Actuator Vol

ELECTRICAL & INSTRUMENTATION SECTION MECON LIMITED DELHI - 110 092

SPECIFICATION FOR INSTRUMENT TUBING SPECIFICATION NO.: MEC/S/05/26/02

Document11

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT TUBING

SPECIFICATION NO. : MEC/S/05/26/02

REV-0

CONTENTS 1.0

GENERAL

2.0

CONSTRUCTION

3.0

TESTING

4.0

SHIPPING

5.0

REJECTION

PREPARED BY

Document11

CHECKED BY

APPROVED BY

Page 1 of 5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/02

SPECIFICATION FOR INSTRUMENT TUBING

REV-0

Page 2 of 5

1.0

GENERAL

1.1

Scope

1.1

This standard specifications, together with the data sheets attached herewith, covers the requirements for the design, materials, testing and shipping of Instrument Tubing which includes the following types:a) b)

1.1.2

SS tubes Copper tubes

The related standards referred to herein and mentioned below shall be of the latest edition prior to the date of Purchaser's enquiry: ASTM A 269

-

ASTM B 251

-

ASTM B 251M

-

ASTM B 68 ASTM B 68M

-

Specification for seamless and welded ferritic stainless steel tubing for general services. Specification for general requirements for wrought seamless copper and copper alloy tube. Specification for general requirements for wrought seamless copper and copper alloy tube (Metric) Specification for seamless copper tube, bright annealed. Specification for seamless copper tube, bright annealed. (Metric)

1.1.3

In the event of any conflict between these specifications, data sheets, related standards, codes, etc., the vendor shall refer the matter to the purchaser for clarifications and only after obtaining the same shall proceed with the manufacture of the items in question.

1.2

Bids

1.2.1

Vendor's quotation shall include a detailed specification sheet for each type of tube which shall provide the following information: a) b)

All the details regarding the type, construction, materials etc. of the items. Overall the dimensions in mm.

1.2.2

All the units of measurement and material specifications for various parts in the vendor's specification sheets shall be to same standards as in purchaser's data sheets.

1.2.3

Vendor shall attach a list of items, typewise, summing up all the deviations from this specification and purchaser's data sheets if there are any. Also vendor shall provide reasons for these deviations.

Document11

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT TUBING

SPECIFICATION NO. : MEC/S/05/26/02

REV-0

Page 3 of 5

1.2.4

Vendor shall enclose catalogues giving detailed technical specifications and other information for each type of tube in the bid.

1.2.5

Vendor's quotation, catalogues, drawings etc. shall be in English language.

1.3

Drawings, Data and Certification Detailed drawings, data, catalogues and manuals etc. required from the vendor are indicated by the purchaser in vendor data requirement sheets. The required number of reproducibles and prints shall be despatched to the address mentioned, adhering to the time limits indicated.

2.0

CONSTRUCTION

2.1

Stainless Steel Tubes

2.1.1

SS tubes of the tubes shall be Rockwell RB 70-70. Tubes shall be free from scratches and to be suitable for bending.

2.1.3

Tube wall thickness shall be 0.049" for 1/2" OD and 1mm for 6 mm unless otherwise specified.

2.1.4

Maximum working pressure shall be 153.0 kg/cm at 38 C for 1/2" OD Tube, unless 2 o otherwise specified and 80.0 kg/cm at 38 for 6mm OD tube.

2.1.5

Tubes shall be supplied in minimum length of 6 metres without brazing in between.

2.1.6

Dimensional tolerances shall be as per ASTM A 269.

2.1.7

The following shall be marked on the tube:

2

a) b) c)

o

Name of manufacturer Type and material grade of tube Tube O.D. and wall thickness

2.2

Copper Tubes

2.2.1

Copper Tubes (PVC Jacket)

2.2.1.1

The tube shall be soft annealed copper with 6mm OD and a wall thickness of 1.0 mm as per ASTM B 68M Copper No.C12200.

Document11

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT TUBING

SPECIFICATION NO. : MEC/S/05/26/02

REV-0

Page 4 of 5

2.2.1.2

The tube shall be jacketed with black PVC. The jacket thickness shall be 1.6mm. The PVC jacket shall confirm to ASTM D-1047.

2.2.1.3

The tube ends shall be plugged prior to transportation.

2.2.1.4

The tube shall be of continuous length without any brazing in between for 100 metres length.

2.2.1.5

Minimum length of single tube shall be 100 metres.

2.2.1.6

The dimensional tolerances shall be as per ASTM B 251M.

2.2.2

Bare Copper Tubes (For Steam Tracing)

2.2.2.1

The tube shall be soft annealed copper with 3/8" OD or 6mm OD with a wall thickness of 1.0 mm as per ASTM B68 copper No.C12200.

2.2.2.2

The tube ends shall be plugged prior to transportation.

2.2.2.3

The tube shall be of continuous length without any brazing in between for 100 metres length.

2.2.2.4

Minimum length of tube shall be 100 metres.

2.2.2.5

The dimensional tolerances shall be as per ASTM B 251.

3.0

TESTING

3.1

The following tests shall be done for SS tubes. a) b)

Hardness test 2 o 2 Hydrostatic test at 153.0 kg/cm at 38 C for 1/2" tube and at 80.0 kg/cm at o 38 C for 6mm tube, unless otherwise specified. 2

3.2

PVC jacketed copper tubes shall be tested at 7.0kg/cm g with dry air for leak check.

3.3

Bare copper tubes shall be hydrostatically tested at 80.0 kg/cm g at 38 C.

3.4

Final test before delivery shall include ball test to ensure clear opening of the tube for copper tubes. The O.D.of the ball shall be minimum 1mm for 6mm O.D tube and 2mm for 3/8" tube.

Document11

2

o

MECON LIMITED Delhi

SPECIFICATION NO. : MEC/S/05/26/02

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT TUBING

REV-0

Page 5 of 5

4.0

SHIPPING

4.1

The tubes shall be plugged at both ends to avoid entry of foreign matter. The tubes shall be packed carefully so as to avoid damage during transport.

5.0

REJECTION Vendor shall make his offer in detail, with respect to every item of the purchaser's specifications. Any offer not conforming to this shall be summarily rejected.

Document11

ELECTRICAL & INSTRUMENTATION SECTION MECON LIMITED DELHI - 110 092

SPECIFICATION FOR INLET / OUTLET SECTIONS AND FLOW STRAIGHTENER SPECIFICATION NO.: MEC/S/05/26/03

Document8

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INLET/ OUTLET SECTIONS AND FLOW STRAIGHTENER

SPECIFICATION NO. : MEC/S/05/26/03

REV-0

CONTENTS 1.0

FLOW STRAIGHTNER

2.0

INLET SECTION/OUTLET SECTION

PREPARED BY

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APPROVED BY

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INLET/ OUTLET SECTIONS AND FLOW STRAIGHTENER

SPECIFICATION NO. : MEC/S/05/26/03

REV-0

Page 2 of 2

1.0

FLOW STRAIGHTNER

1.1

Flow straightner shall be installed in the inlet section upstream of flow meter.

1.2

Flow straightner shall consist of a bundle of tubes designed and assembled as per ISO 5167-1980(E) or AGA Report no.3 or AGA Report no.7.

1.3

Tube diameter shall be 0.2 D or less where D is the diameter of Meter inlet section pipe. Tube shall be seamless quality of SS 316 material thickness 1.5 or 1 mm Tube shall be 2 hydrostatically tested for 75kg/cm pressure and then cut to the required length for assembly.

1.4

On both the sides of tube bundle a very thin retaining rings of SS316 shall be provided for avoiding the dislocation of pipes.

1.5

The tube bundle shall be kept in position by 6mm threaded bolt. After tightening the bolt shall seal welded.

1.6

Tube ends shall be chemphered at 45 angle.

2.0

INLET SECTION/OUTLET SECTION

2.1

Inlet/Outlet sections of pipe for flow meter shall be of same inside diameter (ID) as turbine meter.

2.2

The pipe used should be circular and with no ovality or any other deformation, the inside surface of pipe shall be smooth, welded protion shall be grinded to smooth finish.

Document8

o

ELECTRICAL & INSTRUMENTATION SECTION MECON LIMITED DELHI - 110 092

SPECIFICATION FOR INSTRUMENT TUBE FITTINGS SPECIFICATION NO.: MEC/S/05/26/04

Document9

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT TUBE FITTINGS

SPECIFICATION NO. : MEC/S/05/26/04

REV-0

CONTENTS 1.0

GENERAL

2.0

CONSTRUCTION

3.0

TESTING

4.0

SHIPPING

5.0

REJECTION

PREPARED BY

Document9

CHECKED BY

APPROVED BY

Page 1 of 4

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT TUBE FITTINGS

SPECIFICATION NO. : MEC/S/05/26/04

REV-0

Page 2 of 4

1.0

GENERAL

1.1

Scope

1.1.1

This standard specifications, together with the data sheets attached herewith, covers the requirements for the design, materials, testing and shipping of instrument tube fittings which includes the following types:a) b)

1.1.2

SS compression fittings (SS tube) Brass compression fittings (copper tube)

The related standards referred to herein and mentioned below shall be of the latest edition prior to the date of Purchase's enquiry: ANSI B 2.1 B16.11 IS:319 ISA RP 42.1

-

Pipe Threads Forged steel fittings-socket welding and threaded. Specification for free cutting brass bars, rods and sections. Nomenclature for instrument tubing - fittings.

1.1.3

In the event of any conflict between these specifications, data sheets, related standards, codes etc., the vendor shall refer the matter to the purchaser for clarifications and only after obtaining the same shall proceed with the manufacture of the items in question.

1.2

Bids

1.2.1

Vendor's quotation shall include a detailed specification sheet for each type of tube fittings which shall provide the following information: a) b)

All the details regarding the type, construction, materials, etc. of the items. Overall dimensions in mm.

1.2.2

All the units of measurement and material specifications for various parts in the vendor's specification sheets shall be to same standards as in purchaser's data sheets.

1.2.3

Vendor shall attach a list of items, typewise, summing up all the deviations from this specification and purchaser's data sheets if there are any. Also vendor shall provide reasons for these deviations.

1.2.4

Vendor shall enclose catalogues giving detailed technical specifications and other information for each type of fitting in the bid.

1.2.5

Vendor's quotation, catalogues, drawings, etc. shall be in English language.

Document9

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/04

1.3

SPECIFICATION FOR INSTRUMENT TUBE FITTINGS

REV-0

Page 3 of 4

Drawings, Data and Certification Detailed drawings, data, catalogues and manuals etc., required from the vendor are indicated by the purchaser in vendor data requirement sheets. The required number of reproducibles and points shall be despatched to the address mentioned, adhering to the time limits indicated.

2.0

CONSTRUCTION

2.1

SS Tube fittings:

2.1.1

Nomenclature of all tube fittings shall be as per ISA RP 42.1.

2.1.2

Fittings shall be flareless compression type and of three piece construction with ferrule, nut and body suitable for use on SS tubes conforming to ASTM A 269 TP316, hardness not exceeding RB80.

2.1.3

All parts shall be of SS 316.

2.1.4

Hardness of the ferrules shall be in the range of RB 85-90 so as to ensure a minimum hardness difference of 5 to 10 between tube and fittings, for better sealing.

2.1.5

Nuts and ferrules of 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 2.1.

2.1.8

Copper Tube Fittings

2.2.1

Nomenclature of all tube fittings shall be as per ISA 42.1.

2.2.2

Fittings shall be of flareless compression type and of three-piece construction consisting of ferrule, nut and body suitable for use on copper tubes conforming to ASTM B 68/B 68M hardnesss not exceeding RB 50.

2.2.3

All parts shall be manufactured from Brass as per IS 319 barstock and Nickel plated.

2.2.4

For better grip, vendor shall maintain hardness difference between tube & ferrule and indicate the same along with the offer.

2.2.5

Nuts & ferrules of particular size shall be interchangeable for each type.

2.2.6

Threaded ends of fittings shall be NPT as per ANSI B 2.1.

Document9

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT TUBE FITTINGS

SPECIFICATION NO. : MEC/S/05/26/04

REV-0

Page 4 of 4

2.2.7

Spanner hold shall be metric.

2.2.8

Vendor shall ensure that the ferrules and nuts supplied for fittings shall be suitable for sample tube which shall be supplied during manufacture.

3.0

TESTING

3.1

Random samples of SS tube fittings shall be hydrostatically tested as follows:2

2

o

For 6 mm fittings at 80.0 kg/cm , 1/2" fittings at 153.0 kg/cm at 38 c unless otherwise specified. 3.2

Random samples of brass compression fittings shall be hydrostatically tested as follows:2

2

o

For 1/4" fittings, at 10 kg./cm , 3/8" at 80.0 Kg/cm and all at 38 C. 4.0

SHIPPING

4.1

All thread/ends shall be protected with plastic caps to prevent damage/entry of foreign matter.

5.0

REJECTION Vendor shall make his offer in detail, with respect to every item of the purchaser's specifications. Any offer not conforming to this shall be summarily rejected.

Document9

ELECTRICAL & INSTRUMENTATION SECTION MECON LIMITED DELHI - 110 092

SPECIFICATION FOR INSTRUMENT VALVES AND MANIFOLDS SPECIFICATION NO.: MEC/S/05/26/05

Document12

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT VALVES AND MANIFOLDS

SPECIFICATION NO. : MEC/S/05/26/05

REV-0

CONTENTS 1.0

GENERAL

2.0

CONSTRUCTION

3.0

TESTING

4.0

SHIPPING

5.0

REJECTION

PREPARED BY

Document12

CHECKED BY

APPROVED BY

Page 1 of 5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/05

SPECIFICATION FOR INSTRUMENT VALVES AND MANIFOLDS REV-0

Page 2 of 5

1.0

GENERAL

1.1

Scope

1.1.1

This standard specifications, together with the data sheets attached herewith, covers the requirements for the design, materials, testing and shipping of Instrument Valves & Manifolds which includes the following types:a) b) c)

1.1.2

Miniature instrument valves Instrument valve manifolds Instrument air valves

The related standards referred to herein and mentioned below shall be of the latest edition prior to the date of Purchaser's enquiry: ANSI B 2.1 ANSI B 16.11

-

Pipe threads Forged steel fittings-socket welding and threaded.

1.1.3

In the event of any conflict between these specifications, data sheets, related standards, codes etc, the vendor shall refer the matter to the purchaser for clarifications and only after obtaining the same shall proceed with the manufacture of the items in question.

1.2

Bids

1.2.1

Vendor's quotation shall include a detailed specification sheet for each type of Valves & Manifolds which shall provide the following information: a) b)

All the details regarding the type, construction, materials etc. of the items. Overall dimensions in mm.

1.2.2

All the units of measurement and material specifications for various parts in the vendor's specification sheets shall be to same standards as in purchaser's data sheets.

1.2.3

Vendor shall attach a list of items, typewise, summing up all the deviations from this specification and purchaser's data sheets if there are any. Also vendor shall provide reasons for these in the bid.

1.2.5

Vendor's quotation, catalogues, drawings etc. shall be in English language.

1.3

Drawings, Data and Certification Detailed drawings, data, catalogues and manual etc. required from the vendor are indicated by the purchaser in vendor data requirement sheets. The required number of reproducibles and prints shall be despatched to the address mentioned, adhering to the time limits indicated.

Document12

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT VALVES AND MANIFOLDS

SPECIFICATION NO. : MEC/S/05/26/05

REV-0

Page 3 of 5

2.0

CONSTRUCTION

2.1

Instrument Valves (Miniature)

2.1.1

The instrument valves shall be globe pattern-needle valves forged/ barstock with inside screwed bonnet.

2.1.2

Body and trim material shall be 316 SS unless otherwise specified.

2.1.3

The valve body rating shall be 3000 lbs unless specified in piping material specification which shall govern in in case it is specified.

2.1.4

The end connection shall be 1/2" NPTF to ANSI B2.1.

2.1.5

The packing material shall be teflon unless otherwise specified.

2.1.6

The hand wheel material shall be carbon steel zinc plated.

2.1.7

Flow direction shall be marked on the body.

2.1.8

The valve dimension shall be as follows: a) b)

End to end dimensions 76 mm (approximately). Height in fully open condition - 135mm maximum.

2.2

VALVE MANIFOLDS

2.2.1

3-Valve & 5-Valve manifolds:

2.2.1.1

3 Valve manifold shall be designed for direct coupling to differential pressure transmitters having 2 bolt flanges with 54 mm (2-1/8") centre to centre connections and 41.3 mm (1-5/8") bolt to bolt distance. The manifold shall contain two main block valves and an equalizing by-pass valve. The valves shall be needle valves. They shall use self aligning 316SS ball seats.

2.2.1.2

5 Valve manifold shall contain two main line block valves and a combination double block and bleed for the bypass line.

2.2.1.3

The manifold shall be suitably for mounting directly on the stanchion (2" pipe).

2.2.1.4

All bonnets shall have teflon packings unless otherwise specified.

2.2.1.5

The material of construction shall be 316 SS unless otherwise specified.

2.2.1.5

The material of construction shall be 316SS unless otherwise specified.

Document12

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT VALVES AND MANIFOLDS

SPECIFICATION NO. : MEC/S/05/26/05

REV-0

Page 4 of 5

2.2.1.6

The flanges shall be integral part of the block.

2.2.1.7

The process connection shall be 1/2" NPTF to ANSI B2.1.

2.2.1.8

The manifolds shall be supplied alongwith mounting accessories. The bolts and nuts shall be alloy steel as per ASTM A 193 Gr B ASTM A 194 GR 2H respectively. rings shall be teflon and other accessories shall be cadmium plated.

2.2.1.9

Vendor shall furnish the material certificate for body.

2.2.2

3 Way 2 Valve Manifold for pressure gauges.)

2.2.2.1

The manifold shall be designed for use with pressure gauges.

2.2.2.2

The valve shall be a ball valve.

2.2.2.3

The body shall be either straight or angle as specified in data sheets.

2.2.2.4

The body and trim material shall be 316SS, packing material shall be teflon unless otherwise specified.

2.2.2.5

The inlet connection shall be 3/4" plain end (female) for socket weld as per ANSI B 16.11.

2.2.2.6

The gauge connections shall be with union nut & tail piece threaded 1/2" NPT(F).

2.2.2.7

The drain connection shall 1/2"NPTF.

2.3

Instrument Air Isolation Valves

2.3.1

The valves shall be full bore ball valves.

2.3.2

Body material shall be Nickel or Cadmium plated carbon steel.

2.3.3

Trim material shall be 316SS.

2.3.4

The end connection shall be 1/2" NPTF to ANSI B2.1 unless otherwise specified.

2.3.5

The packing material shall be teflon.

2.3.6

The handle/wrench material shall be cadmium or nickel plated carbon steel.

2.3.7

The valve body rating shall be ANSI 800 lb.

Document12

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTRUMENT VALVES AND MANIFOLDS

SPECIFICATION NO. : MEC/S/05/26/05

REV-0

Page 5 of 5

2.3.8

End to end dimensions shall be 70mm (approximately).

3.0

TESTING

3.1

The instrument valves (miniature) shall be hydrostatically tested at 200kg/cm g at 38 C.

3.2

All manifolds (3 valve, 5 valve and 3 way, 2 valve ) shall be hydrostatically tested at 200 kg/cm2 at 38C.

3.3

The instrument air valves shall be hydrostatically tested at 15.0 kg/cm g at 38 C and at 2 10.5 kg/cm g with dry air.

4.0

SHIPPING

4.1

All threads/ends shall be protected with plastic caps to prevent damage/entry of foreign matter.

5.0

REJECTION

2

2

o

o

Vendor shall make his offer in detail, with respect to every item of the purchaser's specifications. Any offer not conforming to this shall be summarily rejected.

Document12

ELECTRICAL & INSTRUMENTATION SECTION MECON LIMITED DELHI - 110 092

SPECIFICATION FOR JUNCTION BOXES AND CABLE GLANDS

SPECIFICATION NO.: MEC/S/05/26/06

Document7

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR JUNCTION BOXES AND CABLE GLANDS

SPECIFICATION NO. : MEC/S/05/26/06

REV-0

CONTENTS 1.0

GENERAL

2.0

JUNCTION BOXES

3.0

CABLE GLANDS & PLUGS, REDUCERS/ ADAPTORS

4.0

NAME PLATE

5.0

SHIPPING

6.0

REJECTION

PREPARED BY

Document7

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APPROVED BY

Page 1 of 5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR JUNCTION BOXES AND CABLE GLANDS

SPECIFICATION NO. : MEC/S/05/26/06

REV-0

Page 2 of 5

1.0

General

1.1

Scope

1.1.1

This standard specifications, together with the data sheets attached herewith, covers the requirements for the design, materials, nameplate marking, testing and shifting of junction boxes & cable glands which include the following types: a) b) c)

1.1.2

Electrical junction boxes. Pneumatic junction boxes Cable glands (whenever specified)

The related standards referred to herein and mentioned below shall be of the latest editions prior to the date of the purchaser's enquiry: ANSI B 2.1 IS-5 IS-2147

: : :

IS-2148

:

Pipe threads Colours for ready mixed paints and enamels Degrees of protection provided by enclosures for Low voltage switchgear and control gear. Flame proof enclosure of electrical apparatus.

1.1.3

In the event of any conflict between specifications, data sheets, related standards, codes etc.,the vendor shall refer the matter to the purchaser for clarifications and only after obtaining the same should proceed with the manufacture of the items in questions.

1.2

Bids

1.2.1

Vendor's quotation shall include a detailed specification sheet for each type of junction box and cable gland which shall provide the following information: a) b) c) d) e)

All the details regarding the type, construction, materials, housing, entries, etc. All dimensions in millimeter. Sketch for each type of JB with dimensional details showing the terminal and entries arrangement. Mounting details. Vendor shall furnish certificate from statutory body for explosion proof enclosure, indicating the gas group and temperature class.

1.2.2

All the material specifications for various parts in the vendor's specification sheets shall be to the same standards as those in purchaser's data sheets (e.g. BS, IS, etc.)

1.2.3

Vendor shall attach a list of items, tag numberwise, summing up all the deviations from the purchaser's data sheets, if there are any. Also vendor shall furnish reasons for these deviations.

Document7

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/06

SPECIFICATION FOR JUNCTION BOXES AND CABLE GLANDS REV-0

Page 3 of 5

1.2.4

Vendor shall enclose catalogues giving detailed technical specifications and other information for each type of JB/cable glands and its accessories covered in the bid.

1.2.5

Vendor's quotation, catalogues, drawings, etc. shall be in English language.

1.3

Drawings, Data and Certification

1.3.1

Detailed drawings, data, catalogues required from the vendor are indicated in vendor data requirements sheets. The required number of reproducibles and prints shall be despatched to the address mentioned, adhering to the time limits indicated.

1.3.2

After placement of purchaser order, vendor shall submit certified drawings and specifications sheets for each type of JB/cable gland which shall include the following: a) b) c)

Detailed dimensional drawings Weight of each in grams/Kg. Certificate from statutory body suitable for installation in specified hazardous area.

2.1

Junction Boxes

2.0

Junction boxes shall be either of the following type as specified in data sheets. I. II.

Weather proof junction boxes. Weather proof & Explosion proof junction boxes.

