Division 16 -electrical Work

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16000 SOLAR PANEL UNITS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

Discipline: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE Page 1 of 13

REMARKS

DIVISION 16 ELECTRICAL WORKS

SECTION 16000 SOLAR PANEL UNITS

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05

Scope Codes and Standards Submittals Environmental Condition Technical Data

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12

Componenets and Equipments Tagging Units and Scales Description of System Special Requirements Solar Modules and Panels Supporting Structure Charge Regulator Distribution Board AC/DC Battery Charger Cabinets Batteries

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09 3.10 3.11 3.12

EXECUTION General Design Factor Wiring Overcurrent Protection Painting Cables and Cable Laying Installation Workshop Test Site Test Documentation Shipping Spare Parts and Special Tools

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITES

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DIVISION 16 ELECTRICAL WORKS

SECTION 16000 SOLAR PANEL UNITS

PART 1 - GENERAL 1.01

Scope This document covers the requirements for the design, manufacturing, construction, installation, test and commissioning of solar panel units to be used for the remote stations for the Transportation of Treated Water from Taif STP to Ma’aden Gold sites without permanent power supply from SEC or other facilities.

1.02

Codes and Standards The design, manufacturing, construction, installation, test and commissioning of solar panel units shall be in accordance with the following codes and standards, at least. The latest revision of the publication referred to shall apply. IEC 60085

Thermal evaluation and classification of electrical insulation

IEC 60146

Semiconductor Converters

IEC 60255

Electrical relays

IEC 60269

Low-voltage fuses

IEC 60439

Low voltage switchgear and assemblies

IEC 60529

Degrees of protection provided by enclosures (IP Code)

IEC 60891

Procedures for temperature and irradiance corrections to measured I-V characteristics of chrystalline silicon photovoltaic devices

IEC 60904

Photovoltaic devices

IEC 61215

Crystalline silicon terrestrial photovoltaic modules

IEC 61427

Secondary cells and batteries for solar photovoltaic energy systems

IEC 62259

Nickel-Cadmium prismatic rechargeable single cells with partial gas recombination

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16000 SOLAR PANEL UNITS

As far as the power supply authority (SEC) or permits of other authorities require additional codes and standards, respectively impose additional requirements, these are also part of the contract. 1.03

Submittals Forward to the Company Representative for review and approval the following submittals. Refer also to appropriate specification sections for other submittal requirements. A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

B.

Prior to Commencing WORK: Shop drawings of proposed installations that deviate from the original design.

C.

Prior to Final Acceptance: Record documents which shall indicate installed conditions for:

C.

1.

Major raceways systems, size and location, for both exterior and interior; locations of control devices; distribution and branch electrical circuitry; fuse and circuit breaker size and arrangements.

2.

Equipment locations (exposed and concealed), dimensioned from prominent building lines.

3.

Approved substitutions, modifications and actual equipment and materials installed.

Maintenance Manuals: Submit maintenance manuals which shall include the following information for equipment items: 1.

Description of function, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of replacement parts.

2.

Manufacturer's printed operating procedures to include start- up, break-in, and routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; and summer and winter operating instructions.

3.

Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITES

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DIVISION 16 ELECTRICAL WORKS 4. 1.04

SECTION 16000 SOLAR PANEL UNITS Servicing instructions and lubrication charts and schedules.

Environmental Conditions The solar panel units shall be designed and constructed for continuous operation at full load under the climatic and environmental conditions as described in the specification “Design and Construction of Power Supply Systems”. With exception of the solar panels, the units shall be installed in equipment containers without forced ventilation or air conditioning.

1.05

Technical Data The technical data of the solar panel units are defined in the data sheets. The Contractor has to guarantee the fulfillment of these requirements.

PART 2 – PRODUCTS 2.01

Components and Equipment The Contractor has to take care that all components and equipment are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals. All components and equipment shall be designed for continuous duty at rated load and under the given climatic conditions. Standard industrial high performance systems and components of supplier’s standard lists shall be used as far as possible. Components and equipment of same kind and type shall be selected for equivalent functions. The interchangeability must be guaranteed.

2.02

Tagging All components, equipment and installations shall receive the respective tagging plates, labels, etc., which have to be of extremely durable material resistant against the environmental conditions. Tagging plates or labels on fronts of enclosures shall be fixed with screws. For further requirements, reference is made to specification “Design and Construction of Power Supply Systems”.

2.03

Units and Scales The metric system on basis of SI-units shall be used for all scales and indications.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 2.04

SECTION 16000 SOLAR PANEL UNITS

Description of the System

Each solar panel unit shall consist of the following main parts: •

solar panels,

•

charge regulator,

•

supporting structures,

•

battery bank,

•

battery charger,

•

Distribution board.

The solar power units shall supply continuously output voltage of 24 V DC ±10%. On the solar panel units are connected continuous consumers (SCADA and telecommunication system, cathodic protection rectifiers) and the container lighting as a short time consumer. 2.05

Special Requirements The Vendor/Manufacturer shall have local representative in Saudi Arabia and shall have maintenance team available with minimum five years of experience to attend any maintenance issues.

2.06

Solar Modules and Panels The solar panels shall consist of high quality and high efficient solar modules of monocrystalline silicon cells with glass cover fully encapsulated and incorporated in stainless steel or anodized aluminum frame structure. The solar panels must be designed for maximum reliability and minimum maintenance. The modules shall be resistant against water, salt, sand abrasion, hail impact and all other environmental site conditions. Only well proven industrial products with at least 5 years experience in Middle East countries shall be used. In view of very high ultra violet contents in solar radiation in the region the solar panels / solar cells must be designed with consideration of this factor. A test certificate shall be submitted to proof that no detrimental effects resulting from radiation will accelerates aging or cause damage of solar cell junctions The quantity of solar modules and the power is to be selected by the Contractor according to the ambient conditions, the power requirement and the specified design factors.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 2.07

SECTION 16000 SOLAR PANEL UNITS

Supporting Structure The modules shall be installed on suitable standard mounting structures under the desired tilt angle, to be defined by the Contractor. The supporting structures shall be constructed of hot dip galvanized steel. The steel or aluminum frame of the solar modules must be isolated from the steel structure to avoid localized corrosion. Stainless steel fixings shall be used, only. GI structures shall be painted with epoxy paint. The supporting structures shall be constructed in a manner such that a future extension is possible. Internal grounding connections between the panels and the structure shall be foreseen with two connection points to the station grounding mesh. The supporting structure must be designed for the wind load defined in the specification “Design and Construction of Power Supply Systems”.

2.08

Charge Regulator For loading of the batteries and control of the consumer voltage a suitable charge regulator shall be provided. The charge regulator shall mainly consist of the following •

Surge protection for input and output,

•

Fully automated three tier charging system (boost/float charging and equalization),

•

Protection diodes between solar modules and charger

•

Protection devices against overload, overcharge and over-discharging, including all control, indication and monitoring facilities,

•

Switches, circuit breakers, fuse, etc.

For external use the status and the fault signals and as well an over-discharging pre-alarm shall be wired to a common terminal stripe. 2.09

Distribution Board For each solar panel unit a distribution board shall be provided. The distribution boards shall be equipped with 2-pole miniature circuit breaker, sized according to the requirements and with the respective terminal stripes. Further, an earth fault supervision unit shall be provided. For future extension each distribution board shall have at least 20 % full installed spare and further 20 % spare place to install additional devices.

For remote monitoring the summary alarm of molded case circuit breaker tripping and the release of the earth fault supervision shall be wired on terminal stripe. The transfer of the DICIPLENE: ELECTRICAL DOCUMENT No.: MGBM-SPEC-0001 Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16000 SOLAR PANEL UNITS

mentioned signal shall be carried out via potential free contact. The terminals shall be located beside the terminal stripes for remote monitoring of charge regulator. 2.10

AC/DC Battery Charger For maintenance and stand-by purpose of the solar panel unit a separate AC/DC battery charger with a switch over device regulator/battery charger and back shall be provided. The AC/DC battery charger shall be fed from external 400/230 V AC, 60 Hz via power socket and mobile diesel generator. The AC/DC battery charger shall be able to charge the batteries in the shortest possible time and shall have a spare capacity of 30% for future extension.

2.11

Cabinet The charge regulator, the distribution board and the AC/DC battery charger shall be installed in separated parts of a common, metal enclosed, self standing cabinet. The cabinets shall be suitable for installation against the wall. The cabinets shall only be accessible from the front. The hinged front doors shall be swinged out more than 90°. The bottom of cabinets shall be covered with galvanized steel sheets. If necessary for air circulation, holed steel sheets can be used. The cable entries shall be designed in a manner such that a sealing after cable laying is possible without any problem. All nuts for fixing of components shall be welded on the steel structure or threads will be cut in the steel structure. The use of loose nuts or self cutting screws is not allowed. Screws, nuts and washers shall be galvanized or cadmium plated. The degree of protection shall be IP 31, at least.

2.12

Batteries The batteries shall be very low-maintenance NiCd type. Only batteries for photovoltaic application with a high discharging and temperature rate will be accepted. The solar batteries shall be constituted of vented Ni-Cd cells type with pocket plate technology and shall fully comply with IEC 61427 in conjunction with IEC 62259. For low maintenance reasons cells have to be designed with internal recombination system and flame arresting vents. A recombination feature by adding external gas recombination vents only is not acceptable. The cells shall be housed in polypropylene containers. Battery safety and installation shall fully comply with EN 50272-2. Life span of the batteries shall be 15 years at operating maximum temperature of 50°C. The capacity shall be suitable for at least 72 hours without sunshine, including spare margin of 20% and the required de-rating and ageing factors for the actual operating conditions.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16000 SOLAR PANEL UNITS

The battery shall be installed in a separate, metal enclosed, self standing cabinet. The battery cabinet shall be of same type and layout as the cabinet for the other facilities of solar panel units and provided with suitable venting elements in order to reduce the ambient temperatures for the batteries as much as possible. The battery cabinet shall be sized with sufficient space, to allow an arrangement for future extension with batteries of 30% more capacity. The guaranteed battery life time under the given operating conditions has to be defined by the Contractor. PART 3 - EXECUTION 3.01

General The solar panels shall be sized in a manner such that all connected consumers can be supplied. An additional charging and floating of the battery bank must be possible (also applicable, if the battery was drained prior start of charging). To keep the quantity of solar panels on the required minimum, the Contractor shall work in co operation with the manufacturers of the equipment container and of SCADA and telecommunication system. The design of the solar panel units shall be carried out under consideration of the below mentioned design factors. Additional factors may be recommended by the Contractor.

3.13

Design Factors The following factors shall be used for design of the solar power supply units:

3.14

•

De-rating factor 1.10 (for build-up of dust on panels)

•

Ageing factor 1.25

•

Safety factor 1.20 (spare margin) Wiring

The wires shall be selected according to load, insulation level, function and operating requirements. The wires shall be adequately rated and equipped with fuses/circuit breakers of adequate size. The wiring colors and the minimum cross sections shall be according to specification “Design and Construction of Power Supply Systems”.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16000 SOLAR PANEL UNITS

The wiring shall be carried out solid and safe against damages. Wires shall be bundled and fixed. The wiring shall be laid inside of wiring channels, preferably. If wiring channels will be used, a spare of 20 % shall be foreseen. All circuits and auxiliary contacts shall be terminated on terminal stripes. Terminal stripes shall have at least 10 % spare terminals. If wires with different potential will be terminated on one terminal stripe the respective terminals shall be separated by means of isolating plates. The termination of multiple stranded wires has to be carried out by means of multiple core cable ends. Terminals shall be marked durable and easy readable, corresponding to the drawings. Wires shall be marked on the termination of each wire with the number of the corresponding connection point. 3.04

Overvoltage Protection The solar panel units shall be designed in a manner such that overvoltages caused flashes, do not impair the safety in operation of the units. The distribution boards shall be equipped with additionally overvoltage protectors. The electronic devices shall be separately protected against overvoltages.

3.05

Painting All components and devices shall have a resistant, long term stable, high quality painting. At least two layers have to be applied. Damages, caused by transport, installation, cabling or commissioning shall be repaired in a way, that the original quality is restored. An additional painting at location of installation is not allowed.

3.05

CABLES AND CABLE LAYING For the cable connections between the different parts of the solar panel units, PVC insulated copper cables shall be used. The cables shall be selected according to nominal voltage, voltage drop and short circuit current. The minimum cross section for power and signal cables shall be according to specification “Design and Construction of Power Supply Systems”. Signal cables shall be provided with copper screen. The cables to battery banks must be short circuit proof.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITES

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DIVISION 16 ELECTRICAL WORKS 3.07

SECTION 16000 SOLAR PANEL UNITS

Installation The delivery, installation and commissioning of the solar panel units shall include, but not limited to the following items: •

Transport to location of installation (if necessary storage), and the complete mounting,

•

Cable connections between the different parts of solar panel units,

•

Grounding and potential equalization for the parts, including connection with the next grounding bus bars,

•

Termination of all cables at the solar panel units,

•

Commissioning of the functioning solar panel units,

•

Briefing of the operation personnel in operation and maintenance during installation and commissioning phase and during a training on site

The installation and as well the tests and the commissioning shall be carried out with Contractors own staff and with own tools and measuring/test devices. 3.08

Workshop Tests All components of the solar panel units shall be tested completely and detailed in manufacturer’s workshop. The batteries and solar modules may be tested separately. All tests required by the codes and standards as well as all manufactures tests have to be performed. The test program for the work shop test has to be submitted at least 3 weeks prior to start of the tests. The following tests shall be carried out, at least: •

Test of all functions,

•

Check of degree of protection,

•

Mechanical operation test on all equipment,

•

Operation test of the relays and releasers,

•

Tripping of circuit breakers,

•

Test of auxiliary electrical devices,

•

Verification of wiring and terminal blocks,

•

Compliance with the specifications.

Detailed test protocols of all tests performed have to be submitted prior to shipment.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 3.09

SECTION 16000 SOLAR PANEL UNITS

Site Tests The site tests shall include the following steps: •

Pre-commissioning (including “loop testing”),

•

Commissioning and test on completion,

•

Performance test including battery capacity test.

The aim of the tests is to ensure the proper function of the complete scope. 3.10

Documentation Complete documentation shall be provided for the design, manufacturing, testing, commissioning, start-up, operation, maintenance and repair of the solar panel units and their components. All documents shall be in English language. The documentation of the solar panel units shall include the following documents and drawings (minimum requirements): •

Technical data sheets

•

Layout drawings for all devices, cabinets and solar panels

•

Calculation of supporting structure and it’s foundation

•

Foundation drawings for solar panels

•

Schedules

•

Single line diagrams

•

Block diagrams

•

Wiring diagrams

•

Termination drawings

•

Cable lists

•

Spare parts list

•

List of used devices with manufacturer

•

Software and software description (if any)

•

Operation and maintenance manual

•

Reports of tests and commissioning with protocols.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16000 SOLAR PANEL UNITS

The documents listed above shall be handed over for approval. Special attention has to be given to the fact, that documentation must be submitted with sufficient time allocated for approval prior to manufacturing / assembly. Documentation has to be prepared in accordance with the relevant ISO standards or in the absence of relevant details in those standards the DIN standards shall apply The final documentation shall be delivered on paper in sufficient number and with exception of the signed protocols in electronic form, also. The type of the electronic files shall be agreed with the Client. 3.11

SHIPPING All equipment, material and spare parts shall be sufficient packaged. All parts of one solar panel unit should be shipped as a common delivery. The material, especially loose parts and spare parts shall be clearly labeled according to the designation.

3.12

SPARE PARTS AND SPECIAL TOOLS The Contractor shall deliver all spare parts, which are necessary for commissioning and two years operation time (see “General Description of Project and Works”). Spare parts shall be available until ten years after commissioning. All necessary special tools for operation and maintenance of the solar panel units shall be supplied for each location, at least consisting of: •

1 set of all special tools required for operation and maintenance,

•

1 set fuses (6 fuses of each used size),

•

Key set for cabinet doors and locks,

Software for special equipment (if any).

- END OF SECTION -

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITES

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16001 UPS EQUIPMENT

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

Discipline: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE Page 1 of 14

REMARKS

DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05

Scope Codes and Standards Submittals Environmental Condition Technical Data

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11

Componenets and Equipments Tagging Units and Scales Description of System Special Requirements Mechanical Requirements Electrical Requirements Bypass Measuring Instruments Battries Distribution Board

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09 3.10

EXECUTION Wiring Overcurrent Protection Painting Cables and Cable Laying Installation Workshop Test Site Test Documentation Shipping Spare Parts and Special Tools

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITES

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

PART 1 – GENERAL 1.01

Scope This document covers the requirements for the design, manufacturing, construction, installation, test and commissioning of uninterruptible power supply equipment (UPS) for AC consumers for the Transportation of Treated Water from Taif STP to Ma’aden Gold sites.

1.02

Codes and standards The design, manufacturing, construction, installation, test and commissioning of uninterruptible power supplies shall be in accordance with the following codes and standards, at least. The latest revision of the publication referred to shall apply. IEC 60051

Direct acting indicating analogue electrical – measuring instruments and their accessories

IEC 60076

Power Transformers

IEC 60085

Thermal evaluation and classification of electrical insulation

IEC 60146

Semiconductor Converters

IEC 60255

Electrical relays

IEC 60269

Low-voltage fuses

IEC 60289

Reactors

IEC 60439

Low voltage switchgear and assemblies

IEC 60529

Degrees of protection provided by enclosures (IP Code)

IEC 60896

Stationary lead – acid batteries. General requirements and methods of test

IEC 60947

Low-voltage switchgear and control gear

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

IEC 60989

Separating transformers

IEC 61558

Safety of power transformers

As far as the power supply authority (SEC) and permits of other authorities require additional codes and standards, respectively impose additional requirements, these are also part of the contract. 1.03

Submittals Forward to the Company Representative for review and approval the following submittals. Refer also to appropriate specification sections for other submittal requirements. A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

B.

Prior to Commencing WORK: Shop drawings of proposed installations that deviate from the original design.

C.

Prior to Final Acceptance: Record documents which shall indicate installed conditions for:

D.

1.

Major raceways systems, size and location, for both exterior and interior; locations of control devices; distribution and branch electrical circuitry; fuse and circuit breaker size and arrangements.

2.

Equipment locations (exposed and concealed), dimensioned from prominent building lines.

3.

Approved substitutions, modifications and actual equipment and materials installed.

Maintenance Manuals: Submit maintenance manuals which shall include the following information for equipment items: 1.

Description of function, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of replacement parts.

2.

Manufacturer's printed operating procedures to include start- up, break-in, and routine and normal operating instructions; regulation, control, stopping,

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITES

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT shutdown, and emergency instructions; and summer and winter operating instructions.

1.03

3.

Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

4.

Servicing instructions and lubrication charts and schedules.

Environmental Conditions The uninterruptible power supplies shall be designed and constructed for continuous operation at full load under the climatic and environmental conditions as described in the specification “Design and Construction of Power Supply Systems”. The UPS’s shall be installed in rooms of the electrical buildings. The rooms will be equipped with air conditioning.

1.04

Technical Data The technical data of the uninterruptible power supplies (UPS) are defined in the data sheets. The Contractor has to guarantee the fulfillment of these requirements.

PART 2 – PRODUCTS 2.01

Components and Equipment The Contractor has to take care that all components and equipment are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals. All components and equipment shall be designed for continuous duty at rated load and under the given climatic conditions. Standard industrial high performance systems and components of supplier’s standard lists shall be used as far as possible. Components and equipment of same kind and type shall be selected for equivalent functions. The interchangeability must be guaranteed.

2.02

Tagging All components, equipment and installations shall receive the respective tagging plates, labels, etc., which have to be of extremely durable material resistant against the environmental conditions. Tagging plates or labels on fronts of enclosures shall be fixed with screws.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITES

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

For further requirements, reference is made to specification “Design and Construction of Power Supply Systems”. 2.03

Units and Scales The metric system on basis of SI-units shall be used for all scales and indications.

2.04

Description of The System

Each uninterruptible power supply (UPS) shall consist of the following main parts: •

three isolation transformers,

•

two rectifiers,

•

two battery banks,

•

two inverters,

•

static bypass,

•

manual bypass,

•

One distribution board.

During normal network conditions the AC consumers will be supplied via both rectifier/inverter circuits, which work in half-load operation mode. At the same time the battery bank will be trickle charged. In case of interrupt on one feeder or failure of one rectifier/inverter circuit the other circuit takes over the supply of all consumers. If both feeders are without voltage the consumers shall be fed via the battery. After return of the feeders the rectifiers take up the operation automatically, feed the inverters and charge the battery. In case of overload or UPS failure the consumers shall be fed via the static bypass. For maintenance a manual bypass shall be provided. 2.05

Special Requirements The Vendor/Manufacturer shall have local representative in Saudi Arabia and shall have maintenance team available with minimum five years of experience to attend any maintenance issues.

2.06

Mechanical Requirements The uninterruptible power supplies shall be industrial type; metal enclosed factory assembled with self standing cabinets and with fix mounted units and devices.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITES

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

The cabinets shall be suitable for back-to-back installation or installation against the wall. The cabinets shall only be accessible from the front. The hinged front doors shall be swinged out more than 90°. The cabinets will be mounted on cable cellar. The bottom of cabinets shall be covered with galvanized steel sheets. If necessary for air circulation, holed steel sheets can be used. The cable entries shall be designed in a manner such that a sealing after cable laying is possible without any problem. Further, each cover sheet shall be equipped with a grounding connection to the steel frame of cabinet. All nuts for fixing of components shall be welded on the steel structure or threads will be cut in the steel structure. The use of loose nuts or self cutting screws is not allowed. Screws, nuts and washers shall be galvanized or cadmium plated. To have an uniformed layout all cabinets shall be of the same height and depth. 2.07

Electrical Requirements Rectifier The UPS’s shall be equipped with full wave rectifiers. Each rectifier shall be suitable to supply all connected consumers. An additional charging and floating of the battery banks must be possible (also applicable, if the battery was drained prior to start of charging). The rectifiers shall be designed for operation with natural air cooling. Each rectifier shall mainly consist of the following: •

fully-controlled semi-conductor bridge with current and voltage control,

•

filters to limit the AC components of output,

•

moulded case circuit breakers for AC and DC,

•

miniature circuit breakers for control circuits,

•

devices for overvoltage protection,

•

Indicator board for all signals of the system (mounted in the door).

For the indication of the signals one indicator board for both rectifiers can be used. Battery manufacturer’s specification regarding charging voltage, maximum voltage ripples, etc. shall strictly be observed, as well as values given in the data sheets. The rectifier shall be equipped with the following supervisory devices:

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

•

electronic network supervisory (switching off at 85 % voltage; switching on at 90 % voltage),

•

overvoltage supervisory with switching off the rectifier,

•

over-discharging supervisory with disconnection of the battery,

•

supervisory of battery circuit interrupt and short circuit of battery cells,

•

earth fault supervisory on DC side,

The response of the mentioned supervisory devices shall be indicated on the indicator board. Inverter The UPS’s shall be equipped with full electronically inverters. The inverter of one rectifier/inverter circuit shall be located in the cabinet of the respective rectifier. Each inverter shall be suitable to supply all connected consumers. The inverters shall be designed for operation with natural air cooling. Each inverter shall mainly consist of the following: •

self commutating solid-state static inverter unit with voltage regulation,

•

filters for wave form stabilisation,

•

voltage peak limiting,

•

synchronization device,

•

molded case circuit breakers for AC,

•

miniature circuit breakers for control circuits,

•

Indicator board for all signals of inverter (if not part of indicator board of rectifier).

The inverters shall be sized in a manner such that circuit breakers for consumers with 25 A nominal current (B-characteristic) will trip without any difficulties and without support from bypass. The inverter shall be equipped with the following supervisory devices: •

input voltage supervisory,

•

electronic inverter supervisory,

•

output voltage supervisory, which initiates a switch over to static bypass,

•

overload supervisory,

•

Frequency supervisory.

The response of the mentioned supervisory devices shall be indicated on the indicator board.

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DIVISION 16 ELECTRICAL WORKS 2.08

SECTION 16001 UPS EQUIPMENT

Bypass For the inverters an electronically change over device shall be provided. The device shall enable the automatic, uninterrupted, synchronous switch-over to the consumer bus bar in case of failure. The change-over device provided shall be equipped with thyristor switches, control electronics and a check-out-system. The check-out system must make it possible to test the correct functioning of the unit without disturbing the operation of the consumers. For change-over in case of maintenance an additional, manual bypass shall be provided. The switch-over shall be carried out with overlapping, that means without interrupt, too. The operation of bypass shall be indicated on the mimic panel, a summary and fault alarm on the indicator panel of inverter. The automatic and manual bypass shall be fed via a common isolation transformer, which will be supplied from the normal network.

2.09

Measuring Instruments The UPS’s shall be equipped with the following measuring instruments: •

AC input voltage (per rectifier and for bypass),

•

battery current (charging / discharging),

•

battery voltage,

•

AC output current.

The measuring instruments shall be mounted in the front door. Mimic Panel For the uninterruptible power supply a colored mimic panel shall be provided. The mimic panel/diagram shall show the main power circuit with all necessary switch positions, device symbols and important alarms. All measuring instruments shall be allocated to the respective symbols of devices and bus bars. The signals which are incorporated in the mimic panel may not be indicated on the indicator boards. Remote Monitoring For remote monitoring to station control system the following signals shall be wired on terminal strip: •

failure feeder of rectifier (for each rectifier),

•

failure feeder of bypass,

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

•

over-discharging of battery,

•

summary alarm per rectifier/inverter unit,

•

Summary alarm bypass.

The transfer of the mentioned signals shall be carried out via potential free contacts. 2.10

Batteries The batteries shall be from the lead-acid type. Batteries shall be gel-filled and maintenancefree. All batteries shall be clearly marked to show manufacturers name, type, voltage, capacity, etc. If the back-up time is not otherwise specified in the data sheets, the sizing of battery system shall be made in a manner such that in case of loss of power the complete consumer loads will be supplied from the batteries continuously for a duration of minimum three (3) hours and it shall be guaranteed that the cell voltage of any single cell will not fall below 1.8 V during at the end of the minimum back-up time. The AH capacity calculation shall be performed for maximum load demand at ambient temperature of 25 °C. During on-site battery test the above mentioned performance data shall be proved. Manufacturer to confirm that minimum life expectancy of batteries will not be less than 12 – 15 years after commissioning of the same at site. The batteries shall be placed inside a battery room on rack. Between batteries and rectifier/inverter cabinets a respective fuse box shall be installed. The fuse box may be placed either inside the battery room or inside the neighboring room on the wall to the battery room. The cables between battery and fuse box shall be laid short circuit proof.

2.11

Distribution Board For each uninterruptible power supply a distribution board shall be provided. The distribution board shall be located in a separated part of one rectifier/inverter cabinet. If the cabinet is not sufficient for distribution board installation or if inside of the cabinet is no space, a separate cabinet shall be foreseen. The distribution boards shall be equipped with 2-pole miniature circuit breaker, sized according to the requirements and with the respective terminal stripes. Further, an earth fault supervision unit shall be provided. For future extension each distribution board shall have at least 20 % full installed spare and further 20 % spare place to install additional devices. In addition, the bus bars of distribution boards shall be equipped with the following measuring instruments: •

voltmeter,

•

Frequency meter.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

The measuring instruments shall be mounted in the front door. The response of the earth fault supervision shall be shown on the indicator board of the rectifier. For remote monitoring the summary alarm of moulded case circuit breaker tripping shall be wired on terminal stripe. The transfer of the mentioned signal shall be carried out via potential free contact. The terminals shall be located beside the terminal stripes for remote monitoring of rectifier/inverter unit. PART 3 - EXECUTION 3.01

Wiring The wires shall be selected according to load, insulation level, function and operating requirements. The wires shall be adequately rated and equipped with fuses/circuit breakers of adequate size. The wiring colors and the minimum cross sections shall be according to specification “Design and Construction of Power Supply Systems”. The wiring shall be carried out solid and safe against damages. Wires shall be bundled and fixed. The wiring shall be laid inside of wiring channels, preferably. If wiring channels will be used, a spare of 20 % shall be foreseen. All circuits and auxiliary contacts shall be terminated on terminal strips. Terminal strips shall have at least 10 % spare terminals. If wires with different potential will be terminated on one terminal strip the respective terminals shall be separated by means of isolating plates. The termination of multiple stranded wires has to be carried out by means of multiple core cable ends. Terminals shall be marked durable and easy readable, corresponding to the drawings. Wires shall be marked on the termination of each wire with the number of the corresponding connection point.

3.02

Overvoltage Protection The UPS shall be designed in a manner such that overvoltages caused by switching and flashes, do not impair the safety in operation of the units. The incomers of UPS and the bus bar of the distribution boards shall be equipped with additionally overvoltage protectors. The electronic devices shall be separately protected against overvoltages.

3.03

PAINTING All components and devices shall have a resistant, long term stable, high quality painting. At least two layers have to be applied.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

Damages, caused by transport, installation, cabling or commissioning shall be repaired in a way, that the original quality is restored. An additional painting at location of installation is not allowed. 3.04

CABLES AND CABLE LAYING For the cable connections between the different parts of the UPS equipment, PVC insulated copper cables shall be used. The cable connections between rectifiers and batteries shall be carried out with single core cables. The cables shall be selected according to nominal voltage, voltage drop and short circuit current. The minimum cross section for power and signal cables shall be according to specification “Design and Construction of Power Supply Systems”. Signal cables shall be provided with copper screen.

3.05

INSTALLATIONS The delivery, installation and commissioning of the UPS equipment shall include, but not limited to the following items: •

Transport to location of installation (if necessary storage), and the complete mounting,

•

Table connections between the different parts of UPS equipment,

•

Grounding and potential equalization for the parts, including connection with the next grounding bus bars,

•

Termination of all cables at the UPS equipment,

•

Commissioning of the functioning UPS equipment,

•

Briefing of the operation personnel in operation and maintenance during installation and commissioning phase and during training on site.

The installation and as well the tests and the commissioning shall be carried out with Contractors own staff and with own tools and measuring/test devices. 3.06

Workshop Tests All components of the UPS equipment shall be tested completely and detailed in manufacturer’s workshop. The batteries may be tested separately. All tests required by the codes and standards as well as all manufactures tests have to be performed. The test program for the work shop test has to be submitted at least 3 weeks prior to start of the tests. The following tests shall be carried out, at least: •

Test of all functions,

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DIVISION 16 ELECTRICAL WORKS

SECTION 16001 UPS EQUIPMENT

•

Check of degree of protection,

•

Check of protection against touching,

•

Mechanical operation test on all equipment,

•

Operation test of the relays, releasers and measuring equipment,

•

Tripping of circuit breakers,

•

Test of auxiliary electrical devices,

•

Insulation and dielectric test,

•

Verification of wiring and terminal blocks,

•

Compliance with the specifications.

Detailed test protocols of all tests performed have to be submitted prior to shipment. 3.07

Site Tests The site tests shall include the following steps: •

pre-commissioning (including “loop testing”),

•

commissioning and test on completion,

•

Performance test including battery capacity test.

The aim of the tests is to ensure the proper function of the complete scope. 3.08

DOCUMENTATION Complete documentation shall be provided for the design, manufacturing, testing, commissioning, start-up, operation, maintenance and repair of the UPS equipment and their components. The documentation of the UPS equipment shall include the following documents and drawings (minimum requirements): a)

Technical data sheets

b)

Layout drawings for all devices, cabinets and racks

c)

Schedules

d)

Single line diagrams

e)

Block diagrams

f)

Wiring diagrams

g)

Termination drawings

h)

Cable lists

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SECTION 16001 UPS EQUIPMENT

i)

Spare parts list

j)

List of used devices with manufacturer

k)

Software and software description (if any)

l)

Operation and maintenance manual

m)

Reports of tests and commissioning with protocols.

The documents listed above shall be handed over for approval. Special attention has to be given to the fact that documentation must be submitted with sufficient time allocated for approval prior to manufacturing /assembly. Documentation has to be prepared in accordance with the relevant ISO standards or in the absence of relevant details in those standards the DIN standards shall apply. The final documentation shall be delivered on paper in sufficient number and with exception of the signed protocols in electronic form, also. The type of the electronic files shall be agreed with the Client. 3.09

SHIPPING All equipment, material and spare parts shall be sufficient packaged. All parts of one uninterruptible power supply should be shipped as a common delivery. The material, especially loose parts and spare parts shall be clearly labeled according to the designation.

3.10

SPARE PARTS AND SPECIAL TOOLS The Contractor shall deliver all spare parts, which are necessary for commissioning and two years operation time (see “General Description of Project and Works”). Spare parts shall be available until ten years after commissioning. All necessary special tools for operation and maintenance of the UPS equipment shall be supplied for each location, at least consisting of: •

1 set of all special tools required for operation and maintenance of UPS equipment,

•

1 set fuses (6 fuses of each used size),

•

key set for cabinet doors and locks,

•

magnetic warning labels in sufficient number, English and Arabic,

•

software for special equipment (if any),

•

One (1) IC pro-programming kit (suitable for all IC in the system).

- END OF SECTION -

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16003 VALVE ACTUATERS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

Discipline: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

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REMARKS

DIVISION 16 ELECTRICAL WORKS

SECTION 16003 VALVE ACTUATERS

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04

Scope Codes and Standards Submittals Environmental Conditions

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09

Selection of Actuators Components and Equipments Tagging Units and Scales Motor Operated Valve Actuators Hydraulic Operated Valve Actuators\ Accessories Special Requirements External Gear Box

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08

EXECUTION Marking Painting Installation Workshop Test Site Test Documentation Shipping Spare Parts and Special Tools

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DIVISION 16 ELECTRICAL WORKS

SECTION 16003 VALVE ACTUATERS

PART 1 – GENERAL

1.01

Scope This document covers the requirements for the design, manufacturing, installation, test and commissioning of valve actuators for the Transportation of Treated Water from Taif STP to Ma’aden Gold Mines.

1.02

Codes and Standards The design, manufacturing, installation, test and commissioning of motor and hydraulic operated valve actuators shall be in accordance with the following codes and standards, at least. The latest revision of the publication referred to shall apply. IEC 60034

Rotating electrical machines

IEC 60038

IEC standard voltages

IEC 60085

Thermal evaluation and classification of electrical insulation

IEC 60529

Degrees of protection provided by enclosures (IP Code)

IEC 60534

Industrial-process control valves

ASME

Section VIII, Unfired pressure vessels

As far as the power supply authority (SEC) and permits of other authorities require additional codes and standards, respectively impose additional requirements, these are also part of the contract. 1.03

Submittals Forward to the Company Representative for review and approval the following submittals. Refer also to appropriate specification sections for other submittal requirements. A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

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DIVISION 16 ELECTRICAL WORKS B.

Prior to Commencing WORK: Shop drawings of proposed installations that deviate from the original design.

C.

Prior to Final Acceptance: Record documents which shall indicate installed conditions for:

D.

1.04

SECTION 16003 VALVE ACTUATERS

1.

Major raceways systems, size and location, for both exterior and interior; locations of control devices; distribution and branch electrical circuitry; fuse and circuit breaker size and arrangements.

2.

Equipment locations (exposed and concealed), dimensioned from prominent building lines.

3.

Approved substitutions, modifications and actual equipment and materials installed.

Maintenance Manuals: Submit maintenance manuals which shall include the following information for equipment items: 1.

Description of function, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of replacement parts.

2.

Manufacturer's printed operating procedures to include start- up, break-in, and routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; and summer and winter operating instructions.

3.

Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

4.

Servicing instructions and lubrication charts and schedules.

Environmental Conditions The valve actuators shall be designed and constructed for intermitted operation at full load under the climatic and environmental conditions as described in the specification “Design and Construction of Power Supply Systems”.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16003 VALVE ACTUATERS

PART 2 - PRODUCTS 2.01

Selection of Actuators In general it shall be the responsibility of the driven equipment manufacturer to select and coordinate the required actuator type. This includes the co-ordination of the performance data as also the mechanical construction and coupling requirements. The valve closing speed shall be in a rate of 300 mm/min, unless otherwise specified. The speed of actuators for control valves must be according to the purpose of these valves. The actuators shall entirely be suitable for the duty intended (opening and closing of valves) under the maximum differential pressures. If not specified otherwise the actual power output of the actuators must be selected to meet the maximum required torque, multiplied by a factor of 1.25. The actuators shall be suitable to operate at nominal output power with the voltage drops as described in the specification “Design and Construction of Power Supply Systems”. Actuators which will be mounted on valves for pipelines with cathodic protection must be electrically isolated from the valve by means of isolation joints. The joints shall be integrated in the driving shaft.

2.02

Components and Equipment The Contractor has to take care that all components and equipment are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals. All components and equipment shall be designed for continuous duty at rated load and under the given climatic conditions. Standard industrial high performance systems and components of supplier’s standard lists shall be used as far as possible. Components and equipment of same kind and type shall be selected for equivalent functions. The interchangeability must be guaranteed.

2.03

Tagging All components, equipment and installations shall receive the respective tagging plates, labels, etc., which have to be of extremely durable material resistant against the environmental conditions.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16003 VALVE ACTUATERS

For further requirements, reference is made to specification “Design and Construction of Power Supply Systems”. 2.04

Units and Scales The metric system on basis of SI-units shall be used for all scales and indications.

2.05

Motor Operated Valve Actuator General The motor operated valve actuators shall be consist of the following main parts •

electrical motor,

•

gear with handwheel,

•

control unit,

•

Valve connection according to ISO 5210.

All parts of the actuator shall be assembled to a integral unit, suitable for direct mounting on the valve. Motor and Gear The electric actuator motors shall be of the squirrel cage three phase induction types, for operation from a three-phase power supply of 400V AC, 60 Hz and is to be sized for short time operation of minimum 15 min including 20 starts. The motor shall be suitable for direct on line starting and shall be capable of operating the valve under all the specified conditions with 80% of rated voltage at the terminals, without exceeding the permissible temperature rise in any part of the motor. The motor windings shall have class ‘F’ insulation with a temperature rise limited to class ‘B’. The protection against overheating shall be an integral part of the motor. The drive shall be through a gearbox, which incorporates a clutch mechanism to allow manual operation of the valve via a handwheel. The handwheel shall be permanently connected, and may be integral, bolted or clamped. It shall be the locking type with a declutching mechanism. The operating force shall be limited to 245 N (25kgf) at the rim of the wheel. The handwheel must be lockable. A local, mechanical valve position indicator shall be provided within the actuator body.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16003 VALVE ACTUATERS

Control Unit The control unit shall mainly consist of the following devices: •

reversing contactor starter with all necessary accessories,

•

control transformer,

•

anti-condensation heating, powered from internal supply,

•

adjustable torque switches for both rotating directions,

•

min. two (2) limit switches for open position, each equipped with 1NO+1NC contact,

•

min. two (2) limit switches for closed position, each equipped with 1NO+1NC contact,

•

min. two (2) limit switches, easily and independently adjustable for any position of valve travel, each equipped with 1NO+1NC contact,

•

local control station with the functions Open/Stop/Close,

•

selector switch for the operation modes Local/Off/Remote, lockable with pad or key lock,

•

Electronically position indicator, 4 – 20 mA (only for actuators of control valves).

The contacts shall be potential free and suitable for 250 VAC, 1.5 A and 60 VDC, 1 A respectively. All wiring shall be brought to an easily accessible, segregated terminal board. The wires must be suitable labeled according to the wiring diagram. Cable entries shall be threaded ISO to suit cable size. In minimum three (3) entries with cable gland must be provided. If specified, the actuators may be of the intelligent type with control via Data Hiway with position feed back to the station control system. Intelligent actuator shall be provided with isolator switches, which isolate the actuator but maintain the Hiway to permit maintenance of the actuator. 2.06

Hydraulic Operated Valve Actuators General The hydraulic actuator shall be of a double acting piston type and provided with a connection for an external hydraulic power unit or shall be combined unit (actuator and hydraulic power unit). Double acting piston operators shall employ a five port two position solenoid operated shuttle valve. The shuttle valve shall be of sufficient capacity to ensure that the valve can be operated in the required time.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16003 VALVE ACTUATERS

All tubing shall be in 316 stainless steel with a outer diameter of 12 mm and a wall thickness of 1.5 mm. All tube bending shall be carried out cold by gradually applied pressure using an approved type-bending machine. Bending shall not include hammering or the application of any force, which may damage the tube. Tube cutting shall be executed using an approved type tube cutter, saw cuts are not to be made. After cutting, the ends shall be dressed with the appropriate tool to ensure that a restriction has not been introduced. Prior to installation, the tubing shall be internally cleaned, degreased with a suitable solvent and then dried. Cable entries shall be threaded ISO to suit cable size. Hydraulic Power Unit and Accumulators The nominal level of feeding voltage is 400 V, 60 Hz. The supply will be carried out via one (1) moulded case circuit breaker or a fuse, situated in a distribution board. All other elements for control voltage distribution, etc. must be located inside the actuator. Instrumentation within the hydraulic power unit shall relate to the monitoring and control of the power pack unit and shall be as simple as possible and be of the minimum consistent with the requirements for reliability and safety. Redundant components such as dual filter regulators and dual strainers shall be provided to enhance overall system reliability. No single fault shall prevent operation of the system or cause shutdown of the control equipment fed by the hydraulic power pack. The motor for the hydraulic pump to generate the required pressure in the hydraulic system shall be of the squirrel cage three phase induction types. The motor must be equipped with all associated elements for: •

electrical protection of the motor,

•

start/stop facilities (contactor) controlled by local hydraulic pressure,

•

on/off switch,

•

local indicator for power supply and availability,

•

Potential free contacts for remote failure annunciation.

At minimum two junction boxes shall be provided, one for power connection, one for status signals transmission. The system must be provided with sufficient number of accumulators to permit two (2) power strokes of the actuator without the need to recharge the accumulators. Hydraulic accumulators shall be of the bladder type forged construction. Material of construction shall be steel. The hydraulic system shall be fitted with the necessary pressure gauges, switches, and relief valves to ensure safe reliable operation. The following electrical instrumentation is required as a minimum: •

pressure switches for pump on/off control, set point adjustable,

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DIVISION 16 ELECTRICAL WORKS

SECTION 16003 VALVE ACTUATERS

•

pressure switches for oil pressure low remote signal, set point adjustable,

•

level switch for oil level maximum and minimum remote signal,

•

Local pressure gauge.

The type of pressure gauge shall be bourdon tube in stainless steel (nominal size 160 mm, accuracy class 1.0, scaled in “bar”) with liquid filling and laminated safety glass window. The range and working pressure must be according to hydraulic system pressure. The contacts shall be potential free and suitable for 250 VAC, 1.5 A and 60 VDC, 1 A respectively. All switches are to be housed in enclosures of stainless steel. All signals for remote control must be cabled up and terminated to local junction box included the scope of supply. Wiring and termination as well as internal cables, cable glands etc. have to be in accordance with the relevant applicable specifications for e.g. “Cables and Cable Laying”. Each Hydraulic Power Unit cabinet shall be stainless steel and fully insulated. Hydraulic System shall be provided with hand pump to allow the valves to be operated in the event of pressurization failure. Hydraulic reservoirs where provided shall be certified and stamped in accordance with ASME VIII Div. 1 and shall be supplied with ASME VIII certified and stamped pressure relief valves and also pressure gauges. 2.07

Accessories Accessories such as solenoid valves, pressure pilots, relays, etc., shall be supplied and mounted by manufacturer. The actuator shall be equipped with solenoid valves pending on the functionality, fail safe or normal operation, of the valve with a coil rating of 230 VAC. Integral terminals must be provided for the termination of cabling. Flying leads from the coil enclosure are not allowed. Solenoid valves shall be 316 stainless steel bodies and trim as standard. Solenoid valves shall have 1/4” NPT (F) connections and 6 mm orifice as a minimum, and shall be selected to ensure that the specified control stroking times can be achieved. For control valves subject to vibrations the solenoid valves must be separately mounted and not on the valve. Solenoid valves shall be mounted between actuator and position indicator. The actuators shall be equipped with position indicators. The position indicators must be installed directly on the valve stem such that they show valve position rather than actuator position. For remote control the following devices are to be installed: •

two (2) limit switches for open position, each equipped with 1NO+1NC contact,

•

two (2) limit switches for closed position, each equipped with 1NO+1NC contact,

•

Electronically position indicator, 4 – 20 mA (only for actuators of control valves).

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DIVISION 16 ELECTRICAL WORKS

SECTION 16003 VALVE ACTUATERS

The devices shall be properly installed and protected against mechanical damage and/or malfunction. Sensors and switches must be pre-cabled to a junction box mounted on the actuator using 20 mm metallic glands. Cable connection shall also be in metric sizes. The sensors and switches are to be located such that accidental actuation is not possible, including movements caused by wear. They shall be unaffected by vibration. Adjustment facilities shall be locked after setting by drilling and pinning. Actuator’s junction boxes shall be made from 316 stainless steel. Cables shall be clearly identified at both ends using securely fitted PVC cable markers. All cable cores and wiring shall be fitted with core identification ferrules at each end. All cores shall be terminated in terminals. 2.08

Special Requirements The Vendor/Manufacturer shall have local representative in Saudi Arabia and shall have maintenance team available with minimum five years of experience to attend any maintenance issues.

2.09

External Gear Box For larger valves, ball valves or where required for other reasons, between actuator and valve a oil bath or grease lubricated gear box shall be placed. The gear unit shall have the following features: •

self-locking mechanism,

•

valve position indicator, visible from a distance of 20 m,

•

internal limit stops,

•

provisions for lubrication and drain

The body shall be of cast iron, preferably. The connections should be according to ISO 5210 and/or ISO 5211. The installation of a handwheel with locking devise instead an actuator must be possible. PART 3 - EXECUTION 3.01

Marking All actuators shall be fitted with a permanently attached stainless steel labels (not wired-on) showing as a minimum the following information: •

manufacturer’s name,

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DIVISION 16 ELECTRICAL WORKS

SECTION 16003 VALVE ACTUATERS

•

model & serial numbers,

•

instrument tag number,

•

manufacturer’s standard data,

•

Position on actuation medium failure.

In addition, the nameplate shall give the actuator design torque. 3.02

Painting The painting shall be as per the approved manufacturer standard at least consisting of: •

one coat of two-component epoxy zinc chromate rust-inhibiting primer,

•

one intermediate coat of two-component epoxy primer,

•

Two top coatings for two-component resin, colour as per the approved colour code schedule.

Total thickness of dry protective paint coating shall be at least 120 μm. Damages, caused by transport, installation, cabling or commissioning shall be repaired in a way, that the original quality is restored. An additional painting at location of installation is not allowed. 3.03

INSTALLATION Installation and alignment shall be carried out in accordance with the instructions and recommendations of the valve manufacturer.

3.04

Workshop Tests All valve actuators shall be tested completely and detailed in manufacturer’s workshop. All tests required by the codes and standards as well as all manufactures tests have to be performed. After installation of the actuators on the valves, respective tests and the adjustment shall be carried out. The test program for the work shop test has to be submitted prior to start of the tests in compliance with the Project Procedure Manual. Complete tests on valve actuators will normally not be required if respective type tests certificates are available. Detailed test protocols of all tests performed have to be submitted prior to installation.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 3.05

SECTION 16003 VALVE ACTUATERS

Site Tests The site tests shall include the following steps: •

Pre-installation testing,

•

Pre-commissioning (including “Loop Testing”),

•

Commissioning and test on completion,

•

Test runs,

•

Performance tests.

The aim of the tests is to ensure and prove the proper function of the complete scope. 3.06

Documentation Complete documentation shall be provided for the design, manufacturing, testing, commissioning, start-up, operation, maintenance and repair of the valve actuators and its components. All documents shall be in English language. The documentation of motors shall include the following documents and drawings (minimum requirements): a)

Layout drawings

b)

Wiring diagrams

c)

Termination drawings

d)

Technical data sheets

e)

Calculations, protocols, certificates

f)

Spare parts list

g)

Performance curves

h)

Operation and maintenance manual

i)

Reports of tests and commissioning with protocols.

The documents listed above shall be handed over for approval. Special attention has to be given to the fact, that documentation must be submitted with sufficient time allocated for approval prior to manufacturing /assembly. Documentation has to be prepared in accordance with the relevant ISO standards or in the absence of relevant details in those standards the DIN standards shall apply. The final documentation shall be delivered on paper in sufficient number and with exception of the signed protocols in electronic form, too. The type of the electronic files shall be agreed with the Client. DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 3.07

SECTION 16003 VALVE ACTUATERS

Shipping All equipment, material and spare parts shall be sufficient packaged and shall be shipped as a common delivery. The material, especially loose parts and spare parts shall be clearly labeled according to the designation. Actuators shall be coupled with the respective valve before shipping.

3.08

Spare Parts and Special Tools The Contractor shall deliver all spare parts, which are necessary for commissioning and two years operation time (see “General Description of Project and Works”). Spare parts shall be available until ten years after commissioning.

- END OF SECTION -

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

Discipline: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

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TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE Page 1 of 19

DIVISION 16 ELECTRICAL WORKS

SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03

Scope Standards Environmental Condition

PART 2

PRODUCTS

2.01 2.02 2.03

System Characteristics Design and Construction Requirements Wiring

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09

EXECUTION Painting Installation Requirements Battery Limits Shipping Storage Upon Arrival Acceptance and Testing Maintanace Spare Parts Documentation

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DIVISION 16 ELECTRICAL WORKS

SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

PART 1 - GENERAL 1.01

Scope This specification covers the general and overall requirements for design, manufacturing, construction, installation and test of the electrical power supply systems for Transportation of Treated Water from Taif STP to Ma’aden Gold mine sites.

