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STANDARD SPECIFICATION FOR

FLAME PROOF DISTRIBUTION PANEL, PLUGS, SOCKETS, LAMPS AND LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS

DOCUMENT NO: 44LK-5100/E.02/067

Rev No.

Issue Date

Pages

Rev Description

Prepared By

Checked By VDV

Approved By VDV

15.07.08

Issued for FEED

MSJ

Jacobs
Date: 15 July, 2008 Page 2 of 9 Revision No.: 0
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DOCUMENT NO: 44LK-5100/E.02/067 STANDARD SPECIFICATION FOR FLAME PROOF DISTRIBUTION PANEL, PLUGS, SOCKETS, LAMPS AND LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS

TABLE OF CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

SCOPE BASIS OF DESIGN SERVICE CONDITIONS DETAILS OF DESIGN DRAWINGS AND DATA TESTING AND INSPECTION SPARES QUALITY ASSURANCE DEVIATIONS

3 3 4 4 8 8 8 9 9

Jacobs
DOCUMENT NO: 44LK-5100/E.02/067 STANDARD SPECIFICATION FOR FLAME PROOF DISTRIBUTION PANEL, PLUGS, SOCKETS, LAMPS AND LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS Date: 15 July, 2008 Page 3 of 9 Revision No.: 0
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1.0

SCOPE This specification covers design, construction, testing and supply of distribution boards, plugs, sockets, lamps and flameproof lighting fittings. BASIS OF DESIGN In general the equipment covered by this specification shall, unless otherwise specified, conform to the latest edition of Indian Standards/ International Standards including amendments and addenda but not limited to the following: IS: 2148 IS: 2147 IS: 8828 IS: 4064 Part 1 IS: 13346 IS: 13947 IS: 5572 Part - I IEC: 79 (Applicable parts) IEC: 309 Part-3 IS:5572 (Part 1) IS: 5571 IS: 8239 IS: 6381 IS: 8289 IS: 2206 (Part 1 to 4) IS: 8224 IS: 1913 (Part 1) IS:13408 (Part 1) Flameproof enclosure of Electrical Apparatus. Degree of protection provided by enclosure for low voltage switchgear and control gear. Specifications for Miniature Air break circuit breakers for voltages not exceeding 1000 volts. Air break disconnectors, air-break switch disconnectors & fuse combination units for voltage not exceeding 1000 V AC or 1200 V DC. General requirements for electrical apparatus for explosive gas atmospheres. LV switchgear and control gear Classification of hazardous areas (other than mines) for electrical installation Areas having flammable gases & vapours. Electrical apparatus for explosive gas atmosphere.

2.0

2.1 2.2 2.3 2.4

Plugs, socket outlet, connectors and appliance inlets for use in explosive gas atmosphere Classification of hazardous area (other than mines) for electrical installation. Guide for selection of electrical equipment of hazardous areas. Classification of maximum surface temperature of electrical equipment for use in explosive atmosphere. Construction and testing of electrical apparatus with type of protection `e. Electrical equipment with type of protection `n. Flameproof electric lighting fittings (well glass and bulk head type, fittings using glass tubes). Electrical lighting fitting for division 2 areas. General and safety requirements for Luminaires. Code of practice for the selection, installation and maintenance of electrical apparatus for use in potentially explosive atmospheres (other than mining application or explosive processing and manufacture).

Jacobs
Date: 15 July, 2008 Page 4 of 9 Revision No.: 0
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DOCUMENT NO: 44LK-5100/E.02/067 STANDARD SPECIFICATION FOR FLAME PROOF DISTRIBUTION PANEL, PLUGS, SOCKETS, LAMPS AND LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS

3.0

SERVICE CONDITIONS The, distribution panel, plugs, sockets, lamps and flameproof lighting fittings shall be designed to operate under the conditions as specified elsewhere. DETAILS OF DESIGN FLAMEPROOF DISTRIBUTION PANEL The enclosure shall be flame proof and suitable for indoor / out door installation as per requirement. A canopy shall also be supplied, if panel is located in outdoor area. Panel shall have external fixing lugs, and shall be suitable for mounting on vertical face such as wall / column, or steel pedestal. Panel shall comprise of one four-pole incoming isolating device, bus bars and required number of outgoing feeder-isolating devices equally distributed over the phases. Each outgoing shall have 2 pole isolation viz. Phase and neutral. The number of outgoing feeders, and rating of both incomer and outgoing shall be as required. Incomer, busbars, and outgoing feeder elements shall be housed in separate compartments. The separation between the compartments should be such that no flame propagation is allowed. Incomer shall have mechanical ON / OFF indication and facility for pad locking the operating handle in off position. An explosion proof cable gland for incoming cable shall be provided, suitable for cable size required. Crimping type lugs shall be provided for incoming cable. Bus bars shall be made of high conductivity copper and supported by non-hydroscopic insulators. Individual compartments shall have separate inspection covers secured by screws / bolts requiring special tools for opening. All outgoing circuit shall also have ON / OFF indicators. Terminals shall be provided in an independent compartment for connection of outgoing cables. Terminals should be anti-loosening type and suitable for 2.5 sq. mm-copper conductor or of required size such that conductor is not damaged due to over tightening. In addition to two terminals (phase and neutral) for each outgoing circuit having a three core armoured cable, provision shall be made for connection of third core to be used for earthing of the body internally. Explosion proof cable glands shall be suitable for cable size required. Explosion proof threaded plug to block unused outgoing cable entry shall be provided in numbers as required. All cable entries (incoming and outgoing) shall be so designed, that no water leaks in when panels are installed outdoor and if this cannot be met all the entries should be necessarily pointing down. Caution plates shall be provided on the inspection covers to avoid opening without isolation. Nameplates shall be provided for each outgoing circuit, and for the complete panel indicating panel number. All nameplates shall be fixed by screws and shall be made of laminated plastic with white letters on black background. The supply of the panel shall include the panel itself complete with all normal components and devices required for full and proper operation of the equipment even though such component of devices may not be stated in detail in this specification. Complete set of special tools for opening / closing of enclosure bolts / screws (2 sets) shall be supplied with these switchboards.

4.0 4.1 4.1.1

4.1.2

4.1.3

4.1.4

4.1.5

4.1.6 4.1.7

4.1.8

4.1.9

4.1.10

Jacobs
DOCUMENT NO: 44LK-5100/E.02/067 STANDARD SPECIFICATION FOR FLAME PROOF DISTRIBUTION PANEL, PLUGS, SOCKETS, LAMPS AND LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS Date: 15 July, 2008 Page 5 of 9 Revision No.: 0
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4.1.11 4.1.12

Approval certificates from CMRS and general arrangement drawings shall be furnished with the bids. All the non-current carrying metallic parts of the panel shall be inherently bonded together. Two 10 mm dia studs should be provided on the main housing for external earthing connection. Earthing terminals for outgoing circuits should also be bonded to main housing. SOCKET OUTLETS AND PLUGS Flameproof sockets shall be provided with a switch and a mechanical interlock so as to break the electrical circuit before the plug is completely withdrawn and make the circuit after the plug is fully inserted. In order to prevent accidental removal of plug from socket, the engagement & disengagement shall be by two separate and distinct movement & positions. 415 V, 63 A, three phase flameproof plug and socket meant for welding receptacle / any other three phase auxiliary loads shall be provided with either 4 pins (3P+E) or 5 pins (3P+N+E) as required. 4-pin socket shall be provided with 63 A, three-pole heavy-duty switch whereas 5-pin socket shall be provided with four pole (TPN) heavy-duty switch. Both 24 V and 240 V, 15 A single phase flameproof plug and socket shall be provided with 3 pins (2P+E). Provision shall be made so that it shall not be possible to insert 24 V plug on to a 240 V socket. Each outlet shall be provided with either a spring loaded hinged cover, or with a cap connected through metallic chain, to close the outlet when not in service. All internal power wiring shall be done with 660 V grade PVC insulated copper wires of suitable size. Stud type terminals of suitable size shall be provided for all outgoing and incoming cables. All sockets shall be suitable for two cable entries with looping facility and shall be provided with two flameproof double compression brass cable glands and one flameproof brasssealing plug per socket to seal the unused cable entry. 24 V socket outlet unit shall be provided with built in 240 V / 24 V transformer. The transformer shall be designed for 100 VA rating on continuous basis. HRC fuses shall be provided on primary and secondary side of the transformer. The transformer shall have an earthed screen between primary and secondary winding. The socket outlet unit with built in transformer, switch, fuse, internal wiring shall be flameproof as a complete assembly. All units shall be provided with one internal & two external earthing terminals. Scraping earth connection shall be provided between the plug and socket. Earth pin of plug shall first engage with earth pin of switch socket. The plug assembly shall be mechanically rugged, light and shall not unduly stress the socket or its own pins when fitted on to the socket. Each socket outlet unit shall have suitable mounting frame / bracket to facilitate installation on vertical surface of wall / structure.

