WSP ELE ES 002 00 Engineering Specification for Electrical Facilities

8/20/2019 WSP ELE ES 002 00 Engineering Specification for Electrical Facilities

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Doc. No. : WSP-ELE-ES-002WATER SUPPLY PROJECT

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PT Chandra Asri Petrochemical Tbk. ENGINEERING SPECIFICATION FOR

ELECTRICAL FACILITIESPage : 1of 24

ENGINEERING SPECIFICATION FOR

ELECTRICAL FACILITIES

0 12-Dec-2014 Preliminary MKS TKW SRL

REV DATE STATUS DESCRIPTION PRE’D CHK’D APR’D


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CONTENTS

PAGE

1. GENERAL1.1 PURPOSE 41.2 SCOPE 41.3 CODE AND STANDARDS 41.4 AMBIENT CONDITIONS 51.5 UNITS, SYMBOL, AND IDENTIFICATION SYSTEM 51.6 LANGUAGE 51.7 SCREW THREAD 5

2. AREA CLASSIFICATION 5

3. DESIGN BASIS FOR POWER SYSTEM 3.1. POWER SUPPLY AND DISTRIBUTION 63.2. RATED VOLTAGE 63.3 SYSTEM GROUNDING 73.4 VOLTAGE DROP 73.5 POWER FACTOR 73.6 FAULT CALCULATION 73.7 EQUIPMENT SIZING 73.8 EMERGENCY POWER SUPPLY 83.9 110 VOLT DC CHARGER UNIT AND STATION BATTERY SYSTEM 83.10 UNITERUPTIBLE POWER SUPPLY (UPS) 8

4. ELECTRICAAL CONTROL, PROTECTION, AND METERING SYSTEM 4.1 CONTROL SYSTEM 94.2 OVERCURRENT PROTECTION 94.3 GROUND-FAULT PROTECTION 94.4 UNDER VOLTAGE PROTECTION 94.5 TRIP AND ALARM SYSTEM 9

5. MAJOR EQUIPMENT5.1 POWER AND DISTRIBUTION TRANSFORMER 105.2 HIGH VOLTAGE SWITCHGEARS AND MOTOR CONTROLLERS 105.3 LOW VOLTAGE SWITCGEARS 135.4 MOTORS 13

6. MOTOR CONTROL

6.1 CONTROL CIRCUIT 146.2 LOCAL CONTROL STATIONS 146.3 MOTOR OPERATED VALVES 14

7. WIRING

7.1 GENERAL 147.2 TYPE OF CABLE 157.3 CABLE SIZE 157.4 GENERAL WIRING METHOD 167.5 UNDERGROUND WIRING SYSTEM 16

7.6 ABOVE GROUND WIRING SYSTEM 177.7 CABLE RACK 17


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7.8 CONDUIT 187.9 CONDUIT FITTINGS 187.10 JUNCTION BOXES (APROX. 300 mm X 300 mm AND ABOVE) AND ENCLOSURES 187.11 CABLE TERMINATION AND IDENTIFICATION 187.12 SEALING 197.13 COLOR FOR IDENTIFICATION OF CABLES 197.14 POWER OUTLET (380 V, 3 PHASE) AND CONVENIENCE OUTLET (220V, 1 PHASE) 19

8. GRONDING AND LIGHTNING PROTECTION

8.1 GENERAL 208.2 GROUNDING OF SYSTEM NEUTRALS 218.3 GROUNDING OF ELECTRICAL EQUIPMENT ENCLOSURE 218.4 STATIC AND LIGHTNING PROTECTION GROUNDING 21

9. LIGHTING

9.1 GENERAL 229.2 ILLUMINATION LEVELS 239.3 EMERGENCY LIGHTING SYSTEM 239.4 STREET LIGHTING 239.5 OBSTRUCTION AND WARNING LIGHTS 24

10. COMMUNITCATION SYSTEM

10.1 TELEPHONE SYSTEM 2410.2 RADIO COMMUNICATION SYSTEM 24

11. TESTING 24


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1. GENERAL

1.1 PURPOSE

This specification covers the general requirements for design, construction, and testing of electricalfacilities, within the battery limit of PT. Chandra Asri Petrochemical Tbk. (CAP) plant modification

1.2 SCOPE

The general requirement for the electrical facilities inside buildings such as substations, centralcontrol buildings, and other offsite buildings is not included in this specification.Electrical facilities which are supplied as component parts of a package unit are also excluded fromthis specification. For these electrical facilities, the manufacturer’s standards or practices shall be

applicable provided that they have been used, proven and comply with the codes and standardslisted 2.1 below.

1.3 CODE AND STANDARDS

1.3.1 Unless otherwise specified, the electrical design, materials and equipment shall conform to theapplicable requirements of IEC (International Electrotechnical Commission) standards. Followingnational codes and standards may be used as supplements to IEC;

France : NF, UTEItaly : CEIJapan : JIS, JEC, JEMF.R. Germany : VDE, DIN

England : BSUSA : ANSI, NEC, NEMA, IEEE, UL

1.3.2 Electrical equipment for use in classified (hazardous) location must be labeled as approved for usein that location approved equipment must be listed or certified for use in the particular hazardouslocation by a internationally recognized testing organization.

1.3.3This specification shall be used in conjunction with the following relevant engineering

specifications.

CBP-PRS-ES-001-00 “Design Basis”CBP-ELE-ES-001-00 “Intensity Of Illumination“

CBP-ELE-ES-004-00 “Motors“CBP-ELE-ES-005-00 “Transformers“CBP-ELE-ES-006-00 “Bus Duct“CBP-ELE-ES-007-00 “Storage Batteries & Charger“CBP-ELE-ES-008-00 “6 kV Motor Starter“CBP-ELE-ES-009-00 “Medium – Voltage Switchgear“CBP-ELE-ES-010-00 “Motor Control Center“CBP-ELE-ES-011-00 “Low Voltage Switchgear“CBP-ELE-ES-012-00 “Uninterruptible Power Supply System“CBP-ELE-ES-013-00 “Control Switch Station“CBP-ELE-ES-015-00 “Inspection & Test Of Electrical Equipment“CBP-ELE-ES-016-00 “Inspection Of Electrical Equipment Installation“CBP-CIV-ES-005-00 “Building , Clause 2.6 Electrical“

CBP-ELE-017-00 “Diesel Engine Generator“1.4 AMBIENT CONDITIONS


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The electrical facilities shall be designed for safe and correct function under the following ambientconditions.

