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KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specification Number

075-pH-7907
Electrical Design, Ins tallation and Testing

17 JUN 94
7 MAR 93
Date

ISSUED AS KOC ENG GROUP SPEC ISSUED FOR INVITATION TO BID


Revision

0
Rev

BY

Chkd

Section

PE

Client

Engineering Group Specification

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CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 SCOPE

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4 4 6 6 7 7 8 10 11 13 16 16 18
20

STANDARD SPECIFICATIONS SERVICE CONDITIONS

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CLASSIFICATION OF HAZARDOUS AREAS

EQUIPMENT SELECTION FOR HAZARDOUS AREAS POWERSUPPLY

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ELECTRICALSYSTEMS SUBSTATIONS

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POWER GENERATION

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10.0 POWER DISTRIBUTION. CONTROL AND PROTECTION 11.0 MOTORS

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12.0 EARTHING SYSTEM 13.0 LIGHTING

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14.0 EMERGENCY LIGHTING

15.0 ROAD LIGHTING

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21 21 21 22 22 22 23 23 23 27 28 28

16.0 SOCKET OUTLETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1 Hazardous Areas and Outdoor Locations . . . . . . . . . . . . . . . . . . . 16.2 Unclassified Indoor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3 Location of Socket Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4 Socket Outlets Extension Leads . . . . . . . . . . . . . . . . . . . . . . . . . 16.5 Type of Socket Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.0 COMMUNICATION SYSTEMS

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18.0 CABLE DESIGN AND INSTALLATION 19.0 CONDUIT

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20.0 JUNCTIONBOXES

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21.0 NAMEPLATES AND LABELS

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22.0 CATHODIC PROTECTION 23.0 LIGHTNING PROTECTION

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29 29 29 29 29 29 30 30 30 31 31 31 31 31 31 31 32 32 32 32 32
32

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24.0 ELECTRIC SURFACE HEATING 25.0 SAFETY

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26.0 PAINTING

27.0 TESTS AT SITE

27.1 27.2 27.3 27.4 HV Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5 Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.6 LV Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.7 Voltage Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.8 Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.9 Protection Relay System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.10 Battery Equipments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 1 Motors and Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 2 Illumination Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.13 Function of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.14 Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

......................................... General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LV Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HV Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28.0 PACKING. MARKING AND DOCUMENTATION

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29.0 SPARE PARTS AND MAINTENANCE REQUIREMENTS

@ woc
1.0

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SCOPE

1.1

This specification covers the design, manufacture, installation, inspection, site commissioning, testing and supply of the electrical works for installation at the Facility in Kuwait. The electrical work installation shall fully comply with all relevant contractual requirements specified in the Scope of Work and Technical Specification of the Contract. The Contractor shall employ specialist engineers as required. In particular, the Approved Manufacturer's engineers shall supervise the installation and carry out the commissioning and testing at the Site of the following: 1.3.1 Generator sets. 1.3.2 High-voltage switchboards. 1.3.3 Low-voltage switchboards and motor control centres. 1.3.4 Variable speed drive controllers. 1.3.5 Uninterruptible power supply units. 1.3.6 DC supply units.

1.2

1.3

2.0

STANDARD SPECIFICATIONS

2.1

The electrical system shall conform in design, materials and performance, except where otherwise specified, with the current issue and amendments of the following prevailing on the effective date of the Contract: 2.1.1 lnternational Standards IEC standards shall include those listed in the Engineering Group Specification entitled "lnternational Codes and Standards" (Number 0 15-AH- I 002). 2.1.2 British Standards British Standards shall include those listed in the Engineering Group Specification entitled "lnternational Codes and Standards" (Number 0 15-AH-1002). 2.1.3 Other Standards KOC STD 381I 0 7 Hazardous Area Classification: Zonal Boundaries and Requirements for Contained Equipment.

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KOC STD 38 110711

The Completion of Hazard Assessments and Classification of Hazardous Areas. Model Code of Practice in the Petroleum Industry.

institute of Petroleum

2.1.4 Engineering Group Specifications The electrical works installation shall conform w i t h all relevant Engineering Group specifications of which the following are specifically referred t o in this specification: 0 1 5-AH-10 0 1 0 1 5-AH-1 0 0 2 0 1 5-HH-1101 0 1 5-JH-1911 0 1 5-KH-1902 0 1 5-PH-1902 0 1 5-PH-1903 0 1 5-PH-1904 0 1 5-PH- 1905 0 1 5-PH-1906 Basic Design Criteria International Codes and Standards HVAC Equipment and Installation Standard Auxiliary Control Room Cabinets Spare Parts and Maintenance Requirements High-Voltage Switchgear Power Transformers Generator Sets Low-Voltage Switchgear and Motor Control Centres DC Supply Units Electrical Cables Induction Motors Uninterruptible Power Supply Systems Cathodic Protection Transformer Rectifier Units Variable Speed Drive Controller Parking, Marking and Documentation Cathodic Protection Design Philosophy Shop and Field Painting Condition Monitoring, Telecommunication and Security System

0 15-PH- 1907
0 1 5-PH-1908 0 1 5-PH-1909 0 1 5-PH-1910 0 1 5-PH-1911 0 1 5-VH-1001 0 1 5-WH-1006 0 1 5-XH-1005 0 1 5-ZH-1002

Engineering Group Specification


2.2

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Compliance w i t h this specification shall not relieve the Contractor of its responsibility t o supply equipment suited to meet the specified service conditions and applicable regulations. Where conflicts exist between this specification and other Drawings, standards, codes and specifications, the most stringent shall be applied. Equipment may comply with other National Standards subject t o receipt of prior written approval from the Company. Electrical components for incorporation into the installation shall comply with the relevant IEC standards. These shall be selected t o exclude readily combustible insulating and constructional material and excessive heat generation. Electrical and mechanical electrical reliability is of the utmost importance. The components shall have been type tested t o the relevant IEC standards.

2.3

2.4

2.5

3.0

SERVICE CONDITIONS
3.1 The electrical installation shall be suitable for continuous operation at a desert location under high ambient temperatures and humidity. The atmosphere at the Facility is generally dusty and corrosive and may contain traces o f hydrogen sulphide. All materials used for electrical installation shall be new and in all respects suitable for continuous operation in the service conditions stated in Engineering Group Specification entitled "Basic Design Criteria" (Number 0 1 5-AH-1 001). Equipment located inside buildings shall be rated for continuous operation throughout the range of specified ambient temperatures pertaining, without regard for the air conditioning. Equipment located outdoors shall be provided with sunshades, where required, to reduce solar gain. Reliability of all equipment to perform continuously in the service conditions specified is essential. Equipment typical of that being supplied shall have been in operational use elsewhere for a minimum of 2 years. Prototype or unproven equipment not having a well-established record shall not be considered.

