinal reinforcement to maintain its shape and spacing.
6.5 Reinforcement cage shall be sufficiently rigid to withstand handling and

installation without any deformation and damage. As far as possible number
of joints (laps) in longitudinal reinforcement shall be minimum. In case the
reinforcement cage is made up of more than one segment these shall
preferably be assembled before lowering into casing tube / pile bore by
providing necessary laps as per IS : 456

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 167 OF 202
6.6 Laps shall be staggered as far as practicable and not more than 50% bars
shall be lapped at a particular section. Lap joints shall be staggered by at
least 1.3 times the lapped length ( centre to centre ).
6.7 Proper cover and central placement of the reinforcement cage in the pile bore
shall be ensured by use of suitable concrete spacers or rollers cast
specifically for the purpose.
6.8 Minimum clear cover to all main reinforcements in piles shall not less than
50 mm unless otherwise specified.
7.0 PILE INSTALLATION
Installation of piles shall be carried out as per pile layout drawings, installation
criteria and the direction of the Engineer-in-charge.
7.1 EQUIPMENT AND ACCESSORIES
7.1.1 The equipment and accessories for installation of bored cast-in-situ piles shall
be selected giving due consideration to the sub-soil conditions, ground water
condition and the method of casting etc. These shall be of standard type and
shall have the approval of the Engineer-in-charge.
7.1.2 List of details of equipment and accessories proposed to be used for the job
shall be submitted along with the bid.
7.1.3 The capacity of the rig shall be adequate so as to reach the specified
founding level.
7.2 CONTROL OF POSITION AND ALIGNMENT

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 168 OF 202
7.2.1 Piles shall be installed as accurately vertical as possible at the correct

location and truly vertical. Great care shall be exercised of a single pile or
piles in two piles groups under a column. The permissible limits for deviation
with respect to position and alignment (inclination) shall conform to IS : 2911
(Part-I/ sec-2 ), which is reproduced below for ready reference :
a. The maximum deviation of vertical piles shall not exceed 1.5% in

alignment.
b. Piles shall not deviate more than 75 mm (their designed position at cut
off level). In case of single pile, this tolerance should not exceed 50 mm.
In case of piles deviating beyond these limits, the pile shall be replaced
or supplemented by one or more additional piles without any extra cost
to NER/CONSULTANT.
7.3 BORING
7.3.1 Boring operation shall be done by rotary or percussion type drilling rigs using
direct, reverse mud circulation (DMC or RMC) method or grab method. In soft
clays and loose sand, bailer method, if used, shall be used with caution to
avoid the effect of suction. Boring operations by any of the above method
shall be done using drilling mud.
7.3.2 Bidder shall satisfy himself about the suitability of the method to be adopted
for site. If DMC or RMC is used bentonite slurry shall be pumped through drill
rods by means of high pressure pumps. The cutting tool shall have suitable
ports for the bentonite slurry to flow out at high pressure. If on mobilisation,
Bidder fails to make a proper bore for any reason, the bidder has to switch

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 169 OF 202
over to other boring methods as approved by the Engineer-In-charge at no

extra cost to OWNER.
7.3.3 Working level shall be above the cut of level. After the initial boring of about
1.0 to 2.0 m temporary guide casing shall be lowered in the pile bore. The
diameter of guide shall be of such diameter to give the necessary finished
diameter of concrete pile. The centre line of guide casing shall be checked
before continuing further boring. Guide casing shall be minimum 1.0 m length.
Additional length of casing may be used depending on the condition of strata,
ground water level etc.
7.3.4 Use of drilling mud (bentonite suspension/slurry) for stabilising the sides of
the pile bore is necessary wherever is likely to collapse in the pile bore.
Drilling mud to be used shall meet the following requirement:
7.3.4.1 Liquid limit of bentonite when tested in accordance with IS : 2720 ( Part-V )
shall more than 300 percent and less than 450 percent.
7.3.4.2 Sand content of the bentonite powder shall not be greater than 7 percent.
7.3.4.3 Bentonite solution should be made by mixing it with fresh water using pump
for circulation. The density of the freshly prepared bentonite suspension shall
be between 1.034 and 1.100 gm/ml depending on the pile dimensions and
type of soil in which the pile is to be cast. However, the density of bentonite
suspension after mixing with deleterious materials in the pile bore may be
upto 1.25 gm/ml.
7.3.4.4 The marsh viscosity when tested by a Marsh cone shall be between 30 to 60
seconds.
7.3.4.5 The differential free swell shall be more than 540 percent.
7.3.4.6 The pH value of the bentonite suspension shall be between 9 and 11.5.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 170 OF 202
7.3.5 The bentonite slurry and the cuttings, which are carried to the surface by rising
flow of slurry shall pass through settling tanks of adequate size to remove the sand
and soils from the slurry, before the slurry is recirculated to the boring. The
bentonite slurry mixing and recirculation plant shall be suitably designed and
installed.
7.3.6 The bentonite slurry shall be maintained at 1.5 m above the ground water level
during the boring operations and till the pile is concreted. When DMC and RMC
method is used the bentonite slurry shall be under constant circulation still start of
concreting.
7.3.7 The size of cutting tools shall be not less than the diameter of the pile by more
than 75 mm. However, the pile bore shall be of the specified size.
7.3.8 Socketing shall be done as per Geo-technical Report/ pile design requirement
point of view wherever required.
7.4 CHISELLING
7.4.1 Chiselling may be restored with the permission of the Engineer-in-charge below the
socketing horizon. The chiselling tool or bit shall be of adequate size and weight
so as to reach the desired depth.
7.5 CLEANING OF PILE BORE
7.5.1 After completion of the pile bore upto the required depth, the bottom of the pile
bore shall be thoroughly cleaned. Cleaning shall ensure that the pile bore is
completely free from sludge / bored materials, debris of rock/ boulder etc.
Necessary checks shall be made for pile bore as described in the subsequent
clauses to confirm thorough cleaning of the pile bore.
7.5.2 Pile shall be cleaned by fresh drilling mud through tremie pipe before start of
concreting and after placing reinforcement.
7.5.3 Pile bore spoil along with the used drilling mud shall be disposed off from site as
directed by the Engineer-in-charge.
7.6 ADJECENT STRUCTURES


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 171 OF 202
7.6.1 When working near existing structures care shall be taken to avoid any damage
to such structures.
7.7 CONCRETING
7.7.1 Concreting shall not be done until the Engineer-in-charge is satisfied that the
pile termination level is reached and the pile bore is cleaned properly and
thoroughly.
7.7.2 The time interval between the completion of boring and placing of concreting
shall not exceed 6 hours. In case the time interval exceeds 6 hours the pile
bore shall be abandoned. However, the Engineer-in-charge may allow
concreting provided the Bidder extends the pile bore by 0.5 m beyond the
proposed depth, and clean the pile-bore. The entire cost of all operation and
materials for this extra length shall be borne by the Bidder.
7.7.3 Pile bore bottom shall be thoroughly cleaned to make it free from sludge or any
foreign matter before and after placing the reinforcement cage.
7.7.4 Proper placement of the reinforcement cage to its full length shall be ensured
before concreting.
7.7.5 Concreting shall be done by tremie method, the operation of tremie concreting
shall be governed by IS : 2911 ( Part-I/Section-2 ). Drilling mud shall be
maintained sufficiently above the ground water level.
7.7.6 Concreting operation shall not proceed if the contaminated drilling mud at the
bottom of the pile bore posses density more than 1.25 Te/Cu.M. or sand
content more than 7%. The drilling mud bore sample shall be collected from
the bottom of the pile bores as mentioned in subsequent clause.
7.7.7 Consistency of the drilling mud suspension shall be controlled throughout

concreting operations in order to keep the bore stabilised as well as to prevent
concrete getting mixed with the thicker suspension of the mud.
7.7.8 It shall be ensured that volume of concrete poured is at least equal to the
theoretically computed volume of pile shaft being cast.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 172 OF 202
7.7.9 The temporary guide casing shall be withdrawn cautiously after concreting is
done upto the required level. While withdrawing the casing concrete shall not be
disturbed.
7.8 CUT OFF LEVEL (COL)
7.8.1 Cut off level of piles shall be as indicated in drawings released for
construction or as directed by Engineer-in-charge.
7.8.2 The top of concrete in pile shall be brought above the COL to remove all
laitance and weak concrete and to ensure good concrete at COL for proper
embedment in to pile cap.
7.8.3 When the pile cut off level is less than 1.0 metre below the working level,
concrete shall be cast to the piling platform level to permit overflow of
concrete for visual inspection. In case of COL of pile is more than 1.0 metre
below working level then concrete shall be cast to a minimum of one metre
above COL.
7.8.4 In the circumstance where COL is below ground water table, the need to
maintain a pressure on the unset concrete equal to or greater than water
pressure shall be observed and accordingly length of extra concrete above
COL shall be determined by the Bidder with prior approval of Engineer-in-
charge.
7.9 SEQUENCE OF PILING
7.9.1 Each pile shall be identified with a reference number.
7.9.2 The convenience of installation may be taken into account while scheduling
the sequence of piling in a group. This scheduling shall avoid piles being
bored close to other recently constructed piles.
7.10.0 BUILDING UP OF PILES
7.10.1 If any pile, already cast as per construction drawing, requires any extra
casting due to any change in cut off level or cast pile top level is less than
the specified level or any other reason, then the pile shall be building up by

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 173 OF 202
using M-20 grade concrete with minimum 400 kg/Cu.m. of cement ensuring
proper continuity with the existing concrete and to the satisfaction of the
Engineer-in-charge. Necessary reinforcement as per design requirement and
suitable shuttering shall be provided before casting the concrete.
Surrounding soil shall also be built up to the required level by proper
compaction to ensure lateral capacity of the pile.
7.11 BREAKING OFF OF PILES
7.11.1 If any pile already cast requires breaking due to lowering in cut off or for any
other reason, then the same shall be carried out, not before seven days of
casting of, without affecting quality of existing pile such as loosening,
cracking etc., to the satisfaction of the Engineer-in-charge.
7.12 PREPARATION OF PILE HEAD
7.12.1 The soil surrounding the piles shall be excavated upto the bottom of the lean
concrete below the pile cap with provision for working space sufficient
enough to place shuttering, reinforcement, concreting and any other related
operations.
7.12.2 The exposed part of the concrete above COL shall be removed/ chipped off
and made square at COL not before seven days of casting of piles.
7.12.3 The projected reinforcement above COL shall be cleaned and bent to the
required shape and level to be anchored into the pile cap.
7.12.4 The pile top shall be embedded into the pile cap by 50 mm or clear cover to
the reinforcement, whichever is high.
7.12.5 At loose material on the top of pile head after chipping to the desired level
shall be removed and disposed off upto a lead of 2 Km. as directed by
Engineer-in-charge.
7.13 REJECTION AND REPLACEMENT OF DEFECTIVE PILES
7.13.1 The Engineer-in-charge reserves the right to reject any pile which in his
opinion is defective on account of load capacity, structural integrity, position,

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 174 OF 202
alignment, concrete quality etc. Piles that are defective shall be pulled out or
left in places as judged convenient by Engineer-in-charge, without affecting
the performance of adjacent piles. The Bidder shall install additional piles to
substitute the defective piles as per the directions of Engineer-in-charge at
no extra cost to OWNER/ CONSULTANT.
7.14 RECORDING OF PILING DATA
7.14.1 The Bidder shall record all the information during installation of piles. Typical
data sheet for recording pile data shall be as indicated in Annexure - A.
enclosed and the pile load test data shall also be recorded as per the
detailed indicated in Annexure-B enclosed. On completion of each pile
installation, pile record in triplicate shall be submitted to Engineer-in-charge
within two days of completion of concreting of the pile.
8.0 SAMPLING, TESTING AND QUALITY ASSURANCE
8.1. Facilities required for sampling and testing materials, concrete, etc. in field
and in laboratories shall be provided by the Bidder. The Bidder shall carry
out all sampling and testing in accordance with the relevant Indian Standards
and this specification. Where no specific testing procedure is mentioned the
testing should be carried out as per the prevalent accepted engineering
practice to the direction of Engineer-in-charge. Test shall be done in
presence of Engineer of Engineer-in-charge or his authorised representative.
In case the Engineer-in-charge requires additional tests, the Bidder shall
arrange to get these tests done and submit to him the test results in triplicate
within three days after completion of any test.
8.2 RECORDS
The Bidder shall maintain records of all inspection and testing which shall be
made available to the Engineer-in-charge. The Engineer-in-charge at his
discretion may waive some of the stipulations for small and unimportant
concreting operations and other works.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 175 OF 202
UNSUITABLE MATERIALS
Materials found unsuitable for acceptance shall be removed and replaced by

the Bidder. The work shall be done as per specification requirements and to
the satisfaction of the Engineer-in-charge at no extra cost to OWNER.
8.3 QUALITY ASSURANCE PROGRAMME
8.3.1 The Bidder shall submit and finalise a detailed Field Quality Assurance
Programme within 30 days from the date of award of contract according to
the requirements of this specification. This shall include setting up a testing
laboratory, arrangement of testing apparatus/ equipment, deployment of
qualified / experienced manpower, preparation of field quality plan, etc. On
finalised field quality plan, OWNER/ CONSULTANT shall identify, customer
hold points, beyond which the work shall not proceed without written approval
from the Engineer-in-charge. The testing apparatus / equipment installed in
the field laboratory shall be calibrated/ corrected by the qualified persons as
frequently as possible to give accurate testing results.
8.3.2 Frequency of sampling and testing, etc. and acceptance criteria are given in
Table–1. The testing shall be done at field laboratory or any other laboratory
approved by the Engineer-in-charge. However, the testing frequencies set
forth are the desirable minimum and Engineer-in-charge shall have the full
authority to call for tests as he may deem necessary to satisfy himself that the
materials and works comply with the appropriate specifications. The materials
shall be tested to all the specified requirements as per relevant IS codes
before acceptance at manufacturers premises or at independent Government
laboratory. Tests indicated in the Table–1 are for cross checking at site the
conformity of the materials to some of the specifications.
8.4 TESTING OF CONCRETE
8.4.1 a. Concrete and other materials shall be tested for quality and strength and
other properties as per relevant IS codes.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 176 OF 202
b. One sample consisting of six test cubes shall be made from the concrete
used in each test pile, 3 to be tested after 7 days and 3 after 28 days.
8.4.2 For working piles testing should be done as per IS specifications.
8.4.3 In preparation o test cubes/ specimens vibrators shall not be used.
8.4.4 Concrete shall be tested for slump at every one hour interval.
8.4.5 Other materials like aggregate, reinforcement, etc. shall be tested as per
relevant IS codes.
8.5 TESTING FOR POSITION AND ALIGNMENT
8.5.1 Each pile shall be checked for its position with respect to specified location.
Each pile bore shall be checked for its alignment.
8.5.2 Permissible limits for deviations shall be as specified elsewhere in this

section of specification.
8.7 PROPERTIES OF DRILLING MUD
8.7.1 Properties of drilling mud shall be checked as per requirements specified in

clause No. 7.03.4 of this specification. Prior to use in piling work and
thereafter minimum once in a week or as found necessary by Engineer-in-
charge one sample consists of 3 specimens shall be tested.
8.7.2 Density and sand content of the drilling mud shall be checked at least in
each pile for the first 10 piles before concreting. In case of satisfactory
results the frequency of sampling shall not less than one in 25 piles.
8.8 CHECK FOR PILE BORE
8.8.1 On completion of boring and cleaning the bottom of each pile bore shall be
checked by the methods as approved by Engineer-in-charge to ensure that
it is free from pile bore spoil/ debris and any other loose material before
concreting. Concreting shall be done only after the approval of the
Engineer-in-charge.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 177 OF 202
8.8.2 For sampling of drilling mud from the pile bore the following method or any
suitable method shall be adopted.
8.8.2.1 A solid cone shall be lowered by a string to bottom of pile-bore. A sampler

tube closed at top with a central hole (hollow cylinder) is lowered over the
cone, then a top cover shall be lowered over the cylinder. Care shall be
taken for proper fittings of assembly to minimise the leakage while lifting the
cone assembly to the ground surface. The slurry collected in the sampler
tube shall be tested for density and sand content.
9.0 LOAD TEST ON PILES
9.1 TYPE OF TESTS
9.1.1 BIDDER shall carry out two categories of load tests i.e. Initial Load and
Routine Load Tests in accordance with IS: 2911 (Part-IV).
9.1.2 Initial load test shall be conducted to assess the safe load carrying capacity
of pile before start of installation of working piles. This shall include the
following type of tests.
a. Cyclic compression load test to assess safe vertical load capacity.
b. Lateral load test to assess safe horizontal load capacity.
c. Tension load test to assess safe pull out load capacity.
The above tests shall be performed in accordance with IS: 2911 ( Part-IV )
9.1.3 The minimum number of Initial Load Test for each diameter of pile proposed
shall be as under.
a. Vertical compression : 2 Nos.
b. Lateral : 2 Nos.
9.1.4 Routine load tests of piles as per IS: 2911 (Part-IV) shall be conducted to
verify the load capacity of working piles. This shall include the following
types:

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 178 OF 202
a. Direct compression load tests for vertical load capacity.
b. Lateral load test for horizontal load capacity.
9.1.5 The minimum number of routine load test for each diameter and type shall
be 1.5 percent of the total number of working piles or minimum 2 no.’s of
piles whichever is higher. The number of tests may be increased up to 2
percent as decided by the Engineer-in-charge in a particular case depending
upon the nature, type of structure and strata condition.
9.2 TEST OF PILE
9.2.1 The test piles for routine load test shall be identified by the Engineer-in-
charge
9.2.2 A minimum time period of four weeks shall be allowed between the time of
pile casting and testing. Test pile head shall be prepared for testing
purposes only one week after casting the pile.
9.2.3 The test pile shall be cut off at the proper level and provided with a proper
cap so as provide a plane bearing surface for the test plate and for proper
arrangements for seating of the jack and dial gauges.
9.3 VERTICAL LOAD TEST
9.3.1 EQUIPMENT AND TEST SET-UP
I. A steel plate of sufficient thickness not less than 50 mm shall be centred

on the pile head to prevent it from crushing under applied load. The size of
plate shall not be less than the pile size nor less than the area covered the
base of the hydraulic jack(s).
II. The datum bars shall be supported on the immovable supports preferably
of concrete pillars or steel sections placed sufficiently far away from the
test pile. The distance shall not be less than 3 times the diameter of test
pile and in no case less than 2 meter from the edge of test pile. These
supports shall be placed at a sufficient depth below ground to be
unaffected by ground movements.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 179 OF 202
9.3.2 LOADING SYSTEM
The test load on the pile shall be applied in one of the following way as
approved by Engineer-in-charge.
a. By means of hydraulic jack(s) which obtain reaction from kentledge

heavier than the required test load. While using this method care shall
be taken to ensure that the centre of gravity of kentledge is on the
axis of the file. The load applied by the jack shall also be coaxial with
the pile. The nearest edge of the crib supporting the kentledge stack
shall not be closer than 1.5 m to the edge of the test pile
b. By means of hydraulic jack(s) which obtained reaction from anchor

piles and /or suitable loading frame. While using this method all
anchor piles shall be at a centre to centre distance of at least three
times the test pile shaft diameter from the test pile and in no case less
than 2 meter. Care shall be exercised to ensure that the datum bar
supports are not affected by heaving up the soil.
c. By means of hydraulic jack(s) which obtain reaction from suitable rock

anchors. When this method is adopted the anchor transferring the
load to the ground shall not be closer than two times the test pile shaft
diameter to the test pile and in no case less than 1.5 m.
d. By means of combination of kentiledge anchor pile and rock anchors.
9.3.3 MEASURING SYSTEM
Settlement of the pile shall be recorded by four dial gauges placed at

diametrically opposite locations and suspended from the datum bar around
the pile.
9.3.4 TEST PROCEDURES
The test shall be carried out by Direct Loading Method in successive

increments for routine load test and by the Cyclic Loading Method for initial
load test as detailed below and as directed by Engineering-in-charge.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 180 OF 202
9.3.4.1 DIRECT LOADING METHOD
The test shall be carried out as per the procedure out lined below:
a. The load shall be applied to the pile top in increments (step) of about
20% of the rated capacity of the pile or as directed by Engineer-in-
charge. Each increment of load shall be applied as smoothly and
expeditiously as possible. Settlement regarding shall be taken before and
immediately after the application of next increment and at 15, 30, minutes
and thereafter at every half an hour until application of the next load
increment.
b. Each stage of loading shall be maintained till the rate of movement of the
pile top is not more than 0.2 mm/hour. Or until two hours have elapsed
whichever is earlier.
c. The rate of movement of pile shall not be permitted to be extrapolated

from period of test less than one hour.
d. Loading on pile shall be continued till one of the following takes place :
In case of Initial load test applied load reaches three times the assumed
safe load or settlement of pile exceeds a value of 10% of bulb diameter in
case of under-reamed piles.
In case of Routine load test, applied load reaches one and half time the
safe load or maximum settlement of test loading in position attains
12 mm.
e. Where yielding of soil does not occur, the full test load shall be
maintained on the pile head for a minimum period of 24 hours. After the
last increment of load and settlement shall be recorded of 6 hours interval
during this period.
f. Unloading shall be carried out in the same steps as loading. A minimum

period of 30 minutes shall be allowed to elapse between two successive

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 181 OF 202
stages of load decrement. The final rebound shall be recorded 6 hours

after the entire test load has been released.
9.3.4.2 CYLIC LOAD TEST
The test shall be carried out to find out separately skin friction and point
bearing capacity of single pile. However, this test is not applicable for
under-reamed piles. The test procedure shall be given below ;
a. In general this test shall be conducted on similar lines as mentioned in

Direct Loading Method. In addition, alternate loading and unloading up
to zero load shall be done in steps at each stage of loading. The load
increment/decrement for each steps shall be 20% of the rated capacity.
The reading of all the dial gauges shall be recorded at the end of each
step and the total and net settlement for each stage shall be calculated.
b. For each stage, the loading of each step shall be maintained for 15
minutes before reaching the maximum load. The maximum load for each
stage shall be maintained on the pile head for 24 hours.
c. Each step of unloading shall be maintained for 15 minutes and the

subsequent rebound in the pile shall be measured accurately.
d. A period of 15 minutes shall be allowed to pass the successive

unloading and loading operations.
e. To find out separately skin friction an d point bearing capacity of pile the
procedure as given in Appendix-A of IS: 2911 (pat-IV) shall be followed.
9.3.5 ASSESSMENT OF SAFE LOAD
9.3.5.1 The safe vertical load on single pile from the load test shall be the least of the
following:
a. 2/3 of the load at which the total settlement attains a value of 12 mm

unless otherwise specified in tender documents.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 182 OF 202
b. 50% of the final load at which the total settlement equal 10% of the
pile diameter in case of uniform diameter.
9.4 HORIZONTAL LOAD TEST
9.4.4 EQUIPMENT AND TEST SET –UP
a. The test plate shall be set in high strength grout to provide full
bearing against the projected areas of the pile. The size of the test
plate shall be adequate to accommodate the spherical bearing and
transfer the load to the pile.
b. Sufficient clearance shall be allowed between the test pile and the
datum bar for the anticipated lateral movement of the pile when
datum bar (for fixing the dial gauge) is located on the opposite side to
the point load of application.
a. Loading shall be applied by a hydraulic jack of adequate capacity

equipped with spherical bearing at the top of ram and bearing plate
at the bottom side abutting the pile horizontally and reacting against
a suitable system.
b. The reaction may be provided by the wall of the excavated pit when
the test is being conducted below ground level or by a neighbouring
pile in which case thrust pieces shall be inserted on their end of the
jack to make up the gap as approved by Engineering-in-charge.
c. Load shall be applied on the pile at or approximately at cut of level

(COL).
9.4.6.1 The deflection shall be measured at a point diametrically opposite to

the point of load application. In case such a measurement is not possible
the deflection shall be recorded using at least 2 dial gauges keep at a

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 183 OF 202
spacing of 30 cm at a suitable height and the displacement interpolated at

load point from similar triangles.
9.4.6.2 Deflection of the pile at the level of load application shall be measured by
dial gauge fixed to datum bar. The datum bar shall rest on immovable
supports as described elsewhere in this specification.
9.4.4 TEST PROCEDURE
9.4.4.1 The test shall be similar to that of vertical load test.
9.4.4.2 Loading on the pile shall be continued till one of the following takes
place :
a. In case of initial load test applied load reaches thrice the assumed
safe lateral load capacity of deflection pile at the loading point
exceeds.
b. In case of routine Load test, applied load reaches one and half times
the assumed safe load capacity or a deflection of the loading point
exceed 5 mm.
9.4.5.1 The safe lateral load of single pile shall be the least of the following :
a. 50% of the load for which the total deflection is 12 mm.
b. Load corresponding to 5 mm total deflection.
However, for routine test(s) above is not applicable.
Note: The deflection of the pile is at the cut of level of pile.
9.5 PULL OUT TEST
9.5.1 EQUIPMENT AND TEST SET-UP
Uplift force may be applied by means of hydraulic jack(s) using suitable

pullout set up as approved by Engineering-in-charge.


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 184 OF 202
a. Load shall be applied along the longitudinal axis of the pile using an
approved reaction system. Uplift forces on the pile may be applied
directly to the test pile or through a lever system.
b. The reaction may be provided by neighbouring piles or blocks

constructed for this purpose.
c. The reaction supports/blocks/piles shall be at least 2.5 times the test

pile diameter.
Displacement of the pile shall be recorded using two dial gauges placed at
diametrically opposite locations and suspended from the datum bar around
the pile. Datum bar shall be provided with immovable supports as described
elsewhere in this specification.
9.5.4 TEST PROCEDURE
9.5.4.1 The test procedure shall be similar to that for vertical load test.
9.5.4.2 The loading on the pile shall be continued till one of the following takes
place.
a. The loading on the pile top equal three times the estimated safe load.
b. The load displacement curve shows a clear break (downward trend).
9.5.5.1 The safe load of the pile shall be the least of the following :
a. Two third of the load at which the total displacement is 12 mm.
b. 50% of the load at which the load displacement curves shows a clear
break (downward trend).
10 RECORDING OF DATA AND PRESENTATION
10.1 The pile test data essentially concerns three variables, namely load, displacement
and time. These are to be recorded sequentially for the tests under consideration

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 185 OF 202
and shall be recorded in a suitable tabular form along with the information about
the pile as per Annexure–A, Annexure–B and Table-1
10.2 The data may be suitably presented by curves drawn between the variables and
safe loads shown on the graphs. Load displacement curve should be an essential
part of presentation.
ANNEXURE – A
PILE DATA
1. Reference No: Location (Co-ordinates): Area:
2. Sequence of piling:
3. Pile diameter and type:
4. Working Level (Platform level):
5. Cut Off level (COL):
6. Actual length below COL:
7. Pile termination level:
8. Top of finished concrete level:
9. Date & time of start and completion of boring:
10. Depth of Ground Water table in the vicinity:
11. Type of soil at pile tip:
12. Method of boring operation:


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 186 OF 202
13. Detail of drilling mud as used :

a. Freshly supplied mud:
Liquid Limit:
sand content:
density:
Marsh viscosity:
Swelling Index:
pH value:
b. Contaminated Mud:
Density:
Sand content:
14. SPT ( N ) Values in soil ( from the nearest bore hole )

UDS value in rock (from the nearest bore hole)
15. Chiselling, if any From ………..M to …………..M
16. Date and time of start and completion of concreting
17. Method of placing concrete
18. Concrete quality:

Actual:
Theoretical:
19. Ref. Number of test cubes
20. Grade and Slump of concrete
21. Results of Test Cubes
22. Reinforcement Details


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 187 OF 202
Main reinforcement Stirrups: Type

No. : ………………. No. :………………
Dia………………… Dia. ………………
Depth ………………… Spacing …………..
23. Any other information regarding obstructions,

delay and other interruption to the sequence of
work.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 188 OF 202
TABLE -1
FREQUENCY OF SAMPLING AND TESTING
Sl. Type of Material/ Nature of test/ Method of test No. of samples & Acceptance
work characteristics frequency of test criteria
No.
1 Pile-bore size Physical Each pile
measurement
a. Diameter Dia. As per drg.
b. Length Length as
established by
initial test
2. Bentonite (mud )
properties
a. Basic properties of Liquid limit, In laboratory Minimum one As per clause
Bentonite before Marsh viscosity, sample No. 7.03.4
use Specific gravity, consisting of 3
Sand content, specimens once
Swelling Index, in a week.
pH value.
b. Contaminated mud Density & sand In laboratory In each pile for I Density shall
from pile- bore content first 10 piles not be more
bottom before before concreting than 1.25 Te/
concreting in case of Cu.m
satisfactory
Sand content
results, the
Ii shall not be
frequency may
more than
be reduced to
7%
one in 25 piles
3. Position and --- Physical or Each pile As per
alignment any approved specification
method.
4. Cleaning of pile – As per clause Each Pile-bore should .Dispensary

bore No. 8.08.0 be free from
bored materials/
cutting / debris

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 189 OF 202
ANNEXURE – B
PROJECT ____________________________
PILE LOAD TEST: VERTICAL / HORIZONTAL / UPLIFT
PILE No. Date of cast Type of equipment and method of boring

Type of pile Commencement of test Plan pf test arrangement showing position and
distance of kentiledge, supports, tension or
compression piles and reference frame to test
pile etc.
Diameter Completion of test
Capacity Capacity of jack
Type of test Jack constant weight of
initial / routine kentiledge
Loading Method Reaction of pile details.
Direct / cyclic
Date Time Pressure Load Dial Average Net Rebound

Gauge (M.Te) Gauge settlement
( mm )
Reading
Submission of Test Results

i ) Time Vs. settlement
ii) Load Vs. Settlement including the Safe Load.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 190 OF 202
ANNEXURE VII
QUALITY ASSURANCE PLAN

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 191 OF 202
QUALITY ASSURANCE PLAN
SL MATERIAL/ NAME OF TEST FIEL TEST FREQUENCY EXTE REFERENCE

No OPERATIO D/ PROCEDURE OF CHECKING NT DOCUMENT
N LAB. OF
CHEC
KING
1. Earthwork Lines, levels & Field Measurement As per decision 100% Specn.&
in depth of site engr. approved drg.
excavation
2. Concrete
work
a) Course i) % of soft or Lab. As per IS 2386 Once for each -do- Specn.& IS
aggregate deleterious Part IX,1963 source/supply & 2386 (Pt.IX) &
materials shall be IS-
As per IS 2386 repeated in 383
ii) Particle size Lab/ (Pt.I) case source is -do-
distribution Field changed
IS 383,
-do- Specn.
b)Fine i) Silt content Lab Appendix -D of -do- -do- CPWD

aggregate CPWD Specn.
Specn.Vol.I
ii)Particle size
distribution Lab./ IS 383 -do- -do-
Field Specn. & IS
383
c) Cement i) Physical Lab As per IS 269 -do- -do- IS
properties & 4031 269,1489,403
1 & test
certificate
ii) Chemical -do- As per IS 4032 -do- -do-
properties
IS 4032 & test
certificate
d) Reinforcing bars
i) Deformed Physical Field As per IS 1139 -do- -do- IS 1139& test

bars properties & /Lab certificate
dimensions
ii) Cold -do- -do- As per IS 1786 -do- -do- IS 1786& test
twisted bars certificate
iii) Hard -do- -do- As per IS 1566 -do- -do- IS 1566& test
Drawn Steel certificate
Wire Fabric
iv) TMT -do- -do- As per IS 1786 -do- -do- IS 1786& test
bars certificate
v) Physical Field As per IS 456 ALL -do- IS 456 &


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 192 OF 202
Placement, approved
laps, hooks, drawings
spacers etc.
e) Water Chemical test -do- As per IS Single Test -do- IS 3025-1964

3025-64
f) Tests for i) Slump test Field As per IS 1199 For each batch -do- CPWD
concrete of concreting Specn. & IS
1199
ii) Cube test at Field/ As per IS 516 No. of cubes to -do- IS 456,IS 516
7/28 days Lab. be decided as
per given in IS
456/ Specn.
g) Physical Field Measurement All -do- As per
Shuttering drawing,
/Formwork CPWD
Checking of specifications
levels, & instruction
dimensions, of E.I.C
unevenness
, joints,
cleanliness,
oiling etc.
3. Brick Work/Hollow Concrete Block work

a) Brick/ Physical Field/ As specified in Once for each 100% Specn. / IS
Hollow properties & Lab. Specn & IS source 1077
Concrete crushing 1077
Block work strength
b) Mortar Uniformity in mix Field