4.2 4.2.1

4.2.2 4.2.3

4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10

4.2.11 4.2.12

4.2.13 4.2.14 4.2.15 4.2.16

Jacobs
Date: 15 July, 2008 Page 6 of 9 Revision No.: 0
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DOCUMENT NO: 44LK-5100/E.02/067 STANDARD SPECIFICATION FOR FLAME PROOF DISTRIBUTION PANEL, PLUGS, SOCKETS, LAMPS AND LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS

4.3 4.3.1 4.3.2 4.3.3 4.3.4

24 Volt HAND LAMPS The lamp holder of the hand lamp shall be suitable for 60 W, 24 V, 50 Hz lamp with ES cap. The metal casting of the hand lamp shall be corrosion resistant Aluminium alloy LM6. Suitable handle for carrying hand lamp and a stand type guard suspension hook shall be provided. The well glass provided shall be clear, suitable for use under conditions involving exceptional risk of mechanical damage. Mechanical strength of well glass shall satisfy requirement of IS: 2206 (FOR TYPE a GLASS). Hand lamp shall be provided with a galvanised steel wire protective cage having mesh dimension not exceeding 50 mm. Each hand lamp shall be supplied complete with 50 m length of 3 x 1.5 mm2 copper conductor, PVC insulated, metal braided flexible cable duly terminated in the hand lamp while the loose end shall be used for termination in 24 V plug. Lighting fittings for Hazardous locations Construction All equipment shall be suitable for use in outdoor open locations and shall have IP-55 degree of protection. The body of the lighting fixtures, control gearbox and junction boxes shall be cast aluminium LM-6 alloy and shall be free from frictional sparking hazard. The temperature rise of external surfaces shall be limited to applicable temperature class w.r.t. location of fitting. Lighting Fixtures The construction of lighting fixtures shall be such that replacement of lamp or any normal maintenance of fixture shall not affect their suitability for use in classified area. Glass used for lighting fixture shall be clear suitable for use under conditions involving exceptional risk of mechanical damage. Well glass lighting fixture for Zone 2 classified area shall meet requirement IS 6381. Mechanical strength of well glass shall satisfy requirement of IS 2206 (for type A glass) for flameproof lighting fixtures and IS 6381 for Div. 2lighting fixtures. All well glass fixtures shall be provided with a galvanised steel wire protective cage having mesh dimensions not exceeding 50 mm. Glass used for aviation and navigational lighting fixture shall be coloured in itself. The fixing parts of the enclosure, which is to be opened for replacement of bulb, shall be so fastened that they can be unfastened only with special tools. All fixtures shall carry a special warning inscription in English Isolate supply elsewhere before opening. All lighting fixtures which are not certified as flameproof construction but approved for use in Zone-2 are shall have approved enclosed break lamp holder and complete enclosure certified as having restricted breathing type construction. Lamp holder shall be screw type. All lighting fixtures suitable for discharge lamps shall be provided with one ET threaded entry and supplied with approved type double compression nickel-plated brass cable gland.

4.3.5 4.3.6

4.4 4.4.1 4.4.1.1 4.4.1.2

4.4.2 4.4.2.1 4.4.2.2 4.4.2.3

4.4.2.4 4.4.2.5

4.4.2.6

4.4.2.7

Jacobs
DOCUMENT NO: 44LK-5100/E.02/067 STANDARD SPECIFICATION FOR FLAME PROOF DISTRIBUTION PANEL, PLUGS, SOCKETS, LAMPS AND LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS Date: 15 July, 2008 Page 7 of 9 Revision No.: 0
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4.4.2.8

All lighting fixtures suitable for incandescent lamps shall be provided with two ET threaded entry. Two entries shall be used for looping of circuit wherever required. The fixtures shall be supplied with approved type two double compression nickel-plated brass cable glands and one threaded plug for sealing unused entry. The top of all well glass lighting fixtures shall be identically drilled/ threaded to facilitate the installation on pole / column or ceiling. All flood lighting fixtures shall be supplied with adjustable mounting arrangement both in horizontal and vertical plane.