3.2

3.3

3.4

4.0

CLASSIFICATION OF HAZARDOUS AREAS


The classification of hazardous areas is based on the requirements of the Company document STD 381I 0 7 entitled "Hazardous Area Classification: Zonal Boundaries and Requirements for Contained Equipment" and the Institute of Petroleum Model Code of Practice in the Petroleum Industry. Part 15 of this code is being used for additional guidance and clarification.

Engineering Group Specification


5.0

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EQUIPMENT SELECTION FOR HAZARDOUS AREAS


5.1 Equipment suitable for installation in Zone 1 and Zone 2 hazardous areas shall be certified for use i n those areas by a recognised CENELEC Testing Authority or other Authority approved by the Company. Marshalling boxes, cable glands, junction boxes, switches, remote control stations and welding outlets installed outdoors in both Zone 1 and Zone 2 hazardous areas shall be certified Exd. Luminaries located in Zone 1 areas shall be certified Exd. Luminaries in Zone 2 areas may be of the Exe type. All laboratory equipment shall be certified Exd. Materials used for battery rooms shall be certified for Zone 1 Gas Group IIC, Temperature Class T3. Equipment installed shall be certified as follows: 5.6.1 In Zone 1 areas : Exd 5.6.2 In Zone 2 areas : Exd, Exe or Exn. Requirements specified in paragraph 5.2 shall prevail in this regard.

5.2

5.3

5.4 5.5

5.6

6.0

POWER SUPPLY
6.1 The standard voltages which shall be employed are: 6.1.1 1 1-kV, 3-phase, 3-wire, neutral, low-resistance earthed, rated lightning impulse level 75-kV peak. 6.1.2 3.3-kV, 3-phase, 3-wire, neutral, solidly earthed, rated lightning impulse level 40-kV peak. 6.1.3 440-V, 3-phase, 4-wire, neutral, solidly earthed. 6.1.4 250-V, 1-phase, 2-wire, neutral, solidly earthed. 6.1.5 110-V, k 1 %, 1-phase, 2-wire, 50Hz k 0.5Hz neutral solidly earthed UPS. 6.1.6 1 10-VDC k 1 0 % unearthed. 6.2 6.3 6.4 Mains voltage is subject t o a variation of

+ 6%.

The standard frequency is 5 0 Hz k 2.5%. Control voltages for circuit breakers and motor starters shall be 110 VAC

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or 1 1 0 VDC as defined in the Engineering Group specifications for switchgear. 6.5 The Company phase sequence is in the order of Red-Blue-Yellow, which is the opposite order of the Kuwait national sequence. However, all equipment shall be of standard construction w i t h phases arranged Red-Yellow-Blue and connected within equipment in the normal phase sequence with RedYellow-Blue laid out from top t o bottom and left t o right, when viewed from the front. Motor rotation shall be checked, particularly before making off high-voltage (HV) and heavy current cables. Where required, correction of rotation shall be at motor terminals and not elsewhere in the electrical supply. The rated short-time withstand current of switchgear shall be as stated on the single-line diagrams, subject to a design study and verification by the Contractor. Standard ratings shall be: 440 V 3.3 k V 11 kV 5 0 kA for 1 second. 8 0 k A for 1 second. 2 5 kA for 3 seconds. 2 5 kA for 3 seconds.

6.6

6.7

6.8

7.0

ELECTRICAL SYSTEMS
7.1 The basic power system configuration shall be as shown o n the overall single-line diagram giving the minimum Company requirements. During detailed design, the Contractor shall submit t o the Company for approval its proposed equipment ratings, system voltages, fault levels and protection arrangements. The Contractor shall prepare and submit t o the Company for approval a tabulation of estimated loads with diversity factors, an overall electrical single-line diagram and switchgear single-line diagrams showing the main distribution system from the generators and/or the incoming supply terminals through t o the outgoing circuits of the low-voltage (LV) system.

7.2

7.3

The system fault levels and impedances shall be calculated and shown on the single-line diagrams together with the proposed standard ratings, system earthing methods and protective relays t o be used. The calculated fault levels shall include motor contributions. The system voltage drops shall be calculated and shown t o achieve the requirements specified in section 18.0, Cable Design and Installation, of this

7.4

Engineering Group Specification


specification. 7.5

Specification Number

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Main supply cables, generators and transformer ratings under site conditions shall be selected with a 25% spare capacity for future use by the Company. The circuits, cables, switchgear etc. supplied by the above, shall have a continuous rating under site conditions equal t o or exceeding the supply equipment ratings. All switchboards, motor control centres and distribution boards shall incorporate a minimum of 25% spare equipped circuits of each rating or type for future use by the Company. The system is normally run with all bus-section breakers closed. Load centres serving plant necessary for maintaining production, or critical for safety or shutdown shall be provided with dual feeders, each sized for the 1 0 0 % plant load. This shall include the provision of duplicate circuit breakers, cables and transformers so arranged that maintenance can be carried out without interruption of the process operation. Harmonic distortion on the system at each voltage level shall not exceed the limits stated in the Engineering Group Specification entitled "Variable Speed Drive Controller" (Number 0 1 5-PH-1911). Suitable harmonic filtration equipment shall be provided where required as a result of calculations or Site measurements performed by the Contractor.

7.6

7.7 7.8

7.9

7.10 A standby generator set shall be provided. The standby generator set shall be continuously rated to supply: 7.10.1 7.10.2 All desalters and auxiliaries required for desalter operation. Crude product pumps where no mechanically driven standby pump is specified; crude booster pumps and all auxiliaries required for crude oil transmission at a capacity of 5 0 % flow 100% head. All emergency and safety devices including total emergency switchboard load. All plant lighting and remaining HVAC systems. All utilities required for operation of the above. Plus 2 5 % of above total load.

7.10.3

7.10.4 7.10.5 7.10.6

7.1 1 The standby generator set shall be capable of starting the largest connected motor in system with all other loads, including the spare capacity running, while still maintaining the voltage drop within the specified limits.

