8484-SS8201-8010 0 SPECIFICATION SHEET JUNCTION BOXES...

SPECIFICATION SHEET

JUNCTION BOXES

8484-SS8201-8010 0

DOCUMENT NO REV SHEET 1 OF 1

0 9.6.2011 9.6.2011 ISSUED FOR ENQUIRY MANISH RBM SHREE REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD

FORM NO: 02-0000-0021F3 REV2 SS-8201Z:\8484 Engineering Consultancy Services on structural design etc at HPCL , Mumbai\electrical\rbmeena\8484 PLANT PACKAGE (ENQUIRY)\18-8484-SS8201- JB.doc All rights reserved

CLIENT : HPCL, MUMBAI PROJECT : LPG BOTTLING PLANT , ANANTAPUR PLANT : - LPG BOTTLING PLANT ISSUED FOR : PROPOSAL ENQUIRY ORDER FINAL

GENERAL Res. Stds. BIS IEC Encl. Docs. ES 8201 Make Maker’s type Sample Required Yes No

AMBIENT CONDITIONS Temp. Max. / Min. / Design Ref. 45 / 15 / 45 OC Rel. Humidity 100% Alt. Above Sea Level <1000M ATMOSPHERIC

POLLUTION Dusts Dusty Vapours

Area Safe Hazardous Hazardous area classification Zone Encl.Gr. Temp. Class

Location Indoor Outdoor TESTS Routine Type Others : As per agreement

BASIC DATA Item 240V, 1 Ph., 50Hz,HOSE PROOF JUNCTION BOX Quantity 19 Nos. Rated Voltage 240V + 10% Rated Frequency 50HZ + 5% Rated Current 16A No. of Phases & Wires 1 PHASE, 3 WIRE Application INDOOR USE Material of Enclosure CAST ALUMINIUM(LM-6) Shape of Enclosure CIRCULAR Degree of Protection IP-55 Addl. Degree of Protection - Type of Cover SUITABLE FOR ABOVE No. of Outlets 4

PAINTING Type EPOXY ELECTROSTATIC POWDER COATING Shade 631 OF IS:5

SPARE Required REQUIRED Duration 2 YEARS

No. of Terminals SUITABLE FOR 3X2.5 SQ.MM (CU) XLPE, FRLS CABLE Cable gland DOUBLE COMPRESSION NI PLATED BRASS CABLE GLAND CABLE SIZE

Incoming 3X2.5 SQ. MM (cu) XLPE FRLS Outgoing 3X2.5 SQ. MM (cu) XLPE FRLS

NOTES:-

Note:

1. 4 Nos. Double compression Ni plated brass cable gland with 2 No. Stopping plug suitable for 3x2.5sq mm(cu), XLPE FRLS cable shall be provided for each junction box

ENGINERING STANDARD ES: 8201 1

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JUNCTION BOX SHEET 2 OF 8

FORM NO: 02-0000-0021F2 REV1 All rights reserved

SECTION NUMBER

DESCRIPTION SHEET NUMBER

1.0 SCOPE 3

2.0 STANDARDS TO BE FOLLOWED 3

3.0 SERVICE CONDITIONS 3

4.0 GENERAL DESIGN & CONSTRUCTIONAL FEATURES

3

5.0 SPECIAL FEATURES FOR JUNCTION BOXES FOR HAZARDOUS AREA

5

6.0 PAINTING 5

7.0 TESTS & INSPECTION 6

8.0 PACKING 6

9.0 DRAWINGS AND DOCUMENTS 6

10.0 SPARES 6

11.0 DEVIATIONS 7

ANNEXURE - I DOCUMENTATION FOR JUNCTION BOXES 8

CONTENTS


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1.0 SCOPE

1.1 This standard covers the technical requirements of design, manufacture, testing and inspection at works and delivery in well packed condition of junction boxes.

1.2 This standard shall be read in conjunction with relevant specification sheet and other relevant references as specified their in.

2.0 STANDARDS TO BE FOLLOWED

2.1 The design, manufacture and testing of the equipment covered by this standard shall comply with the latest issue of relevant Indian standards unless otherwise specified. Equipment complying with equivalent IEC standards shall also be acceptable.

2.2 Flameproof & increased safety junction boxes shall in addition, comply with the requirement as laid down in IS: 2148 & IS: 6381 respectively.

2.3 The design and constructional features of the junction boxes offered shall also comply with the provision of latest issue of the Indian Electricity Rules and other relevant Statutory Rules & Regulations. The supplier shall, whenever necessary, make suitable modification in the equipment to comply with the above mentioned rules.