4.4.2.9

4.4.3 4.4.3.1

Control Gear Box Lighting fixtures suitable for discharge lamps shall be provided with power factor correction capacitor, choke starter, etc. housed in separate control gearbox. The choke shall be copper wound. The complete control gear shall have power factor not less than 0.9. All components shall be of approved make. Control gearbox shall be provided with three ET threaded entry (incoming, supply to lighting fixture and for looping to other fixture/ control gear box). The control gearbox shall be supplied with approved type three double compression nickel-plated brass cable glands and one threaded plug for sealing used entry. Control gearbox shall be flameproof type. Junction Boxes The junction boxes shall be 3 way or 4-way type as required. All junction boxes for looping of single-phase lighting circuits using cables up to 4 mm2 shall be minimum 100 mm dia size. Each junction box shall be complete with requisite number of : ET threaded cable entries and with approved type double compression nickel-plated brass cable glands and one threaded plug for sealing unused cable entry.

4.4.3.2

4.4.3.3 4.4.4

4.4.5 4.4.5.1

Terminals & Wiring All equipment shall be provided with sufficient number of terminals. More than 2 wires per terminal shall not be permitted. If required, additional terminal with shorting link may be used. Each terminal for external cable connection shall be suitable for termination of 4 mm2 copper conductor or as required using crimped type tinned copper lugs. All terminals shall be of non-sparking, anti-loosening design such that they do not produce any are or spark in normal operation. Flexible wires used for internal wiring shall be minimum 1.5 mm copper conductor and connections shall be done using crimped type tinned copper lugs. Terminals shall be of approved make. All equipment on single-phase supply shall be provided with an independent earth terminal inside the enclosure for connecting the earth core of the cable and shall have facility for looping. All gaskets shall be of neoprene. Three sets of special tools required for maintenance shall be supplied free of cost.
2

4.4.5.2 4.4.5.3 4.4.6

4.4.7 4.4.8

Jacobs
Date: 15 July, 2008 Page 8 of 9 Revision No.: 0
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DOCUMENT NO: 44LK-5100/E.02/067 STANDARD SPECIFICATION FOR FLAME PROOF DISTRIBUTION PANEL, PLUGS, SOCKETS, LAMPS AND LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS

4.5

CERTIFICATION All offered equipment shall be of a type already tested by CMRI (Dhanbad) and approved by CCE for use in specified gas group locations. BIS marking is mandatory. Equivalent testing and certification of the country of origin may be acceptable for imported equipment. Type test certificates for each type of offered equipment shall be furnished along with the offer.

4.6

FINISHING & PAINTING All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The surface shall be prepared by applying a coat of phosphate paint and coat of yellow zinc chromate primer. The surface shall be made free from all imperfections before undertaking the finishing coat. After preparation of the surface, the surfaces shall be powder coated with two coats of epoxy based final paint . Colour shade of final paint shall be 632 as per IS:5. The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint etc. All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust formation. If these parts are moving elements then they shall be greased.

5.0

DRAWINGS AND DATA Drawings and Test Certificates as stipulated in Vendor Document Requirements enclosed elsewhere shall be furnished. TESTING AND INSPECTION The panel shall be tested in accordance with the relevant standards. The following tests shall be conducted on all panels: a) Insulation resistance with 500 V megger. b) High potential test at 2 KV for 1 minute between phases and phase to earth. Test certificates shall be furnished along with the equipment for the above.

6.0 6.1

6.2

CMRS test certificates along with CCE approval certificates as applicable shall be furnished for each type of fixture. All equipment shall be routine tested as per applicable Indian Standards.

6.3

During inspection, facility shall be provided for impact testing of random sample. One well glass of each fixture type from each lot shall be tested for impart strength.

7.0

SPARES The Bidder shall provide with his quotation, separate priced list of recommended operation and maintenance spares.

Jacobs
DOCUMENT NO: 44LK-5100/E.02/067 STANDARD SPECIFICATION FOR FLAME PROOF DISTRIBUTION PANEL, PLUGS, SOCKETS, LAMPS AND LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS Date: 15 July, 2008 Page 9 of 9 Revision No.: 0
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8.0

QUALITY ASSURANCE Quality Assurance shall follow the requirements of Jacobs Q.A. documents, as applicable. Q.A. involvement will commence at bid stage and follow through to completion and acceptance, thus ensuring total conformity to Purchasers requirements.

9.0

DEVIATIONS Deviations from specification must be stated in writing at the bid stage. In absence of such statement, it will be assumed that the requirements of the specification are met without exception.

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