2.2

The enclosure shall be as per IS-2147 for weather proof junction boxes and for Explosion proof it shall be as per IS-2148 suitable for the area classification specified.

2.3

Number of entries and locations shall be as per data sheets.

2.4

Junction boxes shall be provided with telephone sockets and plugs for connection of hand powered telephone set.

2.5

Electrical Junction boxes

2.5.1

Material shall be die-cast aluminium of minimum 5 mm thick (LM-6 alloy)

2.5.2

Explosion proof junction boxes shall have detachable cover which is fixed to the box by means of cadmium plated triangular head/hexagonal head screws.

2.5.3

Weather proof junction boxes shall have doors which shall be hinged type and these shall be fixed with cadmium plated countersunk screws.

Document7

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR JUNCTION BOXES AND CABLE GLANDS

SPECIFICATION NO. : MEC/S/05/26/06

2.5.4

REV-0

Page 4 of 5

Explosion proof junction boxes shall have a warning engraved/integrally cast on the cover as given below: "Isolate power supply elsewhere before opening"

2.5.5

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.

2.5.6

All terminals shall be suitable for accepting minimum 2.5 sq. mm copper conductor, in general. However for power supply distribution boxes, terminal detail shall be as per job specification/Data sheets.

2.5.7

Sizing shall be done with due consideration for accessibility and maintenance in accordance with the following guidelines. i) ii) iii)

50 to 60 mm between terminals and sides of box parallel to terminal strip for upto 50 terminals and additional 25mm for each additional 25 terminals. 100 to 120mm between terminals for upto 50 terminals and additional 25mm for each additional 25 terminals. Bottom/top of terminal shall not be less than 100 mm from bottom/top of the junction box.

2.5.8

Terminals shall be marked as per the various types indicated in data sheets.

2.5.9

Shall be provided with external earthing lugs.

2.6

Pneumatic junction boxes

2.6.1

Pneumatic junction boxes shall be made of 3mm thick hot rolled steel. They shall have necessary neoprene gasket between door and body. Door shall be flush with the box and shall be hinged type and provided with wing nuts.

2.6.2

Single tube entries shall be suitable for 6mm O.D. copper tube with bulk head fittings. Multi tube bundle entry shall be suitable for the data furnished in data sheets.

2.7

Painting

2.7.1

Surface shall be prepared for painting. It shall be smooth and devoid of rust and scale.

2.7.2

Two coats of lead-free base primer and two final coats of lead free epoxy based paint shall be applied both for interior and exterior surfaces.

2.7.3

The colour shall be as specified in data sheets.

Document7

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR JUNCTION BOXES AND CABLE GLANDS

SPECIFICATION NO. : MEC/S/05/26/06

REV-0

Page 5 of 5

3.0

Cable glands & plugs, Reducers/Adaptors

3.1

Cable glands shall be supplied by vendor whenever specified.

3.2

Cable glands shall be double compression type for use with armoured cables.

3.3

The cable glands shall be of Nickel plated brass.

3.4

The cable gland shall be weather proof. Whenever specified they shall be explosion proof and certificate from statutory body shall be furnished.

3.5

Cable glands shall be supplied to suit the cable dimensions indicated along with tolerance indicated 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 above tolerances of cable dimensions.

3.6

Reducers/Adaptors shall be supplied as per details indicated in data sheets. They shall be nickel plated brass. These shall be weather proof in general. These shall also be explosion proof wherever specified and certificate from statutory body for explosion shall be furnished.

3.7

Plugs shall be provided wherever specified. They shall be of Nickel plated brass.

3.8

Plugs shall be certified explosion proof when used with explosion and junction boxes.

4.0

Name Plate

4.1

Each junction box shall have an anodised aluminium name plate permanently fixed to it at a visible place bearing the tag no. & enclosure. The name plate shall also bear the stamp of certifying agency with certificate number.

5.0

Shipping

5.1

All threaded openings shall be 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 Vendor shall furnish his offer in detail, with respect to every item of the purchaser's specifications. Any offer not conforming to this shall be summararily rejected.

Document7

ELECTRICAL & INSTRUMENTATION SECTION MECON LIMITED DELHI - 110 092

SPECIFICATION FOR SIGNAL CABLES

SPECIFICATION NO.: MEC/S/05/26/07

Document10

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/07

SPECIFICATION FOR SIGNAL CABLES

REV-0

CONTENTS 1.0

GENERAL

2.0

CONSTRUCTION

3.0

ELECTRICAL CHARACTERISTICS

4.0

TESTING

5.0

SHIPPING

6.0

REJECTION

PREPARED BY

Document10

CHECKED BY

APPROVED BY

Page 1 of 6

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/07

1.0

GENERAL

1.1

Scope:

SPECIFICATION FOR SIGNAL CABLES

REV-0

Page 2 of 6

This specification together with the job Specifications attached herewith forms the requirements for design, materials, manufacturing, testing and shipping of PVC insulated signal cables. 1.2

Standards: The cables shall conform to the latest editions of the various standards mentioned in the specification. In case of any conflict between any standard and this - specifications the matter shall be referred to the purchaser before proceeding with the manufacture of the cables.

1.3

Bids:

1.3.1

Vendor's quotation shall include the following as a minimum. Completed job specs., Pair identification method, type test certificates, technical literatures, various testing methods and cross sectional dimensional drawings. All information/data shall be in English language.

1.3.2

Vendor's quotation shall include a list of deviations if any from purchaser's specifications and shall also indicate the reasons for such deviations for consideration to arrive at mutually agreed deviations. However vendor shall note that no deviation shall be accepted in respect of the permissible limits of resistance capacitance and L/R ratio of cables.

1.3.3

Vendor shall quote unit price per metre for each type of cable.

1.4

Instructions to Bidder:

1.4.1

The quantity indicated against each type of cable in the job specification may vary by+ _ 25% at the time of placement of order. Vendor shall confirm that there shall be no price implication on this account in unit prices typewise.

1.4.2

Drum length for each type of cable shall be 500 to 1000 metres. Vendor shall indicate the maximum drum length possible for each type of cable in his bid. Exact requirements of drum length will be specified after purchase order during detailed engineering and vendor shall confirm that the same shall not affect the price or delivery schedule. The actual produced drum length shall not vary by more than+ _ 5% from the value indicated in the purchase order.

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/07

SPECIFICATION FOR SIGNAL CABLES

REV-0

Page 3 of 6

1.4.3

Tolerance over the total ordered length shall be as follows: ± 5% for total length less than 5 km. ± 2% for total length 5 km or more.

1.4.4

Cable dimensions furnished by vendor in his bid shall be firm. Vendor shall comply with all the values during excecution.

1.5

All cables shall be suitable for laying in open air, corrosive hydrocarbon plant atmosphere, direct sun and in trenches. The cable shall also be designed for prolonged use in tropical atmosphere.

1.6

On demand vendor shall furnish documents such as invoice and test certificates to prove the quality and composition of the materials used for manufacturing the cable to the satisfaction of client/ consultant or authorised representative during various stages of expediating and inspection.

2.0

Construction :

2.1

Type 1 (single pair/triad shielded cable)

2.1.1

Each core shall be 1.5 sq. mm made of 7 stranded annealed electrolytic copper conductor. Each strand shall be 0.53 mm dia.

2.1.2

Primary insulation shall be 85 C polyvinyl Thickness shall be 0.5 mm minimum.

2.1.3

Each wire shall have twisted cores and No. of twists shall be not less than 10 per metre. Colour of cores insulation shall be black blue in a pair and black, blue and brown in a triad.

2.1.4

Individual pair and triad shall be shielded. Shield shall be Aluminium backed by mylar/polyester tape bonded together with the metallic side down helically applied with either side 25% overlap and 100% coverage. Minimum shielded thickness shall be 0.05mm. Drain wire shall be 0.5 sq.mm multistrand bare tinned annealed copy conductor. The drain wire shall be in continuous contact with Aluminium side of the shield.

2.1.5

Inner and outer jacket shall be made of extruded flame retardant 90 C PVC to IS o 5831-Type ST2 Oxygen index of PVC shall be 30. Temp. Index shall be over 250 C.

o

chloride (PVC) as per IS-5831 Type C.

o

Inner jacket colour shall be black. Outer jacket colour shall be black except for cable to be used in intrinsically safe systems it shall be light blue. 2.1.6

Document10

Armour over inner jacket shall be of galvanised steel wire/flat as per IS-1554 part-I.

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR SIGNAL CABLES

SPECIFICATION NO. : MEC/S/05/26/07

REV-0

Page 4 of 6

2.1.7

A pair or triad identification shall be with numbers at interval of not more than 250 mm as per vendor's standard.

2.1.8

Tolerance in overall diameter of cable shall be within +_ 2mm over offered value for cables with OD less than 30mm and+3mm for cables with OD more than 30mm.

2.2

Type-II (Multipair/multitraid cable with individual pair shield and overall shield) The cable shall be same as single pair shielded cable except conductor size shall be 0.5 sq.mm made of 16 strands of annealed electrolytic copper conductor. Each strand shall be of 0.2mm dia. Additional feature shall be as follows:

2.2.1

Overall shield shall be of Aluminum backed up by mylar/polyester tape helically applied with the metallic side down either side 25% overlap and 100% coverage. Minimum shield thickness shall be 0.075mm Drain wire shall be similar to individual pair drain wire and shall be in continuous contact with the Aluminium side of the overall shield.

2.2.2

Overall twist of all pair/triads shall be as per vendor's standard.

2.2.3

A pair of communication wire shall be provided for multipair/multitriad cables. Each wire shall be 0.5 sq. mm of plain annealed single or multistrand copper conductor with 0.4 o mm thick 85 C PVC insulation. Insulation shall be green and red colour coded.

2.3

Type-III (Multipair/Multitriad cable with only overall shield) These cables shall be same as type-II cables except that the individual pair/triad shall not have shielding.

2.4

Type-IV (Multipair/ multitriad cable with individual pair shield and overall shield) The cable shall be same as Type II except conductor size shall be 1.5 sq.mm made of 7 stranded annealed electrolytic copper conductor. Each strand shall be 0.53 mm dia.

2.5

Type-V (Multipair/ Multitriad cable with overall shield only) The cable shall be same as type IV except that the individual pair/triad shall not have the shielding.

Document10

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR SIGNAL CABLES

SPECIFICATION NO. : MEC/S/05/26/07

REV-0

Page 5 of 6

3.0

Electrical Characteristics

3.1

Maximum d.c. resistance of the conductor of the completed cable shall not exceed 12.3 o o ohms/km at 20 C for cables with 1.5 sq.mm conductor and 39.7 ohms/km at 20 C for cables with 0.5 sq.mm conductor.

3.2

Capacitance

3.2.1

Mutual Capacitance The mutual capacitance of the pairs or adjacent cores shall not exceed a maximum of 250 pF/Meter at a concequency of 1KHz.

3.2.2

Capacitance between any core or screen. The capacitance between any core or screen shall not exceed a maximum of pF/Meter at a frequency of 1KHz.

3.3

L/R ratio of adjacent core shall not exceed 40 micro henry/ohm for cables with 0.5 sq. mm conductor.

3.4

The drain wire resistance including shield shall not exceed 30 ohms/km.

3.5

Electrostatic noise rejection ratio shall be over 76 dB.

4.0

Testing

4.1

Type test: Cable shall be flame retardant to IEC 332 Part III Cat. A. For qualification certificates from third party or client /consultants authorised representative for this test shall be furnished by vendor for cables similar to those being offered.

4.2

Routine tests: (To be carried out by vendor during various stages of manufacture. Purchaser shall review the related documentation).

4.2.1

Insulation and jackets: All tests as per IS-5831 except insulation resistance, voltage and spark test shall be as per BS-5308. Part-II(1986)

4.2.2

Armour test as per IS-3975.

4.2.3

Conductor resistance.

4.2.4

Cable capacitance and L/R ratio.

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR SIGNAL CABLES

SPECIFICATION NO. : MEC/S/05/26/07

REV-0

Page 6 of 6

4.3

Acceptance test (The test shall be carried out in the presence of purchaser or his authorised representative.

4.3.1

Continuity test

4.3.2

Voltage test as per BS-5308 Part II (1986)

4.3.3

Conductor resistance and drain wire resistance.

4.3.4

Cable capacitance and L/R ratio test.

4.3.5

Tests for uniformity of galvanisation of armour as per IS 2633.

4.3.6

Oxygen and temp. index test as per ASTM D 2863-1974.

4.3.7

Dimensional check for overall diameter and under armour/over armour diameter.

4.3.8

Overall finishcheck. In case of any lump purchaser will have the right to cut outer sheath for lump portion and reject the cable.

4.3.9

Check of drum length and overall length tolerances. Immediately after completion of electrical tests, the ends of the cable shall be sealed to prevent ingress of moisture with suitable PVC/Rubber caps.

5.0

Shipping Cables shall be despatched in wooden drums, securely battened with take off end fully protected against damage. Each drum shall be marked with following: a. b. c. d. e. f.

6.0

Manufacturer's name. Details of the cable. Length of the cable contained in the drum in metres. Gross wt. Direction of rotation of drum for unwinding by means of an arrow. Purchase order no.

Rejection Vendor shall make his offer in detail with respect to every item of the purchaser's specifications. Any offer not conforming to this shall be summarily rejected.

Document10

ELECTRICAL & INSTRUMENTATION SECTION MECON LIMITED DELHI - 110 092

GENERAL TECHNICAL SPECIFICATIONS FOR INSTRUMENTATION SPECIFICATION NO.: MEC/S/05/26/08

Document5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

SPECIFICATION NO. : MEC/S/05/26/08

REV-0

CONTENTS

1.0

GENERAL

2.0

DEFINITIONS

3.0

SCOPE OF WORK

4.0

DESCRIPTION OF WORK

5.0

DRAWINGS AND DOCUMENTS TO BE PROVIDED BY OWNER

6.0

DRAWINGS AND DOCUMENTS TO BE PROVIDED BY CONTRACTOR

7.0

SCRAP AND EXCESS MATERTIAL

8.0

SPECIAL INSTRUCTIONS TO CONTRACTOR

PREPARED BY

Document5

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APPROVED BY

Page 1 of 16

MECON LIMITED Delhi

SPECIFICATION NO. : MEC/S/05/26/08

ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

REV-0

Page 2 of 16

1.0

GENERAL

1.1

INTRODUCTION

1.1.1

This part of the technical specifications covers in general, definitions, standards, scope of works, specifications of work, documentation, scope of supply of materials and scrap and excess materials and different requirements to be adhered to during the course of execution of instrumentation works.

1.1.2

Instrumentation works shall be performed in accordance with this technical specifications and various other drawings and schedules supplied during the execution and time to time instructions from Engineer-in-Charge or his authorised representative(s) during the progress of the work.

2.0

DEFINITIONS

2.1

Manifolds

2.1.1

For close coupled instruments "Manifold" shall mean complete piping of instruments from first block valve upto the instruments, if the distance of the Instrument is within 2 feet (0.6m), from the Instrument tapping. If the distance of instrument is more than 2 feet (o.6m) from primary tapping such as orifice, then the installation is to be considered under remote installation.

2.1.2

For remote mounted instrument, "Manifold" shall mean the assembly of nipples, valves and fittings around the instrument to form a block and bleed or by pass manifold or drain manifold as the case may be. These shall be generally according to the hook up drawings enclosed with tender. Wherever the instruments are with 3 -way valve manifold, this definition shall not be applicable as 3-way manifold forms part of instrument.

2.2

First block valve First block valve shall mean the valve/valves that are mounted directly on equipment, columns, pipe, standpipe etc. and shall be operated to isolate the instrument and connected instrument piping from the above items.

2.3

Supports Supports shall mean the MS angles, flats, channels that are generally provided to support the main cable ways, cable ducts, junction boxes, angle trays, perforated trays, instrument piping, signal tubing, instrument air supply lines etc., at specified intervals from the structures, concrete columns etc. to keep all items firmly secured against vibration, warping, bending etc.

Document5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

SPECIFICATION NO. : MEC/S/05/26/08

2.4

Scrap

2.4.1

Salvageable scraps

REV-0

Page 3 of 16

Salvage scrap shall mean lengths of tubes, pipes, multicables, other cables etc. that can be used one time or other at later date and normally they are recovered from the cut-pieces of tubes, pipes, multicables, cables, etc. 2.4.2

Non Salvageable Scrap Non salvagable scrap shall mean the lengths of tubes, pipes, multicables, cables, etc. that cannot be used at all one time or other.

2.5

Standards The instrumentation erection and calibration works shall be carried out generally in accordance with various international and Indian standards in instrumentation listed below but not limited to the following:

2.5.1

API-RP-550 Manual on Practices for instrumentation.

2.5.2

ISA standards and Practices for instrumentation

2.5.3

Instrumentation hook-up standards enclosed.

2.5.4

Instrumentation supports standard enclosed.

2.5.5

Manufacturer's standards and Practices.

3.0

SCOPE OF WORK

3.1.0

The Scope of work shall consist of supply of instrument items (as per schedule of quantities/rates and SCC), instruments, their erection, testing, calibration and commissioning and making it ready for commercial operation. The scope covers various jobs listed under the schedule of quantities/rates. However to ensure proper execution and completeness of instrument--work any or all of the following shall also form the part of the scope and shall be covered in the quoted rates.

3.1.1

Fabrication of pipe nipples, including threading whenever required.

3.1.2

Fabrication of seal pot/syphon/drain pot as per standards. Filling of seal pots with filling liquids as per instructions from Engineer-in-charge.

3.1.3

Back/seal welding of screwed fittings as required by standards.

Document5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

SPECIFICATION NO. : MEC/S/05/26/08

REV-0

Page 4 of 16

3.1.4

Laying of cable underground including excavation, sand filling, brick laying and back filling.

3.1.5

Connection of purging devices for instruments to the systems provide as per drawings.

3.1.6

Civil works including the casting of foundation as per requirements for instruments supports where paved surface do not exist.

3.1.7

Minor civil works like chipping of pavement and grouting on the pavements the instrument panels/supports/stanchions, and chipping and refilling of the pavement for conduits.

3.1.8

Sealing of cables/tube entries into the control room after laying and testing of all tubes, cables etc.

3.1.9

Degreasing of handwheels of control valves, stud bolts, nuts of side and bottom flange of control valves, orifice plates, other primary elements flanges, oxygen service impulse lines, instruments as per manufacturers instructions and other items as required by Engineer- in-charge.

3.1.10

Rotation of control valve bonnet wherever required.

3.1.11

Reversing the action of control valves either a) replacement of springs, accessories or in positioner wherever required.

3.1.12

Minor modification/repairs required to be done on the instruments namely, changing the dial, glasses for pressure gauges, temperature gauges and other instruments, replacement of rotameter tubes, level gauge glasses, replacement of damaged signal tubes, threads, couplings etc.

3.1.13

Painting of all structural supports for trays, pipes, junction boxes, instruments, etc, as per painting specification.

3.1.14

Identification with approved colour of paint the instruments/impulse, lines manifold connected with alarm/trap circuit. Also, punching of tag numbers on items shall be carried out as per instructions of Engineer-in-charge.

3.1.15

Coordination with mechanical and other sub-contractors for proper installation of line/vessels/equipment mounted instruments like control valves, orifice assemblies, turbine meters, PD meters, level transmitters, level gauges, level switches etc. which involves removal of instruments, disconnection of tubes/cables, reconnection for alignment proper installation etc.

Document5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/08

GENERAL SPECIFICATION FOR INSTRUMENTATION

REV-0

Page 5 of 16

3.1.16

Drilling holes on all panels, shut down cabinets, power supply cabinets, control panels pneumatic enclosures etc., for cables/ multitubes/ glands/ groomats.

3.1.17

Grounding of shield of all shielded cables to respective instruments earth bus provided in the control room/local panel/thermocouple head.

3.1.18

Laying and termination at both ends between instrument earth buses provided in control room/local panel to instrument earth pit provided by others.

3.1.19

Supply of all types of consumables required for the execution of the job.

3.1.20

Submission of monthly material appropriation statements for cables, piping materials fittings, including the quantity issued and expended in standard proforma.

3.1.21

Completion of owners drawings/documents, as per the execution of work at site.

3.1.22

Preparation and submission of as built drawings as required.

3.1.23

Start-up and commissioning.

3.1.24

Submission of final material appropriation statements for all the materials issued by the owner.

3.1.25

Any other work not mentioned above, but required for the proper execution of the works.

3.1.26

Where requested by owner/Engineer-in-charge or his authorised representatives, all or any of the works detailed above and schedule quantities shall also be performed on package units, local panels/cabinets/gauge board installed by owner or by others.

3.1.27

Sealing of safety valves/switches with standard lead seals after final setting in the presence of Engineer- in-charge.

4.0

DESCRIPTION OF WORK

4.1.0

INSTRUMENT PIPING

4.1.1

All primary piping shall be installed in the best workman like manner and shall follow installation standards in each case. Where there is no installation standard, the instruction of the Engineer-in-charge shall be followed.

4.1.2

Horizontal and vertical lines shall be installed using levels and plumo bobs.

4.1.3

Unless otherwise specified in the drawings pipelines shall have a slope of 8% on the horizontal runs.

Document5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

SPECIFICATION NO. : MEC/S/05/26/08

REV-0

Page 6 of 16

4.1.4

All welding shall be carried out as per welding procedures and codes with electrodes approved by Engineer-in-charge. Only qualified welders approved by Engineer-in-charge shall carry out welding. Charges for non-destructive testing like radiography, Dye penetration tests, post heat treatment tests and stress relieving shall be carried out on the basis of actual man hours spent towards these works and manhour charges with cost of all materials, test equipments, etc. shall be used. However, any materials like electrode, equipments etc. shall be used. However, any materials like electrode, equipments, testing charges for various tests, etc., required for the initial qualification of the welder/welders shall be or the scope of the contractor.

4.1.5

Pipe shall be bent using pipe benders only and any bending will be totally rejected. Pipes shall be cut using pipe cutting device. Hot cutting will not be allowed.

4.1.6

Piping for steam tracing shall be installed according to the standards and avoiding condensate pockets.

4.1.7

All threaded joints shall be jointed with teflon tape and no other pipe jointing compound shall be used except on high temperature service where graphited sealing compounds shall be used.

4.1.8

All primary piping shall be properly supported at regular intervals of 1.0 meters. Angle supports shall be fabricated from 40mmx40mmx5mm MS angles as minimum.

4.2.0

PVC COVERED/BARE TUBE(COPPER/SS/ALUMINIUM)

4.2.1

Single copper/SS/Aluminium tubes shall be laid as per standards on trays. fabricated out of 2.5 mm thick perforated steel plate. The width of the trays shall be selected as per the number of tubes laid. Tubes shall be clamped to the trays at every 300 mm using clamps made of galvanized steel/Aluminium strips. The practice of flattening tubes for clamping purposes shall be avoided. In case of PVC covered tubes, any exposed portion at ends and connection shall be neatly taped tp appropriate thickness.

4.2.2

Trays shall be properly supported either from any rigid steel structure or concrete memberas detailed under trays and supports below.

4.2.3

All male/female tube connectors shall be installed with teflon tape only. Identification tag plates/ferrules shall be provided on either side of copper tubing as per tubing/junction box schedules. Ferrules shall be single sleeve type with letters and numbers neatly printed.

