C259 N00-X013 01 Electrical Specification for Packages

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Electrical specification

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C259-N00-X013 Mamu Gas Processing Plant FEED Page 1 of 27

Plant: Mamu Gas Processing Plant

TECON-Project: C259 - Mamu Plant FEED

PETROM-Asset. No.: 2 MAD

Electrical Specification for

Packages

1 - 6 7 - 14 15,16 17,18 19-21 22,23 30 31 80

Asset No. Document No. Rev. Installation Code Pl. Or.

TECON-ID: F

2 MAD N00-X013 01 9 1 C 259 4

03

02

01 Final Issue 07.08.2009 FWI TEC HLA TEC

00 First issue 12.05.2009 FWI TEC HLA TEC

Rev.: Description: Date: Prepared: checked:approved PETROM,

Date:


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LIST OF CONTENTS

1

Introduction...............................................................................................................................................4

2 Abbreviations............................................................................................................................................5

3 Scope........................................................................................................................................................6

3.1 Laws, regulations and standards........................................................................................................6

3.2 Application of standards and specifications .......................................................................................6

3.3 Suppliers responsibility .......................................................................................................................6

3.4 Language and measurement of units.................................................................................................7

3.5 Information from Vendor .....................................................................................................................7

4 General Requirements .............................................................................................................................9

4.1 Operating conditions........................................................................................................................ 10

4.2 Life span and spare parts ................................................................................................................ 10

4.3 Tagging............................................................................................................................................ 11

4.4 Painting............................................................................................................................................ 11

4.5 Hazardous Areas............................................................................................................................. 11

5 Mechanical and Electrical Requirements .............................................................................................. 14

5.1 General ............................................................................................................................................ 14

5.2 Integration of the Package Unit in the Main Electrical Network ...................................................... 14

5.3 Package Distribution Boards ........................................................................................................... 14

5.4 Motors.............................................................................................................................................. 19

5.5

Trace Heating .................................................................................................................................. 20

5.6 Other Heating .................................................................................................................................. 20

5.7 Lighting Fixtures .............................................................................................................................. 20

5.8 Cabling............................................................................................................................................. 20

5.9 Earthing ........................................................................................................................................... 22

6 Inspection and Tests ............................................................................................................................. 23

7 Specific Scope of Electrical Supply ....................................................................................................... 24


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7.1 Electrical Contents of Tender .......................................................................................................... 24

7.2

Continuous Electrical Documentation.............................................................................................. 24

7.3 Final electrical Documentation ........................................................................................................ 25

8 APPENDIX : List of Applicable Standards............................................................................................. 26


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Mamu Gas Processing Plant FEED Page 4 of 27

1 Introduction

The purpose of this document is to cover the minimum technical requirements for the design,manufacture, testing and supply of electrical items supplied as part of packaged units.

In this specification, a package unit is considered to be a prefabricated process or utility unit which can

operate on its own, is supplied as a whole and is normally a standard skid-mounted unit. A package unit

can be composed of interconnected elements including distribution and control boards within the

substation building.

The electrical extent of scope for the package unit is described in the associated PROJECT

SPECIFICATION of process or mechanical engineering, regarding the main equipment identified as a

package unit. In the following this paper is referred as PROJECT SPECIFICATION.

The equipment and all necessary ancillary equipment to provide a complete operating system shall be

supplied in accordance with this specification, the relevant data sheet(s), the purchase order and the

documentation listed in the material requisition document.


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2 Abbreviations

EDG Emergency Diesel Generator

EMC Electromagnetic Compatibility

ESD Emergency Shut Down

FAT Factory Acceptance Test

FC

HBC High Breaking Capacity

HVAC Heating, Ventilation and air conditioning

LV Low Voltage

MCC

MCCB

MCB

MSO

MV Medium Voltage

RCBO

RCD Residual Current ProtectionRTD

SAT Site Acceptance Test

UCS

UPS Uninterruptable Power Supply

VFD Variable Frequency Driver


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3 Scope

3.1 Laws, regulations and standards

The design, manufacturing and inspection/commission of the electrical equipment part of the

package shall comply with the following Laws, Regulations, Directives and Standards in

order of their precedence. Latest revisions/editions apply.

Laws and Regulations for Electrical Power Supply and Application in Romania

Applicable EC Directives

Local Romanian Standards

European Standards (EN Standards)

International Standards (IEC Publications)

Other national Standards (DIN, VDE )

3.2 Application of standards and specifications

In general, all applicable standards shall be followed. The quote shall include a list

containing all deviations from project specifications or standards. In the absence of such a

statement, it will be assumed that the requirements of this specification are met without any

exception. Costs for any subsequent modifications necessary to comply shall be borne by

the supplier without detriment to the schedule.

If any deviations and/or contradictions amongst the individual standards and regulations of

the same type (e.g. EN standards) arise, the most stringent wording shall apply. In case they

are mutually exclusive, Romanian federal law has to be considered.

3.3 Suppliers responsibi lity

The implied warranty of fitness of this specification for the intended purpose is within the

Suppliers responsibility. Compliance by the Supplier with the provisions of this Specification

does not relieve him of his responsibility to furnish equipment and accessories of a proper

mechanical and electrical design suitable for the specified service and conditions

guaranteeing health and safety. In case of any objections to the specification, the vendor

has to inform the client in writing.

The Supplier shall be fully responsible for all aspects of the design, manufacture, inspectionand factory acceptance testing within his scope of supply. This shall include responsibility for

the coordination and control of contingent Sub-Supplier activities, and for ensuring that the

equipment meets the requirements of this specification, including the quality

assurance/control requirements defined. If applicable, the Supplier shall provide a complete

list of his preferred sub-suppliers with the bid.