As specified in As & when -do- IS 2250
IS 2250 required
4. Steel works using tubular, angles, plates, channels etc.
i) Structural Dimension, Lab. IS:226 & 2062 Once for each 100% IS Codes &
steel & manufacturers, source/supply test
plates Specn. test certificates
certilficates
ii) Welding -do- -do- IS:814 & 815 -do- -do- -do-
electrodes
iii) Welding Quality of weld, Field Visual As per -do- IS: 823
weld discretion of site
reinforcement, engr.
contour etc.
iv) Painting Cleaning off rust -do- IS:123 -do- -do- IS Code,
on steel dirt, grease etc. 1962 Relevant
works of coats. Specn.
(synthetic
enamel
paint over 3

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 193 OF 202
coats red
oxide coat
zinc primer)
5. Providing & Thickness, slope -do- As per Specn. -do- -do- -do-
laying water etc. & IS 2115
proofing on
roof
6. Flooring
i) Cement Physical Field As per IS 1443 All -do- IS 1443
concrete
floor
i) Glazed Physical Field As per IS All -do- IS 13630 &

tiles 13630 Manufacturer’
s certificate
7. Pre-coated Physical -do- As per IS 277 Once for each -do- IS code, spec.
G.I sheet & 513 source/supply &
roofing Manufacturer’
laying & s certificate
fixing.
8. Gypsum Physical -do- IS 2095 & All -do- IS code,

board false 2542 specn. &
ceiling/ Manufacturer’
Prima board s certificate
Armstrong
false ceiling
9. Doors/windows/ventilators
i) Glazing Physical -do- IS 1081 & All -do- IS code,
2835 specn. &
Manufacturer’
s certificate
ii) Flush Physical -do- IS 2095 & All -do- IS code,
door 2542 specn. &
shutters Manufacturer’
s certificate
iii) Physical -do- IS 1948 & All -do- IS code,
Aluminium 1949 specn. &
Manufacturer’
s certificate
iv) Steel Physical -do- IS 1038 All -do- IS code,
specn. &
Manufacturer’
s certificate
10 Plastering Physical -do- As per specn. All -do- Specn.
.
11 White Physical -do- IS 712, 428 & All -do- IS code &
. washing, 5410 specn.
snowmen,
distemper

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 194 OF 202
12 Toiletries & sanitary fixtures

.
IWC, EWC, Physical -do- IS 771, 775, All -do- IS code,
Urinals, 774, 1239, specn. &
washbasins 2065, 781, Manufacturer’
, G.I pipes & 1729, s certificate
fittings, C.I 1726,,651,412
pipes & 7 etc.
stoneware
pipes etc.
Note: Parameters/guidelines fixed for the quality control in accordance with the contract
document, IS Codes/Technical Specification etc. are just the synopsis of the whole
constructional activities in a bid to visualise the total involvement at a glance. Mere
compliance of the QAP does not relieve the contractor from overall responsibility to
render best quality of work in conformity with all the relevant documents and the best
engineering practices. In order to minimise the size of QAP, only salient/important
features have been taken into account and other small/minor involvement will be dealt
with individually as per the provision of contract.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 195 OF 202
ANNEXURE VIII
VENDOR LIST


PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 196 OF 202
Bidder shall select sub vendors from the vendor list as specified below. Bidder shall
ensure that sub vendor for the specified item has supplied item for the specified service &
the supplied item is in satisfactory service since last 3 years as on date of offer.
Vendor shall have well proven record for the specified services and shall be subjected to
owner/consultant approval.
SL.
ITEM NAME LOCATION BRAND NAME
NO.
1.0 FLOOR FINISHING
a) EUROCON
CEMENT TILES b) ALTRA TILE PVT. LTD.
1.1
(FLOOR/WALL) c) DAZZLE
NITCO
a) NITCO DELHI
1.2 TERRAZZO TILES HINDUSTAN TILES
b) HINDUSTAN TILES DELHI
a) SPARTEK CERAMICS SPARTEK
CHENNAI
b) BELL CERAMICS BELL CERAMICS
BARODA
c) SOMANY CERAMICS
NEW DELHI
1.3 CERAMIC TILES d) H&R JOHNSON JOHNSON
MUMBAI
CERAMICS KAJARIA
DELHIC
e) KAJARIA CERAMICS ORIENT
DELHI
f) ORIENT CERAMICS
a) BHARAT TILES MUMBAI STILAN
b) RESTILE CERAMICS DELHI RANAMITE
HEAVY DUTY FLOOR c) PELICAN CERAMIC DELHI PELICAN
1.4
TILES INDUS. AHMEDABA DIAMOND REGINA
d) DIAMOND REGINA D SONA TUFF
e) SONA TILES BARODA
a) SAMKOCK CHEMICALS
AHMEDABA SAMHARD STD
INDUSTRIAL FLOOR (P) LTD.
D DURONITE
1.5 HARDENER b) STRUCTURAL WATER
KOLKATA CICOSURFACE
ADMIXTURE PROOFING CO. (P) LTD.
DELHI HARDNER
ROBUST
a) PREMIER VINYL DELHI
ARMADA
1.6 PVC ROLLS b) ARMSRONG INARCO MUMBAI
POLYFLOOR
c) PREMIER POLYFILM DELHI
MARBLEX
a) BHOR INDUSTRIES DELHI
CARARA/SPECTRA
1.7 PVC TILES b) ARMSTRONG MUMBAI
SHYAM VINYLES
c) SHYAM VINYLES CHENNAI
ANSTAT
a) PREMIER VINYL DELHI
POLYFLOOR
PVC TILES/ROLL b) PREMIER POLYFILM DELHI
1.8 ANTISTATIC
ANTISTATIC
ARMSTRONG
c) ARMSTRONG MUMBAI
ANTISTATIC
ACID RESISTANT a) H&R JOHNSON OR
1.9 TILES(BATTERY APPROVED EQUIV. NEW DELHI
ROOM)
a) ITALIA
1.10 MOSSAIC TILE b) SPECIFIC GLASS
MUSSAIC INDIA LTD.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 197 OF 202
2.0 WOOD WORK

a) SITAPUR PLYWOOD SITAPUR(UP SITAPUR
b) WOODCRAFT ) WOODCRAFT
2.1 FLUSH DOOR
PRODUCTS CALCUTTA KITPLY
c) KITPLY PRODUCTS CALCUTTA
a) WOODCRAFT CULCUTTA
PLY WOOD/BLOCK PRODUCTS CALCUTTA WOODCRAFT
2.2
BOARD b) KITPLY PRODUCTS KOLKATA KITPLY
c) GREEN PLY
BHUTAN BOARD
a) BHUTAN BOARD BHUTAN HIBOND
b) BEST BOARD DELHI NOVAPAN
PARTICLE BOARD
2.3 c) NOVAPAN INDIA LTD. HYDERABA NOVATEAK
(EXTRA GRADE)
d) THE BOMBAY BURMAN D EASYLAM
TRACING CORPN. LTD. DELHI
NUWUD MDF
MDF BOARD/MD a) NUCHEM LTD.
DELHI DURATUFF
PARTICLE BOARD b) MANGALAM TIMBER
DELHI
2.4 (EXTRA GRADE) PRODUCTS LTD.
ECOBOARD
VENEEREED/LAMINA c) WESTERN BIO SYSTEMS
PUNE
TED LTD.
FORMICA/LUCKY
a) THE BOMBAY BURMAN DELHI
TRADING CORPN. LTD. GREENLAM
DECORATIVE
2.5 b) GREENPLY INDUS. LTD. DELHI DECOLAME/DECOLIT
LAMINATES
c) BAKELITE HYLAM LTD. DELHI E
d) RAMMICA INDUSTRIES DELHI RAMMICA
ANCHOR
a) INDIAN PLYWOOD MFG. DELHI
2.6 MARINE PLYWOOD CO. LTD.
SWASTIK
b) SWASTIC PLYWOOD DELHI
2.7.0 DOORS & WINDOWS FITTINGS
a) GODREJ & BOYCE GODREJ
MUMBAI
MORTICE LOCKS b) EVERITE AGENCIES (P) EVERITE
2.7.1 DELHI
WITH HANDLES LTD. GOLDEN
DELHI
c) GOLDEN INDUSTRIES
SECUR
CYLINDRICAL PIN a) SECURE INDUSTRIES DELHI
GOLDEN
2.7.2 TUMBLER LOCK b) GOLDEN INDUSTRIES DELHI
GODREJ
WITH KNOBS c) GODREJ & BOYCE MUMBAI
DOORKING
a) DOORKING INDUSTRIES
HYDRAULIC DOOR DELHI EVERITE
b) EVERRITE AGENCIES (P)
2.7.3 CLOSER (OVER DELHI HARDWIN
LTD.
HEAD/ FLOOR) DELHI
c) HARDWYN
MISC. DOOR a) EVERITE AGENCIES (P) EVERITE e.g.
DELHI
FITTINGS HINGES, LTD. EBCO
DELHI
TOWER BOLTS, b) EBCO DINSUTRIES ECIE
2.7.4 MUMBAI
LATCHES, SOPPER, c) ECIE (P) LTD. NU-LITE
DELHI
STAYS, ALDROPS d) NU-LITE INDUSTRIES HARDWYN
DELHI
ETC. e) HARDWYN
THREE WAY a) SRIMA SALES &
MUMBAI SRIMA SALES CUM-
2.7.5 BOLTING LOCKING SERVICES
DELHI DHIMAN STEEL WITH
DEVICE HANDLE b) DHIMAN INDUSTRIES
PANIC BAR LATCH a) SRIMA SALES &
2.7.6 (FOR EMERGENCY SERVICES OR APPROVED MUMBAI SRIMA SALES
DOOR) EQUIV.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 198 OF 202
a) FENESTA
2.7.7 UPVC WINDOWS b) ENCRAFT
c) WINDOW MAGIC
a) HILTI INDIA PVT. LTD.

2.7.8 FASTENERS NEW DELHI
b) FISCHER
STEEL/ ALUMINIUM DOORS, WINDOWS & VENTILATOR

3.0
a) RAYMUS ENGINEERS GURGOAN/

PRESSED STEEL
b) DHIMAN STEEL DELHI
DOORS WINDOWS &
c) RDG ENGINEERING MUMBAI
3.1 SECTION DOORS
d) SUPER STEEL WINDOW DELHI
WINDOWS/ROLLING
CO. DELHI
SHUTTER
e) SKS STEEL INDUS.
a) JINDAL ALUMINIUM LTD.
ALMUNIUM / DOORS/
3.2 b) HINDALCO INDUSTRIES
WINDOWS SECTIONS
c) INDAL
VIPER(TAC)
FIRE-PROOF a) NAVAIR INTERNATIONAL DELHI
3.3 RADIANT
DOORS(APPROVED) b) RDG ENGINEERING MUMBAI
SINTEX
PVC DOORS / a) SINTEX Or APPVD
3.4 DELHI
WINDOWS EQUIV.
a) SINTEX Or APPVD SINTEX
3.5 PVC WATER TANKS DELHI
EQUIV.
4.0 PLASTERING
a) STRUCTURAL WATER DELHI CICO NO.1
WATERPROOFING/
PROOFING CO. (P) LTD.
4.1 COMPOUND IN
b) PIDILITE INDUSTRIES MUMBAI PIDIPROOF LW
CEMENT PLASTER
5.0 ROOF TREATMENT (WATER PROOFING)
a) INDIA WATER PROOFING
CO. MUMBAI
5.1 BRICK BAT COBA
b) OVERSEAS DELHI
WATERPROOFING CORPN.
ACRYLIC BASED
CEMENTATIOUS
a) STRUCTURAL WATER DELHI TAPCRETE
PRIMER COATING
5.2 PROOFING CO. (P) LTD.
FOR ROOF
b) SIKA QUALCRETE LTD. DELHI SEALOCFLEX
WATERPROOFING
APP MODIFIED
a) PIDILITE INDUSTRIES MUMBAI
POLYMERIC WASTER
LTD. GURGOAN
5.3 PROOFING
b) STP TEXAS LTD. BANGALOR
MEMBRANE
c) BITUMET CO. LTD. E
6.0 PAINTING WORKS
DULUX
a) ICI INDIA LTD.
BERGER
b) BERGER PAINTS LTD.
PLASTIC EMULSION ASIAN PAINTS
c) ASIAN PAINTS LTD.
6.1 (INTERIOR/EXTERIOR SHALIMAR
d) SHALIMAR PAINTS
) NEROLAC
e) KANSAI NEROLAC
PAINTS LTD.

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 199 OF 202
a) ASIAN PAINTS LTD.

DRY OILBOUND b) KANSAI NEROLAC ASIAN PAINTS
6.2
DISTEMBER PAINTS LTD. NEROLAC
a) ICI/AKZO NOBEL INDIA

b) BERGER PAINTS LTD.
c) ASIAN PAINTS LTD.
d) SHALIMAR PAINTS
INDUSTRIAL /
e) INTERNATIONAL MARINE
6.3 EXPOXY/ SYNTHETIC
COATINGS PVT. LTD.
ENAMEL PAINTS
f) KANSAI NEROLAC
PAINTS LTD.
g) BOMBAY PAINT
SNOWCEM PLUS
WATERPROOF a) KILLICK NIXON LTD. MUMBAI
6.4 ACROCEM
CEMENT PAINT b) RAJDOOT PAINTS DELHI
ASIAN PAINTS
WOOD MELAMINE a) ASIAN PAINTS
6.5 MELLAC
POLISH b) SHALIMAR PAINTS
WASTERPROOFING
TRANSPARENT a) PIDILITE INDUSTRIES REPELLIN S-101
DELHI
EXTERIOR WALL b) INDUSTRIAL PROD. MFG WALL GUARD
6.6 PUNE
COATING (OVER c) STRUCTURAL WATER- EWITEX PERFECT
DELHI
PAINTED SURFACE) PROOFING CO.(P) LTD. CICO- SEALCOTE
a) NAVAIR INTERNATIONAL
FIRE PROOF
6.7 OR APPVD. EQUIV. DELHI VIPER
COATING
7.0 ROOFING SHEETS & ACCESSORIES
a) ETERNIT EVEREST LTD. DELHI EVEREST
7.1 ASBESTOS SHEETS b) CHARMINAR HYDERABA CHARMINAR
INDUSTRIES D
a) ISPAT INDUSTRIES LTD. NIPPON DENRO
b) STEEL AUTHORITY OF SAIL
7.2 C.G.I. SHEETS DELHI
INDIA TISCO
c) TATA STEEL
a) ISPAT INDUSTRIES LTD. NIPPON DENRO
DELHI
b) SHREE PRECOATED META COLOR
DELHI
STEELS LTD.
PRECOATED G.I.
c) INTERARCH BUILDING TRACDEK
PROFILE SHEETS NOIDA
7.3 PRODUCTS (P) LTD.
FOR ROOFING &
d) HARDCASTLE & WAUD FERO COLOR
WALL CLADDING MUMBAI
MFG. CO. LTD.
e) LLOYD INSULATION (I) LLOYDECK
DELHI
LTD.
ALUMINIUM SHEET a) INDIAN ALUMINIUM CO.
7.4 (PLAIN/PROFILE) LTD. Or APPROVED CALCUTTA INDAL
EQUIVALENT
FIBRE GLASS
SHEETS & PANELS a) SIMBA FRP (P) LTD.
7.5 DELHI SIMCRYL
(MACHINE MOULDED) b) GE INDIA
PROOFING J/L
HOOKS, BOLTS & PUNE
a) KATALIST CONSULTANT
OTHER
7.6 (P) LTD. DRIPGRIP
ACCESSORIES BANGALOR
b) ADVANCED MACHINE
(POLYMER COATED) E