(1) Altitude : 1000m or less above sea level

(2) Temperature :Ambient Temperature (dry bulb)- Maximum temperature on record 36.5

0C

- Minimum temperature on record 18.30C

- Average daily maximum temperature 31.40C

- Average daily minimum temperature 22.70C

Design temperature: Maximum

- Indoor temperature 40 deg. C- Outdoor temperature 40 deg. C

(3) Relative humidity :Average daily maximum 85%Average daily minimum 77%Annual average 80.7%

(4) Rainfall : 144 mm/day maximum

1.5 UNITS, SYMBOL AND IDENTIFICATION SYSTEM

1.5.1 The metric system shall be used for all design and engineering documents and drawings whichare listed in para.2 of measurement on the engineering specification for design basis (CBP-PRS-001-00).

1.5.2 Graphical symbols for electrical equipment shall generally be in accordance with IEC Publication60617-1 to 60617-13.

1.6 LANGUAGE

The English language shall be used for all design and engineering documents and drawings.

1.7 SCREW THREAD

1.7.1 The form of thread and diameters and associated pitches of cable glands shall be in accordancewithBS-3643.

1.7.2 In case where NPT cable entries are required in hazardous location, only approved adaptors shallbe utilized.

1.7.3 Any rigid galvanized steel conduit installation, where required, shall be NPT thread.The minimum degree of protection for the enclosures shall be IP2X as per IEC 60947-1.

2. AREA CLASSIFICATION

2.1 Area where volatile liquids, flammable gasses or combustible dusts are handled shall be classified

in accordance with the National Electrical Code (NEC) and as interpreted by API-500A.


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2.2 Area classification drawings “Hazardous Area Plan” shall be prepared to indicate the degrees ofhazard and areas.

2.3 Equipment installed in the classified area shall be suitable for the area.

3.DESIGN BASIS FOR POWER SYSTEM

3.1 POWER SUPPLY AND DISTRIBUTION

3.1.1 Power Supply (to be confirmed with network power)

Main power supply will be 20 kV, 3-phase, 50 Hz, 300 A, resistance grounded.

Frequency and voltage variation at the tie-in point shall be in accordance with standard utilitypractice; i.e., ±1% on frequency and ±5% max. on voltage.

The symmetrical fault level at the tie-in point shall be 35 kA provisionally.

3.2 RATED VOLTAGE

3.2.1 The frequency of all alternating current system shall be 50 Hz.

3.2.2 Unless otherwise specified, the electrical equipments shall be designed for operation at thenominal system voltages listed below.

Sr.

No.

Equipments Rated Voltage Nominal System Voltage

1 Motor, below 0.2 kW rating(1)

220 Volts, 50 Hz;single phase

380/220 Volts 50 Hz;3-phase 4-wire

2 Motors, 0.2 through 150 kWrating

380 Volts, 50 Hz;3-phase

380 Volts, 50 Hz;3-phase

3 Motors, above 150 kW rating 6000 Volts, 50 Hz; 3-phase 6000 Volts, 50 Hz;3-phase

4 Circuit breaker control 110 Volts DC 110 Volts DC

5 Low-voltage motor controlcircuit

110 Volts, 50 Hz;single –phase

110 Volts, 50 Hz;single –phase

6 Lighting fixtures 220 Volts, 50 Hz; single-phase 380/220 V, 50Hz

7 Instrumentation(1) UPS 110 Volts, 50 Hz;

single-phase24 Volts, DC

110 Volts, 50 Hz;single-phase24 Volts, DC

(2) General 110 Volts, 50 Hz;single-phase

110 Volts, 50 Hz;single-phase

Note(1)

: For critical service, 380 V, 3 phase, 50 Hz shall be applied.


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3.3 SYSTEM GROUNDING

3.3.1 20 kV system neutral shall be resistance grounded.

3.3.2 11 kV generator neutral shall be distribution transformer grounded.

3.3.3 6 kV system neutral shall be resistance grounded.

3.3.4 380 V/ 220 V system neutral shall be solidly grounded.

3.3.5 110 V DC system shall be ungrounded.

3.3.6 110 V AC and 24 V DC system for instrumentation shall be ungrounded.

3.4 VOLTAGE DROP

3.4.1 The maximum allowable voltage drop in percentage of the nominal system voltage shall be asfollow;

Feeders - 5%Motor feeders on full load - 5%Motor feeders during starting - 5%Lighting circuits i.e. from 380 Volt distribution board to the furthest lighting fitting - 5%

3.4.2 During starting of motor, either alone or in a group, the voltage drop on any bus shall not exceed20% of the nominal system voltage.

3.4.3 Motor terminal voltage due to starting shall be, at all times, sufficient to produce the torquerequired to accelerate the load to the rated speed.

3.5 POWER FACTOR

3.5.1 The plant overall load power factor measured at the 20 kV bus shall be 0.85 or greater at Plantnormal operation except during the large motor starting. Automatic power factor control shall notbe required.

3.6 FAULT CALCULATION

3.6.1 Fault current calculations to determine short-circuit RMS current shall incorporate all short-circuitcurrent source and all components of circuit impedance in the primary system, secondary systemand branch circuit.

3.6.2 The fault current shall be limited by design to values that can be withstood by the equipmentand/or the equipment shall be selected within the available fault currents.

3.7 EQUIPMENT SIZING

3.7.1 All transformers shall have enough capacity to cover the maximum demand of the plant normaloperation.

3.7.2 Transformer primary and secondary circuit breakers shall have a continuous rating at least equalto maximum rating of the transformer.

