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Electrical Installation Guide
;VXWMP 27( *MRPERH 3] Doc id: Page: Date / Status: Made/Approved: Replaces: Name: Subject: 4S[IV 4PERXW WDAAA055547 1 (1) 19-Aug-1999/ ISSUED GLS / GLS XX
Electrical Installation Guide for WNS Power Plants
1. INTRODUCTION
This guide serves as an instruction for electrical installers/contractors in order to ensure that their products (services, supplied work and equiment) meet quality requirements of Wrtsil NSD /Power Plants. As safe operation, reliability and availability of any power plant installation is strongly dependant of the quality of integrated electrical systems, Wrtsil NSD require any such systems to meet qualifications defined in this document so as to be able to take full commitment for power production systems vs designed criteria. The guide is a complement to the technical specification and purchase order, guide giving general information and guidelines that contribute to the quality of the electrification and which the installer/contractor must be aware of. However, the invitation for tender and contract or order specification will determine the scope of delivery and define the main principles for installation, tests, certificates and other requirements.
1.1. Chapters
1. INTRODUCTION (THIS CHAPTER) 2. SCOPE OF SUPPLY 3. QUALITY REQUIREMENTS 4. SITE RESPONSIBILITIES AND ACCOMMODATION 5. STORAGE AND TRANSPORTATION OF EQUIPMENT 6. ERECTION OF EQUIPMENT 7. EARTHING / GROUNDING SYSTEMS 8. WIRING SYSTEMS 9. CABLE ROUTING 10. CABLE PULLING AND INSTALLATION 11. CABLE TERMINATION 12. LIGHTING, HEATING, AIR CONDITIONING AND MAINT.POWER DISTRIBUTION 13. TELECOMMUNICATION, FIRE / GAS DETECTION SYSTEMS 14. VERIFICATION AND VALIDATION 15. PROTECTION AGAINST LIGHTNING 16. TRANSMISSION VOLTAGE SUBSTATIONS 17. INSTALLATIONS IN HAZARDOUS AREAS
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2. SCOPE OF SUPPLY
Wrtsil NSD, here later referred to as WNS, is engineering and supplying electricity and heat producing power plants based on WNSmade reciprocative internal combustion engines for the world market. WNS supply may comprise any scope from engines alone to turnkey power plants including maintenance and operation of these. The electrical installation (including automation, safety and telecommunication system installation) included within the WNS scope of supply is purchased from a reliable local or international contractor. In specific cases plant owner will himself do or contract the installer to perform the installation, with or without WNS-supervision. In either case the installation and included equipment should meet local authority requirements, contracted client requirements and these normative WNS requirements. Sub-Contractors contracted to perform civil works, electrical installations are here later referred to as civil contractor (sub-contractor) and Contractor (electrical C. if not clear by the context) or Subcontractor.
2.1. General project information

