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MULTI PURPOSE REACTOR PLANT

Discipline Code:

ELProject spec. Title :

ELECTRICAL METHODES AND SYSTEM

Doc. No.:

900-SPE-5001

Contract Job No.:

002/SP/EP7020/08-S0Rev.A

ELECT RICAL METHODES AND SYSTEM

CLIENTS : ECOGREEN OLEOCHEMICALS

PROJECT TITLE : MULTI PURPOSE RECTOR PLANT PROJECT

CONTRACT

TITLE :

LOCATION : BATAM, INDONESIA

Rev.CONTRACTOR OWNER

DATE BY CHKD APVD DATE APVD

1 IFRA 3-Nov-10

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MULTI PURPOSE REACTOR PLANT PROJECT

Discipline Code:

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Project spec. Title :


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Table of Contents

Sec Title Page

1. SCOPE...........................................................................................................................................3

2. REFERENCES..............................................................................................................................3

3. UNITS OF MEASURE AND LANGUAGE...............................................................................3

4. BASIC CONSIDERATIONS.......................................................................................................4

5. SITE CONDITIONS.....................................................................................................................4

6. HAZARDOUS AREA CLASSIFICATION...............................................................................4

7. POWER GENERATION AND DISTRIBUTION.....................................................................5

8. UTILIZATION VOLTAGE........................................................................................................6

9. DEVIATION IN SUPPLY VOLTAGE AND FREQUENCY................................................11

10. EMERGENCY POWER GENERATION AND DISTRIBUTION.....................................12

11. LOAD SHEDDING AND MOTOR RESTART SYSTEM...................................................13

12. ELECTRICAL LOAD DATA CALCULATION ...............................................................13

13. SYSTEM STUDIES..................................................................................................................13

14. LV SWITCHGEAR AND MCC..............................................................................................14

15. SYSTEM PROTECTION AND METERING.......................................................................14

16. UPS SYSTEM..........................................................................................................................15

17. LOCAL CONTROL STATION (LCS) FOR MOTOR CONTROL...................................15

18. SUBSTATIONS........................................................................................................................16

19. PAINTING................................................................................................................................17

20. PROTECTION GRADE OF ELECTRICAL EQUIPMENT..............................................17

21. NAMEPLATES.........................................................................................................................17

22. CABLING SYSTEM................................................................................................................17

23. UNDERGROUND CABLING SYSTEMS.............................................................................18

24. ABOVE GROUND CABLING SYSTEM..............................................................................21

25. CABLE AND CORE MARKER.............................................................................................25

26. TERMINATION.......................................................................................................................25

27. ELECTRICAL WIRE AND CABLES...................................................................................26

28. LIGHTING................................................................................................................................28

29. CATHODIC PROTECTION ................................................................................................30

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1. SCOPE

This specification covers the minimum design requirements for electrical power supply and

distribution systems, motor control and cabling systems for Multi Purpose Reactor Plant

Project.

2. REFERENCES

The latest revision of applicable sections of the codes, standards, and specifications listed

below (including addenda, and documents incorporated by reference) shall be considered an

integral part of this specification.

IEC : International Electro-technical CommissionNFPA : National Fire Protection Associations

NEMA : National Electrical Manufacturers Associations

API : American Petroleum Institute

IP : Institute of Petroleum

BSI : British Standards Institution

Other codes and standards such as ANSI, IEEE, Indonesian code, JIS/JEM/JEC may be also

applied with approval by Owner.

The codes and standards of the countries of origin may be applied to raw materials and mass-

produced components, subject to the Vendor clearly indicating the scope of application in his

technical and commercial quotations.

3. UNITS OF MEASURE AND LANGUAGE

SI units of measure shall be used for electric system designs unless otherwise specified.

The English language shall be used for all documents.

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4. BASIC CONSIDERATIONS

Consistent with reasonable economy and considering investment and operation expenditures,

the design of electrical facilities shall be based on the features and requirements of the plant

where electrical facilities are to be installed. Primary considerations are:

Safety of personnel during operation and maintenance, and adequate protection to

equipment.

Easy maintenance

Interchangeability of equipment

5. SITE CONDITIONS

Altitude : Less than 1000 m

Ambient Temperature : 680F 910F

For design of outdoor Elec. Equipment : 1040F

For design of indoor Elec. Equipment with Air Conditioning systems: 1040F

Average Relative Humidity : 90 %

Soil Temperature at 0.8m deep : 860F

Soil thermal resistivity : 2120F cm / w

Soil thermal resistivity & soil electrical resistivity shall be verified with further tests during

design stage.

6. HAZARDOUS AREA CLASSIFICATION

Plant areas shall be classified according to the API RP505. The selection of electrical

equipment and material to be installed in hazardous areas shall be in accordance with IEC

60079. Electrical equipment shall be selected according to the following Zone

Classification criteria:

Zone 1 Area

Electrical apparatus should be excluded from Zone 1 areas. Where this is not

practical, the equipment shall comply with one (1) of the following types;

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- Ex(e) (Increased safety)

- Ex(p) (Pressurized enclosure)

- Ex(d)( Flame proof enclosure)

Zone 2 Area

- Ex(n) (Type N protection)

- Ex(e) (Increased safety)

- Ex(d) (Flame proof enclosure for internal sparking equipment)

Non-hazardous Area

- Standard Industrial equipment suitable for the installation

Explosion proof electrical equipment / materials suitable for Division 1 or 2 may be

also used in hazardous area. Division 1 is considered equal to Zone 1 and Division 2

is considered equal to Zone 2.