1.02

Standards The electrical power supply systems must be designed, manufactured and erected according to the relevant codes, standards, rules and regulations as listed below, all in latest valid edition: IECIEEEISOSISASOSECHCISS-

Recommendations (International Electrotechnical Commission) Codes (Institute of Electrical and Electronic Engineering) International Organization for Standardization International System of Units Saudi Arabian Standards Organization as far as applicable for equipment direct purchased in the KSA (Kingdom of Saudi Arabia) Codes standards, rules and regulations of the Saudi Electricity Company as far as required for electrical power feeding interface Security and Safety Directives (High Commission for Industrial Security and Safety)

The individual code numbers of the particular standards, rules or regulations are listed in the respective equipment specification and/or in the relevant chapters of this specification. As far as authority permits require additional codes and standards, respectively impose additional requirements, these are also part of the contract. Other standards or regulations will only be allowed for specific equipment or systems, if not covered by any of the above listed standards. However, all such other standards are subject of approval by the Engineer. 1.03

Environmental Conditions The equipment for the electrical power supply systems shall be designed and constructed for continuous operation at full load under the given climatic and environmental conditions. The environmental conditions will be classified as follows: a)

Outdoor Conditions Design temperature Relative Humidity Altitude Wind load

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

max. + 80 °C max. + 50 °C (shade) min. 0 °C up to 100 % from sea level up to 1600 m above sea level up to 160 km/h DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

All equipment and materials provided for outdoor installation shall be resistant against the prevailing climatic conditions, sand, sand storms and strong sun radiation. In general all outdoor equipment must be equipped with sun and rain protection cover or shed. b)

Indoor Conditions For electrical rooms in general air conditioning will be provided. Only in pump buildings and other technical buildings ventilation is foreseen. The temperature in the various rooms depends on the room classification for air conditioning and ventilation (see General Specification for Project and Works). In ventilated buildings the equipment shall be suitable for a design temperature of +55 °C. The design temperature for electrical equipment installed in air conditioned rooms shall be +40 °C suitable for operation even if the HVAC equipment fails. The switchgears shall have type test certificates corresponding to 40°C as per IEC. However, the manufacturer shall include a suitable de-rating factor to allow operation at 50°C. For areas with increased environmental conditions, such as water sprays, aggressive or hazardous atmosphere, the power supply equipment shall be specially protected as outlined in item “Mechanical Protection” and in the detailed specifications. Areas with possible water sprays are pump houses and other buildings/rooms equipped with process equipment, valve shafts, equipment/instrument shafts, etc. Areas with aggressive and dangerous atmosphere are in the chlorination buildings. Areas with hazardous atmosphere are in the Diesel storage tank shaft and in the emergency diesel room at the diesel day tank.

PART 2 - PRODUCTS 2.01

System Characteristics Main Supply Network The specific network feeder configurations and contract limits for the various stations of the Project are shown in the respective single line diagrams. Voltage Levels The applicable main supply network voltages are as follows: • • • •

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33 kV 13.8 kV 4.16 kV 480/230/120 V. DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

The operating and control voltage levels are as follows: •

480 V ± 10%

main distribution, pump motors, feeder voltage of variable speed drive (at Transfer Pump Station STP Taif)

•

4.16 kV ± 10%

main distribution, pump motors, feeder voltage of variable speed drive (at Master Pump Station 56km or 70 km from STP Taif)

•

480 V ± 10%

main distribution, pump motors, feeder voltage of variable speed drive (at Ad-Duaihi Storage Facility)

•

480/230V ± 10%

process equipment, building installation, HVAC, auxiliary systems

•

230/120V ± 10%

Lighting & Power outlets

•

230V AC ± 5%

•

24V DC ± 5%

Uninterrable power supply for process, equipment, control and signal voltage

control

solar power supply voltage for remote stations, if applicable

The grounding of the power supply networks shall be as follows: •

33 kV, 138 Kv

supply network according to the SEC regulations

•

4.16 kV

main distribution network, as per particular requirement (At Master Pumping Station 56 km or 70 km from STP Taif)

•

13.8 kV / 480 V

Transformer star point solidly grounded (at STP Taif)

•

33 kV / 4.16 kV

transformer star point solidly grounded (at Master Pump Station)

•

4.16 kV / 480 V

Transformer star point solidly grounded (at Master Pump Station)

•

230 V

AC not grounded, earth fault monitoring

If the 33 kV / 13.8 kV network will be installed in stations or at areas where this voltage level already exists, the grounding of the new network shall be the same as for the existing facilities. Voltage Drop The allowable voltage drop for all power supply sources shall be in the range of ±5% . DICIPLENE: ELECTRICAL DOCUMENT No.: MGBM-SPEC-0001 Rev. 00 15 Mar, 2011

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SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

Frequency The frequency for all alternating power supply sources shall be 60 Hz ± 5 %. Short-Circuit Power The short-circuit power for the various power supply parts and components have to be calculated on basis of the available short circuit power of the feeding network and shall comply with standard values only. Future extension might be considered as indicated on the detail single line diagrams. The Contractor will be responsible to make the necessary inquiries and shall base the final design on these results. The network data, if given in the relevant Tender Contract Documents, are indicative only. Power Factor The overall power factor of the station equipment on the interface to the supply network shall be better or at least equal to 0.90 at rated load. If necessary, power factor compensation equipment shall be provided as part of the contract. System Grounding The stations will be equipped with an equipotentially meshed grounding network. All exposed conductive parts or elements of the station systems will be connected to this network, in detail: • • • • • •

electrical equipment, electric motors, pumps and other machinery, metallic frame works, structures, walkways, etc., vessels and all kinds of metallic containers, metallic framework of buildings and houses, metallic reinforcement of concrete foundations,

The grounding network must be designed and constructed in compliance with the specification “Earthing and Lightning Protection”, the supporting grounding calculations shall be performed by Contractor. The earth resistance of the overall interconnected station grounding network shall not exceed 1 Ω. For line valve stations a maximum earth resistance of 2 Ω will be accepted. For the water storage tanks cathodic protection system the direct low-ohmic grounding of tanks and with the tank connected electrical equipment is not permitted. For this application respective isolation joints for instruments, actuators, etc. shall be used. Lightning Protection DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

All buildings and exposed high structures of the complete system shall be equipped with static lightning protection system. The lightning protection system shall be designed and constructed in compliance with the specification “Earthing and Lightning Protection”. Electrical Protection All electrical equipment must be protected against direct contact, indirect contact, over voltage, under voltage, over current, earth fault, transformer buchholz relay, loss of field, reverse power, differential potential, thermal protection, and short circuit in normal service and in case of a fault in accordance with the relevant IEC regulations. Installations up to 1000 V will be protected by use of protective multiple earthing (neutral conductor and separate protective conductor). For special application the differential current earth-leakage protection shall be used. The neutral conductor and the protective conductor must be interconnected in the main LV MCC only. The TN-C-S network distribution system in accordance with IEC shall be applied. The electrical protection for high and medium voltage systems above 1000 V must be designed on basis of the given medium voltage network grounding conditions. Earth fault supervision/monitoring must be provided for all ungrounded medium voltage networks. The electrical installation of buildings, including the protection for safety must follow the requirements defined in IEC 60364. Harmonics Generally the harmonic content of the alternate circuits at the supply network side must be reduced as much as possible. The Contractor has to provide a detailed investigation and calculation based on the actual network conditions at each site and considering all installed equipment which may produce harmonic distortion. The design and study with respect to the harmonic load content and harmonic distortion in the power supply system shall be subject to approval. Limits of harmonic distortion shall comply with the requirements of approved international standards and SEC requirements. However, the total voltage distortion at the worst case location of the 13.8 kV side shall not exceed 2.5 %, if the SEC requirements are not more stringent. All necessary fixed installed components and equipments necessary to achieve above mentioned limits must be provided and are part of the contract. Mechanical Protection Depending on the installation and application, the following degrees of protection for enclosures, in line with IEC 60529, are required for the various electrical equipments. The following table is to be considered as guideline for minimum requirements. The finally DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

selected degrees of protection for enclosures of each individual equipment and material are subject of approval. The degrees of protection for lighting fixtures with accessories and electrical installation material for buildings is included in the specification “Electrical Installation for Buildings” and in the specification “Outdoor Lighting”. Forward to the Company Representative for review and approval the following submittals. Refer also to appropriate specification sections for other submittal requirements. * For rooms with HVAC and without water pipes only ** For submersible pumps For switchgear extensions the IP class of the existing switchgear shall be applied. Equipment

Internal, dry locations*

MV switchgears LV main distribution boards LV sub distribution boards UPS rectifier and inverter cabinets UPS distribution boards MV motors MV motor terminal boxes LV motors LV motor terminal boxes Motor operated valve actuators Hydraulic operated valve actuators Equipment terminal boxes Junction boxes

Outdoor

IP 41 IP 41 IP 41

Internal with possible water sprays/ damp --IP 54

--IP 54

Below ground/ shafts --IP 55

IP 21

--

--

--

IP 41 --IP 54 IP54

IP 54 IP 55 IP55 IP 55 IP55

IP 54 IP54 IP54 IP 55 IP55

IP 55 --IP 55/IP58** IP55/IP58**

--

IP 67

IP 67

IP 67

--

IP 55

IP 55

IP 55

IP 31 IP 55

IP 55 IP 55

IP 55 IP 65

IP 55 IP 67

Interference and Electromagnetic Compatibility For design and construction special care is required to avoid all negative effects of high voltage interference caused by: • • •

High voltage installations High voltage cable systems Other high voltage equipment or sources

All necessary precaution and counter measures must be considered for design and layout of the equipment. For limits of interference and protective measure the requirements of IEC 61000. DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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Equipment shall be type tested in accordance with the following criteria and shall show normal performance within the specification limits after the tests: • • •

Immunity against electrical fast transient/bursts acc. to IEC 61000-4-4 test severity level 4 Immunity against interference of static electricity acc. to IEC 61000-4-2 sharpness grade 4 Immunity against electromagnetic fields acc. to IEC 61000-4-3 sharpness grade 3

In addition it is the responsibility of the Contractor that all components and systems delivered within his scope will properly work under the actual conditions prevailing at the location of installations without any disturbance or malfunction and do not influence other equipment in an not allowed way. Radio Interference Suppression Radio interference suppression for all equipment and devices shall be grad N. Hazardous Protection All electrical equipment and components, including their installations which are located in hazardous areas (e.g. diesel storage tanks, EMG diesel day tanks, etc.) must be in compliance with the requirements of the applicable IEC Ex-standards. 2.02

Design and Construction Requirements General In addition to the requirements specified in the Tender Contract Documents and in the individual specifications, the following applies in general for all equipment and components of the power supply systems. The electrical power supply systems including their various components shall be designed, manufactured and installed in such a way that they are able to withstand during full load operation under the given climatic design conditions, the rated currents continuously as well as the maximum expected short circuit interrupting currents and instantaneous short circuit currents in terms of thermal and mechanical stress without any damage, dislocation or dangerous temperature rise. The Contractor has to take care that all components and equipment are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals. Standard industrial high performance systems and components of supplier’s standard lists shall be used as far as possible. Components and equipment of same kind and type shall be selected for equivalent functions. The electrical equipment, as transformers, low voltage boards, cables, etc. shall be calculated

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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including an available spare capacity of 20 % in rating and for number of equipment feeders, as far as not otherwise specified in the detailed specifications or indicated on drawings. Mechanical Construction of Cubicles, Cabinets, Panels and Switchboards The doors of the different cabinets, panels and switchboards must be equipped with a uniform key lock system, consisting of: • •

door handle with locking bolts, to keep the door in the closed position key system to lock the door

The MV equipment shall have different keys than the LV equipment. The proposed key-lock system must be approved by the Engineer and the Client. The uniformity of the key-lock system with the various equipment manufacturers will have to be coordinated by the Contractor. The keys shall be sorted in each electrical/equipment room in suitable key boxes, lockable by pad-lock. All cubicles, cabinets, panels and boards must be protected against dripping water from the top. Pressure relief and ventilation openings on the top of the panels must be designed accordingly. The live parts inside each cabinet, cubicle and board must be adequately protected in order to prevent accidental touching during checking and routine maintenance. Each cabinet shall have its own lighting fixture installed inside, automatic switch on/off shall be provided by opening/closing the door. In addition at least one (1) socket outlet for 230 V AC shall be installed in each cabinet. Space heating devices with humidity control shall be provided. Cable entry into the cubicles, cabinets, panels and boards is in general from the bottom, if not defined otherwise in the respective detailed specification or in the data sheets. 2.03

Wiring For internal wiring circuits in the various cubicles, cabinets, panels and boards, in general PVC insulated single core, stranded copper conductors with the following minimum conductor cross-sections shall be used: • • • • •

power circuits (acc. to rated current and at least 2.5 mm² or 4 mm² voltage drop) measuring circuits 2.5 mm² auxiliary power circuits 1.5 mm² control signaling and annunciation circuits 1.5 mm² for prefabricated control modules, e.g. LV drawers or speed regulation components 0.75 -1.0 mm² (agreement by Engineer necessary)

For the individual voltage levels the following colors of the PVC insulated conductors shall be used: DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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•

400/230 V AC

black or black/brown/black (phase) green/yellow (protective conductor)

blue

(neutral)

•

230 V AC

black or brown (phase) blue (neutral)green/yellow (protective conductor)

•

24 V DC

red (+), black (-)

•

Other voltages

grey or manufacturers standard

All wires and cables including control wiring within cubicles, cabinets, panels and boards shall be clearly tagged on both ends with permanent type wire/cable markers, in conformity with the wiring and termination diagrams, showing the respective equipment terminal number. The control, signal and alarm circuits must be wired separately and protected by individual miniature circuit breakers or fuses within the various cabinets. For connection with the power supply source no looping is allowed, that means if one relay, etc. will be disconnected from the power supply wires the other consumers must remain active without tripping. Cables and Bus Bars For detailed construction and design requirements of cables reference is made to IEC 60227, IEC 60287 and IEC 60502. The cross-section calculation for cables and bus bars must be in accordance with the values for short circuit levels, maximum permissible voltage drops, current capacities and the reducing factors. Unless otherwise specified the current carrying capacity of cables shall be as follows: • • • • •

Transformer feeding cables shall have a current carrying capacity equal to the transformer rated current. For fan-cooled transformers the higher fan-cooled rating must be used. Cables feeding bus bar system shall have a current carrying capacity equal to the design current rating foreseen for the bus bars. Cables feeding a bus bar system, divided into sections and connected by tiebreakers shall have a current carrying capacity such as to withstand the maximum load demand of both bus bar sections. The motor feeding cables shall have a current carrying capacity equal to the motor rated current. All the remaining cables not mentioned above shall have a current carrying capacity equal to the maximum rated current demand of the connected equipment.

The cables for voltage above 1000 V shall be sized in such a way as to withstand without injury the effects of overheating due to short circuits during the time provided for the tripping DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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of circuit breakers immediately up stream of these cables. Further, the sizing of these cables shall consider the fault clearing time of the back-up protection. The maximum short circuit level multiplied by a safety factor of 1.25 shall be used for cable sizing. The cable conductors shall have the following minimum cross section: • • • • • •

low voltage power cables cables for lighting circuits high and medium voltage cables control cables instrumentation cables Telecommunication cables

2.5 mm² 2.5 mm² 70 mm² 1.5 mm² 0.75 mm² (stranded) 0.8 mm (wire diameter)

The cross-section calculation shall be based on the following max. permissible conductor temperature of the various cable types: • • • • • • • • •

PVC insulated cables 70°C XLPE insulated cables 90°C Reducing factors for cable cross-section calculation depending on the laying areas and conditions shall be applied as defined in IEC 60287, considering: laying below ground or above ground, underground soil temperature up to 35°C - 40°C, ambient air temperature up to 55°C, load factors number of multiple core or single core three-phase cable systems in one trench or/on one tray, Thermal resistivity of soil for direct buried cables of max 120°C cm/W after cable installation shall be provided. For cable sizing calculations 240°C cm/W shall be assumed.

All power cables shall have the standard IEC color coding. If the cables will be purchased in KSA and the standard IEC color coding is not available, the wire colors Red, Yellow, Blue, and Black (neutral) will be also allowed. Cable connection to the respective switchboards, cubicles, panels and motor terminal boxes must be possible in an easy and safe way. The terminal boxes, terminals and connection racks must be designed for the number, size and type of cables, cores and wires. For further details, reference is made to the specification “Cables and Cable Laying”. Voltage Drops The voltage drop for the various parts of the electrical system shall be held within the values indicated in the following table. The values are referred to the nominal voltage of the system. The voltage drop calculations in case of re-acceleration of a group of motors after a short voltage drop shall be based on the short circuit impedance value of the motors. DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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The permissible maximum overall worst case voltage drops shall be as follows: • • • • •

at the consumer terminals at rated power 5% at the motor terminals during start up 12 % supply cables for lighting and no-break equipment 2% supply cables for distribution boards at rated power 2% at the bus bar of distribution boards during start up of largest motor 12 %

The voltage available at the motor terminals during start up will in any case be adequate to ensure the start-up or re-acceleration of the motor (even at full load where required) without damage of the motor. The maximum start-up voltage drop of 15 % is the sum of voltage drop in the cables, the bus bars and transformers for motor feeding. Instruments For all instruments and indicators necessary for control and monitoring of the power supply equipment, in general the metric SI-system shall be used for scales. Local Control Stations For each low voltage or medium voltage motor a local control station shall be provided, which is to be placed closed to the respective motor. Regarding the function of the motor (with or without supervision from the station control system) the local control station will be connected directly with the station control system or with the supplying distribution board.

The local control station shall consist of the following operation elements: • • •

key-operated switch for activation of control station, push button for motor “On”, push button for motor “Off”.

If necessary for special machines (e.g. machines with open, rotating devices) the control station shall be equipped with an emergency push button. This push button must also be activated, if the control station is not in operation. Signalling For external signaling circuits between local field mounted panels and equipment to boards and cabinets within the buildings, as also signalization circuits between boards and panels inside the buildings in general 230 V AC shall be used. Internal annunciation and signaling lamp circuits can be supplied by 24 V AC/DC. In this case, DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

the 24V power packs for internal circuits shall be incorporated in the various cubicles, cabinets, boards and panels and will be fed from the 230 V AC UPS system. In general all signal lamps shall be of the multiple LED type. Lamp test circuits with separate push buttons shall be foreseen. Labelling and Marking The labeling and marking of all electrical equipment, panels, cabinets, junction boxes, etc. shall be carried out in conformity with the respective drawings and documents. In general all inscription plates and labels must be clearly visible and durable against the ambient conditions. Fixing of plates and labels by screws or rivets only, adhesive labels may be allowed only for small relays, contactors, etc. within cabinets and panels. Paper labels will be not allowed for any kind of equipment. The following kind of labels shall be used: a) b) c) d)

Name and rating for main equipment (motors, transformers, etc.) All labels and markers shall be of stainless steel plates with engraved black letter and with inscription in English and in Arabic. Name and rating for process and auxiliary equipment These labels shall be of stainless steel plates with engraved black letter and with inscription in English for rating plates and English and Arabic for name plates. Inscriptions for indoor cubicles, cabinets, boards and panels These labels shall be of white hard plastic plates with engraved black letter and with inscription in English. Inscriptions for outdoor cabinets, boards and panels These labels shall be of stainless steel plates with engraved black letter and with inscription in English.

The minimum size of the inscription shall be 5 mm. In addition, each equipment as motors, pumps, motor/hydraulic actuators, cubicles, boards, panels, cabinets, etc. must be equipped to the manufacturers name and rating plate with the respective tag -and/or plant identification number. This number must be fixed on the equipment by appropriate sized stainless steel plates. In case of indoor cubicles, cabinets, boards and panels, hard plastic or aluminum plates can be used. The tag -and identification numbers will be inscribed in English, only. The minimum size of plates and the size of the inscription shall be approved by Client. Furthermore, all Arabic translations are also part of Clients approval. PART 3 - EXECUTION 3.01

Painting Painting of all equipment and devices which forms part of the electrical power supply systems, such as boards, panels, cabinets, motors, etc. shall be in compliance with the approved

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DIVISION 16 ELECTRICAL WORKS

SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

manufacturer standard. The Contractor must submit his painting specification including color code schedule of top layer color for all electrical equipment, as a subject of approval by Client. As a general rule all electrical cabinets, boards and cubicles must be painted outside as well as also inside. The entire painting shall be sufficiently resistant to stand transport, assembly and maintenance operations without abnormal deterioration. Preferable flame retardant paint coatings shall be used. In all cases where site erection work exposes bare metal, such as a drilling or punching out of holes, e.g. for cable gland entry, these areas shall be protected by the immediate application of a protective coat similar to the original. Any machines or bright faces and parts which are not painted (e.g. shaft of motors and valves etc.) must be protected against corrosion by suitable agents prior to installation. Marking, name, rating and tag -number plates shall not be painted and have to be covered during painting or fixed on the equipment after painting. 3.02

Installation Requirements General The below listed requirements shall be treated as a general instruction for layout of electrical rooms, site preparatory works and installation of power supply systems and equipment. For more information reference is made to the detail specifications. Electrical Equipment Rooms In electrical equipment rooms (HV switchgear rooms, MV switchgear rooms, LV switchgear rooms, etc.) no water lines or drain lines shall be routed. One exception is rooms, equipped with water cooled converters, where the water feeder lines shall be installed on the shortest possible way. Independent of this, all electrical equipment must be protected against drip water from the top. Escape ways must be provided for all electrical equipment rooms and rooms containing machinery or other electro-mechanical equipment. HV, MV and LV rooms must be provided with at least two escape way doors. Escape way doors must allow opening from inside without using any key. Escape way signs shall be provided inside the rooms above each escape way door and at other distinct locations.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

Installation of Equipment HV-, MV-, LV switchgears and other cabinets, panels and boards must be installed to guarantee sufficient space for cable connection, operation, maintenance and future installation of further devices. All installation works must be performed in a workmanlike-manner. Installation of structures, equipment, panels, boards, etc. have to be performed in upright, horizontal position and parallel to walls, in accordance with the approved layout and erection drawings. Before installation of equipment the buildings and rooms must be ready for installation that means: • • • • •

walls and ceiling cleaned, painting completed, doors and windows installed and tight, foundation frames, supports, structures installed, screed finished, lighting installed or temporary illumination provided.

The final false floor plates (if any) shall be installed after switchgear and switchboard erection to avoid damages. For additional requirements and special room conditions for erection, the manufacturer instructions of the different equipment and materials must be strictly observed. All cubicles, cabinets and switchboards shall be erected on base frames, which are either embedded in the concrete floor/screed or incorporated in the double floor construction. If not specified otherwise the horizontal tolerance of the frames shall not exceed ± 1.5 mm over a length of 5 m. The alignment of the frames must be checked during installation of frames and prior to commencement of cubicle and cabinet installation. Fixing of cubicles, cabinets and boards at the base frames must be provided as per the detailed instructions of the manufacturer. In each HV-, MV-and LV-room at each station the single line diagram of the respective switchgear and switchboard arrangement shall be fixed on the wall in the respective room. These single line diagrams will be printed on durable and light stable foils and shall reflect the as-built status after plant commissioning. The necessary number and type of special tools and keys, required for operation and routine inspection, including all warning plates and signs shall be stored in each equipment room on suitable racks. Construction and Installation Personnel The installation of the power supply equipment shall be performed by skilled and experienced personnel, only. For each site one well-experienced and responsible construction supervisor will be nominated, working in closed co-ordination with the overall construction manager. DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

For high and medium voltage installations (e.g. cubicle erection, cable termination, cable testing, etc.) only experienced specialists are allowed for execution of such works. Workshop, Tools, Installation Equipment For installation works the Contractor will provide at each individual site electrical workshops with suitable space, workbenches, machines and all required tools for erection of the power supply equipment. The electrical workshops shall be separated from the mechanical workshops and will be maintained for the whole construction period. For line valve stations or other remote and small sites, mobile car mounted workshops may be used. 3.03

Battery Limits If in the detailed Specifications not otherwise specified, the battery limits for the power supply equipment shall be general the terminal strip of the various boards, cabinets, panels or equipment terminal boxes. The field cabling and grounding for all electrical, control, instrumentation telecommunication equipment within the stations is part of the power supply system.

3.04

and

Shipping The equipment should be suitably packaged before shipping. The packaging should be carried out in a manner such that the devices and equipment are protected against damages and influences of water and dust.

3.05

Storage Upon Arrival Upon arrival at site all the equipment and materials shall be promptly stored until their installation. Cases and wrapping-in may only be opened for checking purpose, but shall be closed completely afterwards and brought in the original condition. Boards, panels, cabinets and other sensitive equipment must be stored in closed and dry rooms. Storage specifications of equipment manufacturer must be observed. In general all equipments shall in no case be removed from their original packing during storage. Equipment for outdoor application as power transformers, etc. can be stored in suitable and fenced outdoor areas. Cables can also be stored outside, cable drums must be generally protected by suitable cover plates (wood plates or equivalent). The boxes and packing cases shall be clearly marked with the equipment label in conformity with the plant identification and the transport, shipping and packing procedure.

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DIVISION 16 ELECTRICAL WORKS 3.06

SECTION 16010 BASIC ELECTRICAL REQUIREMENTS

Acceptance and Testing General Electrical equipment shall be subject to acceptance tests to demonstrate that it meets the requirements of the detailed design and the Contract and as required by the applicable codes and standards. The test procedures are subject for approval by Client / Engineer. Tests shall be carried out as factory acceptance tests and as on-site tests on complete installations. The acceptance tests and criteria will be described in the respective detail specifications. TEST CERTIFICATE The Contractor shall submit the certificates in accordance with EN 10204 and as stipulated in the Contract.

3.07

Maintanance The Contractor shall recommend accessories and special tools required for operation and maintenance of the electrical systems. The supplier shall state, how the equipment will be supported on site during operation.

3.08

Spare Parts The Contractor shall recommend spare parts required for commissioning and operation of the electrical systems. SPIR forms (Spare Parts List & Interchangeability Record) shall be submitted for two (2) and five (5) year’s operation. The Contractor shall complete and submit a list of recommended spare parts with prices and delivery time, divided in the above mentioned periods. The spare part lists shall include beside the relevant specification also the supplier code and the order code for all materials, parts and components.

3.09

Documentation The following documentation shall be provided describing component design, material specifications and inspection test results. This shall include, for example, the following: • • • • • • •

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

drawings with all relevant design and construction, calculations, details, material specifications, manufacturing process records, quality plan and inspections and test plans, test procedures, DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS • • •

SECTION 16010 BASIC ELECTRICAL REQUIREMENTS commissioning instructions, Operation instructions, Maintenance instructions.

Prior to shipment, the following documents shall be submitted to the Employer: • • •

test protocols according to factory acceptance tests, test certificates, Packing and shipping specification.

All documents and test certificates shall be in English. Type test certificates will be acceptable only if supplied for standard equipment of the same type and rating.

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DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16050 BASIC ELECTRICAL MATERIALS & METHOD

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16050 BASIC ELECTRICAL MATERIALS & METHOD

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04

Descriptions of Work Quality Assurance Submittals Delivery, Storage and Handling

PART 2

PRODUCTS

2.01 2.02

Soil Material Fire Resistant Fire Sealents

PART 3 3.01

EXECUTION Installation of Fire Stoping Sealants

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16050 BASIC ELECTRICAL MATERIALS & METHOD

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

DESCRIPTION OF WORK A.

1.02

This Section includes general construction materials and methods for application with electrical installations as follows: 1.

Excavation for underground utilities and services, including underground raceways and cables, vaults, and equipment.

2.

Fire-rated sealants for sealing penetrations in fire and smoke barriers, floors and fire-rated walls.

3.

Access panels and doors in walls, ceilings, and floors for access to electrical materials and equipment.

QUALITY ASSURANCE A.

Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: UL Underwriter’s Laboratories ASTM American Society for Testing and Materials ANSI/NFPA 70 National Electrical Code TRANSMISSION MATERIAL STANDARDS AND SPECIFICATION (TMSS) TRANSMISSION ENGINEERING SPECIFICATION (TES) TES-P-104 Underground cable engineering standards

1.03

SUBMITTALS A.

1.04

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections. 1.

Product data for each type or access doors, panels and joint sealers.

2.

Schedules indicating proposed methods and sequence of operations for selective demolition prior to commencement of WORK. Include coordination for shut-off of electrical service, and details for dust and noise control.

DELIVERY, STORAGE, AND HANDLING A.

JOINT SEALANTS 1.

DISCIPLINE: ELECTRICAL

Deliver joint sealant materials in original unopened containers or bundles with labels informing about manufacturer, product name and designation, color, expiration period for use, pot life, curing time, and mixing instructions for multicomponent materials. DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16050 BASIC ELECTRICAL MATERIALS & METHOD

DIVISION 16 ELECTRICAL 2.

Store and handle joint sealer materials in compliance with the manufacturers' recommendations to prevent their deterioration and damage.

PART 2 – PRODUCTS

2.01

2.02

SOIL MATERIALS: Representative.

All fill materials shall be subject to the approval of the Company

A.

On-Site Fill Material: All approved usable material removed from excavation shall be used, as far as practicable, for backfill. Soil rock mixture which is free from organic matter containing no vegetation, masses of roots, rocks or lumps over 150mm (6”)in diameter and having not more than 15% of the rocks and lumps larger than 60mm (21/2” more or less), shall be considered as suitable material for fill.

B.

Borrow Fill: If on-site fill material is unsuitable for backfill as determined by Company Representative, CONTRACTOR shall use materials from approved borrow fill.

C.

Sand envelope for underground cable and conduit installation shall be dry sand free from stones, rubble, debris, waste and other deleterious matter.

FIRE-RESISTANT JOINT SEALANTS Two-part, foamed-in-place, silicone sealant formulated for use in through-penetration firestopping around cables, conduit, pipes, and duct penetrations through fire-rated walls and floors. Sealants and accessories shall have fire-resistance ratings indicated, as established by testing identical assemblies in accordance with ASTM E 814, by Underwriters' Laboratories, Inc., or other approval equal. Install sealant, including forming, packing, and other accessories materials, to fill openings around electrical services penetrating floors or wall assembly in which penetration occurs. Comply with installation requirements established by manufacturer.

PART 3 - EXECUTION 3.01

INSTALLATION OF FIRE-STOPPING SEALANTS Install sealant, including forming, packing, and other accessory materials, to fill openings around electrical services penetrating floors and walls, to provide fire-stops with fire-resistance ratings indicated for floor or wall assembly in which penetration occurs. Comply with installation requirements established by manufacturer..

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16110 RACEWAYS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 12

SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08

Section Includes Coordination Related Sections References Quality Assurance Submittals Delivery Storage and Handling Testing

PART 2

PRODUCTS

2.01

Conduits

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07

EXECUTION Installation of Conduits Installation of Joints, Fittings and Bends Installation of Conduits Stubouts Installation of Conduits Stubups Installation of Empty Conduits Installation of Underground Conduits Installation of Conduit Supports

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

SECTION INCLUDES Install only new conduits in standard lengths, UL labeled. Unless otherwise indicated, all wiring and cables shall be installed in conduits or cable trays or other raceways as indicated. All dimensions will refer to inside diameter of conduits and conduit fill shall be as per Table 1 Chapter 9 of NEC.

1.02

COORDINATION Determine the work to be performed by the building contractors and other trades throughout. Provide the type and amount of raceways as equipment necessary to place this work in proper operation, completely installed, and ready for use.

1.03

RELATED SECTIONS Furnish and install related work and materials in strict accordance with the following sections of this specification:

1.04

A.

Section 16010

Basic Electrical Requirements

B.

Section 16120

Wires and Cables

C.

Section 16135

Cabinets, Boxes and Fittings

D.

Section 16195

Electrical Identification

E.

Section 16452

Grounding and Bonding

REFERENCES A.

Except as modified by this Specification, conform to the provisions and recommendations of the following standards. 1.

National Electrical Code (NEC).

2.

National Electrical Manufacturers Association (NEMA).

3.

National Fire Protection Association (NFPA).

4.

American National Standards Institute (ANSI).

5.

Underwriters Laboratories (UL).

6.

Institute of Electrical & Electronics Engineers (IEEE)

DISCIPLINE: ELECTRICAL

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SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL

1.05

7.

Occupational Safety and Health Act (OSHA)

8.

All Government Laws, Ordinances & Regulations

QUALITY ASSURANCE Provide manufacturer's certificate or furnish such evidences as necessary to PMT Representative to assure that materials meet or exceed minimum requirements as specified.

1.06

SUBMITTALS A.

Before starting installation of any materials or equipment, submit for approval a complete list of materials and equipment to be incorporated in the work. This list shall include catalog numbers, cuts, data sheets, and such other descriptive information as may be required. No consideration will be given to partial list submitted from time to time. Approval of materials will be based on manufacturer's published data, installation and roughing-in data sheets and drawings indicating compliance with the Contract documents.

1.07

B.

Submittals shall be submitted within three (3) weeks after the contract start date.

C.

All metric substitutes for Schedule 40 and 80 conduit and fittings shall be submitted for approval three (3) weeks after the contract start date.

DELIVERY STORAGE AND HANDLING Protect all materials and equipment from damage or corrosion during handling and storage. Refer to specification section 16010 - "Basic Electrical Requirements" for complete work scope. Provide appropriate covering for all stored materials.

1.08

TESTING Before shipment, materials shall be inspected to insure proper operation and conformance with manufacturer's published specifications. Notification of completion of testing shall be sent to Client Representative.

PART 2 PRODUCTS 2.01

CONDUITS A.

CONDUIT REQUIREMENTS 1.

Minimum Size: 20 mm (3/4 inch) unless otherwise specified.

2.

Underground Installations:

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL

a.

Direct buried conduit shall be rigid steel, hot-dip galvanized per ASTM A123 and PVC coated per NEMA RN 1 (minimum thickness of PVC: 40 mils), or Type DB PVC conduit per NEMA TC 8. Rigid steel conduit without a PVC coating is acceptable if hot-dip galvanized in accordance with ASTM A123 and encased in at least 75 mm (3 inch) of concrete. PVC conduits shall not be extended above grade. Where above grade extensions of buried PVC conduits are required, a transition shall be made using threaded PVC to rigid metal conduit adapters.

b. 3.

B.

Minimum Size: 25 mm (1 inch).

Above Grade Installations: a.

Outdoor Locations: Conduit above ground in outdoor location shall be threaded, rigid steel per ANSI C 80.1, except it shall be hot-dip galvanized in accordance with ASTM A 123. Conduit fittings and supports shall be cast or forged steel, cast iron or malleable iron, either hot-dip galvanized (preferably), or zinc electroplated as supplied by the manufacturer. No aluminum fittings shall be used. Only malleable iron sealing fittings shall be used. Gray cast iron split type (EYSR) retrofit sealing fittings may be used if required for repair purposes.

b.

Wet and Damp Locations: use PVC coated rigid steel conduit.

4.

Indoor Locations: Use hot dip galvanized rigid steel conduit for all exposed and subject to mechanical damage; electric metallic tubing (EMT) conduit system above suspended ceiling, in partitions and furred areas.

5.

All installations shall comply with NEC, Electrical general notes and details shown on the Contract Drawings.

6.

Flexible metal conduit and liquid tight flexible metal conduit shall be used as shown on Contract Drawings and as permitted per NEC.

7.

All conduits shall be seamless. Conduits with seams shall not be used on this Project.

GALVANIZED RIGID STEEL CONDUIT 1.

Manufacturers: Refer to Approved Manufacturers list.

2.

Rigid Steel Conduit: ANSI C80.1 and ASTM A123.

3

Fittings and Conduit Bodies: ANSI/NEMA FB 1; conduit fittings and supports shall be cast or forged steel, cast-iron or malleable iron, either hot-dipped

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL

galvanized (preferably) or zinc electroplated. No aluminum fittings shall be used. C.

D.

E.

F.

G.

PVC COATED RIGID STEEL CONDUIT 1.

Manufacturers: Refer to Approved Manufacturers list.

2.

Description: NEMA RN 1; rigid steel conduit with external PVC coating, 0.1 mm (40 mil) thick.

3.

Fittings and Conduit Bodies: ANSI/NEMA FB 1; steel fittings with external PVC coating, 0.1 mm (40 mil) thick, to match conduit.

4.

All PVC-coated conduit and fittings shall be furnished from one manufacturer for uniform appearance and interchangeability of parts.

5.

Only Strap Wrenches are allowed for installing PVC coated rigid steel conduit.

FLEXIBLE METAL CONDUIT 1.

Manufacturers :

Refer to Approved Manufacturers list.

2.

Description

:

Interlocked steel construction.

3.

Fittings

:

ANSI/NEMA FB 1.

LIQUID TIGHT FLEXIBLE METAL CONDUIT 1.

Manufacturers :

Refer to Approved Manufacturers list.

2.

Description

:

Interlocked steel construction with PVC jacket.

3.

Fittings

:

ANSI/NEMA FB 1.

PVC CONDUIT 1.

Manufacturers: Refer to Approved Manufacturers list

2.

Description: NEMA TC 8; Suitable for direct burial (type DB) and 90 degree C (194 degree F) cable operation.

3.

Fittings and Conduit Bodies:NEMA - TC 9.

CONDUIT SEALING COMPOUND 1

DISCIPLINE: ELECTRICAL

Manufacturers

:

3 M Type CP 25 N/S or CP 25 L Kit 3M Scotchcast Brand 4416 Kit DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL

Crouse-Hinds Type Chico (for explosion proof seals). Dow Corning Silicon Foam RTV 3-654B or other Approved Manufacturer. H.

CABLE SEALING The correct sealing compound shall be used with the specified seals. 1.

Manufacturers

:

Raychem Type T (CBK-T) Gas Blocking Kit or other Approved Manufacturer.

PART 3 - EXECUTION 3.01

INSTALLATION OF CONDUITS A.

Install conduit in accordance with NEC, Contract Drawings, NECA “Standard of Installation” and the manufacturer’s instructions.

B.

Arrange supports to prevent misalignment during wiring installation.

C.

Support conduit using epoxy coated steel or malleable iron straps, lay-in adjustable hangers, clevis hangers, and split hangers. Group related conduits; support using conduit rack. Construct rack using steel channel; provide space on each for 25 percent additional conduits. Fasten conduit supports to building structure or surfaces. Damaged PVC coat on conduit or exposed threads shall be coated with PVC patching compound, APCS -22, or APCS - 26 B.

D.

Do not support conduit with wire or perforated pipe straps. Remove wire used for temporary supports. Do not attach conduit to ceiling support wires.

E.

Arrange conduit to maintain headroom and present neat appearance.

F.

Route exposed conduit parallel and perpendicular to walls. Where conduit penetrates wall, fire stopping measures shall be completed per Contract Drawings.

G.

Route conduit installed above accessible ceilings parallel and perpendicular to walls. Install conduit sealing accordingly to Contract Drawings.

H.

Route conduit under slab from point-to-point.

I.

Do not cross conduits in slab.

J.

Maintain 300 mm (12 inch) clearance between conduit and surfaces with temperatures exceeding 104 degrees F (40 degrees C).

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL

K.

Cut conduit square using saw or pipecutter, de-burr cut ends. Threads must be tapered in accordance with ANSI/ASMI B.1.20.1 and remaining threads exposed after make-up shall be coated with rust preventing grease such as Course Hinds thread lubricant.

L.

Bring conduit to shoulder of fittings; fasten securely.

M.

Join nonmetallic conduit using cement as recommended by manufacturer. Coupling and connectors will be in accordance with NEC-346-9(A). Wipe nonmetallic conduit dry and clean before joining. Apply full even coat of cement to entire area inserted in fitting. Allow joint to cure for 20 minutes, minimum.

N.

Use conduit hubs with ground lugs to fasten conduit to sheet metal boxes in damp or wet locations, and to cast boxes.

O.

Install no more than the equivalent of four 90 degree bends between boxes. Size pull boxes per NEC-370-6. Use conduit bodies to make sharp changes in direction, as around beams. Use factory elbows or hydraulic one-shot bender to fabricate bends in metal conduit. The minimum bending radius shall be in accordance with NEC-346-10. Factory elbows are preferred. Heating of conduits for bending is not permitted. Oversized bending form to be used when bending PVC Coated conduits. Only strap type wrenched to be used when installation PVC coated conduits.

P.

Avoid moisture traps; provide junction box with stainless steel drain fitting at low points in conduit system. Install breathers at high points on conduit system.

Q.

Provide suitable fittings to accommodate expansion and deflection where conduit crosses expansion joints.

R.

Expansion fittings shall be installed in each straight conduit run exceeding 45 meters (150 feet). When expansion fittings are installed oversized conduits supports shall be used to allow the conduits to move.

S.

Provide suitable pull wire or nylon rope of adequate strength in each conduit except sleeves and nipples.

T.

All conduit systems shall be swabbed clean before installation of wires or cables. PVC conduits must be checked for clearance using mandrel. Mandrel shall be pulled in both directions. Failure to freely pass the mandrel in either direction shall constitute the failure of the specific conduit section. The failed section shall be replaced.

U.

Use suitable caps to protect installed conduit against entrance of dirt and moisture.

V.

Ground and bond metallic conduit.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL

3.02

W.

Identify conduit.

X

The Contractor shall notify a minimum of 24 hours prior to backfilling of trenches to enable the inspection of underground conduits.

Y.

All cable entries to buildings shall be sealed (using Raychem Gas Blocking Kit Type T or approved equal. Multi-conductor cable shall be stripped and sealing shall be placed between the outside covering and the cables.

Z.

Conduit entering into a manhole or existing spare conduit (duct) used by this projects shall be sealed, inside the manhole, with 3 M Scotch cast Brand 4416 Kit or approved equal sealing compound. Cable installed in manholes shall be adequately supported.

AA.

Direct buried cables and conduit shall be installed in a single layer only except where rearrangement is necessary at transitions to multi-layer concrete encased duct banks or for entering buildings.

AB.

Installation of direct buried cables and conduit shall comply with NEC.

AC.

Location of underground cables and conduits shall be marked.

AD.

PVC conduits shall not be extended above grade. Where above grade extensions of buried PVC conduits are required, a transition shall be made using threaded PVC to rigid galvanized steel conduit adapters.

AE

Install conduit to preserve fire resistance rating of partitions and other elements.

AF.

Route conduit through roof openings for piping and ductwork or through suitable roof jack with pitch pocket. Coordinate location with roofing installation.

INSTALLATION OF JOINTS, FITTINGS AND BENDS A. B.

C.

Where conduit is underground, below slabs on grade, exposed to weather, or in wet locations, make joints tight. Cut threads on rigid conduit to standard taper and to length such that bare metal exposed by the threading operation will be completely covered by the couplings or fittings used. In addition, cut the lengths of the thread such that joints will become secure and wrench-tight before conduit ends butt together in couplings and before conduit ends butt into fittings. Securely tighten threaded connections. Threaded Conduit: Use red lead and oil (or litharge and glycerine) applied to the male threads only and tighten joints securely. For underground conduit, apply a heavy coat of corrosion-preventative paint to surfaces within 6 inches (150 mm) on both sides of fittings and to areas where wrenches or other tools have been applied. On exposed conduits, repair scratches and other defects with galvanized repair stick, " Enterprise Galvanizing" "Galvabar", 3M, or approved equal high-zinc coating.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL

3.03

D.

Plastic Conduit (PVC) : Use approved fittings, accessories and solvent-weld cement specifically manufactured for the purpose. Not to be used for power distribution inside buildings.

E.

Bushings, of the insulating type and where required by NEC, shall be installed on ends of all conduits. Locknuts, of the bonding type and where required by NEC shall be installed on threaded conduits, penetrating outlets, boxes, cabinets, equipment, etc., except cast conduit bodies equipped with threaded hubs.

F.

Threaded conduit connections to outdoor, weatherproof, boxes, cabinets, etc., shall be made using watertight, insulated throat, conduit hubs, unless otherwise indicated.

G.

Electric metallic tubing (EMT) connections to outlets, boxes, cabinets, etc., shall be made using watertight, malleable iron, compression ring type conduit connectors, complete with locknut and insulated bushing. Set-screw conduit connectors and couplings will not be permitted.

H.

Flexible metallic conduit and liquid tight conduit connections shall be made using insulated die cast connectors with ridges that thread into the inside of the conduit. Binding-screw type connectors will not be permitted.

I.

Provide a green insulated grounding conductor of minimum size as required by code but smaller or the same size with the conductors supplying the power in all flexible and non-conductive conduits or ducts and other raceways having a length of flexible conduit or non-conductive raceway as part of the run.

J.

Keep bends and offsets in conduit runs to an absolute minimum. For the serving utilities, make large radius bends to meet their requirements. Replace deformed, flattened, or kinked conduit. Not more than the equivalent of four quarter-bends shall be used in any run between terminals and cabinets, or between outlet and junction or pull boxes.

K.

Rigid steel conduit bends, 1-1/2 inch (40 mm) trade size or larger shall be of the long radius type, factory-made bends, or field bend with a power bender designed for the purpose, utilizing bending shoes sized for the conduit used. All bends shall be free of dents or flattening.

L.

Plastic conduit (PVC) bends shall be factory-made bends, or field bend using approved heat box bender and conduit mandrels to assure full inside diameter and prevent deforming or discolor conduit.

M.

All bends shall have a radius not less than that required by the NEC-346-10.

INSTALLATION OF CONDUIT STUBOUTS A.

Where shown on drawings extend underground conduit for future use, a minimum of 3 feet (1 m) beyond building foundations.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 10 of 12

SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL

3.04

3.05

B.

Cap ends of conduits and wrap entire exposed portions with tape, "Scotch wrap", "Johns-Manville", or approved equal. Plug ends of non-metallic conduit with factorymade caps or Dexseal covered with gravel and redwood planks for mechanical protections. All communications conduits will require a pull string

C.

Exact locations of stubouts shall be indicated on the Project Record Documents. Provide electrical conduit stub markers.

D.

All utility conduit runs outside of building, including stubouts on the site, shall be marked on the Project Record Documents, identified and dimensioned exactly from and referenced building signed by the Contractor and Countersigned by the PMT Inspector.

INSTALLATION OF CONDUITS STUBUPS A.

Use rigid steel conduit and elbows for stubups and risers to grade form non-metallic conduits, unless otherwise shown. Approved adapter fittings from steel to nonmetallic conduits shall be used.

B.

Terminate stubups for connections to movable equipment or below movable partitions with flush floor couplings. Use oil or grease on top of coupling and in threads of plugs to prevent sticking. In exterior locations, terminate with plugged couplings set flush with building exterior.

C.

In electrical rooms, mechanical rooms, and other unfinished areas terminate stubups to a minimum of 6 inches (150 mm) above finished floor unless otherwise indicated.

INSTALLATION OF EMPTY CONDUITS A.

Provide a nylon "pull wire", polyethylene rope rated at 250 pounds (113 kg) tensile strength, or steel fish-wire in all empty conduits in which permanent wiring is not installed. Not less than 12 inches (30 cm) of slack shall be left at ends of pull wires.

B.

Tag empty conduit at each accessible end, identifying the purpose of the conduit and the location of the other end.

C.

In wet, corrosive, outdoor or underground locations, use brass, bronze, or copper No. 16 gage tags or lead tags secured to conduit ends with No. 16 or larger galvanized wire. Clearly inscribe complete identifying information on the tags with steel punch dies.

D.

In dry interior locations, use meta-rimmed paper tags securely affixed with nylon twine. Inscribe on the tags with India ink, clear and complete identifying information

E.

Plug of cap all unused conduit openings with approved fittings designed for the purpose. Caulking and sealing compound shall not be used for plugging empty conduits.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 11 of 12

SECTION 16110 RACEWAYS

DIVISION 16 ELECTRICAL 3.06

3.07

INSTALLATION OF UNDERGROUND CONDUITS A.

Encase all underground conduit in concrete envelopes with a minimum of 3 inches (75 mm) cover all around unless otherwise shown. Use red coloring dye in concrete.

B.

Concrete envelops may be omitted for rigid plastic conduit Schedule 40, below slabs on grade except services above 600 volts.

C.

Use appropriate manufactured concrete or plastic spacers to ensure minimum required spacing and concrete coverage.

INSTALLATION OF CONDUIT SUPPORTS A.

All conduit shall be installed as a complete system and shall be securely fastened in place. Conduit shall be firmly supported within 3 feet (910 mm) of each outlet box, junction box, cabinet, or fitting. Conduit shall be supported at least every 10 feet (3 meter) and in accordance with Table 346-12 of the NEC. Provide additional supports where required or as indicated.

B.

In steel stud construction, rigidly tie conduit at maximum 4 feet (1.2 m) intervals with No.16 gage double annealed galvanized wire to prevent conduit movement from vibration or other causes.

C.

Above suspended ceilings, support conduit on or from the structural members of the building. Use approved beam clamps securely fastened in place, unless otherwise indicated.

D.

Suspended conduit shall be installed on rack hangers made of angle iron, channel or channel framing, threaded suspension rods sized for the weight to be carried. Minimum 3/8 inch diameter (10 mm) where rods are more than 2 feet (0.6 meter) long provide rigid sway bracing. Conduits shall be securely fastened to hangers using onehole malleable straps or malleable iron, factory made split-hinged pipe clamps.

E.

Use one-hole malleable iron straps with metallic expansion anchors and screws or preset inserts for conduit run exposed on concrete. Use preset inserts in concrete when possible.

F.

