STANDARD SPECIFICATION FOR LIGHTING SYSTEM 1.0

SCOPE

The scope in this document defines the requirements for supply of equipment, materials, installation, testing and commissioning of lighting system. 2.0

CODES & STANDARDS

2.1

The equipment shall comply with the requirements of latest revisions of the following standards :

IS-5571 IS-5572 IS-8224 IS-13346 IS-13408

Guide for selection of electrical equipment for hazardous area Classification of hazardous area having flammable gases and vapours for electrical installation. Electrical light fitting for division 2 areas. General requirements for electrical apparatus for explosive gas atmosphere. Code of practice for the selection, installation and maintenance of electrical apparatus for use in potentially explosive atmospheres.

2.2

The equipment shall also conform to the provisions of Indian Electricity Rules and other statutory regulations currently in force in the country.

2.3

In case Indian standards are not available for any equipment, standards issued by IEC/BS/VDE/NEMA or equivalent.

2.4

In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern : -

3.0

Statutory regulations Data Sheets Job Specification This Specification Codes & Standards GENERAL REQUIREMENTS

The equipment shall be suitable for installation and satisfactory operation in classified hazardous locations in tropical, humid and corrosive atmosphere as prevalent in Petroleum Installations. Unless otherwise specified, design ambient temperature of 40 deg C shall be considered. 4.0

CERTIFICATION

The equipment shall have test certificates issued by recognized independent test house (CMRI/BASEEFA/LCIE/UL/FM or equivalent). All indigenous equipment shall conform to Indian Standards and shall be certified by Indian testing agencies. All equipment shall also have valid statutory approvals as applicable for the specified location. 5.0

TECHNICAL REQUIREMENTS

5.1

The enclosures of the lighting fixtures, control gear box and junction boxes shall be of cast light metal alloy and shall be free from frictional sparking hazard. The magnesium content in the alloy shall be as per IS-13346. The temperature rise of external surfaces shall be limited to 200 deg C, unless otherwise specified.

5.2

All equipment shall be suitable for use in outdoor open locations and shall have IP-55 degree of protection.

5.3

The equipment shall be provided with gaskets made of non inflammable and self extinguishing plastic material.

5.4

The enclosures shall be treated and prepared for painting with two coats of epoxy paint with final colour shale of dark admirality grey shade 632 of IS-5.

5.5

A warning inscription “Isolate power supply elsewhere before opening” shall be provided on each enclosure. The warning inscription shall be embossed or a separate warding plate with above inscription shall be fixed to the enclosure with screws. The warning plate shall be of nickel plated brass or stainless steel.

5.6

All accessories like nuts, bolts, washers etc. shall be made of stainless steel SS-304, where as the clamps and supporting brackets shall be hot dip galvanized steel. The thickness of galvanizing shall be 610 gms/m2.

5.7

All equipments on single phase supply shall be provided with an independent earth terminal with lug inside the enclosure for terminating the third (earth) core of the cable and shall have facility for looping.

5.8

A name plate shall be provided to indicate the details of testing agency (CMRI or equivalent), test certificate no. with date, statutory approval no. with date and agency (CCE/DGFASLI/DGMS), BIS license no. and date, applicable gas group etc. The name plates shall be engraved on 3 ply black white black lamicold sheets using square cutters. Black engraved Perspex sheet nameplate shall also be acceptable. Name plates shall be fixed by screws and shall not be pasted. Incase the details given above

are embossed on the enclosures, the same need not be repeated on the name plate. 6.0

LIGHTING FIXTURES

6.1

The construction of lighting fixture shall be such that replacement of lamp or any normal maintenance of fixture shall not affect their suitability for use in classified area.

6.2

Glass used for lighting fixtures shall be clear suitable for use under conditions involving exceptional risk or mechanical damage.

6.3

Well glass lighting fixture for Zone-2 classified area shall meet requirement of IS-8224. Mechanical strength of the well glass shall satisfy requirement of IS-6381 for div 2 lighting fixtures. All well glass fixtures shall be provided with a protective wire cage having mesh dimensions not exceeding 50mm x 70mm. The material of the cage shall be galvanized steel or epoxy powder coated mild steel.

6.4

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.

6.5

For lighting fixtures in Zone-2/Div-2 area, shall have approved type enclosed break lamp holder and complete enclosure certified as having restricted breathing type of construction. In case of lighting fixtures, the holder shall additionally have a spring loaded lock to hold the lamp in position and to prevent the lamp coming off loose in the holder. Lamp holder shall be Edison screw type.

6.6

The lighting fixtures having integral control gear box or to be used with incandescent lamps shall be provided with 2 nos. threaded entries and 2 nos. double compression nickel plated brass cable glands. All other lighting fixtures shall be provided with 1 no. threaded entries and 1 no. double compression nickel plates brass cable glands. The glands shall be supplied with 1 no. nickel plates brass plug for sealing unused entry. The plugs shall be supplied loose.

6.7

The top of all well glass lighting fixtures shall be identically drilled/threaded to facilitate the installation on pole/column.

6.8

The lighting fixtures for aviation purpose shall have neon-felix (cold cathode) lamp of 2 x 75 watts of red colour with transformer of suitable rating and type – A toughened glass.

6.9

All lighting fixtures shall be provided with suitable vitreous enameled or anodized aluminum internal reflector. Additionally all well glass fixtures shall be provided with an epoxy painted external reflector.

