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GENERAL SPECIFICATION
ELECTRICAL DESIGN CRITERIA

2010014-00-E0-GS-001 Rev. 0 Page 2 of 16

TABLE OF CONTENTS
1. 1.1. 1.2. 1.3. 1.4. GENERAL SCOPE CODES AND STANDARDS SITE CONDITIONS SYMBOLS 4 4 4 4 4

2.

ELECTRICAL SYSTEM VOLTAGE

3. 3.1. 3.2. 3.3.

SYSTEM DESIGN REQUIREMENT EMERGENCY POWER SUPPLY VOLTAGE DROP ON THE BUS EQUIPMENT PHASE IDENTIFICATION

5 5 5 6

4. 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 4.7. 4.8. 4.9. 4.10. 4.11. 4.12.

EQUIPMENT DESIGN REQUIREMENTS TRANSFORMERS MV/HV SWITCHGEAR LV MCC AND DISTRIBUTION PANELBOARDS UPS SYSTEM MOTORS LOCAL CONTROL STATION CABLES CABLE GLANDS CABLE TERMINATION BUS DUCTS LIGHTING SYSTEM POWER AND CONVENIENCE RECEPTACLES

6 6 7 7 8 8 9 9 10 10 10 11 12

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4.13. 4.14. 4.15.

JUNCTION BOXES GROUNDING AND LIGHTNING SYSTEM FIRE ALARM SYSTEM

5. 5.1. 5.2. 5.3.

PROTECTION SYSTEM REQUIREMENTS GENERAL MOTOR PROTECTION TRANSFORMER PROTECTION

14 14 14 15

6.

CABLE INSTALLATION

15

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1. 1.1.

GENERAL SCOPE a. This specification covers the general requirements to be followed design, codes, standards and procedures for the engineering and installation of the electrical equipment and system to be installed in Esmeraldas Refinery Rehabilitation Project Phase II, Ecuador.

1.2.

CODES AND STANDARDS The Electrical equipment and materials shall be manufactured in accordance with the IEC recommendations and national standards (equivalent to IEC) including the following codes and standards: a. b. c. d. e. International Electro-technical Commission (IEC) National Electrical Code (NEC) IEEE, ANSI, and NEMA Standards American Petroleum Institute (API) Publications National Fire Protection Association (NFPA)

1.3.

SITE CONDITIONS Electrical equipment & Bulk materials shall be specified for the hereafter climatic conditions: a. b. c. d. e. f. Location Elevation : Esmeraldas in Ecuador : 20m to 160m on the sea level

Ambient air temperature : Maximum. 40, Minimum 16.5 Humidity Seismic Zone Special Condition : 100% : : Tropical weather, Saline, Corrosive environment

1.4.

SYMBOLS Electrical symbols used in drawings will generally be in accordance with the IEC recommendations

2.

ELECTRICAL SYSTEM VOLTAGE a. The system voltages will be as follows: 1) 2) 3) HV power: 13,2kV, 3 phase, 3 wire, 60 Hz, resistance grounded neutral MV power: 4,16kV, 3 phase, 3 wire, 60 Hz, resistance grounded neutral LV power: 480V, 3 phase, 3 wire, 60 Hz, solidly grounded neutral

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4) 5) 6) 7) b.

Circuit breaker and protection relay for MV/HV switchboard : 125VDC Motor space heater control : 120VAC, single phase, 60Hz Lighting & small power : 208V/120VAC, 2/1 phase, 60Hz UPS & Instrument : 120VAC, single phase, 60Hz

The utilization voltages for motor shall be as follows: 1) 2) 3) 4) Motors 151kW and above: 4,160V, 3 phase, 3 wire 60Hz Motors 0.75kW and above: 460V, 3 phase, 3 wire 60Hz Motors 0.18kW and above: 208V/460V, 3 phase, 3 wire, 60Hz Up to 0.12kW and above: 120V, 1 phase, 60Hz

3. 3.1.

SYSTEM DESIGN REQUIREMENT EMERGENCY POWER SUPPLY a. The emergency power supply is only UPS system (120VAC, single phase, 60Hz) for critical equipment as DCS elements.

3.2.