Document5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/08

GENERAL SPECIFICATION FOR INSTRUMENTATION

REV-0

Page 7 of 16

4.3.0

INSTALLATION OF MULTITUBES AND MULTICORE CABLES

4.3.1

Multiple cables/multitubes shall always be installed on ducts/trays and properly clamped. At every vertical drop to junction boxes, they shall be clamped at more frequency intervals (Maximum of 300mm). They shall be connected inside junction boxes strictly according to the number system as mentioned in cable schedule. At bends minimum radius shall be maintained as per manufacturer's standard. The angle tray supports shall be fabricated from 40mmx40mmx5mm angles minimum size.

4.3.2

Identification tags shall be provided on either end of multitube, multicore cables as per cable/tubing/cable schedules. Engraved tag plates or PVC ferrules shall be used for identification of tubes/cables.

4.3.3

All Multitubes and Multicables shall be cut after the exact site measurements are taken between ends and the cable/tube drums shall be selected before cutting the lengths so as to avoid any wastage.

4.3.4

In the field, the cables shall be laid in perforated trays as per layout drawings. Cables shall also be buried or laid in concrete trenches. Inside control room, these shall be laid in concrete trenches or under false floorings.

4.4.0

INSTALLATION OF INSTRUMENTS

4.4.1

All instruments shall be generally installed on supports as per installation standards in each case, and shall be accessible.

4.4.2

Receiver gauges shall be mounted on instrument support itself as per tubing hook up standards.

4.4.3

Filter regulators shall be mounted on the instruments support itself below the instruments or on the control yoke.

4.5.0

INSTRUMENT AIR SUPPLY

4.5.1

The main instrument air header in each area is laid by other contractor. Air supply from the main air header take off valve to individual instrument shall be through either galvanised steel pipe or 1/4" OD PVC covered copper tube or SS tubes.

4.5.2

Individual take off valves shall always be located on top of the main air header. Unions shall be provided at convenient locations. There shall be one isolation valve at each instrument end. The galvanised pipe shall be supported at a minimum interval of 1000 mm with 40mmx40mmx5mm MS angles. Final connection to be instrument shall be copper/SS tubing as per tubing hookup standards.

Document5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

SPECIFICATION NO. : MEC/S/05/26/08

REV-0

Page 8 of 16

4.5.3

Teflon tapes shall be used on all threaded joints.

4.6.0

INSTRUMENT STEAM TRACING

4.6.1

The mainsteam header in each area is laid by the other contractor. From the main steam header take off valve, steam to individual instrument shall be taken through carbon steel pipes supported at regular intervals. Steam tracing around individual instruments shall be to copper tubes. After steam tracing, the line is connected to the drain funnel through individual steam trap/condensate return header/tapper point as the case may be.

4.6.2

Electrical tracing shall be done by others.

4.7.0

PERFORATED TRAYS AND SUPPORTS

4.7.1

The perforated trays/angle trays shall be properly supported at a regular interval of max. 1000mm from insert plates or steel structures. Wherever insert plates are not available supports on concrete structures on ceiling shall be fixed with a minimum 10mm diameter expansion bolts. Angle supports for perforated trays/angle trays shall be fabricated from 40mmx40mmx5mm M.S. angles minimum size.

4.7.2

All supports shall be cut with hacksaw and any work executed by gas cutting for cutting and drilling holes will be totally rejected. Free ends of angle support shall not have sharp edges and shall be properly rounded off.

4.7.3

Perforated trays/angle trays shall be used for branching cables and tubes from main trays. Perforated trays shall be used for branching cables and tubes from main trays. Perforated trays shall be fabricated out of 2.5 mm perforated steel sheet. Width of trays shall be selected according to number of tubes and cables. Trays shall be laid generally as per site conditions with the approval of Engineer-in-charge.

4.7.4

The perforated trays/angle trays shall be properly supported at a regular interval of max 1000mm from insert plates or steel structures. Wherever insert plates are not available supports on concrete structures on ceiling shall be fixed with a minimum 10 mm diameter expansion bolts. Angle supports for perforated trays/angle trays shall be fabricated from 40mmx40mmx5mm M.S. angles minimum size.

4.7.5

All supports shall be cut with hacksaw and any work executed by gas cutting for cutting and drilling holes will be totally rejected. Free ends of angle support shall not have sharp edges and shall be properly rounded off.

4.7.6

Perforated trays/ angle trays shall be used for branching cables and tubes from main trays. Perforated trays shall be fabricated out of 2.5 mm perforated steel sheet. Width of trays shall be selected according to number of tubes and cables. Trays shall be laid generally as per site conditions with the approval of Engineer-in-charge.

Document5

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/08

GENERAL SPECIFICATION FOR INSTRUMENTATION

REV-0

Page 9 of 16

4.8.0

LAYING OF CABLES

4.8.1

All cables shall be laid in accordance with installation drawings and cable schedules. Before laying, cable/multicable on drums shall be meggered and tested to ascertain the transit damages.

4.8.2

All cables routes shall be carefully measured and cables cut to the required lengths, leaving sufficient amount for the final connection of the cable to the terminals on either end. The various cable lengths cut from the cable reels shall be carefully selected to prevent undue wastage of cables. Sufficient extra length of cable shall be kept at the terminal on points.

4.8.3

Cables shall have complete uncut lengths from one terminal to the other.

4.8.4

All cables shall be identified close to their termination point by cables number as per cable schedules/junction boxes schedules. PVC ferrule/tag plate shall be used and these identification tags shall be securely fastened to the cables.

4.8.5

All cores of electrical cables shall be identified by their wire numbers by means of the PVC ferrules. Wire numbers shall be as per schedules. All temporary ends of cables shall be protected against dirt and moisture. For this purpose, ends of all PVC insulation cables shall be taped with an approved PVC or rubber insulating tape. Use of function type or other fabric type is not permitted.

4.8.6

The cable shall be bent in a large radius. Cables installed above ground shall be run exposed on walls, ceilings, structures and shall run parallel or at right angles with beams, walls or columns.

4.8.7

Cables shall be rigidly supported on structural steel and masonary individually or in groups as required using galvanised clips, multiple cable supports or cable trays. If drilling of steel must be resorted to, approval must be obtained and steel must be drilled where the minimum of weakening of the structure will result. Cable shall be supported at every 500 mm.

4.8.8

All special cables and power supply cables will be laid directly to the field instrument without any junction boxes, unless otherwise specified.

4.8.9

While laying cable in trenches or burying them care shall be taken to ensure that low signal cables like alarm, analyser cables, special cables, special cables from turbine meters, compensating cable etc. are separated from other power supply cables.

4.8.10

Each underground cable (either in concrete trenches or burried) shall be provided with identifying tag of lead securely fastened every 30m of its underground length with atleast one tag at each end before the cable leaves/enters the ground.

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/08

GENERAL SPECIFICATION FOR INSTRUMENTATION

REV-0

Page 10 of 16

4.8.11

Directly burried cables shall be laid underground in excavated cable trench wherever specified in layout drawings. Trenches shall have sufficient depth and width to accommodate all cables correctly spaced. Before cables are placed the trench bottom shall be filled with 100 mm layer of sand and levelled. Each layer of cables shall be covered with 150 mm of sand on top and sand shall be lightly pressed. A protective covering of 75 mm thick second class red bricks shall be placed flat on the final layer of sand and cable. The remaining portion of the trench shall be then back filled with soil compacted and levelled. On complete of every group of cable laying and before sand filling, every cable shall be given insulation test in the presence of Engineer-in-charge. Any cable proved to be defective shall be replaced before the next group of cables are laid. Cable route markers indicating number of cables, depth and direction will be placed enroute, on crossovers/turnings, etc. to mark the cable route.

4.8.12

At each road crossings and other places, where cables enter pipe sleeves, adequate bed of sand shall be given so that the cables do not slack and get damaged by pipe ends after pack filling.

4.8.13

At the entry into concrete blocks at road crossings cable loops shall be provided at either ends to prevent any damage to cables. Each cable shall have one tag at each end before the cable enters/leaves conduct pipes

4.8.14

After laying of all the cables and multitubings, cables, the cable entry to control room shall be suitably filled and sealed so as to achieve a positive seal against the entry of gas/water.

4.8.15

All cables and tubes shall be laid in accordance with the layout drawings with sand and precast concrete slabs shall be placed on the trench.

4.9.0

EARTHING

4.9.1

Earthing of junction boxes, local cabinets as per the documents and instruction from Engineer-in-charge.

4.10.0

PAINTING

4.10.1

This part of the specification is applicable to cable ducts, MS cable ways, angle trays, instrument supports, perforated trays, all structural supports for the above items, etc.

4.10.2

The surface to be painted shall be thoroughly cleaned with wire brush, sand paper to remove all scales. After cleaning, the surface is painted with one coat of red oxide zinc chromate primer conforming to IS- 207 and allowed to dry completely.

4.10.3

Primer coated surface is painted with one coat of paint to the colour nearest to the final paint and allowed to dry. The colour number shall be specified from IS-5.

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/08

GENERAL SPECIFICATION FOR INSTRUMENTATION

REV-0

Page 11 of 16

4.10.4

Final second coating shall be with the paint of desired colours and shall be selected from IS-5.

4.10.5

It shall be noted that final second coating of external surfaces not covered by cables, copper tubes etc. shall be applied just before handling over the plant or commissioning of the plant whichever is earlier.

4.10.6

The name of manufacturer, colour and quality of all types of primer paint shall be subject to approval of Engineer-in-charge.

4.11.0

TESTING

4.11.1

Electrical cables for signal power supply alarms, and compensating cables for thermocouples, resistance thermometer cables shall be checked for megger values and continuity before proper termination and ferruling.

4.11.2

Testing shall be carried out after the installation of instrument with primary piping complete in all respects and approved by Engineer-in-charge.

4.11.3

Primary piping shall be tested hydraulically pneumatically to 1.5 times the operating pressure after isolating the instruments. Flushing of piping shall be carried out as per instructions of Engineer-in-charge. Lines shall be blown after hydro-testing. All external displacement /float type level instrument level gauges shall also be tested as per instructions of Engineer- in-charge.

4.11.4

Tubes and air line shall be tested with compressed air to 7 kg/cm upto the filter 2 regulator. The down steam side of the filter regulator shall be tested for 1.5kg/cm . The lines shall be blown with the instrument air upto the regulator for 15 minutes to remove any traces of oil, dust & moisture. All lines shall be checked with soap solution and bubbler unit for possible leak at joints. After pressurizing, source shall be cut off and rate of fall in pressure shall be less than 1 p.s.i. for each 100 ft. of copper tubing for a test period of 2 minutes as per I.S.A.R.P.7-1 "Pneumatic control circuit pressure test".

4.11.5

All test results shall be recorded in the approved format.

4.12.0

CALIBRATION

4.12.1

All instruments shall be calibrated strictly as per manufacturer's instructions prior to installation. The scope of calibration includes all field and control rooms of all types namely, pneumatic, electronic, electrical etc.

4.12.2

Contractor shall use his own oil free instruments, air compressor for calibration purposes.

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ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

SPECIFICATION NO. : MEC/S/05/26/08

REV-0

Page 12 of 16

4.12.16

The level switches (external cage type) shall be set by filling the cage with water to the desired alarm/trip level, while setting the switches, it shall be ensured that the microswitches do not reset for full rated travel of the float.

4.12.17

Control valves and positioners shall be checked for hysteristis and linearity and calibration for rated strokes. Prior to calibration, valves shall be cleaned externally. The stem is then lubricated if required, and stroked few times to extreme positions of plug to ensure that movement is free from friction. The valve shall then be calibrated for rated stroke and linearity also. Subsequently the valves shall be checked for hysterisis to the accuracy of 1% FS with positioner and 5% FS without positioners. Stroke speed has to be evaluated for all trip/shutdown valves.

4.12.18

All calibrartion reading shall be recorded in the enclosed format and submitted to Engineer-in-Charge for approval. Where significant deviations from specifications are obtained, the matter shall be brought to the immediate notice of the Engineer-in- Charge for corrective actions.

4.12.19

Furnished hereunder is a list of recommended caliberation and test equipments required as a minimum for caliberation work. The contractor shall clearly state in his offers the complete list of caliberation and test equipments along with the range, accuracy and quantity which he proposes to use for this job. Contractor should also ensure that any equipment not listed below but required at the time of caliberation shall be made available at his own cost.

4.12.20

All test equipments/kits shall be approved by NPL authorities.

4.12.21.1

Controller test stands

Mft. Standard

4.12.21.2

Indicator/recorder test stands

-do-

4.12.21.3

Squeeze bulb (Flow calibrator) Range: 0-770, 10,000 mm wg.

4.12.21.4

Dead weight testers (Budenberg or equivalent) 2 For ranges upto 350 kg/cm

-

4.12.21.5

Gauge comparator for pressure gauges 2 Rating : upto 350 kg/cm

-

4.12.21.6

Oil bath for temperature calibrations o max. Temp 350 C.

Mfr's Std

4.12.21.7

Standard Mercury in glass thermometers o o _ Range : -50 to + 50 C. 0 to 100 C+ o o (NPL certified) 0-250 C, 0-350 C

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-

0.25%

0.1%

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

SPECIFICATION NO. : MEC/S/05/26/08

REV-0

Page 13 of 16

2+ _

4.12.21.8

Standard gauges for Ranges upto 350kg/cm 0.25%

4.12.21.9

U-tube differential manometers/inclined 2 tube manometer Static pr. rating : 7 kg/cm

4.12.21.10

Single leg manometers Scale: -1500 mm water and 1500 mm hg. 2 Static pr. rating : 7 kg/cm .

4.12.21.11

Decade resistance box

MFR' std.

4.12.21.12

Multimeters+ _

0.05Mv

4.12.21.13

Potentiometer (Cable of generating and measuring mV)

-

4.12.21.14

Meggers 500V/1000V

-

4.12.21.15

Air hydro pump/hydraulic pump

-

4.12.21.16

Vacuum pump

-

4.12.21.17

Instrument air compressor with filters and regulators and deoilers.

-

4.12.21.18

Current generator (instrument checker) 4-20mA dc(YEW make or equivalent)

-

4.13.0

LOOP TEST

4.13.1

Loop test shall be performed after calibration of all instruments and leak test of signal lines. Loop tests are conducted to check the functional performance of all elements comprising the loop, thereby ensuring proper connections and operations.

4.13.2

Before proceeding for loop tests the calibration results of individual elements shall be recorded on the enclosed proforma and shall get it approved by Engineer-in-Charge for correctness of installation, measurements and calibration results.

4.13.3

Loop testing for all control loops shall be generally by simulation of process conditions and shall fix pointsnamely 0%, 25%, 50%, 75% and 100% of full scale inputs. Detailed procedure shall be submitted to Engineer-in-charge for approval before proceeding with the loop testing.

4.13.5

In case of shutdown system field/receiver pressure switches are simulated for abnormality by disconnecting the wires at terminal and function of all associated systems are checked.

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+_ 1mm +_ 1mm

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/08

GENERAL SPECIFICATION FOR INSTRUMENTATION

REV-0

Page 14 of 16

4.13.6

Performance of individual loops may be accepted for an overall accuracy of+ _ 1.5% where deviations exist, contractor shall recalibrate the instruments which form part of loop testing wherever required, at no extra cot.

4.13.6

After the loop test is complete, the contractor shall connect back any terminations and connections removed for loop test.

4.13.7

A loop shall be considered as handed over only after measurements in that particular loop are complete and certified by Engineer-in-Charge, in addition to loop sheets being duly filled in all respects and approved and accepted by Engineer-in-Charge and client.

4.13.8

In case of loops in which certain instruments of the loops are calibrated by other agency, loop testing shall be performed in coordination with the agency involved. Any defect in the calibration of the instrument in contractors scope is observed, same shall be rectified to the satisfaction of the Engineer-in- Charge. However, defect in calibration of the instruments in the scope of other agency, same shall be rectified by the agency involved. After the calibration has been rechecked by the other agency/agencies the loop checking would be performed to the satisfaction of Engineer-in-Charge, and this part covers under the scope of the contract.

4.13.9

Final certified loop sheets shall be submitted in 4 copies and one transparency.

5.0.0

DRAWINGS AND DOCUMENTS TO BE SUPPLIED FOR EXECUTION BY OWNER/ENGINEER IN CHARGE

5.1.1

Piping ad Instrumentation diagrams.

5.1.2

General layout plan for all units, showing all information like position of field instruments junction boxes indicative routes of cables, main ducts/cable trays.

5.1.3

Cable schedules for alarm, signal, shutdown, power supply and pneumatic cables, earthing guide lines.

5.1.4

Termination details/drawings for connecting at control room end.

5.1.5

Individual Instrument specifications

5.1.6

Bill of materials

5.1.7

Installation standards/ Hook-up

5.1.8

Manufacturers hand book with instructions for installation and calibration wherever necessary for reference.

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

SPECIFICATION NO. : MEC/S/05/26/08

REV-0

Page 15 of 16

6.0

DRAWINGS AND DOCUMENTS TO BE PROVIDED BY CONTRACTOR

6.1.1

The drawings for materials that are included on their supply and erection scope namely local control, panel, junction boxes, local cabinets.

6.1.2

The detailed engineering drawing wherever such drawing is assigned.

6.1.3

Two sets of layout drawings, standards bill of materials cable schedules etc., duly incorporating the changes/modification carried out during the course of execution of works.

6.1.4

Final material appropriation statement for all free issue materials indicating shortages of any in the proforma duly approved by Engineer-in-Charge.

7.1.0

SCRAP AND EXCESS MATERIAL

7.1.1

Every month, the contractor shall submit an account for all the materials issued by the Owner in the standard proforma prescribed for this purpose by the Engineer- in-Charge.

7.1.2

On completion of the work, the contractor shall submit `Material appropriation' statements for all materials issued by the Owner in the proforma prescribed by the Engineer-in-Charge.

7.1.3

The following scrap allowances are permissible. ------------------------------------------------------------------------------------------------------Length below Non-salvageable Unaccountable 0.5 mm ------------------------------------------------------------------------------------------------------Steel pipes, SS 2% 0.5% Tubes single pair/ Twocore three Core cables. ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------length below Non-salvageable Unaccountable 20 m ------------------------------------------------------------------------------------------------------Multitube, 2% 0.5% Multicables -------------------------------------------------------------------------------------------------------

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MECON LIMITED Delhi

SPECIFICATION NO. : MEC/S/05/26/08

ELECTRICAL & INSTRUMENTATION SECTION DELHI

GENERAL SPECIFICATION FOR INSTRUMENTATION

REV-0

Page 16 of 16

8.1.4

All excess materials and scrap shall be returned after duly accounting for, to the storage points designated by the Owner. Where materials are to be weighed before return, the contractor shall be responsible for making the necessary section obtained during the course of construction for fabricating temporary supports or other items, without prior permission of the Engineer- in-Charge.

8.1.5

If the contractor fails to return the surplus material as aforesaid, the owner will charge the contractor for such unreturned materials at panel rates, which will deducted from whatever amount is due to the contractor. In case any material issued by the Owner deteriorates during storage by the contractor, new materials will be issued to him at penal rates, but the delay in procuring such materials will be at the contractor's account only.

Document5

ELECTRICAL & INSTRUMENTATION SECTION MECON LIMITED DELHI - 110 092

TECHNICAL SPECIFICATION FOR CABLING SPECIFICATION NO.: MEC/S/05/26/21

Document6

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR CABLING

SPECIFICATION NO. : MEC/S/05/26/21

REV-0

CONTENTS 1.0

SCOPE

2.0

STANDARD

3.0

CABLE SPECIFICATIONS

4.0

MISCELLANEOUS MATERIALS SPECIFICATIONS

5.0

CABLE LAYING

6.0

TERMINATION

7.0

TESTING

PREPARED BY

Document6

CHECKED BY

APPROVED BY

Page 1 of 11

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR CABLING

SPECIFICATION NO. : MEC/S/05/26/21

1.0

REV-0

Page 2 of 11

SCOPE This is to define the requirements for supply, wherever applicable, the installation, testing and commissioning of the cabling system.

2.0

STANDARDS The work shall be carried out in the best workman like manner in conformity with this specification, the relevant specifications, codes of practice of Indian Standards Institution, approved drawings and instructions of Engineer-in-Charge or his authorised representative issued from time to time. In case of any conflict between the standards, the instruction of Engineer-in-Charge shall be binding.

3.0

CABLE SPECIFICATIONS

3.1

Power Cables Power cables for use on 415 V system shall be of 1100 Volts grade, aluminium stranded conductor, PVC insulated, PVC sheathed single wire armoured and overall PVC sheathed. Power cables for 3.3 KV 6.6 KV and 11 KV system shall be aluminium conductor, XLPL insulated, screened, PVC bedded galvanised steel flat armoured and PVC sheathed cable. All L.T. Cables conform to EIL standard specification and relevant sections of IS: 1554 Part-I and H.T. Cables shall conform to IS:7098 (Part II). Unarmoured cables will be used wherever specified on the cable schedule.

3.2

Control Cables: 2

Control cables shall be 1100 Volt Grade, 2.5 mm copper conductor PVC insulated PVC sheathed, single wire armoured with an overall PVC sheath, as per IS: 1554 Pt. I. Unarmoured cables shall be used wherever specified on the cable schedule. 3.3

Communication cables : Communication cables shall comprise 1 pair unarmoured, 2-pair, 5-pair and multipair armoured cables of sizes as specified in the cable schedule. Minimum conductor size shall be 0.5 mm telephone system and 0.71 for plant communication system.

4.0

MISCELLANEOUS MATERIALS SPECIFICATIONS

4.1

Connectors: Cable terminations shall be made with aluminium/tinned copper crimped type solderless lugs of M/s. Dowells make or approved equivalent for all aluminium conductors and stud type terminals.

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/21

4.2

SPECIFICATION FOR CABLING

REV-0

Page 3 of 11

Cable Identification Cable tags shall be of 2 mm thick, 20 mm wide aluminium strap of suitable length to contain cable number, equipment no., etc.

4.3

Ferrules Ferrules shall be of approved type size to suit core size mentioned and shall be employed to designate the various cores of control cable by the terminal numbers to which the cores are connected for case in identification and maintenance.

4.4

Cable Glands: Cable glands to be supplied shall be nickel plated Brass double compression type of approved/ reputed make. Glands for classified hazardous areas shall be certified by CMRS and approved by CCE, Nagpur.

4.5

Cable Trays: This shall be either prefabricated hot dip galvanised sheet steel trays or site fabricated angle iron trays as specified elsewhere. Prefabricated hot dip galvanised sheet steel cable trays shall be used for maximum support span of 2000 mm unless design is approved for larger span. For requirements of larger than 750 mm width two trays shall be run side by side. Cable trays shall be suitable for a cable weight of 50 kg/meter running length of tray. Minimum thickness of sheet steel/galvanising shall be 2mm/86 microns respectively. Cable trays fabricated from standard rolled sections shall use 50x50x6 /ISMC 100 Sections for runners for supporting spans limited to 2000 mm/more than 2000 mm respectively. Cross support shall be 32 x 6 mm flat/ 25x25x6 angle for width upto 500 mm/ more than 500 mm respectively. Vertical supports for both the above type of trays shall be fabricated out of ISMC 100 and horizontal supports with 75 x 50 x 6 angle iron/ ISMC 75 as approved by Engineer-in-Charge. If unit rate is not included in schedule of rates, then cable trays if required, shall be fabricated and installed at site as per tonne rate for electrical structural supports etc.