3.7.3 Feeder breakers or incoming breakers supplying busses shall have a continuous rating at leastequal to the adjusted maximum demand of the total load supplied from the bus. For secondary


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selective sub stations adjusted maximum demand shall be determined with the bus tie breakerclosed one incomer open.

3.74 Bus tie circuit breakers in secondary-selective substation shall have a continuous capacity equalto that of the main secondary circuit breaker.

3.7.5 In secondary selective substation the rating of each transformer shall be such that if any onetransformer is out of service the remainder transformer can meet the adjusted maximum demandof the load.

3.7.6 Cable capacity shall be calculated by taking into account the derating factors for groupedinstallation of the cables. Number and configuration of load carrying cables shall only beconsidered to determine what group derating factor to be used for cables which contain carrying

and stand-by non-current carrying cables.

3.8 EMERGENCY POWER SUPPLY

3.8.1 In order to facilitate the safe shutdown of the plant an emergency 380 V, 3 phase, 4-wire 50 Hzswitchgear shall be provided. The switchgear shall supply all the essential loads and is suppliedfrom the normal power supply and emergency generator. The normal operation is supplied fromnormal power however in case a power failure the switchgear shall automatically switch over tothe emergency generator.

3.8.2 Starting of the diesel generator shall be initiated upon failure of the normal supply detected at theemergency bus in switchgear. If the normal source of supply has not been restored and thegenerator is at acceptable voltage and frequency, then change-over to the generator source shall

be fully automatic

The generator, once started, shall continue to run until it is manually stopped or unless it is trippeddue to fault / trouble.

3.8.3 For further details refer to specification for Diesel Engine Generator CBP/ELE/017/00.

3.9 110 VOLT DC CHARGER UNIT AND STATION BATTERY SYSTEM

3.9.1 A 110 V DC charger unit and station battery system shall be provided for the followings;- Switchgear Operation and Control

3.9.2 The system shall consist of one constant voltage/current limiting rectifier, one set of lead-acidbatteries sized for 30 minutes back-up and a DC distribution panel.

3.9.3 For further details refer to specification CBP-ELE-007-00.

3.10 UNITERUPTIBLE POWER SUPPLY (UPS)

3.10.1 A 24 V DC and 110 V AC UPS system with batteries shall be provided for instrumentation, whichshall generally with the recommendation contained in IEC publication 60439 and 60146.

3.10.2 The 110 V AC UPS system shall consist of one constant voltage/current limiting rectifierconnected to the inverter, one set of lead-acid batteries, a by-pass transformer and atransfer switch providing no-break operation for load application and a distribution panel.

The 24 V DC system shall consist of one constant voltage/current limiting rectifier and one set oflead-acid batteries.


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3.10.3 The batteries shall be sized for 30 minutes operation to supply the power to instrumentation withfull voltage.

3.10.4 A separate uninterruptible power supply system with batteries shall be incorporated in the firealarm system.

3.10.5 For further details refer to specification CBP-ELE-012-00.

4. ELECTRICAL CONTROL, PROTECTION, AND METERING SYSTEM

4.1 CONTROL SYSTEM

4.1.1 Switchgears except motor controllers, shall generally be controlled manually by a ON/OFF controlswitch mounted on the front face of each switchboard.

4.1.2 The power for the control circuit shall be supplied from the 110 V DC unit with station batteries.

4.2 OVERCURRENT PROTECTIONThe overcurrent protection shall be coordinated to ensure correct sequential operation betweenincomers and feeders.

4.3 GROUND-FAULT PROTECTION

4.3.1 In the 6 kV system, each power feeder and motor controller shall be provided with a instantaneousground overcurrent relay (50G) which shall be coordinated with a time delay ground overcurrent

relay (51G) provided at the transformer neutral to ensure correct sequential operation incomersand feeders.

4.3.2 In low voltage system, each power feeder and motor control unit shall be protected against groundfault by the molded case circuit breaker (MCCB) or the fuses in each circuit, and coordinated withtime delay ground overcurrent relay (51G) provided at the transformer neutral to ensure correctsequential operation between incomers and feeders.

4.3.3 Earth leakage relay may be provided in some motor control unit to trip the molded case circuitbreaker (MCCB) or the contactor where the ground fault circuit impedance is not sufficiently smallto trip the MCCB or the fuses.

4.4 UNDERVOLTAGE PROTECTION

4.4.1 All the low voltage motors will be tripped by the electromagnetic contactor drop out whenundervoltage occurs.

4.4.2 All the high voltage motors will be provided with a DC tripping coil in the controller, and shall betripped using an undervoltage trip relay when undervoltage occurs.

4.4.3 Auto-restart of motors following a voltage dip (a brief interruption of electricity) will be provided ifrequired process reasons.

4.5 TRIP AND ALARM SYSTEM


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4.5.1 The normally de-energized (Close to Trip) system by means of relay shall generally be applied forthe electrical trip system.

4.5.2 The normally energized (Open to Alarm) system shall generally be applied to the electric alarmsystem.

4.5.3 Substation AlarmsElectrical equipment in the substation/Switchroom shall have the following alarms for annunciationin the power control room, one dry contact for each.(1) 20 kV trouble(2) 6 kV trouble(3) L.V. trouble(4) Emergency generator troble

(5) D.C. 110 V trouble(6) D.C. 24 V trouble(7) A.C. 110V UPS trouble(8) Air conditioning trouble

4.6 For further details of electrical control and protection refer to the following specification:CBP/ELE/008/00 “6 kV Motor Starter“CBP/ELE/009/00 “Medium – Voltage Switchgear“CBP/ELE/010/00 “Motor Control Center“CBP/ELE/011/00 “Low Voltage Switchgear“

5. MAJOR EQUIPMENT

5.1 POWER AND DISTRIBUTION TRANSFORMER

5.1.1 Power and distribution transformers shall generally comply with recommendations contained in IECpublication 60076.

5.1.2 Power and distribution transformers shall be of outdoor use, oil-immersed and self-cooled type.

5.1.3 Primary windings of transformers shall have four 2.5 % full capacity taps (2 above normal and 2below normal voltage) controlled by an external hand operated on load tap changer.