2.4 Wherever any requirement laid down in this standard differs from that in Indian Standard specifications, the requirement specified herein shall prevail.

3.0 SERVICE CONDITIONS

3.1 Ambient Conditions

These shall be as indicated in specification sheet.

3.2 System Details

The details of power supply system shall be as indicated in the specification sheet.

4.0 GENERAL DESIGN & CONSTRUCTIONAL FEATURES

4.1 The junction boxes shall be dust and weather proof and suitable for installation outdoors without extra protection. The degree of protection shall be IP-55 as per IS: 4691.

4.2 The junction boxes shall be of die cast aluminium alloy LM-6 with domed / suspension covers. As an alternative to cast aluminium, fibre glass enclosure is also acceptable if specified in specification sheet.

4.3 The casting of the junction boxes and their cover shall be pressure die cast. The casting shall be uniform and free from blow holes. All mechanical surfaces shall be free from burrs, dents and internal roughness.

4.4 All external hardware of diameter less than 8 mm shall be of stainless steel and those of diameter 8 mm and above shall be of mild steel cadmium plated or zinc


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passivated. For fibre glass enclosure Nylon PVC bolts of diameter 8 mm may be used.

4.5 The clearances and creepage distances shall be maintained inside the junction boxes as per relevant Indian standard.

4.6 The junction boxes shall be suitable for wall / structure / ceiling mounting and necessary arrangement for mounting the same shall be provided.

4.7 The junction boxes shall be provided with continuous gasket made of neoprene or synthetic rubber to prevent ingress of dust. The gasket shall be held in position in groove provided in the enclosure and shall be pressed all around uniformly by suitably shaped projection of the door. Gaskets simply glued to the surface are not acceptable.

4.8 The junction boxes housing terminal block shall be moulded type made of DMC / Fibre glass. Threaded terminals shall be made of brass (nickel plated or tinned) and provided with two tightening threaded nuts and four washers all made of brass (nickel plated or tinned). The terminals shall have two shorting links each horizontally placed connecting three terminals.

4.9 The terminal block shall be fitted with junction boxes base by means of 2 nos. 1/2” long nickel plated brass screws.

4.10 The junction boxes shall be provided with two nos. external earthing terminals and 1 no. internal earthing terminal.

4.11 All live parts inside the junction boxes shall be insulated and shall withstand a test voltage of 2.5 KV for 1 minute.

4.12 The junction boxes shall be provided with heavy duty double compression type rolled Al cable glands to suit the cable entries.

4.13 Threaded blanking plugs shall be provided for junction boxes to plug out the entries not in use as indicated in bill of quantities enclosed.

4.14 The junction boxes shall be provided with a blank stainless steel tag plate fastened to the junction box top cover with two stainless steel screws. The plate shall be at least 25 mm wide, 100 mm long and 1 mm thick.

4.15 For flameproof / increased safety junction boxes, the manufacturer shall submit copies of test certificates from statutory authorities clearly stating that the junction boxes as well as cable glands / blanking plugs are suitable for hazardous area as indicated in the specification sheet.

4.16 15 Amp. Junction Box

4.16.1 The junction boxes shall be 4 way dome cover type.

4.16.2 The dimensions of the junction boxes with their cover and accessories shall be generally as per PDS: E-547.


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4.16.3 The junction boxes housing terminal block shall be moulded type made of DMC / Fibre glass as per Drg. no. PDS: E-557.

4.17 63 Amp. Junction Box

4.17.1 The junction boxes shall be 3 / 4 way dome cover type.

4.17.2 The minimum internal diameter of the box shall be 240 mm.

5.0 SPECIAL FEATURES FOR JUNCTION BOXES FOR HAZARDOUS AREA

5.1 For increased safety junction boxes, the terminals shall be provided with positive locking device against loosening.

5.2 The enclosure shall be in addition, of increased safety execution, Exe, as per relevant standard and shall be suitable for installation specified in specification sheet.

5.3 The junction boxes shall be liberally dimensioned in order to avoid temperature rise inside the enclosure which may damage the insulating materials or gaskets employed therein.

5.4 Cables shall enter the terminal box through increased safety compression type cable glands. From the terminal chamber to the main enclosure, the connections shall be made through proper bushings.

5.5 An additional earthing terminal inside the terminal chamber shall be provided.

5.6 The junction boxes shall be provided with Brass-Nickel plated shorted links. The terminal block shall be made of non-hygroscopic compound. Bakelite / Hylam shall not acceptable.

5.7 All screws / bolts and nuts shall be of stainless steel.

5.8 Junction boxes and cable glands must be certified by Statutory Authorities for use in the specified hazardous area. Equipments certified by overseas authorities shall obtain certificate of compliance / letter of opinion from respective statutory authorities.