The Supplier shall also be responsible for providing technical support during erection, pre-

commissioning, commissioning and start-up.

The Supplier has further to guarantee the committal of all certificates, acceptance papers,

reports and test logs by delivery of the switchgears


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It is incumbent upon Suppliers to familiarize themselves with all requirements.

3.4 Language and measurement of unitsAll documentation on the specified Low Voltage Switchboards shall be in English language.

Units of measurement shall be in accordance with the International System of Units (SI

System). Preferred units are described in Electrical design architecture philosophy

(C259_N00-J001).

3.5 Information from Vendor

Following electrical information shall be provided by the vendor from the tender stage.

3.5.1 Consumer Data

Following electrical consumer data shall be supplied:

In case of package distribution boards: for the tender a consumer list with the estimatedoverall active and reactive power consumption separated for the type of electrical supplyrequired (230 VAC UPS and 230/400 VAC).

In case of no package distribution boards: for the tender a preliminary consumer listshowing first data for all consumers including type of supply and required protection.

The lists shall be detailed after purchase order and give detailed information on eachconsumer fed by either board. Especially for motors correct rated efficiency, current,power factor and locked rotor current shall be given. For main consumers (e.g. largemotors) detailed data for all operating points shall be given.

The detailed lists shall show data for all feeder protective devices (tripping curves!) inorder to enable cable sizing by contractor.

The maximum electrical level of disturbance acceptable by the package distributionboards and/or consumers.

The type and maximum electrical level of disturbance in the main electrical networkinduced by package distribution boards and/or consumers.

Maximum allowed fuse for 230/400 VAC feeders to package boards.

Maximum allowed fuse or MCCB / MCB for UPS feeders to package boards.

Maximum allowed peak short circuit current for incoming 230/400 VAC feeder to packageboards (usually according to mechanical design of main busbar within the board).

230 VAC UPS loads are rated vital loads and do not allow for any interruption. 230/400 VAC

loads are in general divided in normal and essential loads. The latter will be backuped by a

diesel genset with an interruption of approximately 20 seconds. The vendor may ask for twodifferent feeders where one will be diesel backed up depending on his design.

After purchase order, a cable schedule connecting all equipment of the package scope shall

be delivered. Calculation of cross section for power cables is up to the contractor and will be

made available on basis of vendor layout.

3.5.2 Other Data

Following data shall be supplied:

Dimensions of all package boards, cubicles and panels


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Approx. heat dissipation of boards, cubicles, panels and other equipment located indoors

Maximum environmental and climatic ratings

Approx. weights for boards, cubicles and panels


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4 General Requirements

The following sections give contractor requirements regarding the vendors electrical scope ofwork. Generally, the Electrical design architecture philosophy (C259_N00-J001_02) shall beconsidered for all electrical installations.

The scope of supply shall include, but shall not be limited to design, fabrication, inspection,testing, preparation for shipment, spare parts, special tools, supply of documentation andmanuals and other services as defined in the relevant requisition.

In general (except as indicated below for the motors etc.), each necessary power supply will bemade available as only one feeder up to an agreed interface point at the edge of the packageunit. The same principle will apply to the control cabling intended for remote indication,interlocks, intertrips etc, for which a single interface point, generally a junction box or terminalblock within a cubicle, will be accommodated at the edge of the package unit. All connections ofthe equipment, sensors, push buttons etc. shall be wired up to the corresponding interface point

by the vendor (e.g. a skid mounted junction box).If the motor controllers / VFDs for the motors within the package unit are provided by vendor,then the package MCC board will be located in the electrical substation remote to the packageunit. In such case, the power cables to the motors shall terminate directly on the motor junctionboxes. The power and control cables from MCC to motor shall NOT be provided by the vendor.The vendor shall instead provide a complete cable schedule and connection overviewcoordinated with the client. The overview shall indicate all items, junction boxes and cubicles.Cabling and termination works will be in scope of the electrical subcontract of the client.

Common (trace) heating or lighting within packages may be fed by a package board or thegeneral facilities within the substation. In the latter case, the vendor has to supply a completelist of groups for heating devices or light fittings and a connection overview showing allconsumers, junction boxes on the skid and the package feeder cubicles. For cabling, refer tothe paragraph above.

If there are any specific materials, related to the package unit, which need to be located in theelectrical substation, they shall be supplied by the vendor.

The interface points cover but shall not be limited to:

Control and signaling

All supply feeders

Lighting

Termination points for cabling (terminal blocks, junction boxes etc.)

(Trace) heating

All the electrical material and equipment within the battery limits shall be supplied, installed withall accessories if any, wired, configured and tested by the vendor.

The vendor shall perform all internal cabling, lighting and earthing within the package unit.

Wherever requested in the requisition, the vendor shall supply the MCC, control boards andother material to be located remote to the package unit, i.e. in the substation. The prices forsuch items shall be indicated separately in the bid.

For applicable standards related to electrical equipment on package equipment please refer tochapter 8 of this document.


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4.1 Operating conditions

4.1.1 Climatic and environmental conditions

The switchboards shall be designed and constructed for continuous operation at full load underthe climatic and environmental conditions at the mounted site (usually inside the substationbuilding). The following table briefs about determining parameters. The given values representextreme values following typical environmental site data:

Characteristics min max

Altitude of site (m above sea level) 165 165

Ambient temperature outside (C) -27 39.2

Ambient temperature inside (C) 0 35

Wind speed (m/s) 0 15

Relative humidity (%) 5 % 90%

4.1.2 Voltage supply and tolerances

It can be assumed that the supply voltage, frequency and their tolerances offered by the localpublic supply grid will comply with limits for industrial environments as per EN 61000-2-4 andEN 50160.