5.1.4 Primary and secondary terminations shall be enclosed in air insulated terminal chamber or throatssuitable for cable connections.

5.1.5 Power transformers shall be connected delta-star to provide vector group reference Dy5, and shallhave the secondary star point brought out and terminated at an insulated bushing, enclosed in aseparate cable box.

5.1.6 For further information refer to specification CBP/ELE/005/00.

5.2 HIGH VOLTAGE SWITCHGEARS AND MOTOR CONTROLLERS

5.2.1 20 kV switchgears, 6 kV switchgears, and 6 kV motor controllers shall generally comply with therecommendation contained in IEC publication 62271-200.

5.2.2 All switchgears shall be of the metal enclosed indoor type with draw-out circuit breakersmechanical interlocked to prevent moving of circuit breakers while closed.

5.2.3 All switchgears and motor controllers shall be arranged to form single assembledswitchgear with common bus-bars.


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5.2.4 All circuit breakers shall be either SF6 gas circuit breakers or vacuum circuit breakers, andoperated by solenoid, and operated by solenoid or motor charged spring type stored energymechanism. The 6 kV motor controllers shall be draw-out type vacuum contactors with currentlimiting power fuses.

5.2.5 All switchgears and motor controllers shall be provided with space heaters (panel space heaters)rated 220 V AC with thermostat control at each vertical section. Power to the space heaters shallbe supplied from the 380 / 220 V distribution panel.

5.2.6 Control power for switchgears and motor controllers shall be of 110 V DC supplied from 110 V DCdistribution panel.

5.2.7 Each motor controller shall have a space heater control circuit to provide power to the spaceheater in the motor.

5.2.8 20 kV switchgears shall be equipped with the following protection and meters;

Incomeri) Voltmeter suitably scaled and fitted with phase selector switch.

ii) Ammeter suitably scaled and fitted with phase selector switch.

iii) Inverse Definite Minimum Time Limit (IDMTL) relays for overcurrent and earth

fault protection, having instantaneous high set alarm.

iv) Transformer fault relay activated by Bucholz and oil temperature, having contacts

arranged to trip both the incomer and the feeding breaker. (only for generator

transformer incomer)

v) Transformer differential protection relay. (only for generator transformer incomer)

vi) Power factor meter

vii) KWH and kW meter

viii) Space heater manual on-off switch

ix) Facilities for inter-tripping

x) Hand reset lock-out relay to be tripped by all protective devices.

Transformer or Power Feeder

i) Voltmeter suitably scaled and provided with phase selector switch

ii) IDMTL relay for overcurrent and earth fault protection, having instantaneous high

set element.

iii) KWH and kW meter

iv) Space heater manual on-off switch

v) Facilities for inter-tripping

5.2.9 6 kV switchgear and motor controller shall be equipped with the following protection and meters;

Incomer


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i) Voltmeter suitably scaled and fitted with phase selector switch.

ii) Ammeter suitably scaled and fitted with phase selector switch.

iii) Inverse Definite Minimum Time Limit (IDMTL) relays for overcurrent and earth

fault protection.

iv) Transformer fault relay activated by Bucholz and oil temperature, having contacts

arranged to trip both the incomer and the feeding breaker.

v) Transformer differential protection relay.

vi) Power factor meter

vii) Space heater manual on-off switch

viii) The breaker is to be arranged to allow inter-tripping from the feeding breaker

ix) Hand reset lock-out relay to be tripped by all protective devices

Transformer or Power Feeder

i) Voltmeter suitably scaled and provided with phase selector switch

ii) IDMTL relay for overcurrent and earth fault protection, having instantaneous high

set element.

iii) KWH and kW meter

iv) Space heater manual on-off switch

v) Facilities for inter-tripping

Motor Feeder

i) Ammeter suitably scaled and fitted with phase selector switch

ii) Motor protection relay or equivalent, giving protection against overcurrent, earth

fault, and single phasing

iii) Undervoltage trip

iv) Facilities for connecting a remote ammeter

v) Breaker/contactor auxiliary contact arranged to operate a motor space heater in

the event of the breaker opening or being removed

vi) Space heater manual on-off switch

vii) Local/remote change-over switch, which is key lockable

viii) Breaker/contactor on-off switch, which works only when the breaker/contactor is at

test position and the above change over switch is at remote position.

ix) Current transducer, where required for process / operation

5.2.10 For further information refers to specification CBP-ELE-009-00.5.3 LOW VOLTAGE SWITCHGEAR

5.3.1 380/220 V switchgears, motor control center and distribution panels shall generally comply withthe recommendation contained in IEC publication 60439.


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5.3.2 The low voltage switchgears shall be metal enclosed, indoor type, free standing floor mountingwith circuit breakers. The switchgears will be of multi-tiered construction.

5.3.3 The incoming circuit breaker and the tie breaker shall be three pole draw-out type air circuitbreakers. Molded-case circuit breakers, which shall have sufficient interrupting capacity, may beused as branch breakers.

5.3.4 All low voltage air circuit breakers shall be electrically operated 110 V DC or 220 V AC with storedenergy operating mechanisms.

5.3.5 Each low voltage incomer switchgear shall be provided with the following protection and metering;

i) Voltmeter and phase selector switch

ii) Ammeter and phase selector switch

iii) Inverse Definite Minimum Time Limit (IDMTL) relays for overcurrent and ground

fault protection

iv) The breaker shall be arranged to allow inter-tripping from the primary feeder

breaker

v) Transformer fault relay (depending on the rating of transformers)

5.3.6 Motor Control Centers (MCC) shall be metal enclosed, free standing, with multi-tiered fully

withdrawable control units for motor starters. Control units for large motors may be of fixed type.

5.3.7 Each combination motor control unit in MCC shall be of the direct on line starting, and providedwith a molded-case circuit breaker to provide short circuit protection and disconnecting means,and a magnetic contactor and a thermal relay to provide overload protection. A thermal overloadrelay shall be arranged for hand reset.