Electrical equipment and materials for hazardous areas shall be selected according to theapplicable codes and standards of the country where the equipment/materials are

manufactured.

Approved equipment must be listed or certified for use in the particular hazardous location

by an internationally recognized testing organization.

7. POWER GENERATION AND DISTRIBUTION

The power Supply shall have 0.38 kV voltage rating, 3 phases, 50 Hz and connected to

0.38 kV busbar (main substation) .

The electric power to be required for the plant operation shall be supplied from

Power distribution of 400V shall be secondary selective system with each bus tie breaker

normally open (N.O.). Power loss at one side bus shall cause an automatic transfer to

another side bus with permissive from bus fault condition. The two incoming breakers and

one tie-breaker are interlocked so that only two of the three breakers can be closed. The

returning to normal operation and manual transfer without any power interruption shall be

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performed by operators. The each incoming side of secondary selective system shall be

rated for the total busbar load to cover all loads under its switchgear without incoming

power supply from another side.

Cable sizing to each motor shall be sized based on the motor full load current considering

derating factor from installation method.

The power to building loads (HVAC, Lighting) shall be controlled and distributed from

Distribution Panels properly located in each building.

8. UTILIZATION VOLTAGE

Motors above 150 kW : 6.6 kV, 3 phases, 50Hz

Motors above 0.37 kW up to 150 kW : 400 V, 3 phases, 50Hz

Motors rated 0.37 kW and below : 230 V, 1 phase, 50Hz

Welding Outlet : 380 V, 3 phases, 3 poles + earth

Space Heater/auxiliary power supply : 220 V, 1 phase, 2 wires, 50Hz

Control Supply for Switchgear, Relays, Elec. Controllers : 220 VAC

Control Supply for motors connected to LV & MV MCC : 220 VAC (from self control

transformer at each MCC unit)

SYSTEM EARTHING AND LIGHTNING PROTECTION

8.1 General

Earthing, Bonding and lightning protection facilities shall be provided to:

Protect electrical equipment from damage and to insure operation of electrical

overcurrent devices (System neutral earthing)

Protect personnel against shock from electrical enclosures or equipment (Enclosure

and equipment earthing)

Protect structures and equipment against damage from lightning (Lightning

protection)

Insure against ignition of flammable mixtures by static electricity or stray current

(Static electricity protection)

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8.2 Earthing System

Earthing systems shall consist of networks installed around major process units,

buildings, structures, distribution centers, substations, etc. Networks shall consist

of earthing buses (main loops), earthing electrodes, and earthing conductors for

equipment.

Where different earthing systems, except systems for process control and computer

system, are installed close together, they shall be interconnected at convenient

points to bring all earthing to a common potential.

Earthing for lightning protection for structures/buildings which are equipped with

lightning rods shall be physically isolated from the main earthing system. Earthing

rods shall be located at the base of each protected structures/buildings.

Equipment that is located remotely from the main earthing network may be earthed

by means of individual earthing conductors and earthing electrodes.

All earthing electrodes at substations and generating stations shall be interconnected

in a loop by earthing conductors.

Earthing resistances shall not be exceed the following values:

-Total earthing resistance of loop network : 5 ohms

- An earthing electrode : 25 ohms

- An earthing electrode for lightning protection : 5 ohms

- System neutral earthing : 5 ohms

- Instrument earthing (maximum) : 5 ohms

A separate earthing system shall be provided for electronic instrument boards. It

shall be physically isolated from other earthing systems. For further details, refer to

Instrument Specification.

8.3 Methods and Materials

Earthing, Bonding and Lightning Protection Conductors

All earthing, bonding and earth return conductors shall be PVC insulated (green or

green with yellow stripe) soft-drawn stranded copper wire. Earthing buses for

earthing networks shall have 70 mm2 conductors. All lightning protectionconductors, such as down conductors and electrode conductors shall be bare hard-

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drawn copper or stranded aluminum wire or bar.

All earthing conductor shall be sized as follows:

LV Switchgear and MCCs : 120 mm2

Other electrical panels : 25-35 mm2

Lighting panel board frames : 35 mm2

Welding outlet frame : 16 mm2

Motor frames : 16-70 mm2

Neutral earthing for solid earthing : 150 mm2

Neutral earthing for low resistance earthing : 70 mm2

Static electricity : 35 mm2

Bonding wire : 4-16 mm2

Fences : 16 mm2

Other equipment : 4-16 mm2

Lightning protection : 70 mm2

Note : The equipment earthing conductor shall need not be larger than the

circuit conductors supplying electrical power to the equipment.

Underground earthing conductors shall be directly buried at least 300 mm below

finished grade.