Wrtsil NSDs responsibility portion of any power plant project is mastered by WNS Power Plants Project Manager (PM) and his project group, one mechanical and one electrical, in some cases also one civil wks Chief Design Engineer (CDE) from contract to handover to client. PM and his CDEs hold the ultimate responsibilities in any contractual matters regarding WNSs scope of supply. A number of Design Engineers (DE) are also connected to the project and may participate in processes on behalf of responsible WNS project group PM and CDEs. Site responsibility is held by WNSs Site Manager who may have Site Supervisors (mech., electr. civil) at his assistance. The Site Manager is organising any site activities to be managed by WNS, contracting for local services or equipment etc. The Site Supervisors are on his behalf supervising and guiding contractors doing the construction, mechanical and electrical installation work. Supervisors and Commissioning Engineers in cooperation with Site Manager are there also to advise and remark for corrections required in order to have systems and equipment ready made for precommissioning and delivery tests as also for handover according to schedule. For larger projects a Project Organisation Plan is developed and enclosed with contractual documents. Other general and project specific information such as project main data, schedule and contact information is given in the Invitation for Tender and its appendices. Required electrical data will be found in the Technical documentation.
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2.2. Scope
In general the contractor will carry out the complete or specified portion of the electrical installation performance including unpacking, hauling, erection (including interconnection of assembly sections) and installation of equipment delivered by WNS and basic tests of installed equipment. Normal practice has to be followed. If an item, a work is mentioned in one of the documents, it is considered valid without repetition in other documents for which it is applicable. The contractor is committed to have hold of any authority licences, skills and capacities required for the contracted proportions of work and equipment. He is also to have union and similar acceptance which is needed to ensure troblefree utilisation of his labour force. He must inform his workers to be fully aware of safety and other regulations generally valid and of those specific for this worksite and of risk factors when they are arising. All his workforce must be in confriction free cooperation with Clients and Wrtsil NSDs site management and supervisors and with other contractors labour forces. Cooperation must be such that risks and delays, poor utilisation of skilled workforce and hired machines and unavailing exposition to extreme temperatures, wet and dirty conditions etc. can be avoided. The contractor bears full responsibility for making all necessary applications incorporated within the contracted scope, arranging for tests, inspections and obtaining permits needed (authorities and plant operator) in respect of the contract. He is also responsible to check that all required drawings needed for the installation works are available and make requests for needed additions or modifications in good time before the specific installation work is started. The contractor will himself arrange any temporary scaffoldings, tools and testing equipment etc. needed for the electrical installation works. This is with exception for special tools required for specific items which are arranged to be at disposal by Wrtsil NSD. He shall on his own cost himself or in cooperation with the civil contractor together provide, erect, maintain, dismantle and clear away at completion internal and external scaffoldings so that no signs can be seen of cleared off arrangements. The exact scope of supply shall be stated in the tender or agreed upon in a contract. Following sections are describing the principles of three main alternatives, but any other scope may as well be agreed upon. There shall also be principles agreed for pricing performances, services and equipment needed but exceeding contracted scope of supply and for how such supplements are ordered. In general contractors shall arrange or assist in arranging modification, repair and additional work and equipment needed locally. Such additional work or equipment shall be based on written orders or accepted offers including the prices.
2.2.1.
Installation of equipment supplied by Wrtsil NSD

Wrtsil NSD delivers all the equipment and materials needed to the storage nearby or directly to the construction site. The Contractor will unpack, transport to their final locations, erect and install all this equipment under Wrtsil NSDs supervision to fulfil all the requirements specified in this
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document and in the contract. He will be doing so using his own tools (except for equipment specific tools) and providing capacity; skilled as required manpower of the amount as needed for proceeding as scheduled and as required by constructional and other area works. He will also control and manage his workforce by having a experienced, cooperative foreman located at this site for the time required until all his tasks are fulfilled. All engines, machines and auxiliary units are generally assembled, fully installed with built-on local control / distribution panels and operationally tested at suppliers premises before being shipped to the construction site. Thus this equipment is as site to be connected to power supplies and to centralized supervisory control and monitoring systems mainly. Engine panels and central control panels as also some separate local panel are to be hauled in and installed with all connecting cables. Larger Wrtsil NSD -supplied switch/distributionboards and medium voltage switchgear is to be installed by the electrical contractor who reconnects transportation segments to form the operable assembly before cable connections are built. HPAC equipment, cranes, boilers etc. are installed mechanically by other contractors to have their mainswitch/ distribution - junctionbox with interconnecting and supply cables installed by the electrical contractor. Other systems are mainly installed by mounting and connecting delivered separate appliances the traditional way.
2.2.2.
Installation including equipment

Wrtsil NSD delivers most of the equipment and materials needed to the storage nearby the construction site for the Contractor to unpack, transport to their final locations, erect and install under Wrtsil NSDs supervision exactly as in the previous alternative. There is also a portion of equipment and materials which are included in the contract to be supplied by the Contractor.
2.2.3.
Installation and equipment partly supplied by the client

Wrtsil NSD delivers the engine-generator sets and auxiliary units with integrated electrification, essential switchgear and controlgear to be installed by the contractor like in previous alternatives. The client is supplying and installing e.g. building related systems (such as raceways, lighting installations, specific parts of the distributiongear). In such a case installation works are to be scheduled and performed in close cooperation with the client
2.3. Technical documentation

Remarks regarding technical documents and modifications of these are to be at our hand in written form or brought up at a site meeting within one week after the document have been handed over for execution or at least one week before the work is to be started. Indistinctnesses concerning execution, expectable conditions etc. are, on contractor's initiative, to be cleared out with Wrtsil NSD before they are affecting costs and time schedules. Minor deviations from documentation shall be agreed upon with Site Manager or Supervisor and have his signature before being exe-
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cuted. The contractor shall see to that correct and detailed information about such modifications are taken into the as-built documentation. Drawings and diagrams concerning equipment included into contractors delivery as also drawings and diagrams which are found necessary and made up by the contractor, are to be presented for approval by Wrtsil NSD at least two weeks before assembly or installation works are started. Internal diagrams for minor standard apparatus are to be delivered latest when being installed. Complete and final as-built documentation is delivered for approval before installation will be accepted / at least within two weeks from inspection for acceptance.
2.4. Permits, certificates, licences..