The following table briefs about all supply voltages and mains configurations for the designatedplant site.

Description Voltage (V) Mains configuration

Medium voltage supply (MV) 6kV ~ IT-system

Low voltage supply (LV) 400V ~ TN-S-system

Uninterruptable Low voltage supply 230V ~ IT-system

The voltage tolerances are detailed in the Electrical design architecture philosophy(C259_N00-J001) and shall be accordingly respected.

4.1.3 Electromagnetic Compatibi lity (EMC)

Concerning electromagnetic compatibility, the impact on other systems by alternating magneticfields (radiated emission and susceptibility) shall be respected. Consequently, the relatedregulations and standards shall be followed (mainly EN 61000). All electrical equipment shall beconstructed in order to allow electric and electronic industrial devices with a generic radiatedand conducted immunity at least as per EN 61000-6-2 to operate properly without anyfunctional constriction for typical industrial arrangements.

It is incumbent on the supplier to guarantee, that the offered electrical equipment will notinterfere with other devices subject to the typical conditions at the intended place of installation.

Any kind of low radiation design offered by some manufacturers is not required.

4.2 Life span and spare parts

The electrical equipment has to correspond to the standard of most modern technology andshould have been operated in comparable reference assets for at least two years. A referencelist of those assets is to be attached to the offer giving at least five examples. Suitable spareparts must be available for at least 20 years after installation of the equipment.


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4.3 Tagging

All equipment of the package unit, including control panels, distribution boards, motors,switches, control devices, indicators, junction boxes etc. shall be fully and clearly identified inaccordance with the drawings.

A label shall include the item tag-number of the equipment according to the vendor's drawings.

The labels shall be made from non decomposing material with durably UV- and weather-proofblack inscription on bright background. It is recommended to use engraved resopal plates orapproved equivalent.

Labels shall be attached to non-removable parts using corrosion proof screws, rivets or nonplastic cable ties, adherence is not permissible.

Nameplates shall describe push buttons, indicators etc. on the front side of control panels orpackage boards.

Dymotape lettering or means of a similar kind shall not be used for permanent installations

except for inside cubicles.

Cables shall be fitted at both ends with cable markers showing the cable number stated in thecable schedule.

For all inscriptions the character size shall be at least 8 mm. For smaller devices 6 mm may betolerable. The font shall be ARIAL standard.

The language of the inscription shall be English and Romanian. Directly after the TAG-Numberthe CE-marking shall be placed.

Any electrical symbols used on the equipment should comply with IEC 60417.

4.4 Painting

All components and devices shall have a resistant, long term stable, high quality painting. Atleast two layers have to be applied. Damages, caused by transport, installation, cabling orcommissioning shall be repaired in a way, that the original quality is restored. The RAL code ofcolor for the switchboards will be given on the data sheets or shall be coordinated with theclient. An additional painting at location of installation is not allowed.

4.5 Hazardous Areas

Areas will be classified in accordance to the standard IEC 60079-10 (non hazardous area, zone0, zone1, zone 2). The selection of electrical equipment and material shall take place withrespect of the standard IEC 60079 and with the European Directive ATEX 94/9/EC. Themechanical characteristics of enclosures for electrical components and materials have to be asfollows.

The decision of the temperature rating (T1-T6) and gas group (IIA, IIB, IIC) according to IEC60079-0 will be given by process safety department of TPGY.

For any package units or parts of package units installed outside process areas no EX-proofdesign is required (e.g. instrument air supply, HVAC, EDG).

4.5.1 Induct ion Motors

Regardless of their location within the process area all LV motors and their junction boxes shallhave the following type of protection:

II 2G EEx de

II 2G EEx e


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4.5.2 Lighting Fixtures

Regardless of their location within the process area all lightning fixtures shall have the following

type of protection:II 2G EEx de

4.5.3 Welding and Socket Outlets

Regardless of their location within the process area all outlets shall have the following type ofprotection:

II 2G EEx de

4.5.4 Trace Heating

Regardless of their location within the process area all trace heating shall have the followingtype of protection:

II 2G EEx e

4.5.5 Other Heating

All other heating within the process area shall have the following type of protection:

II 2G EEx d orII 2G EEx de orII 2G EEx dm

Outside of hazardous areas a non-EX design may be considered to reduce costs (e.g. electricalheating within the diesel genset container).

4.5.6 Junction and Control Boxes

All junction and control boxes (e.g. for trace heating or lighting fixtures in package containers)within the process area shall have the following type of protection:

II 2G EEx e

4.5.7 Switches

All switches (e.g. for trace heating or lighting fixtures in package containers) within the processarea and the well sites shall have the following type of protection:

II 2G EEx de

II 2G EEx e (local control box)

4.5.8 Cabling in Hazardous Areas

The methods shall comply with standard IEC 60079-14. If cabling to an interface junction boxwithin zone1 is up to the vendor, the mechanical protection is also within his scope (usually allfactory assembled, skid mounted).

Cable glands suitable for the classification of the area where they are installed shall realizecable entrance to enclosures of electrical apparatus. For flame proof (EEx d) glands andjunction boxes the use of armored cables is mandatory (gas tight!). As a consequence EEx dboxes shall be avoided. The vendor must point out any need for armored cables at tenderstage.


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4.5.9 Certi fication of Electrical Apparatus for Hazardous Area

Electrical apparatus suitable for use in classified areas shall be provided with test certificates by

a Notified Body. The certificates shall be delivered according document schedule. Regardlessof the schedule, the papers for standard equipment shall be available on demand within oneweek. A list shall summarize all EX-proof consumers and related certificates.