Whenever conduit may be affected by movements of the supporting structures or medium, and where secured on both sides of building control joints, provide suitable flexible or expansion joints. Drilling or welding of conduit to structures or medium will not be permitted, unless prior approval is received. Conduit or pipe straps shall not be welded to structures.

G.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 12 of 12

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16111 CABLE TRAYS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 8

SECTION 16111 CABLE TRAYS

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03

Descriptions of Work Quality Assurance Submittals

PART 2

PRODUCTS

2.01 2.02

ManufacturerS Materials

PART 3 3.01 3.02 3.03 3.04 3.05

EXECUTION Installation of Cable Tray Systems Grounding Warning Signs Feild Testing Cleaning and Finish Repair

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 2 of 8

SECTION 16111 CABLE TRAYS

DIVISION 16 ELECTRICAL PART 1 – GENERAL 1.01

DESCRIPTION OF WORK A.

1.02

This section includes aluminum Cable Trays.

QUALITY ASSURANCE A.

Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: 1.

American National Standards Institute/National Fire Protection Association (ANSI/NFPA) ANSI/NFPA 70

National Electrical Code

2.

Factory Mutual Research Corporation (FM)

3.

National Electrical Manufacturers Association (NEMA) NEMA Standard VE 1

4.

1.03

Metallic Cable Tray Systems

Underwriters Laboratories (UL)

B.

Cable trays and components shall be listed and labeled by UL and comply with the NEMA Standards.

C.

Electrical Component Standard: Components and installation shall comply with the National Electrical Code.

A.

Single-Source Responsibility: All cable tray components shall be the product of a single manufacturer.

SUBMITTALS A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections. 1.

Product Data for cable tray products.

2.

Factory Test Reports: Certified copies of factory test reports performed in conformance with NEMA Standard VE 1 on cable trays of types and size specified for this project.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 3 of 8

SECTION 16111 CABLE TRAYS

DIVISION 16 ELECTRICAL PART 2 - PRODUCTS 2.01

MANUFACTURERS A.

Available Manufacturer: Subject to compliance with requirements, manufacturers offering products, which shall be incorporated with WORK include, but not limited to, the following:

B.

Manufacturers: Subject to compliance with requirements, provide products from the following: B-Line Systems, Inc. Chalfant Mfg. Co. The George-Ingraham Corp. GS Metals Corp. Mono-Systems, Inc. MP Husky Corp. P-W Industries, Inc. Square D Co. T.J. Cope, Inc. Chatsworth Products, Inc. Other Approved Manufacturers

2.02

MATERIALS A.

GENERAL REQUIREMENTS 1. Cable tray systems shall be of indicated types, sizes, and NEMA classes and shall be complete with manufacturer's recommended covers, barrier strips, dropouts, fittings, conduit adaptors, hold- down devices, grommets, and blind ends as required and indicated. 2. Cable tray products shall have rounded edges and smooth surfaces.

B.

MATERIALS AND FINISHES 1.

DISCIPLINE: ELECTRICAL

Aluminum Cable Trays, Fittings, and Accessories: Cable tray shall be “copperfree” aluminum (maximum of 0.4 percent copper). Construction and mechanical loading shall be in accordance with NEMA VE 1. a.

Aluminum cable tray shall be the perforated type.

b.

Aluminum cable tray installations in outdoor locations shall utilize ventilated, louvered, cable tray covers, secured with stainless steel banding, one band per 1 meter of cover length, with a minimum of three bands per cover.

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 4 of 8

SECTION 16111 CABLE TRAYS

DIVISION 16 ELECTRICAL Exceptions:

C.

1.

If the cable trays contain only instrument and communication cables, covers may be solid (unventilated).

2.

Cable tray covers may be deleted at the discretion of the facility Proponent. However, cable trays should be located to minimize the potential for mechanical damage and minimize the effects of sunlight on the cables. Cable derating is also required for cables exposed to sun.

SUPPORTS AND CONNECTORS Cable tray supports and connectors, including bonding jumpers shall be as recommended by cable tray manufacturer.

D.

FASTENERS FOR SUPPORTS Unless otherwise indicated on the drawings, fasteners to connect cable tray supports to the building structure shall be as follows:

E.

1.

Expansion Anchors: Carbon steel wedge or sleeve type.

2.

Toggle Bolts: All steel springhead type.

3.

Powder-Driven Threaded Studs: Heat-treated steel, designed specifically for the intended service.

FIRE STOPPING General: Materials shall be UL listed and labeled and FM approved for fire ratings consistent with penetrated barriers. Materials may include but not limited to the following: 1.

Sleeves: Schedule 40, welded, black steel pipe sleeves. Sizes as indicated or minimum NEC size for cable or cable group to be installed.

2.

Sealing Fittings: Suitable for sealing cables in sleeves or core-drilled holes.

3.

Sealing Mortar: Suitable for sealing cable penetration slots/openings in fire barriers.

4.

Sealant: One-part compound for sealing cables, sleeves, and openings in fire barriers.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 5 of 8

SECTION 16111 CABLE TRAYS

DIVISION 16 ELECTRICAL 3.

F.

Two-Part Sealant: Formed-in-place sealant as specified in paragraph "FireResistant Joint Sealers" in Division 16 Section 16050, "Basic Electrical Materials and Methods."

WARNING SIGNS 1.

Lettering: 1-1/2-inch high, black on yellow background with legend (both in English and Arabic): "WARNING! NOT TO BE USED AS WALKWAY, LADDER, OR SUPPORT FOR LADDERS OR PERSONNEL."

1.

Materials and Fastening: Conform to Section "Electrical Identification.

PART 3 - EXECUTION 3.01

INSTALLATION OF CABLE TRAY SYSTEMS A.

Install cable trays in accordance with equipment manufacturer's written instructions. Cable trays shall be installed as a complete system. Cable tray systems shall not have mechanically discontinuous segments of cable tray runs.

B.

Remove burrs and sharp edges of cable trays.

C.

Support cable tray independently from the building structural components.

D.

Conform to manufacturer's recommendations for selection and installation of supports. Exception: Plant structural members used as supports for conduit and other electrical equipment are not included in this section. Attachment hardware (clamps, bolts, nuts, etc.) must however comply to the requirements. 1.

Channel erector system components (Unistrut or similar) used to support conduits, cable trays, enclosures, lighting fixtures and other electrical equipment shall be made of steel and iron, either hot-dip galvanized (preferably), or zinc electroplated as supplied by the manufacturer.

E.

Strength of each support including fastenings to the structure shall be adequate to carry present and future load multiplied by a safety factor of at least four or 200 lbs, whichever is greater.

F.

Support Locations: Locate supports in accordance with the recommendations of NEMA Standard VE 1. Exception: When the following NEMA recommendations are difficult because of the location of the plant structures and equipment, structurally equivalent of supports is permitted with the approval of Client Consulting Services Dept.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 6 of 8

SECTION 16111 CABLE TRAYS

DIVISION 16 ELECTRICAL G.

Installation of supports shall be in accordance with cable tray manufacturer's written instructions and the recommendations of Paragraph 6.5 of NEMA Standard VE 1.

H.

Fastening Supports:. Unless otherwise indicated, fasten cable tray supports securely to the building structure.

I.

Support at Connections to Equipment:

J.

1.

Where cable trays connect to equipment, provide flanged fittings fastened to the tray and to the equipment. Support the tray separately. Do not carry the weight of the tray on the equipment enclosure.

2.

Cables may be extended from the cable trays to equipment if: a.

They are armored or metal clad and are properly supported, or

b.

They are installed in rigid or flexible conduit

Thermal Contraction and Expansion: Install expansion connectors in cable tray runs that exceed the following length: 1.

Aluminum Tray: 90 feet.

2.

Spacing for expansion connectors shall not exceed maximums indicated in Table 6-1 of NEMA Standard VE 1.

3.

Gap Settings for expansion connectors shall be in accordance with Figure 6-9 of NEMA Standard VE 1.

4.

The maximum spacing between expansion joints shall be based on a temperature differential of 38 deg C calculated according to NEMA VE 1.

K.

Direction Changes: Make changes in direction of cable tray with standard cable tray fittings.

L.

Locate cable tray above piping except as required for tray accessibility and as otherwise indicated.

M.

Firestopping: Where cable trays penetrate fire and smoke barriers including walls, partitions, floors, and ceilings, install fire- stopping at penetrations after cables are installed.

N.

Sleeves For Future Cables: Install capped sleeves for future cables through firestopped cable tray penetrations of fire/smoke barriers.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 7 of 8

SECTION 16111 CABLE TRAYS

DIVISION 16 ELECTRICAL O.

Working Space: Install cable trays with sufficient space to permit access for installing cables.

P. Barriers: Where trays carry conductors of different systems, such as power, communications, and data processing, or different insulation levels, such as 600 V, 5,000 V, and 15,000 V, install barriers to separate the systems. 3.02

GROUNDING Electrically ground cable trays and ensure continuous electrical conductivity of cable tray system. Use tray as equipment ground conductor for itself only, not for connected equipment.

3.03

WARNING SIGNS After installation of cable trays is completed, install warning signs, on or in proximity to cable trays, where easily seen by occupants of space.

3.04

FIELD TESTING A. Grounding: Test cable trays to ensure electrical continuity of bonding and grounding connections. B.

Anchorage: For critical requirements only and as directed by the Company Representative, test pull-out resistance of one of each type, size, and anchorage material for toggle bolts and powder-driven threaded studs.

Furnish equipment, including jacks, jigs, fixtures, and calibrated indicating scales required for reliable testing. Obtain the Architect's approval before transmitting loads to the structure. Test to 90 percent of rated proof-load for fastener. If fastening fails test, replace fastener and retest until satisfactory results are achieved. 3.05

CLEANING AND FINISH REPAIR A.

Upon completion of installation of cable trays, inspect trays, fittings, and accessories. Remove burrs, dirt, and construction debris and repair damaged finish including chips, scratches, and abrasions.

B.

PVC or Paint Finish: Repair damage with matching touch-up coating recommended by the tray manufacturer.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 8 of 8

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16118 DUCT BANK

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 6

SECTION 16118 DUCT BANK

DIVISION 16 ELECTRICAL

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09

Section Includes Related Sections Reference Submittals Product Record Documents Qualification Regulatory Requirements Delivery, Storage and Handling Project Conditions

PART 2

PRODUCTS

2.01 2.02

PVC Conduits Accessories

PART 3 3.01 3.02

EXECUTION Examination Duct Bank Installation

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 2 of 6

SECTION 16118 DUCT BANK

DIVISION 16 ELECTRICAL PART 1 – GENERAL 1.01

SECTION INCLUDES A.

1.02

1.03

1.04

1.05

PVC Conduit duct bank.

RELATED SECTIONS A.

Section 02221

Excavating,Trenching, Bacfilling and Compacting

B.

Section 03100

Concrete Formwork.

C.

Section 03200

Concrete Reinforcement.

D.

Section 03300

Cast-In-Place Concrete.

E.

Section 16124

Medium Voltage Cable

F.

Section 16195

Electrical Identification

G.

Section 16452

Grounding and Bonding

REFERENCES A.

ANSI/IEEE C2

National Electrical Safety Code.

B.

ANSI/NFPA 70

National Electrical Code.

C.

NEMA RN 1

Polyvinyl Chloride (PVC) externally coated galvanized rigid steel conduit and intermediate metal conduit.

D.

NEMA TC 8

Extra-Strength PVC Plastic Utilities Duct for Underground Installation.

E.

NEMA TC 9

PVC Fittings for Use with Rigid PVC Conduit and Tubing.

SUBMITTALS A.

Shop Drawings: Indicate dimensions, reinforcement, size and locations of conduit.

B.

Product Data: Provide for PVC conduit

C.

Manufacturer’s Instructions: Include instructions for storage, handling, protection, examination, preparation, and installation.

PROJECT RECORD DOCUMENTS

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 3 of 6

SECTION 16118 DUCT BANK

DIVISION 16 ELECTRICAL

A.

1.06

QUALIFICATIONS A.

1.07

1.08

1.09

Accurately record actual locations of exact routing of ductbank on Drawings to show As- Built installation.

Manufacturer: Refer to Approved Manufacturers List.

REGULATORY REQUIREMENTS A.

Conform to requirements of ANSI/NFPA 70 and ANSI/IEEE C2.

B.

Furnish products listed and classified by Underwriters Laboratories, Inc. or testing firm acceptable to Client, as suitable for purpose specified and shown on Contract Drawings.

DELIVERY, STORAGE, AND HANDLING A.

Deliver, store, protect, and handle Products to site under provisions of Section 16010.

B.

Inspect conduit for damage prior to accepting on site.

C.

Protect conduit from corrosion and entrance of debris by storing above grade. Provide appropriate covering and end caps.

D.

Protect PVC conduit from sunlight. To prevent conduit distortion, do not overstack.

PROJECT CONDITIONS A.

Verify that field measurements are as shown on Contract Drawings and modify to show As-Built conditions.

B.

Verify routing and termination locations of duct bank prior to excavation.

C.

Duct bank routing is shown on Drawings in approximate locations. Route the duct banks as required to complete the system, and to avoid underground interferences.

PART 2 – PRODUCTS 2.01

PVC CONDUIT A.

Manufacturers: Refer to Approved Manufacturers List.

B.

Description: NEMA TC 8; Seamless conduits, suitable for duct bank (type DB) and for 90°C (194°F) cables.

C.

Fittings and Conduit Bodies: NEMA TC 9.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 4 of 6

SECTION 16118 DUCT BANK

DIVISION 16 ELECTRICAL 2.02

ACCESSORIES The location of underground ductbanks, conduit or cable shall be marked.

PART 3 – EXECUTION 3.01

3.02

EXAMINATION A.

Verify excavation under provisions of Section 02221.

B.

Verify that excavation and subgrade preparation is completed and ready for ductbank installation.

DUCT BANK INSTALLATION A.

Install top of duct banks at depths as indicated on Drawings. The minimum depth shall be as specified in SAUDI ELECTRICITY Engineering Standard TES-P-104.

B.

Install duct with minimum slope of 100 mm per 30 m (4 inches per 100 feet). Slope duct away from building entrances.

C.

Cut duct square using saw or pipe cutter, de-burr cut ends.

D.

Insert duct to shoulder of fittings, fasten securely.

E.

Join PVC duct using adhesive as recommended by the conduit manufacturer.

F.

Wipe PVC duct dry and clean before joining. Apply full even coat of adhesive to entire area on the inside of coupling fitting and on the outside of conduit ends. Allow joint to cure for 20 minutes, minimum. Remove excess adhesive build-up using a cleaning solvent as recommended by the conduit manufacturer.

G.

Install no more than equivalent of four 90 ° bends between pull points.

H.

Duct bank shall consist of PVC conduit encased in reinforced concrete as shown on the Contract Drawings. The concrete shall extend at least 75 mm (3 inch) in all directions from the outside surface of conduits or reinforced steel. The top layer of the concrete shall be mixed with red dye. Terminate duct using end bell or protective bushings at both ends.

I.

Use manufacturer designed separators and chairs installed not greater than 2.4 M (8 feet) on centers. Makeshift conduit supports are not acceptable.

J.

Securely anchor duct to prevent movement during concrete placement.

K.

Pour concrete under provisions of Section 03300.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 5 of 6

SECTION 16118 DUCT BANK

DIVISION 16 ELECTRICAL L.

Provide steel reinforcing rebars where specified on Contract Drawings and in accordance with Section 03200.

M.

Connect to existing concrete encasement using dowels.

N.

Snake and Swab duct. Use suitable caps to protect installed duct against entrance of dirt and moisture. Mandrel shall be pulled in both directions. Failure to freely pass the mandrel in either direction shall constitute the failure of the specific conduit section. The failed section shall be replaced.

O.

A nylon pull line of sufficient strength shall be left in place after the duct is cleaned.

P.

Backfill trenches under provisions of Section 02221.

Q.

Interface installation of underground warning markers with backfilling specified in Section 02221.

R.

Provide conduit seals under the provisions of Section 16111.

S.

Provide underground duct bank markers under the provision of Section 16195. - END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 6 of 6

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16120 WIRES AND CABLES

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 8

SECTION 16120 WIRES AND CABLES

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02

Descriptions of Work Quality Assurance

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05

Manufacturers Wires and Cables Connections and Terminations Wire Markers on Conductors Color Coding for Phase Identifications

PART 3 3.01 3.02

EXECUTION Installation of Wires and Cables Field Quality Control

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 2 of 8

SECTION 16120 WIRES AND CABLES

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

1.02

DESCRIPTION OF WORK A.

This Section includes wires, cables, and connectors for power, lighting, signal, control and related systems rated 600 volts and less.

B.

Included in this Section is control wiring used for the interconnection of electrical control devices, such as pushbuttons, electromechanical relays, etc. and also microprocessor based protection, protection relays for power distribution and motors.

C.

Wiring connected on one or both sides to electronic instruments, distributed control systems, computers, etc. (except for AC power connections).

D.

This Section does not cover internal wiring of manufactured equipment approved by Client.

QUALITY ASSURANCE A.

Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: 1.

American National Standards Institute (ANSI)/ National Fire Protection Association (NFPA) ANSI/NFPA 70

2.

American Society for Testing and Materials (ASTM) ASTM B8

3.

DISCIPLINE: ELECTRICAL

Concentric-lay-stranded Copper Conductors, Hard, Medium-hard, or Soft

Underwriters Laboratories (UL) UL 44 UL 83

4.

National Electrical Code (NEC)

Rubber-Insulated Wires and Cables Thermoplastic-Insulated Wires and Cables

International Electrotechnical Commission (IEC) IEC 228 IEC 332-1

Conductors of Insulated Cables Tests on Electric Cables Under Fire Conditions - Part 1: Test on a single vertical insulated wire or cable

IEC 332-3

Tests on Electric Cables Under Fire Conditions - Part 3: Tests on bunched wires and cables

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16120 WIRES AND CABLES

DIVISION 16 ELECTRICAL 5.

6.

Saudi Arabian Standards Organization (SASO) SSA 55

PVC-Insulated Cables with Circular Copper Conductors

TES

Transmission Engineering Specification

PART 2 - PRODUCTS 2.01

MANUFACTURERS A.

Available Manufacturer: Subject to compliance with requirements, manufacturers offering products which shall be incorporated with WORK include, but not limited to, the following:

B.

Manufacturers: Subject to compliance with requirements, provide products from the following: 1.

Wire and Cable: American Insulated Wire Corp. Brintec Corp. Carol Cable Co. Inc. Senator Wire and Cable Co. Southwire Company Saudi Cable Company Other Approved Manufacturers

2.

Connectors for Wires and Cable Conductors: O-Z/Gedney Co. Square D Company Burndy Co. Thomas and Betts Other Approved Manufacturers

2.02

WIRES AND CABLES A.

Low voltage jacketed cables shall comply with NEC or IEC 502. 1. NEC low voltage cables shall be rated 600V, shall have a minimum temperature rating of 90 deg C dry/75 deg C wet, and shall conform to UL

Standards according to the particular type (e.g. UL 1277, including its vertical tray flame test, for type TC tray cables, etc.). 2. DISCIPLINE: ELECTRICAL

IEC 502 type cables shall be rated 600/1000V, shall have a minimum rating of 85 deg C, and shall meet the flame test of IEC 332-3. DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16120 WIRES AND CABLES

DIVISION 16 ELECTRICAL

B.

Low voltage unjacketed insulated wires, shall comply with NEC or SSA 55. 1.

NEC low voltage wires shall be rated 600V, shall have a minimum temperature rating of 90 deg C dry/75 deg C wet, and shall conform to UL Standards according to the particular type (e.g. UL 83 for THHN/THWN and UL 44 for XHHW). Exception: For wiring of equipment such as lighting fixtures, etc., that require higher temperature wires and cables, the above minimum temperature ratings shall be increased accordingly.

C.

Conductors: Power and control conductors shall be stranded copper, except solid copper conductors 6mm square (10 AWG) and smaller may be used. Cables with solid conductors are also permitted.

D.

Conductor Stranding: Stranding shall be ASTM B8 Class B or C or IEC 228 Class 2, except flexible cords, portable cables and motor leads shall have finer stranding in accordance with appropriate ICEA and UL Standards or manufacturers recommendations.

E.

Wiring Insulation for Interior Building Wiring: Unless otherwise indicated, provide THHN/THWN insulation for all conductor sizes, except for equipment grounding conductor which may have PVC or thermoplastic insulation (green).

F.

Minimum Wire Size of Conductors: conductors shall be as follows: Control (600V and below) Power (600V and below)

2.03

Unless otherwise indicated, minimum size of

2.5mm square (14 AWG) 4mm square (12 AWG)

G.

Conductors of multi-conductor control cables shall be numbered or color-coded by colors other than green, green with yellow stripes, white or gray.

H.

Cables for area lighting shall be armored or metal clad. Armored cables shall meet the requirements of TES-P-104.

CONNECTIONS AND TERMINATIONS A.

Provide UL-listed factory-fabricated, solderless metal connectors of sizes, ampacity ratings, materials, types and classes for applications and for services indicated. Use connectors with temperature ratings equal to or greater than those of the wires upon which used.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16120 WIRES AND CABLES

DIVISION 16 ELECTRICAL B.

Copper compression (crimped) type connectors shall be used for splicing and terminating stranded conductors, except as noted below: 1.

Spring pressure type twist-on connectors, and pressure set screw connectors with insulating caps are permitted for: (a) (b)

2.

For lighting and receptacle circuits in non-hazardous locations. In non-industrial applications.

Use of connectors or terminals other than compression type, except solder connectors, supplied as integral parts or components of manufactured equipment such as molded case circuit breakers, contactors, outlets, etc., is permitted.

C.

The use of solder lugs is prohibited. Compression connectors for 120mm square (4/0 AWG) and larger conductors shall be two hole NEMA design.

D.

All compression connectors for 10mm square (8 AWG) and larger conductors shall have a manufacturer’s reference die number and conductor size printed or stamped on the connector. Exception: The use of dieless compression tools is acceptable, provided that the tool is suitable for the connector, and, (for 8 AWG and larger conductor connectors), the tool ram embosses the tool manufacturer’s logo on the crimp.

E.

Insulated ring tongue, locking fork tongue, or flanged fork tongue compression (crimped) terminals shall be used for control wiring. Exception: Only ring tongue compression (crimped) terminals shall be used for current transformer circuits.

2.04

WIRE MARKERS ON CONDUCTORS Other than color-coding requirements identified elsewhere in this Specifications, conductor identification is required when conductor numbering systems are shown on the drawings. Wires at termination points shall be identified by the use of permanently embossed wire markers of the heat-shrinkable or slip-on type. Wrap-around, rigid snap-on, or adhesive type markers are not permitted.

2.05

COLOR CODING FOR PHASE IDENTIFICATION A.

Color code secondary service, feeder, and branch circuit conductors with factory applied color as follows:

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16120 WIRES AND CABLES

DIVISION 16 ELECTRICAL

B.

Phase

208y/120 Volts

480y/277 Volts

A B C Neutral Ground

Black Red Blue White Green

Yellow Brown Orange White Green

Except for ground conductor in which green is mandatory, use conductors with black insulation or jacket and color-code with Scotch No. 35 color-coding tape or equivalent for specified insulations and jackets not manufactured by the selected vendor with integral colors. Color-code each conductor entering every box, cabinet, panelboard, through, and wireway. In wireways and other locations where conductors are accessible, color-code conductors every 1500mm (5 FT).

PART 3 – EXECUTION 3.01

INSTALLATION OF WIRES AND CABLES A.

General: Install electrical cables, wires, and connectors in compliance with NEC.

B

Coordinate cable installation with other Work.

C

Pull conductors simultaneously where more than one is being installed in same raceway. Use UL listed pulling compound or lubricant, where necessary.

D.

Use pulling means including, fish tape, cable, rope, and basket weave wire/cable grips which will not damage cables or raceways. Do not use rope hitches for pulling attachment to wire or cable.

E.

Conceal all cable in finished spaces.

F.

Install exposed cable parallel and perpendicular to surfaces or exposed structural members, and follow surface contours, where possible.

G.

Keep conductor splices to minimum.

H.

Install splice and tap connectors which possess equivalent or better mechanical strength and insulation rating than conductors being spliced.

I.

Use splice and tap connectors which are compatible with conductor material.

J.

Provide adequate length of conductors within electrical enclosures and train the conductors to terminal points with no excess. Bundle multiple conductors, with conductors larger than 6mm square (10 AWG) cabled in individual circuits. Make terminations so there is no bare conductor at the terminal.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16120 WIRES AND CABLES

DIVISION 16 ELECTRICAL K.

Tighten electrical connectors and terminals, including screws and bolts, in accordance with manufacturer's published torque tightening values. Where manufacturer's torquing requirements are not indicated, tighten connectors and terminals to comply with tightening torques specified in UL 486A and UL 486B.

L.

For direct buried cable installation, conform with the requirements of TES-P-104. Direct buried cable splices shall be made with splicing kits approved for such use.

M.

Direct buried cables that cross under paved roads, concrete slabs, railroads, or other areas that would require extensive or impractical excavations to replace, shall be run in duct banks or PVC sleeves. Exception: 1. 2. 3.

3.02

Ground grid conductors Asphalt-paved parking lots Plant areas paved with asphalt for soil stabilization.

FIELD QUALITY CONTROL A.

Cables shall be 1000V DC megger tested after installation and prior to placing in service.

B.

Prior to energizing, test wires and cables for electrical continuity and for short-circuits.

C.

Subsequent to wire and cable hook-ups, energize circuits and demonstrate proper functioning. Correct malfunctioning units, and retest to demonstrate compliance.

D.

Correct the deficiencies found at no cost to Client.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16124 MEDIUM VOLTAGE CABLE

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 8

SECTION 16124 MEDIUM VOLTAGE CABLE

DIVISION 16 ELECTRICAL

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05

Descriptions of Work Quality Assurance Submittals Delivery, Storage and Handling Warrenty

PART 2

PRODUCTS

2.01 2.02 2.03

Manufacturer’s Medium Voltage Cable Splicing and Terminating Products

PART 3 3.01 3.02 3.03 3.04 3.05

EXECUTION Examination Installation of Cables Installation of Splices Grounding Field Quality Control

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16124 MEDIUM VOLTAGE CABLE

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

DESCRIPTION OF WORK A.

This section includes conductor cables and splices, terminations, and accessories for 4.16 kV underground electrical distribution systems.

B.

Related Sections: The following Division 16 Sections contain requirements that relate to this Section: 1.

1.02

16322 "Pad Mounted Power Transformer" for cable termination provisions.

QUALITY ASSURANCE A.

Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: Transmission Engineering Specification TES-P-104 Underground Cable Engineering Standards Transmission Material Standards and Specification (TMSS)

1.03

B.

Installer Qualifications: Splices and terminations on cables rated 1000V shall be made by personnel certified.

C.

Field Testing Organization Qualifications: To qualify for acceptance, an independent testing organization must demonstrate, based on evaluation of organization-submitted criteria conforming to ASTM E 699, that it has the experience and capability to conduct satisfactorily the testing indicated.

D.

Cable Testing After Installation: Conform with the requirements of TES-P-104.

SUBMITTALS A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections. 1.

Product Data on cables and cable accessories including descriptions and detailed specifications.

2.

Shop Drawings of splices and terminations.

3.

Installer Certificates signed by CONTRACTOR that installers of cable splices and terminations meet the experience qualifications specified under Quality Assurance.

4.

Field Test Reports: Conform with the requirements of TES-P-104.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16124 MEDIUM VOLTAGE CABLE

DIVISION 16 ELECTRICAL 1.04

1.05

DELIVERY, STORAGE, AND HANDLING A.

Reels shall be made of steel, lagged with wood, and shall be marked with a durable label securely attached to a flange of the reel and plainly stating Buyer’s Purchase Order number, shipping length of cable on reel, number, type and size of conductors, cable configuration, and voltage rating. Cable ends shall be sealed and capped.

B.

Store cables on reels on elevated platforms in a clean, dry location. And provide chock to every cable reels while on the lay down yard at the job site.

C.

Cable reels shall be covered, or turned on their sides, when not in use for long periods to prevent UV damage.

WARRANTY A.

Special Project Warranty: Submit a written warranty, mutually executed by manufacturer and the principal installer, agreeing to repair or replace medium voltage cables, splices, and terminations that fail in materials or workmanship within the special project warranty period specified below. This warranty shall be in addition to, and not a limitation of, other rights and remedies Client may have against the CONTRACTOR under the Contract Documents.

B.

Special Project Warranty Period: Completion.

2 years beginning on the date of Substantial

PART 2 - PRODUCTS 2.01

MANUFACTURER’S A.

Available Manufacturer: Subject to compliance with requirements, manufacturer’s offering products which shall be incorporated with WORK include, but not limited to, the following: 1.

Cable Jeddah Cable Riyadh Cable Mitsubishi Cable Industries The Okonite Co. Alcatel Saudi Cable Company Or Other Approved Manufacturer’s

2.

Cable Splicing and Terminating Products and Accessories Electrical Products Division 3M.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16124 MEDIUM VOLTAGE CABLE

DIVISION 16 ELECTRICAL

Engineered Products Co. G&W Electric Co. M.P. Husky Corp. Raychem Corp. Or Other Approved Manufacturer’s 2.02

MEDIUM VOLTAGE CABLE A.

General: Cable shall be the types and sizes as indicated on the drawings..

B.

If not indicated on the drawings, cable shall be either cross-linked-polyethylene (XLPE) or ethylene-propylene-rubber (EPR) insulated, conforming to IEC 502 or AEIC (CS5 or CS6). .Substitution of IEC cable with AEIC cable, if IEC cable is specified, and vice versa, is prohibited.

C.

Conductors: Conductors shall conform with one of the following: 1.

IEC 502

Class 2 annealed copper, plain or metal coated

2.

AEIC

Class B annealed copper, plain or metal coated

D.

Conductor Screen: Extruded semi conductive compound, or a layer of extruded semiconducting compound over a semi-conducting tape.

E.

Insulation Screen (Non-metallic part): Layer of extruded semi-conducting compound. Semi-conducting coatings (paints) are not allowed. The extruded compound shall be removable (strippable).

F.

Insulation Screen (Metallic part): Copper shielding tape, helically applied over the silicon-shielded, insulated conductor .

G.

Concentric Neutral Conductor: The concentric neutral conductor shall be provided and it shall take the place of the copper shielding tape. It shall consist of copper wires with the specified cross-section, and shall be plain or metal coated as specified insulation level shall be 133%

H.

Ground Conductors: If specified, ground conductors shall be provided in the interstices of the cable and shall conform with one of the following:

I.

1.

IEC 502.

Class 2 stranded copper ground conductor

2.

AEIC

Class B stranded copper ground conductor

All cables shall have a continuous overall outer PVC jacket, suitable for 90 ºC maximum rated conductor temperature.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16124 MEDIUM VOLTAGE CABLE

DIVISION 16 ELECTRICAL

2.03

J.

Cables shall be suitable for direct burial and for installation in duct banks and cable trays.

K.

Circuit Identification: identified.

Each phase of multi-conductor cables shall be permanently

SPLICING AND TERMINATING PRODUCTS A.

General: Comply with the following standards: 1.

IEEE 404: Standard for Power Cable Joints.

2.

IEEE 592: Standard for exposed semi conducting shields on premoulded high voltage cable joints and separable insulated connectors.

3.

UL 486A: Wire connectors for use with copper conductors.

A.

Types: Compatible with the cable materials.

C.

Connectors: Compression type as recommended by cable or splicing kit manufacturer for the application.

D.

Splicing shall be made with standard splicing kits and shall be one of the following types: 1.

E,

Heat shrink splice kit of uniform cross section polymeric construction with outer heat shrink jacket.

Separable Insulated Connectors: Modular system, complying with IEEE Standard 386, "Separable Insulated Connectors for Power Distribution Systems above 600V." System shall consist of disconnecting, single pole, cable terminators and matching stationary, plug-in, dead-front terminals. System components shall be designed for the system voltage and for sealing against moisture and shall conform to the following: 1.

Cable Terminations at Transformers: Elbow type terminators that mate with bushing terminals in the equipment.

PART 3 - EXECUTION 3.01

EXAMINATION A.

Examine raceways, cable racks and other cable installation locations for cleanliness of raceways, minimum bending radii of cables, and conditions affecting performance of cable. Pull a mandrel through raceways to check for suitable conditions. Do not proceed with cable installation until unsatisfactory conditions have been corrected.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16124 MEDIUM VOLTAGE CABLE

DIVISION 16 ELECTRICAL 3.02

3.03

3.04

INSTALLATION OF CABLES A.

General: Install cable accessory items in accordance with manufacturer's written instructions and as indicated. Comply with the requirements of TES-P-104.

B.

Pull conductors simultaneously where more than one cable is indicated in same raceway. Use UL-listed and manufacturer approved pulling compound or lubricant where necessary. Do not exceed manufacturer's recommended maximum pulling tensions and sidewall pressure values.

C.

Use pulling means including, fish tape, cable, rope, and basket weave wire/cable grips that will not damage cables or raceways. Do not use rope hitches for pulling attachment to cable.

D.

Separation distances between conductors, pipelines, low voltage cables, control and communication cables shall in conformance with TES-P-104.

INSTALLATION OF SPLICES A.

Splicing of conductors shall not be permitted. In case of accidental damage of the cable during installation, additional splices are permitted with the concurrence of the cable Proponent.

B.

Installation of Terminations 1.

Install terminations at ends of conductors and seal multi-conductor cable ends with standard kits. Conform to manufacturer's written instructions. Comply with classes of terminations indicated.

2.

Tighten electrical connectors and terminals in accordance with manufacturer's published torque tightening values. Where manufacturer's torque requirements are not indicated, tighten connectors and terminals to comply with tightening torques specified in UL 486A and UL 486B.

GROUNDING A.

Ground shields of shielded cable at terminations, splices, and separable insulated connectors. Ground metal bodies of terminators, splices, cable and separable insulated connector fittings, and hardware in accordance with manufacturer's written instructions.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16124 MEDIUM VOLTAGE CABLE

DIVISION 16 ELECTRICAL 3.05

FIELD QUALITY CONTROL A.

General: Comply with applicable standards of the International Electrical Testing Association (INETA) including standard ATS, "Acceptance Testing Specifications for Electrical Power Distribution Equipment and system."

B.

Preparation: Perform the following preparations in advance of independent tests: 1.

Test cables insulation resistance.

2.

Test circuits continuity.

3.

Furnish a set of Contract documents and manufacturer's recommendations to test organization.

4.

Make power available at test locations.

5.

Test cables should be promptly removed after testing is complete.

C.

Schedule tests and notify the Company Representative at least ten (10) working days in advance of schedule for test commencement.

D.

Test procedure shall conform to the following: 1.

Independent Testing Organization: Arrange and pay for the services of an Independent electrical testing organization to perform tests on medium voltage cable.

2.

Test Objectives: To assure cable installation is operational within industry and manufacturer's tolerances, is installed in accordance with Contract Documents, and is suitable for energizing.

3.

Procedures: Comply with the INETA Standard and IEEE 400. satisfactory completion of tests, attach a label to tested components.

Upon

E.

Tests shall include all cable testing requirements of TES-P-104.

F.

Reports: The testing organization shall maintain a written record of observations and tests, report defective materials and workmanship, and retest corrected defective items. Testing organization shall submit written reports to the Company Representative and CONTRACTOR.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16135 CABINETS, BOXES AND FITTINGS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 7

SECTION 16135 CABINETS, BOXES AND FITTINGS

DIVISION 16 ELECTRICAL

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03

Descriptions of Work Quality Assurance Submittals

PART 2

PRODUCTS

2.01

Manufacturers

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07

EXECUTION Installation, Generals Applications Installation of Outlet Boxes Installation of Pull and Junction Boxes Installation of Cabinets and Hinged Door Enclousers Grounding Cleaning and Finsh Repair

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16135 CABINETS, BOXES AND FITTINGS

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

DESCRIPTION OF WORK A.

This Section includes cabinets, boxes, and fittings for electrical installations and certain types of electrical fittings not covered in other sections. Types of products specified in this Section include: Outlet and device boxes. Pull and junction boxes. Floor boxes and service fittings. Cabinets. Hinged door enclosures.

B

1.02

Conduit-body-type electrical enclosures and wiring fittings are specified in Division 16 Section "Raceways."

QUALITY ASSURANCE A.

Codes and Standards: Comply with all applicable codes and standards including but not limited to, those listed below ANSI/NFPA 70 IEC IEC 529 NEMA NEMA 250 NEMA ICS 6 UL TES-P-104

1.03

National Electrical Code (NEC) International Electro technical Commission Classification of Degrees of Protection Provided by Enclosures National Electrical Manufacturers Association Enclosures for Electrical Equipment (1000 Volts Maximum) Enclosures for Industrial Control and Systems Underwriters Laboratories Underground Cable Engineering Standards

SUBMITTALS A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections: 1.

Product data for cabinets and enclosures with classification higher than NEMA 1.

2.

Shop drawings for enclosures and cabinets that are to be shop fabricated, (non-stock items). For shop fabricated junction and pull boxes, show accurately scaled views and spatial relationships to adjacent equipment. Show box types, dimensions, and finishes.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16135 CABINETS, BOXES AND FITTINGS

DIVISION 16 ELECTRICAL PART 2 - PRODUCTS 2.01

MANUFACTURERS A.

Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the Work include, but are not limited to, the following:

B.

Manufacturers: Subject to compliance with requirements, provide products by the following: 1.

Cabinets: Electric Panelboard, Inc. Erickson Electrical Equipment Co. Hoffman Engineering Co. Parker Electrical Mfg. Co. Spring City Electrical Mfg. Co. Square D Co. Other Approved Manufacturers

PART 3 – EXECUTION 3.01

INSTALLATION, GENERAL A.

Locations: Install items where indicated and where required to suit NEC, TES-P-100, TES-P-104 requirements and installation conditions.

B.

Cap unused knockout holes where blanks have been removed and plug unused conduit hubs.

C.

Sizes shall be adequate to meet NEC volume requirements, but in no case smaller than sizes indicated.

D. 3.02

Remove sharp edges where they may come in contact with wiring or personnel.

APPLICATIONS Comply with the provisions of the NEC, and in addition, comply with the following: A.

In outdoor plant areas, within the perimeter of process units, equipment and terminal enclosures shall be either one of the following: 1. 2.

DISCIPLINE: ELECTRICAL

NEMA Type 3 or 4 or 4X IEC 529 Type IP65 or better

DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16135 CABINETS, BOXES AND FITTINGS

DIVISION 16 ELECTRICAL

3.03

B.

Enclosures that are rated (a) NEMA Type 3, 4 or 4X, or (b) IEC 529 Type IP54, or better, shall have Type 300 Series stainless steel hardware, except aluminum enclosures may have aluminum or aluminum alloy hinges.

C.

Enclosures and junction boxes having an internal volume exceeding 2000 cubic centimeters (122 cubic inches) shall be provided with Type 300 Series stainless steel breather and drain fittings.

INSTALLATION OF OUTLET BOXES A.

Locations in Special Finish Materials: For outlet boxes for receptacles and switches mounted in desks or furniture cabinets or in glazed tile, concrete block, marble, brick, stone or wood walls, use rectangular shaped boxes with square corners and straight sides. Install such boxes without plaster rings. Saw cut all recesses for outlet boxes in exposed masonry walls.

B.

Gasketed Boxes: At the following locations use cast metal, threaded hub type boxes with gasketed weatherproof covers: 1. 2. 3. 4. 5.

Exterior locations. Where surface mounted on unfinished walls, columns or pilasters. gaskets may be omitted in dry locations). Where exposed to moisture laden atmosphere. At food preparation equipment within four ft. of steam connections. Where indicated.

(Cover

C.

Mounting: Mount outlet boxes for switches with the long axis vertical or as indicated. Mount boxes for receptacles either vertically or horizontally but consistently either way. Locate box covers or device plates so they will not span different types of building finishes either vertically or horizontally. Locate boxes for switches near doors on the side opposite the hinges and close to door trim, even though electrical floor plans may show them on hinge side.

D.

Ceiling Outlets: For fixtures, where wiring is concealed, use outlet boxes 4-inches square by 1-1/2-inches deep, minimum, unless otherwise indicated.

E.

Cover Plates for Surface Boxes: Use plates sized to box front without overlap.

F.

Protect outlet boxes to prevent entrance of plaster, and debris. Thoroughly clean foreign material from boxes before conductors are installed.

G.

Concrete Boxes: Use extra deep boxes to permit side conduit entrance without interfering with reinforcing, but do not use such boxes with over 6-inch depth.

H.

Floor Boxes: When required and indicated on the drawing,, install in concrete floor slabs so they are completely enveloped in concrete except for the top. Where normal slab thickness will not envelop box as specified above, provide increased thickness of

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 5 of 7

SECTION 16135 CABINETS, BOXES AND FITTINGS

DIVISION 16 ELECTRICAL

the slab. Provide each compartment of each floor box with grounding terminal consisting of a washer- in-head machine screw, not smaller than no. 1032, screwed into a tapped hole in the box. Adjust covers of floor boxes flush with finished floor. I.

3.04

INSTALLATION OF PULL AND JUNCTION BOXES A.

3.05

Existing Outlet Boxes: Where extension rings are required to be installed, drill new mounting holes in the rings to align with the mounting holes on the existing boxes where existing holes are not aligned.

Box Selection: For boxes in main feeder conduit runs, use sizes not smaller than 8inches square by 4-inches deep. Do not exceed 6 entering and 6 leaving raceways in a single box. Quantities of conductors (including equipment grounding conductors) in pull or junction box shall not exceed the following: Size of Largest Conductors in Box

Maximum no. of Conductors in Box

No. 4/0 AWG 250 MCM

30 20

B.

Cable Supports: Install clamps, grids, or devices to which cables may be secured. Arrange cables so they may be readily identified. Support cable at least every 30inches inside boxes.

C.

Mount pull boxes in inaccessible ceilings with the covers flush with the finished ceiling.

D.

Size: Provide pull and junction boxes for telephone, signal, and other systems at least 50 percent larger than would be required by Article 370 of NEC, or as indicated. Locate boxes strategically and provide shapes to permit easy pulling of future wires or cables of types normal for such systems.

INSTALLATION OF CABINETS AND HINGED DOOR ENCLOSURES A.

Mount with fronts straight and plumb.

B.

Install with tops 78-inches above floor.

C.

Set cabinets in finished spaces flush with walls, unless indicated shown otherwise.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 6 of 7

SECTION 16135 CABINETS, BOXES AND FITTINGS

DIVISION 16 ELECTRICAL 3.06

GROUNDING a.

3.07

Electrically ground metallic cabinets, boxes, and enclosures. Where wiring to item includes a grounding conductor, provide a grounding terminal in the interior of the cabinet, box or enclosure.

CLEANING AND FINISH REPAIR A.

Upon completion of installation, inspect components. Remove burrs, dirt, and construction debris and repair damaged finish including chips, scratches, abrasions and weld marks.

B.

Galvanized Finish: Repair damage using a zinc-rich paint recommended by the tray manufacturer.

C.

Painted Finish: Repair damage using matching corrosion inhibiting touch-up coating.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 7 of 7

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16143 WIRING DEVICES

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 5

SECTION 16143 WIRING DEVICES

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03

Descriptions of Work Quality Assurance Submittals

PART 2

PRODUCTS

2.01 2.02

ManufacturerS Wiring Devices

PART 3 3.01 3.02 3.03

EXECUTION Installation of Wiring Devices and Accessories Protection Field Quality Control

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 2 of 5

SECTION 16143 WIRING DEVICES

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

DESCRIPTION OF WORK A.

This Section includes the following: Receptacles Ground Fault Circuit Interrupter Receptacles Toggle Switches Photo Cell Relays Lighting Contactors

1.02

QUALITY ASSURANCE A.

Codes and Standards: Comply with all applicable codes and standards including but not limited to, those listed below: 1.

SAUDI Electricicty Transmission Engineering Specification (TES) TES-P-119.25

B.

1.03

Lighting and Recepticles for Substation yard & building

UL and NEMA Compliance: Provide wiring devices which are listed and labeled by UL and comply with applicable UL and NEMA standards.

SUBMITTALS A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specifications Sections. 1.

Product data for each type of wiring devices and coverplates.

2.

Samples.

PART 2 – PRODUCTS 2.01

MANUFACTURERS Available Manufacturers: Subject to compliance with requirements, manufacturers offering products which may be incorporated in the work include, but are not limited to, the following: General Electric Co. Hubbell Inc. Lutron Other Approved Manufacturers

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 3 of 5

SECTION 16143 WIRING DEVICES

DIVISION 16 ELECTRICAL 2.02

WIRING DEVICES A.

General: Provide wiring devices, in types, characteristics, grades, colors, and electrical ratings for applications indicated which are UL listed and which comply with NEMA WD 1 and other applicable UL and NEMA standards. Provide ivory color devices and wall plates except as otherwise indicated.

B.

Receptacles: Comply with UL 498 and NEMA WD 1. Unless otherwise indicated, provide duplex receptacles rated NEMA 5-20R duplex, 2 pole, 3 wire grounding, 125 volts. 1.

Receptacles, Industrial Heavy Duty: Provide pin and sleeve design receptacles conforming to UL 498. Comply with UL 1010 where installed in hazardous locations. Provide features indicated.

2.

Ground-Fault Interrupter (GFI) Receptacles: Provide ground-fault circuit interrupter, with integral heavy-duty NEMA 5-20R duplex receptacle. Provide unit designed for installation in a 2- 3/4 inch deep outlet box without adapter, grounding type, Class A, Group 1, per UL Standard 94.3.

C.

Toggle Switches:. Comply with UL 20 and NEMA WD1. Unless otherwise indicated, provide quiet type AC switches rated 20 A, 120/277 V, 1 pole, heavy duty.

D.

Wall Plates: Single and combination, of types, sizes, and with ganging and cutouts as indicated. Provide stainless steel plates for areas subject to hard usage or open to the public.

PART 3 – EXECUTION 3.01

INSTALLATION OF WIRING DEVICES AND ACCESSORIES A.

Install wiring devices and accessories as indicated, in accordance with manufacturer's written instructions, applicable requirements of NEC and in accordance with recognized industry practices to fulfill project requirements.

B.

Coordinate with other work, including painting, electrical boxes and wiring installations, as necessary to interface installation of wiring devices with other Work.

C.

Install wiring devices only in electrical boxes which are clean; free from excess building materials, dirt, and debris.

D.

Install wiring devices after wiring work is completed.

E.

Install wall plates after painting work is completed.

F

Tighten connectors and terminals, in accordance with equipment manufacturer's published torque tightening values for wiring devices. Where manufacturer's

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 4 of 5

SECTION 16143 WIRING DEVICES

DIVISION 16 ELECTRICAL

torquing requirements are not indicated, tighten connectors and terminals to comply with tightening torques specified in UL Standard 486A. Use properly scaled torque indicating hand tool. 3.02

3.03

PROTECTION A.

Protect installed components from damage.

B.

Replace damaged items prior to final acceptance.

FIELD QUALITY CONTROL A.

Prior to energizing circuits, test wiring for electrical continuity, and for short-circuits. Ensure proper polarity of connections is maintained.

B.

Subsequent to energizing, test wiring devices and demonstrate compliance with requirements, operating each operable device at least six times.

C.

Test GFI receptacle operation with both local and remote fault simulations in accordance with manufacturer recommendations.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 5 of 5

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16150 ELECTRICAL MOTORS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

Discipline: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE Page 1 of 12

REMARKS

DIVISION 16 ELECTRICAL WORKS

SECTION 16150 ELECTRICAL MOTORS

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04

Scope Standards Environmental Conditions Technical Data

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06 2.07

Selection of Motors Components and Equipments Duty Dimensions Noise Requirements Units and Scales Special Requirements

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09 3.10

EXECUTION Tagging Medium Voltage Motors Low Voltage Motors Painting Installation Workshop Test Site Test Documentation Shipping Spare Parts and Special Tools

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16150 ELECTRICAL MOTORS

PART 1 - GENERAL 1.01

Scope This document covers the requirements for the design, manufacturing, construction, installation, test and commissioning of electrical motors for medium and low voltage for the Transportation of Treated Water from Taif STP to Ma’aden Gold mines.

1.02

Standards The design, manufacturing, construction, installation, test and commissioning of electrical motors shall be in accordance with the following codes and standards, at least. The latest revision of the publication referred to shall apply. IEC 60034

Rotating electrical machines

IEC 60038

IEC standard voltages

IEC 60072

Dimensions and output series for rotating electrical machines

IEC 60085

Thermal evaluation and classification of electrical insulation

IEC 60529

Degrees of protection provided by enclosures (IP Code)

ISO 15 ISO 281

Rolling bearings - Radial bearings - Boundary dimensions, general Rolling bearings - Dynamic load ratings and rating life

Plan

As far as the power supply authority (SEC) and permits of other authorities require additional codes and standards, respectively impose additional requirements, these are also part of the contract. 1.03

Environmental Conditions The electrical motors shall be designed and constructed for continuous operation at full load under the climatic and environmental conditions as described in the specification “Design and Construction of Power Supply Systems”.

1.04

Tchnical Data The technical data of the electrical motors are defined in the data sheets. The Contractor has to guarantee the fulfillment of these requirements.

PART 2 – PRODUCTS 2.01

Selection of Motors In general it shall be the responsibility of the driven equipment manufacturer to select and coordinate the required motor type. This includes the co-ordination of the performance data

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16150 ELECTRICAL MOTORS

(motor speed, shaft power and direction of rotation) as also the mechanical construction and coupling requirements. The motors shall be designed as squirrel cage motor and shall be of industrial type. If not specified otherwise the actual power output of the motors must be selected to meet the maximum required shaft power of the driven equipment, multiplied by a factor of 1.2 for motors up to 250 kW and 1.15 for motors above 250 kW and using the next larger standard motor size. •

Motors shall be entirely suitable for outdoor installation without any additional protection.