VOLTAGE DROP ON THE BUS a. The maximum voltage drop in various sections of the electrical system shall be within in the limits stated in the following: 1) 2) 3) 4) 5) 6) 7) 8) 9) b. Bus duct between transformer secondary and LV switchboard : 0.5% Cable between switchboard and MCC : 1%(near), 2.5%(remote) Cables between MV switchgear and motor : 3% Cables between LV MCC and motor : 5% Cables between distribution panel and lighting panel : 1% Cables between lighting panels and lighting fixture : 3% At the normal starting of the motor : 10% At the automatic restarting of the motor : 15% At the normal motor starting of the large motor : 15%

For MV motors, the voltage available at the motor terminals shall not be less than 90% of the rated value during start-up or re-acceleration. For LV motors, the voltage available at the terminals shall not be less than 90% of rated value.

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3.3.

EQUIPMENT PHASE IDENTIFICATION a. Three phase system shall be identified as follows: 1) 2) 3) 4) 5) b. Phase 1 : Red Phase 2 : White Phase 3 : Blue Neutral : Black Earth : Green/Yellow

Single phase system shall be identified as follows: 1) 2) 3) Phase : Red Neutral : Black Earth : Green / Yellow

c.

The DC system shall be identified as follows: 1) 2) Positive: Red Negative: Black

4. 4.1.

EQUIPMENT DESIGN REQUIREMENTS TRANSFORMERS a. Power transformers will be sized for the maximum load plus 20% as spare capacity and be suitable for outdoor continuous operation in dusty atmosphere and exposed to solar radiations. The protection degree shall be IP56. Power transformers shall be outdoor type, liquid-immersed with expansion tank type, threephase, delta-connected primary and wye-connected secondary windings, and with off load tap changer, having four taps, two above and two below rated voltage in step of 2.5%. All transformers shall be designed for continuous operation at rated load without exceeding 55 temperature rise, with natural air cooling. Transformers will have provisions for forced air cooling to increase their output capacity by no less than 25%. Transformers shall have independent windings for primary and secondary circuits. The primary winding will be delta connected and the secondary winding will be wye-connection arranged for bus-duct connection. Transformers shall be designed and manufactured to withstand without damage, under the service conditions on both the primary and secondary windings the affects of the electromagnetic forces a short circuits of any kind on any tapping corresponding to and

b.

c.

d.

e. f.

g.

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asymmetrical current peak value not greater than 2.55 times the over current r.m.s value related to the appropriate conditions. h. Transformers shall also be capable to withstand under the specified service conditions. The affects of the thermal stresses produced by a short circuit of any kind on the terminals of both the primary and the secondary windings during two seconds. Power transformers shall be three phase, double wound type, oil-immersed, naturally cooled (ONAN), shall be comply with all requirements of IEC 60076 and shall have provisions for forced air cooling (ONAF type), suitable for outdoor use in service conditions.

i.

4.2.

MV/HV SWITCHGEAR a. All switchgears shall be metal-clad and free standing structures. Structures shall consist of separate cubicles which may be assembled into a group having a common power bus and forming an enclosure to which additional cubicles may be readily be added at both ends of the board. The switchboards shall be designed for indoor use and the enclosure degree of protection shall be at least, IP41 according to IEC 60529. The switchgear shall be naturally ventilated and have no requirement for forced cooling. Although the switchboard will be in an air-conditioned room it shall be able to operate at ambient temperature for extended periods of time. Each cubicle or panel shall generally consist of the following units; Stationary busbar compartment Power cubicle connecting compartment including current transformers Withdrawable unit with circuit breaker or fused switch or fused contactor. LV compartment housing all the protective and auxiliary relays as well as the necessary indicators, meters and control devices.

b.

c.

d. e.

f.

All switchgears shall be of the fully withdrawable type provided with breakers, switches, contactors of the draw out type having separable contacts on all power and control connections.

4.3.