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 200 OF 202
8.0 SANITARY PLUMBING FITTINGS & FIXTURES

a) HINDUSTAN SANITARY HINDUSTAN
WARE & INDUS. LTD. CALCUTTA
SANITARY FITTINGS b) PARRYWARE SANITARY PARRYWARE
8.1 (W.C. WASH BASIN, WARE CHENNAI CERA
URINAL ETC.) c) MADHUSUDAN DELHI NYCER
CERAMICS CHENNAI
d) NYCER CERAMICS
a) GEM
PLUMBING FITTINGS
8.2 b) PARKO
& FIXTURES
c) KINGSTON
GLASS/MIRROR
a) GUJARAT GUARDIAN
(SHEET/ FLOAT/ DELHI
LTD.
8.3 TOUGHENED/ CHENNAI MODIGUARD
b) SAINT GOBAIN
LAMINATION NEW DELHI
c) ASAHI FLOAT
a) JINDAL
b) SURYA
8.4 GI PIPES
c) PRAKASH
d) SWASTIK
9.0 FLASE CEILING, FLASE FLOORING & UNDERDECK INSULATION
TRAC
FLASE CEILING / a) INTERARCH BUILDING NOIDA
WALL CLADDING PRODUCTS (P) LTD.
9.1 LUXALON
(ALUMINIUM STRIP/ b) HUNTER DOUGLAS MUMBAI
TRULON
TRAY TYPE) c) MASCOT OVERSEAS DELHI
a) MULTI INTERIORS PVT.
LTD. DELHI
b) BESTLOCK SYSTEM & MUMBAI
CONCEPTS
9.2 FALSE FLOORING
c) LLOYD INDUSULATION (I) DELHI
LTD. MUMBAI
d) UNITED INSULATION CHENNAI
e) A.R. & BROTHERS
a) BAKELITE HYLAM LTD.
DELHI PHENOTHERM
UNDERDECK/WALL b) U.P. TWIGA F.G. LTD.
9.3 DELHI TWIGA
HEAT INSULATION c) LLOYD INDULATION (I)
DELHI ROCKLOYD SLAB
LTD.
a) LLOYD INSULATION (I)
LLOYD SPRAY FAOM
OVERDECK HEAT LTD. DELHI
9.4 BESTPLASTRONICS
INSULATION b) BEST PLASTRONICS DELHI
LTD.
TRAC GRG
GYPSUM BOARD a) INTERARCH BUILDING NOIDA
9.5 TILES (FIBRE GLASS PRODUCTS (P) LTD.
GYPBOARD
REINFORCED) b) INDIA GYPSUM LTD. DELHI
SPECIALITY
PRODUCTS
(CEMENT
ADDITIVES/
ADMIXTURES/COR a) FOSROC NOIDA
10.0
ROSION b) SIKA DELHI
INHIBITORS/
SURFACE
TREATMENT/
GROUT &

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 201 OF 202
ANCHORS/SEALIN
G/ COASTING
EPOXY FLOOR
a) FOSROC
COATING (BATTERY NOIDA
10.1 b) SIKA
ROOM) DELHI
c) FAIRMATE
11.0 MISCELLANEOUS ITEMS
WOOD ASCU
11.1 a) ASCU HICKSON LTD. CALCUTTA
PRESERVATIVE
UNITILE
a) UNITILE DELHI
WALL SURFACE SPECTRUM
11.2 b) SPECTRUM PAINTS DELHI
TEXTURED COATING HERITAGE
c) BAKELITE HYLAM DELHI
PVC PLUMBING
a) PRAYAG POLYMERS (P)
11.3 FITTINGS DELHI SYMET
LTD.
REINFORCED FIBRE
GLASS
a) FGP LTD. DELHI
11.4 WATERPROOFING FGP
b) U.P. TWIGA F.G. LTD. DELHI
FELT
ANTI TERMITE
11.5 a) PCI Or APPRVD EQUIV.
TREATMENT
DELHI
a) SHRIRAM TEST HOUSE
DELHI
MATERIAL TEST b) SPECTRO ANALYTICAL
11.6 DELHI
HOUSE LABS
c) BHARAT TEST HOUSE
MUMBAI
a) ACC
b) J K CEMENT
KOLKATTA
c) BINANI CEMENT
d) JP CEMENT
MUMBAI
12.0 CEMENT e) GUJARAT AMBUJA
MUMBAI
f) ALTRA TECH CEMENT
KOLKATTA
g) BIRLA CORPN. LTD.
MP
h) GRASIM
RAJUSTHAN
i) SHREE
a) SAURASHTRA CEMENT
SULPHUR LTD.
12.1
RESISTANT CEMENT b) SHREE DIGVIJAY
CEMENT
a) IIT DELHI
13.0 RCC DESIGN MIX
b) SHRIRAM TEST HOUSE
WRAPPING COATING
a) IWL OR APPROVED
14.0 (I/C TAPE & PRIMER) NEW DELHI PYPKOTECH
EQUIVALENT
FIRE PROOFING a) CAFCO

15.0
MATERIAL b) CARBOLINE
a) SAIL
b) TATA STEEL
c) RINL
STRUCTURAL STEEL d) JINDAL STEEL & POWER
16.0
/ CS PLATE LTD
e) ESSAR
f) ISPAT INDUSTRIES

PC150/E/4004/SEC
0
VI-5.5 (PART A & B)
STRUCTURAL WORK R
Document No.
ev
SHEET 202 OF 202
a) HITEX
b) ASHWANI STEELS
MS PIPES (HAND c) SURYA
16.1
RAIL APPLICATION) d) PRAKASH
e) VIKRANT ISPAT UDYOG
a) SAIL
b) TATA STEEL
c) RINL
17.0 TIMT BAR / REBAR
d) SHYAM STEEL INDUSTRIES
LTD
a) INDIANA GRATINGS
b) WESTCOAST
GRATINGS/HANDRAIL ENGINEERING
18.0
S c) GREATWELD GRATING
d) KANADE ANAND UDYOG
a) ADOR
b) ESAB
WELDING
19.0 c) D & H
ELECTRODE
d) HANOVAR
GENERAL NOTES FOR CIVIL:

i. Only ‘First’ Quality materials shall be used
ii. OWNER / CONSULTANT reserve the right to choose any of the approved make / vendor as per this list.
Make of the item not indicated and any other make for the specified item shall be subject to owner’s /
consultant’s approval.
iii. Specifications of manufacturer’s items shall be checked against tender item / specifications before
selecting any product or brand name. In case of any discrepancy, tender item / specifications shall
prevail, and any such brand of item shall not be used which is not conforming to tender specifications
even if it is listed in this vendor list.
iv. In case of non-availability of any material among approved vendors / makes in a particular site / region,
alternate vendor / make conforming to IS / BS etc. Shall be used subject to approval by OWNER /
CONSULTANT.

PC150/E/4004/Sec-VI--6.0 P2
PROJECTS & DEVELOPMENT INDIA LTD. DOCUMENT NO. REV
SHEET 1 OF 41
SECTION – VI-6.0 (PART A & B)
PROJECT EXECUTION PLAN,

PLANNING & SCHEDULE, INSPECTION




RAW WATER TREATMENT PLANT- DM WATER- PC150/E/4004/Sec-
P2
CONDENSATE POLISHINGUNIT- EFFLUENT TREATMENT VI--6.0
PLANT DOCUMENT NO REV
SHEET 2 OF 41
PROJECT EXECUTION PLAN
CONTENTS
1.0. PROJECT EXECUTION PLAN, PLANNING & SCHEDULING, INSPECTION .......... 4

1.1. General ........................................................................................................................... 4
1.2. Engineering ..................................................................................................................... 5
1.3. Procurement ................................................................................................................... 5
1.4. Construction and Installation ........................................................................................... 5
1.5. Commissioning ............................................................................................................... 6
1.6. Quality Assurance ........................................................................................................... 6
1.7. Statutory Approvals/State Regulations ........................................................................... 6
1.8. Project Management ....................................................................................................... 7
1.9. Organization .................................................................................................................... 7
1.10. Safety .......................................................................................................................... 7
1.11. Sequence for Decisions .............................................................................................. 8
1.12. Vendor List .................................................................................................................. 8
1.13. Waste Disposal / Scrap etc. ........................................................................................ 8
1.14. Environmental Management System .......................................................................... 8
2.0. PROJECT MANAGEMENT AND EXECUTION .......................................................... 8
2.1. Project Management ....................................................................................................... 8
2.2. Detailed Engineering Services: ....................................................................................... 9
2.3. Procurement ................................................................................................................. 11
2.4. Kick-Off Meeting ........................................................................................................... 18
2.5. Early Planning Document/Look Ahead Schedule ......................................................... 19
2.6. Overall Project Schedule .............................................................................................. 19
2.7. Detailed Activity Network .............................................................................................. 20
2.8. Functional Schedules .................................................................................................... 20
2.9. Progress Measurement Methodology ........................................................................... 20
2.10. Vendor Scheduling and Monitoring ........................................................................... 20
2.11. Construction Network ................................................................................................ 21
2.12. Construction Worksheets .......................................................................................... 21
2.13. Construction Contractor Schedule ............................................................................ 21
2.14. Computerisation ........................................................................................................ 21
2.15. Project Review Meetings ........................................................................................... 22
2.16. Progress Reporting ................................................................................................... 22
2.17. Material Control ......................................................................................................... 24
2.18. Project Time Control Methodology ............................................................................ 24

P2
SHEET 3 OF 41
3.0. CONSTRUCTION, CONSTRUCTION SUPERVISION AND MANAGEMENT ......... 27

3.1. Construction .................................................................................................................. 27
3.2. Quality Assurance/Quality Control ................................................................................ 31
3.3. Construction Equipment ................................................................................................ 34
3.4. Construction Manpower ................................................................................................ 35
4.0. QA SYSTEM / INSPECTION REQUIREMENTS FOR BOUGHT OUT ITEMS &
DURING CONSTRUCTION ....................................................................................... 36
4.1. General ......................................................................................................................... 36
4.2. Specification for Turn-Key Bidder's Quality Assurance System .................................... 37
4.3. Inspection Coordination Methodology for Turnkey Package ........................................ 40


P2
SHEET 4 OF 41

1.0. INTRODUCTION
The Joint Venture of four major Public Sector Units – M/s Rashtriya Chemicals
&Fertilizers Ltd. (RCF),M/s GAIL (India) Ltd. (GAIL),M/s Coal India Ltd. (CIL) and M/s
Fertilizers Corporation of India Ltd. (FCIL) has decided to build a world class Coal
based fertilizer complex. The fertilizer complex will consist of Coal Gasification based
Ammonia Synthesis Gas Plant and Urea Plant, and is to be built at Talcher, Angul District,
Odisha (India).
To cater the requirement of DM Water and Effluent Treatment for theabove plants, Talcher
Fertilizers Limited intends to set up “RAW WATER TREATMENT PLANT- DM WATER
CONDENSATE POLISHINGUNIT AND EFFLUENT TREATMENT PLANTunder one package.
Projects and Development India Limited (PDIL) has been retained as Consultant by TFL to
provide services for the selection ofCONTRACTOR.
CONTRACTOR is advised to visit and examine the site conditions and obtain for itself on
its own responsibility all information that may be necessary for preparing the bid and
entering into the Contract. Claims of any kind due to variation or ignorance of site
conditions and environmental conditions will not be eligible in any circumstances.
1.1. General
This Lump-sum Turnkey package has been prepared as a Bidding Package to the extent
enumerated in various sections and documents enclosed.
Detailedscopes of work and discipline-wise technical requirements areprovided in

respective sections of this Tender Document.
The Contractorwill execute the project on Turnkey basis, in accordance with and supported
by Process Engineering Procedures, Procurement Procedures, Construction Management
Procedure, Project Controls and Computer System to be developed to affect the maximum
efficiency of quality of the project. To achieve this goal and requirements of the
Owner/PMC, Contractor will establish his project organization giving due consideration to
the following aspects:
 Effective execution and timely completion of each phase of the project.

 Maintaining high quality in each phase of the project.
 Good relation and coordination between the Owner/PMC and the Contractor.
 Assignment of experienced resources and personnel for immediate and smooth
launching of the project.

P2
SHEET 5 OF 41
1.2. Engineering
Contractor’s scope of work includesdetailed engineering, preparation of engineering
drawings and datasheets, making use of standard specifications, standards, design guides
and technical documents enclosed in this Tender Document. Technical requirements,
technical documents, standard specifications, PMC standards andguides to be followed for
different type of works shall be as provided in this Tender document.
Contractor to carry out the Detailed Engineering defined above. Commissioning of the
project in totality is a part of Contractor’s scope. Engineering required to be done by the
Contractor may arise singularly or in combination due to Manufacturing, Fabrication,
purchased items, Construction, Commissioning, Statutory requirements,
Governmentregulations, Safety requirements, site conditions, resultant total procurement
and Construction, Installation andTesting, Insulation, Painting and Commissioning, etc.
1.3. Procurement
Contractor’s scope includes ordering, all import formalities, fabrication/purchase of
equipment and materials, port clearance, packaging and transportation to site, stores
management which includes preservation and storage of equipment and materials,
uncovered storage. Items contemplated for fabrication at site to be submitted along with the
bid although both these aspects would be covered under the Contractor’s responsibility.
Vendor manuals relating to installation, operation and maintenance and test certificates
should be necessarily sent along with equipment. Please also refer Final Documentation
Submission requirement spelt out in this Tender Document, in this regard.
Before ordering, clearances for technical portion would be taken from Owner / PMC in
respect of the Critical Equipments (Special Equipments) comprising of Mechanical Static
and Rotary Equipments, Electrical and Instrumentation items. Any ordered itemswhich do
not confirm to the contractual requirement identified at any stage of the project shall be
rejected. Replacement/modification and project delay arising out of this shall be to the
Contractors account.
Whenever clearances are to be taken, it would be necessary to submit details of technically

acceptable offer.
Procurement of spares shall be as per spare part philosophy detailed in the scope of
supply.Commissioning spares are also in the Contractor’s scope.
1.4. Construction andInstallation

Contractor’s scope covers detail engineering including barricading of the allocated area
complying with statutory norms, construction, installation and commissioning of the unit as
per P&IDs, datasheets, drawings, standards, specifications, codes, statutory and state

P2
SHEET 6 OF 41
regulation. Supply of construction materials, labour, labour supervision, tools, tackles,

consumable materials and accessories not specifically mentioned herein but nevertheless
necessary, as per the PMC for the construction, installation, testing and commissioning of
the complete system including cranes or any other material handling equipment is also part
of Contractors scope.
1.5. Commissioning
Contractor’s scope covers supply of all initial fill such as lubricants, seal oils, chemicals,
consumables, spares required for start-up, pre-commissioning and commissioning of the
project. Contractor shall arrange necessary loading/ unloading equipments for undertaking
this activity. The scope also includes providing manpower (skilled as well as unskilled) and
organisation for commissioning and is to be indicated alongwith the bid.
1.6. Quality Assurance

The desired quality is to be met for different activities at various stages of the project. The
quality checks by Owner and PMC could be of audit type/involvement at all stages of
project execution by the Contractor and details of the quality plans will be furnished
alongwith the bid. Contractor is required to submit detailed Quality Control (QC) measures
to be adopted by him for all stages/types of activities. A notice period of six weeks is to be
given for imported items and one week for indigenous items for association with respect to
witness QC steps by Owner/PMC. Detailed methodology is enclosed in Tender Document
for compliance. Facilities at shops/site/ Engineering office for carrying out quality checks by
Owner/PMC shall be provided/organised by Contractor.
1.7. Statutory Approvals/State Regulations

Statutory regulations as required during pendency of the contract will be adhered to for
engineering, preparation of drawings/documents, fabrication, manufacturing, purchased
items, construction and commissioning. Documents as required will be generated and
submitted for the approval of statutory authorities. Follow up and obtaining clearances shall
be responsibility of the Contractor.
State regulations as and when applicable for different phases of the project shall be
adhered to by the Contractor. Statutory approval from any authority as per statutory rules
and regulations of Central/State Government shall be the Contractor’s responsibility unless
otherwise specified in bid documents. The application on behalf of Owner/PMC for
submission to relevant authorities along with copies of required certificates complete in all
respects shall be prepared and submitted by the Contractor well ahead of time so that the
actual construction/commissioning of the work is not delayed for want of approval or
inspection by concerned authorities. The inspection of the works by the authorities shall be
arranged by the Contractor and necessary coordination and liaison work in this respect
shall be the responsibility of the Contractor. Statutory fees paid, if any, for all inspections
and approvals by such authorities shall be borne by Contractor.