Underground earthing conductors shall be laid in cable trenches as far as routing

permits. Basically, aboveground earthing conductors shall be laid on cable tray.

Earthing conductors extending aboveground shall be protected by hard PVC

conduit at least 150 mm above and below the finished grade or concrete surface.

Earthing and Bonding Connection

All earthing or bonding conductor connections to structures and equipment shall

be made aboveground. Lug bolted connectors shall be used to allow periodical

maintenance.

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Earthing lugs shall be fabricated from hot dipped galvanized steel.

All aboveground connections of earthing wires shall be made with compression

type connectors and wrapped with PVC tape.

All underground connections of earthing wires shall be made by Cadweld,

Teikaweld or C-clamp and wrapped with PVC tape.

Earthing Electrodes

Earthing electrodes shall be made by long zinc clad steel or copper clad steel

rods driven below grade.

Each earthing rod shall be installed in an earthing well which shall function as

an inspection pit for verifying earthing resistance. The loop conductor shall be

connected to the top of the earthing rod.

The earthing rod shall be connected to the loop conductor by a bolted connector.

If more than one electrode is connected to an earthing system, the electrodes

shall be spaced at least 3 m apart.

Equipment located remotely shall be furnished with a dedicated earthing rod

connected directly to the equipment. No earthing well for inspection purposes is

required.

Electrical System Earthing

Neutral earthing for each system voltage level shall be as follow:

400 V system : Solidly earthed

Enclosure and Equipment Earthing

Earthing Point of Wiring System

o The metal enclosures for wire and cable, such as conduits, cable trays, and

raceways shall be considered electrically continuous by metallic

connection, and earthed at each end by direct connection to earthing

network, bonding or metalic connection to other earthed enclosures.

Connections shall be made to the switchgear or control center earth buses

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when such equipment is used.

o The metal armor of cables shall be bonded together across each splice, and

to the metal enclosures of equipment at each end of the cable utilizing

cable glands.

o The metallic shields in shielded cables shall be earthed at the supply side

only.

Earthing Point of Equipment

o The metal enclosures of all electrical equipment shall be earthed by

connecting to the earthing network using a dedicated earthing conductor

or by a earthing conductor in the multi conductor cables.

o Fences, handrails and stairways at substations shall be earthed to an

earthing network.

o Metal enclosure which may be source of static electricity shall be earthed

to an earthing network.

o Electrical equipment, even though bolted directly to an earthed metallic

structure, shall be earthed separately.

o Machinery skid base containing electrical equipment. (Two points in

diagonally opposite )

o Local control stations shall be connected to an additional earthing

conductor branched from the main earthing loop.

Lightning Protection

Lightning protection systems shall be installed basically in accordance withBS6651.

Non-steel structures higher than 20 m shall, in general, be provided with a

lightning protection system.

Tall steel structures, columns, towers, vessels etc. which require lightning

protection shall be earthed with 70 mm2 earthing wires at two points of their

base and shall be connected into the main earthing loop.

The steel structures, columns, towers, vessels, tanks etc, provided they areelectrically continuous, shall be considered protected against lightning by those

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connection to the earthing network.

Static Electricity Protection

All storage tanks, columns, towers, vessels, heat exchangers and other process

equipment not mounted on an earthed steel structure shall be separately earthed.

Process equipment mounted on an earthed steel structure fixed with carbon steel

bolting shall not require additional earthing.

Buildings or structures having metallic frames or siding shall be earthed at a

minimum of two locations. These locations shall be at opposite extremities ofthe structure.

Above ground pipelines shall be connected to the earthing network only at the

boundary of plant area.

Flanged joints without insulated linings in metallic pipelines shall be

considered electrically continuous.

9. DEVIATION IN SUPPLY VOLTAGE AND FREQUENCY

Voltage and Frequency variation (during normal operation and steady state

conditions)

Voltage variation not more than +/- 10% from the rated voltage at generator

and consumer terminals

Frequency Deviation not more than +/- 10% from the rated

Maximum allowable voltage drop during normal operation and steady state

conditions

Main Feeders : 10%

Motor and plant static load cables from MCC at full loads : 20%

Lighting Circ. (from LV distribution boards to furthest lighting fixtures): 15%

Maximum allowable voltage drop during starting or reacceleration of motors:

At motor terminals: not more than 15 % (except very large motor to be connected

to the captive transformers and to be considered individually based on studies, ifapplicable.)

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10. EMERGENCY POWER GENERATION AND DISTRIBUTION

Emergency power for the plant shall be provided by standby diesel driven generator

to facilitate the start up and safe and orderly shutdown of the plant in the event of

loss of main power generation. The size and number of standby generator shall be

finalized during engineering design.

The diesel generator shall supply power to essential loads such as emergency

lighting including those for control room, substation and generator shelter, UPS

including plant control system and emergency shut down system, DC power supply

units, Hazard Monitoring System, Communication systems, HVAC loads for

Control Room and Generator Operation, auxiliary loads of one main generator

Diesel Engine Generator, critical motor operated valves and essential auxiliaries of

major machinery if any, air compressor to provide instrument air to emergency

services.