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MECON LIMITED Delhi

SPECIFICATION NO. : MEC/S/05/26/21

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR CABLING

REV-0

Page 4 of 11

5.0

CABLE LAYING

5.1

Cable network shall include power, control, lighting and communication cables, which shall be laid in trenches, cable trays or conduits as detailed in the relevant drawings and cable schedules. Erection of cable trays as required shall be checked after erection and marked in as built drawings. Cable routing given on the layout drawings shall be checked in the field to avoid interference with structures, heat sources, drains, piping, airconditioning duct etc. and minor adjustments shall be done to suit the field conditions wherever deemed necessary without any extra cost.

5.2

High voltage, medium voltage and other control cables shall be separated from each other by adequate spacing or running through independent pipes, trenches or cables trays, as applicable. All communication cables (telephones, P.A.S.) RTD Cables shall run on instrument trays/ducts/trenches. Wherever these are not available, cables shall be taken in a separate trench with a minimum clearance of 300 mm away from electrical trench as per the direction of Engineer-in-Charge and Communication cables shall cross power cables at right angles.

5.3

All cable routes shall be carefully measured and cables cut to the required lengths, leaving sufficient lengths for the final connection of the cable to the terminal of the equipment. The various cable lengths cut from the cable reels shall be carefully selected to prevent undue wastage of cables. The quantity indicated in the cable schedule is only approximate. The contractor shall ascertain the exact requirement of cable for a particular feeder by measuring at site and avoiding interference with structure, foundation, pipelines or any other works. Before the start of cable laying, cable drum schedule; shall be prepared be electrician contractor and get that approved by Engineer-in-Charge to minimise/avoid striaght through joints required. The actual number of straight through joints required, shall be worked out by Contractor.

5.4

Cables as far as possible shall be laid in complete, uncut lengths from one termination to the other.

5.5

Cables shall be neatly arranged in the trenches/trays in such a manner so that criss-crossing is avoided and final take off to the motor/switchgear is facilitated. Arrangement of cables within the trenches/trays shall be the responsibility of the Contractor. Cable routing between lined cable trench and equipment/motors shall be taken through GI pipe sleeves of adequate size. Pipe sleeves shall be laid at an angle of o maximum 45 to the trench wall. In case of larger dia cables, i.e., 50 mm and above, adequately sized pipe with larger bend radius shall be provided for ease of drawing of cable or for replacement. In places where it is not possible, a smaller trench may be provided if approved by Engineer-in-Charge.

Document6

MECON LIMITED Delhi

SPECIFICATION NO. : MEC/S/05/26/21

5.6

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR CABLING

REV-0

Page 5 of 11

All cables will be identified close to their termination point by cable numbers as per cable schedule. Cable numbers will be punched on aluminium straps (2 mm thick) securely fastened to the cable and wrapped around it. Alternatively cable tags shall be circular in construction to which cable numbers can be conveniently punched. Each underground cable shall be provided with identity tags of lead securely fastened every 30 m of its underground length with at least one tag at each end before the cable enters the ground. In unpaved areas, cable trenches shall be identified by means of markers as per standard drawing. These posts shall be placed at location of changes in the direction of cables and at intervals of not more than 30 M and at cable joint locations.

5.7

All temporary ends of cables must be protected against dirt and moisture to prevent damage to the insulation. For this purpose, ends of all PVC insulated cables shall be taped with an approved PVC or rubber insulating tape. Use of friction type or other fabric type tape is not permitted. Lead sheather cables shall be plumbed with lead alloy.

5.8

RCC cable trenches with removable covers as shown on the drawings will be provided by the Owner. Cables shall be laid in 3 or 4 tiers in these trenches as indicated on the sectional drawings. Concrete cable trenches shall be filled with sand where specified to avoid accumulation of hazardous gases, RCC covers of trenches in process area shall be effectively sealed to avoid ingress of chemicals etc. Removal of concrete covers for purpose of cable laying and reinstating them in their proper positions after the cables are laid shall be done by the electrical Contractor at no extra cost. Cables shall be handled carefully during installation to prevent mechanical injury to the cables. Ends of cables leaving trenches shall be coiled and provided with a protective pipe or cover, until such times the final termination to the equipment is connected.

5.9

Directly burried cables shall be laid underground in excavated cable trenches where specified in layout drawings. Trenches shall be of sufficient depth and width for accommodation of all cables correctly spaced and arranged with a view of heat dissipation and economy of design. Minimum depth of burried cable trench shall be 750 mm for low voltage and 900 mm for H.V. Cables, the depth andthe width of the trench shall vary depending upon the number of layers of cables. Cables shall be laid in trenches at depth as shown in the drawing. Before cables are placed, the trenches bottom shall be filled with a layer of sand. This sand shall be levelled and cables laid over it. These cables shall be covered with 150 mm of sand on top of the largest diameter cable and sand shall be lightly pressed. A protective covering of 75 mm thick second class red bricks shall then be laid flat. The remainder of the trench shall then be back-filled with soil, rammed and levelled.

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/21

5.10

SPECIFICATION FOR CABLING

REV-0

Page 6 of 11

As each row of cables is laid in place and before covering with sand every cable shall be given an insulation test in the presence of Engineer-in-Charge / Owner. Any cable which proves defective shall be replaced before the next group of cables are laid. All wall openings/pipesleeves shall be effectively sealed after installation of cables to avoid seepage of water inside building/ lined trench.

5.9

Where cables rise from trenches to motor, control station, lighting panels etc., they shall be taken in G.I. Pipes for mechanical protection upto a minimum of 300 mm above grade or as shown in the standard drawings. Cable ends shall be carefully pulled through the conduits, to prevent damage to the cable. Where required, approved cable lubricant shall be used for this purpose. Where cable enters conduit the cable should be bent in large radius. Radius shall not be less than the recommended bending radius of the cables specified by the manufacturer. Following grade of the pipe fill shall be used for sizing the pipe size: a) b) c) d)

1 cable in pipe 2 cables in pipe 3 or more cables Multiple cables -

53% full 31% full 43% full 40% full

After the cables are installed and all testing is complete, conduit ends above grade shall be plugged with a suitable weatherproof plastic compound/ `PUTTI' for sealing purpose. Alternatively G.I. Lidsor PVC bushes shall be employed for sealing purposes. The cost for the same shall be deemed to have been included in the installation of G.I. Pipe and no separate payment shall be allowed. 5.11

Where cables pass through foundation walls or other underground structures, the necessary ducts or openings will be provided in advance for the same. However, should it become necessary to cut holes in existing foundations or structures, the electrical contractor shall determine their location and obtain approval of the Engineer-in-Charge before cutting is done.

5.12

At road crossing and other places where cables enter pipe sleeves adequate bed of sand shall be given so that the cables do not slack and get damaged by pipe ends.

5.13

Drum number of each cable from which it is taken shall be recorded against the cable number in the cable schedule.

5.14

Cables installed above grade shall be run in trays, exposed on walls, ceilings or structures and shall be run parallel or at right angles to beams, walls or columns.

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MECON LIMITED Delhi

SPECIFICATION NO. : MEC/S/05/26/21

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR CABLING

REV-0

Page 7 of 11

Cables shall be so routed that they will not be subjected to heat from adjacent hot piping or vessels. 5.15

Individual cables or small groups which run along structures/walls etc., will be clamped by means of 10 SWG GI saddles on 25x6 mm saddle bars. The cost of saddle and saddle bars shall be deemed to have been included in the installation of cables and no separate payment shall be made on this account. Alternatively small group of cables can be taken through 100 mm slotted channel/ISMC 100. They shall be rightly supported on structural steel and masonary, individual or in groups as required, if drilling of steel must be resorted to, approval must be secured and steel must be drilled where the minimum weakening of the structure will result. Cables shall be supported so as to prevent unsightly sagging. In general distance between supports shall be approximately 300 mm for cables upto 25 mm diameter and maximum 450 mm for cables larger than 25 mm dia.

5.16

All G.I. Pipes shall be laid as per layout drawings and site requirements. Before fabrication of various profiles of pipe by hydraulically operated bending machine (which is to be arranged by the contractor), all the burrs from the pipes shall be removed. GI Pipes with bends shall be burried in soil/concrete in such way that the bends shall be totally concealed. For G.I. Pipes burried in soil, bitumen coating shall be applied on the burried lengths. Installation of G.I. Pipes shall be undertaken well before paving is completed and necessary co-ordination with paving agency shall be the responsibility of Electrical Contractor. The open ends of pipes shall be suitably plugged with G.I. Plugs after they are laid in final position. G.I. Plugs shall be supplied by the Contractor at no extra cost.

5.17

Cable laid on supporting angle in cable trenches, structures, columns and vertical run of cable trays shall be suitably clamped by means of G.I. Saddles/Clamps, whereas cable in horizontal run of cable trays shall be tied by means of nylon cords.

5.18

Supporting steel shall be painted before laying of cables. The painting shall be done with one coat of red lead paint and two coats of approved bitumenious aluminium paint unless otherwise specified.

6.0

TERMINATION

6.1

All PVC cables upto 1.1 KV grade shall be terminated at the equipments by means of compression type cable glands. They shall have a screwed nipple with conduit electrical threads and check nut. All Cable entries shall be through bottom only and top entry terminations are made only after getting approval of Engineer-in-Charge.

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MECON LIMITED Delhi

SPECIFICATION NO. : MEC/S/05/26/21

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR CABLING

REV-0

Page 8 of 11

6.2

Power cables wherever colour coding is not available shall be identified with red, yellow and blue PVC tapes. Where copper to aluminium connections are made, necessary bimetallic washers shall be used. For trip circuit identification additional red ferrules shall be used only in the particular cores of control cables at the termination points in the Switchgear/Control panels and Control Switches.

6.3

In case of control cables all cables shall be identified at both ends by their terminal numbers by means of PVC ferrules or Self-sticking cable markers. Wire numbers shall be as per schematic/ wiring /inter- connection diagram. Bidders shall have the samples of PVC ferrules/cable markers approved before starting the work. All unused spare cores of control cables shall be neatly bunched and ferruled with cable tag at both ends.

6.4

Where threaded cable gland is screwed into threaded opening of different size, suitable galvanized threaded reducing bushing shall be used of approved type, at no extra cost. All switchgear and control panels shall have undrilled gland plate. Contractor shall drill holes for fixing glands wherever necessary at no extra cost. Gland plate shall be of non-magnetic material/aluminium sheet in case of single core cables.

6.5

The cable shall be taken through glands inside the panels or any other electrical equipment such as motors. The individual cores shall then be dressed and taken along the cable ways (if provided) or shall be fixed to the panels with polyethylene straps. Only control cables of single strand and lighting cables may be directly terminated on to the terminals. In case of termination of cables at the bottom of a panel over a cable trench having no access from the bottom close fit hole should be drilled in the bottom plate for all the cables in one line, then bottom plate should be split in two parts along the centre line of holes. After installation of bottom plate and cables it should be sealed with cold setting compound. Cables shall be clamped over the open armouring to connect it to earth bus.

6.6

Cable leads shall be terminated at the equipment terminals, by means of crimped type solderless connectors as manufactured by M/s. Dowell Electroworks or approved equivalent. Crimping shall be done by hand crimping hydraulically operated tool and conducting jelly shall be applied on the conductor. Insulation of the leads should be removed immediately before the crimping. Conductor surface shall be cleaned and shall not be left open.

Document6

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR CABLING

SPECIFICATION NO. : MEC/S/05/26/21

REV-0

Page 9 of 11

6.7

Cable accessories for H.V. Systems

6.7.1

The 11, 6.6 and 3.3 KV cables terminations joints shall be done by skilled and experienced jointers duly approved by the Engineer-in-Charge. Termination including supplying of jointing kit shall be threaded in Contractor scope unless specified otherwise.

6.7.2

The termination and straight thro' joint kit. For use on high voltage system shall be suitable for the type of cables ----red by the contractor or the type of cables issued by owner for installation. The materials required for termination and straight through joints shall be supplied in kit form. The kit shall include all insulating and sealing materials apart from conductor fitting and consumables items. An installation instruction shall be included in each sheet.

6.7.3

The termination kits shall be suitable for termination of the cables to an indoor switchgear or to a weatherproof cable box of an outdoor mounted transformer motor. The terminating kits shall preferably be of the following types : a) b) c) d)

TAPLEX' of M-seal make using non-linear resistance material forstress grading. `PUSH-ON' type of CCI make using factory - moulded silicone rubber insulators. `TROPOLINK' type of CCI make. Heat-shrinkable sleeve type of M/s. Raychem.

For outdoor installations, weather shields/sealing ends and any other accessories required shall also form part of the kit. 6.7.4

The straight thro jointing kits shall be suitable for underground buried installation with uncontrolled backfill and possibility of flooding by water. The jointing kit shall be one of the following types. a) b) c)

`TAPLEX' of M-seal make `TROPOLINK' type of CCI make Heat-shrinkable sleeve type of M/s. Raychem.

6.7.5

Makes of kits other than those specified in 6.7.3 and 6.7.4 may be considered, provided the Contractor furnishes type test certificates, alongwith the offer.

6.7.6

Type tests are to be carried out at manufacturer's works to prove the general qualities and design of a given type of termination/jointing system. The type tests shall include the following tests conforming to the latest IEC 502.2, 466 and VDE 0278 specifications. The type test certificates shall be submitted by the Contractor along with the offer for the jointing system considered. a)

Document6

A.C. Voltage withstand dry test for 1 minute

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/21

b) c) d) e) f) g) h) i) j)

SPECIFICATION FOR CABLING

REV-0

Page 10 of 11

Partial discharge test - Discharge magnitude small be less than 20 p.c. Impulse voltage withstand test with 10 impulses of each polarity. A.C. high voltage test following load cycling test with conductor temperature at o 95 C. o Thermal short circuit test of 250 C for 1 second. DC Voltage withstand test for 30 minutes. Humidity test. Dynamic short circuit test. Salt log test Impact test

7.0

TESTING:

7.1

Before energising, the insulation resistance of every circuit shall be measured from phase to phase and from phase to ground.

7.2

Where splices or termination are required in circuits rated above 600 volts, measure insulation resistance of each length of cable before splicing and or/ terminating. Repeat measurement after splices and/or terminations are completed.

7.3

Measure the insulation resistance of directly burried cable circuits ------------------ before cable trenches are back-filled. Repeat measurement after back- filling. For cables upto 1.1 KV grade 1000 KV Megger and for H.V. Cables 2.5 KV/5 KV Megger shall be used.

7.4

D.C. High Voltage Test shall be conducted after installation on the following and test results are recorded as per EIL Format. a) b)

All 1000volts grade cables in which straight through joints have been made. All cables above 1100 V grade.

For record purposes test data shall include the measure values of leakage current versus time. The D.C. High Voltage test shall be performed as detailed below in the presence of the Engineer-in- Charge or his authorised representative only. Cables shall be installed in final position with all the straight through joints complete. Terminations shall be kept unfinished so that motors, switchgears, transformers etc. are not subjected to test voltage. The test voltage shall be as under:i)

Document6

For cables 3.3 KV grade

5.4 KV DC

MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION NO. : MEC/S/05/26/21

SPECIFICATION FOR CABLING

REV-0

ii)

For cables 6.6 KV grade

10.8 KV DC

iii)

For cables 11 KV grade

18 KV DC

Page 11 of 11

7.5

All cables shall be tested as per EIL standard test proforma available with site engineer.

7.6

Cable schedule and layout drawings must be marked for AS BUILT conditions during the installation work and shall be approved by Site Engineer.

Document6

GUJARAT STATE PETRONET LIMITED (GSPL)

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

GAS OVER – OIL ACTUATOR

MECON LIMITED DELHI

MECON LIMITED NEW DELHI TITLE

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

CONTENTS

Sl.No

Description

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

ACTUATOR SIZING

4.0

DESIGN FEATURES

5.0

COATING

6.0

INSPECTION AND TESTS

7.0

NAME PLATE

8.0

SHIPPING

9.0

DOCUMENTATION

10.0

SPARES AND ACCESSORIES. ATTACHMENTS - GAS COMPOSITION - SKETCH-1

REVISION 0

PAGE 1 OF 11

MECON LIMITED NEW DELHI TITLE

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

REVISION 0

PAGE 2 OF 11

1.0

SCOPE:

1.1

This specification, together with the applicable data sheet, covers the minimum requirements for the design, manufacture, inspection, testing and shipping of valve actuators complete with accessories for quarter turn ball valves.

1.2

This specification indicates the minimum supply requirements and does not relieve the vendor from his responsibilities concerning the design and the safe operation of the supplied equipment.

1.3

The valve manufacturer shall also be responsible for proper operation of the actuator that shall develop a torque or a thrust sufficient to conveniently open and close the valve always within the limits established by the resistance of the mechanical elements of the valve itself.

1.4

Valve and actuator shall be supplied as a single assembly complete in all respect and ready for installation at site.

2.0

REFERENCE DOCUMENTS Reference is made in this specification to the latest edition of the following codes, standards and specifications: Codes and Standards ASME B31.8

:

Gas Transmission and Distribution Piping Systems

ASME B16.5

:

Steel Pipe Flanges and Flanged Fittings

ASME Sec. VIII

:

Boiler and Pressure Vessels, Code

ANSI B2.1

:

Pipe Threads, General Purpose

NEC

:

National Electric Code

IEC

:

International Electro-technical Commission

NEMA

:

National Electrical Manufacturers Association

Purchaser Specification MEC / TS / 05 / 62 / 002

:

Standard Specification for Ball Valves (Onshore)

MECON LIMITED NEW DELHI TITLE

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

REVISION 0

PAGE 3 OF 11

In case of conflict between the requirements of this specification and above referred documents, the requirements of this specification shall govern. 3.0

ACTUATOR SIZING

3.1

PNEUMATIC & GAS – OVER – OIL ACTUATORS. Actuator with all its accessories shall be designed to form a stiff assembly by means of a stiffening support frame or equivalent. All accessories , including pneumatic and electrical parts sall be protected against damage as well in operation as during erection handling. The assembly shall be equipped with minimum two lifting devices.

3.2

For sizing the actuator, the valve manufacturer shall furnish to the actuator manufacturer the following information: i) The maximum break-away torque or thrust required at the valve stem with manual/ remote operation to open and close a valve at the shut off pressure in the line. The actuator shall be sized according to the line pressure.(Refer Table 1 enclosed for Line Pressure details) and meeting the safety factor of 2 as required by the valve operation at the shut-off pressure in the line. ii) The temperature correction factor. iii) The pressure correction factor. iv) As a result of points (i) to (iii) the minimum required torque or thrust output of the actuator. v) Maximum allowable torque or thrust output of the actuator depending on the type and size of valves.

3.3

The maximum time required to open and close a ball valve shall be as indicated in the data sheet. However, the actuator shall be capable of opening/ closing a valve between 0.5 and 3 Secs per inch nominal valve port diameter. Opening and closing times shall be adjustable between these limits.

3.4

Actuator manufacturer shall provide the complete model no. decoding for actuators, limit switches and solenoid valves.

3.5

Complete details of Gas/ Hydraulic circuit with complete sequencing of port from open to close and close to open position shall be furnished in the offer for review.

MECON LIMITED NEW DELHI TITLE

3.6

4.0

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

REVISION 0

PAGE 4 OF 11

Manufacturer shall furnish the detailed calculation for actuator sizing after placement of order. The calculation so furnished by manufacturer shall satisfy the sizing criteria as per above clauses. Manufacturer shall agree to upgrade the actuators offered to meet the sizing criteria without any price and schedule impact.

DESIGN FEATURES 4.1

The actuators shall be powered by Natural Gas from the main pipeline. The gaspowered actuator shall operate at the line pressure (Refer Table-1 enclosed for line pressure details). A typical scheme for tapping the gas from mainline with pressure reduction as shown in Sketch-1. Actuator electrical , hydraulic (Gas – Over Oil ) circuit shall be developed as per the Sketch-2 enclosed.

4.2

Actuator shall be direct gas operated scotch yoke type with manual hydraulic (Gas – Over Oil ) override. The actuator shall be provided with a hydraulic pump for manual operation. If there is no gas pressure available to actuator it shall be possible to actuate Direct Pneumatic Actuator by means of Nitrogen bottles or similar pressure source. Actuator manufacturer shall furnish the capacity and set pressure of nitrogen bottle / suitable oil for at least two opening and two closing strokes of the actuator.The supply of Nitrogen cylinder is in the scope of the vendor.

4.3

The actuator shall be suitable for gas operating conditions and ambient temperature as specified in data sheets. The presence of methanol in the gas shall not affect the service of the Actuator.

4.4

All materials in contact with natural gas shall be suitable for the gas composition attached with this specification.

4.5

The actuator and its accessories shall be suitable; for outdoor installation and have weatherproof enclosure as per NEMA 4 or equivalent. All compartments and housing containing electrical devices such as switches, contactors, relays, fuses, terminal box etc. shall be explosion proof suitable for NEC Class 1 Div. 2 Gr. C & D, T3 or equivalent. The cable glands shall be 1” NPT threaded. The unused cable entries must be plugged off with solid metal plugs. Solenoid valves shall be of explosion proof design certified for NEC Class 1 Div. 2 Gr. C & D, T3 or equivalent with moulded continuous duty coils and stainless steel valve body.

4.6

All pressure containing parts shall be designed to ASME Section VIII.

MECON LIMITED NEW DELHI TITLE

4.7

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

REVISION 0

PAGE 5 OF 11

a)

The actuator shall be suitable for direct mounting to the valve without changing the standard top works of the valve and shall have the capability to be mounted or removed from the valve when the valve is in service. The actuator shall be flanged and bolted directly on the valve body or extension. The connection between actuator and the valve or between the operator, the outer casing of the extension and the valve shall be such that there is no movement between these connections when the valve is actuated by the actuator under any load.

b)

Actuator shall be suitable for installation on a vertical stem unless otherwise specified in the data sheet.

4.8

Provision shall be made to prevent accidental pressure build up in the actuator.

4.9

The construction of the actuator and its controls shall be such that proper manual operation and maintenance can be carried out by skilled personnel without the risk of being injured by moving parts.

4.10

A position indicator on the actuator shall show the valve in the open, closed or partially open positions.

4.11

Bearings shall be factory packed with grease and shall not required additional lubrication for the life of the actuator.

4.12

Unless otherwise specified in the data sheet, the actuator shall be equipped with limit valves, which immediately shut off the gas supply to actuator when the valve reaches one of its end positions.

4.13

Actuator shall be provided with pressure gauges for pneumatic and hydraulic systems. The pressure gauges for the hydraulic system shall be in circuit with the pressure relief system.

4.14

In selection of pressure regulator due consideration shall be given to the effect of cooling of gas at the regulator and its down stream section.

4.15

A high pressure dehydrating filter cartridge shall be provided to remove condensate, moisture, foreign particles and any corrosive contaminants from pipeline gas.

4.16

The sound level of the gas escaping into the atmosphere when the actuator is in operation shall not exceed 90 dBA, measured at a distance of 10 meters.

