GENERAL SPECIFICATION FOR LIGHTING FIXTURES

Page 1 of 15

INDEX

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

INTRODUCTION .................................................................................................................... 3 CODES & STANDARDS .......................................................................................................... 3 POWER SUPPLY REQUIREMENTS ......................................................................................... 4 SITE CONDITIONS ................................................................................................................. 4 TECHNICAL REQUIREMENTS ................................................................................................ 4 EMERGENCY LIGHTING ........................................................................................................ 9 LIGHTING COLUMNS .......................................................................................................... 10 PAINTING ........................................................................................................................... 12 QUALITY ASSURANCE ......................................................................................................... 12

10.0 QUALITY PLAN REQUIREMENTS ......................................................................................... 12 11.0 NAMEPLATES AND LABELS ................................................................................................. 13 12.0 TESTING AND INSPECTION ................................................................................................. 14 13.0 PACKAGING ........................................................................................................................ 14 14.0 ILLUMINATION LEVELS ....................................................................................................... 14

Page 2 of 15

1.0

INTRODUCTION
This Specification covers requirements for the design, supply, manufacture, testing & inspection of the lighting fixtures suitable for indoor & outdoor applications.

2.0

CODES & STANDARDS

Unless otherwise specified in this specification, all components and equipment shall be based on the following standard: IEC IS 1777 1970 IS 1913 International Electro technical Commission Standards Industrial luminaire with metal reflectors. General and safety requirements for Tubular Fluorescent (Part 1) Lamps. Specification for Flameproof enclosures. Construction and testing of electrical apparatus with type of protection o. Electric lighting fitting for division-2 areas. Electrical Equipment with type of protection n. Luminaries: Part-1 - General Requirements Part-2 - Constructional Requirements. Part-4 - Methods of Tests. Luminaries for street lighting. Code of Practice for the design of road lighting

IS 2148 IS 6381

IS 8224 S 8289 IS 10322-1982

IS 2149-1970 BS-5489 BS EN 40 BS 5266 BS EN 13201-2

Emergency Lighting Road Lighting

2) Certificate issued by an internationally recognized testing authority may be acceptable at the owner's decision. In case of different standards regarding equipment and materials, the

Page 3 of 15

Standard in the country where the equipment and materials are manufactured shall apply, provided they are compatible with the above standards and safety requirements.

3.0

POWER SUPPLY REQUIREMENTS

ELECTRICITY SUPPLY Supply voltage (LV) (LV) Frequency : : : 415V (+/- 10%) 240V 50Hz 5%

4.0

SITE CONDITIONS
The equipment and materials to be supplied and installed by the vendor shall be suitable for continuous and trouble free operation at 40C.

5.0 5.1

TECHNICAL REQUIREMENTS GENERAL

All accessories and materials used in the manufacture of lighting fixtures shall comply with the latest relevant applicable standards and shall be of such quality, type and design to satisfy the following. a) They shall ensure to provide adequate protection in normal use against mechanical & electrical failures. b) They shall ensure protection against electro-chemical action and exposure to the risk of injury or electric shock to the personnel. All equipments shall be suitable for use in a hot humid and tropical industrial climate in which corrosive gases/saline atmosphere and chemicals may be present. As a minimum, all equipments and enclosures in field shall be dust proof and weatherproof to IP-55 and IP-54 as per IEC-529/IS-2147 and secure against the ingress of fumes, dampness, insects and vermin. All external surfaces shall be suitably treated to provide protection against corrosive plant atmosphere. c) Lighting fixtures shall be so designed & manufactured that their performance is more reliable, safe, suit the site conditions where the fittings are to be used and efficient in operation. Screwed and other fixed connections between different components shall be made in such a way that they will not work loose by vibration or such other forces occur during normal use.