The contractor is obligated to obtain any official permits, authority certificates, licences etc. needed for building, voltage setting and operation of the electrification. He shall also transfer any drawings and diagrams needed for this process by the authorities and arrange and defray authority acceptance within scheduled time frames.
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3. QUALITY REQUIREMENTS
Any equipment delivered to be installed and any working methods used are to be fit for the heavy conditions and power station requirements. Design, materials, components, installation and tests are to be in accordance with the appropriate codes, standards (latest edition) and local requirements, unless otherwise stated in contractual documents. Quality level in accordance with ISO 9001 is to be fulfilled as to all deliveries, works and functions connected to the project. Every part of the undertakement is to be based on qualified electrical engineering practice and performed with good workmanship. Reference is made to the following codes, standards, etc; - International Electrotechnical Comission (IEC) - International Standard Organization (ISO) - in European projects CEN/CENELEC (EN-standards) and EC directives - National (local) and utility standards and regulations All components included within the scope are to be of approved and reliable design, high extent of uniformity and interchangibility is to be achieved. The design shall facilitate easy maintenance and repair of the components. The equipment is preassembled to highest reasonable extent in the manufacturers, contractors or sub-contractors workshop, e.g. wiring of boards, panels, desks etc., including installation of internal components is readymade. All switchboards and panels supplied complies with IEC 439-1: Low Voltage Switchgear and Control Gear Assemblies. Panels installed in dedicated electrical or control rooms have a degree of protection corresponding to at least IP2X, panels outside electrical rooms at least IP54. Local control and distribution panels are generally to meet WNS Quality Instruction 4V50L3683 requirements. If the contractor, as an alternative, offer design, materials, components etc complying with other recognized codes and standards, he will submit full details of any difference provided they affect the design or performance of the equipment. The electrical Contractor is also obligated to engage workmen which have sufficient skills required for specific work tasks. He must himself train, guide and conduct his workforce to perform any forthcoming tasks so that the work will not endanger supplied equipment nor jeopardize the final quality of the work performed. Take over inspections are performed with reference to revised documents and to this instruction. This inspection is performed as the contractor has conveyed a written announcment regarding finished installations to the Site Manager and the plant has been successfully started up.
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If some item is not acceptable, but will require renewed inspection when repaired, this inspection and all expenses caused thereby are defrayed by the contractor. The contractor will remain responsable for any fault and defect which is detected on his delivery during the guarantee period even if they are not noticed during the take over inspection.
3.1. Power distribution