The emergency generator shall be sized for the required running loads plus its 25%

spare.

The emergency generator shall be started and supply the power to the emergency

power distribution system automatically in the event of total power disturbance of

main generators (Black Start Capability). Electrical synchronizing facilities shall be

provided for emergency generator.

The load running test during commissioning test and periodical maintenance after

plant operation for Diesel Engine Generator shall be performed using plant actual

loads.

The emergency power shall be generated at the 380V low voltage level and

distributed to downstream substations as required.

The control panel of generator set shall be located inside main control building or

substation adjacent to the generator set. Only engine running status, breaker status,

neutral earthing switch status, common alarm & trip status and analogue signals of

V, A, KW, PF, Hz shall be communicated to Main Control Room by hard-wiring or

softlink / RS 485,etc and no control action can be achieved from remote location.

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11. LOAD SHEDDING AND MOTOR RESTART SYSTEM

11.1 Load Shedding System

The electrical loads to be shed under emergency conditions shall be studied and

finalized during engineering stage.

11.2 Motor Re-acceleration

Automatic reacceleration and re-start scheme shall be provided for necessary

motors based on process requirement.

12. ELECTRICAL LOAD DATA CALCULATION

Maximum normal running plant load = x (%) C + y (%) I

Peak load = x (%) C + y (%) I + z (%) S

C : Continuous I : Intermittent S : Stand-by

x, y, z : Diversity Factors

Default values for initial load assessment or if the diversity factors not finalized;

x = 100 % (all driven equipment should be operating at its duty point.

But some diversity may need to be applied to non-process loads, e.g. Office and

workshop power and lighting - typically 80 %)

y = 30 %

z = 10 %

Instead of z (%)S, only one of the largest electrical stand-by units per switchgear

line-up may have to be considered when establishing the peak load.

13. SYSTEM STUDIES

The following calculations shall be performed for the design and study of electrical system

and sizing of electrical equipment;

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Load Data Calculation

Short Circuit Calculation

Load Flow Calculation

Motor Starting Calculation

14. LV SWITCHGEAR AND MCC

LV switchgear 400V shall be metal clad, IP31, single bus, draw-out type, Air

Circuit Breakers. LV MCC shall be metal enclosed, IP31, with drawable motor

control or feeder unit.

Approximately 10 % of total MCC units as spare and approximately 10 % future

space shall be provided per each MCC line-up subject to manufacturers standard

practice.

transformers shall be provided.

15. SYSTEM PROTECTION AND METERING

15.1 Switchgears

Incoming of 380V switchgear

Over current relay with instantaneous unit

Earth fault relay

Feeders of 380 V Switchgear

Over current relay with instantaneous unit

Earth fault relay

Ammeter with selector switch

Multifunction relay which cover all above protections and meters requirement is

preferable (Solid State Relay).

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15.2 LV MCC unit

Magnetic Trip Molded Case Circuit Breaker (sized to be tripped at approximately

10 times of motor full load current) with contactor and thermal relay for motor units

Thermal Magnetic Molded Case Circuit Breaker for feeder units.

Earth Fault Relay for motor units of at least 5.5 kW and above, and for feeder

supply units of breaker over 100 A trip rating

Single phase Ammeter for motor units of 30 kW and above

Running (red) / Stopped (green) / Fault (Amber) Lamp for MCC units

No start / stop control switch for motor units

The intelligent type solid state motor protection and control system can be also

applied for LV MCC unit with manufactures standard central unit and

maintenance facilities.

16. UPS SYSTEM

UPS systems will provide power to the DCS or PLC, Safety Instrumented System

and other critical loads. The UPS system will receive power from the emergency

supply with a bypass circuit from the emergency motor control center. UPS power

supply unit shall be provided in substation. The UPS shall be capable of operating

on small diesel engine driven generators for emergency power that may have larger

frequency variations than the larger primary power generators. UPS systems shall

be double configuration with voltage stabilizer at bypass line.

Battery back-up time for both UPS power supply unit shall be 60 minutes.

17. LOCAL CONTROL STATION (LCS) FOR MOTOR CONTROL

LCS shall be provided with start/stop control function suitable for area

classification with locking feature which is padlock able in off position.

LCS shall be hard-wired directly to the motor starter in the MCC.

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Motors automatically controlled by DCS or PLC shall have Hand-off-Auto selector

switch on LCS.

For all air fin-fan motors, LCS shall be located close to air fin-fan unit.

18. SUBSTATIONS

In general, substations shall be elevated with the height from grade to the under side

of the lowest beam by min. 1500 mm for bottom entry of underground cables with

cable glands.

Substations shall be located in non-hazardous, safe areas and furnished by air

conditioning.

Personnel access doors with panic bar and equipment access double doors of

adequate size shall be provided for all substations.

The under floor space sides of each substation, not covered with firewall, shall be

fenced with proper chain link.

Substation floor shall be concrete surface and steel channel shall be installed, level

and flush with finished floor grade for mounting the electrical panels. Electrical

panels shall be tag welded or bolted to the floor steel.