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7.12 The standby generator set shall automatically start and transfer t o the HV electrical system when all incoming power supplies fail, in accordance w i t h the automatic transfer scheme. 7.13 Loads critical for safety or shutdown as shown on the emergency switchboard single-line diagram and including UPS systems, DC supply units, fire water jockey pumps, control building HVAC and emergency lighting shall be connected t o an emergency switchboard. The emergency switchboard shall be normally supplied from the main power system. 7.14 In the event of loss of normal supply voltage and standby supply voltage, the emergency switchboard shall automatically be transferred t o an emergency generator set, i n accordance w i t h the automatic transfer scheme specified herein. The emergency generator set shall be continuously rated for the total running load connected t o the emergency switchboard plus 2 5 % of that total load and shall be capable of starting the largest connected motor in system w i t h all other loads, including the spare capacity running, while still maintaining the voltage drop within the specified limits. 7.1 5 Provision for automatic restart of loads connected t o the emergency switchboard shall be provided on all circuits. 7.1 6 For the purpose of regular test operation of diesel and gas engine- driven generator sets, load banks rated a t 4 0 % of the generator capacity together w i t h associated switchgear shall be provided. 7.1 7 For a Facility where an incoming supply is not available, onsite generator sets shall be provided. T w o generators, each rated 125% of the total Facility load, shall be provided, complete w i t h equipment for synchronising, parallel operation and load management. Such sets shall be suitable for both continuous parallel operation and duty plus automatic standby operation. In such cases, standby generation is not required, but emergency generation shall be provided as specified above. 8.0
SUBSTATIONS

8.1

Substations shall be located centrally for plant distribution and local t o principal load points. In all cases, substations shall be located in areas classified as non-hazardous. All substation buildings shall be designed t o provide a clean, dust free and dry location for the switchgear, motor control centres and auxiliary equipment. Main substations shall have elevated floors and cable basements. Smaller substations, e.g., crude pumphouse substation, shall have floors a t grade level with structural cable trenches.

8.2

8.3 Air conditioning shall be provided in accordance w i t h the Engineering Group


Specification entitled "HVAC Equipment and Installation" (Number 0 1 5-HH1101).

Engineering Group Specification


8.4

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0 15-PH- 190 1

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A minimum clearance of 1 m shall be provided behind all switchboards for access and maintenance. A minimum clearance of 2.5 m shall be provided in the front of switchboards. A t the ends of all switchboards, space shall be allowed for t w o extension panels at each end plus at least 1 m t o the nearest wall or other equipment. Cable trayslladder racks shall be provided above or below the floor or in structural concrete trenches for incoming and outgoing cables and interpanel connections, as appropriate for the method of cable routing for the building.

8.5

8.6

9.0

POWER GENERATION
9.1 For details of generator set performance and construction, reference should be made t o the Engineering Group Specification entitled "Generator Sets" (Number 0 1 5-PH-1904). All commissioning and testing at the Site, including the provision of any testing equipment, shall be provided by the generator set Approved Manufacturer. Both emergency and standby generator sets shall be available for immediate startup on receipt of an automatically or manually initiated control signal. Each set shall be provided with a starting control mode selector switch located on the generator control panel located adjacent t o the generator set. The control modes shall be OfflAutomaticIManuallTest. 9.4.1 Automatic Start a. With the automatic start control mode selected, failure of the incoming supply or both supplies in the case of a switchboard having dual feeders shall automatically start the generator set. When running, the set shall be automatically connected t o switchboard busbars t o supply loads. Should there be t w o generator sets connected t o the switchboard, both shall start, automatically synchronise and share the load. Connection of a generator set t o the busbars after a busbar fault shall be inhibited. Parallel operation of the generator with the incoming power supply shall be prevented.

9.2

9.3

9.4

b.

c.

A test facility shall be provided t o simulate the normal undervoltage automatic start-up signal. The switchboard incoming supply circuit breaker(s) shall open and the automatic start and run procedure shall be completed.

Engineering Group Specification


9.4.2 Manual Start a.

Specification Number

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0 1 5-PH-1901

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With the manual start mode selected, the generator set shall start by operation of the manual start pushbutton on the generator control panel. Should there be a pre-existing loss of power at this stage or should a loss of power occur after the manual start of the generator set, the automatic connection procedure described above shall proceed.

b.

9.4.3 Test Start a. With the test mode selected, starting and stopping of the generating set shall be by manual operation of the appropriate pushbuttons on the generator control panel. Automatic transfer of the generator t o the switchboard shall not occur in this mode. The test mode shall be used for engine exercising and testrunning operations.

b.

9.4.4 Restoration of Normal Power a. The restoration of normal power shall be detected and annunciated both at the generator control panel and at the central control room. The transfer of the load back t o the normal supply shall be automatically initiated w i t h additional manual transfer facilities. After transfer of load back t o the normal supply, the shutdown of the generator set shall be manually initiated.

b.

c.

9.4.5 Parallel Operation and Synchronising a. All generator sets shall be suitable for parallel operation and shall have adjustable droop controls for both power and reactive load sharing. As indicated on the single-line diagram, when generating sets operate in parallel, after automatic or manual starting, the incoming generators shall automatically synchronise with running generators. For synchronising, automatic and manual control of the generator voltage and frequency shall be possible from the generator control panel. All automatic synchronising shall be

b.

c.

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backed up with check synchronising, which shall also supervise manual synchronisingoperations. Automatic/manual synchronising selector switches shall be provided. 10.0 POWER DISTRIBUTION, CONTROL AND PROTECTION 10.1 The proposed power distribution system is shown on the single-line diagram(s). 10.2 Power transformers shall comply with the Engineering Group Specification entitled "Power Transformers" (Number 01 5-PH-1903) and shall be located outdoors in transformer bays adjacent t o the substation. Where sunshades are not incorporated into the substation construction, separate transformer sunshades shall be provided. 10.3 High-voltage switchgear shall comply with the Engineering Group Specification entitled "High-Voltage Switchgear" (Number 0 1 5-PH-1902). The switchgear and motor control centres shall be located in an airconditioned main substation. 10.4 Low-voltage switchgear and motor control centres shall comply with the Engineering Group Specification entitled "Low-Voltage Switchgear and Motor Control Centres" (Number 0 1 5-PH-1905). The main switchgear and motor control centres shall be located in an air-conditioned main substation. 10.5 DC supply units providing 110-VDC power for switchgear control and indication or for powering rotating plant auxiliaries shall comply with the Engineering Group Specification entitled "DC Supply Units" (Number 0 1 5PH- 1906). 10.6 For details of any other DC supplies, reference shall be made t o the Engineering Group specifications dealing with instrumentation. 10.7 The DC supply units shall be located in air-conditioned substations. The batteries shall be located in a separate battery room in the substation. 10.8 The uninterruptible power supply system for the DCS, ESD and fire and gas systems, shall comply with the Engineering Group Specification entitled "Uninterruptible Power Supply System" (Number 0 1 5-PH-1909). The unit shall be located in an air-conditioned room in the control building with the batteries in a separate battery room. 10.9 Variable speed drive controllers shall comply with the Engineering Group Specification entitled "Variable Speed Drive Controller" (Number 0 1 5-PH19 1 1). The units shall be installed in an air-conditioned substation located adjacent t o the driven equipment, if possible. 10.10 Motor Control Stations and Isolators

QKOC

Engineering Group Specification


10.10.1

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All motors shall be provided with a control station located adjacent t o the motor, consisting of: a. b. Start pushbutton, green, shrouded type. Stop pushbutton, red mushroom-head, stay-put type, padlockable in the stopped position. Local/off/remote selector switch where specified on the P&ID drawings. Ammeter for all drives 15 kW or greater rating.

c.

d. 10.1 0.2

A local power and control supply isolator shall be provided at all motor-operated valves. Control stations shall have a minimum degree of protection of IP55.