The equipment suitable for zone 1 area is suitable for zone 2 and non hazardous area.


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5 Mechanical and Electrical Requirements

5.1 General

The package units shall be designed to ensure the safety of personal during all operatingconditions, inspection and maintenance. They are suitable for operation and utilizationaccording to EN 50110.

The degree of protection for all enclosures shall be in accordance with IEC 60529:

Indoor equipment: IP 21 (minimum)

Outdoor equipment: IP 55 (minimum)

All equipment shall be tagged in accordance with vendor's drawings and identified withnameplates.

It is to be remarked that, if not otherwise specified, the package unit shall be consideredas one machine in view of EC machinery directive 2006/42/EG. A new edition will beavailable per 29.12.2009. Especially IEC 60204 for electrical equipment of machines is tobe respected.

Standard equipment shall be used whenever possible. All material and equipment shall be new,unused and of a good proven quality.

All equipment and ancillaries will be installed in dust and industrial environment and shall becorrosion resistant or effectively corrosion proof.

Electrical installation in the package unit shall be laid out with adequate access for convenientoperation and maintenance. Process equipment, piping, etc, shall not obstruct the access toelectrical equipment.

5.2 Integration of the Package Unit in the Main Electr ical Network

The vendor shall indicate all items within the package unit likely to be responsible of electricaldisturbance in the main electrical network.

The electrical disturbance can be:

Voltage depression

Overvoltage

Wave disturbances such as harmonics

Overcurrents

Electromagnetic disturbances

The vendor shall indicate the type and level of disturbance likely to occur and shall propose a

corrective action in order to be in accordance with the IEC standards and project specifications.For limits reference is made to IEC 61000-2-4.

5.3 Package Distribution Boards

The panels may include the package unit control system (UCS) as well as the motor startersand the distribution feeders as required in the project specification.

The objective shall be to guarantee one common design throughout the whole project also fordistribution boards. The boards may contain specific FCs, thyristor controllers or other deviceswhich shall be embedded into the general design.

Whether distribution boards are within vendors scope or not shall be detailed on the associatedproject specification of process or mechanical engineering. The specification will also indicate


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which package consumers shall be supplied by the boards. If required, the boards and theirfeeders supplied with the package unit shall comply with the following.

5.3.1 General

Protection and control devices of package unit electrical equipment (heaters, lighting, motorsetc) shall be grouped in package panels supplied by the vendor completely pre-wired. Alldevices within the boards shall be completely set.

Power distribution and control shall be installed in 2 separate sections of the panel.

The main power supply shall be disconnected by means of a load switch, padlockable in the offposition. Load switches shall be fault make, load break type. This device shall break all poles ofthe supply, including any neutral (4 poles for 3 phases and neutral, 2 poles for 1 phase andneutral and for DC supply).

For UPS feeds, load switches shall be foreseen within the cubicle. 230 VAC UPS has to bemarked clearly as an external voltage, as it is not switched off by the main supply

disconnector.Conductors and electrical apparatus shall be protected against overcurrents by means of fusesor MCB/MCCB/MSP/RCBO rated for the prospective fault level at the installation location andtaking limiting fuses prior to the device into account. In general, the vendor shall respect shortcircuit levels of all incoming feeders and must design the equipment accordingly. If required, thevendor shall make use of backup fusing to match the short circuit breaking capacity ofMSP/MCB/RCBO devices incorporated.

All protective devices within the boards shall be fully coordinated to ensure selective operationwithin the rating of the concerned equipment.

The boards shall comply with IEC 60439 for partially type tested assemblies.

Distribution boards shall preferably be located at a convenient position within the LV room ofthe plant substation. In case of package containers or dedicated unit buildings, it may be

considered to place boards outside the building, locally in the dedicated housings (localpanels). Outdoor installation shall be avoided. Anyway, an installation within hazardous areasshall not be allowed, as this asks for EX-proof design and will drastically increase costs.

It shall be allowed to locate small panel boards for control etc. within classified areas. In thiscase the design must meet the area classification.

5.3.2 Mechanical Cubicle Design

All LV distribution boards including those of package equipment shall be of same size andlayout to guarantee a continuous design and easy switch room layout. The cubicles/boardsshall mechanically comply as a minimum with the following requirements:

Add-on-design usually without baffles and factory assembled for easy on site installation

H x B x T = 2000 x 800 x 600 mm

Base 200mm

Color for cubicle and base RAL 7035

Ventilation per raised floor and air outlet on top of the cubicle (for ambient indoorconditions)

Cable entry from bottom with ingress protection IP00 for cable terminals to raised floor(no gland plate due to ventilation)

Two-way key bit locks for each door and rotary handle

Lighting fixture with socket outlet fed by 230 VAC UPS and door contact (doubleterminals for loop in and NO protective device; protective device is within feeder cubicle)

20% mechanical spare space for possible future extension within the panel

Completely accessible from front side so that they can be placed against a wall orinstalled back to back


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No space heaters are required for indoor installation; 230 VAC space heaters for outdoorinstallation mandatory with own incoming feeder (main feeder switch off does not affectanti condensation heating; to be included in consumer list.

Design allows cables to be safely connected to outgoing circuits without the necessity ofde-energizing the distribution board

5.3.3 Electrical Cubicle Design

For electrical design of the boards refer to the following points. It is to be pointed out that all liveparts and busbars shall be protected against inadvertent contact by design or by isolatedbarriers (EN 50110 shall be supported).