Page 4 of 15

d)

Vendor shall submit technical data and luminous intensity distribution curves together with the technical response.

e) Vendor shall guarantee and be totally responsible for all mechanical design and fabrications according to the attached all specifications, drawings and applicable standards. f) Vendor will be liable for all purchasers cost resulting from vendors errors in the vendors proposal. g) Vendor is responsible for the drawings and data of items supplied by sub-vendor, which also must comply with the requirements listed in the specifications. h) Any exceptions and deviations from the requirements of this technical information or related specifications shall be clearly indicated in writing for the purchasers approval. l) j) Vendor shall submit the completed data sheets in his proposal. Luminaires shall be confirmed to IS 10322 or BS EN 60598-1

5.2

DESIGN CRITERIA
Luminaires shall be suitable for continuous operation within the voltage range of 230 to 250 volts AC, with normal operating voltage at 240 volts and operating frequency 50 Hz. Lighting Fixtures rated 240V shall be supplied from locally mounted Distribution Board. Distribution board shall be located near the area to be served and shall be conveniently accessible for operation. The finish of the fixtures shall be such that no bright spots are produced either by direct light source or by reflection.

INDOOR LIGHTING CONSTUCTION:

a) In buildings like control room, Substation, Offices etc. fluorescent fixtures shall be used. b) All fluorescent lamp fixtures shall be complete with all accessories like ballasts, power factor improvement capacitors, lamps, starters, holders etc. c) The fitting shall be constructed from cast iron/cast aluminium, finished in grey stove enamel d) Fixtures shall have terminal blocks suitable for 2.5mm2 flexible copper conductors.

Page 5 of 15

e) The fluorescent fixtures, which are located adjacent to each other, shall require adequate terminals to facilitate loop-in loop-out connections of 2.5 mm2 stranded copper conductor. Suitable provisions for the same shall be made available. f) All fluorescent light must be energy saving type with minimum power factor of 0.85. g) All bolts, screws, spring washers, washers, nuts and exposed accessories shall be made of stainless steel materials. h) Each lighting fixtures shall be provided with earthing terminals suitable for connection to 14 SWG GI earthing conductor. i) All lighting fixtures shall be earthed using the third core of the feeding cable or third wire in circuit wiring as per respective lighting layout drawing. j) All metal for metal enclosed parts of the housing shall be suitably constructed so as to ensure satisfactory earthing continuity throughout the fixture up to the earthing terminal. k) Cables shall be supported through proper conduits or channels. l) Control of lighting in sub-station/local station shall be manually ON/OFF by means of 2-way switches.

OUTDOOR LIGHTING CONSTRUCTION:

a) The lighting fixture and enclosures shall be compatible with the environment area classification. b) In process areas High Pressure Sodium, fluorescent fixtures, HPMV shall normally be used. Preferably HPSV lamp shall be used. c) Loading Pump stations requiring high lighting intensity shall be lighted by High pressure sodium flood lights. d) Maintenance area, streets for access road in battery limit shall be lighted by high pressure sodium lights. e) In workshops HPSV High bay or Low bay fittings shall be used. f) Fluorescent fixtures shall be used on tank stairways & platforms.