10.10.3

10.1 1

Protection Relays 10.1 1.1 Electronic/static relays shall be used, where possible, except for motors of 3 0 kW or less, which shall have conventional relays as specified in the Engineering Group Specification entitled "Low-Voltage Switchgear and Motor Control Centres" (Number 0 1 5-PH-1905). All protective relays, except for motor thermal overload type (motors 3 0 k W or less only), shall be flush mounted in switchgear panels and shall comply with IEC 255. All relays shall have hand reset contacts. Auxiliary supply voltage shall be 1 1 0 VDC for all relays, except 440 V motor control which shall be 1 1 0 VAC. Separate flags or indication shall be provided for each function. Generator differential protection relays, transformer differential protection relays and restricted earth fault relays shall all be high impedance, circulating-current type, stabilised for through fault current and immune to DC offset of fault current or transformer inrush current. Motor stalling relays shall have the necessary ambient temperature compensation to operate satisfactorily at the specified service conditions.

10.1 1.2

10.1 1.3

10.1 1.4

10.1 1.5

10.1 1.6

Inverse definite mean time lag (IDMTL) overcurrent relays, non-directional and directional, shall be inverse or very inverse

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type as suited for the application and shall have adjustable current setting range and time multiplier setting range. Threepole IDMTL overcurrent relays shall be provided for phase faults.

10.1 1.7

lnstantaneous overcurrent relays shall be used for short circuit protection. The relays shall have high drop-off to pick-up ratio, low transient overreach, high thermal rating and be immune to DC offsets. Three-pole instantaneous overcurrent relays shall be provided for phase faults. lnstantaneous undervoltage relays, with adjustable range and high drop-off t o pick-up ratio, shall be provided for monitoring all the three phases, for the loss of mains supply. These undervoltage relays shall be used with suitable time delay relays for automatic transfer initiation. Tripping of highvoltage motors shall be by separate time delayed busbar connected undervoltage relays. lnstantaneous rated voltage relays shall be provided for monitoring all three phases for restoration of mains supply. All undervoltage relay circuit fuses shall be coloured red. Frequency relays shall have continuously adjustable ranges from 47.0 t o 52.0 Hz, with continuously adjustable pick-up to drop-off differential from 0 t o 1.0 Hz. The relays shall be complete with the necessary provision t o prevent inadvertent operation due t o harmonics. Auxiliary relays shall be flush type with flag or LED indication and hand-reset contacts. Auxiliary relays with inscriptions shall be provided where required such as Buchholz alarm and trip, winding temperatureloil temperature alarm, trip, and intertrip receive. High-speed, high-burden lockout relays with cut-off contact, hand-reset type shall be provided for trippingllockout functions for each HV circuit breakerlstarter and LV circuit breaker. Two normally open and t w o normally closed volt-free contacts shall be wired t o a terminal block for future use.

10.1 1.8

10.1 1.9 10.1 1.10

10.1 1.1 1

10.1 1.12

10.12

Relay Interface Cabinets

10.12.1

Relay cabinets for interfacing between the DCS and ESD control systems and the electrical switchgear and the motor and starters shall be located in the substations. The relay cabinets are described in the Engineering Group Specification entitled "Standard Auxiliary Control Room Cabinets" (Number 01 5-JH-1911).

10.1 2.2

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10.13

Switchgear Control 10.13.1 Motors shall be operated from the control station local t o the motor, and where specified on the P&ID drawings, by a remote control facility. Low-voltage switchgear (non-motor circuits) shall be operated from the front of the switchgear, or in the case of the emergency switchboard incoming circuit breakers, from the emergency generator control panel. High-voltage switchgear (non-motor circuits) shall be operated from a control panel in the main substation. Switchgear control panels shall comply with the Engineering Group Specification entitled "High-Voltage Switchgear" (Number 0 1 5-PH-1902).

10.13.2

10.13.3

10.14

Alarm Annunciators and Indications 10.14.1 Substation alarm annunciator panels shall display alarms individually from each transformer, statuslalarm signals for each incoming or bus section circuit breaker for each switchboard and status of remote supply circuit breakers when located in Company substations. All other switchgear alarms shall be annunciated, but these may be grouped for each switchboard busbar section. Where specified remote outputs shall be provided for DCS systems or Condition Monitoring Systems. All transducers shall give 4 - 2 0 m A outputs with loop power from the remote (e.g., DCS) end.

10.14.2

11.0 MOTORS
Motors shall comply with the Engineering Group Specification entitled "Induction Motors" (Number 0 1 5-PH-1908).

12.0 EARTHING SYSTEM


12.1 Earthing shall be provided t o protect personnel against electric shock and equipment against damage arising from earth fault currents, static discharge and lightning. 12.2 A n earthing ring of 120-mm2 uninsulated, stranded, copper cable shall be laid around the Facility as shown on the layout Drawings, the ring shall be earthed using earth electrodes. The main substation local ring shall be 300mm2 uninsulated copper cable.

Engineering Group Speci'fication

Specification Number

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0 15-PH- 1 901

17-6-94

170f 32

12.3 All main steel structures, vessels, tanks, pipe supports, electrical equipment and transformer star points shall be bonded t o the earth ring. 12.4 Steel structures, vessels, tanks, and other major items of the plant shall have a minimum of t w o connections t o the earth ring. 12.5 Branch connections t o the ring shall have a minimum size as follows but shall be sized such that the voltage t o earth does not exceed 5 0 V when carrying the maximum earth fault current. HV equipment LV equipment Major non-electrical items Transformer star points Minor equipment 7 0 mm2 3 5 mm2 35/70 mm2 Varies (see layout Drawings) 6mm2/16mm2

12.6 Fences and gates shall be bonded for continuity and earthed at local electrodes. 12.7 Earth electrodes shall be 16-mm diameter extendable type of solid copper or copper-clad steel construction driven directly into the ground to a minimum depth of 3.5 m without excavation or drilling. 12.8 The connections from earth electrodes t o the earthing ring cable shall be made in a concrete inspection pit with cover, using bolted clamps. 12.9 A sufficient number of earth electrodes spaced at no more than 5 0 m apart and no less than the length of the buried electrode shall be driven t o achieve resistance t o the general mass of earth of not more than 4 ohms, or any lesser resistance required t o operate the electrical protection. 12.10 All metallic equipment which comes in contact with any electrical equipment circuit or device shall be earthed. The shells of all steel tanks shall be earthed and pipelines electrically bonded to the tanks t o which they connect. Buried earth conductors shall be run 600 m m minimum below finished grade. Earth busbars of tinned copper and minimum size 5 0 m m x 6 m m shall be located above grade in substations and other locations t o provide means of isolation from the ring and t o terminate branch connections as necessary.

