Wsp Ele Es 002 00 Engineering Specification For Electrical Facilities

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ENGINEERING SPECIFICATION FOR ELECTRICAL FACILITIES

0

12-Dec-2014

REV

DATE

STATUS

Preliminary

MKS

TKW

SRL

DESCRIPTION

PRE’D

CHK’D

APR’D

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CONTENTS

1.

GENERAL

2.

AREA CLASSIFICATION

1.1 1.2 1.3 1.4 1.5 1.6 1.7

PURPOSE SCOPE CODE AND STANDARDS AMBIENT CONDITIONS UNITS, SYMBOL, AND IDENTIFICATION SYSTEM LANGUAGE SCREW THREAD

3. DESIGN BASIS FOR POWER SYSTEM 3.1. POWER SUPPLY AND DISTRIBUTION 3.2. RATED VOLTAGE 3.3 SYSTEM GROUNDING 3.4 VOLTAGE DROP 3.5 POWER FACTOR 3.6 FAULT CALCULATION 3.7 EQUIPMENT SIZING 3.8 EMERGENCY POWER SUPPLY 3.9 110 VOLT DC CHARGER UNIT AND STATION BATTERY SYSTEM 3.10 UNITERUPTIBLE POWER SUPPLY (UPS) 4.

ELECTRICAAL CONTROL, PROTECTION, AND METERING SYSTEM

4.1 4.2 4.3 4.4 4.5

CONTROL SYSTEM OVERCURRENT PROTECTION GROUND-FAULT PROTECTION UNDER VOLTAGE PROTECTION TRIP AND ALARM SYSTEM

5.

MAJOR EQUIPMENT

6.

MOTOR CONTROL

5.1 5.2 5.3 5.4

6.1 6.2 6.3

7. 7.1 7.2 7.3 7.4 7.5 7.6 7.7

POWER AND DISTRIBUTION TRANSFORMER HIGH VOLTAGE SWITCHGEARS AND MOTOR CONTROLLERS LOW VOLTAGE SWITCGEARS MOTORS

CONTROL CIRCUIT LOCAL CONTROL STATIONS MOTOR OPERATED VALVES

PAGE 4 4 4 5 5 5 5 5 6 6 7 7 7 7 7 8 8 8 9 9 9 9 9 10 10 13 13

14 14 14

WIRING GENERAL TYPE OF CABLE CABLE SIZE GENERAL WIRING METHOD UNDERGROUND WIRING SYSTEM ABOVE GROUND WIRING SYSTEM CABLE RACK

14 15 15 16 16 17 17

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7.8 7.9 7.10 7.11 7.12 7.13 7.14

8. 8.1 8.2 8.3 8.4

9. 9.1 9.2 9.3 9.4 9.5

10. 10.1 10.2

11.

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

18 18 18 18 19 19 19

GRONDING AND LIGHTNING PROTECTION GENERAL GROUNDING OF SYSTEM NEUTRALS GROUNDING OF ELECTRICAL EQUIPMENT ENCLOSURE STATIC AND LIGHTNING PROTECTION GROUNDING

20 21 21 21

LIGHTING GENERAL ILLUMINATION LEVELS EMERGENCY LIGHTING SYSTEM STREET LIGHTING OBSTRUCTION AND WARNING LIGHTS

22 23 23 23 24

COMMUNITCATION SYSTEM TELEPHONE SYSTEM RADIO COMMUNICATION SYSTEM

TESTING

24 24 24

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1. GENERAL 1.1

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

1.2

SCOPE The general requirement for the electrical facilities inside buildings such as substations, central control buildings, and other offsite buildings is not included in this specification. Electrical facilities which are supplied as component parts of a package unit are also excluded from this specification. For these electrical facilities, the manufacturer’s standards or practices shall be applicable provided that they have been used, proven and comply with the codes and standards listed 2.1 below.