5.9 Duly wired prototype samples for junction boxes shall be submitted for scrutiny as and when called for.

5.10 Type Test certificates for increased safety type junction boxes and cable glands along with blanking plugs shall be supplied.

6.0 PAINTING

6.1 Epoxy based electrostatic powder coating paint shall be provided on exterior surface while the interior of junction boxes shall be painted with anti-condensate paint. The painting shall be able to withstand corrosive atmosphere as specified in specification sheet.


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6.2 Unless otherwise specified, the finishing shade shall be grey having shade no. 632 as per IS-5.

6.3 The terminal block of junction boxes shall be painted with Red, Yellow, Blue & Black colour for phase indication.

7.0 TESTS AND INSPECTION

7.1 The junction boxes shall be routine tested as per relevant standards.

7.2 Additional tests, wherever specified, shall be carried out on one unit of each rating.

7.3 The procedure & extent of the physical checks, routine & type test shall be governed by Quality Assurance Plan mutually agreed and approved by Inspection Authority.

7.4 All the above mentioned tests shall be carried out in the presence of purchaser’s representative. In addition, the equipment shall be subjected to stage inspection at works and inspection at site for final acceptance.

7.5 These inspections shall, however, not absolve the vendor from their responsibility for making good any defect which may be noticed subsequently.

8.0 PACKING Each junction box and cable gland shall be suitably packed and protected from damage due to transportation, loading and unloading. Threaded fittings shall have plastic caps to protect the threading.

9.0 DRAWINGS AND DOCUMENTS

9.1 Drawings and documents as per Annexure-I shall be supplied, unless otherwise specified.

9.2 All drawings and documents shall have the following descriptions written boldly: - Name of client - Name of consultant - Enquiry / order number with plant / project name - Motor Code No. and Description

10.0 SPARES

10.1 Spares for operation and maintenance Item wise unit prices of spare parts for the following items, as applicable, shall be

offered along with the main equipment with recommended quantity for the period as indicated in specification sheet. i) Cable glands ii) Threaded Plug


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iii) Terminal blocks iv) Terminal bushings

10.2 Commissioning Spares Commissioning spares, as required, shall be supplied with the main equipment.

Item wise list of recommended commissioning spares shall be furnished for approval.

10.3 Any other spare parts not specified, but required, shall also be quoted along with the offer.

10.4 All spare parts shall be identical to the parts used in the equipment.

11.0 DEVIATIONS

11.1 Deviations, if any, from this standard shall be clearly indicated in the offer with reasoning.

11.2 Deviations, if any, from the data furnished in specification sheet shall be indicated therein beside the data by encircling it.


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ANNEXURE - I

DOCUMENTATION FOR JUNCTION BOXES

Documents Required (Y / N) Sl. No. Document Description

With Bid For Approval Final 1. Specification Sheet, duly completed Y Y Y

2. Technical Particulars, duly filled-in Y Y Y

3. Certified dimensional drawing, including mounting details

Y Y Y

4. Drawing showing constructional details Y Y Y

5. Illustrative and Descriptive catalogues Y N Y

6. Spare parts list Y N Y

7. FLP/Exe certificates for junction boxes and terminals conforming to IEC/ISS (CMRI, CCE, DGFASLI and BARC for terminals)

Y N Y

8. Certificate for weather proof construction

for junction boxes as per IPW-55 Y N Y

Note:

1. 4 hard copies & 1 soft copy shall be supplied with bid. 2. 4 hard copies & 1 soft copy shall be supplied for approval after order within 4 weeks

from the date of LOI. 3. 8 hard copies & 2 soft copies in CD shall be submitted as final documents prior to

despatch of the equipment. These shall be made in sets and supplied in fine plastic coated folder.

Y - Yes, N - No

TECHNICAL PARTICULARS JUNCTION BOXES

8484-TP8201-8010 0

DOCUMENT NO REV SHEET 1 OF 1

0 9.6.2011 ISSUED FOR ENQUIRY MANISH REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD FORM NO: 02-0000-0021F3 REV2 TP-8201 All rights reserved

CLIENT : HPCL,MUMBAI PROJECT :LPG BOTTLING PLANT,ANANTPUR PLANT :LPG BOTTLING PLANT ISSUED FOR : PROPOSAL ENQUIRY ORDER FINAL

GENERAL Item No. Ref. Std. Type of Junction Box Make Maker’s type

CONSTRUCTIONAL FEATURES Material of Construction Thickness of Enclosure Enclosure Protection Class Mounting Arrangement Cover Fixing Arrangement Gasketing Material External Cable Sizes Dimensions LX B X H / Dimensional Drg. Ref. No. Weight Painting Type Test Certificate No.