12.1 1

12.12

12.13

Engineering Group Specification


12.14

Specification Number

Rev 1

Date

Sheet

0 1 5-PH-1901

17-6-94

1 8 0 f 32

All joints in the buried earth system, except onto equipment or earth busbars, shall be by the thermite welding process. Connections t o aboveground equipment and earth busbars shall be by crimp-type lugs and bolted connections. All bolted connections shall be protected against corrosion by wrapping with grease-impregnated tape. Earthing cables emerging from the ground shall be protected against mechanical damage by steel pipes up t o 1 5 0 m m above grade level. The pipes shall be sealed with a non-setting, non-flammable compound. Cable lead sheath and armour shall be earthed through the cable gland or joint to the earthed equipment at both ends. Reliance on the cable lead sheath and armouring as the sole earth shall not be acceptable. Single-core cables shall only be earthed at the supply end. All earthing conductors installed aboveground shall be PVC sheathed, coloured green and yellow.

12.15

12.16

12.17

12.18

12.1 9

13.0 LIGHTING
13.1 Lighting illumination levels shall be in accordance with the following list. The values are for average illumination. 13.1.1 Buildings a. Substation, equipment rooms, battery and generator rooms and utilities buildings Control rooms, buildings and offices Workshops 2 0 0 Lux at floor level

b.

500 Lux at 0.85 m above floor level 3 0 0 Lux at 0.85 m above floor level 5 0 0 Lux at 0.85 m above floor level 5 0 Lux at grade level

c.

d.

Laboratories

e.

Substation cable basements and transformer bays

Engineering Group Specifiction


13.2.2

Specification Number

Rev

Date

Sheet

015-PH-1901

17-6-94

19 of 32

Outdoor Areas a. General process areas 5 0 Lux at grade level 7 5 Lux 0.85 m above floor level 5 0 Lux at platform level 2 0 0 Lux 0.85 m above floor level 3 0 Lux at grade level 5 0 Lux at grade level 1 0 0 Lux at Gauge 3 0 0 Lux 0.85 m above floor level To BS 5489, Part 2, Category 2 2 0 Lux at grade level 5 0 Lux at grade level

b.

Under pipeways (with pumps) and pump stations Operating and access platforms Compressor and pump houses

c.

d.

e.

General areas

f.

Walkways and access

g. h.

Gauge glasses Local control panels and instrument panels Roadways

I.

j-

Perimeter fence Tankage area

k.

13.2 Lighting shall comprise internal lighting of buildings, process plant lighting, area floodlighting, perimeter fence and road lighting. 13.3 Lighting in buildings shall be by fluorescent luminaries or, where mounting heights exceed 3.5 m, by high-pressure sodium (SON) (unless otherwise specified) high bay luminaries. Outdoors, local lighting at pumps, valves and gauge glasses shall be by fluorescent luminaries; otherwise, in open areas and around the perimeter, lighting shall be by SON (unless otherwise specified) flood lighting luminaries mounted on high process structures, pipe rack supports or galvanized steel floodlighting poles. The perimeter fence SON (unless otherwise specified) floodlights shall be mounted o n 5 m high posts. 13.4 The control room lighting shall use low glare fluorescent luminaries with electronic control gear together with dimming facilities in selected areas t o

Engineering Group Specification

Specification Number

Rev

Date

Sheet

01 5-PH- 1 901

17-6-94

20 of 32

ensure that the control panel displays and VDU screens can be viewed by operators without glare, reflections or eyestrain. 13.5 All outdoor luminaries shall be provided with readily available safe means of personnel access for maintenance purposes. Such access shall comprise fixed access platforms with permanent ladders. Floodlighting poles shall be 1 2 m high and have permanent fixed access. 13.6 Lighting distribution boards shall be 3 pole and neutral configuration with an incoming isolator. Lighting distribution boards for outdoor lighting shall be photoelectric cell contactor controlled. An override test facility shall be provided. Distribution boards for local plant lighting shall be located in the plant area, distribution boards for perimeter, road and area lighting shall be located in the substations. Distribution boards shall have at least 2 5 % spare circuits with a minimum of t w o spare circuits. 13.7 Lighting circuits shall be single phase. Maximum loading for each circuit shall be 8 0 0 watts for indoor lighting and 2000 watts for outdoor lighting. Distribution board circuit breakers shall be double pole for all lighting circuits other than circuits inside unclassified areas, where single pole circuit breakers shall be used. 13.8 Lighting in control panel areas shall be arranged t o minimise shadows and glare on control panel faces. 13.9 Measures shall be taken to avoid stroboscopic effects. 14.0 EMERGENCY LIGHTING 14.1 Emergency lighting in all process or utility plant areas shall be provided consistent with the requirements of plant operating and personnel safety needs under failure conditions of the normal supply and standby supply and shall be approximately 20% of the total plant or area lighting. The perimeter fence lighting shall be entirely fed from the emergency supply. 14.2 The emergency lighting shall be supplied from emergency lighting distribution boards fed from the emergency supply. 14.3 Selected fluorescent luminaires, which illuminate escape routes, emergency exits and ladders, access routes, control room, generator buildings, substations, etc. shall have individual integral battery inverter devices and shall be put into service upon normal power supply failure. These luminaires shall provide illumination for a minimum period of 3 0 minutes using the normal lighting fluorescent tubes. The illumination provided shall be adequate for personnel safety and escape. 14.4 These luminaires shall be supplied from the emergency lighting distribution boards.

Engineering Group Specification


15.0 ROAD LIGHTING

Specification Number

Rev

Date

Sheet

01 5-PH-1901

17-6-94

21 of 32

15.1 Road lighting shall be provided for all internal plant roadways, car parks, etc. and shall comply with the requirements of BS 5489. 15.2 The road lighting shall be supplied from suitably located contactorswitched distribution boards under the control of photoelectric cells. 15.3 The road lighting lanterns shall be of the side-entry type employing fluorescent or high-pressuresodium lamps (unless otherwise specified) with integral control gear, mounted on 6-m-high galvanised steel columns. Fuse controls shall be located in the base compartment. Alternative lanterns and control gear, suitably certified, shall be used in hazardous areas. 16.0 SOCKET OUTLETS 16.1 Hazardous Areas and Outdoor Locations 16.1.1 Socket Outlets for Welding Welding socket outlets shall be provided throughout the plant for welding purposes during shutdown periods. They shall be of the switched, interlocked type, rated for 440 V, 50 Hz, 63 A, 3 phase, neutral and earth connections with an IEC 309 colour and pin and configuration and shall be certified Exd. A matching plug shall be provided for each socket outlet. Each outlet shall be on a separate circuit. 16.1.2 General-Purpose 250-V Socket Outlets General-purpose socket outlets shall be provided in all outside locations. The socket outlets shall be of the switched, interlocked type, rated for 250 V, 5 0 Hz, 1 6 A, double pole and earth connections with an IEC 309 colour and pin configuration and certified Exd. A matching plug shall be provided for each socket outlet. 16.1.3 50-V Portable Socket Outlet Units a. Each unit shall comprise a 200 VA, 250 Vl50 V transformer with an earthed screen and centre tap, connected t o a switched interlocked type outlet rated for 5 0 V, 1 6 A, double pole and earth connections with an IEC 309 colour and pin configuration. The mains lead shall be 15 m long, have a metal screen armour and be fitted with a plug t o match the general-purposecertified 250-V socket outlets. The unit case shall have mains lead stowage.