Page 6 of 15

g) All sodium vapour lamp fixtures shall be complete with accessories like ballasts, igniters (if any), power factor improvement capacitors, rapid restart accessories etc. These shall be mounted as far as possible in the fitting assembly only. If these cannot be accommodated inside, then a separate metal enclosed box shall be included to accommodate the accessories and in addition with a fuse and terminal block suitable for loop-in, loop-out connections. h) The fitting shall be constructed from cast iron/cast aluminium, finished in grey stove enamel. i) Housing and cover for the fluorescent light fixture shall be of fiberglass reinforced polyester impact resistant and self extinguishing and polycarbonate protective bowl of high mechanical resistance type. j) Outdoor type fixtures shall be provided with outdoor type weatherproof enclosure IP54 or IP55 ingress of protection. k) All bolts, screws, spring washers, washers, nuts and exposed accessories shall be made of stainless steel materials. l) All lighting fixtures and control gears shall be vermin proof, breathing holes, where provided shall also be vermin proof. m) The mounting facility and conduit knock-outs for the fixtures shall be thoroughly cleaned and degreased; the fixtures shall be free from scale, rust, sharp edges and burns. n) Flood lighting fixtures shall be mounted at a sufficient elevation with minimum height of 8m and directed so as not to be objectionable or blinding to personnel. o) Lighting fixtures used for narrow space such as tower platform, shall be provided with a reflector for suitable lighting efficiency control. p) Fixtures located in hazardous area shall be Explosion Proof/Flame Proof type. q) The flame proof fittings shall with stand the internal explosion of gas or vapour for which it is certified without igniting an explosive atmosphere outside the fitting. It shall conform to IS 2206(part 1) and IS-2148 with latest amendments for flame proof well glass and bulk head fixtures and flame proof enclosures respectively.

Page 7 of 15

r) Lighting for outdoor area shall be completed with auto-off manual selector switch and automatically controlled ON/OFF by photocell 24 hour timer switches at the main distribution panel in sub-station/local station and manually controlled in Field.

s) For Road lighting the luminance or illuminance levels should not in service fall below the values specified for the lighting class selected from BS EN 13201-2, as these are maintained levels.

5.3
a)

Lamp Holders and Starter Holders

Lamp holders for fluorescent tubes shall be of the spring loaded, low contact resistance, bi-pin rotor type, resistant to wear and suitable for operation at the specified temperature, without deterioration in insulation value, contact resistance or vacuum. The ballast shall be designed to have a long service life and low power loss. b) Ballasts shall be mounted using self locking, anti vibration fixings and shall be easy to remove without demounting the fixtures. They shall be totally enclosed units.

c) The Ballasts shall be of the inductive, heavy-duty type, filled with thermosetting, insulating, moisture repellent polyester compound filled under pressure or vacuum. The Ballast wiring shall be of copper wire. They shall be free from humming. Ballasts which produce humming sound shall be replaced free of cost by the contractor.

d) Ballasts provided in all types of fitting for high-pressure mercury lamps and high pressure sodium vapor lamps shall be provided preferably with tapings of 200/220/240 V. End connections and taps shall be brought out in a suitable terminals block, rigidly fixed to the Ballast enclosure.
.

e) Separate Ballast for each lamp shall be provided in case of multi-lamp fixtures.

5.4

Reflectors:
The reflectors shall be manufactured from sheet steel or aluminium as applicable of not less as than 20 SWG thickness. They shall be securely fixed to the housing by means of positive fastening device of captive type.

Page 8 of 15

5.5

Starters:
Starters shall have bimetal electrodes and shall be of high mechanical strength. Starters shall be replaceable without disturbing the reflector or lamps and without the use of any tool; Starters shall have brass contacts and radio interference suppressing capacitor.

5.6

Capacitors:
a) The capacitors shall have bimetal electrodes and shall be of high mechanical strength. Starters shall be replaceable without disturbing the reflector or lamps and without the use of any tool; Starters shall have brass contacts and radio interference suppressing capacitor. b) The capacitors shall be suitable for operation at supply voltage as specified and shall have a value of capacitance so as to correct power factor of its corresponding lamp circuits to the extent of 0.98 lag. c) The capacitors shall be hermetically sealed in a metal enclosure.

6.0

EMERGENCY LIGHTING
Emergency lighting shall be provided wherever required in the building & open area As per BS-5266-7 Indoor emergency Lighting shall be provided at each exit door intended to be used in an emergency, near stairways, near any other changes in level, at each change of direction, at each intersection of corridors, near each piece of firefighting equipment and call point The failure of any one luminaire connected to a circuit shall not affect other luminaires connected to the same circuit. The requirements can be satisfied by means of a fuse, relay or other protective devices incorporated in each luminaire, or by protection against excessive fault currents being inherent in the design of the luminaire circuitry/components. The emergency escape route lighting shall reach 50% of the required illuminance level within 5s and full required illuminance within 60s. The ratio of maximum to minimum illuminance shall not be greater than 40:1. In areas of high risk the maintained illuminance on the reference plane shall be not less than 10% of the required maintained illuminance for that task. However it shall be not less than 15 lux & it shall be free of harmful stroboscopic effects.