5.3.8 Each combination motor control unit in MCC shall be arranged for remote push-button controlcircuit energized at phase to neutral voltage. Contactor on (red), off (green) and trip (amber)indicate lamps shall be provided on each unit. No on-off control switch shall be provided on eachunit.

5.3.9 Each feeder unit in MCC shall contain a molded case circuit breaker or fuses manual operation

5.3.10 380/220 V distribution panels, which shall be for lighting, space heaters and miscellaneouspurpose, shall be metal enclosed, free standing with multi fixed type feeders.

5.3.11 For further information refers to specifications CBP-ELE-010-00 and CBP-ELE-011-00.

5.4 MOTORS

5.4.1 Motors shall generally be of the squirrel cage induction type and comply with the recommendationcontained in IEC publication 60034.

5.4.2 Motors shall be suitable for normal starting and continuous operation at name plate kW rating, andhave sufficient starting torque and thermal capabilities to accelerate the connected machine tomaximum speed without injurious heating.


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5.4.3 Protection grade against water and dust for motors, installed where exposed to water jet, shall beIP55 specified in IEC publication 60034-5/60529.

5.4.4 Space heaters shall be provided in motors of rated voltage 6 kV and above. Space heaters shalloperate at 220 Volt, AC.

5.4.5 For further information refers to specification CBP-ELE-004-00.

6.MOTOR CONTROL

6.1 CONTROL CIRCUIT

6.1.1 For high voltage motors, each motor controller shall include the necessary electrical interlocking

and interwiring between units and interlocking provisions to remotely mounted devices. Controlcircuit voltage shall be 220 V AC derived from the main circuit phase and neutral.

6.1.2 For low voltage motors, each motor control unit shall include the necessary electrical interlockingand interwiring between units and interlocking provisions to remotely mounted devices. Controlcircuit voltage shall be 220 V AC derived from the main circuit phase and neutral.

6.2. LOCAL CONTROL STATIONS

6.2.1 Motors shall generally be controlled from STOP-START control switch stations located at, or nearthe motor.

6.2.2 STOP-START control switch stations shall be arranged so that momentary operating of the STOP

switch stops the motors.

6.2.3 Local control stations for motors having a rating of 37 kW and above and driving critical loads forplant operation shall have ammeters. The ammeter shall be connected to a CT in the motorcontroller, rated secondary current 1 ampere.

6.3 MOTOR OPERATED VALVESValve operators shall be complete with integral reversing contactor starter and overload, etc.

7.WIRING

7.1 GENERAL

7.1.1 The electrical wiring in the Plant, shall generally be carried out by armored cables.

7.1.2 Materials used for cable insulation, sheathing and serving must be suitable to withstand anycontaminating liquids or gases likely to be encountered in the area.

7.1.3 Cable and wire shall conform in all respect to the IEC standard. Armoring shall be in accordancewith the regulation of BS, VDE, JIS or equivalent.

7.2 TYPE OF CABLE

7.2.1 The following type of cables shall be used for power, lighting and grounding wiring system.a) 20 kV and 6 kV system power cable : N2XSRY-FL


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b) 380/220 V system and below power cable : N2XRY-FL

c) Control Cable : NYRY-FL

d) Lighting Cable : N2XRY-FL

Legends1. N2XSRY : Cross-linked polyethylene (XLPE) insulated, copper shielded/screened for

each core, flame retardant PVC inner sheathed, single wire armored (SWA)and flame retardant PVC outer sheathed copper conductor cable

Note (1) : The voltage ratings of the cables shall be as follows:

Cable GradeSystem Voltage

Rated Voltage Maximum Voltagea. 6 kV 3.6/6 kV 7.2 kVb. 20 kV 12/20 kV 24 kV

(2) For single core cables, aluminum armor shall be applied instead of steelarmor.

2. N2XRY : 600/1,000 volt grade cross linked polyethylene (XLPE) insulated, flameretardant PVC inner sheathed, single wire armored (SWA) and flameretardant PVC outer sheathed copper conductor cable.For single core cables, aluminum armor shall be applied instead of steelarmor.

3. NYRY :600/1,000 volt grade PVC insulated, flame retardant PVC inner sheathed,single wire armored (SWA) and flame retardant PVC outer sheathed copperconductor multi-core control cable.

7.2.2 In areas where cable installation is well protected from physical damage such as insidesubstation, central control building, etc., cables without wire armor may also be used.

7.3 CABLE SIZE

The sizing of cables for consumers shall be based on their nameplate rating. The allowablecurrent in any conductor shall be calculated in accordance with relevant IEC publications. Cablenominal size shall be 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 95, 120, 150, 185, 240, 300, 400,500, 630; unit is square mm

Minimum size of cable and wire shall be as follows;(1) 20 kv circuit :120 mm

2

(2) 6 kV circuit : 25 mm2

(3) Low voltage power circuit : 2.5mm2

(4) Control circuit : 1.5 mm2

(5) Lighting circuit : 1.5 mm2

(6) External CT circuit for transformer neutral : 2.5mm2

Note: Wire size for small current circuit such as testing and measuring instrument circuit andinternal wiring of power board is not include in this list.

7.4 GENERAL WIRING METHOD

7.4.1 Electrical distribution cable from the substation to each load shall generally be installed in

overhead racks or tray. The racks or trays shall be hot dipped galvanized.


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7.4.2 Single cables leaving a main cable run to a motor, motor control station or lighting fitting may befixed to walls or columns by suitable spacer type saddle and/or cable tray.

7.4.3 3 cores power cable shall be used for motor power supply cable.

7.4.4 Distribution to offsite buildings, street lighting and other loads far from the process area shall bewith direct buried underground cable. Cable route markers shall be installed on the mainunderground cable route.

7.4.5 A distance of at least 600 mm shall be maintained in the main cable route between power cablesand low level signal cables for instrumentation except where the two types of cable cross eachother, in which case the minimum distance between the two types cable shall be 200 mm. All

crossings shall be at 90 degrees angle as far as possible.