1.3 1.3.1

CODE AND STANDARDS Unless otherwise specified, the electrical design, materials and equipment shall conform to the applicable requirements of IEC (International Electrotechnical Commission) standards. Following national codes and standards may be used as supplements to IEC; France Italy Japan F.R. Germany England USA

1.3.2

: NF, UTE : CEI : JIS, JEC, JEM : VDE, DIN : BS : ANSI, NEC, NEMA, IEEE, UL

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

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

1.4

CBP-PRS-ES-001-00 CBP-ELE-ES-001-00 CBP-ELE-ES-004-00 CBP-ELE-ES-005-00 CBP-ELE-ES-006-00 CBP-ELE-ES-007-00 CBP-ELE-ES-008-00 CBP-ELE-ES-009-00 CBP-ELE-ES-010-00 CBP-ELE-ES-011-00 CBP-ELE-ES-012-00 CBP-ELE-ES-013-00 CBP-ELE-ES-015-00 CBP-ELE-ES-016-00 CBP-CIV-ES-005-00 CBP-ELE-017-00 AMBIENT CONDITIONS

“Design Basis” “Intensity Of Illumination“ “Motors“ “Transformers“ “Bus Duct“ “Storage Batteries & Charger“ “6 kV Motor Starter“ “Medium – Voltage Switchgear“ “Motor Control Center“ “Low Voltage Switchgear“ “Uninterruptible Power Supply System“ “Control Switch Station“ “Inspection & Test Of Electrical Equipment“ “Inspection Of Electrical Equipment Installation“ “Building , Clause 2.6 Electrical“ “Diesel Engine Generator“

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The electrical facilities shall be designed for safe and correct function under the following ambient conditions. (1) Altitude

:

1000m or less above sea level

(2) Temperature : Ambient Temperature (dry bulb) - Maximum temperature on record - Minimum temperature on record - Average daily maximum temperature - Average daily minimum temperature Design temperature: -

1.5

Indoor temperature Outdoor temperature

0

36.5 C 0 18.3 C 0 31.4 C 0 22.7 C Maximum 40 deg. C 40 deg. C

(3) Relative humidity : Average daily maximum Average daily minimum Annual average

85% 77% 80.7%

(4) Rainfall

144 mm/day maximum

:

UNITS, SYMBOL AND IDENTIFICATION SYSTEM

1.5.1

The metric system shall be used for all design and engineering documents and drawings which are listed in para.2 of measurement on the engineering specification for design basis (CBP-PRS001-00).

1.5.2

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

1.6

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

1.7

SCREW THREAD

1.7.1

The form of thread and diameters and associated pitches of cable glands shall be in accordance with BS-3643.

1.7.2

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

1.7.3

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

2. AREA CLASSIFICATION 2.1

Area where volatile liquids, flammable gasses or combustible dusts are handled shall be classified in accordance with the National Electrical Code (NEC) and as interpreted by API-500A.

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2.2

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

2.3

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

3.DESIGN BASIS FOR POWER SYSTEM 3.1 3.1.1

POWER SUPPLY AND DISTRIBUTION Power Supply (to be confirmed with network power) Main power supply will be 20 kV, 3-phase, 50 Hz, 300 A, resistance grounded. Frequency and voltage variation at the tie-in point shall be in accordance with standard utility practice; i.e., ±1% on frequency and ±5% max. on voltage. The symmetrical fault level at the tie-in point shall be 35 kA provisionally.

3.2

RATED VOLTAGE

3.2.1

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

3.2.2

Unless otherwise specified, the electrical equipments shall be designed for operation at the nominal system voltages listed below. Sr. No. 1

Equipments

Rated Voltage

Motor, below 0.2 kW rating

(1)

Nominal System Voltage

220 Volts, 50 Hz; single phase

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

2

Motors, 0.2 through 150 kW rating

380 Volts, 50 Hz; 3-phase

380 Volts, 50 Hz; 3-phase

3

Motors, above 150 kW rating

6000 Volts, 50 Hz; 3-phase

6000 Volts, 50 Hz; 3-phase

4

Circuit breaker control

110 Volts DC

110 Volts DC

5

Low-voltage circuit

110 Volts, 50 Hz; single –phase

110 Volts, 50 Hz; single –phase

6

Lighting fixtures

220 Volts, 50 Hz; single-phase

380/220 V, 50Hz

7

Instrumentation (1) UPS

110 Volts, 50 Hz; single-phase 24 Volts, DC

110 Volts, 50 Hz; single-phase 24 Volts, DC

110 Volts, 50 Hz; single-phase

110 Volts, 50 Hz; single-phase

motor

(2) General

Note

(1)

control

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

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3.3

ENGINEERING SPECIFICATION FOR Page ELECTRICAL FACILITIES

SYSTEM GROUNDING

3.3.1

20 kV system neutral shall be resistance grounded.