Transfer voltage (TV) systems (switchyard upside stepup transformer) are generally directly earthed systems, Medium Voltage (MV) systems when built as restricted systems mainly for generator voltage distribution to stepup- and service transformers, are generally built for high impedance earthing employing high ohmic resistors. Low voltage (LV) distribution systems are generally built as TN-S -systems. The project specific solution applied at any level is however dependant of national, utility and client standards and is thus to be checked. Equipment of any kind and working methods employed shall meet requirements for the distribution systems connected to. Apparatus shall be designed and selected to use only standard voltage levels used in WNSsupplied equipment and meeting applicable Wrtsil NSD Quality Instruction requirements.
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;VXWMP 27( *MRPERH 3] Doc id: Page: Date / Status: Made/Approved: Replaces: Name: 7YFNIGX 4S[IV 4PERXW WDAAA055550 1 (3) 19-Aug-1999/ ISSUED GLS / GLS XX
4. SITE RESPONSIBILITIES AND ACCOMMODATION
4.1. Organisation
Wrtsil NSDs Site Manager has the mandate of supreme authority regarding any local concern of Wrtsil NSDs contracts. He is reporting to Wrtsil NSDs Project Manager who has the financial as well as tecnological responsibility of the total project. Wrtsil NSD-engaged Supervising and Commissioning engineers stay at site during erection, testing and start-up of the power plant. They are acting on mandates given by the Site Manager when controlling activities of their own sector or affecting it in any specific way. Furthermore there may be specialists from Wrtsil NSDs sub-supplying companies involved in the erection, installation, testing and startup of their specific part of the equipment. Disputes arising in the cooperatin with these specialists shall be settled by the Wrtsil NSD Site Manager or Supervisor. Client (powerplant owner or operator) presence is to be notified as the topmost involved party. Client requests, orders and actions shall as a principle be met as long as they do not interfere with or affect actions or work which have been agreed with Wrtsil NSD upon. Conflicts and inconsistent orders must immediately be brought to Wrtsil NSDs Site Manager for him to decide upon.
4.2. Sub-contractor
The electrical Contractor shall for the site engage a foreman / chief engineer having the experience, skills and capacity required for managing and controlling all the works included in his contract. The foreman / Chief Engineer shall have the ability to negociate and report in meetings and in writing using the English language as needed for fluent communication with any other parties involved. He is to have the commission and authorization required for everyday management and for decisions needed to be made regardless they are of financial or of technical nature. He shall be within close reach of Site Managers / Supervisors during ordinary working time until the contract is finished and closed. Contractors foreman/chief engineer shall attend site-meetings when called for by WNS Site Manager or Supervisor and in these meetings settle present and fortcoming situation regarding contractors and his subcontractors manpower and schedule. He is also to establish close cooperation with other contractors to avoid colliding activities, to make efficient use of scaffoldings and to coordinate schedules as required. The electrical Contractor shall confine his apparatus, the storage of materials and the operations of his workmen to limits indicated by law, ordinances, permits or directions of Site Management and shall not unreasonably encumber the premises with his materials.
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The electrical Contractor is also responsible for the design, construction, maintenance and removal of all temporary works employed in carrying out his contract. Scheduling, arrangements as also design and layout of temporary works shall be submit to approval by WNSs Site Manager. This will however in no way relieve the Sub-contractor of his responsibilities.
4.3. Accommodation
The Sub-contractor shall provide and maintain on his own cost office and temporary accommodation facilities needed on site for his representative and site staff. Services needed shall be arranged in cooperation with the civil sub-contractor. Sanitary conveniences for the use of persons employed on the construction site are generally provided and maintained by the civil contractor. All persons connected with the works shall be obliged to use them. Dry and levelled areas for storage and location of office and accommodation barracks are when required pointed out by the Site Manager. Furnishing, fencing, if required, is generally to be done by the contractor himself. Needs for temporary electrical power, telephone connections, toilets and dry / heated storage etc is subject to be agreed prior to undesignment of the contract. At demobilisation all temporary systems and buildings are to be cleared out of the site by the responsible sub-contractor at his own costs. Contractors shall when required, at their own costs, provide safe and regular means of transportation for their representatives and site personnel to and from the site also during overtime and holidays when such is needed.
4.4. Safety at Site

Every man working at this site is obligated to himself plan his tasks so as to prevent / minimize any risks - or to bring violation of such rules to Site Managers attention. He is also obligated to inform supporting staff about risks they might not be aware of. The electrical Contractor and his representative shall be entirely responsible for all safety precautions - especially those related to scaffoldings and similar arrangements, to tools and methods used as also precautions for work with live circuits performed by his staff. Employees shall be capable of using fire extinguishers available at marked locations at site to put out fires during any moment and at any location within the site-area. All lifting of equipment must be performed in accordance with instructions on packages or within the documentation supplied by the manufacturer of the equipment using strong and stable enough lifting tools. Watch up for sharp edges wich might cut textile ropes, and for high / unequal gravity points when moving by forklift. Battery acids and similar hazasdous matters must be handled with relevant care. Storage, filling, draining etc must be done strictly according to manufacturers instructions, ensuring sufficient ventilation and using protecting clothing as instructed. Prior to energizing every part of the system must be tested and inspected for being fully protected, clean and capable of carrying intended voltages and currents. Energized systems must be immediately marked up for car-
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rying dangerous voltages, electrical rooms being locked as not to allow unauthorized trespassing and enclosures sealed not to be opened without knowing the electrical hazards. Final warning signs are to be attached to doors, lids, covers etc. behind which live parts carrying hazardous voltages might be exposed as soon as they have got their final finish. Visible enough temporary warning labels are to be used until final signs can be attached.
Where obstacles and dangerous locations form risks for colliding , falling etc. or for electrical shock an angled alternating black and yellow warning label (tape or painting ) is to be used. Rooms, cabinets, and working zones where risks for electrical shock occur shall be clearly marked using the black/yellow label Danger: electricity (see Figure) and required explanatory text written in local language(s). DANGER HIGH VOLTAGE -sign is to be used on swithchyard fence and MV rrom doors, DANGER VOLTAGE -sign is to be placed inside powerhouse where neccessary to call attention that the unit or enclosure contaings live electrical equipment, HIGH VOLTAGE CABLE / POWER CABLE -signs are to be used where HV or power cables may be exposed to damage, WARNING, MEN AT WORK -signs are to be used when systems are being energized to call attention to feeders which are isolated due to ongoing work. When possible spaces where electrical danger might occur shall be locked to prevent access for unauthorized persons. Warnings signs are to be durable enough for the environment where used. Emergency escape routes are to be marked using white/green pictogram signs of rectangular shape (see ISO 3864 or national standards).
Figure 4.4 Danger: electricity
Tidiness is a mandatory requirement for safety and efficiency. All electrical rooms, cable ducts, trenches, floors and racks, and naturally also the insides and outsides of all electrical equipment must be clean and free from any installation waste or other irrelevant oblects. Subcontractors are responsible to follow Site Management instructions for any waste disposal at site.-
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;VXWMP 27( *MRPERH 3] Doc id: Page: Date / Status: Made/Approved: Replaces: Name: Subject: 4S[IV 4PERXW WDAAA055551 1 (2) 19-Aug-1999 / ISSUED GLS / GLS XX
5. STORAGE AND TRANSPORTATION OF EQUIPMENT