4.17

The actuator shall be operated by either of the following two methods:

MECON LIMITED NEW DELHI TITLE

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

REVISION 0

PAGE 6 OF 11

a) For the remote control, the actuator shall have a solenoid valve, limit switches, relays, etc. and shall be suitable for remote and local operation as per description in the attached Actuator Data Sheet(s). Electrical signal supplied is a momentary type with 1-sec duration signal, Actuator shall have a self retaining system of the above signal in its control circuit. b) For the local-control, the actuator shall be suitable for local operation with line gas feed lines or through nitrogen bottles / suitable oil The devices and accessories, which do not require the electricity for their operation, shall be provided in the actuators as per this specification. The actuators shall have a hand pump in conjunction with the oil circuit to achieve local control with hydraulic shock functionality. 4.18

a) The actuators shall be provided with limit switches for open and close positions. The position of switches shall be adjustable near the valve open and close positions. The limit switches shall be wired up to terminal block and shall be numbered for proper identification. The limit switches shall have 2 sets of contacts for each open and close position. The contact rating shall be as specified in the data sheet. The power to solenoid valves shall be cut-off when the actuator has travelled to extreme positions (close and open). b) The limit switches shall be wired in the actuator control circuit by the vendor so as to cut off power to the actuator once the end positions of the valve are reached. This is required to de-energize the solenoid valves in the steady state condition and failure of electrical power will not affect the valve position.

4.19

The stroke of the Actuator shall be easily adjustable in steps of maximum 0.5° for Ball Valves.

4.20

Speed control nozzles for adjusting the valve speed over a wide range shall be provided.

4.21

If remote control is required, a local/ remote switch shall be installed to prevent remote control during maintenance work. This switch shall be provided with a hole of 12 mm in diameter for locking with pad lock in either position. This local/ remote switch shall be wired up to the junction box as per circuit diagram.

4.22

All control accessories, pneumatic and hydraulic, or gas over oil shall be mounted in an enclosure and shall be fully wired and tubed. The enclosure shall be weatherproof as per NEMA-4 or equivalent.

4.23

All bleed and vent connections wherever required shall be piped outside the actuator

MECON LIMITED NEW DELHI TITLE

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

REVISION 0

PAGE 7 OF 11

cabinet so as to prevent gas pocketing inside the actuator cabinet. The actuator shall be of an automatic self-purging design such that any gas pocket in the actuator will be eliminated. 4.24

Vendor shall be responsible for integrating the potential free NO or NC contacts of Remote Telemetry Unit (RTU’s) for open and close command in interlock circuit. These commands will be of momentary type with 1 sec duration.

4.25

All mounting accessories needed for installing the Actuator, Valves etc. are in manufacturer’s scope of supply.

4.26

The interconnecting cabling, interconnecting pipe work between the actuator and the valve, adapters, tubing, cable glands, junction box are in manufacturer’s scope of supply.

4.27

The actuator shall be supplied totally self-contained, wired, tubed and mounted on ball valve. In case of a separate control box, wiring and tubing between control box and actuator is in the vendor’s scope. Three meters of ¾” tubing set including all connectors between the actuator and the control box and three meters of interconnecting piping work upstream & downstream of the valve and the control box to be provided. Owner shall provide 20mm (¾”) SW tapping on process main line for line gas tapping.

4.28

Threading connections shall be NPT as per ANSI B2.1 and flange connection as per ANSI B16.5. The tubing, fittings and valves shall be Stainless steel with SwageLok fittings or equivalent.

5.0

COATING The actuator, including gearboxes and piping, shall be coated as described below:

5.1

Removal of all rust by means of emery cloth or wire brush.

5.2

Short blast as per Swedish Standard No. SIS 055900 latest edition SA 2.5 one layer Primer Epoxy – Polyamide DFT 75 microns intermediate layer Epoxy – Polyamide DFT 25 microns, final layer Epoxy – Polyamide DFT 75 microns. Total DFT 175 microns and colour RAL 5012 (light blue).

6.0

INSPECTION AND TESTS

6.1

Tests at the Actuator Manufacturer’s Shop a)

Electrical and Mechanical operating tests.

b)

Seal test of hydraulic circuits.

MECON LIMITED NEW DELHI TITLE

6.2

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

c)

Check of required functions.

d)

Check of operating time control.

e)

Check of limiting device operation.

f)

Check of actuator torque or thrust.

REVISION 0

PAGE 8 OF 11

Test at the Valve Manufacturer’s Shop a)

Test and check covered by point 6.1 after assembly with ball/plug valve.

b)

No load test (DP=0) or load (DP max) Operations with the minimum required feeding pressure according to the line pressure.

c)

Check of the limiting device operation.

d)

Various tests on the valve according to provisions of specific documentation.

e)

Testing shall confirm to actual field operating conditions

6.3

All actuators shall be visually inspected.

6.4

Dimensional check on actuators shall be carried out as per the Purchaser approved drawings.

6.5

Purchaser reserves the right to perform inspection as indicated above at Manufacturer’s works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchaser’s Inspector. In no case shall any action of Purchaser or his inspector relieve the Manufacturer of his responsibility for material, design, quality or operation of actuators.

7.0

NAME PLATE Actuator shall have an SS nameplate attached firmly to it at a visible place and reporting the following information: a) Instrument tag number as per Purchaser’s data sheets. b) Manufacturer’s model, trade mark, serial no etc. c) Max. allowable operating pressure or voltage. d) Area classification in which the equipment can be used. e) Actuator characteristics data.

MECON LIMITED NEW DELHI TITLE

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

REVISION 0

PAGE 9 OF 11

f) Inspection agency name or logo.

8.0

SHIPPING

8.1

All threaded and flanged opening shall be suitably protected to prevent entry of foreign material.

8.2

The actuator shall be supplied pre-assembled except piping/tubing, actuator, actuator control unit, tanks, and other accessories, which shall be packed separately.

8.3

Protective grease oil coating shall be applied on the surface to protect them from rusting.

8.4

Package shall be marked legibly with suitable marking ink the following information: a)

Order number

b)

Package number

c)

Manufacturer’s name

d)

Model no. & Thrust

e)

Tag number

f)

Inspection agency name or logo

9.0

DOCUMENTATION

9.1

Alongwith the quote, the bidder shall submit the following documents in accordance with EN102043.1C:a)

A detailed specification sheet for valve actuator providing all the details regarding type, materials of construction for various parts etc.

b)

Schematic diagrams showing the complete actuator control circuit.

c)

A detailed dimensional drawing.

d)

Installation drawing complete with valve assembly.

e)

Actuator sizing calculations including relation between required torque of valve and actuator output torque.

f)

Information’s asked for vide section 3.0 of this specification and actuator sizing as per Actuator Data Sheet.

MECON LIMITED NEW DELHI TITLE

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

REVISION 0

PAGE 10 OF 11

g)

Drawing showing connections by Purchaser (piping, electrical etc.)

h)

Wiring diagram (actuator electrical circuitry) incorporating latching of momentary signals, remote/ local switch, limit switches.

i)

Junction box terminal block nos. for I/O signals.

j)

Parts list.

k)

Recommended spare parts with prices.

l)

Assembly details (Valve & Actuator).

m)

Information regarding the past experience on similar actuators including (a) Size (b) Numbers (c) Name of Installations (d) Owner (e) Name of contact person (f) Date of installation.

n)

Technical catalogue giving detailed technical specification and other information for each type of actuator and its accessories covered in the bid.

9.2

Within 30 days from the date of Purchase Order manufacturer shall submit copies of the following for Purchaser’s review and approval. a) Documents and specifications as listed in clause 9.1 of this specification. b) Test certificates and certificates from statutory bodies. c) Manual for installation, erection instructions, maintenance and operation instructions. d) Complete assembly drawing of the ball valve matching with the actuator offered. The approval of these drawings/ documents will not absolve vendor of the responsibility with respect to correct operation of the actuator. Manufacturer’s quotation, catalogues, drawings, operating and maintenance manuals etc. shall be in English language.

10.0

SPARES AND ACCESSORIES

Vendor shall quote for 2 years operational spares, commissioning spares and any special tools needed for maintenance work on the actuator and its accessories.

MECON LIMITED NEW DELHI TITLE

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION NO.: MEC/ TS / 05 / E5 / 002

GAS OVER OIL ACTUATORS

PAGE 11 OF 11

REVISION 0

ATTACHMENTS ASSOCIATED GAS COMPOSITION FOR GSPL PROJECT COMPONENTS

MOL%

C1

81.5

C2

8.0

C3

4.66

i-C4

0.65

n-C4

1.44

i-C5

0.33

n-C5

0.35

C6+

-

H2

-

N2

3.0

O2

-

CO2

0.31

H2S

-

Gas Quality

SATURATED WITH WATER

Specific Gravity

0.7

Net Calorific Value (kcal/Nm3)

9930

Gross Calorific Value (kcal/Nm3)

-

MECON LIMITED NEW DELHI

INSTRUMENTATION SECTION

TITLE

GAS OVER OIL ACTUATORS

DATA SHEET NO. MEC/DS / 05 / E5 / GABV / 01

REVISION 0

PAGE 1 OF 6

DATA SHEET for GAS OVER - OILPOWERED ACTUATORS FOR BALL VALVES

1.

Actuator Manufacturer

:

BY VENDOR

2.

Specification for Gas Powered Actuator

:

MEC/TS/05/E5/002

3.

Actuator Type

:

Emergency Shutdown

4.

Tag No.

:

As per the Table-1

5.

Line No.

:

-----------

6.

Service

:

Natural Gas

7.

Vendor to furnish after sizing the actuator, the filled in torque Table no-2

8.

Actuator Shut-off Pressure

9.

Process Conditions

:

As per the Table-1

Power Gas

:

Natural Gas

Gas Temperature

:

As per the Table-1

Line Gas Pressure

:

As per the Table-1

MECON LIMITED NEW DELHI

INSTRUMENTATION SECTION

TITLE

GAS OVER OIL ACTUATORS

DATA SHEET NO. MEC/DS / 05 / E5 / GABV / 01

REVISION 0

Molecular Weight

:

18.90

Cp/Cv

:

1.41

Compressibility Factor

:

0.92 –0.99

10..

Power Gas Feed Connection from main line

:

¾” SW

11.

Actuator remote operation (For open and close)

:

Required

12.

Actuator Feed Gas

:

a) Line gas b) N2 Bottles C) Oil

13.

Valve Position Limit Switch

:

Required (SPDT contact for open and SPDT Contact for close position separately)

14.

Local/ Remote selector switch and its status contact

:

Required (shall be wired up to junction box as per circuit diagram)

15.

Pneumatic limit valves and solenoid, pilot valves to shut-off gas supply to Actuator when valve reaches one of its end positions

:

Required

PAGE 2 OF 6

MECON LIMITED NEW DELHI

INSTRUMENTATION SECTION

TITLE

GAS OVER OIL ACTUATORS

DATA SHEET NO. MEC/DS / 05 / E5 / GABV / 01

REVISION 0

16.

Self retaining system for retaining momentary open or close signals in the control circuit

:

Required

17.

Electrical conduit connection (cable entries to junction box for purchaser’s cable)

:

1” NPT

18.

Operating voltage for a) Solenoid Valves b) Relays

:

24V D.C. ± 10%

19.

Contact rating for a) Limit Switches b) L/R Switch (Status)

:

2A at 24V D.C.

20.

Pad lock with L/R Switch

:

Required

21.

Enclosure for a) Actuator

:

Certified weatherproof as per IP-55

b)

:

Certified weatherproof toIP55 & Explosion proof certified for Class 1 Div. 2 Gr. C & D T3

22.

Electrical items like solenoid valves, junction boxes, relays, cable glands

Area Classification

:

NEC Class 1 Div. 2 Gr. C & D T3

PAGE 3 OF 6

MECON LIMITED NEW DELHI

INSTRUMENTATION SECTION

TITLE

GAS OVER OIL ACTUATORS

DATA SHEET NO. MEC/DS / 05 / E5 / GABV / 01

REVISION 0

23.

Material of construction for all tubing, Valves, piping and fittings etc.

:

SS 316

24.

Make & Model No. of Actuator

:

By Vendor

25.

Accessories Required

:

Required as per Specification

26.

Manual/ Hydraulic Override

:

Required as per Specification

27.

Time required for full opening/ Closing of the ball valve

:

30 Sec.

PAGE 4 OF 6

MECON LIMITED NEW DELHI

INSTRUMENTATION SECTION

TITLE

GAS OVER OIL ACTUATORS

DATA SHEET NO. MEC/DS / 05 / E5 / GABV / 01

REVISION 0

PAGE 5 OF 6

TABLE-1 PROJECT CLIENT ITEM DATA SHEET NO.

Sl.no 1.0 2.0 3.0

Tag No. GOV-0101 AV - 0501 AV - 0702

: : : :

PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL) GSPL GAS OVER – OIL BALL VALVE ACTUATORS MEC/05 / E5 / GAVB / 01

Size/ Class 12”/ 600# 12”/ 600# 12”/ 600#

Type of Valve Ball

Line No.

Gas Temp (°C) Inlet -20 -20 -20

NOTE ALL VALVES SHALL BE SUPPLIED WITH EXTENDED STEM .

Max 60 60 60

Line Gas Pressure (kg/cm2g) Min Max 50 95 50 95 50 95

Delta P Shut Off (kg/cm2) 95 95 95

Location

MECON LIMITED NEW DELHI

INSTRUMENTATION SECTION

TITLE

GAS OVER OIL ACTUATORS

DATA SHEET NO. MEC/DS / 05 / E5 / GABV / 01

REVISION 0

PAGE 6 OF 6

TABLE-2 PROJECT CLIENT ITEM DATA SHEET NO.

: : : :

PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL) GSPL GAS OVER OIL BALL VALVE ACTUATORS MEC/ DS / 05/ E5/ GAVB / 01

Data from Ball Valve Vendor for Sl. No.

1.0 2.0 3.0 NOTE :

Tag No. Break Torque (Nm)

Ball Valve Torque Figure with a safety Factor of 2.0

Actuator Generated Torque at Regulated Pressure (Note-1)

Max Running Allowable Break Running Break Running Torque (Nm) Valve Stem Torque (Nm) Torque (Nm) Torque (Nm) Torque (Nm) Torque (Nm)

Model Selected

GOV-0101 AV - 0501 AV - 0702

1. THESE FIGURES SHALL BE USED AS BASIS FOR TESTING THE ACTUATOR PERFORMANCE DURING FACTORY TESTING THE ACTUATOR ACCEPTANCE WOULD BE CARRIED OUT AFTER VERIFYING SUCCESSFUL TESTING COMPLETE BALL VALVE WITH ACTUATOR ASSEMBLY. 2. ALL TORQUE FIGURES MUST BE IN Nm.

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

PROJECT TECHNICAL SPECIFICATION FOR TEMPORARY CATHODIC PROTECTION SYSTEM

SPECIFICATION NO. : MEC/PTS/05/62/016A

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

CONTENTS Page No.

Sl.No.

Description

1.0

SCOPE

:

3 OF 21

2.0

CODES AND STANDARDS

:

3 OF 21

3.0

SYSTEM IMPLEMENTATION

:

3 OF 21

4.0

CORROSION DATA:

5.0

CATHODIC PROTECTION DESIGN PARAMETRES

6.0

CATHODIC PROTECTION DESIGN CRITERIA :

6 OF 21

7.0

SYSTEM DETAILS

:

7 OF 21

8.0

INSTALLATION

:

15 OF 21

9.0

CIVIL WORKS

:

16 OF 21

10.0

TESTING AND INSPECTION AT WORKS

:

16 OF 21

11.0

PACKING AND TRANSPORT

:

16 OF 21

12.0

SYSTEM TESTING COMMISSIONING AND INTERFERENCE MITIGATION

:

17 OF 21

13.0

SYSTEM MONITORING

:

20 OF 21

14.0

DRAWINGS AND DOCUMENTS

:

20 OF 21

15.0

INFORMATION REQUIRED WITH BID

:

21 OF 21

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4 OF 21 :

5 OF 21

Page 2 of 21

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

1.0

SCOPE

1.1

This specification defines the requirements of design, engineering, supply of all materials/equipments, installation, testing and commissioning of temporary cathodic protection system to protect the external surface of 12” dia 40 km long Padmala-Godhara underground gas pipeline from corrosion including supplementing of corrosion survey, investigation for interference/ interaction problems and mitigation of the same. Monitoring of the temporary cathodic protection system till the commissioning of permanent C.P. System . This specification defines the basic guidelines to develop a suitable temporary cathodic protection system for the pipeline required to be protected. All data required in this regard shall be taken into consideration to develop an acceptable design and for proper engineering of the system.

1.2

Compliance with these specifications and/ or approval of any of the contractor's documents shall in no case relieve the contractual obligations.

2.0

CODES AND STANDARDS The system design, performance and materials to be supplied shall unless otherwise specified, conform to the requirements of latest relevant applicable standards of :BIS specifications BS specifications and codes of practice ANSI specifications NFPA publications NACE publications IEC publications DNV publications IEEE publications DIN publications ASTM publications In case of conflicting requirements amongst any of the above standards the publication having most stringent requirement shall be governing.

3.0

SYSTEM IMPLEMENTATION All work to be performed and supplies to be effected as a part of contract shall require specific approval of owner or his authorised representative. Major activities requiring approval shall include but not be limited to the following :•

Corrosion survey data interpretation report and design basis for CP system.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

• • • • •

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

CP system design package Purchase requisitions for major equipment and vendor approval Detailed engineering package Field testing and commissioning procedure Procedures for interference testing and mitigation Monitoring procedures

4.0

CORROSION DATA

4.1

The corrosion survey including soil resistivity data along ROW and other data required for CP design is attached with this document. 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 required for completeness of the job. Contractor shall also carry out soil resistivity survey at temporary anode ground bed locations for proper design of ground beds. Wenner's 4-pin method or approved equal shall be used for such measurements. Survey instruments shall have maximum AC and DC ground current rejection feature.

4.2

Additional data to be collected The following data shall be collected to generate design data for evaluation of interaction/ interference possibilities due to presence of other services in ROW/ in vicinity. 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 or any abandoned pipelines.

ii.

Diameter, wall thickness, pressure, pipeline coating against corrosion, soil cover used in case of pipelines.

iii.

Detail of the existing cathodic protection system protecting the services i.e. location, rating, type of protection, anode beds, test station locations and their connection schemes.

iv.

Graphical representation of existing structure/ pipe-to soil potential records. T/R unit current/ voltage readings.

v.

Remedial measures existing on foreign pipeline/services to prevent interaction.

vi.

Possibility of intergration/isolation of CP system, Which may involve negotiations with owners of other services. Crossing and parallel running of electrified and non-electrified traction (along with information regarding operating voltage, type AC/DC etc.) as well as abandoned tracks near ROW having electrical continuity with the tracks in use.

vii.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

viii.

Crossing and parallel running of any HT/AC/DC overhead (existing/proposed) along with details of voltage, type AC/DC etc.

line

ix.

Voltage rating, number of cores and sheathing details of under ground power cables, along ROW or in its vicinity.

x.

Information on existing and proposed DC/AC power sources and system having earth as return path, in the vicinity of the entire pipeline, route such as HV/DC sub stations, fabrication yards with electric welding etc.

xi.

Any other relevant information that may be needed in designing and implementing proper protection scheme for the proposed pipeline. Unless otherwise mentioned, Contractor shall condut necessary potential gradient survey for any existing anode ground bed that may interfere with the CP system of the pipeline covered under this project.

xii.

Any masonry work for other concrete or non conductive constructions in the ROW which may block the CP current or cause interference to the pipeline.

xiii.

Any underground

cable

running

in parallel or crossing the ROW.

4.3

Report On completion of all field work a report incorporating all the results generated from surveys and details of additional data collected shall be furnished. The report shall also contain detailed interpretation of survey results and resistivity data enclosed, probable interference prone areas etc. to form design basis for the scheme of cathodic protection. This report shall be plotted on semi-log graph sheets.

5.0

CATHODIC PROTECTION DESIGN PARAMETERS The following parameters shall be used for design of temporary cathodic protection system. Those parts of sacrificial anode cathdic protection system which will be integrated with permanent CP system shall be designed based on permanent CP parameters & service life of 40 years.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

5.1

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Protection current density (i)

Pipe lines having polyethylene coatings Pipeline surrounding Normal soil Marshyarea/ HDD crossing High resistivity area (more than 100Ω m)

Protection current density* Temporary CP Permanent CP (µA/m²) (µA/m²) 20 20 35 35 15

15

Pipe to soil "ON" potential shall not be more negative than (-) 1.5V w.r.t. Cu-CuSo4 Reference electrode.

* Actual current density to be adopted shall be decided based upon soil and other pipelines and structures affecting interference. Where considered necessary for satisfactory protection of pipeline the current density shall be suitably increased by contractor. 5.2

Safety factor for current density

: 1.3

5.3

Anode utilisation factor

:

0.65 for Mg. Anode 0.80 for Zn Anode

5.4

Pipeline natural potential

:

(-) 0.45 V

5.5

The design life of temporary CP system shall be minimum one year or till commisssioning of permanent CP system whichever is later.

6.0

CATHODIC PROTECTION DESIGN CRITERIA

6.1

Cathodic protection system shall be designed to meet the following criteria: a)

the pipe to electrolyte Potential measurement shall be (–) 0.9S V or more negative as measured between pipe surface and saturated CU-CUS04, reference electrode containing electrolyte when cathodic protection is applied but ON potential measurement shall not go more negative than than (-)1.5 V.

b)

In rare circumstances a minimum polarisation shift of (-) 100 millivolts shall indicate adequate levels of cathodic protection for the pipeline.

However,to use any of the criteria listed above shall solely rest with the owner/owner’s representative.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

6.2

A positive potential swing of 50-100 mV shall be considered the criteria for presence of an interaction 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: -

Sacrificial anodes and anode ground beds Manual Test stations Computerised Test Station Manual Test stations with PSP Convertor & Reference cell Spark Gap Arrester/Grounding cell. Polarisation cells Electrical Resistance Probe Interconnecting cables Cable to pipe connections by PIN BRAZING method.

All equipment shall be new and supplied by approved reputed manufacturers. Equipment offered shall be field proven. Equipment requiring specialised maintenance or operation shall be avoided as far as possible and prototype equipment shall not be accepted. Make and construction of all material shall be subject to owner's approval. The detailed specification of each system and equipment shall be furnished by the contractor. However, certain minimum requirements for the major equipment are highlighted in this document. As far as possible equipment like test stations, etc., shall be located in safe area. All equipment located in hazardous areas shall be of flame proof type as per IS:2148 for gas groups IIA & IIB and temp. class T3. 7.1

ANODE GROUND BEDS

7.1.1

The pipeline shall be protected by prepacked zinc/ magnesium anodes.

7.1.2

Along ROW where soil resistivity is predominantly remains low and ranges from 010 ohm- metre Zinc anodes shall be provided.

7.1.3

Along ROW where soil resistivity is predominantly remains higher than 10 ohm- metre Magnesium anodes shall be provided.