@ KOC

Engineering Group Specification


b.

Specification Number

Rev

Date

Sheet

01 5-PH-1901

17-6-94

22 of 32

The unit shall be certified Exd for use in a Zone 1 area. Ten units with twenty 5 0 V matching plugs shall be provided at each Facility.

16.1.4

250-V socket outlets shall be supplied from small power distribution boards with outgoing circuits incorporating 2- pole circuit breakers, each with a 30-mA earth leakage protection trip provision. Socket outlets in laboratories shall be certified Exd for a Zone 1 hazardous area, rated for 250 V, 5 0 Hz, 1 6 A, with double pole and earth connections and IEC 309 colour and pin configuration and be the switched, interlocked type. A matching plug shall be provided for each socket outlet.

16.1.5

16.2 Unclassified Indoor Locations


16.2.1 General-Purpose Socket Outlets a. 250-V single-phase, surface-mounted 13A. switched socket outlets t o BS 1363 shall be provided in all buildings. A plug shall be provided for each socket outlet. Socket outlets shall be supplied from small power distribution boards, with outgoing ring circuits having a maximum of six sockets per circuit and incorporating single-pole circuit breakers with a 30-mA earth leakage trip facility.

b.

16.2.2

Transformer Bay Socket Outlets A socket outlet shall be provided in every alternate transformer bay for supplying power t o an oil filtration unit. The socket outlets shall be of the switched, interlocked type rated for 440 V, 5 0 Hz, 6 3 A, with 3-phase, neutral and earth connections. They shall comply with IEC 309 and have a minimum IP55 degree of protection. Two matching plugs shall be provided for each Site.

16.3 Location of Socket Outlets


Socket outlets shall be located throughout the process areas and other areas for the use of instruments, tools, inspection lamps, etc.

16.4 Socket Outlets Extension Leads


In process areas and equipment rooms the number of socket outlets provided shall be such that the extension lead lengths given below shall provide full coverage over the plant:

Engineering Group Specification


16.4.1 16.4.2

Specification Number

Rev

Date

Sheet

0 15-PH- 190 1

17-6-94

23 of 32

440-V outlets: maximum 30-m extension leads. 250-V outlets: maximum 15-m extension leads.

16.5 Tvpe of Socket Outlets


All socket outlets shall be suitable for the area in which they are located and consistency of colour code and pin arrangement be uniform in each area for each category of outlet. IEC or BS standards shall apply.

17.0 COMMUNICATION SYSTEMS


The communication systems shall be in accordance w i t h the Engineering Group Specification entitled "Condition Monitoring, Telecommunications and Security System" (Number 01 5-ZH-1002).

18.0 CABLE DESIGN AND INSTALLATION 18.1 Cables shall be direct buried, installed in structural trenches or run overhead o n supports as indicated on the cable routing drawings. Cables shall comply w i t h the Engineering Group Specification entitled "Electrical Cables" (Number 01 5-PH-1907). 18.2 Cables having any part of their length buried shall have lead alloy sheaths. 18.3 During motor starting, the voltage at the motor terminals shall not fall below 85% o f the rated voltage. In addition, when starting any motor, the voltage at any switchboard busbars shall not fall below 90% of the rated voltage. Cables and systems shall be sized t o meet these criteria. 18.4 The basis of voltage drop calcuations shall be for worst case, i.e., minimum fault level and outage of supply feeders or transformers. 18.5 The minimum conductor sizes for cables shall be as follows: 18.5.1 3.3-kV and 1 1-kV grade cables: 35 mm2. 18.5.2 60011000 V grade cables:
Motors

- 4 mm2.

Power feeders - 4 mm2. Lighting and small power, buried - 4 mm2. Lighting and small power, above grade Control - 2.5 mm2.

- 2.5 mm2.

Engineering Group Specification

Specification Number

Rev

Date

Sheet

01 5-PH-1901

17-6-94

24 of 32

18.6 Maximum continuous current ratings shall be derived from IEC 287, BS 7671, or the cable rating tables produced by the Electrical Research Association. Due account shall be taken of the grouping of cables, site soil condition data, soil temperature, depth of laying belowground and method of laying belowground or when in air, ambient temperature. 18.7 Voltage drops in the systems under full-load conditions shall not exceed the following: 18.7.1 18.7.2 18.7.3 18.7.4 Feeders t o area substations: 1 %. Feeders from area substations: 1 %. Final motor circuits: 5%. Lighting circuits: 2 % %.

18.8 Cables shall be sized t o meet both the voltage drop criteria and the short circuit condition for a time determined from the maximum protective relay setting plus operating time and the circuit breaker operating time. 18.9 Cables used for the ESD and the fire and gas systems shall have a fireresistant construction as stated in the Engineering Group Specification entitled "Electrical Cables" (Number 0 1 5-PH-1907). 18.10 Control cables shall have a minimum of 2 0 % spare cores over the original design requirements. Cables buried belowground shall be installed as follows: 18.1 1.1 Structural concrete trenches shall be provided in paved areas. The cables shall be laid on and also covered by 75 m m layers of clean sand. The trench shall be backfilled t o grade level. The cable trench in-situ concrete surface cover shall be coloured red and have clean edges t o clearly define the cable trench. In unpaved areas, the cables shall be directly buried in excavated trenches. Cables shall be laid on and also covered by 7 5 m m layers of clean sand and then concrete cable covers 1 0 0 m m above the cables. The cable covers shall overlap the cables on the extreme outside. The trench shall be backfilled t o grade level. Cable depth t o top of grade or paving shall be: a. b. Systems up t o 1 kV: 7 5 0 m m minimum Systems above 1 kV: 1000 m m minimum

18.1 1

18.1 1.2

18.1 1.3

Engineering Group Speciication

Specification Number

Rev

Date
17-6-94

Sheet

01 5-PH-1901

25 of 32

18.1 1.4

Cables of different voltage levels shall be segregated from each other when in the same trench. Communications cables shall be separated by a minimum of 1 m from HV cables. No instrument cables shall be installed in power cable trenches. Power cable routes running alongside instrument cable routes shall be separated from them as follows: Power Cables Up t o 125 V Above 125 V and up t o 2 5 0 Vl50A Above 2 5 0 V and up t o 4 4 0 Vl200A Above 440 V and up to 11 kVl800A Min Distance 250 mm 4 0 0 mm 500 mm 750 mm