3.3.2

11 kV generator neutral shall be distribution transformer grounded.

3.3.3

6 kV system neutral shall be resistance grounded.

3.3.4

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

3.3.5

110 V DC system shall be ungrounded.

3.3.6

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

3.4 3.4.1

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VOLTAGE DROP The maximum allowable voltage drop in percentage of the nominal system voltage shall be as follow; Feeders Motor feeders on full load Motor feeders during starting Lighting circuits i.e. from 380 Volt distribution board to the furthest lighting fitting

-

5% 5% 5% 5%

3.4.2

During starting of motor, either alone or in a group, the voltage drop on any bus shall not exceed 20% of the nominal system voltage.

3.4.3

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

3.5 3.5.1

3.6

POWER FACTOR The plant overall load power factor measured at the 20 kV bus shall be 0.85 or greater at Plant normal operation except during the large motor starting. Automatic power factor control shall not be required. FAULT CALCULATION

3.6.1

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

3.6.2

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

3.7

EQUIPMENT SIZING

3.7.1

All transformers shall have enough capacity to cover the maximum demand of the plant normal operation.

3.7.2

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

3.7.3

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

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selective sub stations adjusted maximum demand shall be determined with the bus tie breaker closed one incomer open. 3.74

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

3.7.5

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

3.7.6

Cable capacity shall be calculated by taking into account the derating factors for grouped installation of the cables. Number and configuration of load carrying cables shall only be considered to determine what group derating factor to be used for cables which contain carrying and stand-by non-current carrying cables.

3.8

EMERGENCY POWER SUPPLY

3.8.1

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

3.8.2

Starting of the diesel generator shall be initiated upon failure of the normal supply detected at the emergency bus in switchgear. If the normal source of supply has not been restored and the generator is at acceptable voltage and frequency, then change-over to the generator source shall be fully automatic The generator, once started, shall continue to run until it is manually stopped or unless it is tripped due to fault / trouble.

3.8.3 3.9

For further details refer to specification for Diesel Engine Generator CBP/ELE/017/00. 110 VOLT DC CHARGER UNIT AND STATION BATTERY SYSTEM

3.9.1

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

3.9.2

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

3.9.3

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

3.10 UNITERUPTIBLE POWER SUPPLY (UPS) 3.10.1

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

3.10.2

The 110 V AC UPS system shall consist of one constant voltage/current limiting rectifier connected to the inverter, one set of lead-acid batteries, a by-pass transformer and a transfer switch providing no-break operation for load application and a distribution panel. The 24 V DC system shall consist of one constant voltage/current limiting rectifier and one set of lead-acid batteries.

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3.10.3 The batteries shall be sized for 30 minutes operation to supply the power to instrumentation with full voltage. 3.10.4 A separate uninterruptible power supply system with batteries shall be incorporated in the fire alarm system. 3.10.5 For further details refer to specification CBP-ELE-012-00.

4. ELECTRICAL CONTROL, PROTECTION, AND METERING SYSTEM 4.1

CONTROL SYSTEM

4.1.1

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

4.1.2

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

4.2

OVERCURRENT PROTECTION The overcurrent protection shall be coordinated to ensure correct sequential operation between incomers and feeders.

4.3

GROUND-FAULT PROTECTION

4.3.1

In the 6 kV system, each power feeder and motor controller shall be provided with a instantaneous ground overcurrent relay (50G) which shall be coordinated with a time delay ground overcurrent relay (51G) provided at the transformer neutral to ensure correct sequential operation incomers and feeders.