In general, cables shall enter the substation from bottom side.

Suitable cable support frames made of channel, angle and unistrut below the

substation shall be provided to support cables.

All LV and control cables shall be fixed by coated stainless steel all purpose band

'Band it' or equivalent.

For cable glanding below the substation, suitable gland box below SWGR/MCC.

The box shall have removable covers of galvanized sheet on front and rear complete

with neoprene gaskets. The box shall be hot dip galvanized.

Substations shall have a separate battery room with access from outside the

substation. Provisions shall be made for sufficient diffusion and ventilation of the

gases from the battery to prevent the accumulation of an explosive mixture.

Package type substations may be provided wherever practical including small

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power distribution such as tank farm, buildings, offsite users etc.

19. PAINTING

Color of Electrical Equipment (Switchgear / MCC panel, Distribution & Lighting Panels

etc.) shall be RAL7032 or equivalent.

20. PROTECTION GRADE OF ELECTRICAL EQUIPMENT

Protection grade of enclosures of outdoor Electrical Equipment ( Outdoor

Distribution & Lighting Panels etc.) shall be IP55.

Protection grade of enclosures of indoor Electrical Equipment (Substation

Switchger / MCC, UPS, Panel etc.) shall be IP31.

21. NAMEPLATES

All electrical equipment such as Switchgear/MCC, control stations, transformers,

panels, junction box etc. shall have an engraved non-corrosive nameplate.

The nameplates will be attached to the equipment with stainless steel machine

screws wherever possible, or on stainless steel mounting brackets, as required,

adjacent to the equipment.

22. CABLING SYSTEM

Electrical power and control cables for outdoor installation shall be armored cables

and shall be installed underground as direct buried cables or aboveground in cable

trays. In aboveground cabling system, the cable tray system shall be mainly used.

Non armored cables can be utilized for building loads and interconnecting cables

inside substations and control rooms.

The bolts, nuts, washers and U-bolts to be used for electrical installation shall be

made of stainless steel. The support materials for electrical installation such asangles and channels shall be hot dipped galvanized steel.

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23. UNDERGROUND CABLING SYSTEMS

There are two types of underground cabling system as follows:

Direct-buried cable system

Underground conduit system

23.1 Direct-Buried Cable Systems

Direct-buried cable systems shall be either of the following two types:

Cable buried directly in a trench with exposed earth sidewalls and bottom, and

covered with red concrete slabs or tiles for protection.

Cable buried directly in a trench with reinforced concrete or brick sidewalls / covers

and an earth bottom.

23.2 Underground Conduit Systems

Underground conduit systems shall be either of the following two types:

Conduits laid underground. These are called direct-buried conduits.

Conduits laid underground and encased in concrete. These are called duct banks.

23.3 Types of Cable

The types of cable to be used shall be as specified in section 31.

23.4 Routing of Underground Cabling Systems

The route of the underground cable shall be determined by considering the

following:

The route of the cable shall avoid aboveground and underground obstructions so

that reasonable access to the cable is assured.

Wherever practical, trenches shall run in unpaved areas and shall be routed adjacent

and parallel to roadways.

A clearance of not less than 300 mm shall be maintained between the cables and

underground piping.

Cables crossing under main roads, paved heavy traffic roads, shall be run in duct

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banks, or reinforced concrete culverts.

Earth wall cable trench shall be used in unpaved area. Concrete or brick wall trench

shall be used in paved area.

23.5 Design of Direct-Buried Cable Systems

Types of Underground Cable Trench

Earth Wall Trench :

The sides and bottom of earth wall cable trenches shall be exposed earth. Red

concrete slabs or tiles with a minimum thickness of 50 mm shall be laid on the

top layer of the sand fill. These slabs shall extend approximately 150 mm

beyond the cable on both sides of the trench.

Concrete or Brick Wall Trench :

Concrete or brick wall cable trenches shall consist of reinforced concrete or

brick sidewalls and covers, and a bottom of exposed earth.

The trenches and covers shall be designed to withstand the maximum loading

for the area in which they are to be installed. Trench covers shall be painted

red. The covers shall be flush with the adjacent pavement or finish grade.

Cable Depth and Separation

The minimum cover for cables installed in earth wall trenches between surface

of cables at top layer and the finished grade.

The bottom layer of cables in trenches shall be installed on a cushion of

screened sand.

Other voltage cables may be installed in the same trench up to a maximum of

four layers with 100mm vertical separation between layers.

The top layer of cables and all future cables shall be below the bottom of the

trench cover for concrete or brick wall trenches, and below the bottom of the

protective covering for earth wall trenches. The space between the top layer of

cables and the trench cover or protective covering shall be completely filled

with screened sand.

No other cables shall be installed in the same trench with the high-voltage main

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distribution cables except for low-voltage interlock, relaying, and control cables

for the switchgear associated with the distribution cables. These low-voltage

cables shall be separated horizontally from the distribution cables by a masonry

barrier or screened sand.

Turns in trenches shall be constructed so that the cables can be installed with the

required bending radius.