18.1 1.5

18.1 1.6

Where HV cables are laid in the same trench as LV cables, there shall be a minimum spacing of 3 0 0 m m between HV cables and the LV cables. A minimum spacing of 150 mm shall be maintained between HV cables. Where single-core cables are used, they shall be run in a trefoil group using proprietary cleats t o support the cables. The cleats shall be spaced as recommended by the Approved cable Manufacturer. Cables shall be spaced at a minimum of 5 0 0 mm from other services, e.g., pipes. Where cables enter buildings, pass under roads, bunds and similar obstructions, they shall be installed in 150-mm ducts. A t each duct bank, 2 0 % spare ducts shall be provided, with a minimum of t w o spare ducts for future use. All duct ends, including spare ducts, shall be sealed with suitable sealant. Voltage grade separation shall be maintained when installing cables in ducts. No duct shall have more than 4 0 % of its cross-sectional area filled. Where cables surface from belowground, they shall be protected by substantial metal pipes which shall extend from 150 m m below ground level t o a minimum of 150 mm above ground level to provide mechanical protection for cables. Pipes shall be sized t o have 6 0 % of area unused. Route markers shall be provided to identify all trenches not directly visible at grade. Wherever possible, markers shall be

18.1 1.7

18.1 1.8

18.1 1.9

18.1 1 .10

18.1 1.1 1

18.1 1 .12

Engineering Group Specification

Specification Number

Rev

Date

Sheet

01 5-PH-1901

17-6-94

26 of 32

located directly over the centre line of the trench, or, alternatively, suitably marked and located nearby. Inside the Facility where vertical posts would cause interference with pedestrians or traffic, cable markers shall be cast horizontally in concrete at grade level. Markers shall be installed every 3 0 m, at changes of direction and where cables enter buildings. 18.1 1.13 Reservations dedicated t o cable trenches shall have a minimum of 1 0 0 % spare width capacity available over the known requirement. Non-corrodibleplastic cable markers with preprinted characters shall be fixed t o both buried and surface run cables at both ends and every 25 m along the route. The number on each cable shall correspond t o the number allocated t o the cable schedule.

18.1 1 .14

18.12

Cables under raised substation floors shall be laid on heavy-duty, hotdip galvanised steel cable rack or tray suspended from the floor in the clear space between the floor and grade. Cables under suspended floors in buildings, e.g., control room, shall be laid on heavy-duty, hot-dip galvanised cable rack or tray, installed in the underfloor void and supported from the subfloor. Cables in structural concrete trenches in buildings shall be laid on heavy-duty, hot-dip galvanised cable rack or tray fixed t o the trench floor or walls. Trenches in building shall have removable chequer plate covers. Cables above ground shall be installed as follows: 18.15.1 Where cables are run above grade, they shall be securely fixed t o suitably supported, heavy-duty, hot-dip galvanised steel cable racks or trays. Single cables may be individually attached t o structures, but shall not be supported or attached t o personnel ladders attached t o structures. Cable racks and trays shall be attached t o steel-supporting structures of buildings, platforms, pipeways or purpose provided support steelwork. They shall not be supported from process piping. All cable racks and trays installed in open locations shall be fitted with ventilated sunshades t o prevent overheating by direct sunlight. Suitable care shall be taken not t o obstruct free ventilation of cables.

18.13

18.14

18.15

18.1 5.2

18.1 5.3

18.1 5.4

QKOC

Engineering Group SpewZcation

Specification Number

Rev

Date

Sheet

0 1 5-PH-1901

17-6-94

27 of 32

18.16

Cable terminations shall comply with the following: 18.16.1 All conductor terminations shall be by means of compression-type cable lugs, except control circuits and other small wiring which shall be wired t o readily accessible clamptype terminal blocks using pin crimps. H V cables shall be terminated using heat-shrinkable termination kits (Raychem or Company-approved equivalent) w i t h glands in air terminal boxes. Cables shall be terminated using brass compression glands, incorporating an internal armour clamp and a seal o n the outer and inner sheaths, as appropriate. In the interests of standardisation, all glands shall be Exd certified for use in a Zone 1 hazardous area. All glands shall be fitted with PCP shrouds. A t every HV and main IV feeder and motor cable termination, a minimum 2-m-long cable loop shall be provided t o allow for future reconnections. Phase sequence of cable cores shall be checked prior t o termination. Where 1 1 -kV multicore cables are connected t o overhead lines, heat-shrinkable cable termination kits suitable for the environment shall be used. All cables shall be adequately supported t o ensure that no strain is placed o n the termination. Each terminal and connected wire or cable core shall be marked and identified with suitable plastic-type ferrules, in accordance with the relevant wiring diagram.

18.16.2

18.1 6.3

18.1 6.4

18.16.5

18.16.6

18.1 6.7

18.16.8

18.17

Cables shall be installed without through joints unless otherwise approved b y the Company. Cold pour epoxy resin jointing kits shall be used for 1000-V grade cable underground joints. Heat-shrinkable joint kits shall be used for 3.3-kV and I 1-kV cables.

19.0 CONDUIT
The use of conduit shall be limited t o electrical services installations in buildings in unclassified areas. Conduit and fittings shall have a minimum size o f 20-mm nominal outside diameter (OD) and shall be hot-dipped galvanised steel t o BS 4568.

Engineering Group Specification


20.0 JUNCTION BOXES

Specification Number

Rev

Date

Sheet

0 15-PH- 190 1

17-6-94

28 of 32

20.1 Junction boxes shall be provided adjacent t o luminaries and other locations where cables need t o be joined. They shall be of galvanised cast iron or stainless steel, have a minimum degree of protection of IP55 and be suitable for the area classification where they are located. 20.2 Terminals shall be provided suitable for the size of conductors t o be terminated. 20.3 Terminal blocks shall be arranged t o facilitate accessibility for cable cores termination and inspection of terminal identification numbers. Terminals shall be of the pinch-plate type, Exe type of Klippon manufacture or Company-approved equivalent, suitable for a minimum conductor size of 2.5 mm2. 20.4 No more than one wire shall be inserted into any one terminal. Looping between terminals, when required, shall be carried out using the purposemade top of block cross connection or comb-type busbar. 20.5 Adequate space for wiring shall be provided between any terminal face and the gland entry. 20.6 Internal and external earthing stud(s) shall be provided.