Signal lamp RED, with test push button (approx. 2 x 2cm) in the door centre, to indicateany unusual operating condition = COMMON ALARM (e.g. tripping of protectivedevices); shall be supplied by external 230 VAC UPS feeder to maintain function evenwhen regular AC supply of cubicle is cut off

Voltage monitoring relay if the package cable feeder from LV main switchboard is notsupervised (overvoltage, undervoltage, phase failure, symmetry); necessity shall bedetailed on the associated project specification

Main load switch for 230/400 VAC incoming feeders with door handle and padlock-able;for UPS feeds load switches within the cubicle

No incoming feeder fuse or MCCB (also not allowed for UPS); the main LV busbar of thepackage board will be protected by MCC cable feeder within the LV main switchboard

The manufacturer must indicate the maximum allowed fuse ratings and peak short circuitcurrent of the LV busbar on the type plate of the package board (also for UPS)

Voltage metering (switchable if applicable) for all incoming feeders 96x96 mm; range500V for 400V and 400V for 230V.

Type II/C monitored surge protection for AC boards except for UPS (goes to commonalarm of board)

Power distribution per main busbar with sufficient thermal and mechanical design

5.3.4 Motor feeders

If required in the project specification, motor starters for all motors within the package unit willbe designed and supplied by the vendor. They shall be located in a package distribution board.

All components shall be rated to withstand short circuit stresses and temperature applicable atthe appropriate point.

All motor starters shall be provided with:

MSP (thermal overload, short circuit and phase failure protection) appropriately sized toprotect the motor; monitored by auxiliary contact

Instead above, an MCB for short circuit protection and an additional thermal relay (e.g.

digital motor management with current transformer) may be used MSP combined to groups with one fuse per group snapped up on the main busbar

Monitoring of group fuses is usually not necessary as a tripping of one phase causesMSP to trip

Contactor (IEC 60947-4-1 shall be respected: classification 2 for fault clearance by MSPprior to any contactor damage); monitored by auxiliary contact

Control circuits per MSP protected control transformer 230 VAC and one MCB per motorfeeder

Facilities for remote control by means of start/stop local control stations located adjacentto the motors in the process area

Earth fault relays shall be foreseen for all motors


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All equipment relevant to specific operation, such as speed variation, 2 speed motor,reversing motor, break motor, etc.

Any FCs shall be of DC voltage link pulsed type which requires no adaption to the motor. A buslink may be preferred to enable control and monitoring by the packages control. Depending oncable lengths output filters shall be foreseen (sinus or du/dt motor filter). Cable lengths will besupplied by the client together with the results of the cable calculations. Attention shall be paidthat the motor isolation is suitable for all expected peak voltages. For high frequency - EMCissues IEC 61800-3 shall be respected. The environment shall be rated C3. If necessary HFfilters shall be foreseen in the supply. For low frequency harmonic line currents input filters maybe considered to comply with IEC 61000-2-4.

FCs shall be protected by MSPs either directly attached to the main busbars or, for smallerratings, combined to groups with group fuses. Usually the FC offers an alarm when the powersupply fails. Thus a monitoring for the feeder is not necessary.

FCs or soft starters may be required by client instead of direct on line starting of larger motors(change order). The client will calculate voltage drops according to vendors consumer data and

check against the allowed limits.

For ESD shutdowns each feeder must be equipped with a certified relay interrupting the controlcircuit for the contactor.

PTC temperature monitoring and anti condensation heaters (if required) will also be part of themotor feeder. The anti condensation heaters are automatically switched on when the contactorstops the motor. PTC devices interrupt the control circuit of the feeder.

It shall not be possible to energize the contactor when the MSP is turned off.

Variable Frequency Drives (VFDs) above 250kW and all other motor feeders exceeding 160kWshall not be fed by LV, but by 6kV medium voltage. Any need for this power range shall beclearly indicated by the vendor on tender stage, as this requires enhancement of plannedelectrical power supply levels.

5.3.5 Other feeders

For personnel safety, residual current protections (RCDs) shall be provided on all other circuitsfeeding package equipment such as lighting or trace heating. The feeders shall be combined togroups with one three phase fuse per group snapped up on the main busbar. The group fusesshall be monitored.

For trace heating each feeder shall be designed for single phase and equipped with a RCBOB16 in order to improve selectivity. The trace heating shall be grouped according to packagelayout, each group switchable on the front panel of the board.

Other heating shall be fed similarly and will receive individual feeders of either one or threephase design.

If possible, it should be considered to feed heating by the main heating board within the

substation or, for larger heaters, directly be controlled contactor feeders of LV mainswitchboard.

Only locally switched lighting within package containers or housings (normal and assignedemergency) shall be fed by a package board and comparable to trace heating. No groupswitches are required and for standard florescent lighting within packages B6 or B10 RCBOsare sufficient. Emergency lighting will require an own 230 VAC UPS feeder to the board.Outdoor lighting fixtures on package equipment are usually fed by the main lighting board.

5.3.6 Distribution Board Wiring

For all boards a common code for wiring colors, marking and other principles shall be definedby the client. The following table shall be considered a basic guideline.


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Power circuits (L1, L2, L3) black

Neutral conductor (N) blue RAL 5015

Protective conductor (PE) yellow/greenAnalog signals green

DC control +24V grey

DC control +0V blue RAL 5012

AC control (L1) red

AC control (N) red/blue

UPS voltage (L1) brown

UPS voltage (N) blue RAL 5010

DC external control orange (e.g. interlock)

Dry contacts to terminals yellow

Intrinsically safe circuits blue RAL 5015

AC voltage 24V (L1, N) rosy (e.g. HVAC)

Conductors not available in listed color and required conductor size shall be marked by shrinktubes at least at both ends.