7.1.4

At high resistivity area where resistivity remains 50 ohm-metre and above,Magnesium ribbon anodes shall be provided.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

7.1.5

Anodes shall be installed along the pipeline at suitable intervals as per pipeline protection voltage attenuation calculations and ground bed resistance/ current output of anode installations. Minimum one anode installation shall be provided for every one km. of the pipeline. In congested area, minimum one anode installation shall be provided for every 250 meter of pipeline length.

7.1.6

Each electrically continuous section of pipeline shall preferably be protected totally by one type (material) of anodes to avoid inter-anode circulation currents.

7.1.7

The anodes shall be installed at sufficient depth to reach moist soil and shall be separated from the pipe line by at least 5m and 2m for Magnesium and Zinc anodes respectively. The anode connections to pipeline shall be routed through test stations.

7.1.8

At the temporary cathodic protection anode ground bed where two or more numbers of anodes are installed, the leads of all the anodes shall be joined together in a junction box filled with epoxy and buried. A single cable shall be routed from the junction box to the test station.

7.1.9

For sacrificial anode ground bed (Cased crossing) which shall be integrated with permanent CP System, the leads of all the anodes shall be brought up to the test station and shall be terminated individually.

7.1.10

The number of anodes at each ground bed shall be sufficient for providing the specified pipe protection current density taking into consideration, the ground bed resistance, pipe coating resistance, cable resistance, etc. Contractor shall prepare a table for number of anodes required at different soil resistivities to produce the specified protection current.

7.2

ANODES

7.2.1

MAGNESIUN ANODE The anode shall be of high manganese, magnesium alloy packed with special back fill. The metallurgical composition, potential and consumption rate of anode shall be as below: (i)

Composition: Element Manganese Copper Silicon Zinc Aluminum Iron

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Weight 0.5 – 1.3% 0.02% max. 0.05% max. 0.05% max. 0.01% max. 0.03% max.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

7.2.2

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Nickel Other metallic elements Each Total Magnesium

0.001% max.

(ii)

Anode closed circuit potential

1.5 volts

(iii)

Anode consumption rate

7.9 kg/(A yr)

0.05% max. 0.3% Balance

ZINC ANODE The anode shall confirm to the requirements of ASTM – 418 standard. The anode (other than ribbon anode) shall be packaged with special back fill. The metallurgical composition of anode, potential and consumption rate shall be as below: (i)

Composition: Element Aluminium Cadmium Copper Iron Lead Zinc

Weight 0.005% 0.0035% 0.002% max. 0.0014% max. 0.0035% max. Remainder

(ii)

Anode closed circuit potential

1.1 volts

(iii)

Anode consumption rate

11.24 kg/(A yr)

7.2.3

Contractor shall furnish spectographic analysis from each heat both for zinc and magnesium anodes along with electrochemical test results.

7.2.4

Special Backfill The composition of special back fill for anodes shall be as below: Gypsum Bentonite Sodium Sulphate

7.2.5

75% 20% 5%

The anodes shall be provided with cable tail of sufficient length to reach junction box test station as applicable without tension.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

7.2.6

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Tolerance in fabrication of anodes The anode surface shall be free from cracks which may reduce the performance of the anode. Any cracks which follow the longitudinal direction of elongated anodes shall not be acceptable. Small cracks in the transverse direction of elongated anodes and in anodes of other shapes may be accepted provided the cracks would not cause any mechanical failure during service of the anode considering that the combination of cracks and lack of bond to the anode core is detrimental. For transverse cracks the acceptable limits shall be furnished by the bidders along with the offer. The anode shall be free from excessive shrinkages. The following limits shall be used: -

Maximum 10% of the depth of anode or 50% of the depth of the anode core whichever is less. The depression may be measured from the edged of one side. The surface of the anodes shall be free from coatings and slag/dross inclusions etc. The maximum deviation from straightness shall not exceed 2%. The weight tolerance on individual anodes may be taken as ± 5%. The total weight of the anodes shall not have negative tolerance. Recommended dimensional tolerance shall be as follows: Length Width/thickness

± 2.5% ± 5%

7.3

MANUAL TEST STATIONS

7.3.1

Test stations ( A,B,C,D,E,F&I ) including civil foundation as per drg no MEC/SD/05/62/16/04 shall be provided along the pipeline ROW for monitoring the performance of the Cathodic Protection system at intervals not exceeding 1000 meters in uncongested & 250 meters in congested area. In addition to above, test stations shall also be provided at the following locations: a. b. c. d.

At At At At

one side of major road crossings all insulating joints vulnerable locations with drastic changes in soil resistivity connections of surge diverters, grounding cells and polarisation cells

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

e. f. g. h. i. j. k. l. m. n. o. p.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

At HT AC/DC overhead (66kv and above) line crossings or running parallel the pipeline . At one side of railway line crossing. At one side of major river crossings. At high voltage cable crossings or along routes where HV cables are running in parallel. In the vicinity of DC net works or grounding system where interference problems are suspected. At crossings/parallel running of other foreign pipeline structures At one side of cased crossings At any other locations considered vulnerable locations where interference is expected At any other locations considered necessary by owner/owner’s representative At one side of SV Station At selected marshy area where soil resistivity is low (Only 2 nos test stations shall be considered /installed all along the pipeline route for termination of cable from ER Probe & mesurement purpose) At the terminals either dispatch/tap-off point/SV/Receiving terminal where TR unit is not available but SCADA monitoring facilities for the performance of the pipelines are available then test stations along with 4-20 mA PSP Convertor and reference cell including civil foundation shall be provided

7.3.2

Test stations for bonding shall be provided with shunt and resistor as a means to monitor and control current.

7.3.3

Test stations used for sacrificial anodes shall have shunt for measurement of anode current, and provision for resistance insertion to limit the anode current output. Test station with current measuring facility shall be provided at each intermediate CP station drainage point (to measure pipeline current on any one side of pipeline from drainage point), at interference prone areas, on one side of major river crossings and at least at two additional locations along the pipeline ROW between two CP stations.

7.3.4

7.3.5

All test stations shall have weather proof enclosure, having degree of protection IP 55 with hinged lockable shutter. Enclosure shall be made of sheet steel of at least 3 mm thickness and shall be suitable for M.S. post mounting. The test stations shall be designed with terminals required for both temporary and permanent CP system and shall be suitable for total life of permanent CP system.

7.3.6

The test stations shall be installed with the front of the test station facing the pipeline. The name plate of test stations shall in minimum carry following information. -

Test station number Chainage in km Test station connection scheme type

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

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Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Distance from pipeline in meters Direction of product flow

7.3.7

Terminal blocks and different scheme of wiring as required shall be provided in the test station as per the test station connection scheme sketch.

7.3.8

The location of all the test stations shall be marked with their connection schemes and other relevant information's on alignment sheets. A detailed test station schedule shall be prepared.

7.4

COMPUTERISED TEST STATION 4 numbers Computerised test station including civil foundation shall be provided at selected location all along the pipeline route (location to be decided during detailed engineering by owner/owners representative).

7.5

SURGE DIVERER,GROUNDING CELL AND POLARISATION CELL

7.5.1

Where high voltage (66 KV and above) transmission line runs in parallel or crosses the pipeline, the pipeline shall be grounded through polarisation cells & zinc anodes of minimum 20 kg net each. Grounding shall be done at regular intervals where transmission lines run parallel within 25 meter of the pipeline to ground any surges on the pipeline that would appear in case of transmission line faults. The rating shall depend upon anticipated fault current and ground bed resistant at the location of installation. However the rating of polarization cell (krick) shall not be less than 5 KA & number of 20 Kg net wet zinc anode shall not be less than two.

7.5.2

Location along pipeline where continuous induction of voltage on the pipeline beyond the safe limits is expected or observed during commissioning due to HV transmission Line or other line of any rating, the pipeline shall be earthed through polarization cell to the nearest HV transmission tower of the transmisison line causing the voltage induction or the pipeline shall be grounded to a separate earthing system consist of zinc galvanic anodes and polarization cell. The polarization cell to be installed in a vandal proof steel housing box.

7.5.3

One set of Spark gap arrestor with 2 plate zinc grounding cell of 20 kg net wt each shall be connected across each insulating joint to protect it from high voltage surges.

7.5.4

Zinc grounding cell may also be provided across insulating joints along ROW where the pipeline on both the sides of the insulating joint are cathodically protected and difference of protection voltage is not more then 0.4 volts.

7.5.5

The total system including cables, cable termination, anodes/ surge divertors shall be suitable for the anticipated fault current at the location of installation.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

7.5.6

7.5.7

7.5.8

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Unless otherwise specified on data sheet, the minimum rating of grounding cells, polarisation cells and surge diverters shall be as below: (i) -

Grounding Cell Type Current rating

(ii)

Polarisation cell

-

Type

-

Rating

(iii) -

Spark Gap Arrester Type Current, 8/20 wave Spark over AC voltage: 50 Hz Impulse (1.2/50) micro sec)

: :

Zinc, 2 or 4 plate type Suitable to pass more than 10kA surge

:

Solid state or Electrolytic multiple pairs S.S plate type. Suitable to pass anticipated fault current/surges but not less than 5 KA rating

:

: :

Spark gap 100 kA

: :

1 kV 2.2 kV

The grounding cell, spark gap arresters, and polarisation cell system shall be sized for the design life of permanent CP system. The zinc or magnesium anodes meant for pipeline grounding shall also be sized for the life of the permanent CP system taking into account the current discharge from the anodes. The grounding system shall have minimum resistance to earth to restrict the pipeline voltage as per NACE criteria. PAINTING The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surfaces shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under surfaces shall be free from all imperfections before undertaking the finished coat. After preparation of the under surface, spray painting with two coats of final paint shall be done. The finished panel shall be dried in oven in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off paint, etc. All unpainted steel parts shall be cadmium plated to prevent rust information.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

7.6

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

CABLES Cables shall be annealed high conductivity, tinned, stranded copper conductor, XLPE insulated 650/1100 V grade, armoured, PVC sheathed. The size of the copper conductor shall be 6 sq mm for anode cable from anode to buried junction box, 10 sq mm from junction box to test station, 10mm² from test station to pipeline. The size of the conductor shall be 6 sq mm for potential measurement, 10 sq.mm for current measurement and 25mm² for bonding, polarisation cell/grounding cell and surge diverter connection purpose. The anode cable from anode to junction box (buried) shall be unarmoured. The length of anode tail cable shall be sufficient enough to reach junction box (buried) in case of temporary CP anodes and up to test station in case of permanent CP sacrificial anodes. PE Sleeves shall be provided for unarmoured cables.

7.7

ELECTRICAL RESISTANCE PROBE Electrical resistance probes utilising the electrical resistance technique shall be provided along the pipeline at low resistivity areas and at vulnerable locations to monitor the external corrosion activity on the pipeline (selected locations to be decided during the detailed engineering). The lead wires of the probe shall be connected to pipeline and terminated inside test station enabling periodic resistance measurement with the probe using a portable measuring instrument. The material of the E/R probe element shall be of the same alloy as of the pipeline material. The E/R probes shall be provided preferably at the bottom portion of pipeline. The locations of E/R probes shall be got approved. Portable E/R probe reading instrument shall be supplied by contractor.

7.8

COMPUTERISED TEST STATION Each CTSU is a Microprocessor based low CMOS circuitry with built in RTC 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.CTSUs are typically designed fro outdoor applications and are NEMA 4 protected. Once stored,the data can be downloaded as under: a) By a rempote computer by telephone,cellular phone or radio link/OFC. b) By portable handheld data reader using local communication port.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Key features of the CTSU are as under: 1. 2. 3. 4. 5. 6. 7. 8. 9.

Recording Rate

Can be configured from 1 reading per second to 1 reading per 365 days Battery back up. Lithium battery back up option allows CTSU ECU to retain data for 10years on a single charge. Timing Status input sampling time 10m sec to 2.5sec. Power requirement The CTSU is powered by 110/220/440 Volts AC. Battery back up available. The CTSU shall be able PSP and current data of pipeline & foreign to read and record. pipeline/pipelines Inputs available Minimum 10 nos. 5 input for PSP & 5 inputs for current. Protection against Voltage/current surges expected along the pipeline & foreign structure. Test station reader (TSR) Portable type suitable for field transport & handling.Unit enclosure have weather proof, IP55 Input battery for TSR Internal rechargeable battery provided.

8.0

INSTALLATION

8.1

Cable Laying

8.1.1

Cables shall be laid in accordance with approved layout drawings to be prepared by the contractor. No straight through joint shall be permitted in a single run of cable. Cable route shall be carefully measured and cables cut to required length.

8.1.2

All cables inside station/plant area shall be laid at a depth of 0.75 M. Cables outside station/plant area shall be laid at a depth of 1.5m. Cables shall be laid in sand under brick cover back filled with normal soil. Outside the station/plant area the routes shall be marked with Polyethylene cable warning mats placed at a depth of 0.9m from the finished grade.

8.1.3

All underground unarmoured cables forming part of permanent CP system shall run through PE sleeves. Cables along the pipeline shall be carried along the top of the pipe by securely strapping it with adhesive tape or equivalent as required.

8.1.4

RCC or GI pipes of proper size shall be provided for all underground cables for road crossings.

8.1.5

Cables shall be neatly arranged in trenches in such a manner that criss-crossing is avoided and final take off to equipment is facilitated.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

8.2

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Cable to Pipe Connection All the cable connections to the pipeline including charged foreign pipeline shall be made using pin brazing process. A suitable water proof sealing system of the cable connections shall be made which will be compatible with parent coating system of the pipeline after pin- brazing process.

9.0

CIVIL WORKS All civil works associated with the complete cathodic protection work shall be included in the scope of contractor. This shall include providing cable trenches, foundation for equipment and all test stations, etc.

10.0

TESTING AND INSPECTION AT WORKS

10.1

OWNER/OWNER's representative shall visit the works during manufacture of various equipment to assess the progress of work as well as to ascertain that only quality raw material is used for the same. All necessary assistance during such inspections shall be provided.

10.2

The minimum testing, inspection requirements for all components/ equipments shall confirm to the requirements as defined in the relevant codes and standards. Detailed inspection and testing procedures along with the acceptance criteria shall be prepared by CONTRACTOR for OWNER's approval.

10.3

Test certificates including test records, performance curves etc., shall be furnished. All test certificates shall be endorsed with sufficient information to identify equipment to which the certificate refers to and must carry project title, owner's name and purchase order details etc.

10.4

Owner reserves the right to ask for inspection of all or any item under the contract and witness all tests and carry out inspection or authorise his representative to witness test and carry out inspection. CONTRACTOR shall notify the OWNER or OWNER's representative at least 20 days in advance giving exact details of tests, dates and addresses of locations where the tests would be carried out.

11.0

PACKING AND TRANSPORT All equipment/material shall be protected for inland/marine transport, carraige at site and outdoor storage during transit and at site. All packages shall be clearly, legibly and durably marked with uniform block letters giving the relevant equipment/material details. each package shall contain a packing list in a water proof envelope. Copies of the packing list in triplicate, shall be forwarded to owner prior to despatch. All items of material shall be clearly marked for easy identification against the packing list.

12.0

SYSTEM TESTING, COMMISSIONING AND INTERFERENCE MITIGATION Page 16 of 21

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

Gujarat State Petronet Ltd.

MECON LIMITED

12.1

System testing at site

12.1.1

Contractor shall furnish the detailed field testing and commissioning procedure for approval. Field tests as per the approved procedures shall be carried out on the equipment/systems before being put into service. the acceptance of the complete installation shall be contingent upon inspection and field test results.

12.1.2

Before the CP facilities are placed in operation all necessary tests shall be carried out to establish that all equipment, devices, wiring and connection, etc., have been correctly installed, connected and are in good working condition as required for intended operation.

12.1.3

Owner/owner's representative may witness all the tests. At least one week's notice shall be given before commencing the tests.

12.1.4

All tools, equipments and instruments required for testing shall be provided by CONTRACTOR.

12.1.5

Generally following tests shall be carried out and recorded in proforma given in subsequent clauses: Checking : Visual inspection, comparison with drawings and specifications. Inspection

:

Detailed physical inspection

Testing

:

Simulation tests of equipment to determine its operational fitness.

(i)

(ii)

Cables -

Cable no. Voltage grade Conductor cross-section Continuity check Voltage test Insulation resistance values between core and earth All cables shall be tested by 500 V megger

Insulating joint Checking of insulating joint for leakage, before and after energisation of C.P. by means of insulating joint tester. Structure to electrolyte potential of both protected and non-protected sides of insulating joint shall be checked before and after energistaion of CP system.

(iii)

Polarisation cell

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

(iv)

Location Type (no. of anodes) Ratings

Location/identification no. Ratings Check for healthiness

Anode ground beds -

(vii)

Location/identification number Rating Check for electrolyte Check for wiring Check for standby current drain with CP energisation (current drain with respect to voltage across the cell shall be recorded)

Surge diverter -

(vi)

Location/test station number Current output of the ground bed

Spark Gap Arrester -

(viii)

MECON LIMITED

Grounding cell -

(v)

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

Location/ identification No Ratings Check for healthiness

E/R-Probe -Location/Identifier number -Checking of wiring as per schematics -Resistance reading of probe

12.2

Commisssioning

12.2.1

Natural pipe to soil potential shall be measured at each test station location prior to connecting anodes to pipeline. The pipe to soil potential observation shall be repeated after connecting the anodes and allowing sufficient time for polarisation. The current output of the anode installation shall also be measured to ensure that it does not exceed the output current capacity of the anodes. In case the anode . output current exceeds the rated capacity, it shall be controlled by insertion of resistance element in the anode circuit inside test station and the pipe to soil

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Each anode installation shall become individually operational as above. 12.2.2

After connecting all the anode ground beds to pipeline, measurement of pipe to soil potentials shall be taken at each test station to ensure conformity to protection criteria.

12.2.3

In case of insufficient protection as per the CP design criteria on any portion of the pipeline, CONTRACTOR shall carry out necessary additions modification to the provided protection in consultation with the ENGINEER.

12.3.

Interference Mitigation Investigation shall be made for stray current electrolysis of the pipeline, AC induction on pipeline due to overhead high voltage line, interference due to high voltage DC lines, electric traction, etc. Measurements including pipe to soil potential and pipeline current etc., on the pipeline/structure being CP protected shall be made to investigate the current discharge and collection locations. In case of fluctuating stray currents investigation shall be made continuously over a period of time and if required simultaneously at different locations to find out the stray current source. For long time measurements, recorders shall preferably be used. Where foreign pipeline (unprotected or protected by independent CP system) runs in parallel to the pipeline in same trench or very near to the pipeline, and is not bonded to the pipeline then investigation shall be made for current discharge points on both the pipelines. Mitigation measured shall be provided depending on type of interference. These shall include installation of bond with variable resistor and diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment/relocation (if possible) of offending interference source, provision of electric shield etc., depending on the type of interference. Bonding with foreign pipeline/structure as a mitigation measure shall be provided where the owner of the pipeline/structure has no objection, otherwise, alternative mitigation measure shall be provided. Where bonding is provided for mitigation the bonding resistor shall be adjusted for optimum value for minimum/no interference. Galvanic anodes installed as a mitigation measure shall be sized for the life specified for permanent CP.

13.0

SYSTEM MONITORING

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

The temporary CP system provided shall be monitored at all the test stations once in a month for healthiness/adequacy of protection till commissioning of permanent CP or for design life of temporary CP specified, whichever is less. During this period if any deficiency/interference in protection system is noticed the same shall be rectified/augmented by additional anodes as required. The monitoring report shall be submitted regularly to owner for his review/information. 14.0

DRAWINGS AND DOCUMENTS

14.1

General

14.1.1

Within three weeks from the date of issue of PURCHASE ORDER, CONTRACTOR shall submit four copies of the list of all drawings/ data/ manuals/ procedures for approval, identifying each by a number and descriptive title and giving the schedule date. This list shall be revised and extended, as necessary, during the progress of work

14.1.2

All drawings and documents shall be in English and shall follow metric system. Number of copies of each submission shall be as follows unless otherwise specified. Submission a.

For review/approval

b.

Drawings issued for execution construction

c. d.

Final / As built drawings execution/construction Operation/Maintenance manual, vendor data

No. of Copies 6 6 6 6

14.2

Contract drawings and documents

14..2.1

As a part of the contract, drawings and documents shall be furnished which shall include but not be limited to the following: a. b. c.

14.2.2

Report on corrosion survey Basis of system design calculations, equipment selection criteria and sizing calculations. Bill of material, material requisitions, purchase requisitions

Detailed construction drawings (including as built drawings) a. b. c.

Sacrificial anode fabrication drawings Typical layout drawing for anode ground bed installation and connection Equipment layout, cable layout and schedules

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

Gujarat State Petronet Ltd.

d. e. f. g. h.

i. j. k. l.

Fabrication, installation and connection scheme drawing for different types of test stations. Fabrication and installation details of surge diverter, grounding cell and polarisation cell with its enclosure and housing Cable-to-pipe joint details for charged and non-charged pipelines. Incorporation of anode beds, polarisation cell, surge diverters, test stations, etc., and other relevant features of CP system design in Pipeline alignment sheet and other related drawings Identification of section of pipeline affected by interference, source of interference and details of interference mitigation arrangements provided. various measurement data at all relevant test stations with and without mitigation measures provided. Detailed commissioning report including various measurement data at all test stations, etc. Vendor drawings and catalogues, test certificates Operation and maintenance manual Miscellaneous -

15.0

MECON LIMITED

Equipment inspection and testing procedure Construction, installation procedures Field testing and commissioning procedures Procedure for monitoring of cathodic protection after commissioning Quality control procedures

INFORMATION REQUIRED WITH THE BID Bidders are advised in their own interest to provide the following information along with the bid without which the bids are liable for summary rejection. a. b. c. d. e. f. g. h. i.

Basis and calculations for preliminary system design for cathodic protection system. List of formulas to be used for detailed system design calculations. Basis of system design, design calculations, equipment selection criteria, sizing calculations along with characteristics curves for various equipments. Preliminary bill of material for major equipment. Details of the equipment/material offered along with technical leaflets/related literatures/catalogues, make, rating, type test certificates. Dimensions, weight and general arrangement drawings for each offered equipment. List of instruments, tools and tackles offered for maintenance and operation. List of recommended maintenance/operation spares. Clause-wise deviations, if any, to the specifications along with justifications.