LV MCC AND DISTRIBUTION PANELBOARDS a. All assemblies for MCCs and DPs shall be of a manufactures standard type in accordance with the requirement of IEC codes and standards. All MCCs/DPs shall be designed for indoor use and the enclosure degree of protection shall be at least, IP41 according to IEC 60529. The assemblies shall be of fully withdraw-able, dead-front or back to back, metal enclosed construction. They shall consist of power switching devices, bus-bars, protective devices, measuring instruments and other associated equipment, housed in a rigid, floor-mounted, free standing structure composed of individual full-height vertical sections Each equipment of the same type, current rating and circuit duty shall be interchangeable. The use of forced cooling or forced ventilation for all cubicles is not permitted.

b.

c.

d.

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e.

Controllers for three-phase low voltage motors shall be the combination type consisting of molded case circuit breakers and magnetic contactors. Each starter shall have three thermal overload relays and a control power transformer with 120volt secondary. The starters should be able to restart up the equipment, which are required as per operation and safety principle.

f.

g.

4.4.

UPS SYSTEM UPS will consist of fixed units, assembled to have an integral type panel with mechanical protection degree IP31. It will include: 1) 2) 3) 4) 5) 6) Battery charger / rectifier, silicon thyristors control, static type. Inverter, static type Back-up transformer Static and manual transfer switches Distribution panel with outgoing feeders equipped with fixed MCCB. Battery, Ni-Cd type, with an autonomy period of 60 minutes.

4.5.

MOTORS a. Motors shall be of the type and construction described in the motor specifications 2010014-00E9-GS-001 and motor data sheets Motors for use in hazardous area shall be selected as follows: 1) LV motors: Zone 1: Ex-d (flame proof) or CENELEC EN 50018 Zone 2: Ex-n (Non sparking) or Ex-e (increased safety) 2) MV motors: Zone 1: Ex-d (flame proof) or CENELEC EN 50018 Zone 2: Ex-n (Non sparking) or Ex-e (increased safety) c. The motor enclosures will be IP55, totally-enclosed fan cooled type, and shall be suitable for outdoor use and hazardous area. All motors for use in hazardous area shall be limited to temperature class T3, unless more stringent temperature requirements are necessary in areas where gases or vapor having ignition temperature below 200 may occur. All terminal boxes for motor installed in hazardous area shall be of Ex-d, Ex-e and Ex-n type specified in the project specification and data sheets.

b.

d.

e.

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f.

The minimum enclosure ingress protection for motors installed in classified hazardous areas shall be IP55 according to IEC 60034. Motor for use in safe areas shall be totally enclosed fan cooled and weather proof protected. The degree of protection shall be minimum IP55. Motors shall be designed for direct across the line starting and for continuous running operation at rated power, duty service type S1 according to IEC60034 All motors 1,000kW and larger shall have Two(2) Resistance Temperature Detector (RTD) elements installed per phase winding and they shall be wired to separate terminal box. All motors shall be class F insulated. Temperature rise shall be limited to Class B.

g.

h.

i.

j. 4.6.

LOCAL CONTROL STATION a. Local control station will be equipped with start-stop push buttons, ammeter for motors 150kW and larger and local /remote selector switches, if necessary DCS operated motors shall have a manual / automatic selector switch next to the motor. Motor controlled from both the LCS and the DCS shall have a local / off / remote selector switch next to the motors. The enclosure of the local control station can be galvanized cast iron and the materials shall adequate to be installed in hazardous area Class 1, Division 2, Group B and C, T3 as per related IEC standards. All bolts shall be stainless-steel and the minimum mechanical protection degree shall be IP65.

b.

c.

d. 4.7.

CABLES a. General Electrical cables will be suitable to be installed in hazardous area, classified as Class 1, Division 2, Groups B and C, Temperature T3 as per NEC and corresponding to Class 1, Zone 2, Group IIB and C, T3 temperature class as per IEC. b. Conductors The conductors shall be high conductivity concentric stranded copper, manufactured from fully annealed copper wires of physical, mechanical and electrical characteristics in compliance with the applicable codes and standards. Aluminium conductors are not allowed. c. Conductor Insulations Insulation shall comply with the following materials: 1) 2) d. XLPE (Cross-linked polyethylene) : MV power cable PVC (Polyvinyl chloride) : LV power, control and lighting cables

Armour Cables requiring mechanical protection, shall have a galvanized round steel wire armour applied for multi-core cables.

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e.