Space for Future Cables

Trenches for direct-buried cables shall be designed with space for future cables as

listed below. The future cables include additional cables required (means design

allowance) during the detailed engineering stage of the Project.

A minimum of 10 % (with minimum 2 cables line space) of future cables shall

be estimated based on the number of cables originally installed.

The space for future cables shall be in the upper part of the trench.

23.6 Design of Underground Conduit Systems

Types of Conduit

Underground conduit to be used for duct bank shall be rigid polyvinyl chloride

(PVC) or high-density polyethylene.

Direct-Buried Conduits

The Direct-Buried Conduits consist of:

In unpaved areas

In concrete paved areas

Duct Banks

In duct banks, underground conduit runs shall be encased in concrete.

The minimum depth to the top of the concrete encasement shall be 450 mm

from finish grade.

Conduit Separation

The minimum separation between the outside surfaces of conduits shall be 25 mm

for nominal conduit sizes of 42 mm (1-1/2 inch) and smaller, and 50 mm for sizes

larger than 42 mm (1-1/2 inch).

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Conduits Extended to Aboveground

Nonmetallic conduits shall not be extended aboveground except for stub-ups within

switchgear, control center and similar equipment enclosures in non hazardous

locations and except for grounding wires. Where aboveground extensions are

required, a transition to rigid metal conduit shall be made underground. Stub-up

rigid metal conduit shall be properly sealed using soft seal or equivalent after cable

installation. Non metallic conduit shall not be used in the process area and buildings

located in the process area, example: substation.

23.7 Cable Splices and Terminations

Cables shall be laid in one length wherever possible.

All splices and terminations for high voltage cables shall be made according to the

cable manufacturer's recommendations.

23.8 Cable Route Marking

A system of aboveground cable route markers shall be provided to identify

underground cables in unpaved areas as follows:

Markers shall be located at every point where the direct-buried cable or conduit

changes direction.

Markers shall be provided on both sides of the trench which are 2.0 m wide or

more. For cable trenches less than 2.0 m wide, markers shall be provided at their

center. Where cable trenches are identified by painting or equivalent, the markers

are not required. Cable marker shall be provided

24. ABOVE GROUND CABLING SYSTEM

24.1 General

Aboveground cabling and wiring systems are the following:

Cable trays

Rigid metal conduit systems

Thin-wall metallic conduit systems

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Floor raceway systems

24.2 Types of Cable

The types of cables using aboveground vary depending on the services and

conditions as shown in Subsection 31.

24.3 Cable Trays

Cable tray systems shall be heavy duty, ladder type. Punched type trays and othersimilar supports may be utilized if required.

Cable tray systems shall be used in hazardous or non-hazardous, indoor or outdoor

locations. They shall be located so that they will not be damaged, such as by traffic

or during maintenance.

Trays and other fittings shall be made of hot-dipped galvanized steel.

Cable trays shall have removable covers in locations where cables are subject to

damage from falling objects, corrosive liquids or direct sunlight. In other locations,trays shall be open-topped. When removable covers are applied on cable trays in

more than one (1) layer installation, they shall be provided on top layer only.

Cable trays and ladders shall be supported properly at intervals recommended by

the manufacturer.

The arrangement of cable in or on supports shall be as follows:

Control cables shall be laid between power cables wherever possible.

MV and LV cables may be laid in the same cable trays

Trays carrying only control or instrument cables may have cables arranged in

more than two layers.

Cables shall be arranged to minimize the number of crossovers.

Tray supports shall be of heavy duty construction and galvanized or if practical,

painted.

Where there are up to three cables runs, they can be supported directly from / along

the structure by using clip or galvanized steel angle.

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24.4 Rigid Metal Conduit Systems

Conduits, elbows, couplings and other associated fittings shall be hot dipped

galvanized steel.

Conduit feeding equipment that is subject to vibration shall terminate in flexible

conduits suitable for the area classification.

All conduits shall be threaded with an absolute minimum of five full threads.

Threads shall taper 3/4 inch per foot.

Breathers and drains shall be provided at high and low points of the conduit system

to prevent the accumulation of condensed water. Breathers and drains shall also be

provided in junction boxes, explosion proof panel boards and generally in

equipment enclosures subject to accumulating condensed water by its shape and

position in the conduit system

A run of conduit between outlet and outlet, fitting and fitting, or outlet and fitting

shall not contain more than the equivalent of four quarter bends (360 degrees, total).

Minimum conduit used will be 3/4 inch except for those situations of

instrumentation equipment which call for 1/2 inch conduit.

When conduit runs exceed the equivalent of a 61 m (200 feet) straight run or

contain more than the equivalent of three 90 degree bends, pull fittings must be

installed. One 90 degree bend is to be considered to be equivalent to 15.25 m (50

feet) of straight run. No single bend shall exceed 90 degrees.

Conduit and conduit fittings shall not be welded to any structure.

Conduit shall be installed a minimum of 300 mm (1 foot) from un-insulated hot

piping or hot surfaces.

Conduit connections to end devices shall be from below to prevent moisture

ingress. Side entries are acceptable, but top entries should be avoided.