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PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

PROJECT TECHNICAL SPECIFICATION FOR PERMANENT CATHODIC PROTECTION SYSTEM

SPECIFICATION NO.: MEC/PTS/05/62/016B

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PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

CONTENTS 1.0

SCOPE

1 OF 20

2.0

CODES AND STANDARDS

1 OF 20

3.0

SYSTEM IMPLEMENTATION

2 OF 20

4.0

CORROSION SURVEY

2 OF 20

5.0

CATHODIC PROTECTION DESIGN PARAMETERS

4 OF 20

6.0

CATHODIC PROTECTION DESIGN CRITERIA

5 OF 20

7.0

SYSTEM DETAILS

6 OF 20

8.0

INSTALLATION

11 OF 20

9.0

SHOP INSPECTION AND TESTING

12 OF 20

10.0

PACKING AND TRANSPORT

12 OF 20

11.0

FIELD TESTING AND COMMISSIONING

12 OF 20

12.0

INTERFERENCE MITIGATION

16 OF 20

13.0

CLOSE INTERVAL POTENTIAL SURVEY

17 OF 20

14.0

DRAWINGS AND DOCUMENTS

18 OF 20

15.0

INSTRUMENTS, TOOLS AND SPARES

18 OF 20

16.0

INFORMATION REQUIRED WITH BID

19 OF 20

17.0

INSTRUMENTS, TOOLS AND SPARES

20 OF 20

18.0

INFORMATION REQUIRED WITH THE BID

20 OF 20

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PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

1.0

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

SCOPE This specification defines the requirements of system design, engineering,supply of all equipment/ materials, installation, testing, disconnection of sacrificial anodes & commissioning of permanent impressed current CP System for 12 “dia X40 km long Padmala-Godhra underground gas pipelines including integration of the permanent impressed current CP system with the temporary CP system. acquisition of land for anode bed and transferring the title of land in favour of GSPL, soil resistivity survey of the selected plot, ON-OFF survey, close interval potential logging survey, DCVG survey, Pearson survey, investigations for interaction of interference problems and mitigation of the same and taking corrective action of the protection system, if found in adequate/ damaged at any location after mitigation of the same. This specification provides the basic parameters to develop a suitable permanent impressed current cathodic protection system for the underground pipelines requiring protection. All data required in this context shall be taken into consideration to develop an acceptable design and for proper engineering of the system. Compliance with these specifications and / approval of any documents submitted by contractor shall in no case relieve the contractor of his contractual obligations.

2.0

CODES AND STANDARDS The system design, performance and materials to be supplied shall, unless otherwise specified, conform to the requirements of the following latest relevant applicable specifications : BIS Specifications BS specification and codes of practice ANSI specification NFPA publications NACE publications IEC publications DNV publications IEEF publications DIN publications In case of conflicting requirements amongst any of the above standards, the publication having most stringent requirement shall be governing.

3.0

SYSTEM IMPLEMENTATION All work to be performed and supplies to be effected as a part of contract shall require specific approval of owner or his authorised representative. Major activities requiring approval shall include but not limited to the following :

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PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

a) b) c) d) e) f) g) h) i)

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Corrosion survey data interpretation report and plot plans for land acquisition. Conceptual system design. Basic engineering package. Purchase requisition for major equipment and vendor approval. Detailed engineering package. Field testing and commissioning procedures. Procedures for interference testing and mitigation. Procedure for ON-OFF survey/ CPL survey/DCVG survey/Pearson survey As built documentation

4.0

CORROSION SURVEY

4.1

Soil resistivity survey at impressed current anode ground bed plot

4.1.1.

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 resistivitys 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/ basement. The number of subplots at each ground bed plot may vsary from six to ten. The exact number of sub-plots etc shall be decided at site in consolation with OWNER/ OWNER’s representative.

4.1.2

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.

4.1.3

One or more ground bed plots may be required to be selected and surveyed at each CP station to form a suitable ground bed.

4.2

Topographic Surveys Cathodic protection stations consisting of anode ground bed, CP power supply equipment etc. alongwith all associated cabling upto pipeline and any other related equipment and accessories for CP stations shall be demarcated on the ground. Ground plots so demarcated shall be surveyed for all other topographical and cadestral features and topo- sheets shall be developed by the CONTRACTOR which should be suitable for use in land acquisition etc.

4.3

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/ vicinity. Client shall provide assistance for liaison work to the extent possible.

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PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

i) ii) iii) iv) v) vi) vii) viii)

ix) x) xi)

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Route and types of foreign services / pipeline in and around or crossing the right of way (including those existing and those which are likely to come up during contract execution). Diameter, wall thickness, pressure, soil cover, and coating scheme used in case of pipelines. Details of the existing cathodic protection system protecting and services i.e. location, rating, type of protection, anode beds, test station locations and their connection scheme. Remedial measures existing on foreign pipeline/ services to prevent interaction. Graphical representation of existing structure/ pipe-to-soil potential records, T/R unit current / voltage readings. Possibility of integration / isolation of CP systems which may involve negotiations with owners of other services. Information on existing and proposed DC/AC power sources and system using earth return path in the vicinity of the entire pipeline route such as HVDC substations, fabrication yards with electric welding etc. 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 and the track to soil potential measurement using Cu to CuSo4 half cell after tracks in use. Crossing or parallel running of any existing or proposed HT AC/DC overhead power lines alongwith details of voltage, AC/DC type etc. Voltage rating, phases, sheathing details of underground power cables along ROW or in its vicinity. Any other relevant information that may be needed in designing and implementation proper protection scheme for the proposed pipeline.

The 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. 4.4

Report On completion of all field work, a report incorporating all the results generated from surveys and details of additional data collected shall be furnished. The report shall also contain detailed interpretation of survey results and resistivity data enclosed, probable interference prone areas 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. The soil resistivity values shall be plotted on semilog graph sheets.

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PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

5.0

CATHODIC PROTECTION DESIGN PARAMETERS

5.1

Protection current density range : i)

MECON LIMITED

Pipeline with Polyethylene Coating Pipeline Surroundings Normal Soil Marshy Area High Resistivity Area (more than 100 ohm-mtr. Resistivity)

Minimum pipe protection current density Micro-amp./sq. mtr. * 20 35 15

The pipe to soil “ON” potential must not exceed a value more negative than (-) 1.5V. * Actual current density to be adopted shall be decided based on soil and other environmental conditions, proximity of foreign pipelines and structures and other interference areas affecting the installation. Where considered necessary for satisfactory protection of pipeline, the current density shall be suitably increased by Contractor. 5.2

Safety Factory

(SF)

: 1.3

5.3

Protection Current Density to be considered for Pipeline without Coating in Soil

(I2)

: 10 mA/m2

5.4

Service Life

(SL)

: 40 years

5.5

Type of Anode

5.6

Anode Consumption Rate

5.7

Type of Tail Cable

: XLPE Insulated/ PVC Sheathed

5.8

Size of Tail Cable

: 10mm2

5.9

Type of Anode bed

: Horizontal/ Vertical/ Deepwell

5.10

Shape of Anode for Swallow Bed System

: Sheet Steel Canistered Anode prepackaged with petroleum coke breeze

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: MMO Coated Anode 2.0 mg/ Amp Titanium anode

Titanium Year

Tubular

for

Page 4 of 20

MMO

PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

6.0

Tender Document for EPC Contracts

MECON LIMITED

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

5.11

Shape of Anode for deep well anode bed

: String Anode

5.12

Current Density for Anode

5.13

Anode Utilisation Factor

5.14

5.15

Total Circuit Resistance (RC) (Anode to ground resistance, anode & cathode cable resistance & pipe to earth resistance for CP System Coating Resistance

5.16

Steel resistivity

: 2.2 x 10-5 ohm-m

5.17

Cathode Polarisation at Drainage Point (Off Potential)

: (-) 1.18 V (max.)

5.18

Cathode Polarisation at farthest Point (Off Potential)

: (-) 0.95V (min)

5.19

Pipeline Natural Potential

: (-) 0.45 V

75 Amp/m2 anode (UF)

for

MMO

Titanium

: 0.85 for centrally connected MMO Titanium tubular Anode : 0.5 - 1.0 ohm

: 10,000 ohm/m2 for normal soil 4,500 ohm/m2 for marshy area 15,000 ohm/m2 for high resistvity area

CATHODIC PROTECTION DESIGN CRITERIA Cathodic protection system shall be designed to meet the following criteria: i) ii)

The pipe to soil potential measurements shall be between (-) 0.95 V (Off) (-) 1.18 V (Off) with respect to a copper/ copper sulphate reference electrode using current interrupter installed in power supply line. 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 written approval of owner. However to use any of the criteria listed above shall solely rest with owner or owner’s representative.

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PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

iii)

7.0

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

A positive potential swing of 50 to 100 millivolts shall be considered as sufficient to indicate the presence of an interaction situation requiring investigation and incorporation of mitigation measures by the CONTRACTOR.

SYSTEM DETAILS The system shall include the following major equipment / sub-system unless otherwise specified in project specifications : CP stations TR units. Anode ground beds and anodes. Anode lead junction box. Cathode lead junction box. Permanent reference cells. Cables The detailed specification of each system and equipment shall be furnished by the CONTRACTOR. However, certain minimum requirements for the major equipment are highlighted in this document. All equipment shall be new and procured from approved reputed manufacturers. Equipment offered shall be filed proven. Equipment requiring specialised maintenance or operation shall be avoided as far as possible. Protytype equipment shall not be accepted. Make and construction of all materials shall be subject to owner’s approval. As far as possible, equipment including test stations, anode lead junction boxes etc. shall be located in safe non-hazardous areas. However, all equipment to be installed in hazardous areas shall be of flameproof type confirming to IS:2148 and suitable for gas groups IIA & IIB and temperature class – T3.

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) ii) iii)

Number of CP stations and their selected location shall ensure that these remain valid and are adequate for the full design life of the system after considering all foreseeable factors. As far as possible, the availability of nearly low resistivity areas for location of associated ground beds must be ensured while selecting the locations of CP stations. As far as possible, locations of intermediate CP stations shall co-incide with the locations of SV stations.

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PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

The proposed locations of CP stations shall be decided by the contractor based on the guidelines indicated above during detailed engineering and submitted for approval to owners/owner’s representatives. 7.2

Transformer Rectifier Unit

7.2.1

Cathodic protection transformer rectifier unit (T/R Unit) working on controlled rectification principle shall supply power for cathodic protection system. The T/R unit shall be provided at CP stations where reliable power supply is available (to be decided during detailed engineering). The T/R unit shall be filed proven. The design, internal component quality, ratings and layout of components shall ensure high MTBF and low MTTR. The T/R unit shall conform to MECON’s specification no MEC/TS/05/E9/072 and T/R unit data sheet no.MEC/DS/05/E9/23JT/072-1 The rating of T/R unit shall be decided by the contractor after survey during detailed engineering.

7.3

Anode Ground Beds and Anodes i)

Each CP station shall have an independent anode ground bed which may be of shallow or deep well construction depending upon the corrosion data collected by the contractor. Ground bed shall be located electrically remote from the pipeline. Nearest part of the anode bed shall atleast be 100 metres away from the pipeline. 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.

ii)

Anodes shall be of MMO coated titanium anode. alongwith tail cable of required length MMO Titanium Anode

-

MMO Anode Dimension Weight of Anode

-

As per manufacturer’s recommendation Recommended by manufacturer Recommended by manufacturer

Max. Recommended Current density Service Life Anode Cable

-

75 A/m2

-

Cable Length

-

40 years Single MMO Anode –10mm2 XLPE/PVC String MMO Anode – 16mm2 EPR/CSPE As required

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PADMALA – GODHARA GAS PIPELINE PROJECT Gujarat State Petronet Ltd.

7.4

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

iii)

Sheet steel anode canisters of adequate size shall be provided for each anode of selected Anode canisters shall be filled with petroleum coke breeze with a typical carbon content of 91.77%. String anode shall be used for deep well well ground bed. In case of deep well ground beds calcined fluid petroleum coke breeze with a typical carbon content of 91.77% shall be provided in the well surrounding the anodes.

iv)

Each shallow anode bed shall contain anodes with canisters positioned horizontal or vertical in the soil with suitable backfill at appropriate depth with respect to configuration horizontal or vertical.

v)

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 deepwell anode ground bed details shall include the details of anodes, deepwell casing, anode positioning, anode cable supporting, deepwell gas venting, active & passive portions of ground bed etc.

vi)

Anodes shall be supplied complete with tail cables which shall be long enough for termination on their associated junction boxes without intermediate joints. Exact lengths and termination details shall be indicated in construction drawings by Contractor.

vii)

Anode bed separation from pipeline shall be tested for interaction.

viii)

Potential gradient around the anode bed shall be within safety requirements and its effective boundary shall be defined and secured.

ix)

In case two parallel pipelines running in the same ROW. The anode ground beds of respective pipelines shall be located on the respective sides of the pipelines.

x)

The depth of deepwell anode ground bed shall be sufficient enough to reduce anode influence on incidental structures within proposed location.

Anode Junction Box i)

Depending on the size and configuration of anode ground beds, one or more anode junction boxes shall be provided at each ground bed.

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ii)

iii)

7.5

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

All cable tails from individual anodes shall be terminated onto these anode junction boxes which shall be further connected to anode cable coming from CP station power source. Junction boxes shall have sheet steel enclosure of minimum 3 mm thickness and hinged lockable shutters. They shall be weatherproof with degree of protection IP-55. Junction boxes shall have anode bus and terminal plate with adequate number of antiloosening type of identified terminals. Provision shall be made for measurement and control of individual anode current by providing suitable shunt and resistors. Anode disconnecting link shall be provided for each anode circuit. 30% spare terminals shall be provided. In case of sectionalized ground beds, an additional common anode disconnecting link for each section of ground bed shall be provided for disconnection of any section of ground bed.

Cathode Junction Box One cathode junction box shall be provided at each CP Station for Permanent Pipe to soil potential measurement circuit & cathode connection. Junction boxes shall have sheet steel enclosure of minimum 3 mm thickness and hinged lockable shutters. They shall be weatherproof with degree of protection IP-55. Junction boxes shall have cathode bus and terminal plate with adequate number of antiloosening type of identified terminals.

7.6

Permanent Reference Cells i) ii) iv) v) vi) vii) viii)

7.7

High purity copper / copper sulphate reference cells with proven high reliability shall be provided for stable pipe to soil potential measurement reference at CP stations and at computerized test station locations along ROW. Three numbers reference electrodes shall be installed at each cathodic protection station. The reference cell for high resistivity areas shall be suitable for the prevailing dry soil conditions to give maximum service life. Permanent reference cells shall be installed with backfill material. 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 subsoil water or soil shows chlorine concentration more than 300 PPM. The cable from reference cells shall be provided upto CP power source at CP stations. The cable shall be routed through cathod junction box near pipeline. The life of reference cell shall be minimum 20 years under installed condition.

Painting The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a

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Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

coat of phosphate paint and a coat of yellow zinc chromate primer. The under surface shall be free from all imperfections before undertaking the finishing coat. After preparation of the under surface, spray painting with two coats of final paint shall be done. The finished panels shall be dried in ovens in dust free atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint etc. Bidder shall furnish detailed painting procedure alongwith bids. All unpainted steel parts shall be cadmium plated to prevent rust formation. 7.8

Cables i)

ii) 7.9

Cables shall be annealed high conductivity tinned stranded copper conductor, XLPE insulated, PVC sheathed, 650/1100 V grade, armoured for Cathode/Anode / measurement cable. Unless otherwise specified in project specifications, the size of the copper conductor shall be minimum 35 sq. mm. for anode and cathode cables, 6 sq. mm. for potential measurement and reference cells, 10 sq. mm. for current measurement, 25 sq. mm. for bonding/ grounding and 10 sq. mm. for anode tail cables. The anode tail cables shall be XLPE insulated & PVC sheathed and not be armoured and length shall be sufficient for termination on anode lead junction box without any joint. PE sleeves shall be provided for unarmoured cables. The T/R unit incomer cable shall be minimum 10 sq. mm. aluminium, 650/1100 V PVC insulated, armoured, PVC sheathed.

Panel Cabling and cable glands Adequate space shall be provided inside the panel for termination of cables. Termination shall be performed using crimped lugs. Tags with cable numbers engraved on it shall be attached to each cable at both ends. Cable glands shall be double compression type of Nickel/ Chromium plated brass. The lugs shall be of tinned copper. Phases of AC power cables shall be identified with red, yellow, blue PVC adhesive material. The armour of the cables from pipeline to CP 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 one end of the cable to avoid armour carrying CP current.

8.0

INSTALLATION

8.1

Cable Laying j)

Cables shall be laid in accordance with approved layout drawings to be prepared by the contractor. No straight through joint shall be permitted in a single run of cable. Cable route shall be carefully measured and cables cut to

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ii)

iii) iv)

v) vi) 8.2

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

required length. Enough slackness in cable shall be provided near anodes to account for any settling of anode. All cables inside station / plant area shall be laid at a depth of 0.75 M. Cables outside station / plant area shall be laid at a depth of 1.5m. Cables shall be laid in sand under brick cover and back filled with normal soil. Outside station / plant area, the routes shall be marked with polythylene cable warning mats placed at a depth of 0.9 mtr. from the finished grade. In case of above ground cable installations, all un-armoured CP cables shall be laid in GI conduits of sufficiently large size. All underground unarmoured 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 with adhesive tape or equivalent as required. RCC or GI pipes of proper size shall be provided for all underground cables for road crossings. Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and final take-off to equipment is facilitated.

Cable to pipe connections All cable connections to the pipeline either charged or non charged including charged foreign pipelines shall be made by PIN- brazing process.A suitable water proof sealing system of the cable connections shall be made which will be compatible with parent coating system of the pipeline afte PIN- brazing process.

8.3

Ground bed fencing A chain link fencing shall be provided around each ground bed location as per job requirements.

8.4

Civil Works All civil works as per enclosed specifications associated with the complete cathodic protection system are included in scope of contractor. This shall include providing cable trenches and foundations for all equipment, outdoor T/R units, anode lead junction boxes, all test stations, polarisation cells, etc.

9.0

SHOP INSPECTION AND TESTING i)

ii)

Owner/ Owner’s representative shall visit the works during manufacture of various equipment to assess the progress of work as well as to ascertain that only quality raw materials are used. All necessary assistance shall be provided by contractor and vendors during such inspections. The minimum testing, inspection requirements for all components / equipment shall conform to requirement as defined in the relevant codes and standards.

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iii)

iv)

10.0

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Detailed inspection and testing procedures alongwith the acceptance criteria shall be prepared by contractor for Owner’s approval. Test certificates including test records, performance curves etc. shall be furnished with sufficient information to identify the equipment to which the certificate referes and must carry project title, owner’s name and purchase order details etc. Owner reserves the right to ask for inspection of all or any item 7under the contract and witness all tests and carryout inspection or authorise his representative to witness tests and carryout inspection. Contractor shall notify the Owner/ Owner’s representative atleast 20 days in advance giving exact details of tests, dates and addresses of locations where the tests would be carried out.

PACKING AND TRANSPORT All equipment / material shall be protected for inland/marine, transport, carriage at site and outdoor storage during transit and at site. All packages shall be clearly, legibly and durably marked with uniform block letters giving the relevant equipment / material details. Each package shall contain a packing list in a water proof envelope. Copies of the packing list, in triplicate, shall be forwarded to owner prior to despatch. All items of material shall be clearly marked for easy identification against the packing list.

11.0

FIELD TESTING AND COMMISSIONING

11.1

System Testing at Site The contractor shall furnish the detailed field testing and commissioning procedures for approval. Field tests as per these approved procedures 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)

ii)

iii) iv)

Contractor shall carryout pre-commissioning operation 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 performances tests shall be carried out by contractor. Before the electrical facilities are put into operation, necessary tests shall be carried out to establish that all equipment, devices, wiring and connection have been correctly installed, connected and are in good working condition as required for the intended operation. Owner/ Owner’s representative may witness all tests. At least one week’s notice shall be given before commencing the tests. All tools, equipment and instruments required for testing shall be provided by contractor.

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v)

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

Generally, the following minimum tests must be carried out and recorded in proformas given in subsequent clauses : Checking

a) -

MECON LIMITED

:

Inspection

:

Testing

:

Visual inspection, comparison with drawings and specifications. Detailed physical inspection, if necessary, by taking apart the component parts. Simulation tests of equipment to determine its operational fitness.

Cables Cable no. Voltage grade. Conductor cross section Continuity check Voltage test Insulation resistance values between each core & earth, between cores.

All cables shall be tested by 500V megger. b) -

Reference Cell Location Potential reading Type of cell

c)

Insulating Joint Insulation resistance across the joint shall be checked before and after charging the pipeline by means of insulating joint tester. Pipe to soil potential of both protected and non-protected sides of the insulating joint shall be checked before and after energisation of CP system.

d) -

Surge Diverter Location / identification number Rating Check for healthyness

e) -

Polarisation Cell Location / Identification number Rating Check for electrolyte 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.

f)

Spark Gap Arrester

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11.2

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

-

Location/ identification NO Ratings Check for healthiness

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 with respect to anode voltage Total resistance of complete anode bed Mutual interference

h) -

Grounding Cell Location Type / no. of anodes Ratings

CP Commissioning Procedure A model commissioning procedure for a 2 station CP system of a pipeline is given below for general guidance. Contractor shall develop detailed commissioning procedure as per this guideline and get it approved before commencing CP system commissioning activities. i) ii) iii) iv) v) vi) vii) viii) ix)

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. The CP commissioning shall be carried out with current interrupter provided in the output of the CP TR/ ECU Unit to measure CP “ON” & “OFF” potentials. Current dissipated by each anode shall be corrected through anode lead junction box. Electrical continuity of the entire pipeline shall be verified in conformity with design. Input resistance of the pipeline at all the drainage points shall be checked and recorded. All current measuring test stations shall be calibrated and recorded. Temporary protection facilities provided (if any) which do not form part of permanent CP shall be disconnected from the system & removed unless agreed otherwise. The pipeline shall be allowed to depolarize for atleast 72 hours after switching ‘off’ the protection (if any) of all other pipelines in the common R.O.W. Before the pipeline are put on charge by switching ‘on’ any of the CP stations, natural structure-to-electrolyte potential values at all the test stations of the system shall be measured with respect to Copper/ Copper Sulphate half cell.

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x)

xi) xii)

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

CP station no. 1 shall be energised so as to achieve a maximum pipe soil potential (PSP) as specified at the test station nearest to the drainage point, and observations on either spread of protected portion of pipeline under this CP station shall be taken for PSP values pipeline current values across the cross section of the pipeline shall also be determined at all the intended test stations influenced by this station. CP station no. 1 shall now be switched ‘off’’ and CP station no. 2 shall be switched ‘on’ and measurement procedure as adopted in above step (at cl. IX) shall be repeated. All the CP stations of the system shall be switched ‘off’ and the pipelines shall be allowed to depolarize. All the 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 PSP observations shall be taken. Another complete set of PSP observations shall be taken after lines have stayed on charge for 24/ 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 hrs. Maximum drainage point protective potentials shall not be allowed to go beyond the maximum PSP values as specified, in any case. The output of all CP stations shall then be so adjusted that the sites of occurrence of least negative protective potentials are increased to (-) 1.00 V. A full set of observations shall again be taken 72 hrs. after the adjustment of potentials and the protection system shall be left in this state of operation.

xiii)

xiv)

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 polarization. More sets of observations may be advised to be taken by the Owner/ Owner's representative in any of the above mentioned steps. PSP values at each of the test stations of the existing pipelines shall be measured and plotted where existing pipelines run in parallel to the new pipeline and mutual interference situations between the pipelines shall be identified and necessary mitigation shall be carried out. 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 exceed 50 mV.

xv)

Final records of testing and commissioning including graphical representation of final structure to electrolyte potential readings shall be compiled with interpretation in consolation with owner/ owner's representative and submitted.