P2
SHEET 7 OF 41
Any changes/additions required to be made to meet the requirements of statutory

authorities shall be carried out by the Contractor free of charge. The inspection and
acceptance of the work by statutory authorities shall however, not absolve the Contractor
from his responsibilities under this contract.
1.8. Project Management

The project management services will include Planning, Scheduling, Monitoring, Progress
Reporting, Quality Assurance and Quality Control and Overall Project Management
functions. Contractor shall nominate a Project Manager who will be responsible for the total
scope of work under this contract and shall respond to Owner and PMC’s Project
Managers on all matters relating to this contract.
The Contractor is expected to execute the Work/Services under this contract on Task
Forceconcept with a dedicated team of specialists who will be responsible and respond to
the Project Manager.
The Task Force shall be so organized as to give effective management and control of
various services to the Project Manager.
1.9. Organization
The organisation upto working level including period envisaged for different phases of the
project engineering, ordering, follow up for manufacture of equipment, clearances,
transportation, inspection of equipment and materials, warehousing, safety, construction,
commissioning coordination with statutory authorities and government authorities and
project management will be submitted along with the bid. Bio-data of key personnel will
also be submitted with the offer.
1.10. Safety
All measures required for safe constructions are to be taken and the schemes are to be
approved by Owner/PMC before commencement of works. Besides, all personnel
employed on the job are to follow safety requirement of Owner/PMC and state regulations
as applicable from time to time. A list of safety implements/equipment proposed to be used
by the Contractor, are to be indicated along with the bid. At least one safety engineer in
each shift, for the project, shall be provided by the Contractor.
Safety report generation for different situations as per rules and required by Owner/PMC
are to be adhered to. Copy of safety practices to be followed during construction is
enclosed in this Tender Document. Contractor shall comply with the provisions of this
document. This document specifies broad guidelines on safe practices to be adhered to
during construction activities. However, before commencing any job, specific hazards and
its effects should be assessed and necessary corrective/preventive action should be taken
by the Contractor. This document shall supplement the prevailing statutory requirements,
which shall also be followed as applicable.

P2
SHEET 8 OF 41
1.11. Sequence for Decisions

Along with bid submission, it is necessary for the Contractor to bring out variation, if any, in
related data sheets, drawings, specifications, standards, codes, scope, any other
contractual clauses and seek clarifications from PMC/Engineer-In-Charge. The decision of
the PMC shall be final and binding on the bidder in such cases. For those such items,
which arise during execution of the project, the stringent specification/standards will be
applicable, and shall be binding on the Contractor. However, the decision of the
PMC/Engineer-in-Charge shall be final and binding on the Contractor.
1.12. Vendor List

All items required for project are to be purchased through approved vendors of
Owner/PMC, wherever such details are not available, vendor list to be proposed by
Contractor and clearance to be obtained from Owner/PMC before initiating the ordering
process.
1.13. Waste Disposal/Scrap etc.

All waste generated which could be surplus earth after use and or surplus construction
materials will be disposed off from time to time as directed by Owner/PMC.
1.14. Environmental Management System

Bidders should comply with the latest relevant elements of the International Standard for
environmental protection, as applicable to their scope of work.
2.0. PROJECT MANAGEMENT AND EXECUTION

2.1. Project Management
Plot plan, detailed technical requirements along with the detailed scope of work and overall
proposed implementation schedule is issued by Owner / PMC. These will form the basis for
formulation of the Overall Project Master Scheduleof the plant by Contractor. The
Contractor is required to organise his services in a systematic manner to ensure execution
and completion of the unit as per the schedule. The bidder is required to submit along with
his bid the methodology/procedure proposed by him for this unit together with the
organisational set up proposed and bio-data of keypersonnel.
In order to achieve uniformity in execution of various activities of the project, PMC has
developed engineering design basis and project procedures/methodologies to be adopted
by the executing agency. The Contractor is required to carry out detailed engineering,
procurement, tendering, construction supervision and management, planning scheduling,
monitoring, reviewing, reporting, and overall project management activities. All activities to

P2
SHEET 9 OF 41
be performed and services to be rendered by the Contractor under this contract shall be
monitored by Owner / PMC and will be subject to periodic reviews by PMC. The Contractor
shall facilitate such reviews/monitoring by Owner / PMC.
Immediately after the award of job, a Kick-Off Meeting will be held to finalise and establish
the modalities and procedures to be adopted for execution of the contract based on the
enquiry document, commitments made by Contractor and subsequent agreements reached
between Owner/PMC and Contractor during negotiations. The Kick-Off Meeting will be
attended by key members of Owner/PMC and Contractor. This will address all necessary
details and arrangement between Owner/PMC and the Contractor.
The Contractor’s service for Engineering, Procurement, Tendering, Construction,

Supervision and Management, Planning, Scheduling, Monitoring, Reporting, and Overall
Project Management shall meet the requirements given in this section.
English language and Metric Units shall be used in all documents, drawings, reports,
correspondences etc. under this contract.
2.2. Detailed Engineering Services:

TheContractor shall provide the detailed engineering services for the project as mentioned
in this bid document furnished by the Owner/PMC. The services shall cover the detailed
engineering required for execution and completion of the projectalong with the utilities to be
provided inside the battery limit of the Plant.
All critical drawings/documents to be prepared by Contractor/sub-contractors/vendors as

per given in the bid document for review and approval by Owner/PMC. Obtaining all such
approvals shall be the responsibility of the Contractor and the same is included in his scope
of work. Such review and approval by Owner/PMC shall, however, not relieve the
Contractor of his responsibilities.
For achieving the project schedule, it may be necessary in some cases to prepare the
drawings in stages and release it for construction so as to take up simultaneous execution
of detail engineering and construction. Any revision involved for the above is included in the
scope of work of the Contractor. Also any change required to meet site conditions/statutory
requirements shall have to be carried by Contractor at no extra cost.
The Contractor is required to organise a Task Force of dedicated specialists from each
discipline under a Project Engineering Manager who will be assisted by engineering
Coordinator. An engineering schedule will be prepared and submitted to Owner/PMC for
approval. This approved schedule shall be used for all engineering activities. The
engineering coordinator shall coordinate all design and engineering activities and interact
with purchase, inspection, expediting, C&T, tendering, planning, construction and project
groups. His responsibilities shall include.
(a) Engineering coordination for procurement involving:

P2
SHEET 10 OF 41
 Preparation of Material Requisitions (MRs).
 Technical evaluation of offers received (which may involve technical discussions

with vendors and concerned specialists may have to be deputed to vendors works or
to Owner/PMC’s offices as per requirements) and preparation of recommendations.
 Preparation of Technical Purchase Requisition (PRs) on selection of vendor.
 Review/approval of vendor drawings/documents. (This may call for arranging

specialist visits to vendor’s works for timely approvals of critical items.)
(b) Engineering coordination for sub-contractors involving:
 Preparation of schedule of quantities and specifications for various contracts.
 Technical evaluation and recommendation of offers received. This may involve

arranging technical discussions with Tenderers at Owner/PMC’s office if called for
due to job requirements.
 Preparation of technical-agreed variations for incorporation in contracts for the

selected Contractor.
In any case, Contractor has to take owner approval for sub-contractors list prior to
scrutiny and award.
(c) Engineering coordination for construction involving:
 Timely issue of approved construction drawings including drawings duly approved by

Owner/PMC as per requirements.
 Providing/arranging clarification on drawings and specifications wherever called for

including specialists visits to site.
 Making regular periodic visits to project site for review of site requirements in respect
of engineering activities.
 Attending/arranging for discussions with statutory authorities such as Chief Electrical

Inspector, Chief Inspector of Boiler, Tariff Advisory Committee, etc. to arrive at
design basis/documents acceptable to them wherever required for obtaining
statutory approvals and any other local approvals.
(d) Monitoring progress of engineering activities and advising Project Manager on

shortfalls and corrective actions needed. He will also attend the review meetings.

P2
SHEET 11 OF 41
Detailed engineering and construction shall be based on sound engineering practices.

List of applicable codes, standards and mandatory rules to be used in design is also
mentioned in bid document.
Drawings/Documents/MRs etc., which are to be generated by Contractor shall be

numbered as per the Documents Numbering Procedure of Owner/PMC.
Head Office engineering support of Contractor shall be provided to site during

construction including deployment of engineering specialists for field engineering as
and when required by Contractor.
2.3. Procurement
The procurement services to be provided by the Contractor shall cover the purchasing,
inspection, expediting, custom clearance and transportation activities
(a) Purchase
The purchase activities will cover all equipments and materials required for completion
ofthe project.The purchase group shall consist of adequate number of experienced and
qualified Purchase Officers commensurate with the number of material requisitions to be
handled and the time schedule for ordering. A procurement schedule will be prepared and
submitted to Owner/PMC for approval. This approved schedule will be followed for all
procurement activities.
Purchasing activities shall be coordinated by an experienced purchase coordinator who

shall be responsible for:
 Coordinating with engineering group regarding preparation of material requisitions

(MRs), evaluation and clarifications on offers of vendors, technical discussions,
negotiations with vendors, technical recommendations preparation of purchase
requisitionsto form part of purchase requisitions selected vendors purchase order.
 Coordination for processing of change orders as required during execution of the

project on account of additions/modifications as well as transit losses/damages.
 Before ordering, clearance for technical portion for rotating, instrumentation and
electrical items as indicated in technical details would be taken from PMC.
 Preparation and issue of status reports on purchasing activities.
 Attending review meetings with Owner/PMC on all purchase activities.
(b) Inspection and Expediting

P2
SHEET 12 OF 41
The Contractor is required to organise a proper inspection and expediting system so as to

ensure timely delivery of all the items/equipment meeting the specified quality criteria. This
function has to be carried out by appropriate deployment of qualified personnel who have
wide experience in their respective fields. Owner/PMC will reserve the right to inspect items
deemed necessary by them without any additional cost to Contractor/sub-contractor/vendor
/third party.
Expediting is one of the vital activity of successful and efficient procurement system which
enables timely execution on the project. Such expediting has to be carried out by
deployment of expediting coordinator located at Contractor’s Head Office who would be
assisted by expediters located in various regional offices. To enable this function to be very
effective and fruitful, following functions are to be carried out as a minimum.
Expediting Coordinator
Expediting Coordinator located at the Contractor’s HO will liaison with various departments
such as purchase, projects, engineering, transportation etc. on one hand and regional
inspection/expediting offices and vendors on the other. The basic functions of such
expediting coordinator would be:
 Maintain effective communication link between various departments of the Contractor

including his regional offices and vendors on whom the orders are placed.
 Status maintenance of all the orders.
 Analyzing the order status in detail after identifying the critical order and initiation of
suitable remedial measures.
 Acting as an effective instrument in final delivery of the item within CDD.
 Preparation of order close out reports of each order.
 Expediting coordinator shall be a person who is highly communicative and has sound
technical knowledge; he must be highly analytical, alert, quick in gathering up-to-date
information of the various orders.
Responsibility of Expediting Coordinator
 Attending periodical review meetings with Contractor’s project department and

Owner/PMC.
 Distribution of Fax of Intent/Letter of Intent and status maintenance.
 Liaison with regional offices to obtain order to generate acknowledgement of Fax of

Intent/Letter of Intent.

P2
SHEET 13 OF 41
 Intimate Owner/PMC of reservations (if any) from the vendor in purchase order
acceptance.
 Distribution of POs / PRs to vendors and regions.
 Expediting of vendor’s drawings and other related documents.
 Expediting of approval of drawing by respective engineering department and timely

return of the same to the vendor.
 Ensure receipt of periodical expediting reports and preparation of monthly status report
against each order as per the requirement of Owner/PMC.
 Identification of critical orders/issues and initiate of remedial action.
 Expediting of decision on deviation sought by the vendor.
 Follow up actions with various concerned departments regarding all the issues
discussed in the review meetings.
 Prompt despatch of material after inspection with the assistance of transportation

department.
 Follow up of despatch particulars after despatch.
 Ensure preparation of order close out report for each order giving complete details of
the order including ordered quality, contractual delivery date (CDD).
 Date of completion, delay, if any and reasons for delay, status of final documents etc.
 Ensure receipt/distribution of vendor documents including final documents as per PR.
 Preparation of final procurement closing report. The order close out reports shall be
accompanied with two sets of complete documents in respect of each order bound/put
together in a folder comprising of: purchase order, purchase requisition, change orders
(if any), inspection certificates, material test certificates, final vendor drawings (if
applicable), operation/maintenance manuals, any other document as specified in PR.
Expeditor
Expeditor’s responsibility commences from the time he receives the intimation of placement
of TOI/LOI/order on vendor located in his region till the time he furnishes the despatch
particulars of the item under a particular PO. During this process expeditor shall monitor
and maintain all activities of the vendors such as:
 Vendor’s understanding of the order.
 Submission of design drawing documents for approval.

P2
SHEET 14 OF 41
 Sub-ordering, planning and scheduling.
 Manufacturing testing and despatch.
 Delays, power cuts, strike lock out etc.
 Submission of final documents as per PR.
Above functions may be possible only by frequent visits to vendor’s office and shops
including their sub-vendor’s establishments as the case may be. Expeditor shall be able to
visualise the problems in advance and suggest timely corrective measure. In nutshell,
expeditor is not a mere progress reporter but a vital catalyst for successful completion of
the job. Expeditor’s responsibilities are as below:
 Ensure order acknowledgement from the vendor.
 Communicate the person concerned the reason for vendor’s inability to accept the
order (if so).
 Progress reporting of various orders located in the region.
 Communication with the vendors whenever he finds lack of efforts on their part.
 Raise alarm report at an appropriate time on possible serious delay or vendor’s inability
in meeting with scheduled date of delivery and also to suggest action plan.
 Liaise with inspection department for timely inspection, including third party
inspection/statutory inspection as specified/required.
 Liaise with engineering department for approval of drawing, acceptance of deviation

etc. through the expediting coordinator.
 Liaise with transportation department for sound and quick despatch of material.
(c) Inspection Quality Assurance System
The objective of the quality assurance scheme of the Contractor shall be to ensure the
conformity of equipment, material, site construction (if any) to various standards,
specifications, drawings and technical requirements that are being mutually agreed
between the Contractor and Owner/PMC. Quality Assurance System should clearly
indicate the organisational approach for quality control and quality assurance of the various
equipment/construction activities (if any) and also provide a verifiable evidence of the
Contractor having carried out all the activities laid down in the bid document and the
procedure. Such conformity to quality level shall be ensured by controlling the quality level
of purchased items at vendor’s/sub-vendor’s shop/site and shall cover from source

P2
SHEET 15 OF 41
surveillance to final inspection. The Contractor to submit a detailed inspection and testing
plan for various shop/site activities as a part of his Procurement Manual which shall be duly
approved by Owner/PMC. The Procurement Manual shall as a minimum include:
In house Inspection Programs
 Inspection procedures consistent with mandatory codes.
 Procedures for material identification and transportation.
 Certification of non-destructive testing.
Inspection responsibility shall include but not be limited to the following:
 Single or multiple visits to the vendor’s shop/site as per the requirement.
 Pre-inspection liaison meeting with the vendor for vendors correct understanding of the
inspection requirements.
 Approval of quality assurance/quality control plan procedure clearly indicating stages of

inspection with specific reference to witness and review.
 Ensure submission of quality control procedure and approval of the same for critical
sub-orders.
 Inspection of various equipment/items as per relevant codes, specifications/drawings

including witnessing of final acceptance test at vendors works/site.
 Maintenance of inspection reports periodically highlighting hold, deviation etc.
As indicated for expediting coordinator, Contractor should nominate an inspection

coordinator with similar responsibility who will liaise various inspection offices/vendors for
proper coordination.
Inspection through an Approved Third Party Inspection Agency
Inspection requirements shall be fulfilled through Owner/PMC approved ThirdParty

Inspection Agency. The payments to be made to the Third Party Inspection Agency shall
be the responsibility of the Contractor. Further, the responsibility for inspection/testing as
per specification approved documents and agreed Quality Assurance procedure and plans
shall be that of the Contractor. Inspection activities of the Third Party Inspection Agency
shall be coordinated by the Inspection Coordinator of Contractor.
(d) Customs Clearance and Transportation
The Contractor is required to organise a custom clearance and transportation (C&T)

system to ensure prompt clearance of imported equipments from customs and

P2
SHEET 16 OF 41
transportation of equipments/materials to project site from ports/vendors works. This

function shall be carried out by deployment of qualified and experienced personnel. C&T
functions shall include, but not be limited to thefollowing:
Appointment of Contractors
 Clearing forwarding of imported equipments/materials.
 Collection and transportation of bulk materials by road from vendor’s works.
 Transportation of consignments from port to site by road.
 Handling of consignments at project site.
 Transportation of general cargo and over dimensioned consignments by road/rail

wherever applicable.
 Clearing and handling of air consignments, if applicable.
 Any other contracts relating to C&T services.
Supervision of Contractors
Supervision, monitoring and coordination of above contracts for import clearance and
transportation as detailed below by Contractor. EC (Essentiality certificate) shall be
provided by Owner to main Contractor of Indian origin. Essentiality certificate is not
applicable to foreign Contractor.
Import Clearances
 Monitoring and coordination with clearing agents, customs, ports, steamer agents,
airlines, railways and transport agencies for clearance of imported consignments.
 Registration of contracts with custom under project imports.
 Control of payment of import duty to customs, payment of port dues, etc.
 Conducting surveys with various agencies for imported consignments landed in

damaged condition and corrective action for timely replacement of items.
Despatch of Indigenous Project Goods
 Coordination with inspection/expediting group and all indigenous suppliers for

expeditious despatch of consignments.
 Monitoring movement of consignments from vendors works to project sites.