•

Lifting lugs and drain hole for condensation shall be provided on all motors.

•

The motors shall be suitable to deliver rated power continuously at

•

±10% nominal voltage and rated frequency,

•

Nominal voltage and ±5% of rated frequency,

•

±10% combined variation of nominal voltage and frequency, with frequency variation ≤±5%.

The type of MV motors (fixed or variable speed) has to be specified. In case variable speed motors are selected, speed control mode of operation need to be detailed. 2.02

Components and Equipment The Contractor has to take care that all components and equipment are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals. All components and equipment shall be designed for continuous duty at rated load and under the given climatic conditions. Standard industrial high performance systems and components of supplier’s standard lists shall be used as far as possible. Components and equipment of same kind and type shall be selected for equivalent functions. The interchangeability must be guaranteed.

2.03

Duty The motors shall be designed for continuous running duty, S1 according to IEC, at the specified conditions. Motors connected to electric / electronic speed control or start-up equipment such as frequency converters or start-up transformers have to be selected / matched to the special requirement of such duty.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 2.04

SECTION 16150 ELECTRICAL MOTORS

Dimensions All motors of the same size shall be interchangeable. The motor dimensions shall be in accordance with IEC 60072.

2.05

Noise Requirements The sound pressure level of electrical motors shall not exceed 85 dB (A) @ 1 m under no load conditions.

2.06

Units and Scales The metric system on basis of SI-units shall be used for all scales and indications.

2.07

Special Requirements The Vendor/Manufacturer shall have local representative in Saudi Arabia and shall have maintenance team available with minimum five years of experience to attend any maintenance issues.

PART 3 - EXECUTION 3.01

Tagging All components, equipment and installations shall receive the respective tagging plates, labels, etc., which have to be of extremely durable material resistant against the environmental conditions. For further requirements, reference is made to specification “Basic Electrical Requirements”.

3.02

Medium Voltage Motors Motor Start and Torque Requirements The motors shall be designed for direct on-line starting at full load; the starting current shall not exceed 5.5 times the rated current. The motors shall not break out if during normal operation the voltage at the motor terminals remains 0.8 UN, but the operation at 0.8 UN shall be limited to 10 seconds. The motors shall be designed to allow 4 starts successively from cold (max. ambient temperature) or 3 starts successively from hot service temperature without tripping of any protection device.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16150 ELECTRICAL MOTORS

Insulation / Winding Protection The motors shall have tropicalied insulation. The motors shall be designed for class F insulation, thermal utilization of the motors shall be for class B only. The Motors shall be designed for operation in isolated neutral or unearthed systems. Therefore the level of insulation required shall be suitable for this condition. The stator winding shall be insulated by high quality modern synthetic resin insulation system based on mica-glass tape. After insertion of the coils into the stator core the whole winding shall be vacuum impregnated with epoxy resin, free from any solvent. The allowable impulse-stress-voltage for the insulation system shall meet the requirements of IEC 60034 part 15. The motors shall be designed for re-acceleration against 100% residual field at phase opposition. In each stator winding phase at least two (2) Pt 100 temperature elements (4-wire system) shall be imbedded at the hottest place and wired to the auxiliary terminal box. The motors shall be equipped with surge arrestors, which are to be installed in the motor stator connection terminal box. The surge arrestor design must match to the actual network configuration, the used circuit breakers and the connected cable arrangement. If technically recommended additional surge arrestors shall be installed at the MCC side for cable protection during vacuum circuit breaker switching. Method of Cooling The motor cooling shall be according to the data sheets, either air cooled or with air/water heat exchanger. If the motor cooling will be performed via an air/water heat exchanger, the water outlet of the heat exchanger shall be equipped with a thermostat or an equivalent device for control of water temperature and flow. Equipment room on suitable racks. Current Transformers for Differential Protection For all motors with a rating at 2000 KW or above a differential relay for winding protection shall be provided and installed in the associated MCC. In that case the star-point connection shall be brought out separately to terminals box and three current transformers at motor end shall be provided, one for each winding between line and neutral side at motor. The differential current transformers shall be designed to class 5P10 or class X to BS with a rating matched to the protection system. The CTs shall be provided by the motor supplier and accommodated in the star-point terminal box. The current transformers for the motors and as well the current transformers for installation inside of MV MCC shall be delivered by the motor manufacturer. DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16150 ELECTRICAL MOTORS

The current transformers for motors must be installed prior to workshop tests. The current transformers for the MV MCC shall be handed over to MCC manufacturer before workshop tests of the respective MCC. Bearings The motors shall be fitted with ball or rolling contact bearings, supplied with life time grease. Grease regulator and nipples, as also surplus grease discharge openings shall be provided if required. For larger motors, self-cooled sleeve bearings are acceptable, too. Sleeve bearings shall be equipped with oil ring lubrication; the bearing housings shall have an oil level indication. External lube oil systems shall only be used, if necessary and shall be combined with the lube oil system of driven equipment. Temperature monitoring with Pt 100 temperature elements (4-wire) is required for the bearings. Terminal Boxes A stator connection terminal box shall be provided and fitted with terminals, including surge arrestors and cable glands for the connection of the actual number and type of cables. Dimension of cable glands shall be as per requirement. Pressure relief flaps shall be foreseen. Auxiliary terminal boxes with terminals and cable glands for current transformers, instrumentation and anti condensation heater connection shall be foreseen. Surge arrestors shall be installed for all monitoring instrument circuits. Anti Condensation Heater The motors shall be equipped in general with electrical anti condensation heaters, to be switched on if the motor circuit breaker is off. The voltage level for the anti condensation heater shall be 1 x 230 V AC, 60 Hz. 3.03

Low Voltage Motors Motor Start and Torque Requirements The motors shall be designed for direct on-line starting at full load. For motors of 132 kW shaft power and above, the starting current shall not exceed 5.5 times the rated current. The motors shall not break out if during normal operation the voltage at the motor terminals remains greater than 0.8 UN, but the operation at 0.8 UN shall be limited to 10 seconds.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16150 ELECTRICAL MOTORS

The motors shall be designed to allow 4 starts successively from cold (max. ambient temperature) or 3 starts successively from hot service temperature without tripping of any protection device. Insulation / Winding Protection The motors shall have tropicalised insulation. The motors shall be designed for class F insulation, thermal utilisation of the motors shall be for class B only. The stator winding shall be insulated by high quality modern synthetic resin insulation system based on mica-glass tape. After insertion of the coils into the stator core the whole winding shall be vacuum impregnated with epoxy resin, free from any solvent. The motors shall be designed for re-acceleration against 100% residual field at phase opposition. Motors of a rated power of 90 kW and above shall be equipped with winding protection by means of embedded positive temperature coefficient thermistors. Two thermistors per phase (one set service – one set spare) shall be provided and wired to the auxiliary terminal box. Method of Cooling Motors shall be totally enclosed and fan cooled by ambient air, equivalent to cooling code IC0141 or IC0151 according to IEC 60034 part 6. Bearings The motors shall be fitted with ball or rolling contact bearings, supplied with life time grease. Grease regulator and nipples, as also surplus grease discharge openings shall be provided if required. Self-cooled sleeve bearings are acceptable, too. Sleeve bearings shall be equipped with an oil ring lubrication, the bearing housings shall have an oil level indication. External lube oil systems for LV motors will not be accepted. Terminal Boxes Terminal boxes shall be provided and fitted with terminals and cable glands for the connection of the actual number and type of cables. Dimension of cable glands as per requirement. If required, auxiliary terminal boxes with terminals and cable glands for instrumentation and anti condensation heater connection shall be foreseen. All terminal boxes shall be IP55 enclosure type. DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16150 ELECTRICAL MOTORS

Anti Condensation Heater Motors with 90 kW rated power and above shall be equipped in general with electrical anti condensation heaters, to be switched on if the motor circuit breaker is off. The voltage level for the anti condensation heater shall be 1 x 230 V AC, 60 Hz. 3.04

Painting The painting shall be as per the approved manufacturer standard at least consisting of: • • •

One coat of two-component epoxy zinc chromate rust-inhibiting primer, One intermediate coat of two-component epoxy primer, Two top coatings for two-component resin, color as per the approved color code schedule.

Total thickness of dry protective paint coating shall be at least 120 μm. All paint coatings shall be resistant against temperature conditions up to 140 °C and intermittently up to 180 °C. Damages, caused by transport, installation, cabling or commissioning shall be repaired in a way, that the original quality is restored. An additional painting at location of installation is not allowed. 3.05

Installations Installation and alignment shall be carried out in accordance with the instructions and recommendations of the manufacturer and with due regard to the requirements of the driven machine.

3.06

Workshop Tests All motors shall be tested completely and detailed in manufacturer’s workshop. All tests required by the codes and standards as well as all manufactures tests have to be performed. The test program for the work shop test has to be submitted prior to start of the tests in accordance with the Project Procedure Manual. All motors shall be subjected to at least the ‘abbreviated’ tests in accordance with the applicable standard test procedures. Complete tests on motors up to 90 kW will not normally be required if evidence of type tests on identical machines is produced at the time of quotation.

For machines of 90 kW and above it will be acceptable that ‘complete’ tests are made on only one of several identical machines with ‘abbreviated’ tests on the remaining machines. DICIPLENE: ELECTRICAL DOCUMENT No.: MGBM-SPEC-0001 Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16150 ELECTRICAL MOTORS

The following tests shall be performed, at least: a)

Abbreviated tests (‘routine’ tests) • • • • • • •

b)

Measurement of no-load losses at rated voltage and frequency, Measurement to allow calculation of locked rotor current and torque, High voltage tests plus insulation resistance test, Inspection (at no-load) of bearings and mechanical operation of motor, Vibration, High voltage and continuity tests on built-in temperature detectors, Bearing insulation integrity (if applicable).

Complete test (‘full’ tests) • • • • • • • • • • • • • • •

Measurement of winding resistance (cold and hot), Measurement of no-load losses at rated voltage and frequency, Measurement to allow calculation of locked rotor current and torque, Full load heat run, High voltage test after heat run and insulation resistance before and after heat run, Inspection (at full load) of bearings and mechanical operation of motor, Measurement of slip at full load, Measurement to allow calculation of pull-out torque, Measurement to allow calculation of starting torque, Measurement to allow calculation of efficiency at full, three quarter and half load, Measurement to allow calculation of power factor at full, three quarter and half load, Vibration, Noise, High voltage and continuity tests on built-in temperature detectors, together with tests to demonstrate satisfactory operation and compliance with stated characteristics, Bearing insulation integrity (if applicable).

Detailed test protocols of all tests performed have to be submitted prior to installation. Type test certificates for LV motors will be acceptable, if the same type and rating of motor is covered. 3.07

Site Tests The site tests shall include the following steps: •

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS • • • •

SECTION 16150 ELECTRICAL MOTORS Pre-commissioning (including “Loop Testing”), Commissioning and test on completion, Test runs, Performance tests.

The aim of the tests is to ensure and prove the proper function of the complete scope. 3.08

Documentation Complete documentation shall be provided for the design, manufacturing, testing, commissioning, start-up, operation, maintenance and repair of the motors and its components. All documents shall be in English language. The documentation of motors shall include the following documents and drawings (minimum requirements): a) b) c) d) e) f) g)

Layout drawings Wiring diagrams Termination drawings Technical data sheets Calculations, protocols, certificates Spare parts list Performance curves

h) i)

Operation and maintenance manual Reports of tests and commissioning with protocols.

The documents listed above shall be handed over for approval. Special attention has to be given to the fact, that documentation must be submitted with sufficient time allocated for approval prior to manufacturing / assembly. Documentation has to be prepared in accordance with the relevant ISO. The final documentation shall be delivered on paper in sufficient number and with exception of the signed protocols in electronic form, too. The type of the electronic files shall be agreed with the Client. 3.09

Shipping All equipment, material and spare parts shall be sufficient packaged and shall be shipped as a common delivery. The material, especially loose parts and spare parts shall be clearly labeled according to the designation. Motors shall be coupled with the respective work machine before shipping.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 3.10

SECTION 16150 ELECTRICAL MOTORS

Spare Parts and Special Tools The Contractor shall deliver all spare parts, which are necessary for commissioning and two years operation time (see “General Description of Project and Works”). Spare parts shall be available until ten years after commissioning. The following special tools shall be supplied: •

One digital HV Insulation resistance testing kit (Megger) with PI measuring facilitity

•

Four digital LV Insulation resistance testing kit (Megger)

- END OF SECTION -

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16160 ENCLOSURES

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 5

SECTION 16160 ENCLOSURES

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05

Section Includes Related Sections References Submittals Regulatory Requirements

PART 2

PRODUCTS

2.01 2.02 2.03

Manufacturer Hinged Cover Enclosures Terminal Blocks

PART 3 3.01 3.02

EXECUTION Examination Installation

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. A 15 Mar, 2011

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SECTION 16160 ENCLOSURES

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

1.02

1.03

1.04

1.05

SECTION INCLUDES A.

Hinged Cover Enclosures.

B.

Terminal Blocks.

C.

Accessories.

RELATED SECTIONS A.

Section 16170

Circuit and motor disconnects

B.

Section 16195

Electrical Identification

REFERENCES A.

NEMA 250

Enclosures for Electrical Equipment (1000 Volts maximum)

B.

NEMA ICS 4

Terminal Blocks for Industrial Control Equipment and Systems.

C.

ANSI/NFPA 70

National Electrical Code.

SUBMITTALS A.

Product Data :

Provide manufacturer's standard data for enclosures.

B.

Manufacturer's Instructions:

Indicate application conditions and limitations of use stipulated by Product testing agency specified under Regulatory Requirements. Include instructions for storage, handling, protection, examination, preparation, and installation of product.

REGULATORY REQUIREMENTS A.

Conform to requirements of ANSI/NFPA 70. a.

Furnish products that complies with underwriters laboratories (UL) standard acceptable to Client as suitable for purpose specified and shown or products manufactured to IEC standard which are exact equivalent to UL standard.

b.

Approval and acceptable by Client.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. A 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 3 of 5

SECTION 16160 ENCLOSURES

DIVISION 16 ELECTRICAL PART 2 - PRODUCTS 2.01

MANUFACTURERS Refer to Approved Manufacturers List.

2.02

HINGED COVER ENCLOSURES A.

2.03

Construction

:

NEMA 250 Steel enclosure.

Non-Classified Area :

Type 1 for indoor dry locations. Type 4X for outdoor locations.

B.

Gasketed Covers

Continuous hinge, held closed by flush latch operable key.

C.

Provide Interior metal panel for mounting terminal blocks and electrical components; finish with white enamel.

D.

Enclosure Finish

:

Manufacturer's standard enamel.

E.

Construction

:

12 gauge (mm) steel, seams continuously welded, surface flat, smooth and rigid.

:

TERMINAL BLOCKS A.

Manufacturers

:

Refer to Approved Manufacturers List.

B.

Terminal Blocks

:

ANSI / NEMA ICS 4.

C.

Power Terminals

:

Unit construction type with closed back and tubular pressure screw connections, rated 600 Volts.

D.

Signal and

:

Modular construction type, suitable for channel mounting, Control Terminals with tubular pressure screw connectors, rated 300 Volts.

E.

Provide ground bus terminal block, with each connector bonded to enclosure.

PART 3 - EXECUTION 3.01

EXAMINATION A.

Verify that surfaces are ready to receive work and provide sufficient support.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. A 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 4 of 5

SECTION 16160 ENCLOSURES

DIVISION 16 ELECTRICAL

3.02

INSTALLATION A. B.

Install nameplates in accordance with Section 16195. Install products in accordance with manufacturer’s instructions.

C.

Install enclosures and boxes plumb. Anchor securely to wall and structural support at each corner.

D.

Ground or Bond Enclosure in accordance with Section 16170.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. A 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 5 of 5

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16170 CIRCUIT AND MOTOR DISCONNECTS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 5

SECTION 16170 CIRCUIT AND MOTOR DISCONNECTS

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03

Descriptions of Work Quality Assurance Submittals

PART 2

PRODUCTS

2.01 2.02 2.03

Manufacturer Circuit and Motor Disconnect Switches Accessories

PART 3 3.01 3.02

EXECUTION Installation Field Quality Control

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 2 of 5

SECTION 16170 CIRCUIT AND MOTOR DISCONNECTS

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

DESCRIPTION OF WORK A.

1.02

QUALITY ASSURANCE A.

1.03

This Section includes circuit and motor disconnects (otherwise known as enclosed switches, disconnects, disconnect switches or safety switches).

Code and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: 1.

TES-P-104

Underground Cable Engineering Standards

2.

Electrical Component Standards: Provide components complying with ANSI/NFPA 70 "National Electrical Code" and which are listed and labeled by UL. Comply with UL Standard 98 and NEMA Standard KS 1.

SUBMITTALS A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specifications Sections. 1.

Product data for each type of product specified.

2.

Maintenance data for circuit and motor disconnects, for inclusion in Operation and Maintenance Manual specified in Division 16 Section 16010 "Basic Electrical Requirements"

PART 2 - PRODUCTS 2.01

MANUFACTURERS A.

Available Manufacturers: Subject to compliance with requirements, manufacturers offering products which shall be incorporated in the work include, but are not limited to, the following:

B.

Manufacturers: Subject to compliance with requirements, provide products by the following: Appleton Cutler-Hammer Inc. Furnas Electric Co. General Electric Co. General Switch Corp. Square D Company. Westinghouse Electric Corp.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 3 of 5

SECTION 16170 CIRCUIT AND MOTOR DISCONNECTS

DIVISION 16 ELECTRICAL Other Approved Manufacturers 2.02

2.03

CIRCUIT AND MOTOR DISCONNECT SWITCHES A.

General: Provide circuit and motor disconnect switches in types, sizes, duties, features, ratings, and enclosures as indicated. For motor and motor starter disconnects, provide units with horsepower ratings suitable to the loads.

B.

Non-Fusible Disconnects: Heavy duty switches of classes and current ratings as indicated.

ACCESSORIES A.

Electrical Interlocks: Provide number and arrangement of interlock contacts in switches as indicated.

B.

Captive Fuse Pullers: Provide built-in fuse pullers arranged to facilitate fuse removal.

PART 3 - EXECUTION 3.01

INSTALLATION General: Follow switch manufacturers' printed installation instructions. Comply with the provisions of the NEC and TES-P-104 requirements and installation conditions. In addition, comply with the following: A.

In outdoor non-industrial areas, equipment and terminal enclosures shall be either one of the following: 1. 2.

3.02

NEMA Type 3R, 3 or 4 IEC 529 Type IP34 or better

B.

Enclosures that are rated (a) NEMA Type 3, 4 or 4X, or (b) IEC 529 Type IP54, or better, shall have Type 300 Series stainless steel hardware, except aluminum enclosures may have aluminum or aluminum alloy hinges.

C.

Enclosures and junction boxes having an internal volume exceeding 2000 cubic centimeters (122 cubic inches) shall be provided with Type 300 Series stainless steel breather and drain fittings.

FIELD QUALITY CONTROL A.

Testing: Subsequent to completion of installation of electrical disconnect switches, energize circuits and demonstrate capability and compliance with requirements. Except as otherwise indicated, do not test switches by operating them under load. However, demonstrate switch operation through six opening/closing cycles with circuit unloaded. Open each switch enclosure for inspection of interior, mechanical and

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 4 of 5

SECTION 16170 CIRCUIT AND MOTOR DISCONNECTS

DIVISION 16 ELECTRICAL

electrical connections, fuse installation, and for verification of type and rating of fuses installed. Correct deficiencies then retest to demonstrate compliance. Remove and replace defective units with new units and retest.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 5 of 5

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16180 EQUIPMENT WIRING SYSTEM

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 5

SECTION 16180 EQUIPMENT WIRING SYSTEM

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05 1.06

Section Includes Related Sections References Sumittals Regulatory Requirements Coordination

PART 2

PRODUCTS

2.01

Cords and Caps

PART 3 3.01 3.02 3.03

EXECUTION Examinations Electrical Connections Equipment Connection Schdule

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 2 of 5

SECTION 16180 EQUIPMENT WIRING SYSTEM

DIVISION 16 ELECTRICAL PART 1 – GENERAL 1.01

SECTION INCLUDES A.

1.02

1.03

1.04

1.05

1.06

Electrical connections to equipment specified under other sections.

RELATED SECTIONS A.

Section 16110

Raceways.

B.

Section 16120

Wires and Cable.

C.

Section 16135

Cabinets,Boxes & Fittings.

REFERENCES A.

TES-P-104

B.

ANSI/NFPA 70 - National Electrical Code.

SUBMITTALS A.

Product Data: Provide wiring device manufacturer's catalog information showing dimensions, configurations, and construction.

B.

Manufacturer's Instructions: Indicate application conditions and limitations of use stipulated by Product testing agency specified under Regulatory Requirements. Include instructions for storage, handling, protection, examination, preparation, installation, and starting of Product.

REGULATORY REQUIREMENTS A.

Conform to requirements of ANSI/NFPA 70 and TES-P-104.

B.

Furnish products listed and classified by Underwriters Laboratories, Inc. testing firm acceptable to authority having jurisdiction, SAMSS as suitable for purpose specified and shown.

COORDINATION A.

Obtain and review shop drawings, product data, and manufacturer's instructions for equipment furnished under other sections.

B.

Determine connection locations and requirements.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 3 of 5

SECTION 16180 EQUIPMENT WIRING SYSTEM

DIVISION 16 ELECTRICAL C.

Sequence rough-in of electrical connections to coordinate with installation schedule for equipment.

D.

Sequence electrical connections to coordinate with start-up schedule for equipment.

PART 2 – PRODUCTS 2.01

CORDS AND CAPS A.

Manufacturers: 1.

Carol Cable Co. Division, Model: 02725

2.

ITT Royal Electric Division, Model: PC10205

3.

Manhattan Electric Cable Corp., Model: M2773

B.

Attachment Plug Construction: Conform to NEMA WD 1.

C.

Configuration: NEMA WD 6; match receptacle configuration at outlet provided for equipment.

D.

Cord Construction: ANSI/NFPA 70, Type SO multi conductor flexible cord with identified equipment grounding conductor, suitable for use in damp locations.

E.

Size: Suitable for connected load of equipment, length of cord, and rating of branch circuit overcurrent protection.

PART 3 - EXECUTION 3.01

EXAMINATION A.

3.02

Verify that equipment is ready for electrical connection, wiring, and energization.

ELECTRICAL CONNECTIONS A.

Make electrical instructions.

B.

Make conduit connections to equipment using flexible conduit. Use liquid tight flexible conduit with watertight connectors in damp or wet locations.

C.

Make wiring connections using wire and cable with insulation suitable for temperatures encountered in heat producing equipment.

D.

Provide receptacle outlet where connection with attachment plug is indicated. Provide cord and cap where field-supplied attachment plug is indicated.

DISCIPLINE: ELECTRICAL

connections

in

accordance

with

equipment

manufacturer's

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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Page 4 of 5

SECTION 16180 EQUIPMENT WIRING SYSTEM

DIVISION 16 ELECTRICAL

3.03

E.

Provide suitable strain-relief clamps and fittings for cord connections at outlet boxes and equipment connection boxes.

F.

Install disconnect switches, controllers, control stations, and control devices as indicated.

G.

Provide interconnecting conduit and wiring between devices and equipment where indicated.

EQUIPMENT CONNECTION SCHEDULE A.

As per scope of work and SAMSS Standards.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 5 of 5

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16195 ELECTRICAL IDENTIFICATION

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 8

SECTION 16195 ELECTRICAL IDENTIFICATION

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03

Descriptions of Work Quality Assurance Submittals

PART 2

PRODUCTS

2.01 2.02

Manufacturers Electrical Identification Products

PART 3 3.01

EXECUTION Installation

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 2 of 8

SECTION 16195 ELECTRICAL IDENTIFICATION

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

DESCRIPTION OF WORK This Section includes identification of electrical materials, equipment, and installations. It includes requirements for electrical identification components including but not limited to the following:

1.02

A.

Identification labeling for raceways, cables, and conductors.

B.

Operational instruction signs.

C.

Warning and caution signs.

D.

Equipment labels and signs.

QUALITY ASSURANCE A.

1.03

Codes and Standards: Comply with all applicable codes and standards including but not limited to, those listed below: 1.

Electrical Component Standard: Components and installation shall comply with ANSI/NFPA 70 "National Electrical Code."

2.

ANSI Compliance: Comply with requirements of ANSI Standard A13.1, "Scheme for the Identification of Piping Systems," with regard to type and size of lettering for raceway and cable labels.

SUBMITTALS A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections: 1.

B.

Product Data for each type of product specified.

For unusually complex projects such as laboratories, communication centers and utility plants, provide the following: 1.

Schedule of identification nomenclature to be used for identification signs and labels.

2.

Samples of each color, lettering style, and other graphic representation required for identification materials; samples of labels and signs.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 3 of 8

SECTION 16195 ELECTRICAL IDENTIFICATION

DIVISION 16 ELECTRICAL

PART 2 - PRODUCTS 2.01

MANUFACTURERS A.

Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the Work include, but are not limited to, the following:

B.

Manufacturers: Subject to compliance with requirements, provide products by the following: Calpico, Inc. Cole-Flex Corp. Emed Co., Inc. George-Ingraham Corp. Ideal Industries, Inc. Kraftbilt LEM Products, Inc. Markal Corp. National Band and Tag Co. Panduit Corp. Radar Engineers Div., EPIC Corp. Seton Name Plate Co. Standard Signs, Inc. W.H. Brady Co. Other Approved Manufacturers

2.02

ELECTRICAL IDENTIFICATION PRODUCTS A.

Colored Adhesive Marking Tape for Raceways of Certain Systems: Self-adhesive vinyl tape not less than 3 mils thick by 1 inch to 2 inches in width.

B.

Pretensioned Flexible Wraparound Colored Plastic Sleeves for Raceway Identification: Flexible acrylic bands sized to suit the raceway diameter and arranged to stay in place by pre-tensioned gripping action when coiled around the raceway.

C.

Wire/Cable Designation Markers: Permanently embossed wire markers of the heatshrinkable or slip-on type. Wrap-around, rigid snap-on, or adhesive type markers are not permitted.

D.

Engraved, Plastic-Laminated Labels, Signs, and Instruction Plates: Engraving stock melamine plastic laminate, 1/16-inch minimum thick for signs up to 20 square inches, or 8 inches in length; 1/8-inch thick for larger sizes. Engraved legend in white letters on black face and punched for mechanical fasteners.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 4 of 8

SECTION 16195 ELECTRICAL IDENTIFICATION

DIVISION 16 ELECTRICAL E.

Baked-Enamel Warning and Caution Signs for Interior Use: Preprinted aluminum signs, punched for fasteners, with colors, legend, and size appropriate to the location.

F.

Exterior Metal-Backed Butyrate Warning and Caution Signs: Weather-resistant, nonfading, preprinted cellulose acetate butyrate signs with 20-gauge, galvanized steel backing, with colors, legend, and size appropriate to the location. Provide 1/4-inch grommets in corners for mounting.

G.

Fasteners for Plastic-Laminated and Metal Signs: Self-tapping stainless steel screws or number 10/32 stainless steel machine screws with nuts and flat and lock washers.

H.

Cable Ties: Fungus-inert, self-extinguishing, one-piece, self- locking nylon cable ties, 0.18-inch minimum width, 50-lb minimum tensile strength, and suitable for a temperature range from minus 50 deg F to 350 deg F. Provide ties in specified colors when used for color coding.

PART 3 - EXECUTION 3.01

INSTALLATION A.

Coordinate names, abbreviations, colors, and other Lettering and Graphics: designations used in electrical identification work with corresponding designations specified or indicated. Install numbers, lettering, and colors as approved in submittals and as required by code.

B.

Install identification devices in accordance with manufacturer's written instructions and requirements of NEC.

C.

Sequence of Work: Where identification is to be applied to surfaces that require finish, install identification after completion of finish work.

D.

Conduit Identification: 1.

Identify Raceways of Certain Systems with Color Banding: Band exposed or accessible raceways of the following systems for identification. Bands shall be pre-tensioned, snap-around colored plastic sleeves, colored adhesive marking tape, or a combination of the two. Make each color band 2 inches wide, completely encircling conduit, and place adjacent bands of two-color markings in contact, side by side. Install bands at changes in direction, at penetrations of walls and floors, and at 40-foot maximum intervals in straight runs. Apply the following colors: a. b. c. d. e.

DISCIPLINE: ELECTRICAL

Fire Alarm System: Red Fire Suppression Supervisory and Control System: Red and Yellow Combined Fire Alarm and Watchmen's Report System: Red and Blue Watchmen's Report System: Blue Security System: Blue and Yellow DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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Page 5 of 8

SECTION 16195 ELECTRICAL IDENTIFICATION

DIVISION 16 ELECTRICAL f. g. h. I.

Civil Defense System: Yellow Clock System: Green Mechanical and Electrical Supervisory System: Green and Blue Telephone System: Green and Yellow

E.

Identify Junction, Pull, and Connection Boxes: Code-required caution sign for boxes shall be pressure-sensitive, self-adhesive label indicating system voltage in black, preprinted on orange background. Install on outside of box cover. Also label box covers with identity of contained circuits. Use pressure- sensitive plastic labels at exposed locations and similar labels or plasticized card stock tags at concealed boxes.

F.

Conductor Color Coding: 1.

Provide color coding for secondary service, feeder, and branch circuit conductors throughout the project secondary electrical system as follows: Phase

208y/120 Volts

460y/277 Volts

A B C Neutral Ground

Black Red Blue White Green

Yellow Brown Orange White Green

2.

For specified insulations and jackets not manufactured by the selected vendor with integral colors, use conductors with black insulation or jacket and colorcode with Scotch No. 35 color-coding tape or equivalent. Color-code each conductor entering every box, cabinet, panelboard, through, and wireway. In wireways and other locations where conductors are accessible, color-code conductors every 1500mm (5 FT).

3.

The following field-applied color-coding methods may be used in lieu of factory-coded wire for sizes larger than No. 10 AWG.

DISCIPLINE: ELECTRICAL

a.

Apply colored, pressure-sensitive plastic tape in half- lapped turns for a distance of 6 inches from terminal points and in boxes where splices or taps are made. Apply the last two laps of tape with no tension to prevent possible unwinding. Use 1-inch-wide tape in colors as specified. Do not obliterate cable identification markings by taping. Tape locations may be adjusted slightly to prevent such obliteration.

b.

In lieu of pressure-sensitive tape, colored cable ties may be used for color identification. Apply three ties of specified color to each wire at each terminal or splice point starting 3 inches from the terminal spaced 3 inches apart. Apply with a special tool or pliers, tighten for snug fit, and cut off excess length. DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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Page 6 of 8

SECTION 16195 ELECTRICAL IDENTIFICATION

DIVISION 16 ELECTRICAL

4.

For control and communications/signal wiring, use color coding or wire/cable markers at terminations and at intermediate locations where conductors appear in wiring boxes, troughs, and control cabinets. Use consistent letter/number conductor designations throughout on wire/cable markers.

G.

Match identification markings with designations used in panel boards shop drawings, Contract Documents, and similar previously established identification schemes for the facility's electrical installations.

H.

Apply warning, caution, and instruction signs and stencils as follows:

I.

1.

Install warning, caution, or instruction signs where required by NEC, where indicated, or where reasonably required to assure safe operation and maintenance of electrical systems and of the items to which they connect. Install engraved plastic-laminated instruction signs with approved legend where instructions or explanations are needed for system or equipment operation. Install butyrate signs with metal backing for outdoor items.

2.

Emergency Operating Signs: Install engraved laminate signs with white legend on red background with minimum 3/8-inch high lettering for emergency instructions on power transfer, load shedding, or other emergency operations.

3.

All signs must be in English and has Arabic translation.

Install equipment/system circuit/device identification as follows: 1.

Apply equipment identification labels of engraved plastic- laminate on each major unit of electrical equipment in building, including central or master unit of each electrical system. This includes communication/signal/alarm systems, unless unit is specified with its own self-explanatory identification. Except as otherwise indicated, provide single line of text, with 1/2-inch-high lettering on 1-1/2-inch-high label (2-inch-high where two lines are required), white lettering in black field. Text shall match terminology and numbering of the Contract Documents and drawings. Apply labels for each unit of the following categories of electrical equipment: Panelboards, electrical cabinets, and enclosures. Access doors and panels for concealed electrical items. Panelboard. Motor starters. Pushbutton stations. Contactors. Control devices. Transformers.

2. DISCIPLINE: ELECTRICAL

Apply circuit/control/item designation labels of engraved plastic laminate for disconnect switches, breakers, pushbuttons, pilot lights, motor control centers, DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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Page 7 of 8

SECTION 16195 ELECTRICAL IDENTIFICATION

DIVISION 16 ELECTRICAL

and similar items for power distribution and control components above, except panel boards and alarm/signal components, where labeling is specified elsewhere. For panel boards, provide framed, typed circuit schedules with explicit description and identification of items controlled by each individual breaker. J.

Install labels at locations indicated and at locations for best convenience of viewing without interference with operation and maintenance of equipment.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 8 of 8

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16250 AUTOMATIC TRANSFER SWITCH

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 9

SECTION 16250 AUTOMATIC TRANSFER SWITCH

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1 1.01 1.02 1.03 1.04 PART 2 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 PART 3

GENERAL References Related Sections System Description Submittals PRODUCTS Mechanically Held Transfer Switch Bypass Isolation Switch Microproccessor Control Panel Emclosures Voltage and Frequency Sensing Time Delay Additional Features Testing EXECUTION

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 2 of 9

SECTION 16250 AUTOMATIC TRANSFER SWITCH

DIVISION 16 ELECTRICAL

PART 1 - GENERAL 1.01

REFERENCES A

IEEE C37.90.1

Surge Withstanding Capability (SWC) Test for Protective Relays and Relay Systems

B

IEEE 446

Emergency & Standby Power System

C

NEMA ICS 1

Industrial Controls and Systems

D

NEMA ICS 2

Industrial Control Devices, Controllers and Assemblies

E

NEMA ICS 10

AC Automatic Transfer Switches

F

NEMA ICS 6

Enclosure for Industrial Control and Systems

G

NFPA 70

National Electrical Code (NEC)

H

UL 1008

Automatic Transfer Switches

I

NFPA 99

Essential Electrical Systems for Health Care Facilities

J

NFPA 110

Emergency and Standby Power Systems

1.02

RELATED SECTIONS A.

1.03

Section 16620:

Standby Power Generator Systems

SYSTEM DESCRIPTION A.

Furnish and install automatic closed transition & bypass-isolation switch ACTS/BPS with number of poles, amperage, voltage, and withstand current ratings as shown on the plans. Each ACTS/BPS system(s) shall consist of a closed transition transfer switch and a two-way bypass/isolation switch. All ACTS/BPSs and control modules shall be the product of the same manufacturer.

B.

The ACTS/BPS shall transfer the load without interruption (closed transition) by momentarily connecting both sources of power only when both sources are acceptable and present. The maximum interconnection time is 100 milliseconds. The ACTS shall operate as a conventional break-before-make (open transition) switch when the power source serving the load fails. Designs that transfer in a delayed transition manner (intentional delay in the neutral position) when closed transition transfer is bypassed are not acceptable.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 3 of 9

SECTION 16250 AUTOMATIC TRANSFER SWITCH

DIVISION 16 ELECTRICAL 1.04

SUBMITTALS A.

Drawings

B.

Design Data

C.

Manufacturer’s Catalog Data

D.

Instruction

E.

Operation and Maintenance Manual

F.

Factory Test Reports

G.

Field Test Reports

PART 2 – PRODUCTS 2.01

MECHANICALLY HELD TRANSFER SWITCH A.

The transfer switch unit shall be electrically operated and mechanically held. The electrical operator shall be a solenoid mechanism, momentarily energized. Main operators which include overcurrent disconnect devices will not be accepted.

B.

The switch shall be positively locked and unaffected by momentary outages so that contact pressure is maintained at a constant value and temperature rise at the contacts is minimized for maximum reliability and operating life.

C.

All main contacts shall be of silver composition. Switches rated 600 amperes and above shall have segmented, blow-on construction for high withstand current capability and be protected by separate arcing contacts.

D.

Inspection of all contacts shall be possible from the front of the switch without disassembly of operating linkages and without disconnection of power conductors. A manual operating handle shall be provided for maintenance purposes. The handle shall permit the operator to manually stop the contacts at any point throughout their entire travel to inspect and service the contacts when required.

E.

Designs utilizing components of molded-case circuit breakers, contactors, or parts thereof which are not intended for continuous duty, repetitive switching or transfer between two active power sources are not acceptable.

F.

Where neutral conductors must be switched as shown on the plans, the ACTS shall be provided with fully-rated overlapping neutral transfer contacts. The neutrals of the normal and emergency power sources shall be connected together only during the transfer and retransfer operation and remain connected together until power source contacts close on the source to which the transfer is being made. The overlapping

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16250 AUTOMATIC TRANSFER SWITCH

DIVISION 16 ELECTRICAL

neutral contacts shall not overlap for a period greater than 100 milliseconds. Neutral switching contacts which are not overlapping are not acceptable. G.

2.02

Where neutral conductors are to be solidly connected as shown on the plans, a neutral conductor terminal plate with fully-rated AL-CU pressure connectors shall be provided.

BYPASS-ISOLATION SWITCH A.

A two-way bypass-isolation switch shall provide manual bypass of the load to either source and permit isolation of the automatic transfer switch from all source and load power conductors. All main contacts shall be manually driven.

B.

Power interconnections shall be silver-plated copper bus bar. The only field installed power connections shall be at the service and load terminals of the bypass isolation switch. All control interwiring shall be provided with disconnect plugs.

C.

Separate bypass and isolation handles shall be utilized to provide clear distinction between the functions. Handles shall be permanently affixed and operable without opening the enclosure door. Designs requiring insertion of loose operating handles or opening of the enclosure door to operate are not acceptable.

D.

Bypass to the load-carrying source shall be accomplished with no interruption of power to the load (make before break contacts). Designs which disconnect the load when bypassing are not acceptable. The bypass handle shall have three operating modes: “Bypass to Normal,” “Automatic,” and “Bypass to Emergency”. The operating speed of the bypass contacts shall be the same as the associated transfer switch and shall be independent of the speed at which the manual handle is operated. In the “Automatic” mode, the bypass contacts shall be out of the power so that they will not be subjected to fault currents to which the system may be subjected.

E.

The isolation handle shall provide three operating modes: “Closed,” “Test,” and “Open.” The “Test” mode shall permit testing of the entire emergency power system, including the automatic transfer switches with no interruption of power to the load. The “Open” mode shall completely isolate the automatic transfer switch from all source and load power conductors. When in the “Open” mode, it shall be possible to completely withdraw the automatic transfer switch for inspection or maintenance to conform to code requirements without removal of power conductors or the use of any tools.

F.

When the isolation switch is in the “Test” or “Open” mode, the bypass shall function as a manual transfer switch of the load between the two sources.

G.

Designs requiring operation of key interlocks for bypass isolation or ACTS which cannot be completely withdrawn when isolated are not acceptable.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16250 AUTOMATIC TRANSFER SWITCH

DIVISION 16 ELECTRICAL 2.03

MICROPROCESSOR CONTROL PANEL A.

The control panel shall direct the operation of the transfer switch. The sensing and logic shall be controlled by a built-in microprocessor in the panel for maximum reliability, minimum maintenance, and inherent serial communications capability. The control panel shall be connected to the transfer switch by an interconnecting wiring harness. The harness shall include a keyed disconnect plug to enable the control panel to be disconnected from the transfer switch for routine maintenance.

B.

The control panel shall be completely enclosed with a protective cover and be mounted separately from the transfer switch unit for safety and ease of maintenance. Sensing and control logic shall be provided on printed circuit boards. Interfacing relays shall be industrial grade plug-in type with dust covers.

C.

The control panel shall meet or exceed the requirements for Electromagnetic compatibility (EMC) as follows: 6.1

Ring Wave Test per

IEEE 472 (ANSI C37.90A)

Electrostatic Discharge (ESD)

IEC 801-2, Level 4

Electrical Transients (EFT) Surge Withstand

IEC 801-4, Level 4

fast

IEC 801-5, Level 4

Electromagnetic Interference 2.04

ENCLOSURE A.

2.05

Mil Std 461. Class 3C

The ACTS/BPS shall be furnished in a NEMA type 12 enclosure unless otherwise shown on the plans.

VOLTAGE AND FREQUENCY SENSING A.

The voltage of each phase of the normal source shall be monitored, with pickup adjustable from 85% to 100% of nominal and dropout adjustable from 75% to 98% of pickup setting for open transition operation.

B.

Single-phase voltage sensing of the emergency source shall be provided, with pickup voltage adjustable from 85% to 100% of nominal and independent frequency sensing with pickup adjustable from 90% to 100% of nominal for open transition operation.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16250 AUTOMATIC TRANSFER SWITCH

DIVISION 16 ELECTRICAL

2.06

2.07

C.

Repetitive accuracy of all settings shall be within ± 2% over an operating temperature range of -200C to 700C.

D.

Voltage and frequency settings shall be field adjustable in 1% increments without the use of tools, meters or power supplies. Actual settings shall be clearly defined in the operator’s manual.

E.

An inphase monitor shall be provided for closed transition operation. The monitor shall control transfer/retransfer between live sources so that closure on the alternate source will occur only when the two sources are within 5 electrical degrees maximum, 5% maximum voltage difference, and 0.2 Hz maximum frequency difference.

F.

Closed transition shall be accomplished with no power interruption and without altering or actively controlling the standby generator set.

TIME DELAYS A.

A time delay shall be provided to override momentary normal source outages and delay all transfer and engine starting signals. Adjustable from 0 to 6 second.

B.

A time delay shall be provided on transfer to emergency, adjustable from 0 to 5 minutes for controlled timing of transfer of loads to emergency.

C.

A time delay shall be provided on retransfer to normal, adjustable from 0 to 30 minutes. Time delay shall be automatically bypassed if emergency source fails and normal source is acceptable.

D.

A time delay shall be provided on shutdown of engine generator for cooldown, adjustable from 0 to 60 minutes.

E.

All time delays shall be fully adjustable without the use of tools.

ADDITIONAL FEATURES A.

A set of DPDT gold-flashed contacts rated 10 amps, 32 VDC shall be provided for a low-voltage engine start signal.

B.

A momentary-type test switch shall be provided to simulate a normal source failure.

C.

Terminals shall be provided for a remote contact which opens to signal the ACTS to transfer to emergency.

D.

Auxiliary contacts, rated 10 amps, 380 VAC shall be provided consisting of one contact, closed when the ACTS is connected to the normal source and one contact, closed when the ACTS is connected to the emergency source.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16250 AUTOMATIC TRANSFER SWITCH

DIVISION 16 ELECTRICAL

2.08

E.

Indicating lights shall be provided, one to indicate when the ACTS is connected to the normal source (green) and one to indicate when the ACTS is connected to the emergency source (red).

F.

A visual position indicator shall be provided to indicate bypass-isolation switch position. Pilot lights shall indicate availability of power sources. A prominent and detailed instruction plate shall be furnished.

G.

Terminals shall be provided to indicate the actual availability of the normal and emergency sources, as determined by the voltage sensing pickup and dropout settings for each source.

H.

Engine Exerciser -An engine generator exercising timer shall be provided, including a selector switch to select exercise with or without load transfer. The exerciser shall be programmable to enable exercise for 1 minute to 24 hours per day in 1 minute increments for 1 to 7 days per week. The exercising timer shall be equal to ASCO Accessory 11C.

I.

Inphase Monitor - An inphase monitor shall be inherently built into the controls. The monitor shall control transfer in the “open-transition” mode so that motor load inrush currents do not exceed normal starting currents.

J.

Communications Networks - A fully duplex RS485 interface shall be built into the ACTS control panel to enable serial communications with remotely located annunciators and/or network supervisors. The serial communication interface shall be equal to ASCO Accessory 72A.

TESTING

In addition to other factory tests, each completely assembled ACTS/BPS unit shall be subjected to dielectric and operational tests and withstand tests. A.

Withstand Test in Excess of UL 1008 Requirements: The ACTS/BPS shall be tested and rated to withstand available fault or short circuit current.

B.

Dielectric Tests: Tests shall be performed in accordance with NEMA ICS1. Wiring of each control panel shall be subjected to voltage surge tests as stipulated in IEEE C37.90.1. Impulse withstand rating tests shall be performed accordance with the requirements of NEMA ICS 1.

C.

Operational Tests: Tests shall be performed and shall demonstrate that the operational sequence of each ACTS/BPS unit conforms to the requirements of the specifications with regard to operating transfer time, voltage, frequency, and timing intervals.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16250 AUTOMATIC TRANSFER SWITCH

DIVISION 16 ELECTRICAL PART 3 – EXECUTION A.

Installation: The ACTS/BPS shall be installed as indicated and in accordance with approved manufacturer’s instructions.

B.

Operational Testing: The Operational Testing shall provide certified field test reports to the Client Representative following successful completion of the operational tests. The tests reports shall describe all adjustments and settings made and all operational tests performed. - END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16300 LOW VOLTAGE MCC

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

Discipline: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

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REMARKS

DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05

Scope Codes and Standards Submittals Environmental ConditionS Technical Data

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08

Componenets and Equipments Tagging Units and Scales Wiring Cable and Cable Laying Low Voltage MCC Special Requirements Distribution Boards

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08

EXECUTION Painting Installation Workshop Test Type Test Site Test Documentation Shipping Spare Parts and Special Tools

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 1.01

SECTION 16300 LOW VOLTAGE MCC

Scope This document covers the requirements for the design, manufacturing, construction, installation; test and commissioning of low voltage MCC form the stations for the Transportation of Treated Water from Taif STP to Ma’aden Gold sites.

1.02

Codes and Standards The design, manufacturing, construction, installation, test and commissioning of low voltage MCC shall be in accordance with the following codes and standards, at least. The latest revision of the publication referred to shall apply. IEC 60044

Instrument transformers

IEC 60051

Direct acting indicating analogue electrical – measuring instruments and their accessories

IEC 60085

Thermal evaluation and classification of electrical insulation

IEC 62271

Alternating current disconnectors (isolators) and earthling switches

IEC 60044

Voltage transformers

IEC 60255

Electrical relays

IEC 60529

Degrees of protection provided by enclosures (IP-Code)

IEC 60439

Low voltage MCC and control gear assemblies

IEC 60664

Insulation co-ordination for equipment within low voltage systems

IEC 60715

Dimensions of low voltage MCC and control gear

IEC 60947

Low voltage MCC and control gear

IEC 61641

Enclosed low-voltage MCC and control gear assemblies

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

As far as the power supply authority (SEC) or permits of other authorities require additional codes and standards, respectively impose additional requirements, these are also part of the regulations. 1.03

Submittals Forward to the Company Representative for review and approval the following submittals. Refer also to appropriate specification sections for other submittal requirements. A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

B.

Prior to Commencing WORK: Shop drawings of proposed installations that deviate from the original design.

C.

Prior to Final Acceptance: Record documents which shall indicate installed conditions for:

D.

1.

Major raceways systems, size and location, for both exterior and interior; locations of control devices; distribution and branch electrical circuitry; fuse and circuit breaker size and arrangements.

2.

Equipment locations (exposed and concealed), dimensioned from prominent building lines.

3.

Approved substitutions, modifications and actual equipment and materials installed.

Maintenance Manuals: Submit maintenance manuals which shall include the following information for equipment items: 1.

Description of function, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of replacement parts.

2.

Manufacturer's printed operating procedures to include start- up, break-in, and routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; and summer and winter operating instructions.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

1.04

SECTION 16300 LOW VOLTAGE MCC

3.

Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

4.

Servicing instructions and lubrication charts and schedules.

Environmental Conditions The low voltage switchboards shall be designed and constructed for continuous operation at full load under the climatic and environmental conditions as described in the specification “Design and Construction of Power Supply Systems”. Main MCC, main / sub distribution boards, low voltage MCC shall be installed inside electrical buildings or rooms, which are equipped with air conditioning. Other distribution boards/disconnect switches for special purposes can be installed in ventilated or non ventilated rooms or in shafts. The installation of switchboards at outdoor locations shall be avoided.

1.05

Technical Data The technical data of the low voltage MCC are defined in the data sheets. The Contractor has to guarantee the fulfillment of these requirements.

PART 2 – PRODUCTS 2.01

Components and Equipment The Contractor has to take care that all components and equipment are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals. All components and equipment shall be designed for continuous duty at rated load and under the given climatic conditions. Standard industrial high performance systems and components of supplier’s standard lists shall be used as far as possible. Components and equipment of same kind and type shall be selected for equivalent functions. The interchangeability must be guaranteed.

2.02

Tagging All components, equipment and installations shall receive the respective tagging plates, labels, etc., which have to be of extremely durable material resistant against the environmental conditions. Tagging plates or labels on fronts of enclosures shall be fixed with screws. For further requirements, reference is made to specification “Design and Construction of Power Supply Systems”.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

2.03

SECTION 16300 LOW VOLTAGE MCC

Units and Scales The metric system on basis of SI-units shall be used for all scales and indications.