Outer jacket Cable outer jacket shall be of polyvinyl chloride suitable for direct buried underground installation or above ground on cable trays of clamped to the wall, having good moisture resistant and flame retardant characteristics.

f.

Cable will be sized for the rated current of the load and for the following maximum voltage drops: 1) 2) 3) 5% at full load condition for motor 2% for lighting feeders 3% for lighting branch circuits

g. 4.8.

Cables shall be sized to withstand short circuit, and will be in compliance with the IEC standards.

CABLE GLANDS a. The cable glands shall be suitable for installation in an area of the site conditions specified in section 1.3 of this specification. The material of the cable glands with reducers and adaptors shall be metallic, made of electropassived brass type. All threads shall be NPT type, minimum thread of cable glands will be 3/4. All cable glands shall be engraved with their type designation, size, type of thread and certificate number. All cable glands shall be double seal and suitable for cables with galvanized round steel wire armour and PVC outer jacket. Cable glands shall have a degree of protection IP66, minimum for outdoor installation. Explosion proof double seal cable glands suitable for area classified as Classs 1, Division 2, Group B and C, T3, as per NEC and corresponding to Class 1, Zone 2, Group IIB and C, T3 as per IEC recommendation for outdoor installation.

b.

c. d.

e.

f. g.

4.9.

CABLE TERMINATION a. Conductors shall be connected by means of crimped cable lugs and cable lugs for shall be tinned copper. MV cable terminations shall be made with proprietary termination kits. Full air clearances within cable and bus duct boxes shall be maintained with all termination lugs and fixing bolts in position. Copper shields, lead sheaths and steel armour shall be earthed.

b. c.

d. 4.10.

BUS DUCTS a. Bus ducts for connection between power transformers and motor control centers will be copper bus metal enclosure type, non-segregated type having insulated bus bars.

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b.

The insulation shall be flame retardant, non-hygroscopic, and corrosion resistant. Outdoor sections of the bus duct shall be weatherproof protection, corrosion resistant, and dust-tight. Bus duct shall be provided with degree of protection of IP56 as a minimum requirement. Bus bars shall be made from hard drawn, high conductivity copper. Bus bars shall be suitably supported at regular intervals and both bus bars and supports shall be adequately sized and clamped to withstand rated short circuit current without permanent deformation.

c. d.

4.11.

LIGHTING SYSTEM a. Illumination Levels The lighting system will be designed in order to given the following average illumination levels: 1) 2) 3) 4) 5) 6) 7) 8) 9) b. Pump areas, operation platforms, and stairs: 50 lux Compressor and boiler house: 200 lux Other outdoor process area: 20 lux General individual control room: 200 lux General central control room: 500 lux Substation area: 200 lux Warehouse: 50 lux Roads and parallels: 20 lux Tank yards: 20 lux

Normal Lighting 1) In hazardous classification of the area, division 1 and 2 locations, only Ex-d lighting fixture will be used. Indoor and non-hazardous area fixtures for control room, offices, laboratories, switchgear building, etc, shall be fluorescent type. Illumination of control rooms shall be arranged to minimize reflected glare when viewed from anywhere within the supervising position. In general, outdoor lights shall be metal halide or pulse star metal type. All outdoor lights shall be timer-clock controlled Lighting fixtures for outdoor installation will be provided with a mechanical protection degree IP65. High pressure sodium vapor for street and open areas lighting. Road lighting circuit shall be automatically controlled by a timer-clock device.

2)

3)

4)

5) 6) c.

Emergency Lighting

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Emergency and safety lighting will be carried out with fluorescent lighting fixtures containing battery, battery charger and inverter capable of maintaining illumination for 60 minutes. 4.12. POWER AND CONVENIENCE RECEPTACLES a. In the process areas and where necessary power and convenience outlet units shall be provided The power outlets shall be installed at ground level in the plant area. The convenience outlets shall be installed at ground level and also on the elevated platforms. Number and location of power and convenience outlets will be defined in order to reach every point of the plant area, distance between power outlets shall be 50m maximum and about 25m for the convenience outlets. Power outlets will be 63A rated, 480V, 3phase and earth with MCCB and plug. Convenience outlets will consist of outlets 20A rated, 220V, two phase and 20A rated, 110V single phase and earth with switch and plug. They will be mechanical protection degree IP55.

b. c. d.

e.