6.10

Unless until specified all fixtures shall be supplied complete with lamps, ballast, starters and capacitor as required.

7.0

CONTROL GEAR BOX

7.1

Lighting fixtures suitable for discharge lamps shall be provided with power factor correction capacitor, choke starter etc. housed in separate control box. The choke shall be copper wound. The complete control gear shall have power factor not less than 0.9.

7.2

The control gear boxes shall be provided with 3 nos. entries and 3 nos. double compression nickel plates brass cable glands. The glands shall be suitable for the specified cable size. 20% of the control gear boxes shall be supplied with 1 no. nickel plated brass plug for sealing unused entry.

8.0

JUNCTION BOXES

8.1

All junction boxes for looping of single phase lighting circuits using cables upto 4 mm2 shall be minimum 125mm diameter in size. Each junction box shall be complete with requisite no. of cable entries and double compression flameproof nickel plated brass cable gland to suit specified cable size.

9.0

TERMINALS & WIRING

9.1

The fixtures and boxes shall be provided with sufficient no. of terminals. More than 2 wires per terminal shall not be permitted. If required, additional terminal with shorting link may be used. The terminals for external cable shall be suitable as per the cable size specified. In case lugs are required for cable termination, tinned copper type lugs shall be provided.

9.2

All internal wiring shall employ 2.5mm2 660V grade, PVC insulated copper conductor wires, colour coded for phase, neutral and earth.

9.3

All terminals in increased safety/div-2 equipments shall be of non-sparking and anti-loosening design such that they do not produce any arc or spark during normal operation.

10.0

LIGHTING POLES

Lighting poles shall be fabricated from ERW steel tubular pipes of specified section, with joints, swaged together when hot and beveled on outside edges as per the standard drawing. Poles shall be coated with bituminous preservative solution on the ground portion of the outside surface. Remainder of the outer surface shall be given one coat of redoxide primer and finished with two coats of aluminium paint. The pole shall have, a marshalling box near thebottom to contain HRC fuses, a neutral link, an earth stud and terminal block. 11.0

LIGHTING INSTALLATION

11.1

The lighting layout furnished by owner will indicate the tentative locations of lighting towers. The electrical contractor in coordination with Engineerin-charge and with his approval shall finalise the location of the poles so that there is least hindrance with other equipment like piping etc.and in view to obtain maximum unhindered illumination.

11.2

All outdoor terminations should be from bottom or from side. Top entries should be avoided to avoid water entry. Cable glands to be double compression glands and gland shall be covered with PVC or rubber boot shroud.

11.3

Circuit cables in a group shall be cleated to structure by using galvanized strip clamps. Spacers and cleats shall be of required size to accommodate the cables. All hardware shall be galvanized or zinc passivated. Underground lighting cables coming above ground shall be in GI pipe which is to be extended to 300mm above FFL. Exact termination/layout of GI pipes shall be decided at site by Engineer-in-charge as per site conditions.

11.4

The cable shall be straightened after unwinding from drum. All cables shall be clamped/laid in straight run without any sag and kink.

11.5

Street lighting poles to be located on road side shall be installed at a minimum distance of 300mm from the edge of the walkway of the road.

11.6

Each pole shall be earthed at two points by connecting to the plant earth grid.

11.7

The foundation for street light pole and high mast towers are in the scope of electrical contractor.

11.8

The poles shall be numbered as per the drawings/direction of Engineer-incharge.

12.0

INSPECTION, TESTING & COMMISSIONING

12.1

For equipments, Type test certificates from CMRI or equivalent test house, applicable CCE/ DGFASLI/DGMS approval certificates and original drawings referred in type test certificates shall be submitted as required.

12.2

All equipments shall be subjected to various acceptance tests as per standards but not limited to the following :

a. b. c. d. e.

General Visual Inspection Dimensional Inspection Verification of mechanical and electrical operation Dielectric tests. Any other applicable tests like routine pressure test, static hydraulic test, thermal shock test, durability test etc. for flame proof items.

12.3

Lighting installation shall be tested and commissioned by contractor for correct illumination levels after installing fittings.

12.4

Precommissioning checks shall be carried out as below :

a. The insulation resistance of each circuit without the lamps (load) being in place shall be measured and it should not be less than 500000 ohms (Between phases, phases to neutral, phase/neutral to earth) b. Current and voltage of all the phases shall be measured at the lighting panel busbars with all the circuits switched on with lamps. If required load shall be balanced on the three phases. c. The earth continuity for all socket outlets shall be checked. d. Operation of ELCB’s shall be checked. 12.5

Contractor shall duly fill in all the above test results and submit the test reports to the Engineer-in-charge in triplicate. All lighting layout drawings shall be submitted “As Built” in three sets.

13.0

PACKING & DESPATCH

All equipment shall be divided into several shipping sections for protection and ease of handling during transportation. The equipment shall be properly packed for selected mode of transportation (i.e. by ship/rail/trailer etc). The equipment shall be wrapped in poly ethylene sheets before being placed in crates/cases to prevent damage to finish. Crates/cases shall have skid bottoms for handling. Special precaution notations such as Fragile, This side up, centre of gravity, weight, Owners particulars, Purchase details etc. shall be clearly marked on the package together with other details as per purchase order. The equipment may be stored in covered shed for long periods before installation. The packing should be suitable for such storage.