2.04

Wiring The wires shall be selected according to load, insulation level, function and operating requirements. The wires shall be adequately rated and equipped with fuses / circuit breakers of adequate size. The wiring colors and the minimum cross sections shall be according to “Specification for Design and Construction of Power Supply Systems”. The wiring shall be carried out solid and safe against damages. Wires shall be bundled and fixed. The wiring shall be laid inside of wiring channels, preferably. If wiring channels will be used, a spare of 20 % shall be foreseen. Terminal strips shall have 10 % spare terminals. If wires with different potential will be terminated on one terminal strip the respective terminals shall be separated by means of isolating plates. The termination of multiple stranded wires has to be carried out by means of multiple core cable ends. Terminals shall be marked durable and easy readable, corresponding to the drawings. Wires shall be marked on the termination of each wire with the number of the corresponding connection point.

2.05

Cable and Cable Laying For connection between different cabinets of one MCC or one distribution board copper cables with PVC insulation shall be used. All cables shall be selected according to load, insulation level, function and operating requirements. The minimum cross section for power and signal cables shall be according to specification “Design and Construction of Power Supply Systems”. Signal cables shall be provided with copper screen.

2.06

LOW VOLTAGE MCC Mechanical Requirements General The low voltage MCC shall be industrial type, metal-enclosed, factory assembled, type tested MCC with self standing cabinets and withdrawable units.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

The MCC shall be suitable for installation against the wall or for back-to-back installation. The cabinets shall only be accessible from the front. The bottom shall be covered with galvanized sheet steel, which is to provide with holes for cable entry. The cable entries shall be designed in a manner such that a sealing after cable laying is possible without any problem. Further, each cover sheet shall be equipped with a grounding connection to the steel frame of cabinet. The low voltage MCC shall be suitable for indoor installation on cable cellar. All nuts for fixing of components shall be welded on the steel structure or threads will be cutting in the steel structure. The use of loose nuts or self cutting screws shall be avoided. Screws, nuts and washers shall be galvanized or cadmium plated. Hinged front doors shall be swinging out more than 90°. Separation Each cabinet shall consist of bus bar compartment, cable termination compartment and compartments for withdrawable units. Each compartment shall be separated against the next compartment by means of steel sheets. Only small openings for plugs, ventilation or air circulation are allowed. The separation shall be carried out in a manner such that overpressures, caused by shortcircuit, will be safe compensated and that exist no danger for operation personnel and for other parts of the MCC. The bus bar bushing from the bus bar compartment to the compartments for withdrawable units shall be arc protected. The bus bars shall be coated with insulation material. Cable Termination Compartments The cable termination compartments shall be run about the whole height of the cabinets, shall only be accessible from the front and shall be separated against neighboring cabinets. The cable termination compartments shall be equipped in a manner such that an easy cable laying will be possible. For fixing of cables the respective rails shall be installed.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

The width of the cable termination compartment shall be 400 mm, preferably. For each cable termination compartment a hinged door shall be provided, which is running about the whole cabinet length. Additional cable termination shall also be possible during the operation of the MCC. For cabinets, where air circuit breakers for incomers and coupling are installed, a cable termination compartment about the whole length is not necessary. Electrical Requirements Bus Bars The bus bars shall be selected according to the electrical requirements and shall be of highconductivity electrolytic copper. The cabinets shall be equipped with bus bar systems consisting of 5 conductors. All bus bars shall be located inside the bus bar compartment and shall have the same cross sections throughout all cabinets. An additional PE bus bar shall be installed about the whole length of the cable termination compartment. Regarding the function either two bus bar sections will be provided or the MCC will be divided into three bus bar sections. Each bus bar section shall get a separate supply with a coupling possibility. The bus bars shall be equipped with an adequate number of earthing studs. Operation Modes For low voltage MCCs the following configurations are possible: (1)

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

Configuration 1 (for Transfer Pump Station) •

Bus A fed from SEC network (Line 1) through transformer T301.

•

Bus B fed from SEC network (Line 2) through transformer T302

•

Bus A & Bus B coupled with a Bus Coupler.

•

Bus C fed from In-house Emergency Generator Set.

•

Bus C coupled with Bus A and Bus B through ATS. DOCUMENT No.: MGBM-SPEC-0001

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC (2)

Configuration 2 (Master Pump Station) •

Bus 1 fed from SEC network (Line 1) through transformer T4X01.

•

Bus 2 fed from SEC network (Line 2) through transformer T4X02.

•

Bus 1 and Bus 2 coupled with a Bus Coupler.

•

Bus A fed from station service transformer T201.

•

Bus B fed from In-house Emergency Generator Set.

•

Bus B coupled with Bus A through ATS.

(3)

Configuration 3 •

Bus B fed from In-house Working Generator Set.

•

Bus A fed from In-house Stand-by Generator Set.

•

Bus A and Bus B coupled through ATS.

For the four configurations the following operation modes are applicable: (1)

Configuration 1 Under normal network conditions both bus bars (Bus A and Bus B) sections will be supplied via the SEC network feeders in parallel operation the coupling is closed and the main switch for generator supply to Bus C is opened. Either Bus A or Bus B can bare full demand load. In case of voltage interrupt on any line / network feeder, other incomer from SEC network can bear the full load and the coupling remains closed. In case of both SEC network feeders interrupt the emergency generator set starts with a respective time delay. After the emergency generator is ready for taking over the load, the main switch for generator supply closes and the essential loads will be fed via generator set. After voltage return the normal network will be switched on and the generator will be synchronized with the normal network. After synchronizing the coupling will be closed and the main switch for generator will open.

(2)

Configuration 2 Under normal network conditions both bus bars (Bus 1 and Bus 2) sections will be supplied via the SEC network feeders in parallel operation the coupling is closed. In case of voltage interrupt on any line / network feeder, other incomer from SEC network can bear the full load and the coupling remains closed.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC Under normal operation Bus A is fed from station service transformer (T201) whose primary is fed from Bus 1. In case of both SEC network feeders interrupt, the emergency generator set starts with a respective time delay. After the emergency generator is ready for taking over the load, the main switch for generator supply closes and the essential loads will be fed via emergency generator set. After voltage return the normal network will be switched on and the generator will be synchronized with the normal network. After synchronizing the coupling will be closed and the main switch for generator will open.

(3)

Configuration 3 Under normal network conditions both buses are fed from working generator and the coupling being closed. . In case of working generator’s failure, the standby generator set starts with a respective time delay. After the standby generator is ready for taking over the full load, the main switch for generator supply closes and the full load will be fed via standby generator set. After the working generator returns to service, the working generator will be switched on and the generator will be synchronized with the normal network. After synchronizing the coupling(s) will be closed and the main switch for the standby generator opened. The mentioned switching over shall be carried out by means of automatic transfer switch devices. The switching over in case of network interrupt shall be automatically with a delay time, adjustable form 1 sec. to 30 sec. The switching back and stopping of emergency generator shall also be carried out automatically, but with a manual initiation from remote or local. For the Variants 1 and 2 it shall be possible to select the preferred supply alternative from remote or local. If after a voltage interrupt and voltage return the preferred supply alternative is not present, it shall be possible to switch back to these supply conditions with a manual initiation from remote or local. Further, for a test of the generator set the automatic transfer switch device shall switch the already synchronized generator on the network and shall decouple the essential bus bar. The switching over to this kind of supply and the switching back after test must be carried out immediately without interrupt in the power supply of the consumers. If during the test run the normal network fails, the system shall switch over automatically to emergency supply. For smooth operation of the emergency generator (working generator) in case of network break down and test of the generator set the

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC following signals shall be transferred between automatic transfer switch device and generator set control device: a)

b)

From automatic transfer switch device to generator set control device •

Generator set start

•

Generator set stop

•

Voltage value for synchronization

From generator set control device to automatic transfer switch device •

Generator set not available

•

Emergency shutdown

•

Ready for taking over the load

•

Synchronized to network

•

Switching over to generator supply/network supply (for test of generator set)

The signal “generator set start” shall also be used to initiate the changing of generator set sequence during test to automatic operation mode. The automatic transfer switch devices shall be a programmable logic control unit and shall be placed in the cabinet of coupling of the respective MCC. To prevent an automatically switching, a lockable hand/automatic switch must be provided. By means of this switch the local operation of all in feed circuit breakers and coupling circuit breakers shall be possible. The signal “emergency shutdown” from generator set shall be forwarded to the respective circuit breaker to initiate the switching off. The circuit must be hard wired. The situation, those two incomers from normal network feed on coupled MCC, must be avoided. Control and Monitoring The control and monitoring shall be carried out via hardwired components and with digital and analogue signals between the parts of the MCCs and from/to the station control system. The Contractor may provide the MCCs with a programmable control and monitoring system, which has serial connections between the different parts and to the station control system. DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

For this kind of control and monitoring system the reliability must be in accordance with the hardwired system (redundancy, each bus bar section equipped with separate RTU and separate connection with station control system, etc.). Control Voltage The control voltage supply will be carried out from a 230 V AC UPS. Each bus bar section of the respective low voltage MCC will be provided with one power supply, protected by means of a 25 A miniature circuit breaker situated in the UPS Distribution Board. The sub-distribution of control voltage shall be carried out selective from the cabinet equipped with the incomer to the other cabinets of the bus bar section. The digital signals from and to the remote control system will be transferred with a voltage level of 24 V DC. All coils of coupling relays and all potential free contacts shall be suitable for this voltage. Overvoltage Protection For protection against overvoltage from network side the incomers of MCCs shall be equipped with overvoltage protectors. For all electronic devices inside the MCCs additional overvoltage protection shall be provided. Cable Termination The cable termination compartments shall be equipped with terminals for power cables, cables for control and signal voltage supply and cables for signal connection. For each withdrawable unit separate terminal stripes shall be provided. The terminals shall be selected according to nominal current and conductor cross section, but shall be at least for a conductor cross section of 4 mm² and a nominal current of 16 A. For all incoming or outgoing feeders, which require more than two parallel cables, parallel connection bars or parallel terminal shall be installed. For signal connection, copper shielded or copper screened cables will be used. By means of suitable measures shall be ensured, that the shields / screens of these cables can be adequate grounded.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

Protection Relays All protection relays shall be of the latest state-of-the-art technology, electronic type, programmable with displays of operating and set point values along with self test facility, etc. visible without the need to open the door. The relays shall be either arranged for panel installation behind the doors or windows of the individual withdrawable units or integrated in the circuit breaker. Each circuit breaker shall be equipped with a three-phase, overcurrent time relay with continuously variable short-circuit trip (including time delay for relay protection coordination). Incomers from emergency generator sets with a power above 150 kVA shall be equipped with differential protection relays. Current Transformers \ The thermal withstand capability of the current transformers shall be based on a disconnection time of min. 0.5 sec. in the outgoing feeders to consumers and min. 1.0 sec. in the incomers. The transformer shall have the following data: •

Measurement class 1.0 M 5

•

Protection class 10 P 10

•

Secondary current 1 A

•

Primary current according to the requirements

Cast-resin insulated, corona-free transformers shall be used. The current transformers must withstand the dynamic and thermal short-circuit stresses. For protection and measurement separate cores shall be provided. Current transformer terminals shall be equipped with short-circuiting links. Current transformers for differential protection of emergency generator sets will be procured by the gen. set manufacturer and handed over prior to workshop test.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

Anti-Condensation Heaters Each cabinet of MCCs shall be equipped with anti-condensation heaters, which shall be fed from the 230 V, 60 Hz level. Each bus bar section of the respective low voltage MCC will be provided with one power supply, protected by means of a 16 A or 25 A miniature circuit breaker situated in a low voltage distribution board. The sub-distribution of voltage for heaters shall be carried out selective from the incomer cabinets to the other cabinets of the bus-bar section. The heaters shall be humidity or temperature controlled. A failure of heaters shall be indicated on local indicator board. Heater indicator lamp “ON” shall be provided. General Description of withdrawable Units The withdrawable units shall be standardized units with different sizes according to power and kind of consumer. Completion and wiring shall be carried out according to the following description and the single line diagrams. All devices inside of withdrawable units shall be functionally placed. A withdrawl or an engage of the withdrawable units must only be possible with opened power circuit. To meet this requirement a mechanical/electrical interlocking shall be provided for each withdrawable unit. The withdrawable units shall be distributed in a manner such that the nominal current of the distribution bus bars will not be exceeded. Withdrawable Air Circuit Breaker Air circuit breakers shall be withdrawable without use of special tools. The withdrawable units shall be supported from the frame as far as the whole unit can be lifted out. The switch position of circuit breaker shall be discernible from outside, also if the front door is closed. For the air circuit breakers a defined operating position, test position and outside position shall be provided which shall be discernible from outside, too. DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

In test position the main contacts shall be opened, but the control circuits shall be in function. The operation of air circuit breakers shall be carried out via motor driven spring loaded buffers. In case of control voltage fault the buffers shall be manually operable. Each withdrawable circuit breaker unit shall be provided with separate miniature circuit breakers for the following functions: •

Local control and interlocks,

•

Local signals and faults indications,

•

Local power supply to motor drive,

A tripping of the mentioned miniature circuit breakers shall be indicated locally. For monitoring from the station control system the following signals shall be provided: •

Circuit breaker “On”,

•

Circuit breaker “Off”,

•

Circuit breaker in operating position,

•

Circuit breaker in test position,

•

Circuit breaker in outside position,

•

Overcurrent / short circuit tripping,

•

Undervoltage tripping (only for incomers),

•

Differential protection released (gen sets above 150 kVA),

•

No control voltage,

•

No bus bar voltage (only for incomers),

•

Feeder line under voltage (only for incomers),

•

Summary alarm.

The signals shall be wired to a common terminal strip. For remote control the respective signals shall be wired to the circuit breakers, too. To prevent a remote control a lockable local / remote switch shall be installed. Air circuit breakers shall be equipped as follows: • DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

Overload / short-circuit protection DOCUMENT No.: MGBM-SPEC-0001

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

For protection against overload a current-dependent, delayed releaser shall be used. The setting range shall be from 0.2 to 1.2 of nominal current and the time delay adjustable from 2 to 30 seconds. For selective short-circuit protection an independent releaser shall be used. The setting range shall be from 2 to 12 of the setting range of overload releaser. The delay time of the independent releaser shall be adjustable. •

Undervoltage protection

The undervoltage protection shall be realized with voltage relays. The relays shall have an adjustable minimum operating voltage and an adjustable time delay (1-15 sec.). In the front door of air circuit breaker compartments/cabinets the following devices shall be installed: •

One voltmeter for feeder voltage, single phase (only for incomers),

•

One voltmeter for bus bar voltage, three phase with selector switch,

•

Three ammeters,

•

One push button “On”,

•

One push button “Off”,

•

One indication light “On”,

•

One indication light “Off”,

•

One indication light “Control voltage fault”

•

One indication light “Fault”,

•

One push button “Fault-receipting”.

Air circuit breakers for coupling shall be equipped with the mentioned indication lights and push buttons. For measuring instruments only square flush-mounting types (class 1.5) shall be used. Withdrawable Units for Consumers General For consumers the following withdrawable units shall be provided: DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC •

Motor direct on line,

•

Load isolator and fuses,

•

Circuit breaker.

The units shall be withdrawable without use of special tools. The withdrawable units shall be supported from the frame as far as the whole unit can be lifted out. For the units a defined operating position, test position and an outside position shall be provided. In test position the main contacts shall be opened, but the control circuits shall be in function. Contactors shall be designed for category AC 3 and with a minimum power of 7.5 kW. An operation of the coils shall be possible with voltages down to 75 % of nominal voltage. Molded case circuit breakers can be used up to a size of 800 A, above 800 A air circuit breakers shall be installed. In general the circuit breakers will be hand operated. If required by process the circuit breakers shall be provided with motor or magnetic drives. Circuit breakers shall be equipped with motor or magnetic drives, if the connected consumers are normal loads which shall be automatically switched off during emergency generator supply. In this case the respective circuit breakers shall be controlled from the automatic transfer switch device. From all withdrawable units the operating position and a signal “Unit not available” (in test position or withdrawn) shall be transferred to the station control system. For the different types of withdrawable units further indications, operations and signalization shall be possible, which are described in the following items. The fuses of main circuits, if any, shall be equipped with fuse monitoring. The trip of a fuse shall be indicated on the withdrawable unit and shall be transferred to the station control system. In case of withdrawable units for motors the trip can be wired into the respective failure indication/status signal circuit. Motor direct on line (under 90 kW) The power circuits of withdrawable units shall be equipped with the following main components: • DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

Fuses, DOCUMENT No.: MGBM-SPEC-0001

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC •

Load isolator (operable from the front of the unit), lockable,

•

Contactor,

•

Thermal overload relay.

The installation of moulded case circuit breakers instead of fuses is prefered. In this case the trip signals shall be wired into the failure indication/status signal circuits. The control circuits shall be equipped with control miniature circuit breakers, auxiliary relays, coupling relays, indication lights and all other necessary devices to allow the control and monitoring. Further, each control circuit shall be provided with facilities to integrate an external emergency shutdown. On the front of the withdrawable units the following indication lights shall be placed: •

Contactor closed (red),

•

Contactor opened (green),

•

Failure (white or yellow).

Between station control system and withdrawable unit the following signals shall be transferred: a) Status signals: •

Failure,

•

Contactor closed/opened,

•

No control voltage.

b) Commands: •

Start motor,

•

Stop motor.

An operation possibility for the motor from the withdrawable unit shall not be provided. Motor direct on line (90 kW and larger). The withdrawable units shall be from the same configuration as described for motors under 90 kW, but with the following additional devices:

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

•

Circuit for anti-condensation heater of motor (with yellow indication light on front on withdrawable unit for heater on),

•

Single-phase current indication with current transformer and ammeter, DOCUMENT No.: MGBM-SPEC-0001

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC •

Monitoring device for positive temperature coefficient thermistors of motor.

The release of monitoring device for positive temperature coefficient thermistors shall be incorporated in the failure indication of withdrawable unit and in the failure signal to the station control system. Due to the size of motors the units can be provided with devices for star-delta start. •

Load Isolator

The power circuit of withdrawable units shall be equipped with line side HRC fuses and load isolators. The load isolators shall be operable from the front of the unit.

The installation of miniature circuit breakers or moulded case circuit breakers instead fuses is prefered. As described above the trip signals shall be indicated on the withdrawable unit and shall be transferred to the station control system, also. •

Circuit Breaker

Withdrawable units with circuit breaker shall be provided for feeders of distribution boards with large power consumption or boards where large motors are connected, to guarantee the selectivity of the distribution system down to the consumer. The circuit breakers shall be operable from the front of the unit. The control circuit shall be equipped with control miniature circuit breaker, auxiliary relays, indication lights and all necessary devices for local and remote monitoring. If circuit breakers will be provided with motor or magnetic drives, the respective push buttons for “On” and “Off”, local/remote key switches and facilities for remote control shall be installed. On the front of the withdrawable units the following indication lights shall be placed: •

Circuit breaker on (red),

•

Circuit breaker off (green),

•

Circuit breaker tripped (white),

•

Failure (yellow)

The indication lights for “on / off” may not be necessary, if the switch position is discernible by means of other indications. DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

The following signals shall be transferred to the station control system: •

Circuit breaker on/off,

•

Circuit breaker tripped,

•

Failure.

Reactive Power Compensation Construction All devices for the reactive power compensation shall be installed in a metal enclosed self standing cabinet, which shall be from the same layout as the MCC. The connection with the MCC shall be carried out either with bus bar or with cables. In the hinged door the following devices shall be installed: •

Reactive power regulator,

•

Varmeter (indication from 0.7 inductive to 0.7 capacitive),

•

Indicators for each capacitor bank.

The reactive power consumption shall be designed for compensation to a power factor of min. 0.9 inductive. Capacitors The capacitors shall have the following characteristics: • Low-loss • Self-cured, • Large life time, • High capacity continuance. For rapid discharge the capacitors shall be equipped with drain coils. Further, each capacitor module shall be equipped with fuses to isolate the module in case of failure. Contactors For switching only contactors shall be used, which can switch capacitive loads without damage of the contacts.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

Regulator For the reactive power compensation a regulator with optimal dynamic characteristics shall be used, that means, short alternations of load shall not lead to a constant switching of the capacitor banks. The conditions of the compensation unit (inductive, regulated, and capacitive) shall be indicated on the regulator. A summary alarm shall be transferred to the station control system. The hand operation of the capacitor banks in connection with a hand / automatic switch shall be possible. In case of voltage interrupt all capacitors shall be switched off automatically. The regulation shall continue two minutes after voltage return. 2.07

Special Requirements The Vendor/Manufacturer shall have local representative in Saudi Arabia and shall have maintenance team available with minimum five years of experience to attend any maintenance issues.

2.08

Distribution Boards Mechanical Requirements Distribution boards shall be industrial type, metal enclosed, factory assembled boards with self standing or wall mounted cabinets. The cabinets shall be equipped with hinged doors and fix mounted units and devices. The cabinets shall be accessible from the front only. Hinged front doors shall be swinged out more than 90°. If cabinets will be mounted on raised floor or cable cellar, the bottom shall be covered with galvanized steel sheets. Wall mounted cabinets shall be equipped with cable glands. For distribution boards located in ventilated rooms, process rooms or outdoor, the cable glands shall only be located in the bottom. The cable termination compartments shall be located in the lower part of the distribution boards. If for special boards (only for indoor dry rooms with air conditioning) a part of the cables shall be carried to upwards, a cable compartment in the upper part can be provided, too. The cable termination compartments shall be sized in a manner such that an easy cable laying is possible and all cables can be sufficient fixed.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

All nuts for fixing of units/ devices shall be welded on the steel structure or threads will be cutted in the steel structure. The use of loose nuts or self cutting screws is not allowed. Screws, nuts and washers shall be galvanized or cadmium plated. Construction The distribution boards shall mainly consist of the following: •

Bus bars (copper) in the upper part of the cabinets

•

Neutral bus bar (copper) in the lower part of the cabinet,

•

Grounding bus bar (copper) in the lower part of the cabinet,

•

Arrestors for all incoming feeders from the network and for bus bars,

•

Terminal strips for power and control cables connection,

•

Installation channels for internal wiring,

•

Fix installed equipment, mounted on supporting frames and rails,

•

Operation and supervision devices, mounted in the front door,

•

Flexible wires protected with flexible pipes from fixed part to the front door,

•

Document – pocket in the door.

Completion and wiring of the distribution boards shall be carried out according to the requirements. For main switches on-load isolator switches shall be used, preferably. Outgoings to the consumers shall be equipped with miniature circuit breakers (up to 63A) or moulded case circuit breakers. If necessary for special circuits, leakage current switches shall be provided. For external control and monitoring the respective potential free contacts shall be foreseen and shall be wired on terminal stripe. In most of the cases the tripping of circuit breakers and leakage current switches shall be transferred, only. Other signals shall be provided according to the requirements (e. g. lighting panels). All live parts within the cabinets, which will be entered during normal routine maintenance, shall be protected by means of suitable covers. The distribution boards shall be designed under consideration of spare place of at least 20 % of the fully equipped boards.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

Control Voltage The control voltage shall be provided from a 230 V AC UPS, preferably. For remote distribution boards or boards with secondary supply function control transformers may be installed. PART 3 - EXECUTION 3.01

Painting All components and devices shall have a resistant, long term stable, high quality painting. At least two layers have to be applied. Damages, caused by transport, installation, cabling or commissioning shall be repaired in a way, that the original quality is restored. An additional painting at location of installation is not allowed.

3.02

Installation The delivery, installation and commissioning of the low voltage switchboards shall include, but not limited to the following items: •

Transport to location of installation (if necessary storage), and the complete mounting,

•

Cable connections between the different cabinets of one switchboard,

•

Grounding and potential equalization for the cabinets, including connection with the next grounding bus bars,

•

Termination of all cables at the switchboards,

•

Commissioning of the functioning switchboards, including voltage feeding of the bus bars and adjustment of all relays, protection devices, etc.,

•

Briefing of the operation personnel in operation and maintenance during installation and commissioning phase and during training on site.

The installation and as well the tests and the commissioning shall be carried out with Contractors own staff and with own tools and measuring/test devices. 3.03

Workshop Tests All components of the factory-assembled low voltage MCC shall be tested completely and detailed in manufacturer’s workshop. All tests required by the codes and standards as well as all manufactures tests have to be performed. The test program for the work shop test has to be submitted at least 3 weeks prior to start of the tests.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

The following tests shall be carried out, at least: •

Visual inspection,

•

Inspection of painting,

•

Check of degree of protection,

•

Check of passive and active protective measures,

•

Electrical test on the main circuits,

•

Mechanical operation tests on all equipment,

•

Operation tests of the protection relays, releasers and measuring equipment,

•

Circuit breakers interchangeability check,

•

Test of auxiliary electrical devices,

•

Dielectric test of the auxiliary circuits,

•

Verification of wiring and terminal blocks.

Detailed test protocols of all tests performed have to be submitted prior to shipment. 3.02

Type Tests Type tests and verifications according to IEC shall not be performed, if the Contractor supplies a copy of the certified test results.

3.03

Site Tests The site tests shall include the following steps: •

Pre-commissioning (including “loop testing”),

•

Commissioning and test on completion,

•

Performance test.

The aim of the tests is to ensure the proper function of the complete scope. 3.04

Documentation Complete documentation shall be provided for the design, manufacturing, testing, commissioning, start-up, operation, maintenance and repair of the switchboards and their components.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16300 LOW VOLTAGE MCC

All documents shall be in English language. The documentation of the low voltage switchboards shall include the following documents and drawings (minimum requirements): a)

Technical data sheets

b)

Layout drawings for all devices and cabinets

c)

Layout drawings for the whole switchboard

d)

MCC/distribution board schedules

e)

Single line diagrams

f)

Bock diagrams

g)

Wiring diagrams

h)

Termination drawings

i)

Cable lists

j)

Spare parts list

k)

Protection relay schedule, selectivity calculations

l)

List of used devices with manufacturer

m)

Software and software description

n)

Operation and maintenance manual

o)

Reports of tests and commissioning with protocols.

The documents listed above shall be handed over for approval. Special attention has to be given to the fact, that documentation must be submitted with sufficient time allocated for approval prior to manufacturing /assembly. Documentation has to be prepared in accordance with the relevant ISO standards. The final documentation shall be delivered on paper in sufficient number and with exception of the signed protocols in electronic form, also. The type of the electronic files shall be agreed with the Client.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 3.05

SECTION 16300 LOW VOLTAGE MCC

Shipping All equipment, material and spare parts shall be sufficient packaged. Each MCC should be shipped as a common delivery. The material, especially loose parts and spare parts shall be clearly labeled according to the designation.

3.06

Spare Parts and Special Tools The Contractor shall deliver all spare parts, which are necessary for commissioning and two years operation time (see “General Description for Project and Works”). Spare parts shall be available until ten years after commissioning. All necessary special tools for operation and maintenance of the switchboards shall be supplied for each switchboard, at least consisting of: •

1 set of all special tools required for operation and maintenance of the switchboard equipment

•

1 set of circuit breaker tools and consumables,

•

1 set fuses (6 fuses of each used size),

•

Circuit breaker lifting truck (for MCCs only),

•

Key set for cabinet doors and locks,

•

Magnetic warning labels in sufficient number, English and Arabic,

•

Software for protection relay parameter assignment (if any).

•

Ten multimeter with different range (Ohm-Voltage-Current-frequency)

•

Five AC clamp-meter

•

Five DC clamp-meter

For storage of the mentioned special tools per MCC a suitable cabinet, shelf or console shall be delivered. The accessories for distribution boards can be stored within the shelf/console of MCC.

- END OF SECTION -

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16322 TRANSFORMERS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

Discipline: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

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DIVISION 16 ELECTRICAL WORKS

SECTION 16322 TRANSFORMERS

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05

Scope Codes and Standards Submittals Environmental Condition Technical Data

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05

Componenets and Equipments Tagging Units and Scales Equipment Characteristics Special Requirements

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09

EXECUTION Painting Marking Installation Workshop Test Type Test Site Test Documentation Shipping Spare Parts and Special Tools

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16322 TRANSFORMERS

PART 1 - GENERAL 1.01

Scope This document covers the requirements for the design, manufacturing, construction, installation, test and commissioning of distribution transformers and other auxiliary transformers for the Transportation of Treated Water from Taif STP to Ma’aden Gold sites.

1.02

Codes and Standards The design, manufacturing, construction, installation, test and commissioning of transformers shall be in accordance with the following codes and standards, at least. The latest revision of the publication referred to shall apply. IEC 60038

IEC standard voltages

IEC 60071

Insulation co-ordination

IEC 60076

Power transformers

IEC 60085

Thermal evaluation and classification of electrical insulation

IEC 60137

Insulation bushings for alternating voltages above 1000 V

IEC 60270

Partial discharge measurements

IEC 60296

Specification for unused mineral insulating oils for transformers and switchgear

IEC 60076

Loading guide for oil-immersed power transformers

IEC 60529

Degrees of protection provided by enclosures (IP Code)

IEC 60616

Terminal and tapping markings for power transformers

As far as the power supply authority (SEC) and permits of other authorities require additional codes and standards, respectively impose additional requirements, these are also part of the contract.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 1.03

SECTION 16322 TRANSFORMERS

Submittals Forward to the Company Representative for review and approval the following submittals. Refer also to appropriate specification sections for other submittal requirements. A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

B.

Prior to Commencing WORK: Shop drawings of proposed installations that deviate from the original design.

C.

Prior to Final Acceptance: Record documents which shall indicate installed conditions for:

D.

1.

Major raceways systems, size and location, for both exterior and interior; locations of control devices; distribution and branch electrical circuitry; fuse and circuit breaker size and arrangements.

2.

Equipment locations (exposed and concealed), dimensioned from prominent building lines.

3.

Approved substitutions, modifications and actual equipment and materials installed.

Maintenance Manuals: Submit maintenance manuals which shall include the following information for equipment items: 1.

Description of function, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of replacement parts.

2.

Manufacturer's printed operating procedures to include start- up, break-in, and routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; and summer and winter operating instructions.

3.

Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

4.

Servicing instructions and lubrication charts and schedules.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 1.04

SECTION 16322 TRANSFORMERS

Environmental Conditions The transformers shall be designed and constructed for continuous operation at full load under the climatic and environmental conditions as described in the specification “Design and Construction of Power Supply Systems”.

1.05

Technical Data The technical data of the transformers are defined in the data sheets. The Contractor has to guarantee the fulfillment of these requirements.

PART 2 – PRODUCTS 2.01

Components and Equipment The Contractor has to take care that all components and equipments are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals. All components and equipment shall be designed for continuous duty at rated load and under the given climatic conditions. Standard industrial high performance systems and components of supplier’s standard lists shall be used as far as possible. Components and equipment of same kind and type shall be selected for equivalent functions. The interchangeability must be guaranteed.

2.02

Tagging All components, equipment and installations shall receive the respective tagging plates, labels, etc., which have to be of extremely durable material resistant against the environmental conditions. For further requirements, reference is made to specification “Design and Construction of Power Supply Systems”.

2.03

Units and Scales The metric system on basis of SI-units shall be used for all scales and indications.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 2.04

SECTION 16322 TRANSFORMERS

Equipment Characteristics Base Frame The base frame shall be fitted with removable flat-rim wheels which can be arranged for either longitudinal or cross travel. The base frame shall be welded to the tank bottom and shall be equipped with four towing lugs. Tank The transformer tanks shall be welded and made of steel of the required thickness. All welding seams shall be stress relieved and must withstand possible impacts during short circuit without distortion. The walls of the tanks shall be reinforced by stiffeners of structural steel. The tanks shall have sufficient strength to withstand without any deformation, mechanical shocks during transportation and oil filling by vacuum. Gaskets and joints shall be weather – proof, hot oil resistant, oil tight, water – tight and carefully designed for the relevant operating conditions. Bolts and screws shall be used only. The employed metals shall be corrosion resistant. After assembling, the screws shall receive normal protection by painting. The tanks shall be equipped with radiators, bracketed and connected with piping to be tank for natural oil circulation, which shall be welded into one piece. The transformers shall be provided with suitable eyebolts and/or lugs for lifting the essential parts and for lifting the completely assembled transformer. Bushings Bushings shall be absolutely oil-tight and shall be able to be maintained and replaced without disassembling of the lid. They shall be provided to withstand, without damage all thermic and dynamic stress to which they may be exposed to, as well as the specific conditions. Bushings with full-thread stud bolts shall be provided with nuts and lock nuts made of brass and lockwashers, permitting the connection of the conductor with a lug. Bushings with smooth type stud bolts shall be provided with connection pieces allowing the connection of the conductor with a lug.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16322 TRANSFORMERS

The primary and secondary terminals of the transformers shall be designed to allow connection with cables. For primary and secondary cable connection the respective termination boxes with suitable cable glands shall be provided. The terminal boxes shall have a degree of protection of IP 55. Off-Load Tap Changers The transformers shall be fitted with manual off-load tap changers on the primary side, which are accessible from outside. The tap range shall be 0, ±2.5, ±5% of the rated primary voltage. Cores The core of the transformer shall be constructed from highest quality non-aging cold rolled grain-oriented silicon steel. The transformer average sound level due to operation of the transformer and accessories shall be determined in accordance with the IEC. Flux distortion assembly shall be provided with suitable lugs for purposes of lifting of the entire assembly. The core stack shall be earthed internally through grounding links located on top of the core. Insulation The insulation levels and the test voltages shall correspond with the different voltages of the networks to which the transformers are connected. The insulating oil shall confirm with the regulations, silting has to be prevented and only mineral oil shall be used. Insulation material according to IEC 60076 shall be provided. The selected class shall be suitable for the environment temperature conditions. Cooling The transformers described in this specification shall be of natural air cooling type. The cooling fluid shall be mineral oil with natural circulation. The cooling agent in contact with the outdoor cooling system will be air with natural circulation.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16322 TRANSFORMERS

Instrumentation In order to ensure a good and safe operation of the transformers at least the following basic supervision and protection devices shall be provided: •

Buchholz protection relay, with normally closed and normally open contacts, alarm and tripping and manual test button or alternative protection for sealed tanks (overpressure, gas accumulation, sudden pressure),

•

Dial type thermometer with two adjustable maximum contracts (placed in such a position that accurate reading is possible), incl. maximum pointer,

•

Oil level indicator gauge with maximum and minimum contact.

All contacts shall be suitable for operation between 24 V DC and 220 V AC. All instrumentation shall be wired on the transformer to a common terminal box with degree of protection of IP 55. All wiring must be provided in sealed steel pipes. Auxiliary Equipment The transformers shall be equipped with all auxiliary equipment which is necessary for a safe operation and an easy maintenance (e. g. oil draining valve, sampling valve, oil filling plug, pressure relief device, air dehydrating device for transformers with conservator, etc.). 2.05

Special Requirements The Vendor/Manufacturer shall have local representative in Saudi Arabia and shall have maintenance team available with minimum five years of experience to attend any maintenance issues.

PART 3 - EXECUTION 3.01

Painting The transformer tanks, radiators and the other devices shall be spray galvanized. An alternative painting system or an oil resistant coating of tanks and radiators will be accepted as well.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16322 TRANSFORMERS

All painting work shall be performed in accordance with the approved manufacturer standards. The finish top layer color shall be in line with the approved color code schedule. Damages, caused by transport, installation, cabling or commissioning shall be repaired in a way, that the original quality is restored. An additional painting at location of installation is not allowed. 3.02

Marking The following plates (may be combined also) shall be mounted on the low-voltage side of each transformer tank at a height of about 1.5 m above ground: •

A rating plate as specified in IEC 60076, including space for Owner’s serial number, and alpha-numerical identification number,

•

A diagram plate with internal connections of windings,

•

A general plate showing the layout of the transformer covering the locations of terminals, control devices, valves and all essential transportation details.

All the above plates shall be made from brass or stainless steel. Inscriptions shall be written in English language. 3.03

Installation The delivery, installation and commissioning of transformers shall include, but not be limited to the following items: •

Transport to location of installation (if necessary storage), and the complete mounting,

•

Grounding and potential equalization for the transformers, including connection with the next grounding bus bars,

•

Termination of all cables at the transformers,

•

Commissioning of the functioning transformers and adjustment of all protection devices,

•

Briefing of the operation personnel in operation and maintenance during installation and commissioning phase.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16322 TRANSFORMERS

The transformers shall be mounted after erection of the oil catch basins and the fire protection walls. Sun shades and protection fences can be installed later, but before energizing of the transformers. For each oil type transformer a separate transformer box with oil catch basin, suitable for the complete oil volume contained in the transformer, must be foreseen. 3.04

Workshop Tests All transformers shall be tested completely and detailed in manufacturer’s workshop. All tests required by the codes and standards as well as all manufactures tests have to be performed. The test program for the work shop test has to be submitted at least 3 weeks prior to start of the tests. Tests in factory shall be carried out in accordance with the requirements of the relevant standards. These are according to IEC regulations mainly but not limited to the following: • Measurement of winding resistance, • Measurement of ratio, • Measuring of short circuit voltage, short circuit impedance and short check of on-load circuit losses, • Measuring of no-load losses and no-load current, • Operation tests of the measuring equipment, • Test of transformer oil, • Test of auxiliary electrical devices. Detailed test protocols of all tests performed have to be submitted prior to installation.

3.05

Type Tests Type tests and verifications according to VDE shall not be performed if the Contractor supplies a copy of the certified test results.

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DIVISION 16 ELECTRICAL WORKS 3.06

SECTION 16322 TRANSFORMERS

Site Tests The site tests shall include the following steps: • Pre-installation testing, • Pre-commissioning (including “Loop Testing”), • Commissioning and test on completion, • Test runs, • Performance tests. The aim of the tests is to ensure and prove the proper function of the complete scope.

3.07

Documentation Complete documentation shall be provided for the design, manufacturing, testing, commissioning, start-up, operation, maintenance and repair of the transformers and its components. All documents shall be in English language. The documentation of transformers shall include the following documents and drawings (minimum requirements): a) Technical data sheets b) Layout drawings for all transformers and devices c) Block diagrams d) Wiring diagrams e) Termination drawings f) Cable lists g) List of used devices with manufacturer h) Spare parts list i) Operation and maintenance manual j)

Reports of tests and commissioning with protocols.

The documents listed above shall be handed over for approval. DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16322 TRANSFORMERS

Special attention has to be given to the fact, that documentation must be submitted with sufficient time allocated for approval prior to manufacturing /assembly. Documentation has to be prepared in accordance with the relevant ISO standards or in the absence of relevant details in those standards the DIN standards shall apply. The final documentation shall be delivered on paper in sufficient number and with exception of the signed protocols in electronic form, too. The type of the electronic files shall be agreed with the Client. 3.08

Shipping All equipment, material and spare parts shall be sufficient packaged and shall be shipped as a common delivery. The material, especially loose parts and spare parts shall be clearly labeled according to the designation.

3.09

Spare Parts and Special Tools The Contractor shall deliver all spare parts, which are necessary for commissioning and two years operation time (see “General Description for Project and Works”). Spare parts shall be available until ten years after commissioning. The following special tools shall be supplied: •

Two oil filter machine with filer earth filter.

•

One digital HV Insulation resistance Testing kit (Megger) with PI measuring facility.

•

Two oil dielectric strength test kit.

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DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16440 DISCONNECTS SWITCHES

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

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SECTION 16440 DISCONNECTS SWITCHES

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08

Section Includes Coordination Related Sections References Quality Assurence Submittals Delivery, Storage and Handling Testing

PART 2

PRODUCTS

2.01

Disconnect Switches

PART 3 3.01 3.02

EXECUTION Installation Manufacturer

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16440 DISCONNECTS SWITCHES

DIVISION 16 ELECTRICAL

PART 1 - GENERAL 1.01

SECTION INCLUDES Furnish and install motor and circuit disconnects of ratings shown on drawings. Disconnects shall be of the non-fusible and fused wire specified heavy-duty type safety switches having electrical characteristics as hereinafter specified. All switches shall be "Underwriters Laboratories Inc." (UL) listed, and meet "National Electrical Manufacturers Association" (NEMA) specification KSI-1969.

1.02

COORDINATION Determine the work to be performed by the building contractors and others throughout. Provide the type and amount of materials and equipment necessary to place this work in proper operation, completely installed, wired, tested, and ready for use.

1.03

1.04

RELATED SECTIONS A.

Section 16010

Basic Electrical Requirements.

B.

Section 16110

Raceways.

C.

Section 16120

Wires and Cables

D.

Section 16195

Electrical Identification

E.

Section 16452

Grounding and Bonding.

REFERENCES A.

Except as modified by this Specification, conform to the applicable provisions and recommendations of the following standards. 1.

National Electrical Code (NEC).

2.

National Electrical Manufacturers Assoc. (NEMA).

3.

National Fire Protection Association (NFPA).

4.

American National Standards Institute (ANSI).

5.

Underwriters Laboratories (UL).

6.

Institute of Electrical & Electronics Engineers (IEEE)

DISCIPLINE: ELECTRICAL

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Rev. 00 15 Mar, 2011

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SECTION 16440 DISCONNECTS SWITCHES

DIVISION 16 ELECTRICAL

1.05

7.

Occupational Safety and Health Act (OSHA).

8.

All Government Laws, Ordinances and Regulations.

QUALITY ASSURANCE Provide manufacturer's certificate or furnish such evidences as necessary to Client to assure that materials meet or exceed minimum requirements as specified.

1.06

1.07

SUBMITTALS A.

Before starting installation of any materials or equipment, submit for approval a complete list of materials and equipment to be incorporated in the work. This list shall include catalog numbers, cuts, data sheets, and such other descriptive information as may be required. No consideration will be given to partial lists submitted from time to time. Approval of materials will be based on manufacturer's published data, installation and roughing-in data sheets and drawings indicating compliance with the Contract documents.

B.

Submittals shall be submitting within three (3) weeks after the contract start date.

DELIVERY, STORAGE AND HANDLING Protect all materials and equipment from damage during handling and storage. Refer to specification Section 16010 - "Basic Electrical Requirements" for complete work scope.

1.08

TESTING A.

Before shipment, the disconnect switches shall be tested to ensure proper operation and conformance with manufacturer's published specifications. Notification of completion of testing shall be sent to Client Representative.

B.

The type test certificate for each type of disconnect switches may be accepted in lieu of the actual tests on the disconnect switches being supplied on this project.

PART 2 - PRODUCTS 2.01

DISCONNECT SWITCHES A.

Switches shall be furnished in NEMA Type 1 general purpose enclosures and/or NEMA Type 4 stainless steel watertight for outdoor use and wet locations. Covers for general purpose enclosures shall be of the hinged type. Provisions for pad-locking covers in the closed position, with defeatable interlocks to prevent the cover from opening when the operating handle is in the "on" position shall be

DISCIPLINE: ELECTRICAL

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Rev. 00 15 Mar, 2011

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SECTION 16440 DISCONNECTS SWITCHES

DIVISION 16 ELECTRICAL

provided. Enclosures shall be fabricated of code gauge steel, coated with a rust inhibiting primer and finished in baked enamel, ANSI-611 gray. Factory installed ground lugs shall be provided in each enclosure. B.

C.

SWITCH INTERIORS AND MECHANISMS 1.

All switches shall have switch blades which are fully visible in the "off" position when the cover is open. Removable arc suppresser shall be furnished where necessary to permit easy access to line-side lugs. Lugs shall be of the solderless type, UL listed for copper cables, and shall be front removable. all heavy duty switches shall have live terminal shields.

2.

Switch mechanism shall be of the quick-make, quick-break type, with pad lockable operating handle as an integral part of the enclosure base. Switches shall have dual cover interlocks to prevent unauthorized opening of the switch when handle is on the "on" position, or closing of mechanism with cover in the open position.

RATINGS Provide horsepower-rated switches for use as motor circuit disconnects, of ratings as shown on drawings. Switches shall be Model "H-600" as manufactured by "Westinghouse Electric Corporation", with number of poles, voltage and rating as shown on drawings. Factory mounted, metal nameplate with permanent stamping of switch type, voltage, catalog number and horsepower rating shall be provided and installed on front cover.

PART 3 EXECUTION 3.01

INSTALLATION A.

Mount all individually enclosed disconnects rigidly, and align properly on the building structure 1 inch (25 mm) off the wall and 5 foot 10 inches(1.8 M) above finish floor. Use steel supporting frames as necessary or as shown on drawings.

B.

Provide and install a nameplate for disconnects. Nameplates shall be engraved in both Arabic and English, indicating the name of equipment served with circuit or motor number.

C.

Nameplates shall be black-on-white, laminated phenolic, engraved in minimum 1/4 inch (6.5 mm) high lettering. Provide other or additional information on nameplates as required. Refer to specification Section 16195 for complete requirement for identification plates.

D.

Install nameplates to disconnects with appropriate sheet metal screws. Glue-on types and pop-rivet types are not acceptable. Submit samples where requested.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16440 DISCONNECTS SWITCHES

DIVISION 16 ELECTRICAL

3.02

MANUFACTURER The above named manufacturers are only for general conformance with the design concept. Equal approved products are acceptable, providing all evidence required to support this contention is in accordance with the above specifications.

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DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16452 EARTHING AND LIGHTING PROTECTION

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

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REMARKS

DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03

Scope Codes and Standards Submittals

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05

Tagging Earthing System Installation of Earthing System Lightning Protection Special Requirements

PART 3 3.01 3.02 3.03

EXECUTION Test Documentation Spare Parts and Special Tools

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

PART 1 - GENERAL 1.01

Scope This specification covers the technical requirements for design, construction, installation and test of the earthing and lightning protection systems within the station areas for the Transportation of Treated Water from Taif STP to Ma’aden Gold mines.

1.02

Codes and Standards The design, construction, installation, test and commissioning of earthing and lightning protection systems shall be in accordance with the following codes and standards, at least. The latest revision of the publication referred to shall apply. IEC 60364

Electrical installations of buildings

IEC 61024

Protection of structures against lightning

IEC 61312

Protection against lightning electromagnetic impulse

As far as the power supply authority (SEC) or permits of other authorities require additional codes and standards, respectively impose additional requirements, these are also part of the contract. 1.03

Submittals Forward to the Company Representative for review and approval the following submittals. Refer also to appropriate specification sections for other submittal requirements. A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

B.

Prior to Commencing WORK: Shop drawings of proposed installations that deviate from the original design.

C.

Prior to Final Acceptance: Record documents which shall indicate installed conditions for: 1.

Major raceways systems, size and location, for both exterior and interior; locations of control devices; distribution and branch electrical circuitry; fuse and circuit breaker size and arrangements.

2.

Equipment locations (exposed and concealed), dimensioned from prominent building lines.

3.

Approved substitutions, modifications and actual equipment and materials installed.

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DIVISION 16 ELECTRICAL WORKS D.

SECTION 16452 EARTHING AND LIGHTING PROTECTION

Maintenance Manuals: Submit maintenance manuals which shall include the following information for equipment items: 1.

Description of function, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of replacement parts.

2.

Manufacturer's printed operating procedures to include start- up, break-in, and routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; and summer and winter operating instructions.

3.

Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

4.

Servicing instructions and lubrication charts and schedules.

PART 2 - PRODUCTS 2.01

Tagging All components, equipment and installations shall receive the respective tagging plates, labels, etc., which have to be of extremely durable material resistant against the environmental conditions. For further requirements, reference is made to the specification “Basic Electrical Requirements”.

2.02

Earthing System General The stations shall be equipped with an equipotentially meshed grounding network. All exposed conductive parts or elements of the station systems will be connected to this network. The earthing systems of the various stations are part of the protection systems for electrical power supply, instrumentation, control and supervisory system. The earthing system consists of the main grounding grid, the grounding rods, the building foundation grounding and the equipment grounding. For stations, which are to be extended, the existing earthing system shall be considered. The layout of new earthing system shall match to the existing installations. The new and the existing grounding network must be interconnected at two (2) locations, at least.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

Soil Conditions The grounding network system will be installed in different soil materials according to the location of the stations. Before design and installation of the grounding network the actual soil conditions in the station areas must be determined by adequate soil resistance measurements.