CABLE GLAND Type Material of Construction Make

TERMINAL BLOCK Nos. of Terminals Material Type Current Rating Fixing Arrangement Make

TECHNICAL ENQUIRY SPECIFICATION FOR

HOSEPROOF ELECTRICAL ITEMS

8484-DS-8010 0 DOCUMENT NO. REV.

Page 1 of 3

FORM NO:02-0000-0021F1 REV2 All rights reserved

Documentation schedule for 125Watt HPMV and 160 Watt MLL Blended hose proof well glass lighting Fixture.

Sl. No. Documents

With bid (No. of Copies)

After Order For Approval For Final

To PDIL

To HPCL

To PDIL

To HPCL

(No. of weeks)

To PDIL

To HPCL

1. Specification sheet - 6 - 6 8 - 10+E 2. Technical particular - 6 - 6 8 - 10+E 3. Illustration & descriptive

catalogue indicating general arrangement, light distribution, light absorption & utilisation factors, full load currents, power factors & power requirement for each type of fixture including control gear losses.

- - - 6 8 - 10+E

4. Sketch showing mounting arrangement with dimensions

- - - 6 8 - 10+E

5. Type of certificate for : a) Hose proof fixtures b) Flame proof fixtures c) Division 2 area

fixtures

- - - 6 8 - 10+E

6. Spare parts lists - 6 - 6 8 - 10+E 7. Test certificates - - - 6 8 - 10+E 8. Guarantee certificates - - - 6 8 - 10+E



8484-DS-8010 0 DOCUMENT NO. REVPage 2 of 3

FORM NO: 02-0000-0021F2 REV1 Z:\8484 Engineering Consultancy Services on structural design etc at HPCL , Mumbai\electrical\rbmeena\8484 PLANT PACKAGE (ENQUIRY)\22-8484 DS for HOSE PROOF ITEMS Rev 0.doc(e2)

Documentation schedule for hose proof Junction Boxes.

Sl. No. Documents



To PDIL

To HPCL

To PDIL

To HPCL

(No. of weeks)

To PDIL

To HPCL

1. Specification sheet - 6 - 6 8 - 10+E 2. Technical particular - 6 - 6 8 - 10+E 3. Certified dimensional

drawing , including mounted details

- - - 6 8 - 10+E

4. Drawing showing construction details - - - 6 8 - 10+E

5. Illustrative and Descriptive catalogues - - - 6 8 - 10+E

6. Spare parts lists - 6 - 6 8 - 10+E 7. Certificate for weather

proof construction for junction box as per IPW-55

8. Test certificates - - - 6 8 - 10+E 9. Guarantee certificates - - - 6 8 - 10+E



8484-DS-8010 0 DOCUMENT NO. REVPage 2 of 3

FORM NO: 02-0000-0021F2 REV1 Z:\8484 Engineering Consultancy Services on structural design etc at HPCL , Mumbai\electrical\rbmeena\8484 PLANT PACKAGE (ENQUIRY)\22-8484 DS for HOSE PROOF ITEMS Rev 0.doc(e2)

Documentation schedule for 15 A switch socket

Sl. No. Documents



To PDIL

To HPCL

To PDIL

To HPCL

(No. of weeks)

To PDIL

To HPCL

1. Specification sheet,Technical Particularscompletely filled in

- 6 - 6 8 - 10+E

2. General arrangement (GA)drawings - 6 - 6 8 - 10+E

3. Illustrative and descriptiveliterature - 6 - - - 10+E

3. Catalogue for bought outaccessories - - - - - - 10+E

4. Installation operation and maintenance manual - - - - - - 10+E

5. Descriptive catalogue - - - 6 8 - 10+E 6. Guarantee certificates - - - 6 8 - 10+E 7. Test certificates - - - 6 8 - 10+E Documentation schedule for hose proof Lighting Sub - Dist. Board.

Sl. No. Documents



To PDIL

To HPCL

To PDIL

To HPCL

(No. of weeks)

To PDIL

To HPCL

1. Specification sheet - 6 - 6 8 - 10+E 2. Technical particular - 6 - 6 8 - 10+E 3. General arrangement

drg - - - 6 8 - 10+E

4. Schematic diagram - - - 6 8 - 10+E 5. Descriptive Literature of

various equipment - 6 - 6 8 - 10+E

6. Test certificates - - - 6 8 - 10+E 7. Guarantee certificates - - - 6 8 - 10+E

Date post:	21-Mar-2018
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