Page 9 of 15

The requirement of emergency lighting fixtures shall vary based on project requirement.

7.0

LIGHTING COLUMNS
Lighting Columns shall be confirmed to BS EN 40. The lighting column height is based on both technical and economic constraints and day time appearance. The means for attaching the luminaire to its support shall be appropriate to the weight of the luminaire. The connection shall be designed to withstand wind speeds of 150 km/h on the projected surface of the assembly without undue deflection. Fixings which carry the weight of the luminaire and internal accessories shall be provided with means to prevent the dislodgement of any part of the luminaire by vibration, either in service or during maintenance.

COLUMNS FOR STREET AND FLOOD LIGHTING Street lighting/Flood lighting columns shall be octagonal or round steel columns according to BS standard, columns shall be hot dip galvanized with access to the lamp for repair and maintenance work. When the columns have a direct buried part a cable entry 0.5m below grade shall be provided.

A weather proof door with locking device shall be included in the pole or a separate terminal box shall be provided outside the pole. The terminal box shall be at 1500mm height from the ground level.

MS conduit shall be provided in side of the pole for the purpose of taking the supply from the base to the lighting unit at the top. Suitable opening shall be provided to pole at top for taking cable to flood light fitting through flexible conduit.

COLUMNS FOR HIGH MAST

The mast shall be continuously tapered of polygonal cross section. Minimum height of mast shall be 30 meters unless otherwise specified.

Page 10 of 15

The mast shall be fabricated from steel plates in suitable number of sections, telescopically jointed giving a continuous tapered profile and presenting good visual appearance. The base flange shall be provided with gaskets and high tensile anchor bolts. The bottom section shall have adequate sized opening with a hinged door to accommodate electric drive for winch, cable, plug socket, etc. The opening shall be such as to permit clear access to the above components inside the mast. The opening shall be complete with a close fitting and vermin proof door, weather protected with gaskets of durable material and provided with a heavy duty double locking arrangement.

The means of natural ventilation of the mast shall be provided. Both the inner and outer surfaces of the entire fabricated mast shall be hot dip galvanized. The hole head frame assemble shall be covered and protected by an aluminium canopy secured to the frame by stainless steel nuts & bolts. The canopy shall have suitable prevention arrangement against entry of birds etc. The mast shall have integral power tool for winch unless otherwise specified.

All fuses provided for HML system including feeder pillar, control gear etc. shall be HRC type. The mast shall have suitable earthing terminal at base compartment and these shall be suitable for connection with 40x5 mm GI strip to the plant earthing network unless otherwise specified.

The need for lightning protection should be evaluated in accordance with IS 2309 & BS 6651.

Where a structure is a continuous metal frame, it requires no air termination or down conductor. However it should be ensured that the connecting path is electrically and

mechanically continuous. The complete design of the mast and associated foundation shall be such that mast is structurally and mechanically safe.

The lantern carriage shall be of steel tubular ring type construction designed to accommodate the specified number of lighting fixtures. It shall have perfect self balancing arrangement so as to avoid swing and to prevent damage to mast surface or other installed parts, during lowering/raising operation of carriage.

Page 11 of 15

The high mast lighting shall have a minimum deign life of 25 years unless otherwise specified.

High mast lighting systems and other specialized installations using more complex, mechanical, hydraulic or electrical equipment shall additional maintenance. They should be inspected and maintained regularly in accordance with manufacturer recommendations, and depending on local conditions.