Design Requirements The earth resistance of the overall interconnected station grounding network shall not exceed 1 Ω. For block valve stations without high and medium installations a maximum earth resistance of 2 Ω will be accepted. For the UPS, the SCADA and telecommunication systems with their equipment a separate grounding network with sufficient cross-section to avoid interference shall be installed. This grounding network shall be connected to the common station grounding network on one (1) separable and indicated connection point, within the electrical building or equipment container (for line valve stations), respectively. The actual soil conditions in the stations areas must be determined by soil resistance measurements. The required conductor spacing, the total length of the grounding grid and the required grounding material cross-section shall be calculated under consideration of the maximum earth fault current, to maintain touch and step voltages within reasonable limits. The impedance of the fault current path and protective devices shall be chosen that the faulted circuit will be disconnected from the supply within the required time. A respective grounding calculation with report shall be performed for each station and is to be submitted to the Client for approval. Multiple connections of grounding conductors shall only be carried out above ground. For these connections the respective grounding bars are to be installed. Extensions of single grounding conductors can be permitted below ground under use of compression connectors or welding connections, with repair painting and coating of the connection point. All connections of conductors on equipment shall be performed with pressure type lugs or connectors and threaded bolts, screws, spring-washers and washers. Special care must be taken to avoid the arising of a chemical element. Connections between bare copper and iron parts must be protected in a special manner and shall only be executed on above-ground connection points (grounding bars) or inside of pits.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

Earthing Material The material and minimum dimension shall be selected in conformity with the relevant standards. The grounding network shall consist of copper rope, galvanized strip iron, grounding and potential equalization bars, grounding rods, copper cable and fastening / connection parts. For the different application the following materials with the minimum measures shall be provided: Main grounding grid, directly buried Grounding rods

Stranded copper rope, lead sheathed Cu/Pb, minimum cross section 70 mm² Hot dip galvanized steel, Ø 25 mm, minimum length 3 m

Grounding bars

Copper, 50 x 5 mm, minimum length 300 mm

Potential equalization bars, within Brass, tinned, 10 x 10 mm, minimum length buildings 200 mm, with cover Foundation grounding

Strip iron, St/tZn 30 x 3.5 mm

Grounding ring within buildings, on Stranded copper rope, lead sheathed Cu/Pb the wall, in tubes with minimum cross section of 70 mm² or grounding/potential equalization bars connected with PVC insulated copper cables with minimum cross section of 70 mm²

Connection between inner and outer PVC insulated copper cable, minimum cross grounding ring of buildings section 70 mm² Connecting lugs on foundation PVC insulated copper cable, minimum cross grounding to outside concrete section 70 mm² Equipment connections

2.03

PVC insulated copper cable,70, 50, 35 or 16 mm², depending on equipment

Installation of Earthing System Main Grounding Grid The ropes for main grounding grid shall be laid at least 50 cm below final grade in natural soil. Common laying of grounding and cable in one cable trench is permitted, in this case the ropes have to be placed beside the cable route and surrounded with compacted material prior to sand bedding necessary for the cable laying.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

In areas of rocky ground the grounding conductor must be laid in a compacted ground material bed, if necessary the conductor can be washed in by using of water and mud. Grounding rods shall be installed in sufficient number to reduce the effective resistant to earth (if necessary). The grounding rods shall be driven into ground and are to be provided with a pit. The connection to the main grounding grid shall be performed inside the pit by compression connectors or screwed connection terminals. Foundation Grounding For foundation grounding a closed loop of strip iron shall be laid in the concrete of foundations for the outer building walls. Larger buildings (e.g. pump houses, electrical buildings, etc.) are to be equipped with additional cross-connections between the loop, to form a mesh. The reinforcement must be interconnected at suitable points by welding and is to be connected at least every 10 m to the foundation grounding loop or cross-connections respectively. Rooms or buildings with switchgears and the pump houses shall be provided with a welded steel wire fabric, laid inside the screed and interconnected with the foundation grounding. For connection to inside and outside the buildings the respective connecting lugs shall be installed. Outdoor Connecting Lugs The outdoor connecting lugs on the foundation grounding are intended as surface connections for the conductor of the lightning protection system and the main grounding grid. The following distances shall be observed: • •

buildings containing control system approx. 10 m other buildings and shafts approx. 20 m

In each case, buildings or shafts shall be equipped with two connection lugs, at least. The connecting lugs on the foundation grounding shall be embedded in concrete and their outlets should be located above the ground surface. The connecting lugs are to be terminated on grounding bars. Indoor Connecting Lugs The indoor connecting lugs on foundation grounding are intended for the indoor potential equalization system and indoor screening connections. All buildings and rooms containing power supply/distribution facilities and control systems, such as high-voltage substations medium-voltage rooms, low-voltage room, rooms with subdistribution boards, control rooms etc. and rooms, buildings shafts with process installations shall be provided with indoor connecting lugs. DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

The quantity of connecting lugs depends on size of structure and the equipment placed in the respective building or room. In the case of several connections per building or room, potential equalization bars shall be installed. These bars must be permanently accessible for inspection purposes. Buildings and Supports, Steel Structures All foundations and shafts shall be equipped with foundation grounding. Small foundations for lighting poles, grounding bars or electrical equipment (switches, socket outlets etc.) and small concrete supports do not need foundation grounding. In a distance of approximately 1 m around all buildings, foundations for steel structures and shafts a grounding conductor (lead sheathed copper) shall be laid in a loop of at least 0.5 m depth. The connection between the loops and the foundation grounding of these buildings, steel structures and shafts shall be performed on grounding bars. These bars shall be installed every 10 or 20 m respectively at the outlet-points of foundation grounding connection lugs in a height of min. 0.35 m above ground level. The internal loops or internal potential equalization bars shall be connected with the outside grounding bars at suitable points by means of additionally cables. Steel structures have to be welded together in a manner such that a good conductivity of these connections is ensured. Each steel structure column is to be connected to the grounding system. For grounding connection of equipment inside of buildings the PVC insulated copper conductor shall be laid in cable ducts or conduits, on cable trays, direct wall mounted with clamps depending on the different equipment and locations. Transformers Power transformers have to be connected with their steel tank, transport rails and foundation steel structures to the corresponding grounding network. The connection of the neutral or star-point of the transformers to the grounding network depends on the general system grounding of the various voltage levels. The neutral/star-point connection must be placed at an identified and easy accessible place, separate for each transformer. Switchgears, Sub-Distribution Boards If several devices form part of a larger unit (such as switchgears, sub-distribution boards, control cabinets, control boards, etc.), this unit shall be provided with one earthing screw or plate with which the earthing screws or plates of each individual device shall have solid contact.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

When control boards, control desks, switchgears, sub-distribution boards consist of several individual cabinets, each cabinet shall be connected to a common earthing bar unless all panels are solidly welded together or other approved means are applied ensuring a solid connection. If, in this case, units or larger conductive extensions are formed, provisions for earthing shall be available at least at both ends. Power Consumers All motors, generators, valve actuators, ventilators and other power consumers shall be connected to the grounding network with the grounding conductor of their feeding power cable. In addition the power consumer casings and/or their steel base frames shall be connected to the grounding network by separate copper cable. Cables and Cable Jointing Boxes In each cable jointing box the earthing conductor of the two cables has to be connected. When using metal sleeves, the earthing conductor shall be connected to the sleeve casing, too. Medium voltage cables have to be connected with their screens or shields to the earthing terminal in the equipment terminal box and in the switchgear. The metal screens or shields of the power, control and instrument cables have to be connected with the ground conductor. For instrument circuits the grounding conductor and screen shall be connected on one side only, preferably in the instrument cabinet or marshalling rack. Inside of junction boxes the screens and shields are to be interconnected and connected with the earthing system. Towers The steel structure of towers has to be welded or screwed together in a manner such that the good conductivity of these connections is ensured. Each tower must be connected at two points to the station grounding network. For remote towers a suitable earthing system must be installed for connection of these towers and lightning protection of the installed equipment. Pipes Each metallic pipe shall be connected with the grounding direct behind of its entry in a building or shaft. The grounding of pipes inside of shafts for a cathodically protected pipeline must be performed via special AC-voltage limitation devices (e.g. polarization cell replacements) to avoid problems for the cathodic protection system. Pipes installed on supports and the respective supports do not need any additional connection to the grounding system.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

Fence, Lighting Poles The station fence shall be connected on four locations to the grounding network. Each lighting pole and mast shall be connected to the station earthing system. For termination with the buried part of grounding grid a multiple underground connection allowed, which is to be provided following the procedure for grounding conductor extensions. Passage Earth to Air At passages from ground to air all conductors shall be protected with rigid non metallic, heavy duty conduits approx. 30 cm below and 30 cm above ground level. The conduits have to be sealed with durable sealing compound and must be fixed on foundations, structures, etc. Surge Arrestors For all equipment, which might be affected by lightning shocks, the necessary protection measures shall be provided. Surge arrestors shall be provided in order to protect the sensitive equipment and instruments (this applies in particular to electrical equipment, field instrument circuits, station and unit control system, telephone system and radio equipment). The surge arrestors shall be connected to the station earthing system. 2.04

Lightning Protection General All buildings, towers and other high structures of the stations must be protected against lightning and electrostatic discharges by means of a lightning protection system. The lightning system consists of collector rods (air terminals), collector lines and down conductors from hot dip galvanized round iron (St/tZn Ø10 mm) and the necessary fixing, connection and termination elements. The lightning protection systems of the several buildings and structures are to be connected with the earthing system via the grounding bars of these buildings or structures. Shafts shall not be equipped with separate lightning protection. All outer metallic parts will be connected either with the internal potential equalization bars or the grounding bars at outside. The layout and design of lightning protection systems for building extensions or new buildings and structures provided within existing station areas shall match the existing design.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

All connections between the different parts of lightning protection systems and the connections to the earthing system must be performed in a manner such that the arising of chemical elements will be avoided. Collectors Collectors shall be determined in accordance with the lightning ball method. Collectors may comprise a combination of the following components: • •

Collector lines, Collector rods.

Natural Components of Collectors Metal cladding, metal roof structures, metal components of roof structures, gutters and railings may be considered as natural components of collectors. The requirements of the standards, such as the following, have to be considered: • • •

parts must be permanently conductively connected, minimum thickness of the metal involved, Cross-sections of the parts.

Installations with metal casings need not to be fitted with collectors taking into consideration the above-mentioned minimum requirements. Protective coatings or insulation between metal parts shall be electrically bridged. Mesh-Type Collectors Buildings shall be provided with mesh-type collector lines. The collectors have to be configured in a way such that no point of the roof is at a distance of more than 5 m from a collector. The maximum permitted mesh size is as follows: • •

buildings with telecommunication or control rooms 10 x 10 m Other buildings 10 x 20 m

Protruding roof superstructures, such as ladders, chimney stacks, pipes, antenna mounting brackets, etc. and other metallic parts of buildings which are located near the roof (e.g. louvers of ventilation openings) must be directly connected to the collector lines.

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

Collector Rods Collector rods shall be used for roof superstructures featuring mechanically or electrically operated equipment, such as ventilators and non-conductive parts projecting from the mesh plane by 0.3 m. The angle of protection and a certain minimum distance have to be observed. Outdoor electrical facilities for HVAC or other purposes not located in the protective area of earthed structures, installations or buildings, including exposed electrical equipment shall be protected by collectors. Buildings with sheet metal roofs where the thickness of the sheet is smaller as the required value, the collector mesh must be equipped with collector rods of sufficient quantity and length to avoid lightning strokes in the sheet metal. Down Conductors Down conductors shall be selected in a manner such that there are several parallel current paths between the collector and the earthing system. The length of each down conductor is to be kept as short as possible. Steel structures and steel columns of buildings may be used as down conductor, if the minimum sizes according to the standards are guaranteed. In each case the connections with the earthing system and collectors respectively must be visible and removable. Starting from the corners of the structure involved, conductors should be distributed around the exterior as evenly as possible. They must be configured in such a way as to constitute the direct continuation of the collector. The minimum distance between conductors and doors, windows and other apertures must be 0.5 m. If not already connected with the collectors or with the internal potential equalization, larger metal parts mounted in/on the building outer walls (e.g. frames of doors, ventilation louvers) shall be terminated on the down conductors. The number of down conductors and the minimum distance between the conductors is given as follows: a) Buildings containing telecommunication and control systems • minimum number of conductors: 4 • maximum distance between conductors: 10 m b) Other buildings • minimum number of conductors: 2 • maximum distance between conductors: 20 m All down conductors which are connected to the earthing system must be provided with an accessible isolating point for measuring purposes. For termination the grounding bars of grounding loops shall be used, preferably. DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16452 EARTHING AND LIGHTING PROTECTION

No conductors are required for outdoor metal structures of adequate size. Inadmissibly Short Distances Inadmissibly short distances between the lightning protection system and metal installations or electrical equipment shall be prevented. In the event of potential hazard due to flash-over or disruptive discharge caused by lightning, appropriate measures shall be taken. Admissible distances between lightning protection systems and metal installations, electrical wiring and equipment shall be determined in compliance with the standards. This also applies to the use of special roof-mounted collectors. 2.05

Special Requiremets The Vendor/Manufacturer shall have local representative in Saudi Arabia and shall have maintenance team available with minimum five years of experience to attend any maintenance issues.

PART 3 - EXECUTION 3.01

Test After erection of the earthing and lightning protection system all installations shall be tested in accordance with applicable regulations. The following tests shall be carried out, at least: • • • • • •

measures against corrosion protection and arising of chemical elements, check of all connections, measurements of earthing system resistance, measurements of lightning protection system conductivity, check of mechanical details, compliance with specifications.

The aim of the tests is to ensure the proper function of the complete scope. The measuring results and the locations of the measuring points have to be indicated in respective drawings as a basis for future measurements. 3.02

Documentation Complete documentation shall be provided for the design, construction, testing, maintenance and repair of the earthing and lightning protection systems and their components. The documentation shall be in English language. The final documentation of earthing and lightning protection system shall at least include the following documents and drawings (minimum requirements):

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DIVISION 16 ELECTRICAL WORKS a) b) c) d) e) f) g) h) i)

SECTION 16452 EARTHING AND LIGHTING PROTECTION

Technical data sheets, Layout drawings, Circuit diagrams, Construction drawings, Calculation of earthing system, List of used devices with manufacturer, Spare parts list, Operation and maintenance manuals, Reports of tests with protocols.

The documents listed above shall be handed over for approval. Special attention has to be given to the fact, that documentation must be submitted with sufficient time allocated for approval prior to manufacturing /assembly. The documentation has to be prepared in accordance with the relevant ISO standards. The final documentation shall be delivered on paper in sufficient number and with exception of the signed protocols in electronic form, also. The type of the electronic files and the number of copies shall be agreed with the Client. 3.03

Spare part and Special Tools The Contractor shall deliver all spare parts, which are necessary for commissioning and two years operation time (see “General Description for Project and Works”). The following special tools shall be supplied: One Earth resistance measurement device

- END OF SECTION -

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16461 DRY TYPE TRANSFORMER

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

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SECTION 16461 DRY TYPE TRANSFORMER

DIVISION 16 ELECTRICAL SUBSECTION INDEX PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08

Section Includes Related Sections References Submittals Quality Assurance Qualification Regulatory Requirments Delivery, Storage and Handling

PART 2

PRODUCTS

2.01 2.02

Dry Type General Purpose Transformer Source Quality Control

PART 3 3.01 3.02 3.03

EXECUTION Examination Installation Field Quality Control

DISCIPLINE: ELECTRICAL

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SECTION 16461 DRY TYPE TRANSFORMER

DIVISION 16 ELECTRICAL

PART 1 - GENERAL 1.01

SECTION INCLUDES A.

1.02

1.03

1.04

Dry type general purpose transformer.

RELATED SECTIONS A.

Section 16195

Electrical Identification.

B.

Section 16452

Grounding and Bonding

REFERENCES A.

NEMA ST 1

Specialty Transformer

B.

NEMA ST 20

Dry Type Transformer for General Applications.

C.

NFPA 70

National Electric Code.

D.

ANSI/IEEE C57.12

General Requirements for Dry-Type Distribution and Power Transformers.

E.

ANSI/IEEE C57.96

Guide for Loading transformers.

F.

ASTM D635

ASTM Standard Test Method.

G.

NECA

Standard of Installation.

Dry-Type

Distribution

and

Power

SUBMITTALS A. Product Data: Provide outline and support point dimensions of enclosures and accessories, unit weight, volltage, kVA, impedance ratings and characteristics, tap configurations, insulation, insulation system type, and rated temperature rise. B. Test Reports: Indicate loss data, efficiencies and sound levels at 25, 50, 75 and 100 percent rated loads. C. Manufacturer’s Instructions: Indicate application conditions and limitations of use stipulated by product testing agency specified under Regulatory Requirements. Include instruction for storage, handling, protection, examination, preparation, installation, and starting of product.

DISCIPLINE: ELECTRICAL

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SECTION 16461 DRY TYPE TRANSFORMER

DIVISION 16 ELECTRICAL

D. Manufacturer’s Certificate: Certify that Products are designed, manufactured and tested in accordance with all the latest applicable ANSI, NEMA and IEEE Standards. 1.05

QUALITY ASSURANCE A. Perform Work in accordance with NECA Standard of installation.

1.06

QUALIFICATIONS A. Manufacturer: A approved Manufacturer specializing in manufacturing Products specified in this Section with a minimum of three years documented experience.

1.07

REGULATORY REQUIREMENTS A. Conform to requirements of NFPA 70. B. Conform to requirements of ANSI/IEEE C57.12 and C57.96. C. Conform to NEMA ST20.

1.08

DELIVERY, STORAGE, AND HANDLING A. Store, protects, and handles products to site under provision of Section 16010. B. Deliver transformers individually wrapped for protection and mounted on shipping skids. C. Accept transformer on site. Inspect for damage. D. Store in clean, dry space. Maintain factory wrapping or provide an additional heavy canvas or heavy plastic cover to protect units from dirt, water, construction debris, and traffic. E. Handle in accordance with manufacturer's written instructions. Lift only with lugs provided for the purpose. Handle carefully to avoid damage to transformer internal components, enclosure, and finish.

PART 2 – PRODUCTS 2.01

DRY TYPE GENERAL PURPOSE TRANSFORMER A. Manufacturers: Refer to Approved Manufacturers List. B. Description: Transformer shall be designed, manufactured and tested in accordance with NEMA ST 20, and shall be factory-assembled, air cooled dry type transformer, factor K=13, with ratings and voltages as indicated on Contract Drawings.

DISCIPLINE: ELECTRICAL

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SECTION 16461 DRY TYPE TRANSFORMER

DIVISION 16 ELECTRICAL

C. Transformer shall be designed for continuous operation rated at 75 KVA, for 24 hours per day, 365 days per year operation, with normal life expectancy as defined in ANSI C57.96. D. Core and Coil Assemblies.

Transformer core shall be constructed with high grade, non-aging, grain-oriented silicon steel with high magnetic permeability, and low hysteresis and eddy current losses. Maximum magnetic flux densities shall be substantially below the saturation point. The transformer core volumes shall allow efficient transformer operation at 10% above the highest tap voltage. The core laminations shall be tightly clamped and compressed. Coils shall be wound of electrical grade copper with continuous wound construction. E. Winding Taps Transformers 30 KVA: NEMA ST 20. F. Sound Levels: Transformer Sound Level shall not exceed the following ANSI and NEMA levels for self-cooled ratings measured in accordance with NEMA ST 20. Sound Levels in Decibles: 50 db G. Basic Impulse Level: 10 kV. H. Ground core and coil assembly to enclosure by means of a visible flexible copper grounding strap. I. 30 KVA transformer mounting; Floor Mounting only. J. Enclosures The enclosure shall be made of heavy gauge steel and shall be finished utilizing a continuous process of degreasing, cleaning and phosphatizing, followed by electrostatic deposition of a thermosetting polyester powder coating and subsequent baking. The coating color shall be ANSI 61 and shall be UL recognized for outdoor use. K. Manufacturer’s Nameplate: Include transformer ratings, connection data and overload capacity based on rated allowable temperature rise. L. Lamacoid nameplate shall be in accordance with Section 16195. M. Provide oversize lugs for the termination of cable sizes as shown on the Contract Drawings. 2.02

SOURCE QUALITY CONTROL A. Provide production testing of each unit in accordance with NEMA ST 20. The following shall be made on all transformers:

DISCIPLINE: ELECTRICAL

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SECTION 16461 DRY TYPE TRANSFORMER

DIVISION 16 ELECTRICAL

1.

Ratio test at the rated voltage at all tap connections.

2.

Polarity and phase-relation tests on each rated voltage connection.

3.

Applied potential tests.

4.

Induced potential test.

5.

No-load and excitation current at rated voltage on each rated voltage connection.

PART 3 - EXECUTION 3.01

EXAMINATION A.

3.02

Verify that surfaces are suitable for installing transformer supports.

INSTALLATION A.

Install Products in accordance with manufacturer's instructions.

B.

Set transformer plumb and level.

C.

Mount transformers on vibration-absorbing pads suitable for isolating transformer noise from the building structure.

D. 3.03

Provide grounding and bonding in accordance with Section 16170.

FIELD QUALITY CONTROL A.

Check for damage and tight connections prior to energizing transformer.

B.

Measure Primary and Secondary voltage and make appropriate tap adjustments.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16470 PANELBOARDS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL SUBSECTION INDEX PART 1

GENERAL

1.01 1.02 1.03 1.04

Descriptions of Work Quality Assurance Submittals Extra Materials

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06 2.07

Manufacturers Panelboards, General Requirements Load Centers Lighting and Applience Branch ircuit Panelboards Distribution Panelboards Accessory Components and Features Identifications.

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07

EXECUTION Installation Indentifiation Grounding Connections Field Quality Control Cleaning Commissioning

DISCIPLINE: ELECTRICAL

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

DESCRIPTION OF WORK A.

1.02

QUALITY ASSURANCE A.

1.03

This Section includes lighting and power circuit breaker type panelboards and associated auxiliary equipment rated 600V or less.

Applicable Codes and Standards: Conform to the codes and standards listed, but not limited to: 1.

Provide products that are listed and labeled by UL, NEMA, or other, nationally recognized testing laboratory.

2.

Electrical Component Standard: Components and installation which shall comply with NFPA 70, “National Electrical Code.”

3.

NEMA Standard: Comply with NEMA PB1, “Panelboards.”

4.

UL Standards: Comply with UL 61, “Panelboards,” and UL 50, “Cabinets and Boxes.”

SUBMITTALS A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections. 1.

Product data for each type panelboard, accessory item, and component specified.

2.

Shop drawings from manufacturers of panelboards including dimensioned plans, sections, and elevations. Show tabulations of installed devices, major features, and voltage rating. Include the following:

DISCIPLINE: ELECTRICAL

a.

Enclosure type with details for types other than NEMA Type 1.

b.

Bus configuration and current ratings.

c.

Short-circuit current rating of panelboard.

d.

Features, characteristics, ratings, and factory settings of individual protective devices and auxiliary components.

e.

Spare Fuse Cabinets: Show materials, dimensions, and features including storage provisions for fuse cartons.

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL

1.04

3.

Wiring diagrams detailing schematic diagram including control wiring, and differentiating between manufacturer-installed and field-installed wiring.

4.

Qualification data for field-testing organization certificates, signed by the Contractor, certifying that the organization complies with the requirements specified in Quality Assurance below. Include list of completed projects with project names, addresses, and names of Architect and Owner plus basic organization qualifications data.

5.

Report of field tests and observations certified by the testing organization.

6.

Panel schedules for installation in panelboards. Submit final versions after load balancing.

7.

Maintenance data for panelboard components, for inclusion in Operating and Maintenance Manual specified in Division 1 and in Division 16 Section "Basic Electrical Requirements." Include instructions for testing circuit breakers.

EXTRA MATERIALS A.

Keys: Furnish six spares of each type for panelboard cabinet locks.

B.

Touch-up Paint for surface-mounted panelboards: One half-pint container.

PART 2 – PRODUCTS 2.01

MANUFACTURERS A.

Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the Work include, but are not limited to, the following:

B.

Manufacturers: Subject to compliance with requirements, provide products by the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

DISCIPLINE: ELECTRICAL

ABB Power Distribution, Inc. American Circuit Breaker Corp. Asco Electrical Products Co., Inc. Challenger Electrical Equipment Corp. Crouse-Hinds Distribution Equipment. Eaton Corp. General Electric Co. GTE Sylvania Lighting. Siemens Energy & Automation, Inc. Square D Co. Wadsworth Electric Mfg. Co., Inc. Westinghouse Electric Corp.

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL 2.02

PANELBOARDS, GENERAL REQUIREMENTS A.

Over current Protective Devices (OCPDs): Provide type, rating, and features as indicated. Comply with Division 16 Section "Overcurrent Protective Devices," with OCPDs adapted to panelboard installation. Tandem circuit breakers shall not be used. Multi pole breakers shall have common trip.

B.

Enclosures: Cabinets, flush or surface mounted as indicated. NEMA Type 1 enclosure, except where the following enclosure requirements are indicated. 1.

NEMA 3R: Raintight.

2.

NEMA 3S: Raintight and dust tight.

3.

NEMA 4X: Corrosion-resistant fiberglass enclosure, watertight, dust tight, and resistant to oil and coolant seepage.

4.

NEMA 7: Hazardous locations: Div. 1 Group C&D.

5.

NEMA 12: Dust tight, drip proof, and resistant to oil and coolant seepage.

C.

Front: Secured to box with concealed trim clamps except as indicated. Front for surface-mounted panels shall be same dimensions as box. Fronts for flush panels shall overlap box except as otherwise specified.

D.

Directory Frame: Metal, mounted inside each panel door.

E.

Bus: Hard drawn copper of 98 percent conductivity.

F.

Main and Neutral Lugs: Compression type.

G.

Equipment Ground Bus: Adequate for feeder and branch-circuit equipment ground conductors. Bonded to box.

H.

Service Equipment Approval: Listed for use as service equipment for panelboards having main service disconnect.

I.

Provision for Future Devices: Equip with mounting brackets, bus connections, and necessary appurtenances, for the OCPD ampere ratings indicated for future installation of devices.

J.

Special Features: Provide the following features for panelboards as indicated. 1.

DISCIPLINE: ELECTRICAL

Isolated Equipment Ground Bus: Adequate for branch-circuit equipment ground conductors; insulated from box.

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL

2.03

2.

Hinged Front Cover: Entire front trim hinged to box with standard door within hinged trim cover.

3.

Split Bus: Vertical bus of indicated panels divided into two vertical sections with connections as indicated.

4.

Skirt For Surface-Mounted Panels: Same gage and finish as panel front with flanges for attachment to panel, wall, and floor.

5.

Contactors in Mains: Mechanically held, with current rating, poles, and connections as indicated. Conform to Division 16 Section "Motor Controller," except omit overload protection.

6.

Control Power Source: Control power transformer of capacity indicated, for contactor shunt trip or other devices. Mount in cabinet of panel indicated. Protect primary with current- limiting OCPD as indicated. Provide fused protection of control circuits.

7.

Extra Gutter Space: Dimensions and arrangement as indicated.

8.

Gutter Barrier: Arranged to isolate section of gutter as indicated.

9.

Auxiliary Gutter: Conform to UL 870, "Wireways, Auxiliary Gutters and Associated Fittings."

10.

Column-Type Panelboard Configuration: Narrow cabinet extended as wireway to overhead junction box equipped with ground and neutral terminal buses.

11.

Subfeed: OCPD or lug provision as indicated.

K.

Feed-Through Lugs: Sized to accommodate feeders indicated.

L.

Surge Arresters: IEEE C62.11, "Standards for Metal-Oxide Surge Arresters for AC Power Circuits," or IEEE C62.1, "Surge Arresters for Alternating Current Power Circuits."

LOAD CENTERS A.

Provide load-center-type panelboards only where specifically indicated.

B.

General: Conform to above article "Panelboards, General Requirements" except as follows: 1.

OCPDs: Plug-in full module (nominal 1-inch width) circuit breaker.

2.

Circuit Breakers for Switching Lights at Panelboards: Indicated type SWD.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL

2.04

2.05

3.

Circuit Breakers for Equipment Marked HCAR Type: Indicated HCAR type.

4.

Interiors: Provide physical means to prevent installation of more OCPDs than the quantity for which the enclosure was listed.

5.

Main, Neutral, and Ground Lugs and Buses: Have mechanical connectors for conductors.

LIGHTING AND APPLIANCE BRANCH CIRCUIT PANELBOARDS A.

Branch OCPDs: units.

Bolt-on circuit breakers, replaceable without disturbing adjacent

B.

Double-Width Panels: Where more than 42 poles are indicated or where otherwise indicated, provide two panelboards under single front.

C.

Doors: In panel front, with concealed hinges. Secure with flush catch and tumbler lock, all keyed alike.

DISTRIBUTION PANELBOARDS A.

Doors: In panel front, omit single panelboard door in cabinet front for fusible switch panelboards except as indicated. Secure with vault-type with tumbler lock, all keyed alike.

B.

Branch-Circuit Breakers: Where OCPDs are indicated to be circuit breakers, use bolton breakers except circuit breakers 225-ampere frame size and greater may be plugin type where individual positive locking device requires mechanical release for removal.

C.

Motor Starter Branches: Conform to Division 16 Section "Motor Controllers" and provide units equipped for panelboard mounting. Include the following accessories and pilot devices as indicated:

D.

1.

Individual control power transformers.

2.

Fuses for control power transformers.

3.

Pilot lights.

4.

Extra interlock contacts.

5.

Pushbuttons.

6.

Selector switches.

Motor Starter Disconnects: Include overcurrent protection as indicated. Mount integral with or, in same panelboard, adjacent to motor starter. Mechanically interlock

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL

starter door with disconnect device. Provide auxiliary contacts on disconnect to deenergize control connections to starter. 2.06

2.07

ACCESSORY COMPONENTS AND FEATURES A.

Accessory Set: Include tools and miscellaneous items as required for overcurrent protective device test, inspection, maintenance, and operation.

B.

Portable Test Set: Arranged to permit testing of functions of solid-state trip devices without removal from panelboard.

C.

Spare Fuse Cabinet: Identified, compartmented, lockable steel box or cabinet with compartments suitable for surface mounting on wall.

D.

Fungus Proofing: Permanent fungicidal treatment for panelboards interior including OCPDs and other components.

IDENTIFICATION A.

General: Refer to Division 16 Section "Electrical Identification" for labeling materials.

B.

Panelboard Nameplates: Engraved laminated plastic or metal nameplate for each panelboard mounted with epoxy or industrial cement or industrial adhesive.

PART 3 – EXECUTION 3.01

INSTALLATION A.

General: Install panelboards and accessory items in accordance with NEMA PB 1.1, "General Instructions for Proper Installation, Operation and Maintenance of Panelboards Rated 600 Volts or Less" and manufacturers' written installation instructions.

B.

Ground Fault Protection: Install panelboard ground fault circuit interrupter devices in accordance with installation guidelines of NEMA 289, "Application Guide for Ground Fault Circuit Interrupters."

C.

Mounting Heights: Top of trim 6'-2" above finished floor, except as indicated.

D.

Mounting: Plumb and rigid without distortion of box. Mount flush panels uniformly flush with wall finish.

E.

Circuit Directory: Typed and reflective of final circuit changes required to balance panel loads. Obtain approval before installing.

F.

Install filler plates in unused spaces.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL

3.02

G.

Provision for Future Circuits at Flush Panelboards: Stub four 1- inch empty conduits from panel into accessible ceiling space or space designated to be ceiling space in future. Stub four 1-inch empty conduits into raised floor space or below slab other than slabs on grade.

H.

Auxiliary Gutter: Install where a panel is tapped to a riser at an intermediate location.

I.

Wiring in Panel Gutters: Train conductors neatly in groups, bundle, and wrap with wire ties after completion of load balancing.

IDENTIFICATION A.

3.03

3.04

Identify field-installed wiring and components and provide warning signs in accordance with Division 16 Section "Electrical Identification."

GROUNDING A.

Connections: Make equipment-grounding connections for panelboards as indicated.

B.

Provide ground continuity to main electrical ground bus indicated.

CONNECTIONS A. Tighten electrical connectors and terminals, including grounding connections, in accordance with manufacturer's published torque- tightening values. Where manufacturer's torque values are not indicated, use those specified in UL 486A and UL 486B.

3.05

FIELD QUALITY CONTROL A.

Independent Testing Organization: Arrange and pay for the services of an independent electrical testing organization in to perform tests on low-voltage power panelboards and accessories.

B.

Pre-testing: Upon completing installation of the system, perform the following preparations for independent tests:

C.

1.

Make insulation resistance tests of panelboard buses, components, and connecting supply, feeder, and control circuits.

2.

Make continuity tests of circuits.

3.

Provide set of Contract Documents to test organization. Include full updating on final system configuration and parameters where they supplement or differ from those indicated in original Contract Documents.

Quality Control Program: Conform to the following:

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL D.

E.

F.

Procedures: Make field tests and inspections and prepare panelboard for satisfactory operation in accordance with manufacturer's recommendations and these specifications. 1.

Schedule tests with at least one week in advance notification.

2.

Reports by Testing Organization: Report written reports of tests and observations. Report defective materials and workmanship and unsatisfactory test results. Include records of repairs and adjustments made.

3.

Labeling: Upon satisfactory completion of tests and related effort, apply a label to tested components indicating results of tests and inspections, responsible organization and person, and date.

4.

Protective Device Ratings and Settings: Verify indicated ratings and settings to be appropriate for final system configuration and parameters. Where discrepancies are found, recommend final protective device ratings and settings. Use accepted ratings or settings to make the final system adjustments.

Visual and Mechanical Inspection: Include the following inspections and related work: 1.

Inspect for defects and physical damage, labeling, and nameplate compliance with requirements of up-to-date drawings and panelboard schedules.

2.

Exercise and perform of operational tests of all mechanical components and other operable devices in accordance with manufacturer's instruction manual.

3.

Check panelboard mounting, area clearances, and alignment and fit of components.

4.

Check tightness of bolted electrical connections with calibrated torque wrench. Refer to manufacturer's instructions for proper torque values.

5.

Perform visual and mechanical inspection and related work for overcurrent protective devices as specified in Division 16 Section "Overcurrent Protective Devices."

Electrical tests: Include the following items performed in accordance with manufacturer's instruction: 1.

Insulation resistance test of buses and portions of control wiring that disconnected from solid-state devices. Insulation resistance less than 100 megohms is not acceptable.

2.

Ground resistance test on system and equipment ground connections.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16470 PANELBOARDS

DIVISION 16 ELECTRICAL 3. G.

3.06

Retest: Correct deficiencies identified by tests and observations and provide retesting of panelboards by testing organization. Verify by the system tests that the total assembly meets specified requirements.

CLEANING A.

3.07

Test main and subfeed overcurrent protective devices in accordance with Section "Overcurrent Protective Devices."

Upon completion of installation, inspect interior and exterior of panelboards. Remove paint splatters and other spots, dirt, and debris. Touch up scratches and mars of finish to match original finish.

COMMISSIONING A.

Balancing Loads: After Substantial Completion, but not more than two months after Final Acceptance, conduct load-balancing measurements and circuit changes as follows: 1.

Perform measurements during period of normal working load as advised by the Company Representative.

2.

Perform load-balancing circuit changes outside the normal occupancy/working schedule of the facility. Make special arrangements with Company Representative to avoid disrupting critical 24-hour services such as FAX machines and on-line data processing, computing, transmitting, and receiving equipment.

3.

Recheck loads after circuit changes during normal load period. Record all load readings before and after changes and submit test records.

4.

Tolerance: Difference between phase loads exceeding 20 percent at any one panelboard is not acceptable. Rebalance and recheck as required to meet this minimum requirement.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

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Page 1 of 14

SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04

Descriptions of Work Quality Assurance Submittals Extra Materials

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06

Manufacturer Overcurrent Protection Devices Fuseable Switches Fused Power Circuit Devices Molded Case Circuit Breakers Insulated – Case Circuit Breakers

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08

EXECUTION Installation Identification Control Wiring Installation Connections Grounding Field Quality Control Cleaning Demonstration

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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Page 2 of 14

SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

DESCRIPTION OF WORK A. B.

1.02

This Section includes overcurrent protective devices (OCPDs) rated 600V and below and switching devices commonly used with them. Panelboards and Motor Controls: Application, installation, and other related requirements for overcurrent protective device installations in distribution equipment are specified in other Division 16 sections.

QUALITY ASSURANCE A.

Electrical Component Standard: Components and installation shall comply with NFPA 70 "National Electrical Code."

B.

Listing and Labeling: Provide products specified in this Section that are listed and labeled. 1.

1.03

1.04

The terms "listed" and "labeled" shall be defined as they are in the National Electrical Code, Article 100.

C.

Listing and Labeling Agency Qualifications: A "Nationally Recognized Testing Laboratory" (NRTL) as defined in OSHA Regulation 1910.7.

D.

Single-Source Responsibility: Obtain similar OCPDs from a single manufacturer.

SUBMITTALS A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

B.

Product data for fuses, fusible switches, circuit breakers, and OCPD accessories specified in this Section, including descriptive data and time-current curves for all protective devices and let- through current curves for those with current limiting characteristics. Include coordination charts and tables and related data.

EXTRA MATERIALS A.

Maintenance Stock Fuses: For types and ratings required, furnish spare fuses, amounting to one unit for every 5 installed units, but not less than one set of 3 of each kind.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL PART 2 - PRODUCTS 2.01

MANUFACTURERS A.

Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the Work include, but are not limited to the following:

B.

Manufacturers: Subject to compliance with requirements, provide products by the following: 1.

Cartridge Fuses: Brush Fuses Inc. Bussmann Div., Cooper Industries, Inc. Eagle Electric Mfg. Co., Inc. Ferraz Corp. General Electric Co. Gould Inc. Littelfuse Inc.

2.

Fusible Switches: Allen-Bradley Co. Challenger Electrical Equipment Corp. Crouse-Hinds Distribution Equipment. Eaton Corp. General Electric Co. General Switch Corp. Siemens Energy & Automation, Inc. Square D Co. Wadsworth Electric Mfg. Co., Inc. Westinghouse Electric Co.

3.

Fused Power Circuit Devices: Challenger Electrical Equipment Corp. General Electric Co. Kinney Electrical Mfg. Co. Pringle Electrical Mfg. Co. Square D Co.

4.

Molded-Case Circuit Breakers: American Circuit Breaker Corp. ABB Power Distribution, Inc. Challenger Electrical Equipment Corp. Crouse-Hinds Distribution Equipment.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL Eaton Corp. General Electric Co.

General Switch Corp. Heinemann Electric Co. Siemens Energy & Automation, Inc. Square D Co. Wadsworth Electric Mfg. Co., Inc. Westinghouse Electric Corp. 5.

Combination Circuit Breaker and Ground Fault Circuit Interrupters: American Circuit Breaker Corp. Challenger Electrical Equipment Corp. Crouse-Hinds Distribution Equipment. General Electric Co. Siemens Energy & Automation, Inc. Square D Co. Westinghouse Electric Corp.

6.

Molded-Case Current-Limiting Circuit Breakers: General Electric Co. Siemens Energy & Automation, Inc. Square D Co. Westinghouse Electric Corp.

7.

Molded-Case Circuit Breakers With Solid-State Trip Devices: General Electric Co. Siemens Energy & Automation, Inc. Square D Co. Westinghouse Electric Corp.

8.

Integrally Fused Molded-Case Circuit Breakers: General Electric Co. Siemens Energy & Automation, Inc. Westinghouse Electric Corp.

9.

Insulated-Case Circuit Breakers: General Electric Co. Siemens Energy & Automation, Inc. Square D Co. Westinghouse Electric Corp.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 5 of 14

SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL 2.02

2.03

2.04

OVERCURRENT PROTECTIVE DEVICES (OCPDs), GENERAL A.

General: Provide OCPDs in indicated types, as integral components of panelboards, switchboards, and motor control centers; and also as individually enclosed and mounted single units.

B.

Enclosures: NEMA 250 "Enclosures for Electrical Equipment (1,000 Volts Maximum)."

FUSIBLE SWITCHES A.

General: UL 98 "Enclosed and Dead Front Switches" and NEMA KS 1 "Enclosed Switches," quick-make, quick-break heavy-duty units.

B.

Rating: Load-breaking capacity in excess of the normal horsepower rating for the switch.

C.

Withstand Capability: In excess of the let-through current permitted by its fuse when subject to faults up to 100,000 RMS symmetrical amperes.

D.

Operation: By means of external handle.

E

Interlock: Prevents access to switch interior except when in "off" position.

F.

Fuse Clips: Rejection type.

G.

Padlocking Provisions: For 2 padlocks, whether open or closed.

H.

Enclosure for Panelboard Mounting: Suitable for panel mounting where indicated.

I.

Enclosure for Switchboard Mounting: Provide individual mounting where indicated.

J.

Enclosure for Independent Mounting: NEMA Type 1 enclosure except as otherwise indicated or required to suit environment where located.

FUSED POWER CIRCUIT DEVICES A.

General: UL 977, "Fused Power Circuit Devices," with either bolted- pressure-type or high-pressure contact-type switch.

B.

Operation: 1. 2. 3.

C.

Manually opened and closed. Manually closed, electrically tripped. Electrically closed and tripped.

Operation: As indicated.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL D.

Ground Fault Protection: Integral, self-powered type with mechanical ground fault indicator, test function, adjustable pick- up current and delay time with inverse and constant time characteristics, internal memory arranged to integrate intermittent arcing ground faults, and ground fault current sensor located as indicated.

E.

Open Fuse Trip Device: Arranged to trip switch open if a phase fuse opens.

F.

Enclosure for Switchboard Mounting: Suitable for individual mounting.

G.

Enclosure for Independent Mounting: NEMA Type 1 enclosure, except as indicated or except as required to suit environment where located.

H.

Minimum Fault Current Rating: 1. 2. 3. 4.

2.05

100,000 rms symmetrical amperes. 150,000 rms symmetrical amperes. 200,000 rms symmetrical amperes. As indicated.

MOLDED-CASE CIRCUIT BREAKERS A.

General: UL 489, "Molded Case Circuit Breakers and Circuit Breaker Enclosures," and NEMA AB 1, "Molded Case Circuit Breakers."

B.

Construction: Bolt-in type, except breakers 225-ampere frame size and larger may be plug-in type if held in place by positive locking device requiring mechanical release for removal.

C.

Construction: Bolt-in type, except breakers in load-center-type panelboards and breakers 225-ampere frame size and larger may be plug-in type if held in place by positive locking device requiring mechanical release for removal.

D.

Characteristics: Indicated frame size, trip rating, number of poles, and a short-circuit interrupting capacity rating of 10,000 amperes symmetrical, unless a greater rating is indicated.

E.

Tripping Device: Quick-make, quick-break toggle mechanism with inverse-time delay and instantaneous overcurrent trip protection for each pole.

F.

Adjustable Instantaneous Trip Devices: Factory adjusted to low- trip-setting current values.

G.

Enclosure for Switchboard or Panelboard Mounting: Suitable for panel mounting in switchboard or panelboards where indicated.

H.

Enclosure for Switchboard or Motor Control Center Mounting: mounting where indicated.

DISCIPLINE: ELECTRICAL

Provide individual

DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL I.

Enclosure for Independent Mounting: NEMA Type 1 enclosure, except as otherwise indicated or required to suit environment where located.

J.

Combination Circuit Breakers and Ground Fault Circuit Interrupters: UL 943 "Ground Fault Circuit Interrupters," arranged for sensing and tripping for ground fault current in addition to overcurrent and short-circuit current. Provide features as follows: 1.

Match features and module size of panelboard breakers and provide clear identification of ground fault trip function.

2.

Trip Setting for Ground Fault: 4 to 6 milliamperes, listed and labeled as a class A, type 1 device.

3.

Trip Setting for Ground Fault: 30 milliamperes.

4.

Trip setting for ground fault as indicated.

K.

Current-Limiting Circuit Breakers: Arranged to limit let-through ampere-squaredseconds during fault conditions to a value less than the ampere-squared-seconds of one-half-cycle wave of the prospective symmetrical fault current. The circuit breaker shall use no fusible devices in its operation. The current-limiting characteristic shall be in addition to normal time-delay and instantaneous-trip characteristics and other features as indicated.

L.

Integrally Fused Circuit Breakers: Arranged to limit let-through ampere-squaredseconds during fault conditions to a value less than the ampere-squared-seconds of one-half-cycle wave of the prospective symmetrical fault current. The current-limiting characteristic shall be achieved through the use of replaceable current-limiting fuses internally mounted within the circuit- breaker case. The opening of any one fuse shall trip all poles of the circuit breaker. For each trip rating the time-current characteristic of the fuses shall be coordinated with that of the normal inverse-time and instantaneous-trip devices of the circuit breaker so current- limiting fuse melting does not occur for faults within the interrupting rating of the basic breaker.

M.

Circuit Breakers With Solid-State Trip Devices: Provide indicated circuit breakers with solid-state trip devices having the following features: 1.

Ambient Compensation: Trip device insensitive to temperature changes between minus 20 deg C and plus 55 deg C.

2.

Adjustability: Breaker ratings and trip settings shall be changeable by operation of controls on front panel of breaker, by change of plug-in element without removing breaker from mounting, or by a combination of the two methods.

3.

Ground-Fault Tripping: Adjustable for pick-up and time-delay values. Provide for indicated units.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL 2.06

INSULATED-CASE CIRCUIT BREAKERS A.

General: UL 489, "Molded-Case Circuit Breakers and Circuit Breaker Enclosures," and NEMA AB 1, "Molded-Case Circuit Breakers."

B.

Ratings: Continuous-current, interrupting, and short-time- current ratings, and voltage and frequency ratings as indicated.

C.

Operating Mechanism: Mechanically and electrically trip-free, stored-energy operating mechanism with the following features:

D.

1.

Moving Contacts Closing Speed: Independent of both control and operator.

2.

Stored-Energy Mechanism: Manually charged.

3.

Stored-Energy Mechanism: Electrically charged, with provision for optional manual charging.

4.

Operation Counter: Include except as otherwise indicated.

Circuit-Breaker Trip Devices: Solid-state over current trip device system that includes one integrally mounted current transformer or sensor per phase, a release mechanism, and the following features: 1.

Functions: Long-time-delay, short-time-delay, and instantaneous- trip functions, which are independent of each other in both action and adjustment.

2.

Temperature compensation to assure accuracy and calibration stability from minus 20 deg C to plus 55 deg C.

3.

Field-adjustable, time-current characteristics.

4.

Current Adjustability: Effected by operating controls on front panel or by changing plug-in elements or current transformers or sensors.

5.

Three bands for long-time- and short-time-delay functions marked "minimum," "intermediate," and "maximum."

6.

Five pickup points, minimum, for long-time- and short-time- trip functions.

7.

Six pickup points, minimum, for instantaneous-trip functions.

8.

Ground fault protection with at least three short-time-delay settings and three trip-time-delay bands. Adjustable current pickup.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL 9.

Trip Indication: Labeled lights or mechanical indicators on trip device shall indicate type of fault causing breaker trip. If lights are used, integral power source shall maintain indication for 60 hours, minimum.

E.

Auxiliary Contacts for Remote Indication: Where remote indication of breaker position is indicated, provide a spare auxiliary switch in addition to other auxiliary switches required for normal breaker operation. The spare auxiliary switch shall consist of two Type "a" and two Type "b" stages (contacts), wired to a terminal block in the breaker housing.

F.

Draw out Features: Circuit-breaker mounting assembly equipped with a racking mechanism that properly positions the power circuit breaker and holds it rigidly in connected, test, and fully disconnected positions and includes the following features:

G.

1.

Interlock arrangement, preventing movement of the circuit breaker to or from the connected position when it is in the closed position and closure of the circuit breaker unless it is in the connected, test, or disconnected position.

2.

Construction, permitting racking an open circuit breaker to or from the connected, test, and disconnected positions with the associated compartment door closed or equivalent dead-front barrier protection, and manual withdrawal to a position for removal from the structure with the door open.

3.

Primary disconnecting devices disengaged and secondary disconnecting devices engaged when breaker is in test position.

4.

Primary and secondary devices disengaged when circuit breaker is in the disconnected position.

5.

Ground contact engaged when the circuit-breaker element is in the connected and test positions.

Circuit-Breaker Features and Accessories: Include the following: 1.

Padlocking Provisions: For installing at least three padlocks on each breaker to secure its enclosure and prevent movement of the draw out mechanism.

2.

Operating Handle: Provide one for each manually operated breaker.

3.

Electric Close Button: Provide one for each electrically operated breaker.

4.

Indicating Lights: Contacts for "Breaker Open" and "Breaker Closed," for main and bus tie circuit breakers, and for other indicated breakers.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL PART 3 – EXECUTION 3.01

3.02

INSTALLATION A.

Independently Mounted OCPDs: Locate as indicated and install in accordance with manufacturer's written installation instructions.

B.

OCPDs in distribution equipment shall be factory installed.

IDENTIFICATION Identify components in accordance with Division 16 Section "Electrical Identification."

3.03

CONTROL WIRING INSTALLATION A.

3.04

Install wiring between OCPDs and control/indication devices as specified in Division 16 Section "Wires and Cables" for hard wired connections.

CONNECTIONS A. Check connectors, terminals, bus joints, and mountings for tightness. Tighten fieldconnected connectors and terminals, including screws and bolts, in accordance with equipment manufacturer's published torque tightening values. Where manufacturer's torquing requirements are not indicated, tighten connectors and terminals to comply with tightening torques specified in UL 486A and UL 486B.

3.05

GROUNDING A.

3.06

Provide equipment grounding connections for individually mounted OCPD units as indicated and as required by NEC. Tighten connectors to comply with tightening torques specified in UL Standard 486A to assure permanent and effective grounding.

FIELD QUALITY CONTROL A.

Independent Testing Organization: Arrange and pay for the services of an independent electrical testing organization to perform tests and observations on OCPDs.

B.

Reports: Prepare written reports certified by Testing Organization on tests and observations. Report defective materials and workmanship and unsatisfactory test results. Include complete records of repairs and adjustments made.

C.

Labeling: Upon satisfactory completion of tests and related effort, apply a label to tested components indicating test results, date, and responsible organization and person.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL D.

Schedule visual and mechanical inspections and electrical tests with at least one week's advance notification.

E.

Pretesting: Upon completing installation of the system, perform the following preparations for independent tests: 1.

Make insulation resistance tests of OCPD buses, components, and connecting supply, feeder, and control circuits.

2.

Make continuity tests of circuits.

3.

Provide set of Contract Documents to test personnel. Include full updating on final system configuration and parameters where they supplement or differ from those indicated in original Contract Documents.

4.

Provide manufacturer's instructions for installation and testing of OCPDs to test personnel.

F.

Visual and mechanical inspection: Include the following inspections and related work.

G.

Overcurrent-Protective-Device Ratings and Settings: Verify indicated ratings and settings to be appropriate for final system arrangement and parameters. Where discrepancies are found, test organization shall recommend final protective device ratings and settings. Use accepted revised ratings or settings to make the final system adjustments.

H.

1.

Inspect for defects and physical damage, NRTL labeling, and nameplate compliance with current single line diagram.

2.

Exercise and perform operational tests of all mechanical components and other operable devices in accordance with manufacturer's instruction manual.

3.