7.4.6 Cables for fire alarm system will be installed in the instrumentation cable duct or in the electricalcable ladder with barrier separation.

7.4.7 Cable shall be arranged to minimize the number of crossover.

7.4.8 Cables shall be installed according to manufacturer’s recommendation. In no case shall themanufacturer’s maximum allowable pulling tension be exceed during cable installation.

7.4.9 Minimum cable bending radii, either during installation or in the final arrangement, shall never beless those allowed by the manufacturer.

7.4.10 As far as practical all cable runs shall be continuous without splices.

7.4.11 Cable must be placed a minimum of 300 mm to the side of or 600 mm above any hot line, fitting orvessel above 55

oC unless an insulating barrier is provided.

7.5 UNDERGROUND WIRING SYSTEM

7.5.1 Armored cables shall be buried directly in the ground.Minimum burial depth from the finished grade to the top surface of the largest cable shall be 600mm.

7.5.2 The cable trench shall be of sufficient width to accommodate the cables installed in the mannerdescribed in section 7.5.10 and 7.5.11.

7.5.3 The bottom of the trench shall be covered with 100 mm of sand.

7.5.4 Prior to laying of the cables all neutral soil which has fallen in the trench shall be removed.

7.5.5 After laying of the cables, the cables shall be covered with 100 mm of sand measured from thetop of the largest cable.

7.5.6 The sand shall be clean and free of organic matter.

7.5.7 Backfill material shall be free of all large stones and rocks. Backfill shall be compacted.

7.5.8 After installation of all cabling as described in section 7.5.5, 50 mm thickness of red concrete tilesor red lean concrete shall be placed over the cables.


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7.5.9 Warning tape shall be placed in the cable trench. The tape shall be 150 mm wide yellowpolyethylene with legend caution buried electric lines continuously along the length.

7.5.10 Cables shall generally be laid in flat formation, touching. Long runs of power cables shall beinstalled with adequate separation. Where high voltage and low voltage cables run in the sameformation, a minimum of 150 mm horizontal separation shall be maintained. Where the 150 mmseparation cannot be maintained, concrete separators are to be provided.

7.5.11 Cables other than high voltage main distribution cables running in the same trench may beinstalled up to a maximum of two layers. If two layers of cables are installed 75mm of clean sandshall be placed between them.

7.5.12 Cables crossing roads shall run in underground conduits or other approved raceways. For

crossing of pipes or other underground obstructions, cables can run in sleeves.

7.5.13 Cables entering or leaving the ground shall be protected from mechanical damage by placing thecables in rigid galvanized steel conduits between 150 mm above and 300 mm below grade. Theupper opening of the conduits shall be fitted with a conduit bushing and sealed with softcompound.

7.5.14 Where cables pass thru floors, protecting covers for groups of cables or conduits for single cablesshall be provided. In either case, the upper opening of covers or conduits shall be sealed with softcompound.

7.6 ABOVE GROUND WIRING SYSTEM

7.6.1 All cables routed above ground shall generally be fixed to cable racks in the main cable route andcable trays in branch cable routes.

7.6.2 High voltage cables shall be installed in a separate cable racks or tray from that for low voltagecables, or separator in the same rack or tray.

7.6.3 Cables shall in general be installed side by side touching for 6 kV power in single layer, for lowvoltage power cable size 95 mm

2 in a maximum of two layers. Under no circumstances shall the

cables protrude above the side rail of the cable rack/tray. The total cable fill shall comply with theNEC code articles 318-9 to 318-12.

7.6.4 Cables shall be secured to the racks or trays by means of clamps or nylon cable ties.

7.6.5 Individual cables which run above grade between adjacent items of equipment may be supporteddirectly on local steelwork.

7.6.6 Where cables enter a building above grade, the cable entry shall be sealed with water tight andflame reatardative agent.

7.7 CABLE RACK

7.7.1 Cable rack and accessories shall comply with standard NEMA, VEI or equivalent standard.

7.7.2 Cable rack shall be of the heavy duty type with a minimum of 100 mm depth and 300 mm rungspacing.

7.7.3 Cable rack shall be hot dipped galvanized. The coating thickness shall conform to BS 729 orequivalent standard.

7.7.4 Accessories such as bolts & nuts etc. shall be of stainless steel.


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7.7.5 Cable rack fittings shall be designed with proper radius, which is no less than the minimumbending radius of the largest cable to be installed.

7.7.6 Cable rack shall be provided with metallic covers where exposed to sunlight or where mechanicalprotection is required.

7.7.7 Cable rack shall be adequately supported to prevent sag utilizing the manufactures recommendedspans.

7.8 CONDUIT

7.8.1 Conduit utilized outdoors, shall be rigid galvanized steel.

7.8.2 Conduit utilized indoors in non-classified areas where subject to clean, dry non-corrosive locationsonly, shall be galvanized steel thin wall conduit (EMT).

7.9 CONDUIT FITTINGS

7.9.1 Conduit fittings shall comply with applicable IEC publications.

7.9.2 Fittings shall be of corrosion resistant materials such as copper free aluminum or hot dippedgalvanized iron or iron alloy.

7.10 JUNCTION BOXES (APROX. 300 mm X 300 mm AND ABOVE) AND ENCLOSURES

7.10.1 All junction boxes and enclosures shall comply with applicable IEC publications.

7.10.2 All junction boxes shall be properly sealed against the entrance of moisture and shall be equippedwith breathers and drains. Degree of protection for junction boxes shall be IP54.

7.10.3 Cable entry (gland) or conduit shall be preferably from the bottom. Side entry is acceptable. Topentry should be avoided whenever possible. In sheet metal enclosures tight entry shall be madeusing corrosion resistant conduit hubs.

7.10.4 Terminal blocks when required shall be installed in such a manner as to allow ample wiringaround the terminals.

7.11 CABLE TERMINATION AND IDENTIFICATION

7.11.1 Cables shall in general be terminated by means of compression type cable glands. The cablegland shall be of brass construction and shall be suitable for the type of armoured cable used.