4.3.2

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

4.3.3

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

4.4

UNDERVOLTAGE PROTECTION

4.4.1

All the low voltage motors will be tripped by the electromagnetic contactor drop out when undervoltage occurs.

4.4.2

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

4.4.3

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

4.5

TRIP AND ALARM SYSTEM

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4.5.1

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

4.5.2

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

4.5.3

Substation Alarms Electrical equipment in the substation/Switchroom shall have the following alarms for annunciation in the power control room, one dry contact for each. (1) 20 kV trouble (2) 6 kV trouble (3) L.V. trouble (4) Emergency generator troble (5) D.C. 110 V trouble (6) D.C. 24 V trouble (7) A.C. 110V UPS trouble (8) Air conditioning trouble

4.6

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

5. MAJOR EQUIPMENT 5.1

POWER AND DISTRIBUTION TRANSFORMER

5.1.1 Power and distribution transformers shall generally comply with recommendations contained in IEC publication 60076. 5.1.2

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

5.1.3

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

5.1.4

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

5.1.5

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

5.1.6

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

5.2

HIGH VOLTAGE SWITCHGEARS AND MOTOR CONTROLLERS

5.2.1 20 kV switchgears, 6 kV switchgears, and 6 kV motor controllers shall generally comply with the recommendation contained in IEC publication 62271-200. 5.2.2 5.2.3

All switchgears shall be of the metal enclosed indoor type with draw-out circuit breakers mechanical interlocked to prevent moving of circuit breakers while closed. All switchgears and motor controllers shall be arranged to form single assembled switchgear with common bus-bars.

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5.2.4

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

5.2.5

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

5.2.6

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

5.2.7

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

5.2.8

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

i)

Voltmeter suitably scaled and fitted with phase selector switch.

ii)

Ammeter suitably scaled and fitted with phase selector switch.

iii)

Inverse Definite Minimum Time Limit (IDMTL) relays for overcurrent and earth fault protection, having instantaneous high set alarm.

iv)

Transformer fault relay activated by Bucholz and oil temperature, having contacts arranged to trip both the incomer and the feeding breaker. (only for generator transformer incomer)

v)

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

vi)

Power factor meter

vii) KWH and kW meter viii) Space heater manual on-off switch ix)

Facilities for inter-tripping

x)

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

Transformer or Power Feeder i)

Voltmeter suitably scaled and provided with phase selector switch

ii)

IDMTL relay for overcurrent and earth fault protection, having instantaneous high set element.

5.2.9

iii)

KWH and kW meter

iv)

Space heater manual on-off switch

v)

Facilities for inter-tripping

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

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i)

Voltmeter suitably scaled and fitted with phase selector switch.

ii)

Ammeter suitably scaled and fitted with phase selector switch.

iii)

Inverse Definite Minimum Time Limit (IDMTL) relays for overcurrent and earth fault protection.

iv)

Transformer fault relay activated by Bucholz and oil temperature, having contacts arranged to trip both the incomer and the feeding breaker.

v)

Transformer differential protection relay.

vi)

Power factor meter

vii) Space heater manual on-off switch viii) The breaker is to be arranged to allow inter-tripping from the feeding breaker ix)

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

Transformer or Power Feeder i)

Voltmeter suitably scaled and provided with phase selector switch

ii)

IDMTL relay for overcurrent and earth fault protection, having instantaneous high set element.

iii)

KWH and kW meter

iv)

Space heater manual on-off switch

v)

Facilities for inter-tripping

Motor Feeder i)

Ammeter suitably scaled and fitted with phase selector switch

ii)

Motor protection relay or equivalent, giving protection against overcurrent, earth fault, and single phasing

iii)

Undervoltage trip

iv)

Facilities for connecting a remote ammeter

v)

Breaker/contactor auxiliary contact arranged to operate a motor space heater in the event of the breaker opening or being removed

vi)

Space heater manual on-off switch

vii) Local/remote change-over switch, which is key lockable viii) Breaker/contactor on-off switch, which works only when the breaker/contactor is at test position and the above change over switch is at remote position. ix)

Current transducer, where required for process / operation

5.2.10 For further information refers to specification CBP-ELE-009-00. 5.3 LOW VOLTAGE SWITCHGEAR 5.3.1

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

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5.3.2

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

5.3.3

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

5.3.4

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

5.3.5

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

Voltmeter and phase selector switch

ii)

Ammeter and phase selector switch

iii)

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

iv)

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

v)

Transformer fault relay (depending on the rating of transformers)

5.3.6

Motor Control Centers (MCC) shall be metal enclosed, free standing, with multi-tiered fully withdrawable control units for motor starters. Control units for large motors may be of fixed type.