Check tightness of electrical connections of OCPDs with calibrated torque wrench. Refer to manufacturer's instructions for proper torque values.

4.

Clean OCPDs using manufacturer's approved methods and materials.

5.

Verify installation of proper fuse types and ratings in fusible OCPDs.

Electrical Tests: Include the following items performed in accordance with manufacturer's instructions: 1.

DISCIPLINE: ELECTRICAL

Insulation resistance test of OCPD conducting parts. Insulation resistance less than 100 megohms is not acceptable.

DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL 2.

Contact resistance test or measurement of milli volt drop across contacts of draw out circuit breakers and fused power circuit devices at rated current. Compare contact resistance or milli volt drop values of adjacent poles and of similar breakers. Deviations of more than 50 percent are not acceptable.

3.

Insulation resistance test of fused power circuit devices and insulated-case and molded-case circuit breakers over 600- ampere frame size at 1000 V d.c. for one minute from pole to pole and from each pole to ground with breaker closed and across open contacts of each phase. Insulation resistance less than 100 megohms is not acceptable.

4.

Use primary current injection to check performance characteristics of trip units of insulated-case circuit breakers and molded-case breakers over 600-ampere frame size. Trip characteristics not falling within manufacturer's published timecurrent characteristic tolerance bands when adjusted to approved parameters are not acceptable. Perform the following tests: a.

Determine minimum pickup current acceptable per manufacturer's instructions.

b.

Determine long-time delay at 300 percent pickup current.

c.

Determine short-time-pickup current and corresponding delay time.

d.

Determine ground-fault current pickup and corresponding delay time.

e.

Determine instantaneous pickup current value.

5.

Verify trip unit reset characteristics for insulated-case circuit breakers.

6.

Make adjustments for final settings of adjustable-trip devices.

7.

Activate auxiliary protective devices such as ground fault or under voltage relays, to verify operation of shunt-trip devices.

8.

Check stored-energy charging motors for proper operation of motor, mechanism, and limit switches.

9.

Check operation of electrically operated OCPDs in accordance with manufacturer's instructions.

10.

Check key and other interlock and safety devices for operation and sequence. Make closing attempts on locked-open and opening attempts on locked-closed devices including moveable barriers and shutters.

11.

Circuit breakers of all types & voltage levels shall be field trip-tested at site.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16475 OVERCURRENT PROTECTIVE DEVICES

DIVISION 16 ELECTRICAL I.

3.07

Retest: Correct deficiencies identified by tests and observations and provide retesting of OCPDs by testing organization. Verify by the system tests that specified requirements are met.

CLEANING Upon completion of installation, inspect OCPDs. Remove paint splatters and other spots, dirt, and debris. Touch up scratches and mars of finish to match original finish.

3.08

DEMONSTRATION A.

Arrange and pay for the services of factory-authorized service Training: representatives to demonstrate OCPDs and train Owner's maintenance personnel.

B.

Conduct a minimum of one half day of training in operation and maintenance as specified under "Instructions to Owner Employees" in the "Project Closeout" Section of these specifications. Include both classroom training and hands-on equipment operation and maintenance procedures.

C.

Schedule training with at least seven days' advance notification.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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Page 14 of 14

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16480 MOTOR STARTER EQUIPMENT

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITES Page 1 of 16

DIVISION 16 ELECTRICAL WORKS

SECTION 16480 MOTOR STARTER EQUIPMENT

SUBSECTION INDEX PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05

Scope Standards Submittals Environmental Condition Technical Data

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10

Componenets and Equipments Tagging Units and Scales Wiring Special Requirements General Number of Stars Starting Procedure and Limitation Safety Interlocking Devices Equipment Characteristics

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07

EXECUTION Painting Installation Workshop Test Site Test Documentation Shipping Spare Parts and Special Tools

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16480 MOTOR STARTER EQUIPMENT

PART 1 - GENERAL 1.01

Scope This document covers the requirements for the design, manufacturing, construction, installation, test and commissioning of motor starter equipment for indoor application at the Pumping Stations for the Transportation of Treated Water from Taif STP to Ma’aden Gold mines.

1.02

Standards The design, manufacturing, construction, installation, test and commissioning of motor starter equipment shall be in accordance with the following codes and standards, at least. The latest revision of the publication referred to shall apply. IEC 60038

IEC standard voltages

IEC 60051

Direct acting indicating analogue electrical – measuring instruments and their accessories

IEC 60056

High voltage alternating-current circuit-breakers

IEC 60071

Insulation co-ordination

IEC 60085

Thermal evaluation and classification of electrical insulation

IEC 60129

Alternating current disconnectors (isolators) and earthing switches

IEC 60044

Current transformers

IEC 60044

Voltage transformers

IEC 60255

Electrical relays

IEC 60265

High-voltage switches

IEC 60282

High-voltage fuses

IEC 60529

Degrees of protection provided by enclosures (IP-Code)

IEC 60076

Determination of transformer and reactor sound levels

IEC 60076

Application guide for power transformers

IEC 60616

Terminal and tapping markings for power transformers

IEC 60664

Insulation co-ordination for equipment within low voltage systems

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16480 MOTOR STARTER EQUIPMENT

IEC 60694

Common clauses for high-voltage MCC and control gear standards

IEC 60076

Guide to the lightning impulse and switching impulse testing of transformers and reactors

IEC 60076

Dry-type transformers

IEC 60905

Loading guide for dry-type power transformers

IEC 62271

High-voltage MCC and control gear

power

As far as the power supply authority (SEC) and permits of other authorities require additional codes and standards, respectively impose additional requirements, these are also part of the contract. 1.03

Submittals Forward to the Company Representative for review and approval the following submittals. Refer also to appropriate specification sections for other submittal requirements. A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

B.

Prior to Commencing WORK: Shop drawings of proposed installations that deviate from the original design.

C.

Prior to Final Acceptance: Record documents which shall indicate installed conditions for:

D.

1.

Major raceways systems, size and location, for both exterior and interior; locations of control devices; distribution and branch electrical circuitry; fuse and circuit breaker size and arrangements.

2.

Equipment locations (exposed and concealed), dimensioned from prominent building lines.

3.

Approved substitutions, modifications and actual equipment and materials installed.

Maintenance Manuals: Submit maintenance manuals which shall include the following information for equipment items: 1.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

Description of function, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of replacement parts. DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 4 of 16

DIVISION 16 ELECTRICAL WORKS

1.04

SECTION 16480 MOTOR STARTER EQUIPMENT

2.

Manufacturer's printed operating procedures to include start- up, break-in, and routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; and summer and winter operating instructions.

3.

Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

4.

Servicing instructions and lubrication charts and schedules.

Environmental Conditions The motor starter equipment shall be designed and constructed for the intended purpose of main motor start-up under the climatic and environmental conditions as described in the specification “Basic Electrical Requirements”. The motor starter equipment shall be installed in rooms of the electrical buildings. The rooms will be equipped with air conditioning.

1.05

Technical Data The technical data of the motor starter equipment are defined in the data sheets. The Contractor has to guarantee the fulfilment of these requirements.

PART 2 - PRODUCTS 2.01

Components and Equipment The Contractor has to take care that all components and equipment are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals. Standard industrial high performance systems and components of supplier’s standard lists shall be used as far as possible. Components and equipment same kind and type shall be selected for equivalent functions. The interchangeability must be guaranteed.

2.02

Tagging All components, equipment and installations shall receive the respective tagging plates, labels, etc., which have to be of extremely durable material resistant against the environmental conditions. Tagging plates or labels on fronts of enclosures shall be fixed with screws. For further requirements, reference is made to specification “Design and Construction of Power Supply Systems”.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS 2.03

SECTION 16480 MOTOR STARTER EQUIPMENT

Units and Scales The metric system on basis of SI-units shall be used for all scales and indications.

2.03

Wiring The wires shall be selected according to load, insulation level, and function and operating requirements. The wires shall be adequately rated and equipped with fuses / circuit breakers of adequate size. The wiring colors and the minimum cross sections shall be according to specification “Basic Electrical Requirements”. The wiring shall be carried out solid and safe against damages. Wires shall be bundled and fixed. The wiring shall be laid inside of wiring channels, preferably. If wiring channels will be used, a spare of 20 % shall be foreseen. All circuits and auxiliary contacts including not used contacts for disconnecting devices and relays shall be terminated on terminal strips. Terminal strips shall have 10 % spare terminals. If wires with different potential will be terminated on one terminal strip the respective terminals shall be separated by means of isolating plates. The termination of multiple stranded wires has to be carried out by means of multiple core cable ends. Terminals shall be marked durable and easy readable, corresponding to the drawings. Wires shall be marked on the termination of each wire with the number of the corresponding connection point.

2.04

Special Requirements The Vendor/Manufacturer shall have local representative in Saudi Arabia and shall have maintenance team available with minimum five years of experience to attend any maintenance issues.

2.05

General The motor starter equipment shall start-up centrifugal pipeline pumps, which will be driven by medium voltage asynchronous squirrel cage motors. The motor starter equipment per motor consists of the following main parts: • • •

MCC panel, Auto-transformer, Control devices.

For each applicable pump motor unit a separate starter shall be provided. All parts of the motor starter equipment for one motor shall be assembled to a common unit, exchangeable to each other for the same motor size.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS 2.06

SECTION 16480 MOTOR STARTER EQUIPMENT

Number of Starts The motors are designed to allow 4 starts successively from cold (max. ambient temperature) or 3 starts successfully from hot service temperature without tripping of any protection device. The starting time sequence is as follows: • • •

(1)– (2) immediately, (3) After 20 min, (4) After further 20 min.

The motor starting transformer equipment shall be designed and constructed to meet these requirements. 2.07

Starting Procedure and Limitations For the motor starter equipment the following starting procedure and limitations shall be valid: a)

b) c) d)

The pump units will be started against fully closed or partial closed discharge valve, to be defined and coordinated with the pump manufacturer, depending on the final hydraulic requirements. The motor start-up time shall be in the range of 20 seconds, but shall not exceed 30 seconds. The motor start-up current shall be reduced to value ±3 times of the rated motor current. The motor start-up torque shall not be lower than 0.3 of rated torque, the available torque difference between motor and driven pump shall not be lower than 15%.

The detailed pump and motor data and the actual curves shall be requested by the respective manufacturer. The feeding network configuration including feeding transformers and MV MCC is shown on the single line diagrams. The actual layout and feeding network data are subject to confirmation. 2.08

Safety and Interlocking Devices The motor starter equipment shall be equipped with safety and interlocking devices to prevent the following: • • •

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

Closing of the circuit breakers in the service position, if they are not connected to the auxiliary circuit, On-load operation of the isolation and earthing apparatus, Access to the live parts.

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS 2.09

SECTION 16480 MOTOR STARTER EQUIPMENT

Equipment Characteristics MCC Panel Mechanical Requirements General The MCC panels shall be air insulated, industrial type, metal-clad, factory assembled, type tested panels with self-standing cubicles and fix mounted switching devices. The cubicles shall only be accessible from the front. The MCC panels shall be suitable for indoor installation on cable cellar. The bottom shall be covered with galvanized sheet steel, which is to provide with holes for cable entry. The cable entries shall be designed in a manner such that a sealing after cable laying is possible without any problem. Further, each cover sheet shall be equipped with a grounding connection to the steel frame of cubicle. The cubicles of the MCC panels shall be equipped with hinged doors, which are able to swing out more than 90°. All nuts for fixing of components shall be welded on the steel structure or threads will be cutted in the steel structure. The use of loose nuts or self-cutting screws shall be avoided. Screws, nuts and washers shall be galvanized or cadmium plated. Separation The MCC panel shall consist of cable termination cubicle(s), cubicles for bypass circuit breaker and star-point circuit breaker and the necessary bus bar, surge arrestors and cabling accessories. The circuit breakers may be installed in a common cubicle. Each cubicle shall be equipped with a low voltage compartment, which is to placed in the upper part. The different cubicles and the low voltage compartment shall be separated against each other by means of steel sheets. The isolation must be arc-proof. All cubicles shall be equipped with separate pressure relief flaps. The pressure relief shall be carried out upwards. Cable Termination Cubicle The cable termination cubicles shall be supplied with suitable metal fastenings for connection of cable ends, or if necessary for bus bars. These fastenings shall be adapted, for each cubicle, to the number and type of cables or bus bars used. The cable connecting and fastening bars shall be arranged in such a way to allow easy and safe connection of the number and type of cables and cores, designed for the particular MCC panel.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16480 MOTOR STARTER EQUIPMENT

Suitable cable fixing supports must be foreseen to secure the cable termination from any pull tension. Low Voltage Compartment All measurement instruments, push buttons, switches, indication and alarm lamps, etc. shall be mounted in the hinged front door and flexibly wired to the fixed part of the LV compartment. All relays, miniature circuit breakers, etc. within the LV compartment shall be rail mounted. The LV compartment shall have a layout and arrangement to allow easy access to all installed devices. On the door of the LV compartment a mimic diagram with position indication of switching devices shall be placed. For the wiring from the low voltage compartment to the bottom a covered cable duct shall be foreseen. Electrical Requirements Protection The system of protection shall be selected and coordinated in line with the feeding MCC data and the connected equipment requirements: • • •

To guarantee personnel and plant safety. To ensure a sufficient protection against damages of the equipment, this may arise from the internal and external short circuits as well as from possible atmospheric discharges. To ensure as far as possible the continuity of operation for those parts not concerned by the fault. This will be achieved by selecting the setting in a way such that in case of a fault the closest protection device to the fault operates at first.

Bus Bars The bus bars shall be selected according to the electrical requirements and shall be of highconductivity electrolytic copper. The bus bar cross section shall be the same throughout the panel. It shall be adapted to service and installation conditions. Flexible joints shall be provided wherever necessary to avoid displacement due to expansion, or transmission of shocks and vibrations from the MCC panel to the connections. The utmost care shall be taken in the design of the position of the bus bar supports and the layouts of the connections taking into consideration the following: • • DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

Electro-dynamic stresses in disturbed conditions, Resonance phenomena, DOCUMENT No.: MGBM-SPEC-0001

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16480 MOTOR STARTER EQUIPMENT • •

Isolation distances, Temperature rises of conductors in these conditions.

Circuit Breakers Circuit breakers shall be selected and equipped according to the requirements and will be fix mounted. Only one type of circuit breaker for each making and breaking capacity shall be used. The circuit breakers shall be three-pole vacuum type. The operation of circuit breakers shall be carried out via motor driven spring loaded buffers. In case of control voltage fault, the buffers shall be manually operable. The circuit breaker position shall be visible with closed front doors. Each circuit breaker shall be equipped with the following devices: • • • • • • • •

Electrical control, closed contact operated, with anti-pumping device and electric resetting device, Tripping coil with supervision relay, Auxiliary spare contacts, at least 4 NO and 4 NC brought out to terminals, Mechanical position indicators for switching position, Indications for tripping and failure, Operating push buttons for “On” and “Off”, The necessary interlocks to prevent any fault operation. The circuit breakers shall be suitable for short-time interrupt. For switching of the circuit breakers the respective secondary releases and locking magnets shall be provided.

Auxiliary Relays Auxiliary relays shall be of plug-in type and shall be provided with test plugs for measurement on the front side. The test facilities shall be provided to permit testing without interruption of the entire installation and service (on service testing). Auxiliary relays shall be of the electromechanical type. Auxiliary contacts shall be able to carry the maximum foreseen current. In any case their contact load shall be suitable for 230 V AC/DC. The relays shall be suitable for tropical climate and must be dust proof. Overvoltage Protection The MCC panels shall be designed and rated in a manner such that overvoltages caused by switching and flashes, do not impair the safety in operation of the units. The circuit breakers shall be provided with surge arrestors, equipped with easy visible indicators for the healthiness of arrestors. The equipment inside of low voltage compartment shall be separately protected against overvoltages. DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16480 MOTOR STARTER EQUIPMENT

Control and Monitoring The control system shall be an integrated part of the MCC panel and shall include the control and monitoring of the circuit breakers and the autotransformer. The control and monitoring shall be performed with an integrated PLC unit, which shall also control the motor feeder circuit breaker located in the MV MCC. The following signals shall be transferred from/to remote systems, at least: a)

Data exchange with the station/unit control system • Commands - Motor “On”, - Motor “Off”. • Signals - By-pass circuit breaker open, - By-pass circuit breaker closed, - Star-point circuit breaker open, - Star-point circuit breaker closed, - Summary alarm.

b)

Data exchange with the motor feeder circuit breaker • Commands - Circuit breaker “On”, - Circuit breaker “Off”. • Signals - Circuit breaker open, - Circuit breaker closed.

The data exchange with the station/unit control system shall be performed via serial link, the data exchange with the motor feeder circuit breaker will be carried out hardwired. On the front door of one voltage compartment an indicator board shall be installed. All signals and alarms shall be indicated on this board. Earthing All exposed conductive parts likely to be accidentally charged shall be joined together by an earthing circuit. For this purpose a minimum 100 mm² cross section bare copper earthing bus shall be installed. This earthing bus shall be connected to the general grounding system by means of conventional cable connection terminals. Within the panels, fastening screws and bolts shall ensure electric continuity. The opening type panels, assembled on hinges shall be bonded to the enclosure by a tinned copper braid, or hinges shall be certified for this purpose.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16480 MOTOR STARTER EQUIPMENT

The following shall be also connected to the earthing circuit: • • •

Secondary side of surge arrestors, Leads of braid of the MV cables, Operating handles, mounting plates, doors, etc.

In addition, two ends of the MCC panel shall be terminated to the general grounding system by separate cables. Control Voltage The control voltage supply will be carried out from a 230 V AC UPS. Each MCC panel will be provided with one power supply, protected by means of a 20 A or 25 A miniature circuit breaker situated in the UPS distribution board. The sub-distribution of control voltage inside MCC panel shall be carried out selective from the supply to the consumers. For motors of spring loaded buffer and for control/monitoring different monitored miniature circuit breakers shall be used. All other necessary control and signal voltage levels shall be generated inside the MCC panel of motor starter. Anti-Condensation Heaters If necessary, the MCC panels shall be equipped with anti-condensation heaters, which shall be fed from the 230 V, 60 Hz level. Each MCC panel will be provided with one power supply, protected by means of a 16 A miniature circuit breaker situated in a LV distribution board. The heaters shall be humidity or temperature controlled. A failure of heaters shall be indicated on the local indicator boards. Compartment Lighting The low voltage compartment of each cubicle shall be equipped with a lighting fixture, switched via door contact. The lighting fixtures may be fed from the circuits of anti-condensation heaters. Auto - Transformer General The autotransformer shall be of the dry type, suitable for indoor installation within electrical rooms.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16480 MOTOR STARTER EQUIPMENT

The transformer shall be installed behind the MCC panel inside a separate, factory assembled steel sheet enclosure. The enclosure shall be equipped with sufficient ventilation openings to guarantee an adequate air circulation. The main connection with the MCC panel shall be carried out with bus bars. Cooling The cooling of the transformers shall be air with natural circulation. Base Frame The base frame shall be fitted with flat-rim wheels which can be arranged for either longitudinal or cross travel. The base form shall be screwed and shall be equipped with four towing lugs. Windings The transformer shall be provided with copper windings, which shall be insulated with humidity proof insulation. Tap Changer For tapping of secondary voltage a respective off-load tap changer with two additional adjustable tap positions shall be provided. The tap position of the secondary winding shall be calculated and proposed by the motor starter equipment manufacturer, considering the given operating conditions and the pump and motor data. Instrumentation The transformers shall be equipped with a temperature monitoring system. For each winding two PTC temperature sensors (one for alarm and one for trip) shall be provided. PART 3 – EXECUTION 3.01

Painting All components and devices shall have a resistant, long term stable, high quality painting. At least two layers have to be applied. Damages, caused by transport, installation, cabling or commissioning shall be repaired in a way, that the original quality is restored. An additional painting at location of installation is not allowed.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS 3.02

SECTION 16480 MOTOR STARTER EQUIPMENT

Installation The delivery, installation and commissioning of the motor starter equipment shall include, but not limited to the following items: •

Transport to location of installation (if necessary storage), and the complete mounting,

•

Grounding and potential equalization for the cubicles, including connection with the next grounding bus bars, Termination of all cables at the MCC panels, Commissioning of the functioning motor starter equipment, including voltage feeding of the bus bars and adjustment of all relays, protection devices, etc., Briefing of the operation personnel in operation and maintenance during installation and commissioning phase and during a training on site. For transport and site installation purpose the transformer enclosure shall be segregated from the MCC panel, if necessary the transformer itself may be shipped separately.

• • • •

3.03

Workshop Tests All components of the motor starter equipment shall be tested completely and detailed in manufacturer’s workshop. All tests required by the codes and standards as well as all manufactures tests have to be performed. The test program for the work shop test has to be submitted prior to start of the tests in accordance with the Project Procedure Manual. The following tests shall be carried out, at least: • • • • • • • • • • • • • •

Test of all functions, Voltage withstand test, (1) Short circuit withstand test, (1) Test of warming, (1) Check of degree of protection, Check of protection against touching, Power frequency voltage dry test, 1 minute, Voltage test on auxiliary circuits, 1 minute 2 kV r.m.s, Mechanical operation test on circuit breakers, including all adjacent equipment, Operation test of the relays, Test of auxiliary electrical devices, Verification of wiring and terminal blocks, Check of mechanical details, Compliance with the specifications.

(1)

Only type test certificates necessary

Detailed test protocols of all tests performed have to be submitted prior to shipment. DICIPLINE: ELECTRICAL DOCUMENT No.: MGBM-SPEC-0001 Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 3.04

SECTION 16480 MOTOR STARTER EQUIPMENT

Site Tests The site tests shall include the following steps: • • •

Pre-commissioning (including “loop testing”), Commissioning and test on completion, Performance test.

The workshop tests described in item except the power frequency voltage shall be repeated on site by the Contractor after erection and before connection to outside sources. Special care shall be taken for setting of protection devices, relays and timers, setting must be done according to the approved start-up procedure, considering the data of the connected pump motor equipment and the feeding MCC. The aim of the tests is to ensure the proper function of the complete scope. 3.05

Documentation Complete documentation shall be provided for the design, manufacturing, testing, commissioning, start-up, operation, maintenance and repair of the motor starter equipment and their components. All documents shall be in English language. The documentation of the motor starter equipment shall include the following documents and drawings (minimum requirements): a) b) c) d) e) f) g) h) i) j) k) l) m)

Technical data sheets Layout drawings for all devices, cubicles and enclosures Layout drawings for the whole motor starter equipment Single line diagrams Block diagrams Wiring diagrams Termination drawings Cable lists Spare parts list List of used devices with manufacturer Software and software description Operation and maintenance manual Reports of tests and commissioning with protocols.

The documents listed above shall be handed over for approval. Special attention has to be given to the fact, that documentation must be submitted with sufficient time allocated for approval prior to manufacturing /assembly.

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16480 MOTOR STARTER EQUIPMENT

Documentation has to be prepared in accordance with the relevant ISO standards or in the absence of relevant details in those standards the DIN standards shall apply. The final documentation shall be delivered on paper in sufficient number and with exception of the signed protocols in electronic form, also. The type of the electronic files shall be agreed with the Client. 3.06

Shipping All equipment, material and spare parts shall be sufficient packaged. Each unit should be shipped as a common delivery. The material, especially loose parts and spare parts shall be clearly labeled according to the designation.

3.07

Spare Parts and Special Tools The Contractor shall deliver all spare parts, which are necessary for commissioning and two years operation time (see “General Description of Project and Works”). Spare parts shall be available until ten years after commissioning. All necessary special tools for operation and maintenance of the motor starter equipment shall be supplied for each location, at least consisting of: • • • • • • •

1 set of all special tools required for operation and maintenance of MCC panel and transformer, 1 set of circuit breaker tools and consumables, High voltage fuse tongs (if any), High voltage detector, Key set for cubicle doors and locks, 1 set of grounding equipment (ground rope and spider including fastening bolts and clamps, connections tongs etc.), Software for the PLC.

For storage of the above mentioned special tools per location a suitable cabinet, shelf or console shall be delivered.

- END OF SECTION -

DICIPLINE: ELECTRICAL Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16483 VARIABLE FREQUENCY DRIVE

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 16

SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05 1.06 1.07

Scope References Sumittals - For Review / Approvals Submittals – For Construction Qualification Regulatory Requirements Operation and Maintenence Manuals

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06 2.07

Manufacturers Construction Control Fuctions System Interfaces Monitoring and Displays Spare Parts Enclosures

PART 3 3.01 3.02 3.03 3.04 3.05

EXECUTION Factory Testing Feild quality Control Manufacturer’s Certification Traning Harmonic Study

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 2 of 16

SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

SCOPE This specification describes the electrical, mechanical, environmental, agency and reliability requirements for three-phase, adjustable frequency drives as specified herein and as shown on the contract drawings. The VFD shall be install inside MCC and shall be part of the MCC.

1.02

REFERENCES The adjustable frequency drives and all components shall be designed, manufactured and tested in accordance with the latest applicable standards of IEC, UL, CUL, and NEMA.

1.03

SUBMITTALS – FOR REVIEW/APPROVAL The following information shall be submitted to the Engineer: 1.

Dimensioned outline drawing

2.

Schematic diagram

3.

Power and control connection diagram(s)

4.

Product data sheets.

Where applicable, the following additional information shall be submitted to the Engineer: 1. Connection details between close-coupled assemblies

1.04

2.

Composite front view and plan view of close-coupled assemblies

3.

Key interlock scheme drawing and sequence of operations

SUBMITTALS – FOR CONSTRUCTION The following information shall be submitted for record purposes: 1.

Final as-built drawings and information for items listed paragraph 1.04

2.

Installation information.

The final (as-built) drawings shall include the same drawings as the construction drawings and shall incorporate all changes made during the manufacturing process. 1.05

QUALIFICATIONS

A. For the equipment specified herein, the manufacturer shall be ISO 9001 or 9002 certified. B. The supplier of this equipment shall have produced similar electrical equipment for a minimum period of five (5) years. When requested by the Engineer, an acceptable list of DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 3 of 16

SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL

installations with similar equipment shall be provided demonstrating compliance with this requirement. C. The AFD manufacturer shall maintain, as part of a national network, engineering service facilities within 250 miles of project to provide start-up service, emergency service calls, repair work, service contracts, maintenance and training of customer personnel. D. The equipment and major components shall be suitable for and certified to meet all applicable seismic requirements of Uniform Building Code (UBC) for Zone 4 application. Guidelines for the installation consistent with these requirements shall be provided by the switchgear manufacturer and be based upon testing of representative equipment. The test response spectrum shall be based upon a 5% minimum-damping factor, UBC: a peak of 2.15g’s (3.2– 11 Hz), and a ZPA of 0.86g’s applied at the base of the equipment. The tests shall fully envelop this response spectrum for all equipment natural frequencies up to at least 35 Hz. E. For all connection and loading combinations of power and all energization and loading combinations of the VFD’s. The voltage and current distortion at the point of connection of the VFD to power source shall meet the following criteria and the values are based upon 480V systems. 1. The voltage Total Harmonic Distortion (THD) shall not exceed 5% and individual harmonic voltage distortion shall not exceed 3%. 2. Current distortion limits shall not exceed the values presented within IEEE 519 for General Distribution Systems. 3. The maximum commutation notch depth shall be 20%. 4. The maximum notch area shall be 22,800 volt-microseconds. 5. The valves above are based upon 480V systems. Valves must be adjusted for actual system voltage. F. The following minimum mounting and installation guidelines shall be met, unless specifically modified by the above referenced standards. 1. The Contractor shall provide equipment anchorage details, coordinated with the equipment mounting provision, prepared and stamped by a licensed civil engineer in the state. The manufacturer based upon approved shake table tests used to verify the seismic design of the equipment shall provide mounting recommendations. 2. The equipment manufacturer shall certify that the equipment can withstand, that is, function following the seismic event, including both vertical and lateral required response spectra as specified in above codes. 3. The equipment manufacturer shall document the requirements necessary for proper seismic mounting of the equipment. Seismic qualification shall be considered achieved when the capability of the equipment, meets or exceeds the specified response spectra. DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL 1.06

REGULATORY REQUIREMENTS

A. Equipment shall be handled and stored in accordance with manufacturer’s instructions. One (1) copy of these instructions shall be included with the equipment at time of shipment. B. VFD Manufacturer shall perform all analysis and supply any equipment needed to ensure that these performance criteria are met. C. VFD Manufacturer shall perform a computer-simulated harmonic analysis. The analysis result shall be provided to Client for review prior to the installation of the equipment. VFD Manufacturer shall identify what electrical system information is required to perform analysis. VFD Manufacturer shall allow a minimum of four (4) weeks for this information to be provided by Client. D. VFD Manufacturer shall contact motor manufacturer to coordinate the design of the motor/VFD combination. VFD Manufacturer shall contact Client for the contact information of the motor manufacturer. VFD Manufacturer shall provide documentation confirming that this coordination has taken place, a maximum four (4) weeks after the placement of the order. E. Motor shall be controlled by a buyer supplied AFD. AFD manufacturer to contact motor manufacturer to coordinate the design of AFD/motor combination. Motor manufacturer shall provide documentation confirming that this coordination has taken place, a maximum of four (4) weeks after the placement of the order. F.

Following electrical information shall be given to the AFD manufacturer:One line showing electrical system that he will be connecting his equipment to.Short circuit levels (phase and ground)X/R ratio at the point where the AFD manufacturer is connecting his equipment.

G. Several motors shall be controlled with VFD'S and as shown in Project Drawings. VFD manufacturer shall coordinate with motor manufacturer on the design of VFD/Motor combination. Motor manufacturer shall provide documentation confirming that coordination had taken place, a maximum of Four (4) weeks after placement of the order. 1.07

OPERATION AND MAINTENANCE MANUALS

A. Equipment operation and maintenance manuals shall be provided with each assembly shipped, and shall include instruction leaflets and instruction bulletins for the complete assembly and each major component.

PART 2 - PRODUCTS 2.01

MANUFACTURERS

1. Cutler-Hammer 2. ABB 3. Siemens 4. Schneider Electric

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL

The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety. Products in compliance with the specification and manufactured by others not named will be considered only if pre-approved by the Engineer ten (10) days prior to bid date. 2.02

CONSTRUCTION

WHERE SHOWN ON THE DRAWINGS, ADJUSTABLE FREQUENCY DRIVES 1 THROUGH 150 - 600 HP SHALL HAVE THE FOLLOWING FEATURES: THE VFD SHALL BE RATED 480VAC. THE VFD SHALL PROVIDE MICROPROCESSOR-BASED CONTROL FOR THREE-PHASE INDUCTION MOTORS. The VFDs shall be of the Pulse Width Modulated (PWM) design converting the utility input voltage and frequency to a variable voltage and frequency output via a two-step operation. Adjustable Current Source VFDs are not acceptable. Insulated Gate Bipolar Transistors (IGBTs) shall be used in the inverter section. Bipolar Junction Transistors, GTOs or SCRs are not acceptable. The VFDs shall have efficiency at full load and speed that exceeds 95% for VFDs below 15 Hp and 97% for drives 15 Hp and above. The efficiency shall exceed 90% at 50% speed and load. The VFDs shall maintain the line side displacement power factor at no less than 0.96, regardless of speed and load. The VFDs shall have a one (1) minute overload current rating of 150% and a two (2) second overload current rating of 250% for constant torque drives. The VFDs shall have a one (1) minute overload current rating of 110% for variable torque drives. The VFDs shall be capable of operating of operating any NEMA design B squirrel cage induction motor, regardless of manufacturer, with a horsepower and current rating within the capacity of the VFD. The VFDs shall have a 3% nominal impedance integral AC three-phase line reactor. DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL

The VFDs shall be able to start into a spinning motor. The VFDs shall be able to determine the motor speed in any direction and resume operation without tripping. If the motor is spinning in the reverse direction, the VFDs shall start into the motor in the reverse direction, bring the motor to a controlled stop, and then accelerate the motor to the preset speed. Standard operating conditions shall be: Incoming power: Three-phase [380] VAC, +10% to -5%, and 60 Hz (+/2 %) power to a fixed potential DC bus level Frequency stability of +/-0.5% for 24 hours with voltage regulation of +/-1% of maximum rated output voltage Speed regulation of +/- 0.5% of base speed Load inertia dependant carryover (ridethrough) during utility loss Insensitive to input line rotation Humidity: 0 to 95% (non-condensing and non-corrosive) Altitude: 0 to 3,300 feet (1000 meters) above sea level Ambient temperature: -10 to 50 degrees C (CT), -10 to 40 degrees C (VT) Storage temperature: -40 to 60 degrees C. Phase unbalance + or -2%. Spikes with a amplitude of 3.0 per unit and duration of 2ms (triangle step). Spike shall be considered an ideal voltage. Continuous but at reduce output power/torque: Input voltage level: -5% to +10% for up to 200ms at reduced power/torque. 2.03 A.

CONTROL FUNCTIONS Frequently accessed VFD programmable parameters shall be adjustable from a digital operator keypad located on the front of the AFD. The VFDs shall have three-line alphanumeric programmable display with status indicators. Keypads must use plain English words for parameters, status, and diagnostic messages. Alphanumeric codes and tables are not acceptable.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL B.

Standard advanced programming and troubleshooting functions shall be available by using a personal computer’s RS-232 port and Windows® based software. In addition the software shall permit control and monitoring via the VFD’s RS232 port. The manufacturer shall supply the required software.

C.

The operator shall be able to scroll through the keypad menu to choose between the following: 1. Monitor 2. Operate 3. Parameter setup 4. Actual parameter values 5. Active faults 6. Fault history 7. LCD contrast adjustment 8. Information to indicate the standard software and optional features software loaded.

The following setups and adjustments, at a minimum, are to be available: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 2.04

Start/stop command from keypad, remote or communications port Speed command from keypad, remote or communications port Motor rotation selection Maximum and minimum speed limits Acceleration and deceleration times, two settable ranges Critical (skip) frequency avoidance Torque limit Multiple attempt restart function Multiple preset speeds adjustment Catch a spinning motor start or normal start selection Programmable analog output DC brake current magnitude and time Proportional/integral process controller.

SYSTEM INTERFACES: Inputs – A minimum of six (6) programmable digital inputs, two (2) analog inputs and serial communications interface shall be provided with the following available as a minimum: 1. 2.

DISCIPLINE: ELECTRICAL

Remote manual/auto Remote start/stop DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL 3. 4. 5. 6. 7. 8. 9. 10.

Remote forward/reverse Remote preset speeds Remote external trip Remote fault reset Process control speed reference interface, 4-20 mAdc Potentiometer and 1-10V DC speed reference interface RS232 programming and operation interface port Serial communications port.

Outputs – A minimum of two (2) discrete programmable digital outputs, one (1) programmable open collector output, and one (1) programmable analog output shall be provided, with the following available at minimum. Programmable relay outputs with one (1) set of Form C contacts for each, selectable with the following available at minimum: a.

Fault

b.

Run

c.

Ready

d.

Reversing

e.

Jogging

f.

At speed

g.

In torque limit

h.

Motor rotation direction opposite of commanded

i.

Overtemperature.

Programmable open collector output with available 24V DC power supply and selectable with the following available at minimum: a. Fault b. Run c. Ready d. Reversing e. Jogging f.

At speed

g. In torque limit DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL

h. Motor rotation direction opposite of commanded i.

Overtemperature.

Programmable analog output signal, selectable with the following available at minimum: a) Output current b) Output frequency c) Motor speed d) Motor torque e) Motor power f)

Motor voltage

g) DC link voltage. 2.05

MONITORING AND DISPLAYS The VFD’s display shall be a LCD type capable of displaying three (3) lines of text and the following thirteen (13) status indicators: a) Run b) Forward c) Reverse d) Stop e) Ready f)

Alarm

g) Fault h) Local i)

Panel

j)

Remote

k) Hand l)

Auto

m) Off. The VFD’s display shall be capable of displaying the following monitoring functions at a minimum:

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL 1. Output frequency 2. Output speed 3. Motor current 4. Motor torque 5. Motor power 6. Motor voltage 7. DC-link voltage 8. Heatsink temperature

9. Total operating days counter 10. Operating hours (resettable) 11. Total megawatt hours 12. Megawatt hours (resettable) 13. Voltage level of analog input 14. Current level of analog input 15. Digital inputs status 16. Digital and relay outputs status 17. Motor temperature rise, percentage of allowable.

C.

Protective Functions The VFD shall include the following protective features at minimum: a) Over-voltage b) Inverter fault c) Under-voltage d) Phase loss e) Output phase loss f)

Under-temperature

g) Over-temperature h) Motor stalled

DISCIPLINE: ELECTRICAL

i)

Motor over-temperature

j)

Motor under-load

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL

k) Logic voltage failure l)

Microprocessor failure

m) DC injection braking. The AFD shall provide ground fault protection during power-up, starting, and running. AFDs with no ground fault protection during running are not acceptable.

Diagnostic Features Fault History Record and log faults. Indicate the most recent first, and store up to 9 faults. OPTIONS Optional features to be included in the AFDs: (choose appropriate features) 1.

HMCP or thermal-magnetic breaker to provide a disconnect means. Operating handle shall protrude from the door. The disconnect shall not be mounted on the door. The handle position shall indicate ON, OFF, and TRIPPED condition. The handle shall have provisions for padlocking in the OFF position with at least three (3) padlocks. Interlocks shall prevent unauthorized opening or closing of the AFD door with the disconnect handle in the ON position. This shall be defeatable by maintenance personnel.

2. Provide motor dv/dt filter, as described below, for use on motor cable runs exceeding 100 feet. The dv/dt filter shall be located at the AFD and shall reduce the dv/dt clamp any voltage overshoots of the AFD output. It will return the energy in the voltage overshoots to the AFDs DC bus. A power dissipative resistance device is not acceptable. Filter shall be a Cutler-Hammer MotoRX 1000 volt per microsecond type for motor leads between 100 and 300 feet and 1000 volt per microsecond type for motor leads between 300 and 600 feet. Output line reactors are not acceptable for any motor lead lengths. AC input line current limiting fuses shall provide a means of disconnecting the AFD from the line under fault conditions. Three contactor bypass shall include a drive input disconnect, an AFD input isolation contactor, bypass contactor and an AFD output contactor that is electrically and mechanically interlocked with the bypass contactor. DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL

This circuit shall include control logic, status lights and motor overcurrent relays. The complete bypass system Hand-Off-Auto with Inverter-Bypass selector switch(s), and inverter/bypass pilot lights shall be packaged with the AFD. The unit may be set up for 1[manual] [automatic] bypass operation upon an AFD trip. AC output contactor to provide a means for positive disconnection of the drive output from the motor terminals Fused space heaters with thermostat to operate when drive is shut down. Laminated plastic or steel nameplate engraved with user’s identifying name or number. Pneumatic process follower allowing motor speed control proportional to a 3-15 PSIG pneumatic signal. 120V AC control to allow AFD to interface with remote dry contacts. Motor overcurrent relay to provide motor overcurrent sensing of a given level of load current. Input isolation transformers, separately mounted, with NEMA 1 enclosure. Dynamic braking control circuitry shall be provided to decelerate the motor faster than the internal losses can absorb. Dynamic braking shall cause an optional resistor bank, when specified, to be switched onto the DC link as required to absorb the regenerative energy. This shall allow the fastest controlled deceleration and/or stop without an overvoltage condition. The resistor bank, when specified, shall be located external to the drive enclosure to prevent overheating of the drive. Resistor bank for dynamic braking load rated for [100] percent braking torque for a [50] percent duty cycle based on a sixty-second cycle time Graphical keypad The operator interface shall consist of a LCD keypad located on the front of the AFD. Features shall include: DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL

Twelve (12) pushbuttons for selection, display, and modification of the AFD characteristics as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Scroll left Scroll right Scroll up/increase Scroll down/decrease Parameter Monitor Page Operate Enter Reset Start Stop.

The keypad LCD panel shall provide a choice of eight (8) lines of text or a 64x128 pixel graphical display of key waveforms or a combination of both. The operator shall be able to scroll through the keypad menu to choose between the following screens: 1. Monitor 2. Operate 3. Parameter setup 4. Actual parameter values 5. Operating parameter trends 6. Menu for selection of parameters for graphical trend display 7. Active faults 8. Fault history 9. LCD adjustment 10. Info/files selection to indicate the standard software and optional features software loaded. Communication card for interface with (Johnson N2) (Modbus RTU) (DeviceNet) (Interbus-S) (Profibus-DP) (Lonworks) (IMPAAC/PowerNet) (FLN -- Floor Level Network) control system. Provide an input EMI filter to minimize conducted electrical noise to meet the requirements of IEC 61800-3. DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL 2.06

SPARE PARTS A spare main logic board, keypad and power supply board shall be supplied for each different type of drive supplied under this specification.

2.07

ENCLOSURE The AFD enclosure shall be NEMA 1 and shall be install as part of MCC.The AFD shall have complete front accessibility with easily removable assemblies.

PART 3 - EXECUTION 3.01

FACTORY TESTING The following standard factory tests shall be performed on the equipment provided under this section. All tests shall be in accordance with the latest version of UL and NEMA standards. All final assemblies shall be tested at full load with application of line-to-line and line-to-ground bolted faults. The adjustable frequency drive shall trip electronically without device failure. After all tests have been performed, each AFD shall undergo a burn-in test. The drive shall be burned in at 100% inductive or motor load without an unscheduled shutdown. After the burn-in cycle is complete, each AFD shall be put through a motor load test before inspection and shipping. The manufacturer shall provide three (3) certified copies of factory test reports.

3.02

FIELD QUALITY CONTROL Provide the services of a qualified manufacturer’s employed Factory Authorized Field Service Engineer to assist the Contractor in installation and start-up of the equipment specified under this section. Sales representatives will not be acceptable to perform this work. The manufacturer’s service representative shall provide technical direction and assistance to the Contractor in general assembly of the equipment, installation as specified in manufacturer’s installation instructions, wiring, application dependant adjustments, and verification of proper AFD operation. The following minimum work shall be performed by the Contractor under the technical direction of the manufacturer’s service representative:

DISCIPLINE: ELECTRICAL

1.

Inspection and final adjustments

2.

Operational and functional checks of AFDs and spare parts

3.

The contractor shall certify that he has read the drive manufacturer’s installation instructions and has installed the AFD in accordance with those instructions. DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16483 VARIABLE FREQUENCY DRIVE

DIVISION 16 ELECTRICAL

The Contractor shall provide three (3) copies of the manufacturer’s field startup report before final payment is made. 3.03

MANUFACTURER’S CERTIFICATION A qualified factory-trained manufacturer’s representative shall certify in writing that the equipment has been installed, adjusted and tested in accordance with the manufacturer’s recommendations. The Contractor shall provide three (3) copies of the manufacturer’s representative’s certification.

3.04

TRAINING The manufacturer’s qualified representative shall conduct the training. The training program shall consist of the following:

3.05

1.

Instructions on the proper operation of the equipment

2.

Instructions on the proper maintenance of the equipment.

HARMONIC STUDY The AFD manufacturer shall perform harmonic measurements at the point where the utility feeds multiple customers (PCC) to verify compliance with IEEE5191992. A report of the voltage THD and current TDD shall be sent to the Engineer. The contractor shall provide labor, material, and protection as needed to access the test points. The readings shall be taken with all drives and all other loads at full load, or as close as field conditions allow. - END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL WORKS SECTION 16512 OUTDOOR LIGHTING

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

Discipline: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE Page 1 of 12

REMARKS

DIVISION 16 ELECTRICAL WORKS

SECTION 16512 OUTDOOR LIGHTING

SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04

Scope Codes and Standards Submittals Environmental Condition

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05 2.06

Componenets and Equipments Tagging Units and Scales Description of Lighting System Rated Design Data Special Requirements

PART 3 3.01 3.02 3.03 3.04 3.05 3.06

EXECUTION Construction Requirements Installation Test Documentation Shipping Spare Parts and Special Tools

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS

SECTION 16512 OUTDOOR LIGHTING

PART 1 - GENERAL 1.01

Scope This specification covers the technical requirements for design, manufacturing, construction, installation and test of the outdoor lighting within the station areas for the Transportation of Treated Water from Taif STP to Ma’aden Gold mines.

1.02

Codes and Standards The design, manufacturing, construction, installation, test and commissioning of outdoor lighting shall be in accordance with the following codes and standards, at least. The latest revision of the publication referred to shall apply. IEC 60085

Thermal evaluation and classification of electrical insulation

IEC 60364

Electrical installation of buildings

IEC 60529

Degrees of protection provided by enclosures (IP Code)

IEC 60598

Luminaires

IEC 60621

Electrical installations for outdoor sites under heavy conditions

IEC 60664

Insulation coordination for equipment within low-voltage systems

HCISS

Security and safety directives (High Commission for Industrial Security and Safety)

SSD 13

Security Lighting Systems

As far as the power supply authority (SEC) or permits of other authorities require additional codes and standards, respectively impose additional requirements, these are also part of the contract. 1.03

Submittals Forward to the Company Representative for review and approval the following submittals. Refer also to appropriate specification sections for other submittal requirements. A.

General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

B.

Prior to Commencing WORK: Shop drawings of proposed installations that deviate from the original design.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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DIVISION 16 ELECTRICAL WORKS C.

SECTION 16512 OUTDOOR LIGHTING

Prior to Final Acceptance: Record documents which shall indicate installed conditions for: 1.

Major raceways systems, size and location, for both exterior and interior; locations of control devices; distribution and branch electrical circuitry; fuse and circuit breaker size and arrangements.

2.

Equipment locations (exposed and concealed), dimensioned from prominent building lines.

3.

D.

1.04

Approved substitutions, modifications and actual equipment and materials installed. Maintenance Manuals: Submit maintenance manuals which shall include the following information for equipment items: 1.

Description of function, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of replacement parts.

2.

Manufacturer's printed operating procedures to include start- up, break-in, and routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; and summer and winter operating instructions.

3.

Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

4.

Servicing instructions and lubrication charts and schedules.

Environmental Conditions The outdoor lighting shall be suitable for continuous operation at rated load under the climatic and environmental conditions defined in the specification “Basic Electrical Requirements”. The various equipments shall be appropriate for outdoor installation.

PART 2 – PRODUCTS 2.01

Components and Equipment The Contractor has to take care that all components and equipment are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals. All components and equipment shall be designed for continuous duty at rated load and under the given climatic conditions. Standard industrial high performance systems and components

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16512 OUTDOOR LIGHTING

of supplier’s standard lists shall be used as far as possible. Components and equipment of same kind and type shall be selected for equivalent functions. 2.02

Tagging All components, equipment and installations shall receive the respective tagging plates, labels, etc., which have to be of extremely durable material resistant against the environmental conditions. Tagging plates or labels on fronts of enclosures shall be fixed with screws. For further requirements, reference is made to the specification “Design and Construction of Power Supply Systems”.

2.03

Units and Scales The metric system on basis of SI-units shall be used for all scales and indications.

2.04

Description of Lighting Systems For the purpose of illumination at outdoor areas within stations, the lighting system shall be divided into the following lighting sub-systems: Station area lighting The station area lighting will be provided for all above ground, non sheltered industrial areas of a station, where operation and maintenance during night could be necessary. The lighting shall mainly consist of flood light and street light fixtures, equipped with high pressure discharge lamps mounted on poles and if necessary, with street lighting or build on fixtures, equipped with fluorescent lamps mounted on poles or structures. As far as possible, the maximum horizontal illumination levels of the lighting shall be near the equipment, which must be controlled and operated. Road/street and parking area lighting The road/street and parking area lighting will be provided for all maintenance roads, traffic areas and parking areas. The lighting shall mainly consist of pole mounted street lighting fixtures, equipped with high pressure discharge lamps. The maximum horizontal illumination level of the lighting shall be in the middle (axis) of the roads and parking areas, respectively. Entrance lighting The entrance lighting will be provided for all doors and gates of industrial and non industrial buildings.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16512 OUTDOOR LIGHTING

The entrance lighting shall mainly consist of wall mounted lighting fixtures, equipped with fluorescent lamps. Fence lighting The fence lighting will be provided for the border fences of stations. The fence lighting shall mainly consist of pole mounted flood light fixtures, equipped with high pressure discharge lamps. The poles of fence lighting have to be installed inside the fence. Distance, number of poles, illumination level and the design of the devices of fence lighting must be in accordance with the HCISS and SSD 13 requirements. 2.05

Rated Design Data The outdoor lighting shall be designed on basis of the following minimum requirements: a)

Average of illumination levels (Em) • • • • •

Station areas 30 lx, Roads, streets 10 - 12 lx, Parking areas 10 lx, Entrances 50 lx, Fences 5 – 10 lx or other values, if required by HCISS.

b) Uniformity of illumination levels • • • •

Station areas 1 : 3, Roads, streets 1 : 6, Parking areas 1 : 6, Fences 1: 5.