For internal wiring PVC isolated stranded conductors shall be used. The calculation of crosssection shall be according to the standard. It is not allowed to use cross sections below 2,5mmfor power and 1,0mm for other wiring. Bundles of single core cables shall be routed neatly invertical or horizontal plans.

Package boards shall be supplied by vendor completely pre-wired to terminal blocks mountedat the bottom of the panel.

5.3.7 Terminals

All terminal blocks shall be equipped with a spare of at least 20% for future extension. Differentvoltage levels within a terminal block shall be separated by strips. Stranded conductors shall beequipped with cable compression lugs. Each termination point shall only serve oneinterconnection. In case of multiple connections terminals with internal connection clamp shallbe used. Control and metering circuit terminals shall be designed as disconnect terminals formetering purposes.

Terminal sizes shall be according to the cable schedule.

A free space of at least 200 mm in height shall be available between the lowest cable terminaland the bottom plate of the panel.

5.3.8 Conduits

Wires within the boards shall be held within insulated channels in order to avoid mechanicaldamages.

The conduits shall be sized for at least 20% spare capacity. They shall be closed and easilyaccessible for further enhancement. The wiring for voltage levels below and above 50V shouldbe separated if possible. Intrinsically safe wiring must be separated and laid in BLUE conduits.In case of inevitable crossing of other conductors protective wrappers shall be used.

Wiring between cubicle and devices on door shall be protected against mechanical damage bythe use of flexible conduits.


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5.3.9 Installation devices

The following points shall be respected for all other live parts installed within the cubicles of the

package boards: Control voltage transformers if necessary (fusing primary and secondary side; secondary

fusing may be omitted if instantaneous tripping of primary fuse is guaranteed for all faultlocations on secondary side)

No N-PE link within the cubicle, TN-S supply by LV main switchboard

Special attention to be paid on the required safety margins to intrinsically safe signals(blue cable ducts and blue cabling!)

Special attention to be paid on minimum clearances of equipment according tomanufacturer instructions

All MCB rated class III with a breaking capacity of >= 10kA, neutral switched andmonitored by auxiliary contact

All RCD or RCBO to be of type A (pulse current sensitive) and G or K (lagged and peakcurrent proof); monitored by auxiliary contact

Fuses shall be monitored if required (e.g. necessary for group fuses but not necessaryfor single fusing of MSP)

All interposing or control relays shall be of pluggable design

For different devices a specific type/brand may be stipulated by the client in order to stick to oneplant design. A list with allowed vendors may be supplied in addition to this specification.

One complete set of fuses shall be provided for all fusible equipment furnished or installed bythe supplier as part of his work.

Fuses shall be high breaking capacity (HBC) type, general purpose with time characteristics inaccordance with IEC 60269-2, with an interrupting rating greater than or equal to expected faultcurrent.

IEC 60947 is to be pointed out as the major standard for low voltage switchgear and control

gear.Devices mounted in the control panel shall be easily accessible for maintenance.

5.4 Motors

This chapter represents an overview for LV motors. For details refer to the Specification of LVmotors(C259-N00-X010 Specification for LV Motors) or MV motors (C259-N00-X011Specification for MV Motors). For DOL or softstarter motors above 160kW and for VFDs above250kW medium voltage 6kV shall be used.

All LV AC motors shall be of three phase squirrel cage induction type. For fraction powermotors a one phase induction design may be used.

A typical local control for motors if within the package scope shall be made up as follows.

The design may be adapted by specific package vendors needs.

For local control a manual switch within a control box next to the motor shall be foreseen in theprocess area, linked to the feeders digital control device within the drawer. The local switchshall offer the following positions:

ON Motor ON regardless of package UCS but secondaryto ESD

OFF Motor OFF regardless of package UCS

REMOTE Motor control is up to package UCS

The box shall be rated IP 55 minimum and be connected by one control cable.


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The local controls shall be installed on structural steelworks, against walls or piles. If notpossible the vendor shall provide an adequate support.

Motor control stations shall be installed in such a way that the relation between the controlstation and the corresponding motor is clear and without any doubt.

No intermediate junction boxes are allowed for motors within packages. The feeder directlyconnects the motor terminals to the distribution board.

5.5 Trace Heating

Electrical trace heating may be in the scope of the package supplier as indicated in the packagespecification. Self regulated, self limiting trace heating shall be foreseen if required by processdesign.

Special attention shall be paid on isolation tests after mounting according to manufacturerdirectives. The tests shall be recorded and prepared for authority attestations.

5.6 Other Heating

If required by process, other heating may be fed by a package board (e.g. in case a thyristorcontroller is planned). Any heaters exceeding 160kW shall be indicated clearly by the vendor inorder to respect the electrical system design.

5.7 Lighting Fixtures

Area lighting is not in the package vendor scope, but local lighting fixtures inside a package(e.g. enclosures, control panels, containers, process racks, structural steelwork) shall bedesigned and installed by the vendor.

The vendor shall supply and install the complete package unit lighting system including: Lighting fixtures with supports

Cables and conduits up to terminal boxes

Electrical feeders including protection devices of lighting circuits if required

Switches and/or push buttons

Only locally switched lighting shall be supplied by a package distribution board. All other lightingfixtures will be supplied by the common lighting board not in scope of the vendor.

Lighting shall be based on the use of 1 or 2 x 36W or 58W fixed to structural steelwork bymeans of hangers. The fixtures shall be complete with all necessary accessories such aselectronic ballast, globe, guard, reflector and wired/cabled to junction boxes. The junction boxesare the interface to cabling in scope of client.

The vendor shall submit to client prior approval, the lighting levels used for calculation and theselected type of lighting fixtures to be installed, according to the required area classification asdescribed in the Electrical design architecture philosophy(C259_N00-J001).