5.3.7

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

5.3.8

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

5.3.9

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

5.3.10

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

5.3.11

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

5.4

MOTORS

5.4.1

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

5.4.2

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

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5.4.3

Protection grade against water and dust for motors, installed where exposed to water jet, shall be IP55 specified in IEC publication 60034-5/60529.

5.4.4

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

5.4.5

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

6.MOTOR CONTROL 6.1

CONTROL CIRCUIT

6.1.1

For high voltage motors, each motor controller shall include the necessary electrical interlocking and interwiring between units and interlocking provisions to remotely mounted devices. Control circuit voltage shall be 220 V AC derived from the main circuit phase and neutral.

6.1.2

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

6.2.

LOCAL CONTROL STATIONS

6.2.1

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

6.2.2

STOP-START control switch stations shall be arranged so that momentary operating of the STOP switch stops the motors.

6.2.3

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

6.3

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

7.WIRING 7.1

GENERAL

7.1.1

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

7.1.2

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

7.1.3

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

7.2 7.2.1

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

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b)

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

c)

Control Cable

: NYRY-FL

d)

Lighting Cable

: N2XRY-FL

Legends 1. N2XSRY

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: Cross-linked polyethylene (XLPE) insulated, copper shielded/screened for each core, flame retardant PVC inner sheathed, single wire armored (SWA) and flame retardant PVC outer sheathed copper conductor cable

Note (1) : The voltage ratings of the cables shall be as follows: System Voltage a. 6 kV b. 20 kV

7.2.2 7.3

Rated Voltage 3.6/6 kV 12/20 kV

Cable Grade Maximum Voltage 7.2 kV 24 kV

(2)

For single core cables, aluminum armor shall be applied instead of steel armor.

2. N2XRY

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

3. NYRY

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

In areas where cable installation is well protected from physical damage such as inside substation, central control building, etc., cables without wire armor may also be used. CABLE SIZE The sizing of cables for consumers shall be based on their nameplate rating. The allowable current in any conductor shall be calculated in accordance with relevant IEC publications. Cable nominal size shall be 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 95, 120, 150, 185, 240, 300, 400, 500, 630; unit is square mm Minimum size of cable and wire shall be as follows; (1) 20 kv circuit (2) 6 kV circuit (3) Low voltage power circuit (4) Control circuit (5) Lighting circuit (6) External CT circuit for transformer neutral

7.4 7.4.1

2

:120 mm 2 : 25 mm 2 : 2.5mm 2 : 1.5 mm 2 : 1.5 mm 2 : 2.5mm

Note: Wire size for small current circuit such as testing and measuring instrument circuit and internal wiring of power board is not include in this list. GENERAL WIRING METHOD Electrical distribution cable from the substation to each load shall generally be installed in overhead racks or tray. The racks or trays shall be hot dipped galvanized.

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7.4.2

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

7.4.3

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

7.4.4

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

7.4.5

A distance of at least 600 mm shall be maintained in the main cable route between power cables and low level signal cables for instrumentation except where the two types of cable cross each other, in which case the minimum distance between the two types cable shall be 200 mm. All crossings shall be at 90 degrees angle as far as possible.

7.4.6

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

7.4.7

Cable shall be arranged to minimize the number of crossover.

7.4.8

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

7.4.9

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

7.4.10

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

7.4.11

Cable must be placed a minimum of 300 mm to the side of or 600 mm above any hot line, fitting or o vessel above 55 C unless an insulating barrier is provided.