21.0 NAMEPLATES AND LABELS


21 .I Each item of manufactured equipment shall have a nameplate clearly and indelibly marked with the data specified in the appropriate IEC standard. Nameplates shall be fixed with non-corrodible screws or rivets. 21.2 Warning labels shall be provided in all locations where necessary to warn personnel of potentially dangerous situations. 21.3 All pushbutton stations, instruments, selector switches, indicators, junction boxes and distribution board, etc. shall be provided with descriptive identification labels giving reference and function. 21.4 Labels shall have black characters on a white background, except warning labels shall have white characters o n a red background. 21.5 All labels shall be engraved on plastic-laminated sandwich material and secured with non-corrodible screws; adhesive or self-tapping screws are unacceptable. 21.6 Each distribution board shall be provided with a circuit directory.

Engineering Group Specifiction


22.0 CATHODIC PROTECTION

Specification Number

Rev

Date

Sheet

0 15-PH-190 1

17-6-94

29 of 32

Cathodic protection of tank bases, underground piping and other structural steelwork underground shall be provided as defined in the Engineering Group Specification entitled "Cathodic Protection Design Requirements" (Number 0 1 5WH-1006).

23.0 LIGHTNING PROTECTION


Lightning protection shall be provided on all structures in accordance with the recommendations of BS 6651. Lightning down conductors shall be connected directly t o earth electrodes.

24.0 ELECTRIC SURFACE HEATING


Electric surface or trace heating shall be provided on piping or vessels where shown in the P&ID1s and piping isometric drawings. The materials and installation shall comply fully with BS 6351, Electric Surface Heating. The cable shall be selflimiting current type. The circuits shall be thermostatically controlled where necessary. The installation shall be suitable for the hazardous area classification of the area where it is located. Earth leakage protection shall be provided on all sub-circuits located in hazardous areas.

25.0 SAFETY
25.1 The Contractor shall be responsible for the provision of miscellaneous items and equipment for the safe operation, maintenance and protection of the electrical systems and personnel.

25.2 The materials shall include the following: 25.2.1 Electrical danger notices on the outside of all substations, switch and transformer yards. Electric shock treatment notices. Rubber mats. Special tools for equipment operation and maintenance.

25.2.2 25.2.3 25.2.4

26.0 PAINTING
Painting shall be in accordance with the Engineering Group Specification entitled "Shop and Field Painting" (Number 0 1 5-XH-1005).

27.0 TESTS AT SITE


This section shall be read in conjunction with Contract requirements for Facility Completion and Acceptance in the Scope of Work and Technical Specification of the Contract.

Engineering Group Specification


27.1 General

Specification Number

Rev 1

Date

Sheet

01 5-PH-1901

17-6-94

30 of 32

27.1 .I

The tests a t Site described herein are a minimum, and the Contractor shall carry out all tests necessary t o prove compliance w i t h the Engineering Group specifications. The checking and tests cover the mechanical completion and commissioning checks and tests which shall be carried out on electrical systems before they are put into service. As a guide, mechanical completion checks shall establish that the installation work has been done correctly and the commissioning checks and tests are t o establish that the systems are i n a ready t o energise condition. Testing programmes for commissioning shall be prepared for all electrical systems and shall require approval by the Company. Electrical systems shall as far as practicable be fully assembled before starting final electrical testing and commissioning. The Contractor shall provide all test equipment and is responsible for its calibration and accuracy. All test results shall comply w i t h the requirements of the Engineering Group specifications and shall be approved before any electrical equipment is connected up and energised for use. All Site test results shall be recorded o n test record sheets for each equipment item, circuit or device. Each shall be countersigned by the Company. The format of the test record sheets shall be subject t o Company approval.

27.1.2

27.1.3

27.1.4

27.1.5 27.1.6 27.1.7

27.1.8

27.1.9

27.2 LV Installations
All low-voltage installations shall be tested in accordance w i t h the requirements of BS 7671 (IEE wiring regulations).

27.3 HV Cabling

27.3.1 27.3.2

High-voltage cables shall be subjected t o a voltage test as defined i n IEC 502, Clause 18. Cables connected t o switchgear, transformers and motors shall be disconnected prior t o dielectric tests. If this is not

Engineering Group Spedfication

Specification Number

Rev

Date

Sheet

015-PH-1901

17-6-94

31 of 32

practicable, a reduced test voltage may be used subject t o Company approval.

27.4 HV Switchgear
High-voltage switchgear shall be subjected t o a voltage test as defined in IEC 694, Table 1. ( 8 0 % of the values specified shall be used.)

27.5 Transformers
27.5.1 Transformers shall be subjected t o tests as defined in Part 3, Clause 8.

IEC 76,

27.5.2

Samples of oil from each transformer shall be tested t o IEC 2 9 6 and 422.

27.6 LV Switchgear
Low-voltage switchgear shall be subjected t o tests as defined in BS 5486, Part 1, Clause 8.2.2.

27.7 Voltage Transformers


Voltage transformers shall be subjected t o tests as defined in BS 3941, Clause 18.3.

27.8 Current Transformers


Current transformers shall be subjected t o tests as defined in BS 3938, Clause 2.6.

27.9 Protection Relav Svstem


27.9.1 Primary and secondary injection tests shall be carried out on all protection systems t o prove the calibration of all relays and the operation of the protection circuits. Protective relay calibration shall be checked at minimum, maximum and design settings and for a range of operating currents.

27.9.2

27.10

Batterv Equipments
All equipment units containing batteries shall be subjected t o battery discharge and recharge tests t o prove the duration time of both functions comply w i t h the appropriate specification. The ability of the batteries t o supply the required loads after loss of mains power shall also be proved.

Engineering Group Specification


27.1 1

Specification Number

Rev

Date

Sheet

015-PH-1901

17-6-94

32 of 32

Motors and Generators


27.1 1 . I All machine windings and the heaters shall be given continuity and insulation resistance tests. Generators and HV motors shall be subjected t o a dielectric tests at 8 0 % of the works voltage test values. Generators shall be tested t o provide data for open-circuit and short circuit curves, verification of all AVR functions and full load rejection together w i t h AVR response measurements.

27.1 1.2

27.1 1.3

27.12

Illumination Levels
lllumination levels shall be measured in all areas t o prove compliance with the specified illumination levels.

27.13

Function of Equipment
27.13.1 All equipment and systems shall undergo full functional testing t o prove correct operation. This shall include the proving of operation of all controls, interlocks, indications, and each individual protective device in all control circuits, prior t o main power circuit energisation.

27.13.2

27.14

Earthing
In addition t o the earthing tests specified b y BS 7671, the earthing system shall be tested t o establish the overall resistance of the system t o earth.

28.0 PACKING, MARKING AND DOCUMENTATION


28.1 For all relevant requirements, refer t o the Engineering Group Specification entitled "Packing, Marking and Documentation" (Number 0 1 5-UH-1001).

29.0 SPARE PARTS AND MAINTENANCE REQUIREMENTS


29.1 For all relevant requirements, refer t o the Engineering Group Specification entitled "Spare Parts and Maintenance Requirements" (Number 0 1 5-KH1902).