The uniformity of illumination levels means the ratio between the lowest and the highest measured horizontal illumination level in the reference area. The outdoor lighting shall be fed with a voltage of 3 x 480/230 V, 60 Hz, or with other voltages if supplied from existing switchboards (extension of existing stations). 2.06

Special Requirements The Vendor/Manufacturer shall have local representative in Saudi Arabia and shall have maintenance team available with minimum five years of experience to attend any maintenance issues.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16512 OUTDOOR LIGHTING

PART 3 - EXECUTION 3.01

Construction Requirements General The outdoor lighting shall be supplied from a common outdoor lighting panel, which shall be placed indoor. To minimize the cable lengths, the mentioned panel should be installed at a central location. If necessary for large areas, a second panel shall be used. The entrance lighting may be fed via the distribution panel of electrical building installation of the respective building. The outdoor lighting panels shall be provided with a main conductor, controlled via photocell/twilight switch. The panels shall be equipped with a sufficient number of 3-phase circuits (including 20 % spare circuits), which shall be fused in maximum with 16 A miniature circuit breakers (B-characteristic). The load on each of the circuits should not exceed 4 kW. Each lighting circuit shall be provided with a manual override to allow the operation from the outdoor lighting panel. The operation elements shall be located behind the hinged door(s) of the panel. The different kinds of outdoor lighting shall be supplied via separate circuits that mean the supplies for station area lighting, road/street lighting, entrance lighting and fence lighting shall not be mixed. As mentioned above, the main supply for outdoor lighting circuits shall be 400 V AC. To arrive the lighting supply voltage of 230 V AC, each lighting pole will be equipped with an inside located fuse box and for entrances the lighting will be divided into three 1-phase circuits by means of a main junction box. If the entrance lighting will be fed from the distribution panel of electrical building installation, the supply can be provided via a 230 V AC single-phase circuit with contactor, photocell/twilight switch and manual override per building. The load on these circuits should not exceed 1 kW. If the outdoor lighting will be installed as an extension of an existing outdoor lighting system, the new poles, towers, lighting fixtures and as well the arrangement of the new outdoor lighting system part shall be according to the existing facilities. Lighting Poles Poles for Flood Light Flood light poles shall be provided as conical columns, fabricated from hot dip galvanised steel. The height of the poles shall be between 10 and 20 m. The poles shall be equipped with the following accessories: •

Flange plate (hot dip galvanized steel) with 4 to 6 slots including stud bolts and screws, which allow also the adjustment of the pole, • Brackets or platform for installation up to six flood light fixtures, • Fix mounted, hot dip galvanized steel ladder to the brackets/platform with protection grid, DICIPLENE: ELECTRICAL DOCUMENT No.: MGBM-SPEC-0001 Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS • • • •

SECTION 16512 OUTDOOR LIGHTING

Door opening with cover in the lower part of the pole, Fuse/terminal box (IP44), mounted within the pole, Internal wiring from fuse/terminal box to fixtures, Identification label with pole number (stainless steel).

The cable entry shall be provided with PE conduits, running through the foundation of the pole. Poles for Street Light Street light poles shall be provided as conical fiberglass columns. The height of the poles shall be 10 m. The poles shall be equipped with the following accessories: • • • • • •

Flange plate (hot dip galvanized steel) with 4 to 6 slots including stud bolts and screws, which allow also the adjustment of the pole, Brackets for installation of one or two street light fixtures, Door opening with cover in the lower part of the pole, Fuse/terminal box (IP44), mounted within the pole, Internal wiring from fuse/terminal box to fixtures, Identification label with pole number (stainless steel).

The cable entry shall be provided with PE conduits, running through the foundation of the pole. Poles for special Applications of Area Light Poles for special applications of area light or light for footpaths shall be provided as conical columns, fabricated from hot dip galvanized steel. The height of the poles shall be between 4 and 6 m. The poles shall be equipped with the following accessories: • • • • • •

Flange plate (hot dip galvanized steel) with 4 slots including stud bolts and screws, which allow also the adjustment of the pole, Bracket/cross arm for installation of one or two fixtures with fluorescent lamps (luminary incline 15°), Door opening with cover in the lower part of the pole, Fuse/terminal box, mounted within the pole, Internal wiring from fuse/terminal box to fixtures, Identification label with pole number (stainless steel).

The cable entry shall be provided with PE conduits, running through the foundation of the pole.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16512 OUTDOOR LIGHTING

Lighting Fixtures Flood Light Fixture The flood light fixtures shall consist of the following main parts: • • • • • • •

High pressure die-cast aluminium body and front cover frame, polyester powder coated (IP65), Electro polished, anodized and sealed aluminium reflector, Lamp holder with adjustable for centralizing the lamp within the fixture, toughened front glass, hinged front cover, integral gear with capacitor, Galvanized steel stirrup with protractor for setting of elevation angle.

The flood light fixtures shall be equipped with high pressure mercury vapour lamps or high pressure sodium vapour lamps with sufficient wattage. For sodium vapour lamps only types shall be used, which have a quality of color reproduction equal to mercury vapour lamps (yellow light will not be accepted). The fixtures shall be specially protected against damage in case of sandstorms.

Street Light Fixture The street light fixtures shall consist of the following main parts: • • • • •

high pressure die-cast aluminium canopy, polyester powder coated (IP65), hydro formed, one piece reflector in high purity aluminium, anodized and brightened, high resistant polycarbonate bowl with snap-fit side catches, integral gear with capacitor, Re-positional steel column clamping bracket for post top fixing (angle of inclination 0° to 15°).

The street light fixtures shall be equipped with high pressure mercury vapour lamps or high pressure sodium vapour lamps with sufficient wattage. For sodium vapour lamps only types shall be used, which have a quality of color reproduction equal to mercury vapour lamps (yellow light will not be accepted). The fixtures shall be specially protected against damage in case of sandstorms. Lighting Fixture with Fluorescent Lamps The lighting fixtures with fluorescent lamps shall consist of the following main parts: DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS • • • • •

SECTION 16512 OUTDOOR LIGHTING

 canopy from high resistant glass reinforced polyester (IP54), reflector from polycarbonate, high resistant polycarbonate bowl with snap-fit side catches, integral electronic gear with power factor correction, Steel column bracket for side entry or brackets for wall/structure mounting. The lighting fixtures shall be equipped with fluorescent lamps up to 2 x 58 W. The fixtures shall be specially protected against damage in case of sandstorms. Cables and Grounding The lighting cables shall be three phase single pole connection with single phase. The connection shall take into consideration the load balance on the three phase system. The cross section must be determined according to the current capacities and the voltage drops. The minimum cross section shall be 2.5 mm². Separate grounding connection of the lighting poles and lighting towers with the grounding network shall be provided. The cables and the grounding shall be in accordance with specification “Cables and Cable Laying” and “Earthing and Lightning Protection”, respectively.

3.02

Installation The excavation of the cable trenches and foundation holes for outdoor lighting shall be coordinated with the excavation for cable laying and grounding. For cable laying, cable trenches and grounding see specification “Cables and Cable Laying” and “Earthing and Lightning Protection”, respectively. The erection of the lighting poles and towers including the concrete foundation is part of this specification, the depth and the construction of the concrete foundation must be designed in accordance with the soil conditions and the kind of the lighting pole. Concrete foundations shall be equipped with connection plates and stud bolts for fastening and adjustment of poles. A removable cover shall be provided for these bolts. The electrical connection of the lighting poles to the supply cable must be executed in alternating cycle to guarantee a constant load distribution to the phases. The various outdoor lighting systems must be divided in different lighting circuits.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS 3.03

SECTION 16512 OUTDOOR LIGHTING

Test After erection of the outdoor lighting system all electrical installations shall be tested in accordance with applicable IEC regulations. The horizontal lighting levels shall be checked by the Contractor in the presence of the Client. The test results of the lighting level measurements shall be recorded in a respective report by the Contractor. The checking method shall be worked out by the contractor prior to tests and shall be subject to the Client's approval. The aim of the tests is to ensure the proper function of the complete scope.

3.04

Documentation Complete documentation shall be provided for the design, manufacturing, testing, commissioning, start-up, operation, maintenance and repair of the outdoor lighting and its components. The documentation shall be in English language. The final documentation of outdoor lighting shall at least include the following documents and drawings (minimum requirements): a) Technical data sheets, b) Leaflets of devices, c) Layout drawings, d) Circuit diagrams, e) Wiring diagrams, f) Termination drawings, g) Cable lists, h) Calculation of illumination levels, i) Calculation of stability for poles, j) List of used devices with manufacturer, k) Spare parts list, l) Operation and maintenance manuals, m) Reports of tests and commissioning with protocols. The documents listed above shall be handed over for approval. Special attention has to be given to the fact, that documentation must be submitted with sufficient time allocated for approval prior to manufacturing /assembly. The documentation has to be prepared in accordance with the relevant ISO standards.

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORKS

SECTION 16512 OUTDOOR LIGHTING

The final documentation shall be delivered on paper in sufficient number and with exception of the signed protocols in electronic form, also. The type of the electronic files and the number of copies shall be agreed with the Client. 3.05

Shipping All equipment, material and spare parts shall be sufficient packaged. The material, especially loose parts and spare parts shall be clearly labeled according to the designation.

3.06

Spare Parts and Special Tools The Contractor shall deliver all spare parts, which are necessary for commissioning and two years operation time (see “General Description for Project and Works”). Spare parts shall be available until ten years after commissioning. The following spare parts and special tools shall be supplied: • • •

special tools for maintenance, spare fuses, spare lamps and lighting fixtures in sufficient number for commissioning and two years operation, one mobile hydraulic operated lifting platform for each major station, in order to reach the lighting fixtures at the poles.

- END OF SECTION -

DICIPLENE: ELECTRICAL Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16530 SITE LIGHTINGS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16530 SITE LIGHTINGS

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08

Section Includes Coordination Related Sections References Quality Assrence Submittals Delivery, Storage and handling Testing

PART 2

PRODUCTS

2.01

Lighting Fixtures

PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09

EXECUTION Installation Grounding Pole Standards Concrete Pads Tests Adjustment Adjustment and Cleaning Final Acceptance Manufacturer

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16530 SITE LIGHTINGS

DIVISION 16 ELECTRICAL

PART 1 - GENERAL 1.01

1.02

SECTION INCLUDES A.

This section of the specifications covers the furnishing of all labor and materials for a complete area lighting system.

B.

The work to be performed consists of the installation of pole standards, lighting fixtures, lighting controls, secondary power distribution, including conduit work, complete as indicated on drawings and as hereinafter specified.

COORDINATION A.

1.03

Determine the work to be performed by the building contractors and other trades throughout. Provide the type and amount of materials and equipment necessary to place this work in proper operation, completely installed, wired, tested, and ready for use.

RELATED SECTIONS Furnish and install related work and materials in strict accordance with the following sections of this specification:

A.

1.04

Section 16010

Basic Electrical requirements.

B.

Section 16110

Raceways

C.

Section 16120

Wires and Cables

D.

Section 16195

Electrical Identification

E.

Section 16452

Grounding and Bonding.

F.

Section 16470

Panelboards.

REFERENCES A.

Except as modified by this Specification, conform to the applicable provisions and recommendations of the following standards: 1.

SAUDI Electricity Standards specifically: a.

DISCIPLINE: ELECTRICAL

TES-P-119.25

DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16530 SITE LIGHTINGS

DIVISION 16 ELECTRICAL

1.05

1.07

3.

National Electrical Manufacturers Assoc. (NEMA).

4.

National Fire Protection Assoc. (NFPA).

5.

American National Standards Institute (ANSI).

6.

Underwriters Laboratories (UL).

7.

Institute of Electrical & Electronics Engineers (IEEE).

8.

Occupational Safety & Health Act (OSHA).

9.

All Govt. Laws, Ordinances and Regulations.

Provide manufacturer's certificate or furnish such evidences as necessary to Client to assure that materials meet or exceed minimum requirements as specified.

SUBMITTALS A.

Before starting installation of any materials or equipment, submit for approval a complete list of materials and equipment to be incorporated in the work. This list shall include catalog numbers, cuts, data sheets, and such other descriptive information as may be required. No consideration will be given to partial lists submitted from time to time. Approval of materials will be based on manufacturer's published data, installation and roughing-in data sheets and drawings indicating compliance with the Contract documents.

B.

Submittals shall be submitted within three (3) weeks after the contract start date.

C.

All metric substitutes for Schedule 40 and 80 conduit and fittings shall be submitted for approval three (3) week after the contract start date.

DELIVERY, STORAGE AND HANDLING A.

1.08

National Electrical Code (NEC).

QUALITY ASSURANCE A.

1.06

2.

Protect all materials and equipment from damage during handling and storage. Refer to specifications Section 16010 - "Basic Electrical Requirements" for complete work scope.

TESTING A.

Before shipment, each piece of equipment shall be tested to insure proper operation and conformance with manufacturer's published specifications. Notification of completion of testing shall be sent to the Client Representative.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16530 SITE LIGHTINGS

DIVISION 16 ELECTRICAL

PART 2 - PRODUCTS 2.01

LIGHTING FIXTURES A.

Refer to lighting fixture schedule.

PART 3 - EXECUTION 3.01

INSTALLATION A.

Coordination: Coordinate all work with other crafts and other utilities and construction items of project. Determine in advance of trenching the location and the depth of other utilities and structures in order to determine possible conflict, to prevent damage, and whether they can be passed with proper clearance.

B.

Trench Excavation and Backfilling: Shall be in accordance with Section -Earthwork, General. Sand bedding shall be as shown on the drawings. Place precast red concrete planks in backfill as shown on the drawings.

C.

Underground Secondary: To be installed in PVC conduit of sizes indicated. Cap or plug conduit ends during construction. Before any wire is pulled in a conduit, pull thru the conduit a mandrel 1/4 inch smaller in diameter than the I.D. of the conduit; then swab thoroughly with a stiff brush. Use factory elbows where possible. Make necessary field bends as recommended by the pipe manufacturer. Do not install any conduit that has been flattened in bending. PVC conduit must transit to rigid steel, PVC coated conduit before emerging above grade. Accessible ends shall support a grounded bushing and shall be bonded to equipment grounding system.

D.

Above Ground wiring shall be installed in rigid galvanized steel conduit PVC coated.

E.

Bond conduits throughout to form an electrically continuous system.

F.

Install conduit vertically or horizontally or parallel to supporting structure. Make field bends and offsets uniform and symmetrical without flattening. All field bends shall be of approved code radius. Use factory elbows wherever possible, of the approved allowable radius for conductor applicable.

G.

Joint conduit with couplings and fittings. All conduit shall be watertight, apply red lead to the male thread. No running threads will be allowed. Do not remove the galvanized coating with excessive threads. Install conduits, fittings and cast boxes in a manner to prevent moisture from entering the conduit system cap or plug conduit ends during construction. Clean conduits after installation with a mandrel and wire brush prior to pulling conductors.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16530 SITE LIGHTINGS

DIVISION 16 ELECTRICAL

3.02

GROUNDING A.

3.03

POLE STANDARDS A.

3.04

3.08

Perform all tests required. Test shall be performed in the presence of the Client Representative.

ADJUSTMENT AND CLEANING A.

3.07

Provide concrete pads in accordance with TES-P-1119.25. Pole standard size and details shown on the drawings. Support rebar shall be incorporated into the concrete pad pour.

TESTS A.

3.06

Install all pole standards in strict accordance with TES-P-119.25 and the manufacturer's recommendations. All pole standards shall be plumb with lighting fixtures.

CONCRETE PADS A.

3.05

All steel conduit, poles and metal equipment housings including light fixtures shall be effectively and permanently grounded in strict accordance with the National Electrical Code and as shown on the drawings. Conduit shall not be used as an equipment ground path.

Repair damage to building, piping or equipment. During Progress of work, maintain job in orderly condition. At completion of work, remove excess debris and materials.

FINAL ACCEPTANCE A.

No work shall be accepted until it has the approval of the Client Representative as being in accordance with this Specification and the Drawings.

B.

It shall be the responsibility of the contractor to provide "as-built" drawings prior to final acceptance of the project.

MANUFACTURER A.

The above named manufacturers are only for general conformance with the design concept. Equal approved lighting and poles are acceptable, providing, all evidence required to support this contention is in accordance with these specifications.

- END OF SECTION DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16535 EMERGENCY LIGHTING

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

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SECTION 16535 EMERGENCY LIGHTING

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05

Description of Work Quality Assurence Submittals Delivery, Storage and Handling Extra Materials

PART 2

PRODUCTS

2.01 2.02 2.03

Manufacturers Emergency Light Set, Exist Light Emergency Flourecent Power Supply

PART 3 3.01 3.02 3.03 3.04

EXECUTION Installation Adjusting and Cleaning Grounding Feild quality Control

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16535 EMERGENCY LIGHTING

DIVISION 16 ELECTRICAL PART 1 - GENERAL 1.01

DESCRIPTION OF WORK A.

This Section includes emergency light sets, exit fixtures with integral emergency battery backup, and emergency fluorescent fixture power supplies with integral battery backup.

B.

Related Sections: Section:

The following Section contain requirements that relate to this

Division 16 Section "Interior Lighting Fixtures" for regular fixtures that may be connected to emergency circuits to provide emergency lighting. 1.02

1.03

QUALITY ASSURANCE A.

Electrical Component Standard: Components and installation shall comply with NFPA 70 "National Electrical Code."

B.

UL Compliance: Emergency lighting fixtures shall be UL listed and labeled.

C.

NFPA Compliance: Comply with applicable requirements of NFPA 99, "Health Care Facilities" and NFPA 101, "Life Safety Code."

D.

Local Code Compliance: Comply with applicable local codes and regulations for emergency lighting and exit signage including, but not limited to, colors and letter heights for exit signs.

SUBMITTALS A.

Product data for each type of emergency lighting unit specified. Assemble in booklet form with separate sheet for each fixture, arranged in unit "type," alphabetical, or numerical order, with proposed fixture and accessories clearly indicated on each sheet.

B.

Samples of specific individual products for approval where indicated.

C.

Maintenance data for units specified, for inclusion in Operating and Maintenance Manual specified in Division 1 and in Division 16 Section "Basic Electrical Requirements." Submit complete manual material concurrently with system submittal and updated final versions of manuals with closeout procedures specified in Division 1 Section "Project Closeout."

D.

Installation instructions written by manufacturers for all specified products.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16535 EMERGENCY LIGHTING

DIVISION 16 ELECTRICAL 1.04

DELIVERY, STORAGE, AND HANDLING A.

1.05

Deliver products in factory containers. Store in clean, dry space in original container. Protect products from fumes and construction traffic.

EXTRA MATERIALS A.

Furnish stock of replacement lamps amounting to 15 percent (but not less than one lamp in each case) of each type and size lamp used in each type unit.

PART 2 - PRODUCTS 2.01

MANUFACTURERS A.

Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the Work include but are not limited to the following:

B.

Manufacturers: Subject to compliance with requirements, provide products by the following: 1.

Chloride Systems Cooper Industries, Inc. Dual-Lite, Inc. Emergi-Lite, Inc. Fulton Industries Halo Lighting Holophane Lighting Hubbell, Inc. Legion Lighting Co., Inc. Lightalarms Electronics Corp. Lithonia Lighting L.P.I., Inc. Mule Emergency Lighting, Inc. Siltron Illumination, Inc. Thomas Industries, Inc.

2.02

EMERGENCY LIGHT SET, EXIT SIGN A.

Self-contained, a.c. battery-illuminated exit sign unit, universal mounting with downlight. 1.

Lamps: Manufacturer's standard, furnished with unit. Style, shape, trim, material, finish, and arrangement of housing as indicated.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16535 EMERGENCY LIGHTING

DIVISION 16 ELECTRICAL

2.03

2.

Faceplate: High-impact, UL 94 V-O rated, plastic with snap- out arrows and color of letters as indicated.

3.

Mounting provisions shall suit individual installation conditions. Sealed, maintenance-free, lead-acid type, with 10- year nominal life.

4.

Charger: Minimum 2-rate, fully automatic, solid-state type, with sealed transfer relay.

5.

Finish: Matte white for exposed parts, or as indicated.

6.

Operation: Sign is illuminated by a.c.-powered lamps under normal conditions. Relay turns emergency lamps on automatically when supply circuit voltage drops to 80 percent of nominal or below. Lamps operate for duration of outage, up to 1.5 hours. Lamps automatically disconnect from battery when voltage approaches deep-discharge value. When normal voltage is restored, a.c.-powered lamps are relighted and d.c. lamps are switched off. Battery is automatically recharged within 16 hours and maintained on trickle charge.

Battery:

EMERGENCY FLUORESCENT POWER SUPPLY A.

B.

Internal Type: For designated fluorescent fixtures, provided under Division 16 Section "Lighting Fixtures," provide internal self-contained, modular, battery-inverter unit, factory mounted within the fixture body. 1.

Arrange unit with test switch and LED indicator light, visible and accessible without opening fixture or entering ceiling space.

2.

Battery: Sealed, maintenance-free, nickel-cadmium type, with normal 10-year life, minimum.

3.

Charger: Fully automatic, solid-state, constant-current type.

4.

Operation: Relay turns two lamps on automatically when supply circuit voltage drops to 80 percent of nominal or below. Lamps operate for duration of outage, up to 1.5 hours. When normal voltage is restored, battery is automatically recharged.

External Type: For designated fluorescent fixtures, provided under Division 16 Section "Lighting Fixtures," provide external self-contained, modular, battery-inverter unit. 1.

Arrange unit with test switch and LED indicator light, visible and accessible without entering ceiling space.

2.

Battery: Sealed, maintenance-free, nickel-cadmium type, with normal 10-year life, minimum.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16535 EMERGENCY LIGHTING

DIVISION 16 ELECTRICAL

3.

Charger: Fully automatic, solid-state, constant-current type.

4.

Operation: Relay turns two lamps of associate fixture on automatically when supply circuit voltage drops to 80 percent of nominal or below. Lamps operate for duration of outage, up to 1.5 hours. When normal voltage is restored, battery is automatically recharged.

PART 3 - EXECUTION 3.01

3.02

3.03

INSTALLATION A.

Setting and Securing: Set units plumb, square, and level with ceiling and walls and secure in accordance with manufacturer's written instructions and approved shop drawings. Conform to the requirements of NFPA 70.

B.

Mounting heights specified or indicated are to bottom of fixture for suspended or ceiling-mounted fixtures and to center of fixture for wall-mounted fixtures.

C.

Support: Recessed and semi recessed fixtures may be supported from suspended ceiling support system if the ceiling system support rods or wires are installed at a minimum of four rods or wires per fixture and located not more than 6 inches from fixture corners. For fixtures smaller than the ceiling grid, install a minimum of four rods or wires per fixture and locate at corner of the ceiling grid in which the fixture is located. Do not support fixtures by ceiling acoustical panels. Where fixtures smaller than the ceiling grid are indicated to be centered in the acoustical panel, support fixtures independently with at least two 3/4-inch metal channels spanning and secured to the ceiling tees. Rods or wires for Section "Acoustical Treatment." Install support clips for recessed fixtures, securely fastened to ceiling grid members, at or near each fixture corner.

D.

Lamping and Connection: Lamp units in accordance with manufacturer's instructions. Make external wiring connections required for proper functioning.

E.

Coordinate with other electrical installations as appropriate for proper installation of emergency lighting fixtures.

ADJUSTING AND CLEANING A.

Clean emergency units light set upon completion of installation.

B.

Adjust aimable fixtures to provide light intensities in egress paths.

GROUNDING A.

Ground non-current-carrying parts of equipment. Where the copper grounding conductor is connected to a metal other than copper, provide specially treated or lined connectors suitable for this purpose.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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Page 6 of 7

SECTION 16535 EMERGENCY LIGHTING

DIVISION 16 ELECTRICAL A. 3.04

Tighten grounding connections to comply with tightening torques specified in UL Standard 486A.

FIELD QUALITY CONTROL A.

Tests: After emergency lighting units have been installed and building circuits have been energized with normal power source, apply and interrupt electrical energy to demonstrate proper operation. Remove and replace malfunctioning units with new units and proceed with retesting. Give the Company Representative advance notice of dates and times for all field tests. Provide instruments as required to make positive observation of test results. Include the following in tests: 1.

Duration of supply.

2.

Low battery voltage shutdown. Normal transfer to battery source and retransfer to normal.

3.

Low supply voltage transfer.

B.

Insulation Resistance Test: Perform as specified in Division 16 Section "Wires and Cables" both before and after connection of fixtures and equipment.

C.

Electrical Continuity Tests: Perform as specified in Division 16 Section "Wires and Cables."

D.

Lamp Replacement: Prior to tests, install new lamps in emergency lighting units. After testing, place malfunctioning lamps.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 7 of 7

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 ELECTRICAL SECTION 16721 FIRE ALARM SYSTEMS

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 15/03/2011 RE DATE

DISCIPLINE: ELECTRICAL

Issue for Bid DESCRIPTION

IGA MAM PREPARE CHECKED

MFU APPROVED

REMARKS

DOCUMENT No.: MGBM-SPEC-0001 CONTRACT NO. 10-1448-HQ-715

TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 1 of 8

SECTION 16721 FIRE ALRAM SYSTEMS

DIVISION 16 ELECTRICAL SUBSECTION INDEX

PART 1

GENERAL

1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10

Section Includes Coordination Related Sections References Quality Assurence Submittals System Operation Company Representative Testing Delivery, Storage and Handling

PART 2

PRODUCTS

2.01 2.02 2.03 2.04 2.05

Materials System Devices Enviromental Conditions Indoor Air Conditioned Equipment Electrical Power

PART 3 3.01 3.02

EXECUTION Installation Manufacturer

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

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Page 2 of 8

SECTION 16721 FIRE ALRAM SYSTEMS

DIVISION 16 ELECTRICAL PART 1 -GENERAL 1.01 SECTION INCLUDES A.

The Fire Alarm System shall be a real time monitoring system that shall provide a fire alarming to allow early fire detection. The Fire Alarm System shall accurately locate a fire and shall provide the required directions for an effective fire fighting procedure.

B.

Fire Alarm System shall be analogue type for all buildings.

C.

Fire Alarm detectors, and essential hardware for the fire alarm system shall be procured, installed, and tested by CONTRACTOR.

1.02 COORDINATION A. Determine the work to be performed by the building contractors and other trades throughout. Provide the type and amount of materials and equipment necessary to place this work in proper operation, completely installed, wired, tested, and ready for use. 1.03 RELATED SECTIONS A. Section 15891 Metal Ductwork-low pressure B. Section 16010 Basic Electrical Requirements C. Section 16110 Raceways. D. Section 16120 Wires and Cables E. Section 16195 Electrical Identification G. Section 16452 Grounding And Bonding.

1.04 REFERENCES A. Conform to the applicable provisions and recommendations of the following standards. 1.

National Fire Protection Association (NFPA) STD No. 72.

2.

National Electrical Code (NEC).

3.

National Electrical Manufacturers Association (NEMA).

4.

American National Standards Institute (ANSI).

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

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SECTION 16721 FIRE ALRAM SYSTEMS

DIVISION 16 ELECTRICAL 5.

Underwriters Laboratories (UL).

6.

Occupational Safety and Health Act (OSHA).

7.

All Government Laws, Regulations and Ordinates

1.05 QUALITY ASSURANCE A. The system shall be installed, connected and tested under the supervision of a qualified Contractor and/or Subcontractor normally engaged in this type of work and shall have performed such work for at least the past three years and shall be prepared to furnish such evidence to Client. 1.06 SUBMITTALS A. In compliance with requirements of the contract, submit the following Shop Drawings and catalog cuts where applicable for the Client's review and certification: 1. Catalog Cuts a. Duct mounted smoke detectors(HVAC ducts). b. Visual / audible alarms bells. 2. Shop Drawings a. System wiring schematics. b. Interconnection diagrams. B. In addition to the above, submit operating and maintenance manuals, complete with spare parts list. C. Test Reports: Indicate satisfactory completion of required tests and inspections. D. Manufacturer’s Installation Instructions: Indicate application conditions and limitations of use stipulated by Product testing agency. Include instructions for storage, handling, protection, examination, preparation, installation, and starting of products.

1.07 SYSTEM OPERATION A.

The actuation of automatic initiating device shall cause alarm signals to sound and visual signals to illuminate, from which the device was actuated. The automatic

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 4 of 8

SECTION 16721 FIRE ALRAM SYSTEMS

DIVISION 16 ELECTRICAL

device which initiated the alarm shall be equipped with an indicator fitted into the base or body of the detector. In addition, the duct smoke detector shall deactivate all air input fan units simultaneously via auxiliary relays. 1.08 COMPANY REPRESENTATIVE A.

A company trained representative shall personally supervise the complete installation and final testing of the system. Upon completing of the acceptance tests, the Contractor shall instruct the Client Representative in the proper operation and testing of the system.

1.09 TESTING A.

Before shipment, each piece of equipment shall be tested to insure proper operation and conformance with manufacturer's published specifications. Notification of completion of testing shall be sent to the Client Representative.

1.10 DELIVERY, STORAGE AND HANDLING A.

Protect all materials and equipment from damage during handling and storage. Refer to specification Section 16010 - "Basic Electrical Requirements" for complete work scope.

PART 2 - PRODUCTS 2.01 MATERIALS A.

Contractor shall supply and install a complete and ready-to-use HONEYWELL, PYROTRONICS, SIMPLEX or equivalent system devices as described herein and shown on the drawings. The intent of these specifications is to provide a complete and satisfactorily operating system complete with all equipment and installation materials required, whether or not enumerated herein or shown on the plans. Coordinate with the mechanical plans to insure proper location of smoke duct detectors.

B.

It is the intent of this specification for a single source fire alarm manufacturer to supply all detectors in the system whether they are shown on the electrical or mechanical drawings. Manufacturer is to coordinate any mounting provisions required for his devices with the HVAC equipment supplier finally selected.

C.

Upon completion of system installation and before final inspection, Contractor shall thoroughly check the devices. He shall certify in a letter to Client Representative that each duct smoke detector, have been checked and are as specified, that all items have been prepared and Client Representative has been instructed in the fire alarm system.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16721 FIRE ALRAM SYSTEMS

DIVISION 16 ELECTRICAL

2.02

D.

Upon acceptance of fire alarm system, equipment manufacturer shall assume complete responsibility for replacement of any defective equipment during warranty period of one year at no cost to Client.

E.

Primary power source shall be 120V, 60 Hz as provided on the drawings.

F.

Equipment manufacturer shall furnish wiring diagrams and equipment specification submittals for Client Representative approval prior to installation.

G.

System wiring shall be installed in accordance with this specification and manufacturer's recommendations and shall be run in conduit as required by this specification, sizes as recommended by the equipment manufacturer and in strict accordance with the NEC and SAUDI Electricity Engineering Standards. Systems shall test free from grounds, opens or short circuits. Circuitry shall be Class A supervised system so long as the system operation listed below is met. All wiring to be color coded.

System Devices a.

Duct smoke detectors i.

Ionization duct smoke detectors shall contain a unipolar dual chamber configuration with one reference chamber to compensate for ambient conditions with nominal sensitivity of 1.5%/foot obscuration.

ii.

Each Duct smoke detector shall contain an LED.

iii.

Each duct smoke detector shall contain a magnetically actuated test switch such that it can be tested for the required alarm functionality.

b.

All fire alarm bells/horns shall be UL listed for fire protective service and operated from 120VAC and shall provide an audible/visual indication of fire condition.

c.

General fire alarm should be distinct from any background noise or any signaling device used for other purposes.

d.

General alarm shall provide 92 dB level at 10 feet.

e.

Bell/horn shall include an integral flashing strobe light with white polycarbonate lens and red "FIRE" lettering. The strobe shall be factory wired to operate in unison with the bell/horn and shall produce 800 peak candle power at approximately one flash per second. Bells or/and horns shall be mounted indoor or outdoor as shown on the drawings.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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Page 6 of 8

SECTION 16721 FIRE ALRAM SYSTEMS

DIVISION 16 ELECTRICAL f.

Audible alarm bell shall be mounted as indicated on drawings. Provide single stroke solenoid plunger type, with dull chrome plated gong and bright red finished base suitable for standard 100mm (4") box mounting.

2.03 ENVIRONMENTAL CONDITIONS The system shall be capable of operating continuously when subject to the environmental conditions of the installation Site. 2.04 INDOOR AIR CONDITIONED ENVIRONMENT The temperature range is 10oC to 35oC with a maximum rate of change 0.5C per minute. The relative humidity range is 20% to 80% non condensing. 2.05 ELECTRICAL POWER All electrical equipment shall conform to the National Electrical code, NFPA 70. All equipment shall be capable of operating from 120 VAC with +/- 5 percent variation. PART 3 - EXECUTION 3.01 INSTALLATION A.

Equipment manufacturer shall furnish wiring diagrams and equipment specification submittals for the Client Representative approval prior to installation.

B.

System wiring shall be installed in accordance with this specification and manufacturer's recommendations and shall be run in conduit as required by this specification, sizes as recommended by the equipment manufacturer and test-free grounds, opens or short circuits.

C.

All detector locations shall be reviewed by the Contractor with respect to HVAC equipment and building features to insure that devices will operate properly. Submittals shall include shop drawings indicating any proposed changes in detector locations. C. Upon completion of system installation and before final inspection, Contractor shall thoroughly check the fire alarm system. He shall certify in a letter to the Client Representative that each duct smoke detector, have been checked and are as specified, that all items have been prepared and the Client Representative has been D. Instructed of the operation of the system.

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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SECTION 16721 FIRE ALRAM SYSTEMS

DIVISION 16 ELECTRICAL 3.02 MANUFACTURER A.

The above named manufacturers are only for general conformance with the design concept. Equal approved Fire Detection / Alarm System Equipment are acceptable, providing, all evidence required to support this contention is in accordance with these specifications.

- END OF SECTION -

DISCIPLINE: ELECTRICAL

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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Page 8 of 8

CONSTRUCTION CONTRACTOR’S STAMP:

DESIGN CONSULTANT’S STAMP:

DIVISION 16 SITE WORKS SECTION 16890 FIBER OPTIC CABLE

SAUDI ARABIAN MINING COMPANY KINGDOM OF SAUDI ARABIA

P.O.BOX 684 AL-KHOBAR KINGDOM OF SAUDI ARABIA

IFB ISSUE

00 25/3/2011 RE DATE

Issue for Review DESCRIPTION

DICIPLINE: TELECOMMUNICATION

IGA MAM PREPARE CHECKED

MFU APPROVED

DOCUMENT No.: MGBM-SPEC-0001

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Page 1 of 11

REMARKS

DIVISION 16 ELECTRICAL WORK

PART-1: 1.1

SECTION 16890 FIBER OPTIC CABLE

GENERAL

SCOPE This specification defines the minimum requirements on manufacturing, testing and delivery of the Fiber Optic Cable (FOC). The cable shall serve as the transmission medium for a Fiber Optic Transmission System. The laying of the Fiber Optic Cable, the Conduit and the Transmission System are subject of separate specification Division-16 Section-16890 ”Fiber Optic Cable Conduit and FOC Installation”.

1.2

1.3

RELATED WORK Division-1

General Requirement of Project and Works/Project Execution

MGBM-SOW-0001

Project Description

Section 02210

Excavation, Trenching, Backfilling and Compacting

Section 01400

Quality Control

CODES AND STANDARDS The manufacturing, construction, labeling and testing of the FOC system shall meet the requirements established in the following codes standards and recommendations and in the enclosed data sheet: A. Standards - Fiber Optical Cable (FOC) Optical fiber ITU-T G.652 D IEC 60793-1-1 IEC 60793-2 ITU-T L.10 IEC 60794 -1 IEC 60794 -2 IEC 60794 -3 IEC 60304 IEC-60794-1 (or)

• • • • • • • • •

characteristics of a single-mode optical fiber cable and/or optical fibers - generic specification optical fibers - product specifications fiber optical cable optical fiber cables for duct and tunnel application and/or optical fiber cables - generic specification optical fiber cables - indoor cables optical fiber cables - outdoor cables Fiber or Tube Colors EIA/TIA-455 – Testing Procedures

B. Standards – Measuring methods •

IEC 60793-1-2 Optical Fibers – generic specification – measuring methods for dimension

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DOCUMENT No.: MGBM-SPEC-0001

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DIVISION 16 ELECTRICAL WORK

SECTION 16890 FIBER OPTIC CABLE

•

IEC 60793-1-3 Optical Fibers – generic specification – measuring methods for mechanical characteristic

•

IEC 60793-1-4 Optical Fibers - generic specification - measuring methods for transmission and optical characteristic

•

IEC 60811 Common test methods for insulating and sheathing materials of electric and Optical cables.

•

ITU-T G.650 (2000), Definition and test methods for the relevant parameters of singlemode fibers.

C. Other Standards

1.4

1.5

•

ITU-T K.25 protection of optical fiber cables

•

IEC 60304 standard colors for insulation for low-frequency cables and wires Wherever codes, standards and recommendations are mentioned, the latest Published revision or issue shall be applicable.

QUALITY ASSURANCE A.

Quality Assurance:

The Contractor shall comply with ISO 9001 quality assurance and quality control requirement

B.

Pre-Installation Test: Each fiber of the fiber optic cable will be pre-tested, prior to start of open trenching operation/lying of cable. An OTDR will be used to verify length, continuity and attenuation of each fiber. Results of the tests will be documented, recorded and signed by the contractor project manager and the MAADAN representative. On completion of this test, the tester will satisfactorily reseal both of the cable.

SUBMITTALS Delivery Documents: The documents to be provided per cable drum shall comprise: Manufacturer test procedure and recommended installation procedure, manufacturer’s specifications, catalog data, descriptive matter, illustration and certification.

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DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORK

SECTION 16890 FIBER OPTIC CABLE • • • • • • •

1.6

Drum number Manufacturer Cable type Cable length Data sheet Test results of manufacturer Results of RoC test

SPECIAL REQUIREMENT The Manufacturer shall have local representative in Saudi Arabia and shall have minimum five (5) years experience in supplying FOC, conduit and other accessories and also able to supply necessary tools required for the installation.

1.7

CONFLICTING REQUIREMENTS, EXCEPTIONS The contractor shall notify the client Representative any conflict between this specification, the codes and standards and any other specifications included as part of the contract documents, which may be applicable for all as show in scope. Any exceptions to this specification and referenced documentation shall be raised by the contractor and approved by the client Representative in writing

1.8

DELIVERY, STORAGE AND HANDLING The contractor/vendor shall be responsible for providing FOC on site, unloaded and stored (if necessary) in such a way that damages are avoided. The FOC shall be suitably protected against damage during shipment and storage, pack the material to ensure environmental and transit protection of the equipment and the contractor shall submit packing design and packing details for Ma’aden & Design office approval. Storage supports and stacking heights must be selected in such a way that steady deformations of the cable conduits are avoided. Drums shall be secured against roll off.

PART-2: PRODUCTS 2.1

TECHNICAL REQUIREMENT:

2.1.1 General: The fiber optic cable will be laid in parallel to the water pipeline in the same trench, the FOC shall be outdoor rodent proof, direct buried cable without conduits. Therefore a fully dielectric fiber optic cable suitable for direct buried applications, filled with compound to prevent axial and longitudinal ingress of water and / or soluble chemicals throughout the cable shall be provided. The cable shall have loose tubes as secondary coating of fibers.

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DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORK

SECTION 16890 FIBER OPTIC CABLE

The cable shall contain a number of 6 fibers. Traction elements shall be made out of Kevlar or equivalent. The allowable tensile loading of the cable shall be 2.500 – 3.000 N, suitable for direct blowing or pulling the cable into cable ducts. The outer cladding of the cable shall consist of black PE. Other colour Coding and labeling of the particular cable components shall be according to IEC 60304.The colour-coding system shall be discernible throughout the design life of the cable. Cable markings shall be printed on the outer fiber cable jacket. The markings shall be permanent, insoluble in water and be legible for the duration of cable life. The markings shall be printed at intervals of not more than 2 meters. 2.1.2 Detail Description: Fiber optic cable specifications the following parameters of the fiber shall be met: • Performance characteristic at 1310 window & 1550 window • Attenuation @ wavelength: 1310 nm <= 0.5 db/km & 1550 nm <=0.3db/km • Variation of attenuation between 0º c & 70º c: - 0.01 db • Chromatic dispersion coefficient <= 3.5 ps/(nm.km) & 5.3 ps/nm.km • Zero dispersion slope: <=0.085 ps/(nm2.km) • Cable cutoff wavelength: < 1260 nm • Attenuation discontinuities at 1310 nm < 0.1 db • Attenuation change 1300 to 1324 nm < 0.09 db/km ITU G.652 compliance: • All dielectric, loose buffered, filled, for underground and direct buried environment. • Non-metallic, including strength member • Tensile strength: >= 10n • Mode field diameter: 8.6 - 9.5 microns +-10% @ 1310 nm • Cladding diameter: 125.0 microns • Concentricity error: < 1 micron • Proof-test stress 0.69gpa (minimum) • Expected fiber life span: 20 years • Fiber will comply with ccitt recommendation ITU G652.

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DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORK

SECTION 16890 FIBER OPTIC CABLE • Otical path discrete reflectance and return loss in accordance with requirements of 4, ITUG.652

2.1.3 Cable design in general: • The structure of the cable core shall permit high cable flexibility with minimum. • Stress to the individual fibers. • One or more strength members shall be an integral part of the cable construction. • The strength members shall be sufficient to support the stress of installation and to protect the cable in service. • Loose, fiber bundle (tube) or a slotted core type cable with multiple fibers per tube or slot. • The core shall be filled with a compound to inhibit water migration and wrapped • With a barrier tape.will at least be sufficiently translucent for fiber identification. • Individual fibres shall be color coded. • The filling compound shall not affect the color of the individual fibers. • The filling compound shall be non-toxic and present no dermal hazards. • The drop point of the filling compound shall be not less than 85 deg c. • The filling compound shall remain stable and unaffected long term exposure to weather. • The filling compound shall have chemical and mechanical compatibility with other cable • Components and splicing hardware. • Cable jacket; the cable shall be lszh (low smoke zero halogen), double sheath and contain • A ripcord under the sheath for easy sheath removal. the outer jacket shall provide the DISCIPLINE: TELECOMMUNICATION

DOCUMENT No.: MGBM-SPEC-0001

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DIVISION 16 ELECTRICAL WORK

SECTION 16890 FIBER OPTIC CABLE • Cable with a tough, flexible; protective covering which can withstand exposure to sunlight, to atmospheric temperatures and to stresses that can be expected in the installation of this cable. • The inner sheath thickness shall have a nominal value of 1.2 mm mimimum. • The outer jacket shall be sheathed with a high-density polyethylene (hdpe) with a • Thickness that is suitable for the proposed environment, but not less than 1.6 mm. • The cable jacket shall be resistant to crude oil, hydrocarbons, sulfur • Compounds and salt water. • The

cable

jacket

shall

have

permanent

surface

printed

sequentially • Numbered length markers at one-meter intervals. • The cable jacket shall have permanent surface printed marks at regular intervals of not more than two (2) meters consisting of: manufacturer, (number of fibers) \fiber optic cable and the actual year of manufacture. 2.1.4 Properties of cables: The cable shall be manufactured to ITU G.652 (The cable ITU G. 652 is considered based on the initial details from service provider-STC, however this needs to be officially confirmed ) specifications and meet performance characteristic. The described above which allows the use of non-metallic sheath. Parameters shall be detailed for all the cables: • Number, materials and dimensions of strength members • Material quantity and dimensions of filler, wrappings, belts etc. • Material and dimensions of sheaths, jacket, moisture barriers, etc. • Diameter overall of finished cable • Tensile strength, minimum (finished cable) • Compressive strength, minimum (finished cable) • Bending radius, minimum (cable) • Final placement radius • Weight of cable per kilometer DISCIPLINE: TELECOMMUNICATION

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORK

SECTION 16890 FIBER OPTIC CABLE • Minimum cable drum length 6 km long haul fiber • Cable life span

Cable batch test results (cert): with the following information as a minimum: mrd/concentricity, cut off wavelength, attenuation coefficient, and chromatic dispersion. PART-3: EXECUTION 3.1

INSTALATION

3.1.1

Fiber optic cable lying:

1.

Minimum horizontal distance between the cable & the Pipeline shall be 0.15m. Vertically observed, FOC shall be laid on the first ground compact layer above the pipeline. Cable shall be routed in accordance with submitted and approved contract drawings and the Engineer’s instruction.

2.

The Cable shall be laid over a sand layer of approx. 30cm thick. The trench shall not be back filled before being inspected and approved by Engineer’s resentative.ackfilling shall be carried out in layers not more than 50mm thick and shall be well consolidated by punning of each layer. Each cable shall be protected from mechanical damage by forced concrete covers over the entire buried length. The covers shall be at least 150mm wide and shall interlock to resist lateral displacement following installation. The cover shall be laid centrally 300mm above the cable during back filling of the trench. Splice points are spaced to coincide with designated reel lengths.

3.1.2

FOC network accessories: Cable warning tapes shall be installed 300mm above the cable covers during back filling of the trench. The tape shall be made of high grade PVC and shall be 150mm wide with a minimum thickness of 0.1mm. The tape shall be colored yellow with a warning message printed in black continuously along its length. The printing shall be fully resistant to deteriorating effects of direct burial. For cases of crossings, locations, where a FOC cable passes under a road way reinforced concrete trench or similar structure, the contractor shall supply and install HDPE ducts/ conduits of approx. 110mm diameter. Cable surface markers shall be provided and installed to mark the location and route of buried cable, the quantity, material, inscription and method of installation markers shall be subject of Engineer’s approval. All the necessary fiber optic network accessories, draw/splice pits and manholes shall be included.

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DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

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DIVISION 16 ELECTRICAL WORK

SECTION 16890 FIBER OPTIC CABLE

Optical joint boxes/ FO splice cases/closures shall be used for splicing of the FOC along the lines, where necessary. Contractor shall refer the FOC specification document for Joint box characteristics. The Contractor shall be responsible for forming holes through walls and floors and all other work necessary for the installation of outdoor FOC inside the Transfer pump station building. Fiber optic network shall be terminated at fiber distribution panel (FDP) with all fibers pig tails and patch cabling, per each termination point. Fiber distribution panel shall be designed for wall installation. FDP shall have cable gland to accept loose-buffered FOC with 6 core single mode outdoor fibers. Each FDP is equipped with Pigtails. The Optical connectors shall be F.C- P.C type. FDP shall be tamper-proof sealed and of rugged construction. The fiber optic indoor cables connecting to FDP in Transfer pump station shall have the same characteristics as of fiber optic approach cable, with the following expectations.

3.1.3

3.1.4

•

Anti-termite for cable protection is not required.

•

Fibers shall be connectorized at both the ends in the factory.

Testing Requirements: •

Outer Jacket

•

Cable Bend Test

•

Cable Impact Test

•

Cable Compression Test

•

Cable Twist Test

•

Cable Flex Test

•

Water Penetration Test (filled cables only)

•

Compound Flow Test (filled cables only)

Splices - Methods, Tests & Cautions Splice fibers with approved fusion splicing equipment or approved mechanical splices. Fiber optic splices shall be tested for splice loss as splices are being made, using an approved optical time domain reflectometer (OTDR) or local injection detection

. 1.

Suitable splice locations are selected.

2.

Splice locations are accessible.

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DOCUMENT No.: MGBM-SPEC-0001

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DIVISION 16 ELECTRICAL WORK

3.1.5

SECTION 16890 FIBER OPTIC CABLE

3.

The number of splice points are kept to a minimum.

4.

Buried splices and isolated conduit ends are identified with Electronic Marking System (EMS) markers.

5.

Splice locations are safe for personnel.

Splice Placement Only direct buried type splice enclosures shall be used in direct buried cable systems. The fiber optic cable "out-of-pit" cable slack shall be coiled and housed inside the splice pit. Splice Locations Splice and other access points shall be located so as to avoid areas that:

3.1.6

1.

Are vulnerable to damage by vehicular traffic or other means.

2.

Are subject to flooding or standing water.

3.

Have a number of obstacles (which would tend to increase the need to cut and splice the Fiber optic cable), such as: •

Railroads.

•

Highways.

•

Pipelines.

•

Driveways.

•

Parking lots

Testing & Inspection The testing and acceptance of fiber optic telecommunication cables shall be done in accordance with this standard. The Inspection Department shall be notified prior to the testing of fiber optic telecommunication

3.1.7

Factory Acceptance Test Each particular cable length shall be factory acceptance tested and shall be delivered together with the respective test reports. Required tests are: Attenuation tests of each fiber at 1.300 +30/-15 nm and at 1.550 +30/-70 nm with Optical Time Domain Reflectrometry (OTDR) according to IEC 60793-1-4 double-sided shall be performed. Dispersion tests of each fiber at 1.300 and 1.500 nm according to IEC 60793-1-4 shall be performed. These measurements shall be performed on each fiber prior to cable manufacturing and on the fabricated cable.

DISCIPLINE: TELECOMMUNICATION

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 10 of 11

DIVISION 16 ELECTRICAL WORK

SECTION 16890 FIBER OPTIC CABLE

Tension and temperature test of the fiber optic cable, as homologation test, and determination of resulting attenuation and variation in attenuation according to IEC 60793-1-4 shall be performed. Prior to the factory acceptance test the contractor shall provide a test Procedure which is subject of approval by the owner’s engineer. 3.1.8

Receipt of Cable Test Each particular cable length shall be tested upon receipt on site. Attenuation tests of each fiber at 1.300 +30/-15 nm and at 1.550 +30/-70 nm With OTDR according to IEC 60793-1-4 double-sided shall be performed. Determination of optical length shall be performed.

3.1.9

Test protocols Test protocols shall be provided for all activities conducted in course of tests.

3.1.10

Spare parts and accessories In addition to the normal splicing tools, the following materials shall be required: 1. Optical fiber splicing kit. 2. Lint free tissue. 3. Isopropyl alcohol. 4. Approved cable cleaner. 5. Approved cleaver tool. 6. Means of communication. 7. Approved mechanical stripping tool to remove fiber coating.

- END OF SECTION -

DISCIPLINE: TELECOMMUNICATION

DOCUMENT No.: MGBM-SPEC-0001

Rev. 00 15 Mar, 2011

CONTRACT NO. 10-1448-HQ-715 TRANSPORTATION OF TREATED WATER FROM TAIF TO MA’ADEN MINE SITE

Page 11 of 11