7.5

UNDERGROUND WIRING SYSTEM

7.5.1

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

7.5.2

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

7.5.3

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

7.5.4

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

7.5.5

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

7.5.6

The sand shall be clean and free of organic matter.

7.5.7

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

7.5.8

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

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7.5.9

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

7.5.10

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

7.5.11

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

7.5.12

Cables crossing roads shall run in underground conduits or other approved raceways. For crossing of pipes or other underground obstructions, cables can run in sleeves.

7.5.13

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

7.5.14

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

7.6

ABOVE GROUND WIRING SYSTEM

7.6.1

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

7.6.2

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

7.6.3

Cables shall in general be installed side by side touching for 6 kV power in single layer, for low 2 voltage power cable size 95 mm in a maximum of two layers. Under no circumstances shall the cables protrude above the side rail of the cable rack/tray. The total cable fill shall comply with the NEC code articles 318-9 to 318-12.

7.6.4

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

7.6.5

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

7.6.6

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

7.7

CABLE RACK

7.7.1

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

7.7.2

Cable rack shall be of the heavy duty type with a minimum of 100 mm depth and 300 mm rung spacing. Cable rack shall be hot dipped galvanized. The coating thickness shall conform to BS 729 or equivalent standard.

7.7.3 7.7.4

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

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7.7.5

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

7.7.6

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

7.7.7

Cable rack shall be adequately supported to prevent sag utilizing the manufactures recommended spans.

7.8

CONDUIT

7.8.1

Conduit utilized outdoors, shall be rigid galvanized steel.

7.8.2

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

7.9

CONDUIT FITTINGS

7.9.1

Conduit fittings shall comply with applicable IEC publications.

7.9.2

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

7.10

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

7.10.1

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

7.10.2

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

7.10.3

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

7.10.4

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

7.11

CABLE TERMINATION AND IDENTIFICATION

7.11.1

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

7.11.2

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

7.11.3

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

7.11.4

Each power and control cable shall be clearly marked with PVC markers. The markers shall be secured with nylon ties. A cable marker shall be installed at both end of each cable. Direct buried cables shall be marked every 10 meters maximum with lead markers giving cable number.

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

7.12.1

Sealing shall be installed in accordance with applicable IEC publications.

7.12.2

In division 1 and 2 locations seals are required: -

In every cable run entering any of enclosure containing arcing devices At the terminating ends of cables crossing division 1 location applicable shall be so constructed not to transmit gases or vapors.

7.12.3

Sealing fittings should be accessible during and after installation.

7.12.4

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

7.12.5

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

7.13 7.13.1

COLOR FOR IDENTIFICATION OF CABLES The color for identification of cable shall be as follows; (1) Overall sheath (a) H.V. power cable -------------------- Black (b) L.V power and control cable------ Black (2) Core (a) H.V. power cable Single core -------- Red 3 cores ------------- Red, Yellow, Blue (b) L.V. power cable Single core --------- Red 2 cores -------------- Red, Black 3 cores -------------- Red, Yellow, Blue 4 cores -------------- Red, Yellow, Blue, Black (c) Control cable Individual cores shall be identified by number 1,2…. Printed on the cores at some interval throughout the length.

7.14

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

7.14.1

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

7.14.2

Branch circuits supplying the power and convenience outlets shall server no other equipment and not more than six outlets shall be supplied by one circuit. Each branch circuit shall be protected by thermal magnetic moulded case circuit breaker of suitable current rating or fuses, located in the 380/220 volt distribution panel.

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8.

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GROUNDING AND LIGHTNING PROTECTION

8.1

GENERAL

8.1.1

The grounding arrangements shall provide for: (1) (2) (3) (4)

Grounding of system neutrals Grounding of electrical equipment enclosures Static protection grounding Lightning protection grounding

8.1.2

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

8.1.3

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

8.1.4

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

8.1.5

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

8.1.6

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

8.1.7

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

8.1.8

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

8.1.9

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

8.1.10

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

8.1.11

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

8.1.12

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

8.1.13

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

8.1.14

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

8.2 8.2.1

GROUNDING OF SYSTEM NEUTRALS Each power transformer or generator neutral shall be grounded (solid via resistor or distribution transformer) by means of driven ground rods which are interconnected below grade with a ground grid. In the substation / switchroom a copper ground loop or bar of sufficient size shall be provided