Temperatures during transportation and storage of electrical equipment in general must not exceed limits given in appropriate standards e.g. IEC 439-1 (i.e. -25C...+55C, maximum +70C for periods shorter than 24h) and humidity should stay moderate. For some equipment only room conditions (i.e. +5...+45C) are allowed. As most of the switchgear and controlgear is very delicate equipment, these items are to be carefully moved and unpacked. Packings must be lifted and transported using hoists and fork trucks and correct lifting devices supporting the packing as indicated on the packing box and in manufacturers installation instructions. Note that the gravity points of panel and switchgear assembly packings as of unpacked units are high and may require packings/units to be tied to the truck when being transported on forklift trucks. Unpacking is made by the contractor. Every unit is checked for signs of damage as soon as possible after unpacking. Until the installation begins, electrical equipment shall be stored, protected against mechanical damage and water only in a dry room. Unpacked assemblies shall again be lifted and transported only in accordance with manufacturers instructions using correct tools and applying forces to indicated points etc. Short term (a couple of days) storage of equipment in open air is allowed only if the equipment is still in the protecting packing which is covered by plastic wrapping or tarpaulin and during tempered, dry conditions well protected from damage of any kind. The installation of boards, panels and cabinets can be started when the installation site is dry, painted and finished and the dimensions of foundations and floor-openings are checked to be correct. Office type equipment is installed only immediately before system tests and startup.
5.1. Wrtsil NSDs equipment

The equipment will generally be delivered to the construction site by trucks. All of the eqipment is packed in seaworthy packings and / or in standard containers. The contractors (civil / mechanical / electrical) will unpack and take out the material for erection and installation works when it is needed in cooperation with Wrtsil NSD supervisors. Contractor and WNS Supervisor shall make an immediate receiving inspection of unpacked material and report any defects for ensurance inspection before taken to erection / installation. All heavy and delicate equipment (transformers, switchgear cubicles, panels etc.) are transported to site and moved onto the site of erection, in upright positions, fastened, lifting and pushing /pulling exclusively at intended points using tools as recommended by the manufacturer. All units should be moved in their packings as close as possible to the final location before unpacked unless good premises promote centralized unpack-
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ing. When possible unloaded assemblies shall be directly unpacked, inspected and lifted directly into the building as close as possible to their final locations. Instructions for storage provided by the manufacturers of the equipment are to be strictly observed. Note that longer storage of generators require turning of the machine with specified intervals. Oil immersed transformers must be filled with oil and having the drying breather in operating condition. Lead-acid batteries in DC panels and Uninterrupted Power Supplies (UPSes) may require charging so as not to be damaged by self discharge before installed and powered up.
5.2. Contractors equipment