Emergency lighting within the battery limits shall also be in the scope of the vendor andinstalled and separately wired/cabled to junction boxes.

5.8 Cabling

5.8.1 General

Power and control cables interconnecting separated package boards (e.g. a control and adistribution board) and going from separated package boards to process equipment shall not be


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in vendor scope. Interconnections between adjacent boards (arrays) shall be within the scope.Cabling on skids or within containers shall be provided up to the interface points as defined inthe project specification. An interface point may be given by the terminals of a junction box, a

local board or control panel (terminal blocks within the boards). An example for a local boardwould be a cubicle within housing on a skid.

For all cabling connected to package items the vendor shall

provide all terminating facilities and cable glands complying with the type of cable and thearea classification.

supply a complete system connection overview for all cabling.

provide a complete cable schedule based on the cable types given by client andindicating the scope of the cable (vendor or client). The list will be reviewed and crosssections for power cables as per calculation will be added together with lengths. Lengthsand cross sections for package cables on skids etc. shall be preliminary given by thevendor

supply tripping curves or data on protective devices for outgoing feeder cables of

package boards to allow calculation of cross sections

All terminals and terminal boxes shall be sized for the calculated conductor cross sections. Allcable glands are within the vendors scope and shall be sized according to the cable diameters.Data sheet of cable manufacturers will be supplied by client.

All cabling requiring interconnection to the general network (power or control) shall be providedwith junction boxes or terminal blocks in panels, etc, located at convenient positions, agreed bycontractor, along one side of the package unit battery limit.

Power cables will be supported within the package unit up to the interfacing terminal boxes orterminal blocks.

Within the package unit, all cabling and wiring between electrical equipment shall be adequatelysupported and fixed within cable trays or conduits up to the terminal boxes.

5.8.2 Cables and Cable Laying

All types for cables within the scope of the vendor as defined above shall be conform toElectrical design architecture philosophy(C259_N00-J001_02). Generally following points shallbe considered:

mechanical protection by conduits or clads

laying and protection in hazardous areas rated zone1

supports by trays, ladders, conduits or clamps

cable marking

separation of cable types

fixing by clamps or similar

Main issues for cable laying are:

Cables shall be provided with mechanical support and protection by the use of hot dipgalvanized cable trays or heavy-duty hot dip galvanized conduits

Cabling shall not be supported by process piping, nor shall they be fastened directly tostructures

When 3 or more cables are routing paralleled, they shall be installed on cable trays orcable ladders

Unless otherwise specified, cable trays and cable ladders shall be only 75% occupied atthe moment of completion of the installation

Cables for different voltage levels (High Voltage, Low Voltage, instrumentation) shall beinstalled in separate trays or conduits


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The conductor color coding and minimum cross sections depending on the application isdefined within the specification.

The calculation of cross sections for package cabling (e.g. for a lighting fixture to a commonjunction box or within a package container) shall be done by vendor and according to layingconditions following the national Romanian standard. In case of a local supply board within thepackage also voltage drop and short circuit tripping as per above specification is to berespected for definition of package cables.

For long package cabling directly connected via client cables to a separated (package) board,the client may ask for a larger cross section in order to guarantee voltage drop tolerances orshort circuit tripping for most distant faults. This may prevent an upgrade of the feeder cablewithin his scope of supply.

5.9 Earthing

Earthing within the package shall be according to the Electrical design architecture philosophy

(C259_N00-J001). Although lightning protection is covered by the specification it shall be in thescope of others and not considered to be up to the vendor.

The specification shall also be considered in view of external interfaces. This means thatearthing connections to skids, containers etc, which are not in the scope of the vendor, shall beprepared in form of tags, termination points etc.


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6 Inspection and Tests

All electrical equipment, including sub-supplier equipment, shall be subject to inspection by thecontractor or appointed representative.

The vendor shall provide a witness testing schedule and the tests procedure for the vendor toreview by contractor at least 2 weeks before the proposed test date. The schedule shall reflectall necessary electrical issues. It shall further include all final factory and site acceptance test(FAT, SAT) in an electrical point of view.

Testing of electrical equipment within the package shall verify satisfactory operation inaccordance with the relevant inspection and test plans required by the project specification.

The vendor shall provide all facilities to carry out these tests. All test equipment and metersused during tests shall have a valid calibration certificate issued by an independent authority.

The vendor shall provide to contractor the test reports within 2 weeks after testing.

From an electrical point of view, the package supplier shall in particular be responsible for: Isolation tests on all cables within his scope

Initial electrical loop tests for all package consumers supplied by package boards withinthe suppliers scope, regardless of the scope of the feeder cables (measuring loopimpedance; RCD check; verification of short circuit tripping)

Motor startup tests (rotary field check; MSP setting and optimizing etc.) for all motors fedby package boards within the suppliers scope

Signal and control testing for all consumers fed by package boards within the suppliersscope (e.g. local control switches or local protective RTDs)

All tests for package boards according to IEC 60439-1, -2


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7 Specific Scope of Electrical Supply

7.1 Electr ical Contents of Tender

The offered package has to comply with all requirements of this electrical specification and allother electrical and mechanical purchaser supplied data on the attached data sheet etc. Thebidder is asked to fill out all empty fields on the data sheet and has to guarantee the fulfillmentof all stipulations. Empty fields offer a free choice for the vendor within the constraints of thisspecification including all referenced laws, regulations, standards, papers etc.