24.5 Thin-Wall Metallic Conduit Systems

Thin-wall metallic conduit systems shall not be used for outdoor areas and

classified locations. (EMT shall be used for only indoor wiring system.)

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24.6 Floor Raceway Systems

Acceptable floor raceway systems shall be restricted to under floor raceways and

cellular concrete floor raceways.

Floor raceway systems shall not be used for outdoor areas and classified locations.

The total cross-sectional area of all contained conductors at any cross section of a

floor raceway shall not exceed 40 % of the interior cross-sectional area of the floor

raceway.

Metal junction boxes shall be used with floor raceways and shall be electrically

continuous with the raceway. The junction boxes shall be located at floor grade and

sealed to exclude water or concrete.

Splices and taps shall be made only in header access units or junction boxes.

24.7 Routing of Aboveground Wiring Systems

Cable shall be installed according to the manufacturer's recommendation. In no

case shall manufacturer's maximum allowable pulling tension, armor compression,

etc., be exceeded during cable installation.

Wiring systems shall not be installed closer than 150 mm from surfaces with

temperatures of 1130F to 1490F and not closer than 300 mm from surfaces with

temperatures above 1490F. Where it is necessary to route a wiring system close to a

high-temperature surface, a high-reflectance thermal barrier shall be installed

between the system and the surface.

All cables shall run in one length wherever possible.

24.8 Splices and Terminations

Splices and terminations for cables operating above 600 volts shall be made

according to the cable manufacturer's recommendations by one of the following

methods:

Straight (in-line) splices

Heat shrink sleeve or similarly terminating device.

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25. CABLE AND CORE MARKER

All cables except for lighting systems shall be marked with a Type 316 stainless

steel tag with embossed lettering secured with Type 316 stainless steel ties or nylon

markers enclosed in a clear heat shrink sleeve. A cable marker shall be installed on

both ends of each cable. Where cables pass through duct banks, a marker shall be

installed on both sides of each penetration in addition to being marked on both ends

of the cable.

All cores of control cables shall have wires clearly identified with permanentlyembossed type or equal heat-shrinkable wire markers at every termination point.

Where it is determined that heat-shrinkable wire markers are not practical, slip-on

permanently embossed sleeves shall be used. For internal wiring of electrical

equipment and panels, equivalent vendor standard core identification system is

acceptable. These wire numbers must correspond to the wire numbers shown on

electrical drawings. An individual wire shall have the same assigned number at

each end and at each location where it is terminated.

Cable marker shall be provided on both ends of each cable and in every 5 meterlong distance between both ends.

26. TERMINATION

Control and instrument wires shall be terminated on terminal blocks in junction box

for external cables with suitable insulated compression terminals installed with a

ratchet type crimping tool with proper dies. Ring tongue or locking fork type

terminals shall be used when terminating to screw-type terminals. Straight pin type

ferrules shall be used when terminating to screw-clamp type terminals.

A removable bottom plate or threaded hub(s) for cable gland installation of external

cables shall be provided at local panel and / or junction box for package unit.

Where control and instrument wires terminate in a device where terminal points are

not provided (such as instruments or solenoids with pigtails), terminal blocks are to

be installed if the number of terminal points exceed four within a junction box. If

four or less, terminations are to be made utilizing self-insulated crimp type butt

splice connectors.

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No more than two wires shall be terminated on any one terminal point. Jumper

links or combs shall be used to connect together extra terminals to allow

termination of more than two wires to the same terminal point.

Splices at lighting fixtures and receptacles not located indoors shall be made with

self insulated crimp type butt splice connectors. These connections shall be water

proofed with rubber tape and vinyl plastic electrical tape to prevent the entrance of

moisture into the connector.

Where a lug or terminal is not provided with equipment, power wire shall be

terminated with compression ring tongue terminals. Terminals shall be installed

with a ratchet type or hydraulic crimping tool with the proper dies.

Motor terminations shall be made with ring tongue compression terminals installed

on the power wire and the motor lead. Stainless steel bolts, nuts, and lock washers

shall be used to connect the ring tongue compression terminals.

The threaded hub shall be provided at terminal box of motors for cable gland

installation of external cables. The type of thread shall be per ISO metric and size

of thread shall be designated on data sheet during design stage.

27. ELECTRICAL WIRE AND CABLES

27.1 Cable Specifications

All power and control cables (wires) shall conform to the following types:

XLPE/SWA/PVC : Cross-linked polyethylene insulated, PVC bedded,

galvanized steel wire or non-magnetic metal wire (only for

single core cable) armored and PVC outer sheathed able.

XLPE/PVC : Cross-linked polyethylene insulated and PVC outer sheathed

cable.

PVC/SWA/PVC : Polyvinyl chloride insulated, PVC bedded, galvanized steel

wire or non-magnetic metal wire (only for single core cable)

armored and PVC outer sheathed cable.

PVC/PVC : Polyvinyl chloride insulated and PVC sheathed outer cable.

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PVC : Polyvinyl chloride insulated cable (wire).

All cables shall conform to IEC 60502 except for PVC insulated single core cables

(wires) which shall conform to IEC 60227.