P2
SHEET 17 OF 41
 Collection, transportation and delivery of bulk-material to project site.
(e) Monitoring Movement of Consignments
Total monitoring of movement of all consignments dispatched to project site from various
points of despatch. A chaser has to be deployed from Contractor, for transportation of all
ODC Consignments as well as important consignments (imported andindigenous) as and
when advised by Owner/PMC.
(f) Reporting
Preparing and issuing Weekly, Fortnightly and Monthly Status Reports on clearance of
imported equipments/materials and movement of equipments/materials from various
despatch points to project site.
Monthly Reports on Over/Short Rejected/Damaged (OSRD) items. It shall be Contractor’s

responsibility to arrange for timely replacement of OSRD items.
(g) Tendering
Tendering activities of the Contractor shall be properly organised to ensure award of

various contracts in line with the project schedule. The tendering group shall consist of
sufficient number of contract engineers/officers who are having adequate professional
experience and qualifications.
Contractor shall prepare a Tender schedule for carrying out different works such as civil
and structural equipment erection, piping, electrical, instrumentation, painting etc. All
tendering activities shall be carried out in accordance with this approved tender schedule.
The Contractor shall deploy a contract coordinator for coordination of tendering activities.
The contract coordinator shall be responsible for:
 Coordinating with the Resident Construction Manager during execution of the contracts
regarding clarifications on contract terms and conditions as required.
 Preparation and issue of status reports on contracting activities.
 Attending review meeting with Owner/PMC on all contracting activities.
 Preparation of tender documents, issue of enquiry to approved Contractors through

receipt of bids, techno-commercial evaluation of offers for award of contract will be
carried out by Contractor.
All major tenders will be handled by the Contractor from his Head Office. However, tenders
for certain minor construction will be handled by Contractor’s site office.

P2
SHEET 18 OF 41
The Contractor is required to institute and maintain a proper planning, scheduling and
monitoring system and employ professionally qualified and experienced planning engineers
for the project. The system shall have latest state of the art technique. To this
effect,Contractor shall implement this system through the Prima Vera Project Planner. The
system developed should be capable to support and enforce proper control mechanism in
the project. It should be based on hierarchical breakdown of works with elaborate level of
detailing and control. The levels of controls should be such that it supports and foster
controls at activity level, function level and management level with greater emphasis on
target, scope and commitment at various stages of contract for accountability and action
planning, such multi-level/multi-tier system of planning, scheduling and monitoring,
supports, effective information generation, assimilation, summarisation and reporting in
proper and adequate manner.
The system shall be predictive type and should constitute pre-warning mechanism to
diagnose and anticipate the problem well in advance and provide preventive
features/measures. It is required that work breakdown structure should consist of details of
systems, work packages, functions, work items and activities from monitoring point of view
at micro level and summarisation at higher levels. It is expected that the work breakdown
structure coding system or methodology to be followed shall be informed/discussed with
the successful bidder during the kick-off meeting.
2.4. Kick-Off Meeting

On award of job, the Contractor is required to submit the following documents which will be
discussed during the kick-off meeting to establish planning requirements, inputs and
outputs for overall schedule, monitoring and progress reporting.
 List of work package/areas.
 List of critical drawings.
 Breakdown of work packages to work items level.
 Input requirements of each work item/activity.
 Schedule start and finish dates of all milestone/activities in line with overall schedule of
the project.
 Procedure for Project Planning, Scheduling, Monitoring & Control System including all
reporting formats.
 Progress Measurement Methodology and Unit, Function, Discipline and Deliverable

wise weightages breakdown. Overall system-wise, discipline-wise weightages for each
item/activity.
 Procedure/presentation on proposed Bulk material control system

P2
SHEET 19 OF 41
 Three month Front-End Schedule within a week of award.
In this kick-off meeting, it will be endeavoured to reach complete understanding with

Contractor on activities, inputs and logic to establish planning documents for monitoring.
Venue of the kick-off meeting to be held between the successful Bidder, PMC and the
Owner, shall be either at PMC Office or Owner Office.
2.5. Early Planning Document/Look Ahead Schedule

Immediately after the award of contract and pending finalisation of overall project
schedule, detailed activity chart/network, functional schedules etc., the Contractor in
consultation with PMC shall prepare a look ahead schedule as a guideline for the activities
to be performed during the relevant periods.
2.6. Overall Project Schedule

The Contractor shall submit within 30days of Fax of Intent / Award of Work, the Work
Breakdown Structure (Plant wise / Facility wise) showing project work load, that is,
preparation of tenders, material requisitions, construction drawings equipments etc.
alongwith a sufficiently detailed overall project schedule in the activity network form, clearly
indicating the major milestones, inter relationship/interdependencies between various
activities such as process, engineering, procurement tendering, manufacture, delivery,
construction etc. together with computer analysis of critical path and floats as well as
quantum of work for major activities.
The time and the date of completion of the works as stipulated in the
CONTRACTOR's proposal and accepted by the OWNER shall be deemed to be of
utmost importance. The CONTRACTOR shall so organise his resources and perform his
work as to complete it not later than the date agreed to.
The CONTRACTOR shall submit The detailed Primavera Level 4 Project Master Schedule
within thirty (30) days or as specified elsewhere after effective date of the
CONTRACT.
The Primavera Level 4 Project Master Schedule shall be for OWNER / PMC review and be
based on a Proposal Schedule as attachment to the CONTRACT. Such Proposal
schedule shall show the execution periods for (i) Engineering, (ii) Procurement & Delivery
of Equipment and Materials, (iii) Construction & Erection and (iv) Commissioning, Testing.
Bidding consortium shall be contractually obliged to issue a Primavera Level 4 Project

Master Schedule, provided that such schedule shall not (i) accelerate the OWNER
obligations (to be agreed upon prior to Contract award) (ii) change the agreed
GUARANTEED COMPLETION DATE (date to be agreed upon prior to Contract award)

P2
SHEET 20 OF 41
The above Primavera Level 4 Project Master Schedule shall be periodically updated,&
reviewed and reports shall be submitted by the CONTRACTOR as directed by the
OWNER / PMC.
The schedule will be reviewed and approved by Owner/PMC and the comments if any
shall be incorporated in the network issued for implementation within two weeks from
receipt of comments. The network thus finalised shall form part of the Contract and will
become the basis for developing further detailed activity network. This schedule shall not
be revised without the prior permission from the Owner/PMC during the entire period of
contract. The changes made during revision of the contract shall be approved by
Owner/PMC.
2.7. Detailed Activity Network

The Contractor should develop Detailed Activity Networks for various systems of the
project, based on approved Overall Master Project Schedule. Such networks would be
computerised for further monitoring and reporting.
2.8. Functional Schedules

The Contractor should prepare resource-based detailed functional schedules in line with
detailed activity networks for functional monitoring, scheduling and control. This should
clearly reflect strategies and philosophy of execution. Owner/PMC reserves the right to
check the functional schedule and status of activities at anytime and at any location of
performance/execution. Further, the functional schedules shall be submitted by the
Contractor on demand by the Owner/PMC.
2.9. Progress Measurement Methodology

The Contractor is required to submit during the Kick-Off Meeting, the detail Methodology of
Progress Measurement of Engineering, Procurement, Manufacturing, Delivery,
Computation of total Service/Physical Progress at the unit-wise level and on the overall
basis. The progress basis shall be physical realisation of work such as in terms of
deliverables and construction quantity/volume accomplished. The amalgamation of such
output across the project to compute overall progress shall be suitably established with
proper rational and norms and maintained throughout the project. Owner/PMC reserves the
right to modify the methodology in part or in full.
2.10. Vendor Scheduling and Monitoring

The Contractor shall establish schedules for Pre-Ordering and Post Ordering for follow up.
The vendor monitoring preferably should be on logical networks and commitments atleast
on critical items in order to monitor them on regular basis for effective control. Owner/PMC
may demand such follow up procedure and logical networks for various Critical Equipment
at any time during the course of order execution. The manufacturing schedule shall be

P2
SHEET 21 OF 41
established and agreed with the vendors and acceptance shall be brought to the notice of
Owner/PMC in time.
2.11. Construction Network

The Contractor shall prepare and submit a Detailed Construction Network with full
consideration of logistics, construction studies and method for Owner/PMC approval. The
Contractor shall describe the resources required and special construction equipments,
Tools andtackles to be mobilized. The network shall be developed subsequent of
substantial progress of engineering and ordering with fairly known construction workload
and quantities.
2.12. Construction Worksheets

The Contractor shall further detail out the construction network into area-wise details in
terms of work, quantity and schedule, to firm up basis for area control. The construction
schedule should be worked out based on work front generation criteria which will call for
availability of input like drawings, materials and access for each/group of activity to be
performed. It may be in the form of resource loaded barchart with ‘S’ curve. Owner/PMC
reserves the right to access the same.
2.13. Construction Contractor Schedule

The Contractor shall agree upon the construction schedules with sub-contractors for proper
mobilisation, monitoring and control. Owner/PMC reserves the right to ask for such
programme and status of any time as may be required.
2.14. Computerisation
Contractor should follow proper computerised control for the following project modules:
 Activity network
 Engineering (Residual)
 Purchasing, delivery and expediting

 Tendering
 Construction planning and control
 Materials control at head office.
 Material allocation and control at field office
 Proper warehousing control

P2
SHEET 22 OF 41
 Project documents and construction drawings
The above distinct but integrated components of project should be monitored asdeliverable
and quantum level. To perform such elaborate level of input-outputcontrol at each
deliverable, the packages used should forecast resources based on recovery plan in
dynamic manner for adequate control.
As indicated earlier, Project Schedules as above shall be developed/evolved using the

Latest Version of the Primavera (P6) Project Planner Software Package.
2.15. Project Review Meetings

Contractor shall present programme and status at various review meetings as required.
Monthly Review Meeting
Level of participation : Project andplanning of PMC, OWNERandContractor

Agenda : Monthly Programme v/s Progress Status/Statistics
Major hold ups/Slippage
Completion outlook
Assistance required
Areas of concern and critical issue
Recovery Action Plan
Venue : Owner/PMC Office or As Mutually Agreed Venue
Weekly Review Meeting
Level of participation : Contractor/PMC’s site in-charge / Project Manager

and Job Engineers
Agenda : Weekly programme v/sactual achieved in week
Programme for nextweek
Purchase requisition status report
Recovery actions and hold up analysis,
Safety related incidents and action taken for the same
Man-Power status
Venue : Site office or As Mutually Agreed Venue
2.16. Progress Reporting
The Contractor shall submit the following Progress Reports on a regular basis for
Owner/PMC review.
Monthly Progress Report
This report shall be submitted on a monthly basis within seven calendar days from cut-off
date, or as agreed upon, covering overall scenario of the project.The report shall include,
but not limited, to the following:

P2
SHEET 23 OF 41
 Executive summary or summary of major events/activities.
 Schedule v/s actual percentage progress and progress curves for engineering,
ordering, manufacturing, delivery, contracting, construction, commissioning, overall.
 Areas of concern/problem/hold-ups, impact; recovery action plans/catch-up plans.
 Activities executed achievements during months and targets for the following month.
 Analysis of critical activities and impact on overall completion.
 Chronological achievements of key events indicating schedules and actual date.
 Annexure giving status summary for drawings material requisitions, equipment and
materials delivery, contracting and construction.
 Resource requirement deployment status.
 Statutory requirements / compliance status
 Change order status.
 Invoice status.
 Construction photographs.
 Updated Project Schedule
Weekly Reports
This report will be prepared for Head Office and construction site in summarized fashion
and submitted on every Tuesday taking status as of Sunday by the Contractor on weekly
basis and will cover following items:
 Activities completed (engineering, procurement, contracting, construction. etc.)
 Programme for subsequent week.
 Resource deployed – man and machine.
 Quantities and productivity achieved in key areas of work.
 Progress on procurement activities including material requisition status reports.
 Constraints, if any.

P2
SHEET 24 OF 41
The report/information may be transmitted preferably through fax to Owner/PMCHO.
Daily Reports
 Important activities for the day at site.
 Engineering Deliverables Status
 Material/equipments receipts for the day.
 Labour deployment report.
2.17. Material Control

It is essential that the Contractor follow an integrated material control system for the
project. In the system, material identification in the drawing office, procurement and
allocation, are all channelized and controlled in an orderly manner. The Contractor should
follow a system for material identification like system-wise or area-wise/zone-wise, and
should give construction orientation to material control. The Contractor, right from the
beginning, at the drawing office stage will start identifying materials system-wise or area-
wise. The system will be based upon backing of material from the material take off stage
through material requisitioning, placement of purchase order, manufacturing at vendor’s
shop upto receipt at site for making the material available for performing planned and
sequential construction work.
At the construction site, the Contractor will develop and implement a system of inspection,
receipt and effective utilisation of materials received by re-examining the work front
availability and priority between and amongst various systems and areas.
In the case of multiple agencies carrying out construction at site, the Contractor must adopt
methodology of allocation and de-allocation and timely issue of the materials thereby
preventing possible idle storage of items at the Contractor’s level. Contractor must follow
proper warehousing procedure at project store to maintain various planned and unplanned
issues and dynamic stock status records. Through periodic reviews, the Contractor will
have a system of generating hold up reports well in advance to identify exception on
material availability and to track such material by the expeditery through a systematic follow
up procedure from the vendors.
Owner/PMC may introduce checkpoints at procurement, allocation and construction stages

to know the development, status and behaviour of the system and the Contractor shall
submit the following reports on monthly basis: bulk material status report, and material hold
up/shortage report.
2.18. Project Time Control Methodology

P2
SHEET 25 OF 41
2.18.1. The time for completion of the complete scope of work shall be strictly as per the time
schedule given in the tender document.
2.18.2. The CONTRACTOR shall furnish the following documents along with the bid:
(a) An overall schedule in the form of network, clearly indicating all important milestones in
design, engineering, fabrication, procurement construction, testing, commissioning,
etc. for the plant commensurate with the overall time schedule.
(b) Resource deployment schedule indicating mobilisation of all critical resources including
manpower and machinery for the smooth execution of the job at engineering offices,
fabrication shops and construction site. The resource schedule shall also contain
various construction aids envisaged to be deployed for execution.
(c) Organisation structure for effective project management and control, clearly indicating
the responsibility centre as well as bio-data of the key personnel, who are permanent
employees of the Contractor.
2.18.3. Within 30 days of issue of fax/letter of intent, the Contractorshall finalise the following as
detailed earlier:
(a) Overall Project Schedule
Overall project schedule in line with the agreed milestone and detailed to adequate
work breakdown structure level covering all phases of the work such as detailed
engineering, procurement, manufacturing, shipment, tendering and field erection. This
schedule shall also include the interface activities to be provided by the
Owner/Engineer-in-Charge and the dates by which such facilities are needed.
Contractor shall get the schedule reviewed by Owner/Engineer-in-Charge and the
agreed schedule shall form part of the Contract monitoring document based on which
performance would be reported and evaluated. This document shall be signed by both
the parties. The Owner/Engineer-in-Charge shall also review the weightage allotted to
various activities and method of reporting to be adopted by the Contractor. During the
progress of the contract if in the opinion of Owner/Engineer-in-Charge, desired
progress as physically/sequentially is not maintained, it would be obligatory on the
Contractor to re-programme the work schedule in order to accommodate the backlog
and/or provide work front to other agency, without any obligation to the Owner/PMC.
(b) Functional Schedules
 Engineering Schedule