The tender letter, for electrical items of the package, has to be completed by following papersas a minimum. Incomplete tenders may not be respected:

Index sheet for all electrical attachments to the tender letter

First vendor information

General layout and arrangement drawing showing electrical items Electrical connection/system overview drawing

General brochures and flysheets for major items

List of major sub-suppliers (e.g. motors, distribution board, lighting fixtures, VFDs)

List with deviations to this electrical specification

Filled out data sheet for motors etc.

7.2 Continuous Electr ical Documentation

A list with required electrical deliverables will be included in the tendering papers. The deliveryschedule will be stated in the purchase order for each type of deliverable. The delivery dates,as part of the contractual schedule, are subject to penalties in the event of delays. The papers

will be subject to client approval or review and have to be prepared in English language.The continuous electrical documentation shall include but in respect of the list of deliverables is not limited to the following documents:

Detailed information according to chapter 3.5

Detailed layout and arrangement drawings showing all electrical items

Electrical connection/system detailed drawings

Layout drawings for all major electrical equipment

All equipment data sheets (e.g. motors, electrical panels, transformers, converters,cables)

Detailed wiring diagrams for all electrical panels and boards

Cable list for all cables

Cable routing on skids, in containers etc. (drawings)

Cable sizing calculation notes for package cabling All characteristics of the motors (current, torque, efficiency, power factor, locked rotor

conditions data) with the associated resistant torque

For main consumers (e.g. large motors) detailed data for all operating points

Terminal block diagrams and/or junction box drawings for all external connections withsuitable numbering

Test certificates for electrical material to be used in hazardous areas and list showing allequipment plus certificate number

Inspection and test schedule and procedures according to chapter 6

Reports on electrical loop tests, cable isolation tests, motor startup and signal & controlcheck

Reports on convenient progress, kickoff meetings etc. covering also electrical issues


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7.3 Final electr ical Documentation

Complete documentation of the electrical part shall be provided for the design, manufacturing,

testing, commissioning, start-up, operation and maintenance. All final documentation shall bewritten in English language and should agree with typical national and international standardsfor documentation (especially for drawings in digital form and used symbols according to IEC60417 and IEC 60617). Preliminary papers for acceptance and review may only be supplied inEnglish Language.

The final electrical documentation shall include, but is not limited to, all papers of the continuousdocumentation (as built status) and shall include:

Overall package instruction manual with respect of electrical issues

Operation and maintenance manuals for electrical items of package

Operation and maintenance manuals for all electrical auxiliaries

Outline drawing for the electrical items indicating all dimensions, weights

Outline drawing for the electrical auxiliaries indicating all dimensions

All technical data sheet for the electrical package items All technical data sheet for auxiliary electrical items

All routine test reports for the electrical equipment (motors, boards, panels etc.)

Reports on factory and site acceptance tests (FAT, SAT) of the package equipmentmanufacturer reflecting electrical issues

Separate list of used electrical equipment, auxiliaries, materials and their manufacturers

Assembly and mounting instructions for electrical equipment

Declarations of conformity for equipment (especially EC machinery directive 2006/42/EGfor the whole package)

Any other electrical declarations of the manufacturer or his sub-suppliers

Any electrical calculation notes

Priced spare parts list including major electrical items


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8 APPENDIX : List of Applicable Standards

Code Description

IEC 60079 Electrical apparatus for explosive gas atmospheres

IEC 60034 Rotating Electrical Machines

IEC 60072 Dimension and output series for rotating Electrical Machines

IEC 60364 Low-voltage electrical installations

IEC 60439 Low-voltage switchgear and control gear assemblies

IEC 60529 Degrees of protection by enclosures

IEC 60204 Safety of machinery Electrical equipment of machines

IEC 60947 Low-voltage switchgear and controlgear

IEC 61000 Electromagnetic compatibility

IEC 61800 Adjustable speed electrical power drive systems

IEC 60269 Low voltage fuses

IEC 60417 Graphical symbols for use on equipment

IEC 60617 Graphical symbols for use on circuit diagrams

IEC 60445Basic and safety principles for man-machine interface, marking andidentification

IEC 60059 IEC standard current ratings

IEC 60073 Basic and safety principles for man-machine interface

IEC 60445-60447 Basic and safety principles for man-machine interface

IEC 61140 Protection against electric shock

IEC 61496 Safety of machinery - Electro-sensitive protective equipment

IEC 62061Safety of machinery - Functional safety of safety-related electrical,electronic and programmable electronic control systems


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IEC 60598 Luminaries

IEC 60968-60969 Self-ballasted lamps for general lighting services

IEC 61347 Lamp control gear

IEC 62035 Discharge lamps

IEC 60898Circuit-breakers for overcurrent protection for household and similarinstallations

IEC 61008Residual current operated circuit-breakers without integral overcurrentprotection for household and similar uses (RCCBs)

IEC 61009Residual current operated circuit-breakers with integral overcurrent

protection for household and similar uses (RCBOs)

IEC 61095 Electromechanical contactors for household and similar purposes

IEC 61643 Low-voltage surge protective devices

IEC 61238Compression and mechanical connectors for power cables for ratedvoltages up to 30 kV

IEC 60228 Conductors of insulated cables

IEC 60146Corrigendum 1 - Semiconductor convertors - General requirements andline commutated convertors

IEC 61204 Low-voltage power supply devices, d.c. output

IEC 62041Power transformers, power supply units, reactors and similar products -EMC requirements

EN 50110 Operation of electrical installations

EN 50288Multi-element metallic cables used in analogue and digitalcommunication and control

EN 50300Low-voltage switchgear and controlgear assemblies. Generalrequirements for low-voltage substation cable distribution boards

EN 50274Low-voltage switchgear and controlgear assemblies - protection againstunintentional direct contact with hazardous live parts

Documents

C259 N00-X013 01 Electrical Specification for Packages