The electrical contractor bears the full responsibility for the transportation to site, storage, unpacking, erection, installation and powering up and testing of any equipment within his scope of delivery. Equipment intended for installation shall be presented for acceptance to Wrtsil NSDs electrical supervisor in good time before the installation is started. This inspection does however not free the contractor from any part of his obligations to supply and install and prove full operabity to clients (plant operators) full satisfaction.
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;VXWMP 27( *MRPERH 3] Doc id: Page: Date / Status: Made/Approved: Replaces: Name: Subject: 4S[IV 4PERXW WDAAA055553 1 (5) 19-Aug-1999/ ISSUED GLS / GLS -
6. ERECTION OF EQUIPMENT
Do not initiate erection of sensitive equipment until the appliances can be safely transported to and protected against damages on the location where it is to be installed.
6.1. Arc welding

When welding is performed on or nearby machines or where cables are connected to electronic equipment, for fastening panels, cable trays etc. greatest care must be taken to prevent damages due to uncontrolled current loops. Welding current path must always be checked for closing the loop to the return connection without passing, not even partly, through bearings, crane wires, power distribution wiring etc. Neither must it form a loop along structures or conductors passing nearby laid out signalling cables or unprotected electronics. The return cable must be clamped firmly to a place wherefrom it will not be struck loose by accident thus loosing control of the current path. Also damages due to welding splashes are to be prevented by carefully screening off plastic sheathed cables and rubber hoses. Whenever taking to welding where installations are going on, the supervisors are to be contacted to assess the arrangements and to disconnect sensitive electronics before any arc will be lit. Figure 6.1
6.2. Generators and power transformers

6.2.1. Generators
Generating machines are hauled into the building - onto the engine bed by the transporter or civil contractor. It is mechanically installed and connected to the engine under supervision of Wrtsil NSD-specialists. The electrical contractor builds the cable-racking for main and auxiliary cables and carries out the cabling and connections in accordance with the electrical drawings and manufacturer's instructions delivered with the generator.
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6.2.2. Transformers
Transformers need a foundation capable of carrying the total weight when filled with oil. An oil pit, large enough to gather the oil from any point of a transformer and to hold the total oil quantity, should be built under any oilimmersed transformer. The pit is normally covered by a wire net and/or coarse gravel to extinguish an oil fire. Transformer foundations and oil pits with filling are generally built by the civil contractor (if not in electrical contractors scope of supply) but are to be inspected for suitability and to meet requirements before the transformer is placed onto it. Oil-immersed transformers are installed in a slightly slanting position so that the angle of ascent into the gas relay is 1 to 2% to assure that any gas generated will find its way into the gas relay. This is accomplished by inserting intermediate plates (generally delivered with the transformer) at the supporting points. Breathers on non-hermetically sealed oil-filled transformers are to be immediately assembled and oil-airlocks filled to correct level (see manufacturers instructions) by the contractor. Station service transformers and similar (MV/LV) are erected by the electrical contractor. When the transformer is on rollers on profile rails, they must be well locked to their places by applying securing bolts on both sides of one pair of rollers. Step-up power transformers are hauled and jacked onto their foundation by the manufacturer, transporter or civil contractor. Large transformers of this kind are generally disassembled to some extent for the transportation. Re-assembly and re-filling are generally to be performed by electrical contractors men conducted and supervised by manufacturers or Wrtsil NSDs expert: Large oil-immersed transformers are transported without oil and are thus to be filled with oil before starting the installation work or for longer storage on site:
Transformer is kept under vacuum (ca 133 Pa, or as recommended by manufacturer) by means of a suction pump for at least 8 hours whereafter the filling of the transformer is started, while the suction pump is still working, pumping the cleaned and dried oil from transportation tanks, through a filter to the transformer tank until windings and insulation parts are below the oil level, pumping being carried out slowly - not to considerably decrease the vacuum during filling operation. See manufacturers instructions.
All parts which have been disconnected for transportation such as coolers, oil conservator, bushings etc are refitted and temporarily fitted solid flanges are removed according to manufacturers instructions. All bushings and gaskets are checked and tightened. Additional oil filling is executed according to the manufacturer's instructions.
6.3. Auxiliary units

Process units for fuel treatment, compressed air etc. are lifted in and erected by the mechanical contractor. The electrical installation of supply and control cables to external systems can take place when a unit has been fixed to the bed, but cooperation with the mechanical contractor is required in order to avoid encounters with piping or other structures being built and to avoid damages during this work.
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6.4. Switchgear and controlgear assemblies