27.2 Cable Sizing

For the sizing of power cables, the following aspects shall be considered:

Thermal short circuit capacity ( for over 3 kV cables )

Voltage drop

Current rating

Minimum conductor sizes shall be as listed below:

LV control cables : 1.5 mm2

LV power cables : 2.5 mm2

27.3 Cable Construction

The conductor shall be either compact round stranded uncoated copper wires or

solid soft annealed uncoated copper wires, as specified in IEC 60228.

Suitable fillers (as specified in IEC) shall be used in the interstices of the cable to

give the completed cable a substantially circular cross section.

The outer sheath shall be flame retardant (not applied for cable installations outside

the plant).

27.4 Color Identification of cable core and outer sheath

HV / MV cable

Three cores : Red, Yellow, Blue

One core : Vendor Standard

Outer Sheath : Red

LV Power & Control cable

One core : Black

Two cores : Red, Black

Three cores : Red, Yellow, BlueThree core + Grounding : Red, Yellow, Blue + Green

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Four cores : Red, Yellow, Blue, Black

Four core + Grounding : Red, Yellow, Blue, Black + Green

Five cores and above : Black with white numbers

Outer Sheath : Black

28. LIGHTING

28.1 General

Lighting shall be provided for the following areas:

Process operating areas

Utility areas

Offsite Pump areas

Storage tank areas

Loading and unloading areas

Parking areas

Plant main roads

Buildings (Indoor & Outdoor)

Lighting shall not be provided for the following outdoor areas, unless otherwise

specified:

Waste disposal ponds

Plant perimeter and/or security fences

Access road outside battery limit

Future area

Street lighting systems shall High Pressure Sodium fixtures mounted on poles.

Outdoor general plant lighting and street lighting shall be controlled by a photo-cell

located at each substation and manual by operator.

Tank farm shall be provided with flood lighting. No lighting fixture is required on

the tank stairs and tank roof.

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28.2 Types of Lighting Fixture and Receptacle

The number of different types of lighting fixture used in an area shall be restricted

as follows to simplify maintenance work:

For outdoor area lighting

Mercury vapor lamp : 70 W, 100 W, 150 W, 250 W, 400 W

Fluorescent lamp : 20 W, 40 W (20 W x 2)

For street lighting

Mercury vapor lamp : 400 W, 250 W

For emergency lighting

Fluorescent lamp : 20 W, 40 W (20 W x 2)

Incandescent lamp : 100 W

For convenience receptacle (outdoor use): 15 A, 2 poles + 1 ground

Lighting fixtures in outdoor locations shall be equipped with a gasketed glove,

reflector and guard.

Mercury vapor lamps shall be a high power factor type.

Fluorescent lamps shall have a high power factor and rapid start type ballast.

All incandescent fixtures shall be a screw-in type.

Lighting fixtures in hazardous area shall be suitable type as per applicable codes

and standards for each classified area.

28.3 Emergency Lighting

Emergency lighting shall be fluorescent type fixtures, shall be provided in outdoor

areas to permit safe movement of personnel in normal operating areas during power

outages. Approximately 10 % of the total number of lighting fixtures in the process

and important utility areas such as around stage of towers, generator and air

compressor shall be provided as emergency lighting. Emergency lighting shall not

be required at operation vessels and tanks.

Emergency lighting for buildings shall be provided in the plant control rooms,

substations, generator shelter, HVAC panel and mechanical rooms, workshops,laboratories, and escape exit light at all manned buildings.

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Power for emergency lighting shall be supplied from distribution line backed up by

an emergency diesel generator. There shall be separate distribution panels fed from

the emergency generator.

The emergency lighting fixtures inside plant control rooms, substations and

generator shelter shall be provided with self battery pack for 30 minutes operation.

28.4 Receptacles, Welding Outlet

Convenience receptacles 15A, 230 V, two poles (phase and neutral) + Earth shall be

located so that any point in the plant areas where repairs, adjustment, or inspections

may be made can reach nearest receptacle with a 30m extension cord.

The plug for convenience receptacles shall be supplied at the rate of 1 piece per 10

receptacles.

Convenience receptacles shall be installed at 1 meter above grade or floor.

All convenience receptacles and plugs shall be suitable for the area classification.

Welding Outlets, 380V, 3 phases, 63A, 3 poles + Earth shall be provided in process

and utility areas where welding is performed on the basis of 50m extension cord.

Power supply to welding outlets shall be distributed from LV MCC in substations.

28.5 Illumination Levels

The lighting system shall be designed to provide minimum average maintained (in

service) horizontal lighting illuminance requirement as per API 540.

Lighting intensities are measured at 1 m above floor level. A maintenance factor of

0.8 is used to calculate these intensities.

29. CATHODIC PROTECTION

Design, material, installation, testing of cathodic protection system, in general shall be as per

the recommendation of National Association of Corrosion Engineers (NACE) RP-01-69, and

National Electrical Code (NEC) NFPA-70.

The detailed design of cathodic protection is covered in Specification Doc. No. 900-SPE-

5010.

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