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to enable termination of all electrical equipment grounds. The loop or bar shall be connected to the main ground grid with a minimum of two ground conductors. 8.2.2

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

8.2.3

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

8.3

GROUNDING OF ELECTRICAL EQUIPMENT ENCLOSURE

8.3.1

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

8.3.2

The ground grid shall generally be installed below grade. The main grid shall be 70 mm stranded copper conductor PVC insulated. The grid shall interconnect all driven ground rods as detailed in 8.1.14. All equipment requiring grounding shall be connected to this grid minimum wire size 16 2 mm (for mechanical protection).

8.3.3

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

8.3.4

Low voltage cables shall have a protective conductor which size shall be selected on a below basis.

2

Cross-sectional area of phase conductor of the installation S (mm2) S 16 16 < S 35 S > 35

Minimum cross-sectional area of the corresponding protective conductor S0 (mm2) S 16 S/2

8.3.5

Lighting panels shall be connected directly to the grounding systems with a separate grounding 2 wire of 16 mm .

8.3.6

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

8.3.7

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

8.3.8

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

8.4

2

STATIC AND LIGHTNING PROTECTION GROUNDING

8.4.1

Process equipment containing hazardous materials and located in hazardous area, shall be grounded to prevent static discharges. 2 Each equipment shall be connected to the main grounding loop by means of 25 mm branch wire.

8.4.2

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

8.4.3

Lighting protection shall be in accordance with NFPA78-Lightning Protection Code. Lightning protection shall generally be connected with any other grounding system in the direct vicinity, and

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shall take the form of “cone protection”. The cone protection system shall smart at the tallest structure within the plant and shall be continued until complete plant protection is achieved. 8.4.4

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

8.4.5

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

8.4.6

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

8.4.7

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

9.

LIGHTING

9.1

GENERAL

9.1.1

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

9.1.2

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

9.1.3

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

9.1.4

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

9.1.5

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

9.1.6

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

9.1.7

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

9.2

ILLUMINATION LEVELS Illumination levels shall not be less than the values listed below in average (measured in above grade):

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Area

Average Intensity in Lux

Process Plant Tank Yard Sea Water Intake Cooling Water Air Supply Nitrogen Supply Water Treatment & Fire Fighting Waste Water Treatment Ware House Control Room & Laboratory Work Shop General Area Machine & Lathe Work Fine Work Instrument Work Other Office Substation Steam Generation Unloading Platform Street Lighting

50/20 * 10 50/20 * 50/20 * 50/20 * 50/20 * 50/20 * 50/20 * 100 500 400 550 1000 1500 400 150 50 10/20/100 ** 10

–

A: Around Rotating Machine B: Around Tank and Vessel

* A/B/C – A: Access Way B: Cat Walk C: Unloading Point 9.3

EMERGENCY LIGHTING SYSTEM

9.3.1

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

9.3.2

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

9.4

STREET LIGHTING

9.4.1

Street lighting will be as follows; (1) Fixture (2) Fixture mounting height (3) Pole type (4) Pole spacing (5) Wiring

9.4.2

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

9.5 9.5.1

--- Sodium vapor --- Approx. 10 m above finished grade --- Galvanized steel or concrete --- Approx. 50 m --- Underground direct burial cable

OBSTRUCTION AND WARNING LIGHTS The obstruction and warning lights shall generally be installed as per the International Civil Aviation Organization (ICAQ) requirements.

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Circuits for obstruction and warning lights shall be energized during night by emergency lighting power source.

10. COMMUNICATION SYSTEM 10.1 TELEPHONE SYSTEM Telephone system will be provided to cover central control building sub-stations. Paging system will not be provided as radio communication system is provided

11. TESTING Electrical equipment shall be subjected to routine shop test to ensure that they are free from electrical or mechanical defects, and that they meet design specifications. Engineering Specification (CBP-ELE-01500) shall apply to the inspection and test for each electrical equipment.