4.13.

JUNCTION BOXES a. The enclosure of the junction boxes can be cast aluminium alloy(without copper). Interior metal parts shall be protected from corrosion. The materials shall be adequate to be installed water-proof junction boxes, to be installed in not hazardous area. Increased safety type(Ex-e) to be installed in an area classified as Class 1, Division 2, Group B and C, temperature T3 as per NEC, corresponding to Class 1, Zone 2, Group IIB and C, T3, as per IEC. The minimum mechanical protection degree of the junction boxes shall be IP55 and all gaskets shall be neoprene and the metallic blank plugs made of electropassived brass. Hole for cable glands shall be NPT thread type.

b.

c.

d.

e. 4.14.

GROUNDING AND LIGHTNING SYSTEM a. b. A grounding system shall be provided for personnel safety and protection of equipment. In general, a loop grounding system shall be provided for each process unit or area. However, smaller process units or areas may be grouped into a single grounding system. The following shall be grounded: metallic non-current carrying parts of electrical apparatus, current and potential transformer secondary side, structural steel, vessels, towers, stacks, storage tanks, motor frames, fences, transformer housings, and armoured cable shields. Equipment rated 600 volts or less, which is solidly mounted on a metallic switch rack, need not be individually grounded if each end of the switch rack is connected to the ground bus. Minimum size for grounding conductors shall be as follows; 1) 2) Main Ground loop ---------------------------- 95 mmsq Substation ground loop---------------------- 95 mmsq

c.

d.

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3) 4) 5) 6) 7) 8) 9)

Transformers & Generators enclosure---- 35 mmsq Switchgear & MCC----------------------------- 35 mmsq 6.6kV Motor-------------------------------------- 35 mmsq 460V Motor -------------------------------------- 35 mmsq Welding Receptacle--------------------------- 35 mmsq Lighting Panel----------------------------------- 35 mmsq Street Lighting Fixture------------------------- 35 mmsq

10) Other Lighting Fixture------------------------- 35 mmsq 11) Cable Tray--------------------------------------- 35 mmsq 12) Tank, Vessel, Tower-------------------------- 35 mmsq e. The resistance of grounding electrode for transformers neutral grounding and equipment frame grounding will not be larger than 4 ohms. The main ground conductors shall be hard drawn bare stranded copper wire, and those to equipment shall be soft drawn stranded copper wire with green 600V PVC insulation. Unavoidable underground joints shall be welded. Above ground connections shall be solderless connectors accessible for inspection or test. Tanks and towers containing flammable gas or liquid shall be also directly grounded through grounding conductors from their feed, frames of enclosures. The new grounding system shall be connected to the existing ground network. All piping for flammable or combustible materials shall be bonded to the pipe rack at the plant entrance and at every 30 m. All below grade grounding conductors shall be directly buried with a minimum depth of 600 mm. The grounding for lightning protection shall be common with one for electrical equipment and static electricity protection.

f.

g.

h.

i.

4.15.

FIRE ALARM SYSTEM a. The fire alarm panel installed in control room will receive all the signals coming from: 1) 2) 3) 4) 5) b. Smoke detection system Temperature detection system Halon system Manual pushbuttons strategically installed around all the areas of the plant. Manual pushbutton s for each control room and substation building entrance(indoors)

Fire alarm system will consist essentially of fire monitoring main panel, a number of stations and connecting cable network. The monitoring panel have the task of performing alert signals both

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visual and acoustic on incoming alarm. To give complete performance, alarm sirens and buzzers will be provided. c. Fire alarm communication cables shall be of Polyethylene insulated PVC sheathed with shield cable and PVC insulated wire.

5. 5.1.

PROTECTION SYSTEM REQUIREMENTS GENERAL a. System protective devices (relays, fuses, breaker trip units, etc.) shall be selected and coordinated to ensure that the interrupter nearest the point of short circuit (or high overload) will open first and minimize disturbances on the rest of the system. Protection system shall be implemented so as to ensure: 1) 2) 3) 4) 5) c. d. Ensure safety of personnel Maintain stability and integrity of the power system Maximize continuity of power supply Minimize damage to equipment and system Assist with identification of faulted equipment

b.