8.0

PAINTING
All surface of equipment shall be prepared and coated with manufacturer's standard finish for corrosive and high humidity atmosphere.

9.0

QUALITY ASSURANCE
All materials supplied by Vendor shall be new and comply with the specifications. When material are not specified on the specifications, Vendor shall provide such material as are fit for the purposes for which they are to be used and that have been proven to be resistant to those elements, pressures and chemicals with which they are expected, in accordance with the specifications, to come into contact.

The quality of the materials supplied by Vendor in accordance with the terms set forth in this article may be verified at any time by Purchaser.

Vendor shall comply with the following requirements of Quality Assurance and Quality Plan.

The Quality Plan shall be submitted by the vendor for review by the Client and the Purchase in accordance with the Test and Inspection Procedure.

10.0

QUALITY PLAN REQUIREMENTS

a) Vendor shall submit a detailed Quality Plan specifically developed to the requirements of this specification within twenty one (21) days of award.

Page 12 of 15

b)

This plan will integrate the practices and procedures contained in the vendors Quality Control System with the specifications and requirements. The Detailed Quality Plan will include, but not be limited to the following; I. A complete listing of Quality Control activities to be performed including with factory acceptance test, site acceptance test, etc. ii. Acceptance criteria showing specific Code, Standard and Specification references. iii. Listing of other major ordered items, the level of vendor source inspection and the extent of vendors receipt inspection. iv. Quality Control forms and reports to be used to document inspections and test performed, non conformance and corrective actions v. A quality alignment meeting with owner, the vendor may be held at the vendors manufacturing facility prior to start of fabrication. The purpose of the meeting will be to review the Quality Plan, Quality Requirements, Specification Requirements and

reference document.

11.0

NAMEPLATES AND LABELS

a) Unless otherwise specified, nameplates shall be of 316 stainless steel, and information shall be etched or embossed. b) Nameplate shall be mounted on equipment in a visible location. Consideration shall be given to mounting, so nameplate can be readily visible after installation of equipment. c) Label plates shall be engraved, 3-laminate, colored plastic. d) Non-corrosive methods shall be used to permanently and clearly identify all components. e) Nameplates shall be permanently mounted on the unit in an accessible location using stainless steel pins f) All nameplate details shall be shown on drawings and submitted for Company review and comment. g) Major equipment components shall have a permanently attached, engraved, or stamped nameplate with the following information: Name of manufacturer Date of manufacture Manufacturers serial number

Page 13 of 15

 Item tag number Capacity and Lux level

12.0

TESTING AND INSPECTION

All fittings to be tested and inspected being witness by the Purchaser or his representative.

The following tests and inspections shall be conducted by VENDOR/MANUFACTURER. Test result/certificates shall be submitted for approval by the Purchaser and/or his representative.

Test for Ingress of Dust & Moisture Visual check of workmanship finish construction and quantities Humidity test Insulation Resistance test Electric Strength test Thermal Test Resistance to corrosion

13.0

PACKAGING
The light fittings and accessories for installation shall be packed in suitable wooden crates to prevent damage during transportation.

14.0

ILLUMINATION LEVELS

No. Location 1 Control room 2 Auxiliary rooms 3 4 Outside, near entrances Process area Pumps MOVs Loading Arms Compressors Jetty Road Lighting

Lux 500 150/ 300 150

150

Page 14 of 15

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Switch rooms, including relay and auxiliary rooms Workshops and garages Tank yard Warehouses and stores Canteens (dining areas) Car parks Catering areas (food preparation and serving) Communications rooms Computer rooms Conference rooms Corridors and stairways Drawing offices First aid rooms Libraries and reading rooms Lifts Offices Plant rooms Print rooms Reception areas Recreation rooms and lounges Store rooms Toilets and locker rooms

150 250400 20 150 100 1 300 400 400 400 100 400 400 400 100 400 150 250 150400 300 150 100

Page 15 of 15