P2
SHEET 26 OF 41
This shall indicate list of drawings, specification and sketches to be prepared discipline
wise for each plant and scheduled date of issue of each document.
 Ordering, Manufacturing & Delivery Schedule
This will be in the form of bar chart and shall indicate item-wise all the major activities
regarding ordering, shop fabrication/manufacturing and delivery of materials.
 Construction Schedule
This will be in the form of a detailed bar chart showing all the construction activities
(civil structural, piping, equipment erection, electrical, instrumentation, insulation,
painting, etc.) at site with their durations and workload and highlighting the inputs
namely drawings, materials availability, etc., compatible with the related functional
schedule. The Contractor shall provide on request key construction net work of any
work module for critical review and control.
 Resource Deployment Schedule
A detailed deployment schedule indicating manpower, machinery, construction,

equipment in line with the overall project schedule
 Pre-commissioning and Commissioning Schedule
Contractor shall develop this schedule in the form of a bar chart and submit the same to
OWNER / PMC for review.
 Any other document required for monitoring.
2.18.4. In line with the construction schedule, the Contractor shall submit a monthly programme
for site activities and the target set in shall be strictly adhered to. In all matters concerning
the extent of targets set out in the monthly programme and the degree of achievement,
the decision of PMC shall be final and binding. The monthly programme shall be further
broken into weekly programmes. At the end of each week, a report shall be submitted by
the Contractor indicating the achievement during the week against the targets, reason for
shortfall if any and the construction programme for the following week.Contractor shall
also attend weekly/monthly review meeting conducted by PMC or by his representative to
review project status.
2.18.5. The Contractor shall regularly submit a detailed progress report in respect of:
 Release of drawings
 Sub-ordering of materials

P2
SHEET 27 OF 41
 Manufacturing
 Delivery of equipment/material status report
 Construction
 Other features like mobilisation, safety etc.
 Report indicating the critical activities governing the timely completion of the projectand
actions to overcome the same to be submitted every month.
This report will be issued every month on an agreed cut off date and shall include the
following brief description of the progress achieved during the month. Reason for short fall
if any and action plan to make up short-fall.
 Scheduled and actual percentage progress discipline-wise/system-wise as well as

overall physical progress.
 Job completion trend in the form of updated overall schedule.
 Progress photograph highlighting major achievement.
2.18.6. The Contractor at any point of time of operating would be permitted to revise the
accepted schedule/control documents with the Owner/Engineer-in-Charge without
changing the contractual completion date.
2.18.7. The review of the performance of work would be made at different levels of management
and Contractor is expected to ensure proper participation for effective reviewing and
action plan.
2.18.8. The Contractor should ensure availability of professionally qualified planning engineer
both at HO and site deemed adequate by the Owner/Engineer-in-Charge.
2.18.9. The Contractor at his own cost should maintain a control room at site highlighting all the
features, schedule and achievements of the project.
2.18.10. Weighted percentage of each discipline/group of work shall be mutually agreed to

between the Contractor and Owner/Engineer-in-Charge after the award of contract to
facilitate compilation of progress.
3.0. CONSTRUCTION, CONSTRUCTION SUPERVISION AND MANAGEMENT
3.1. Construction

P2
SHEET 28 OF 41
3.1.1. The Contractor will carry out the construction works in accordance with all relevant
codes, standards, specifications, his documents and drawings, and based on the most
efficient use of local resources. The Contractor will act as principal employer on the
labour employed for construction activities and will follow Indian Labour Act, and all
statutory regulations in this regard. The Contractor will have total responsibilities for the
following:
 Construction, erection and installation of all equipment, machinery, piping and materials
supplied by the Contractor.
 Site supervision, planning and coordination at site.
3.1.2. Major categories of construction work performed by the Contractor will comprise of but
not limited to the following:
 Civil work: Aboveground structure work;refractory, brick and castable work.
 Civil foundation work shall be done by the bidder.
 Machinery: Installation of machinery and equipment; assembling of large size

equipment, if any
 Piping Work: Prefabrication of piping, installation of piping; welding work of piping; non-
destructive test for welded parts.
 Electrical Work: Installation of transformer, cubicles and electrical equipment; power

cable and control cable wiring; installation of lighting fixtures and lighting wiring;
installation of communication system and wiring; installation and wiring work for fire-
alarm system; grounding work for equipment and structures.
 Instrument Work: Installation of local panel, all field devices like transmitters, control
valves and other instruments/equipments; installation of cable duct and cable laying
etc.; cable wiring work; air piping and tubing work; instrument pressure-piping work.
 Painting/Insulation Work: Painting of equipment, piping, impulse piping and steel

structures; insulation of equipment and piping
 Safety work during construction period.
 Test and inspection work.
3.1.3. The Contractor is required to organise and mobilise construction management services
in a systematic and sequential manner to ensure that the plant installation is carried out
in accordance with the approved engineering drawings, specifications, standards,
QA/QC procedures etc. and its mechanical completion is achieved within targeted time

P2
SHEET 29 OF 41
schedule. For this purpose, the Contractor shall deploy a construction management
team headed by a Resident Construction Manager (RCM) at site.
The construction management team shall include engineers/specialists in QA/QC,

project control (planning, scheduling, monitoring), contracts, construction supervision,
progress measurement/billing, safety, warehousing, purchasing etc.
Construction supervision, coordination and management activities shall be carried out by

Contractor in accordance with the approved construction procedures by PMC.
Contractor will prepare construction schedules based on the overall project schedule of
the plant and submit to Owner/PMC for approval. Monitoring and control of the
construction activities will be carried out as per the approved construction schedule and
procedure.
A construction management team headed by a Resident Construction Manager will be

deployed at site by Contractor. The Contractor shall ensure delegation of adequate and
sufficient power to his RCM for effective and smooth functioning of the field
management. HO support shall be provided to the RCM at site during construction as
and when required on all matters of project execution including the following:
 Field engineering
 Vendor specialists required during construction
 Rectification/replacement of defective supplies, if any, noticed during construction
 Inspection/expediting of replacement orders/field purchase order for ordered items

placed by field purchase
 Expediting replacement of imported items found short/damaged.
3.1.4. The Contractor shall establish and maintain a material testing laboratory for carrying on
field tests during execution of contracts under different disciplines by Sub-contractors, at
no extra cost to owner. Also, all material handling equipment shall be subjected by the
Contractor to required load test initially and then periodically to ensure safe/stable
operation including witnessing and maintaining records of such tests.
3.1.5. The construction organisation will include the following for effective execution,
monitoring and control: planning, scheduling, monitoring reporting, construction
supervision, quality assurance and quality control, warehouse management and material
control, field engineering/purchase, safety personnel administration.
(a) Quality Assurance and Quality Control (QA/QC):

QA/QC personnel will be responsible for ensuring quality of construction carried out by
different Sub-contractors in accordance with the approved QA/QC procedures and
management of material testing laboratory.

P2
SHEET 30 OF 41
(b) Warehouse Management and Material Control:

This discipline will be responsible for carrying out the warehouse management and
material control in accordance with the warehousing procedure and material control
procedure. The material control plan and warehousing procedure shall be Contractor
for Owner/PMC’s review/approval. The activities of the contractor will include:
 Transport Liaison, filing of insurance claims and follow up.
 Receipt, handling, identification, inspection, and acceptance of materials including

free issue materials to be supplied by owner.
 Documentation for control and accounting of materials.
 Materials control and issue
 Inventory checks
 Field requisition and purchase
 Spare and tools
 Material appropriation and handing over
 Security
 Taking with suppliers on short supplied items and placing replacement orders for
lost/damaged items.
 Intimating HO regarding short, lost, damaged items and taking up with suppliers
and taking replacement action when applicable.
 Perform material reconciliation and identification of surplus material and its handing
over to the Owner after certification by the PMC.
 Contractor will generate and issue following reports: fortnightly statement of

consignments in transit; daily report of material received; report on over, short,
reject, and damage receipts against each consignment on receipt at warehouse;
weekly status of consignments, material receipt report; monthly status of field
purchase; monthly status of excess, shortage rejected and damage settlement.
(c) Field Engineering:
This discipline will be responsible for controlling and issue of technical drawings and
documents, preparation of field sketches, field modifications, checking/preparation of

P2
SHEET 31 OF 41
as-built drawings, technical assistance for field purchase and field tendering etc.
Specialist engineers from Vendor HO will also be deployed at site as per requirements.
 Field tendering will be responsible for carrying out field tendering activities if
required.
 Field purchase contractor will be responsible for carrying out field purchase
activities if required. The bulk of procurement action will be done from HO. Field
purchase items are restricted to those required for running and maintenance of the
field offices, items required for field, items required to expedite construction work
and items found short, missing or damaged against the main order when received
at the site.
(d) Safety:
It is the responsibility of the Contractor to ensure that safe construction procedures are
complied with. They will also ensure that adequate first aid medical facilities are
available for emergency purpose and that safety procedures as per the approved safety
procedure are followed by the different Contractors. To assist in the development of an
effective safety programme, a safety checklist for various jobs shall be developed and
the same shall be reviewed by the Contractors Site Incharge.
The responsibilities will include the following: coordination and supervision of the details
of the job safety programme; initiation and supervision of the use of accident report and
investigation form; preparation of periodic accident summaries; tallying safety
inspection of the job site and submission of summary inspection report to site PMC in
charge.
3.2. Quality Assurance/Quality Control

All work/services to be performed by the Contractor under this contract shall be of
specified/approved quality and Contractor shall have a quality assurance/quality control
(QA/QC) system during the performance of various activities such as engineering,
procurement, tendering, construction etc. Review/approval of activities by Owner/PMC
shall not however dilute the responsibility of Contractor for maintaining quality.
(a) QA/QC Procedure:

Contractor shall submit the QA/QC procedure to be adopted for engineering
procurement and construction activities of plant for review and approval to Owner/PMC.
The QA/QC procedure shall cover all activities to be performed by Contractor. Some
important activities and procedures to be evolved are listed below:
 General:
Document control, coordination, non-conformance report of Sub-contractors, output
identification and traceability, QA system review

P2
SHEET 32 OF 41
 Procurement/Inspection:
Incoming material control, welding qualification and repair, manufacturing or
fabrication process control, applicable non-destructive examination, coating/lining,
preservation, post-weld heat treatment wherever applicable, packaging and
despatch control, transportation, inspection/test plans for all specific and mandatory
tests (as per drawings and codes) with clear indication of witness, verification and
hold points.
 Construction:
Pre-construction activities, job construction, welding qualification and repair,
inspection/test plans for all specified tests (as per drawing and codes) with clear
indication of witness, verification and hold points. Contractor shall prepare
construction QA plans for review of the Owner/PMC and the same shall cover as
minimum the areas as under, and shall confirm their compliance to approved
codes/standards/specifications, etc.
 Site Preparation:
Tie-ins, structures, incorporation of all witness tests/hold points of construction
work, clean-up testing, instrumentation installation and construction.
(b) As a part of Construction and Quality Assurance, the Contractor shall also comply with
the following activities:
 Stage-wise inspection of quality of work as per approved QA plan and contract

specifications.
 Develop welding procedures and welders qualification procedures for their work.
 Ensure compliance of various statutory rules, regulations and safety measures and
to arrange and co-ordinate site inspection, testing etc. as required under local
statutory rules and regulations prevalent in India.
 Take all necessary precautions to protect construction work and material from
damage by climate, outside elements and construction activities.
 Ensure that materials used are in accordance with drawings/project specification.
 Review safety procedures prepared by the Contractor for compliance with

applicable codes, regulations and Owner requirements.
 Prepare schemes for heavy/critical equipment's erection/lifts/rigging before and

submit the same for PMC review/approval.
 Ensure alignment (hot/cold) of all critical rotary equipment/machinery and their

upkeep/maintenance as per suppliers’ recommendations.

P2
SHEET 33 OF 41
 Perform housekeeping activities, which include maintaining sanitary facilities,

sweeping clean up, removal of excess materials/temporary facilities, scaffolding, as
necessary.
 Conduct periodic quality/technical audits for ensuring quality and conformance with
the contract.
 To take immediate appropriate corrective actions as and when such discrepancy

arises to fulfil quality, safety obligations.
(c) QA/QC procedure shall also include quality plans, mostly in tabular formats defining the
specific quality practices and flow of every identifiable activity of a discipline. All
disciplines concerned with the performance of work are to be covered. These quality
plans should indicate the following:
 For Design and Engineering: Activity description; preparation, checking, review and
approval requirements; code of conformance (applicable standard specification
number); applicable procedure number; QA data/records produced.
 For Procurement and Construction: Activity description; procedure number,

inspection and test plan number, conformance code, testing and inspection code
(d) QA/QC procedure and quality plans will be discussed during kick-off meeting. Hold,
witness and verification points and Owner/PMC review/audit requirements will be
finalised between Contractor and Owner/PMC.
(e) During the performance of the contract, the Contractor shall:
 Implement approved quality assurance programme including but not limited to:
(i) Performance of internal quality audits, preparation of audit reports and

submission for review of PMC. Contractor shall evolve a comprehensive
system of planned and documented audit to verify whether various performed
activities comply with detailed procedures, specifications, guidelines etc. and to
determine the effectiveness of quality system. Scope of such internal audits
shall be furnished to PMC for review. Verification documents shall be
generated during audit and submitted periodically to PMC for review.
Throughout all stages of the scope of contract, the Contractors procedures,
documents, activities, products and services and those of his Sub-contractor's
shall be subject to Owner/PMC review/approval. Such surveillance and audit
are optional and shall not relieve the Contractor of his contractual obligations
and liabilities.
(ii) Generation of QA records (mostly inspection and test plans) as per quality plan
and submission for review by Owner/PMC. The Contractor shall submit all

P2
SHEET 34 OF 41
quality records (generated during activity execution) and audit results on well
laid formats/performance for Owner/PMC review. The rights of such review are
reserved by Owner/PMC. Owner/PMC may review it in full, parts or selectively.
However, complete correctness of the QA records shall be the sole
responsibility of the Contractor irrespective of its review by Owner/PMC.
 Facilitate Owner/PMC in the quality audit at works.
 Certify QA Programme documents of Contractors and submit to Owner/PMC for

review.
 Carry out audits/inspection at Contractors works as per approved QA programme

and submit the reports for review by Owner/PMC
 Get similar QA system implemented at his Sub-contractor’s works/office. QA

records from the Contractor shall be reviewed and certified for compliance by the
Contractor before submitting to Owner/PMC for information.
 Carry out audits at Contractors' office/works and submit the report to Owner/PMC
for information.
 Ensure that all personnel shall be assigned tasks commensurate with their
qualification. Specialized workmen shall be qualified and certified.
 Handle non-conformance brought out by internal and external sources as follows:
(i) Non-conformance brought out by Contractor's own review/audit shall be

resolved by Contractor himself. One level higher than those responsible to
carry-out the activity shall resolve the non-conformance. Such resolution shall
be in full knowledge of Departmental Manager. Corrective action shall be
initiated at the earliest. Report of such resolution shall be submitted to
Owner/PMC for information.
(ii) Non-conformance brought out by Owner/PMC through any of the following shall
be resolved by the Contractor. Such corrective actions shall be submitted to
Owner/PMC for review. However, corrective action shall be initiated at the
earliest for : technical reviews, QA review and surveillance, inspection, external
audit (Owner/PMC)
3.3. Construction Equipment

The Contractor is required to organize and mobilize the construction equipment and other
tools tackles in a sequential manner to ensure that plant installation is carried out in a
mechanized manner and its mechanical completion is achieved within targeted time
schedule. The Contractor shall without prejudice to his responsibility to execute and
complete the work strictly as per the specifications and other laid down procedures by

P2
SHEET 35 OF 41
mechanizing the construction activities to the maximum extent by deploying all necessary
construction equipment/machinery of adequate capacities and numbers. For this purpose,
the Contractor shall deploy a rigging team headed by a rigging foreman reporting to Area
Engineer responsible for equipment erection.
Area Engineer should be well conversant with various erection techniques and shall be
responsible for preparing erection schemes in accordance with the approved procedures
and based on crane manuals suiting to plan layout. Area Engineer will have to foresee
various other constructive activities in the surroundings while planning erection schedules
including safety aspects of man and machinery also.
Contractor will prepare erection schedule based on the overall project schedule of the plant
in phased manner with erection schemes of various equipments, vessels and submit to
Owner/PMC for approval, monitoring and control of erection schedule. Erection activities
will be carried out as per the approved construction procedures.
For efficient working and maintenance of construction aids, Contractor shall establish and
maintain crane yard/workshop equipped with regular maintenance facility for various
construction aids for carrying out routine field maintenance during performance for the
contract. Temporary approach road, wherever required for the movement of the crane and
other vehicles for equipment erection and transportation of material shall be properly
planned and be made by the Contractor for quick mobilisation of the transportation system.
The proper padding for the crane movement shall be done to avoid any delays of erection
schedule. Weekly/fortnightly maintenances shall be planned in such a way that it should
not hamper the erection schedule.
Contractor shall ensure the timely augmentation of the plant, equipment and machinery
depend upon the exigencies of the requirement to meet the overall project schedule.
During performances of the work, Contractor must ensure that structures, materials or
equipments are adequately braced by guys, struts or otherwise approved means which
shall be supplied and installed by the Contractor as required till the erection works is
satisfactorily completed. Such guys, shoring, bracing, strutting, planking supports etc. shall
not interfere with the work of other agencies and shall not damage or cause distortion to
other works executed by him or other agencies. Contractor to submit the construction
equipment schedule along with the bid.
3.4. Construction Manpower

The Contractor is required to organise and mobilise construction staff in a sequential
manner to ensure that plant installation is carried out in accordance with the S curve
defined with other chapter of the Bid package. Mobilisation of construction staff should be
such that ‘S’ curve based on the time schedule and progress achieved in the phased
manner should match with the overall project time schedule. For this purpose, the
Contractor shall clearly indicate in his construction methodology that work shall be done
departmentally or by engaging such Sub-contractor or the combination of both.