The protection system shall be based on the philosophy of overlapping zones. The setting of protection devices shall be selected to be stable during motor starting and transient conditions caused by current surges in circuits outside the protected zones. Microprocessor-based protection relays shall be provided on their associated circuit breaker or motor starter cubicle. All protective relays shall be multi-functional digital type and shall be suitable to communicate with DCS and Electrical Control System of plant.

e.

f.

5.2.

MOTOR PROTECTION a. The following devices for low voltage motor shall be provided, as a minimum: 1) 2) b. Thermal over load Short circuit

The following devices for medium voltage motor shall be provided, as a minimum: 1) 2) 3) 4) Phase over load Short circuit Ground fault Stalled rotor

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5) 6) 7) 8) 5.3.

Phase unbalance Winding and bearing RTDs (1,000 kW and above) Differential protection (2000 HP and above) Under voltage

TRANSFORMER PROTECTION a. The following function shall be provided for transformer incomer, as a minimum: 1) 2) 3) 4) 5) b. Phase over-current protection (51) Instantaneous phase over-current protection (50) Earth over-current protection (51G) Differential protection (87G) Under voltage protection (27)

The following functions shall be provided for each transformer outgoing feeder as a minimum; 1) 2) 3) Phase over-current protection (51) Instantaneous phase over-current protection (50) Instantaneous earth over-current protection (50G)

6. 6.1.

CABLE INSTALLATION General In general medium and voltage feeder cables shall be installed in underground direct buried or above grade in cable tray and duct banks system for road crossing area. Instrumentation cables shall be installed above-grade in cable trays.

6.2.

Cable Tray a. The design and installation of the cable tray systems shall conform to the manufacturers recommended support and loading instructions Cable trays shall be of steel, hot dipped galvanized after fabrication. Proprietary trays shall be used to accommodate all major changes in tray direction or elevation (e.g. 90-deg bends and tees). Site fabrication of items will not normally be permitted. Where required, trays shall be covered to provide proper mechanical protection. Trays will not be supported from piping. Cable trays shall not be installed within 300 mm of hot process lines. Where trays cross a pipe run and such separation is not possible, the tray shall be separated from the pipe insulation by at least 150 mm.

b. c.

d.

e.

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f.

Straight run in excess of 30 meters shall be provided with expansion joints and bonded with approved jumpers. Cable tray systems shall be of the design of one manufacturer, and shall be designed so that there are no burrs, projections or sharp edges to damage cable insulation. All fittings shall have the same load capacity as straight sections. All cable tray runs will be made electrically continuous by means of suitable approved jumpers where necessary. Tray section shall be connected in such a way as to ensure electrical continuity. Cable tray cut or drilled during installation shall be restored by the application of cold galvanizing type compound. Twenty percent future space shall be allowed for in each tray.Terminals

g.

h. i.

j.

k. 6.3.

Conduits and Fittings a. Underground conduit shall be a minimum of 3/4 inch hot dipped galvanized steel. All elbows shall be rigid steel galvanized with a bending radius in accordance with NEC Table 346-10. All underground conduits and duct banks shall be encased in a concrete envelope with a minimum wall thickness of 75 mm and with a minimum spacing of 38 mm between adjacent conduits. The top of this envelope shall be a minimum of 600 mm below finished grade. Underground manhole locations and configurations shall be designed so that able will not be damaged when properly pulled. Above grade conduit shall be rigid, hot dipped galvanized steel. The threads of material shall be NPT (ASAB.2.1) Conduits between pipe supports and equipment may not be supported from piping. Power and control cables and wires for motors shall be installed in separate conduits. Flexible conduit shall be liquid tight and suitable for the hazard classification of the area in which it is installed. Flexible conduit shall be used to connect vibrating equipment. Connections to equipment requiring removal from service or subjected to vibration or movement shall be made with flexible conduit. Liquid-tight flexible metal conduit and approved fittings shall be used for outdoor equipment in unclassified and Class I, Division 2 locations. Conduit connections to heavy outdoor pendant lighting fixtures subjected to vibration or movement shall be made with approved flexible couplings.

b.

c.

d.

e. f. g.

h.

i.