7.11.2 Cable lugs, where used, shall be crimp/compression type and shall be installed with ratchet orhydraulic crimping tools utilizing the proper dies.

7.11.3 Terminal blocks shall in no case be used to terminate more than two wires, one per side. Ifmultiple connections are required, terminal block jumper bars shall be utilized. Wire shall be leftwith sufficient spare length to enable wiring modifications to be made. Spare cores shall be leftwith sufficient length to terminate at the furthest terminal from entry.

7.11.4 Each power and control cable shall be clearly marked with PVC markers. The markers shall besecured with nylon ties. A cable marker shall be installed at both end of each cable. Direct buried

cables shall be marked every 10 meters maximum with lead markers giving cable number.


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7.11.5 Conductors of all control cables shall be identified at both ends with a suitable wire marker. Therewire markers must correspond to the wire numbering shown on the electrical drawings.

7.12 SEALING

7.12.1 Sealing shall be installed in accordance with applicable IEC publications.

7.12.2 In division 1 and 2 locations seals are required:

- In every cable run entering any of enclosure containing arcing devices- At the terminating ends of cables crossing division 1 location applicable shall be so

constructed not to transmit gases or vapors.

7.12.3 Sealing fittings should be accessible during and after installation.

7.12.4 Sealing fittings shall only be mounted in the position for which they were designed.

7.12.5 Approved sealing compound and fibre shall be used, and the manufacturer’s instructions shouldbe followed in preparation of dams, the preparation and pouring of sealing compound.

7.13 COLOR FOR IDENTIFICATION OF CABLES

7.13.1 The color for identification of cable shall be as follows;

(1) Overall sheath(a) H.V. power cable -------------------- Black

(b) L.V power and control cable------ Black

(2) Core(a) H.V. power cable

Single core -------- Red3 cores ------------- Red, Yellow, Blue

(b) L.V. power cableSingle core --------- Red2 cores -------------- Red, Black3 cores -------------- Red, Yellow, Blue4 cores -------------- Red, Yellow, Blue, Black

(c) Control cableIndividual cores shall be identified by number 1,2…. Printed on the cores at some intervalthroughout the length.

7.14 POWER OUTLET (380 V, 3 PHASE) AND CONVENIENCE OUTLET (220V, 1 PHASE)

7.14.1 Power outlets and convenience outlets shall be installed at convenient points to serve the plantarea. Power and convenience outlets shall in general be located so that the total plant area canbe served with 100 meters cords from power outlet, and 50 meters cords from convenience outlet.

7.14.2 Branch circuits supplying the power and convenience outlets shall server no other equipment andnot more than six outlets shall be supplied by one circuit. Each branch circuit shall be protected bythermal magnetic moulded case circuit breaker of suitable current rating or fuses, located in the

380/220 volt distribution panel.


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8. GROUNDING AND LIGHTNING PROTECTION

8.1 GENERAL

8.1.1 The grounding arrangements shall provide for:

(1) Grounding of system neutrals(2) Grounding of electrical equipment enclosures(3) Static protection grounding(4) Lightning protection grounding

8.1.2 Grounding of system neutrals and electrical equipment enclosures shall be by means ofinterconnecting conductors to the bellow grade ground grid.

8.1.3 Static, system and electrical equipment grounding shall be integrated to form a commongrounding network.

8.1.4 Grounding system around the flare stack area will be independent from that in the plant area.

8.1.5 An independent grounding system shall be provided for all electronic equipment.

8.1.6 The conductor used for the grounding system shall be stranded copper wire with green yellowPVC insulation.

8.1.7 All buried or concealed connections in the grounding system shall be made by thermoweldconnection. Bare metal at taps shall be covered with one layer of self-adhesive tape and two

layers of insulation tape.

8.1.8 All screw, bolts, nuts, clamps, and connectors shall be compatible with the grounding materialbeing used.

8.1.9 Equipment that is located remotely from the main grounding network may be grounded by meansof individual grounding conductors and grounding electrodes.

8.1.10 Underground grounding conductors shall be installed at least 460 mm below grade.

8.1.11 Grounding conductors leaving the ground shall be protected by rigid galvanized steel conduitbetween 150 mm above grade and 150 mm below grade.

8.1.12 Armor of cables shall be electrically grounded at both ends, unless otherwise specified.

8.1.13 All conveying line/resin transport lines shall be electrically continuous and properly bonded andgrounded.

8.1.14 Grounding electrodes shall be 20 mm (3/4) diameter X 3000 mm (10 FT) long carbon steel copperclad rod.

8.2 GROUNDING OF SYSTEM NEUTRALS

8.2.1 Each power transformer or generator neutral shall be grounded (solid via resistor or distribution

transformer) by means of driven ground rods which are interconnected below grade with a groundgrid. In the substation / switchroom a copper ground loop or bar of sufficient size shall be provided


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to enable termination of all electrical equipment grounds. The loop or bar shall be connected tothe main ground grid with a minimum of two ground conductors.

8.2.2 Ground conductors shall be rated for the prospective fault current and shall be sized inaccordance with the applicable IEC publication.

8.2.3 The ground resistance value for system neutrals shall not exceed 4 ohm as a loop or grid.

8.3 GROUNDING OF ELECTRICAL EQUIPMENT ENCLOSURE

8.3.1 Non current carrying parts of electrical equipment shall be grounded. In general, a separateground conductor shall be attached to each item for which grounding is required, except forequipment that shall be considered as satisfactorily grounded when the structural steel on which it

is supported is grounded.

8.3.2 The ground grid shall generally be installed below grade. The main grid shall be 70 mm2

strandedcopper conductor PVC insulated. The grid shall interconnect all driven ground rods as detailed in8.1.14. All equipment requiring grounding shall be connected to this grid minimum wire size 16mm

2(for mechanical protection).