P2
SHEET 36 OF 41
Contractor will prepare detailed methodology for the work to be carried out departmental as
well as by Sub-contractor clearly defining the scope and responsibility of main Contractor
and Sub-contractor.
In case, Contractor proposes to engage Sub-contractor for the erection of various activities,
he must enter into an agreement of Memorandum of Understanding and same shall be
furnished along with their credential with the bid. Sub-contractor’s credential will be
evaluated along with the offer. Contractor shall not be permitted to change the Sub-
contractor after the award of work under any circumstances. Non-compliances of the above
will be strictly dealt with relevant provisions of the contract.
During the execution of works at site, if the principal Contractor engages Sub-contractors
for execution of works at site as per approval obtained from Owner/PMC in line with
contract provisions and in the event Sub-contractor complains in writing to the Owner with
regard to the non-payment of their dues from the principal contractor for the works
executed by them and site (excluding final payments and payments due after termination of
Sub-contractors' services by the main contractor), Owner reserves their right to make such
payment to the Sub-contractors based on approved measurement with due notice to the
principal Contractor. Owner shall release such payments to Sub-contractor at the cost and
risk of the main Contractor in order to ensure smart execution of work at site.
The above such payment made by Owner to the Sub-contractor shall be adjusted in the
running account bills or any other payment due to the concerned principal contractor.
Contractor to submit the construction manpower schedule.
All Sub-contractors will be managed by the main Contractor construction staff who will
perform the duties of construction management and will administer, coordinate, and inspect
the work of the Sub-contractor and be responsible for the quality.
The contractor will establish the prerequisite for successful construction of sub-contractor
work. However, by deploying the Sub-contractors as approved by Owner/PMC for any
discipline, does not absolve the principal Contractor for his total responsibility under the
subject contract
The Contractor to ensure that in case of Sub-contract failure to execute the works as per
standards/specifications/drawings and negligence and disobedience in carrying out any
order or instruction of Owner/PMC will be viewed very seriously and dealt with
appropriately in accordance with provisions of the contract. Contractor to submit the
construction manpower schedule along with the bid
4.0. QA SYSTEM / INSPECTION REQUIREMENTS FOR BOUGHT OUT ITEMS &

DURING CONSTRUCTION
4.1. General

P2
SHEET 37 OF 41
Contractors are required to follow a well-documented quality assurance and quality control
system covering all phases of project viz. engineering, procurement, installation, testing
and commissioning. Similarly, Contractors are required to develop their own resources for
inspection of all bought-out items supported by third party inspection services for specific
cases. Supervision of construction activities is the responsibility of turnkey contractor;
Owner/PMC role during construction phase is for quality surveillance.
4.2. Specification for Turn-Key Bidder's Quality Assurance System

(a) Introduction
This specification establishes the quality assurance requirements to be met by the turnkey
bidder during execution of contracted services. in case of any conflict between the
requirements of this specification and other documents such as technical specifications,
contract conditions etc., the contractor shall notify Owner/PMC of all such conflicts for final
resolution.
(b) Scope of Work by Contractor
Prior to the award of contract, the following documents shall be submitted along with the
bid for evaluation:
 Quality policy
 Quality objective
 Company quality manual
 Project quality plans
 Copy of certificate of approval of quality management system
After the award of contract, within four weeks after the award of the contract, the Contractor
shall participate in the pre-start meeting with Owner/PMC to finalize ‘Project Quality Plans’
as regards to the following:
 Standard practices specified by the Contractor
 Hold, witness and verification point
 Owner/PMC’s review/audit requirements
During job execution, implement approved project quality plan including but not limited to:
 Performance of internal quality audits, preparation of audit reports and submission for
Owner/PMC's review.

P2
SHEET 38 OF 41
 Generation of QA records as per quality plan and submission for Owner/PMC's review.
 Records of management review of quality system
 Contract review records
 Design review, verification and validator’s records
 Assessment records of acceptable vendors/sub-vendors
 Records of nonconformity
 Records of external quality audit
 Records of training
 Inspection reports
 Test data/inspection and test plans
 Qualification reports
 Material review reports
 Calibration data
 Quality cost report
 Schedule control and progress reports
 Facilitate Owner/PMC in the quality audit at his works.
 Certify QA Programme documents of sub-contractor and submission for review to

Owner/PMC.
 Carry out audits/inspection at sub-contractor's works as per approved QA programme

and submit the reports for Owner/PMC's review.
(c) Quality Assurance System Requirement
 Requirements stipulated in this specification shall be fulfilled by the Contractor/Sub-

contractor. All other features of QA System shall be as per Contractor’s standards.
 The Contractor shall ensure that the quality system is clearly understood and faithfully
implemented at all levels in his organisation.
 The Contractor shall develop quality consciousness’ among all personnel working for
the contract.
 Non-conformances brought out by Contractors/Sub-contractors’ own internal

review/audit shall be resolved by Contractors'/Sub-contractors, themselves. One level
higher than those responsible to carry out the activity shall resolve the non-
conformances. Such resolution shall be in full knowledge of Departmental Manager.
Corrective action shall be initiated at the earliest. Report of such resolution shall be
submitted to Owner/PMC for information.
 Non-conformances brought out by Owner/PMC through any of the following: technical

reviews, QA reviews and surveillance, inspection, external audit (Owner/PMC), post
construction quality audit (by Owner/PMC) to be carried out immediately after

P2
SHEET 39 OF 41
declaration of mechanical completion by the Contractor. Non-conformances brought out

due to the above, shall be resolved by the Contractor/Sub-contractor. Such corrective
actions shall be submitted to Owner/PMC for review. However, corrective action shall
be initiated at the earliest.
 The Contractor shall evolve a comprehensive system of planned and documented audit
to verify whether various performed activities comply with detailed procedures,
specifications, guidelines etc. and to determine the effectiveness of quality system.
Scope of such internal audits shall be furnished to Owner/PMC for review. Verifiable
documents shall be generated during audit and submitted periodically to Owner/PMC
for review. Audits shall be carried out by independent engineers not responsible for
execution of the activity to be audited.
 Throughout all stages of the scope of contract, the Contractor's procedures,

documents, activities, products and services and those of his Sub-contractors' shall be
subjected to quality surveillance and audit by Owner/PMC. Such surveillance and audit
are optional and shall not relieve the Contractor of his contractual obligations and
liabilities.
 The Contractor shall submit all quality records (generated during activity execution) and
audit results on well laid formats/proforma for Owner/PMC's review. The rights of such
review are reserved by Owner/PMC. Owner/PMC may review it in full, parts or
selectively. However, completes correctness of the QA records shall be the sole
responsibility of the Contractor irrespective of its review by Owner/PMC.
 The Contractor shall get similar QA system implemented at his Subcontractors’

works/office. QA records from the Subcontractor shall be reviewed and certified for
compliance by the Contractor before submitting to Owner/PMC for information.
 Contractor shall carry out audits at Subcontractors, office/works and shall submit the
report to Owner/PMC for information.
 All personnel shall be assigned tasks commensurate with their qualification. Specialized
operators shall be qualified and certified. The Contractor shall have a system for
identifying personnel training needs in line with the latest ISO guidelines.
 Immediately after submitting written declaration of mechanical completion by the

Contractor, Owner/PMC will carry out post-construction quality audit. Contractor shall
extend all help and cooperation to carry out this audit including providing all necessary
resources to Owner/PMC and shall implement all corrective measures, based on the
post-construction quality audit findings and observations at no cost to the Owner/PMC.
 A pre-startup safety review (PSSR) checklist is a tool used by a PSSR team during a
safety review of a new facility before commissioning. This checklist helps ensure that a
facility will be safe for employees and that equipment will operate according to design
specifications. This may be added here to ensure safety aspect before pre-
commissioning. All the points in the PSSR has to be complied by contractor before start
up of the unit.

P2
SHEET 40 OF 41
4.3. Inspection Coordination Methodology for Turnkey Package

4.3.1. All equipment and materials are to be procured from vendors listed in the approved Vendor
List enclosed in this Bid, or from other reputed vendors after obtaining specific approval of
the Owner/PMC. In this regard, no difference is made between the equipment and
materials purchased by the contractor directly or by his contracted agencies.
4.3.2. After finalisation of purchase order, a detailed QA/QC plan shall be developed by the
vendor, duly reviewed by the Contractor and shall be submitted for approval of the
Owner/PMC. It is envisaged that QA/QC plans for the critical Items shall be
reviewed/approved by the Owner/PMC and for the balance items QA/QC plans shall be
submitted for records. The management of quality control system is to be developed
generally based on the categorisation of various equipment and materials. Preliminary
categorisation of various items involved is enclosed. For items not included here,
categorisation shall be decided during detailed engineering and Owner/PMC may change
inspection category based on final information and quantities. For indigenous items,
Contractor shall employ an approved third party inspection agency to carry out inspection
on his behalf, whose involvement must be brought out in the detailed QA/QC plans. For
imported items, contractor should engage Owner/PMC approved Third Party Inspector
(TPI). Each stage of inspection by the TPI, must define whether it is a hold point, witness
point, verification point or internal inspection point by the vendor. Contractor shall make
independent QA Plans through the approved Third Party Agency which shall be having a
confirmation of meeting the minimum inspection requirements spelt out. All inspection
stages where Owner/PMC desires to participate (which shall be preferably only for critical
items) shall be marked on the QA/QC plan and these stages must necessarily be attended
by the Contractor in addition to the other stages being attended by him. In case the QA/QC
plans are not submitted in sufficient detail, the Contractor may be asked to re-submit the
plans.
4.3.3. The personnel to be deployed by the third party inspection agency must have adequate
qualification and experience for the type of work involved and the owner may ask for
approval of the personnel employed for the job and his replacement, if required.
4.3.4. The Contractor shall submit a detailed vendor's inspection schedule for the coming two
months at the beginning of each month as well as notify owner's involvement at the
appropriate inspection stage, giving a clear notice period of 15 days. The contractor shall
submit monthly inspection and expediting reports of the inspection agency regularly to the
Owner/PMC.
4.3.5. PMC’s inspector shall witness the test on a mutually agreed date according to contractor's
inspection notification, wherever applicable.

P2
SHEET 41 OF 41
4.3.6. Submission of category-wise inspection plan by Contractor at PMC HO for review. It is

envisaged that the QA/QC plans shall be submitted to the PMC in accordance with the
clauses as defined above.
4.3.7. After finalisation of the vendor, the copy of PO or technical specification for sub-ordered
items along with QAP will be submitted by Contractor to PMC covering the location where
the sub-ordered items are manufactured. The QAP is to be duly approved by the PMC.
4.3.8. Contractor will be totally responsible for furnishing the complete and correct technical
document/specifications to his sub-vendor. It is responsibility of the contractor to ensure
that relevant specifications indicated in the tender documents are incorporated in the sub-
order/sub-order specification. Each PO shall categorically indicate involvement of various
agencies for inspection.
4.3.9. Contractor shall forward the approved copy of relevant drawings/documents to the TPI
before giving inspection call. The final inspection will be done by the TPI, based upon
drawings/documents reviewed by TPI/PMC in Code ‘AP’ (Approved) wherever applicable.
4.3.10. Contractor will ensure presence of their inspection engineer at sub-vendor's works during
inspection by TPI or Owner/PMC inspection engineer (wherever applicable).
4.3.11. Contractor shall expedite to ensure delivery of all the materials as per CDD.
4.3.12. All correspondence by contractor to the PMC for submission of documents and inspection
calls shall also be intimated to Owner.


Section - Vi Index: Projects & Development India LTD

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Section - Vi Index: Projects & Development India LTD

Uploaded by

Copyright:

Available Formats

PC150/E/4004/SEC-VI 0

PROJECTS & DEVELOPMENT INDIA DOCUMENT NO REV

PLANT: RAW WATER TREATMENT PLANT- DM WATER-

FORM NO: 02-0000-0021F1 REV4 All rights reserved

VI-1.0 PROJECT DESCRIPTION

VI-2.0 RAW WATER,CONDENSATE & TREATED WATER QUALITY

VI-3.0 CONTRACTOR’S SCOPE OF WORK

Attachment: Sec VI 3.2 Static

Attachment: Sec VI 3.3 Piping

Attachment: Sec VI 3.4 Electrical

Attachment: Sec VI 3.5 Instrumentation

Attachment: Sec VI 3.6 Civil & Structural work

Attachment: Sec VI 3.7 Construction

VI-4.0 DESIGN BASIS

VI-5.0 DESIGN PHILOSOPHY

VI-5.1 DESIGN PHILOSOPHY – PROCESS

VI-5.2 DESIGN PHILOSOPHY – MECHANICAL

VI-5.2.1 DESIGN PHILOSOPHY – STATIC EQUIPMENT

VI-5.2.2 DESIGN PHILOSOPHY – ROTATING EQUIPMENT

VI-5.2.3 DESIGN PHILOSOPHY – PIPING

VI-5.3 DESIGN PHILOSOPHY – ELECTRICAL

VI-5.4 DESIGN PHILOSOPHY – INSTRUMENTATION

VI-5.5 DESIGN PHILOSOPHY – CIVIL & STRUCTURAL WORKS

VI-6.0 PROJECT EXECUTION PLAN

VI-9.0 DRAWINGS & DOCUMENTS

FORM NO: 02-0000-0021 F2 REV3 All rights reserved

VI-10.0 SPARE PARTS

VI-11.0 VENDOR LIST

VI-12.0 INFORMATION REQUIRED IN THE TECHNICAL PROPOSAL

VI-13.0 SITE WORKING AND SAFETY CONDITIONS

FORM NO: 02-0000-0021 F2 REV3 All rights reserved

VI-1.0 PROJECT DESCRIPTION

VI-2.0 EFFLUENT –SEWAGE & UTILITY QUALITY

VI-3.0 CONTRACTOR’S SCOPE OF WORK

Attachment: Sec VI 3.2 Static:

Attachment: Sec VI 3.3 Piping:

Attachment: Sec VI 3.4 Electrical

Attachment: Sec VI 3.5 Instrumentation

Attachment: Sec VI 3.6 Civil & Structural work

Attachment: Sec VI 3.7 Construction:

VI-4.0 DESIGN BASIS

VI-5.0 DESIGN PHILOSOPHY

VI-5.1 DESIGN PHILOSOPHY – PROCESS

VI-5.2 DESIGN PHILOSOPHY – MECHANICAL

VI-5.2.1 DESIGN PHILOSOPHY – STATIC EQUIPMENT

VI-5.2.2 DESIGN PHILOSOPHY – ROTATING EQUIPMENT

VI-5.2.3 DESIGN PHILOSOPHY – PIPING

VI-5.3 DESIGN PHILOSOPHY – ELECTRICAL

VI-5.4 DESIGN PHILOSOPHY – INSTRUMENTATION

VI-9.0 DRAWINGS & DOCUMENTS

FORM NO: 02-0000-0021 F2 REV3 All rights reserved

VI-10.0 SPARE PARTS

VI-11.0 VENDOR LIST

FORM NO: 02-0000-0021 F2 REV3 All rights reserved

SECTION – VI 1.0 (PART-A)

PLANT: RAW WATER TREATMENT, DMW PLANT &

PROJECT: INTEGRATED COAL BASED FERTILIZER COMPLEX AT

FORM NO: 02-0000-0021F1 REV4 All rights reserved

Annexure Number Description Drawing No. Number

Annexure - I Overall Plot Plan – TFL PC009-0000-0001-REV 6_OP 1

Annexure - II Schematic Process Flow 1. PC150-7318-021 REV 0 5

FORM NO: 02-0000-0021 F2 REV3 All rights reserved