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xvi)

xvii)

xviii)

12.0

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

As a result of these tests, if any deficiencies are found in the system, the same shall be rectified by the contractor at no extra cost or time effect, to the complete satisfaction of Owner/ Owner's representative. Such deficiencies shall include mitigation of interference problems that may be found existing in the course of testing and commissioning. A set of PSP observations shall also be taken during the peak of the first dry season after commissioning the system into regular operation. Any deficiency found in the protection of the pipeline shall have to be rectified by the contractor at his own cost. If it is found during commissioning that the sites of occurrence of least negative protective potentials are less negative than (-) 1.00 V even after 72 hrs. of operation, then the drainage point potentials shall be increased depending upon anode ground bed currents in consolation with Owner/ Owner's representative In any case, the drainage point protective 'ON' potential values shall not exceed the PSP values specified at cl. 5.1 of this document and the pipe to soil 'OFF' potential shall not exceed a value more negative than (-) 1.18 V at any location on the pipeline. 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.

INTERFERENCE MITIGATION

12.1

Investigation 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 high voltage power lines, interference due to high voltage DC lines, electric traction etc.

12.2

Measurements including pipe to soil potentials and pipe 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 be preferably be used for long time measurements.

12.3

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.

12.4

Mitigative measures shall be provided depending upon the type of interference. These shall include installation of bond with variable resistor and diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment/ relocation (if possible)

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Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

of offending interference source, provision of electrical shield etc. depending on the type of interference. Bond with foreign pipelines / structures as a mitigation measure shall be provided where the owners of the foreign pipelines / structures have no objection. Otherwise alternative mitigatio measures shall be provided. Wherever bonding is provided for mitigaiton, the bonding resistor shall be adjusted for optimum value for minimum / no interference. Galvanic anodes installed as a mitigaiton measure shall be adequately sized for the design life specified for permanent CP system. 12.5

Where high voltage (66 KV and above) transmission lines run in parallel or cross the pipeline, the pipeline shall be grounded through polarisation cells at regular intervals to ground any surge on the pipeline that would appear in case of transmission line faults. Alternatively, grounding could also be done with galvanic anodes (Magnesium or Zinc depending on pipeline voltage) at the discretion of the owner. These grounding installation shall be provided wherever transmission lines run within 25 mtr. of the pipeline. A.C. voltage measurements shall also be made on the pipeline to find out continuous induction of voltage beyond safe limits. In such a case, the pipeline shall be grounded to ht enearest transmission galvanic (zinc or magnesium) anodes at the discretion of the owner.

13.0

“ON” –“OFF” AND CLOSE INTERVAL POTENTIAL SURVEY The contractor shall carry out a close internal potential survey over the entire length of pipeline by computerised potential logging method and identify suspected holiday spots on the pipeline coating, after the back filling has been consolidated sufficiently and CP system has stabilized. Contractor shall identify the necessary pipe coating required to be repaired. Detailed procedures for running this survey shall be submitted for approval. The close interval potential logging survey shall be carried out at approx. 0.75m intervals & both “ON & “OFF” potentials shall be measured by operating the current interrupters of CP TR unit during survey

14.0

DCVG AND PEARSON SURVEY The contractor shall carryout post commissioning surveys such as DCVG & Pearson for evaluating deficiencies on the pipeline coating & taking rerquisite corrective measures.Detailed procedures fro running the surveys shall be submitted for approval.

15.0

DRAWINGS AND DOCUMENTS

15.1

General

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16.0

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

i)

Within three weeks from the date of issue of Purchase Order, Contractor shall submit four copies of the list of all drawings / data/ manuals / procedures to be submitted for approval, identifying each document by a number and descriptive title and schedule date. This list shall be revised and extended, as necessary, during the progress of work.

ii)

All drawings and documents shall be in English and shall follow metric system. Number of copies for each submission shall be as follows unless specified otherwise : Submission

No. of copies

a)

For Review/ Approval

6 copies

b)

Drawings issued for execution / construction

6 copies

c)

Final / As-built drgs.

6 copes and one set of reproducible.

d)

Operation / Maintenance Manual, Vendor data

6 copies

Contract Drawings and Documents As a part of the contract, drawings and documents to be furnished by the contractor shall include but are not limited to the following : i) ii) iii) iv) a)

b) c) d) e) f)

Report on corrosion survey. Basis of system design and design calculations, equipment selection criteria and sizing calculations. Bills of material, material requisitions and Purchase requisitions. Detailed construction drawings (including as-built status). Separate layout drawings for each CP station showing anode- ground bed location, anode- ground bed installation details, CP station location, cable laying, ROW location. Drainage connection location, permanent reference cell locations and topographic details of the entire area. Equipment layout, cable layout and schedules. Marker drawings for cable route, anode-ground bed, drainage connection point, permanent reference cell, E/R probe, polarisation cell, pipeline grounding anodes, grounding cells, etc. Fabrication details of High Silicon cast iron canistered anode with tail cable. Fabrication, connection and installation drawing for anode-junction box. Anode- ground bed construction and installation details for horizontal anodeground bed and deep well ground bed.

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g) h) i) j) k)

l)

m) n) o) p) 16.0

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Fabrication, installation and connection scheme drawing for different types of test-stations. Fabrication and installation details of Copper/ Copper Sulphate type, Silver/ Silver Chloride type and Zinc type permanent reference cells, E/R probes, grounding cells, surge divertor, etc. Fabrication and installation details of polarisation cell and its enclosure/ housing. Cable to pipe joint details for charged and non charged pipelines. Incorporation of corrosion survey data, CP stations, test stations, anode beds, polarisation cells, grounding cells, grounding anodes, surge divertors etc. and other relevant features of CP system in pipeline alignment sheets and other related drawings. Identification of sections of pipeline affected by interference, sources of interference, details of interference mitigation arrangements provided. Various measurement data at all relevant test stations with and without mitigaiton measures provided. Detailed commissioning report including various measurement data at all test stations. Vendor drawings and catalogues, test certificates. Operation and maintenance manual. Miscellaneous Equipment inspection and testing procedures. Construction, installation procedures. Field testing and commissioning procedures. Procedures and report on close interval potential survey. Procedure for monitoring of cathodic protection after commissioning. Quality control procedure.

INFORMATION REQUIRED WITH THE BID Bidders are advised in their own interest to provide the following information alongwith the bid offer without which the bids are liable for summary rejection: a) b) c) d) e) f)

Basis and calculations for preliminary system design of permanent cathodic protection system. List of formula to the used for detailed system design calculations, with brief explanations.1 Basis of system design, design calculations, equipment selection criteria, sizing calculations alongwith characteristic curves for various equipments. Preliminary bill of material for major equipment. Details of the equipment/ material offered along with technical leaflets / related literature / catalogues, make, rating, type test certificates etc. Dimensions, weight and general arrangement drawings for each offered equipment.

1

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g) h) i)

Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

List of instruments, tools, and tackles offered for maintenance and operation. List of recommended maintenance / operation spares. Clause wise deviations, if any, to the specifications alongwith justifications.

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PROJECT TECHNICAL SPECIFICATION FOR TRANSFORMER RECTIFIER UNIT FOR CATHODIC PROTECTION SYSTEM

SPECIFICATION NO. MEC/PTS/05/E9/072

MECON LIMITED DELHI - 110 092

CONTENTS Sl.No.

Description

1.0

SCOPE

2.0

STANDARDS

3.0

GENERAL REQUIREMENT

4.0

DRAWINGS AND DOCUMENTS

5.0

INSPECTION

6.0

ANNEXURES 1) 2)

DATA SHEETS APPROVED VENDORS FOR COMPONETS

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

1.0

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

SCOPE The intent of this specification is to define the requirements of Transformer Rectifier Unit for Cathodic Protection System for underground pipelines.

2.0

STANDARDS

2.1

In general the equipment covered by this specification shall unless otherwise specified be in the line with the requirement of any of the latest applicable standards of: a) b) c) d)

Bureau of Indian Standards (BIS) British Standard Institution (BSI) American Standard Institution (ANSI) International Electroc Technical Commission (IEC)

2.2

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

3.0

GENERAL REQUIREMENTS

3.1

Constructional Features a) Sheet steel clad, floor mounted, freestanding design. b) Minimum sheet steel thickness shall be 2mm (3mm for out door application). c) IP-55 for Outdoor type (dust & weather proof) as specified in MR/ Location. d) Assembled on base channel of minimum height 50mm and 2.5mm thickness. e) Zinc bichromated and passivated hardware. f) Suitable lifting arrangement. g) Cable entry from bottom, 2mm thick removable gland plates. h) Panel designation with screwed nameplate shall have letter not less than 2.5mm high. i) Device identification on front door and inside the panel shall be of non-rusting metal. j) All metal parts of the panel to under go surface treatment that includes cleaning, chemical degreasing, pickling in acid, cold rinsing, phosphating and passivating followed by spraying with two coats of epoxy based primer and two coats of epoxy based paint of approved colour & shade.

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k) l) 3.2

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Natural cooled dry type. Space heater with necessary thermostat and panel illumination shall be provided in the Transformer Rectifier Unit.

EQUIPMENT DESCRIPTION The TR unit shall be complete with following main section: -

3.2.1

Transformer and input controls. Rectifier and filter. Out put protection. System controls. Controls, indication and metering Transformer and Input Controls The transformer shall be natural cooled, class-F insulation, and dry type with separate primary and secondary windings. An intermediate earth screen shall be provided between primary and secondary windings. Transformer shall be vacuum impregnated with epoxy varnish and backed. Unless otherwise specified transformer shall have primary with tappings for ± 2.5%, ± 5%.

3.2.2

A moulded case circuit breaker with thermal over load and short circuit release shall be provided at the input of the transformer and shall also serve as power ON/ OFF switch.

3.3

Rectifier and Filters

3.3.1

The rectifier shall be made of thyristors and diodes as basic components. The rectifier shall be full wave and fully controlled type. The current rating of thyristors and diodes shall be at least two times the nominal load current and voltage rating shall be sufficient to coordinate protection with lightning arrestor provided at the output. Shunt Zeeners/ 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. The rectifier elements shall have protection against high dv/ dt and di/ dt.

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3.3.2

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Adequate filtering shall be provided on the DC output of the rectifier to limit the ripple content to less than 5% at rated output. The rectifier system shall be of natural air-cooled type.

3.3.3

For TR units with multiple output circuits, each output circuit shall have independent rectifier and filter fed from separate secondary windings of the transformer.

3.4

Output Protection MCB having thermal over load shall be provided on both the terminals of the output mainly for output isolation purpose. A lightning arrestor rated for 10 KA impulse current discharge capacities and rated voltage, maximum spark over voltage rating suitable to protect the TR unit against lightning surges. For TR units with multiple output circuits each output circuit shall have independent protections.

3.5

System Controls

3.5.1

The TR unit shall have two distinct modes of operation (independent for each output circuit) as below: a)

Manual Mode (Automatic Voltage & Current Control Mode) In manual mode the output voltage of TR unit shall be continuously adjustable over the entire rated output voltage range. The set output voltage (VOS) shall remain constant irrespective of output current. Current limit feature shall be provided in this mode of operation. The current limit (IPS) shall be continuously adjustable from zero to rated output current.

b)

Auto Mode In this mode operation the output of the TR unit shall operate in an external closed loop with pipe-to-soil potential (PSP) in feed back loop. The TR unit shall adjust the output voltage so that the PSP as measured by reference cell always remains equal to the set potential.

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Page 3 of 6

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

The set potential (Vps) shall be continuously adjustable over the specified range. The unit shall be designed to operate with the number of reference cells as specified in data sheet. The TR unit shall automatically select the lowest reference cell having less negative potential than the others and use the same for auto control (e.g. (-)0.85 V is less negative than (-)0.95 V) In case of open circuit or short circuit potential being less negative than a minimum set potential (Vrs) for the controlling reference cell, the TR unit shall sense these conditions as reference cell failure and shall automatically switch over to the other healthy reference cell for control. Should a fault occur in all the reference cells, the output current of the TR unit shall adjust automatically to a preset value (Vps), which shall be adjustable. In no case shall the maximum PSP be allowed to exceed the specified maximum potential in any combination of circumstances. (The maximum potential is the maximum PSP measured by any of the connected non-faulty ref. cell). 3.5.2

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).

3.5.3

The output regulation for no load to full load variation with input voltage variation from max. to min. shall be better than ±0.5% through out the range of output voltage and over the specified ambient temperature variation.

3.5.4

The TR unit shall be suitable for grounding of positive terminal of the output.

3.6

Controls, Indication and Metering

3.6.1

Followings controls shall be provided on TR units front door. a)

On/ Off controls for input through MCCB.

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Page 4 of 6

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

3.6.2

b)

On/ Off controls for output through MCB.

c)

Auto/ Manual Selector switch.

d)

Potentiometers for VOS, VPS and IPS settings

MECON LIMITED

Followings controls shall be provided inside the module: a)

3.6.3

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

Potentiometer for Vrs, Vpm and Vpn settings.

TR units shall have following indicating lights : a)

TR unit On/ Off.

b)

Reference cell controlling (number of lamps same as number of reference cells).

c)

Reference cell faulty (number of lamps same as number of reference cells).

d)

Pipeline over protected.

e)

Pipeline under protected.

f)

Auto-mode failure.

It shall be possible to switch-off all the indication lamps by a single switch. 3.6.4

Followings metering (Digital type) shall be provided on the TR unit : a)

Output voltage.

b)

Output current.

c)

Voltmeter to measure PSP (Set and actual through a selector switch for all the reference cells).

d)

Input voltage and current.

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Page 5 of 6

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

3.6.5

For units having multiple output, each output circuit shall have independent controls, Indication and metering.

4.0 4.1

DRAWINGS AND DOCUMENTS The following documents shall be submitted alongwith the offer: 1 List of Deviation – no deviations are allowed. a) b) List (break-up) of two years operation and maintenance spares. c) List of special tools and tackles required. d) Block diagram of TR system offered. e) TR Panel dimensions.

4.2

The following drawings shall be submitted for approval within 2 weeks of award of contract: a) GA b) Schematic c) Bill of Material d) Wiring diagram for reference

4.3

Final drawings, test certificates, operation & maintenance manual, erection and field-testing procedure shall be submitted alongwith despatch of equipments.

5.0

INSPECTION Inspection and testing of equipment shall be carried out by the Owner/ Consultant at the works of the contractor on final product to ensure conformity of the same with the acceptable criteria of technical specification, approved drawings and reference national/ international standards.

5.1

The contractor shall submit Quality Assurance Plan (QAP) for respective equipments within 3 weeks of award of contract. QAP shall be prepared and furnished by the contractor in MECON Form No. 11.20(4.4). F-10 alongwith their internal in process quality checks.

5.2

Temperature Rise (Heat Run) Test shall be conducted on one unit of each rating.

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Page 6 of 6

ANNEXURE-I 1.

Purchaser’s specification no

:

MEC/PTS/05/E9/ 072

2.

Type

:

3.

AC Input voltage

:

IP-42, Floor mounted,Indoor Type Air Cooled 240V± 10%,3 phase,50 Hz± 5%

4.

AC Input Current

:

To be indicated by Vendor

5.

KVA Rating of Transformer

:

To be indicated by Vendor

6.

Rated Output Voltage (+ve earthed)

:

To be indicated by Vendor

7.

Rated Output Current

:

To be indicated by Vendor

8.

Number of output circuits

:

To be indicated by Vendor

9.

Modes of Operation

:

a) Auto Ref. b) AVCC c) Manual mode

10.

Number of reference cell for contro

:

Three

11.

Derating factor for transformer

:

50% excess current capacity

12.

Derating factor for diodes/ SCRs

:

13.

Ripple & Hum

:

14.

Pipe to soil potential setting range (Vps) :

0 to (-) 2500 mV,

15.

Minimum set potential range (Vrs)

(-)0.4 V to (-)1 V

16.

Maximum pipeline potential range (Vpm):

(-)1.2 V to (-)2.5 V

17.

Minimum pipeline potential range (Vpn) :

(-)0.7 V to (-)1.0 V

REV NO.

DATE

DSGN

NAME S.A

DRWN

S.A

APPROVED

ZONE REVISION DATE 23/11/06

DESCRIPTION

:

Voltage-300 % factor of safety Current-400 % factor of safety Less than 5 % at rated load

BY

APPD REFERENCES

CHKD DKP

DATE 23/11/06

DRG. NO.

CLIENT:Gujrat State Petronet Ltd.

MECON LIMITED

PROJECT:PADMALA-GODHRA GAS PIPELINE PROJECT DATA SHEET FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

SCALE : NTS

Sheet 1 of 5

DATA SHEET NO.:MEC/DS/05/E9/23JT/072-01

REV 0

18.

Full Load efficiency of Rectifier

:

More than 75 %

19.

Full Load efficiency of Transformer

:

More than 95 %

20.

Full Load Power factor

:

Not less than 0.8 lagging

21.

Peak Inverse Voltage

:

22.

Insulation level

:

Diode : 1200 V min. SCR : 1200 V min. 2 KV for 1 minute

23.

Filtering Circuit

:

LC Filter

24.

DC Voltage Regulation

:

±0.25 V

25.

DC Current Regulation

:

±0.5 Amp

26.

PSP Voltage Regulation

:

Better than ±15 Mv

27.

Input Fault Level

:

10 KA (for 1 second)

28.

Protection

REV NO.

DATE

DSGN

NAME S.A

DRWN

S.A

APPROVED

ZONE REVISION DATE 23/11/06

:

DESCRIPTION

a) Lightning arrestor on AC & DC sides. b) 2 pole MCB In AC input & DC output c) HRC fuses in input supply lines and in each DC leads. d) Surge supressors on input, output and across each diode & SCR. e) Adjustable current limit,overcurrent and short circuit protection.

BY

APPD REFERENCES

CHKD DKP

DATE 23/11/06

DRG. NO.

CLIENT:Gujrat State Petronet Ltd.

MECON LIMITED

PROJECT:PADMALA-GODHRA GAS PIPELINE PROJECT DATA SHEET FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

SCALE : NTS

Sheet 2 of 5

DATA SHEET NO.:MEC/DS/05/E9/23JT/072-01

REV 0

29.

Scada

Monitoring

Facility

30. Current Interruption Facility

:

:

Followings signals/contacts shall be provided: a) Isolated 4-20 mA analog signal for the following i) P.S.P. ii) DC output voltage iii) DC output current b) Potential free digital contacts for the following C.P. faults i) Pipeline under protected ii) Pipeline over protected iii) All ref. fail. iv) TR Unit in AUTO REF mode v) TR Unit in Manual/ AVCC mode vi) AC input supply fail To be provided by means of a built-in current interruptor & microprocessor based synchronisable digital timer with real time clock & ON/OFF time display.The timer will have facilty fro adjusting the ON time & OFF time from 0-999 sec.by means of digital setting facilty.Timer will have START/STOP facility through local key pad or through remote potential free contacts.The timer will have facility for Synchronisation to Master Timer or smilar Timer in another unit.Facility for interconnection of an external timer, a removable bypass link will be provided for bypassing the interrupter contactor contacts.The timing error shall be less than 5 parts per million.

REV NO. DATE ZONE DESCRIPTION BY AD REVISION REFERENCES

DRG. NO.

31.

Meters

: 1) DigitalMeters(Three&HalfDigits)for a) AC input voltage and current b) DC output voltage and current c) Reference voltage (P.S.P.) 2)

32.

Alarm & Indication

33.

Reference Electrode

34.

Reference Fail Safe Features

REV NO.

DATE

DSGN

NAME S.A

DRWN

S.A

APPROVED

ZONE REVISION DATE 23/11/06

:

a) b) c) d)

Mains on (visual) DC output on (visual) DC supply fail (Audio) Structure/ pipe under protection (Audio & Visual) e) Structure/ pipe overprotection (Audio & Visual) : Cu CuS4 Automatic Reference Selector logic shall be provided to automatically select the lowest (least protected)reference signal out of three reference signal out of three reference signal fed to the unit simultaneously.Facility shall also be provided to select one out of three ref Electroded by means of a Manually Operated Reference Selector switch. :

DESCRIPTION

Analog Meters (96 X 96 mm) a) AC input voltage & current

In the event of failure of all the Reference Electrodes,DC ouptput voltage of the unit will get set to a preset value.This preset valut is adjustable from 0 to rated value.

BY

APPD REFERENCES

CHKD DKP

DATE 23/11/06

DRG. NO.

CLIENT:Gujrat State Petronet Ltd.

MECON LIMITED

PROJECT:PADMALA-GODHRA GAS PIPELINE PROJECT DATA SHEET FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

SCALE : NTS

Sheet 4 of 5

DATA SHEET NO.:MEC/DS/05/E9/23JT/072-01

REV 0

35.

Control Element

36.

Shade for final paint

:

The DC output will be controlled using latest solid state SCRs.This SCR will be controlled by the commands from the control ckt.All the electronic ckt. will be assembled on plug in type control cards. : RAL 7032

37.

Guaranteed Technical Particulars

:

37.1

Efficiency (Better than 75% on Full Load):

At At At At At

37.2

Voltage regulation (from zero to 100% : load variation and throughout the output voltage range) Better than ±0.25V

(Manual mode) (Auto mode)

37.3

PSP Regulation (Better than ±15 mV)

*

37.4

Output ripple at full load : current (less than 5% RMS):

* *

10% Load 25% Load 50% Load 75% Load 100% Load

At 10% output voltage At 100% output voltage

* * * * * * *

Note: All pipe to soil potentials (PSP) measured/ set values specified are w.r.t. copper-copper sulphate half cell. •

To be furnished by Vendors alongwith the offer.

REV NO.

DATE

DSGN

NAME S.A

DRWN

S.A

APPROVED

ZONE REVISION DATE 23/11/06

DESCRIPTION

BY

APPD REFERENCES

CHKD DKP

DATE 23/11/06

DRG. NO.

CLIENT:Gujrat State Petronet Ltd.

MECON LIMITED

PROJECT:PADMALA-GODHRA GAS PIPELINE PROJECT DATA SHEET FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

SCALE : NTS

Sheet 5 of 5

DATA SHEET NO.:MEC/DS/05/E9/23JT/072-01

REV 0

ANNEXURE-II ACCEPTABLE MAKES FOR COMPONENTS Material

Make

Contactors

:

Siemens/ L&T/ BCH/ Telemechnique

Moulded Case Circuit Breaker

:

GE/ Cromption/ L&T

Miniature circuit breaker

:

MDS/ Indoasian/ Havell

Transformer

:

Indcoil/ Kappa Electrical/ AE

Switches, Fuses, Fuse base

:

Siemens/ L&T/ GE

PB Elements/ Indication Lamps

:

Siemens/ L&T/ Teknic/ Concord/ BCH

Selector Switch

:

EE/ Siemens/ Kaycee/ L&T

Terminals

:

Elmex/ Connect Well/ Phoenix

Meters

:

AEP/ Simco/ IMP/ GEC/ Rishab

Cable Glands

:

Commet/ Baliga / Flexpro/ Sudhir

(List of suppliers for solid state devices shall be furnished by the vendor for Owner’s approval).

REV NO.

DATE

DSGN

NAME S.A

DRWN

S.A

APPROVED

ZONE REVISION DATE 23/11/06

DESCRIPTION

BY

APPD REFERENCES

CHKD DKP

DATE 23/11/06

DRG. NO.

CLIENT:Gujrat State Petronet Ltd.

MECON LIMITED

PROJECT:PADMALA-GODHRA GAS PIPELINE PROJECT DATA SHEET FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

SCALE : NTS

Sheet 1 of 1

DATA SHEET NO.:MEC/DS/05/E9/23JT/072-02

REV 0