8.3.3 Each H.V. and L.V. switchgears shall be connected to the grounding network with two copperground conductors one at each end of the single assembled switchgear sized in accordance withthe applicable IEC publication.

8.3.4 Low voltage cables shall have a protective conductor which size shall be selected on a belowbasis.

Cross-sectional area of phase conductor ofthe installation S (mm

2)

Minimum cross-sectional area of thecorresponding protective conductor S0 (mm

2)

S 16 S16 < S 35 16

S > 35 S/2

8.3.5 Lighting panels shall be connected directly to the grounding systems with a separate groundingwire of 16 mm

2.

8.3.6 Street lighting poles shall be grounded by a wire of 16 mm2.

8.3.7 The cable racks and tray shall be grounded at intervals of approximately thirty (30) meters.

8.3.8 The armoring of cables interconnecting the equipments may be considered as one of groundingpath where electrically connected to the equipment.

8.4 STATIC AND LIGHTNING PROTECTION GROUNDING

8.4.1 Process equipment containing hazardous materials and located in hazardous area, shall begrounded to prevent static discharges.Each equipment shall be connected to the main grounding loop by means of 25 mm

2 branch wire.

8.4.2 The tallest structures, columns and stacks in each area shall be grounded for the protectionagainst lighting.

8.4.3 Lighting protection shall be in accordance with NFPA78-Lightning Protection Code. Lightning

protection shall generally be connected with any other grounding system in the direct vicinity, and


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shall take the form of “cone protection”. The cone protection system shall smart at the talleststructure within the plant and shall be continued until complete plant protection is achieved.

8.4.4 Any structure within a cone of protection shall be considered adequately shielded against lightningand shall not require further protection.

8.4.5 The resistance to ground for lightning protection shall not exceed 7 ohms.

8.4.6 Where the lightning protection system is installed close to any other grounding system, they shallbe interconnected at convenient points.

8.4.7 The pipes, generating static electricity, on the pipe racks/sleepers shall be grounded at theboundary of hazardous area or at interval of approximately thirty (30) meters in order to minimize

potential differences.

9. LIGHTING

9.1 GENERAL

9.1.1 Sufficient lighting shall be provided to enable operators to circulate freely and safely within theaccessible area of the plant and perform whatever duties are required.

9.1.2 General illumination of outdoor area shall be provided by suitably located floodlights. Wheresupplementary lighting is required for items such as instruments, gauge glasses, etc. , individualfixtures shall be used. Sodium vapor lamps shall generally be used.

9.1.3 Armored cables specified in Par.7.2 shall, in general, be used for the lighting circuits.

9.1.4 Floodlights shall generally be mounted on structures, pipe support or poles of hot-dip galvanizedsteel or concrete.

9.1.5 Lighting supply shall be at 220 V volts single phase and neutral, obtained from local lightingdistribution boards installed at convenient location in the plant. These boards shall receive 380volts, 3-phase 4-wire supply from a contactor feeder unit, controlled by photo electric cell withmanual override control in the distribution panel located in the substation. The local emergencylighting distribution boards shall be similarly controlled but fed from the emergency powerdistribution panel in the substation.

9.1.6 Branch circuit breakers in each local distribution panel shall be of 20 amperes, initially loaded to amaximum of 80% of the breaker rating.

9.1.7 Minimum lighting levels as listed in 9.2 shall be attained when the light output for the lamps havedropped to 70% of the initial rated value.

9.2 ILLUMINATION LEVELSIllumination levels shall not be less than the values listed below in average (measured in abovegrade):


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Area Average Intensity in Lux

- Process Plant 50/20 *- Tank Yard 10- Sea Water Intake 50/20 *- Cooling Water 50/20 * - Air Supply 50/20 * - Nitrogen Supply 50/20 *

- Water Treatment & Fire Fighting 50/20 * - Waste Water Treatment 50/20 * - Ware House 100- Control Room & Laboratory 500- Work Shop General Area 400

- Machine & Lathe Work 550- Fine Work 1000- Instrument Work 1500- Other Office 400- Substation 150- Steam Generation 50- Unloading Platform 10/20/100 **- Street Lighting 10

Note : * A/B – A: Around Rotating MachineB: Around Tank and Vessel

* A/B/C – A: Access Way

B: Cat WalkC: Unloading Point

9.3 EMERGENCY LIGHTING SYSTEM

9.3.1 Emergency lighting shall be provided throughout the plant at all essential operating points andshall give adequate lighting for the safe movement of personnel during emergency conditionswhen production operations are still being affected. It shall be separated in every way from thenormal lighting system, and supplied from the 380V emergency power distribution panel and thussubject to change over to emergency supply in the event of normal power outage.

9.3.2 The emergency lighting fixtures for the process areas shall be of incandescent type or fluorescenttype. All incandescent fixtures shall be of screw-in type.

9.4 STREET LIGHTING

9.4.1 Street lighting will be as follows;(1) Fixture --- Sodium vapor(2) Fixture mounting height --- Approx. 10 m above finished grade(3) Pole type --- Galvanized steel or concrete(4) Pole spacing --- Approx. 50 m(5) Wiring --- Underground direct burial cable

9.4.2 Circuits for street lighting shall be energized during night by normal power source.

9.5 OBSTRUCTION AND WARNING LIGHTS

9.5.1 The obstruction and warning lights shall generally be installed as per the International CivilAviation Organization (ICAQ) requirements.


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9.5.2 Circuits for obstruction and warning lights shall be energized during night by emergency lightingpower source.

10. COMMUNICATION SYSTEM

10.1 TELEPHONE SYSTEM

Telephone system will be provided to cover central control building sub-stations. Paging system willnot be provided as radio communication system is provided

11. TESTING

Electrical equipment shall be subjected to routine shop test to ensure that they are free from electrical ormechanical defects, and that they meet design specifications. Engineering Specification (CBP-ELE-015-00) shall apply to the inspection and test for each electrical equipment.

WSP ELE ES 002 00 Engineering Specification for Electrical Facilities

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Transcript of WSP ELE ES 002 00 Engineering Specification for Electrical Facilities