Medium Voltage (MV)-switchgear prefabricated cubicles installed in dedicated electrical rooms are of factory made indoor, compartmented or metalclad type and have a degree of protection corresponding to at least IP3X (acc. to IEC 529). The construction is such that it is possible to gain access to the cable box chamber in any cubicle without having the busbars out of service after earthing of conductive elements. The terminal blocks, relays and instruments are so located as to be safely accessible while the equipment is in service. Metal Clad-type cubicles require disassembling according to manufacturers instruction to give access to cable terminals. MV switchgear assemblies are generally delivered as single or dual cubicle units per packing case, circuit breakers are inserted in and locked to their cubicles. Busbars, truck for moving circuit breakers and other maintenance tools as also other items to be attached to the switchgear assembly when being installed are in separate packings. The base for the MV-switchgear is prepared for installation by levelling out a highest point and filling levels of the supporting points below that point. See footprint drawings and manufacturers instructions for installation. The cubicles are provided with ways and means for intended type of fixing to the floor. When locating a MV switchgear assembly close to a wall or pillar, a minimum arc discharge space may be required behind the cubicle as described for the type installed. Footprint drawing details and installation instructions are thus to be strictly followed. No installations are allowed (electrical or other) which prevents or limits arc discharge lid openings on top of the cubicle nor within reservations for arc discharge. Cubicles are moved into the installation site in accordance with the manufacturers recommendations, detaching from the transportation case, lifting and pushing/pulling only at intended points and using tools as recommended. Always use lifting ropes of sufficient length and beams as required. Cubicle elements must be taken apart or laid lying through bottlenecks of the route only in accordance with manufacturers instructions. Placing, levelling and fixing to the floor and to other cubicles is carried out using recommended methods, components and tools. Note that busbars may have to be inserted before all cubicles are located onto their places if there is not space enough to insert long beams when all cubicles have been assembled. Each end cubicle and at least every third cubicle are normally fixed to the floor after busbars have been assembled and checking that the assembly is mechanically fully operable. Damages caused to painted surfaces, isolators or other apparatus are repaired immediately before covered during proceeding assembly. Busbars are assembled by the contractor in the order and stage, using tools, methods, jointing compounds and tensional forces strictly as prescribed by the manufacturer of the assembly. Roof plates / discharge lids are to be fitted in accordance with manufacturers instructions. Also earthing bar interconnections are to be built and control wiring interconnector plugs/sockets joined or a number of interconnnections to be built to form an operable switchgear assembly.
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Maintenance accessories etc. are placed in holders which normally are fixed to a free wall surface in the HV-room. Low Voltage switchgear / main distributiongear units are generally to be installed in dedicated electrical rooms. These factory made assemblies are of indoor, metal compartmented type and have a degree of protection corresponding to at least IP2X, WNS standard being IP31. Subdistributionboards and in some installations also the main LV-switchgear assembly may be located in the engine hall or in auxiliary system rooms. Such assemblies shall have an ingress protection of at least IP44 or IP54 or even higher depending of location and environment. Manufacturers Instructions for installation are to be followed strictly. Foundation / floor levelling and inspections to meet manufacturers requirements must be made before erection is started. The distributionboard-assemblies are transported and moved into the installation site in one or several transportation sections each. Lifting and moving swgassembly packages as well as unpacked sections shall be made in accordance with markings and manufacturer's recommendations and drawings, lifting and pushing /pulling only at intended points using tools as recommended. Multiple-cubicle type distribution boards for floor mounting are normally built for upright transportation and assembly only. This type of construction should be laid laying only with permission from the manufacturer and should also be thoroughly prevented from steep tilting. Locating, levelling and fixing to the floor and to other sections of the unit is carried out by the contractor using recommended methods and tools. When locating the distributionboard close to a wall, an arc discharge space may be required between the assembly and the wall as indicated by the manufacturer. Feeder busducts shall be fitted in with the switchgear assembly and cable routes out from cable compartments shall be checked free from obstacles before fixing the assembly to the floor. No installations are allowed (electrical or other) which prevents or limits arc discharge lid openings on top of the swg nor within reservations for arc discharge. The assembly shall be fixed to the floor or smaller distributionboards to the wall in accordance with manufacturers instructions. Generally it shall be anchored at both ends and in intermediate points at a maximum distance of 1 m, e.g. at both edges in each cable compartment. Interconnections of transportation section busbars are to be made strictly following the instructions and using the components and composants provided by the manuafacturer and using correct tools, applying correct torques etc. There may also be internal control circuit wiring disconnected for transportation there to be reconnected to complete the erection of the assembly. Panels and control cabinets or desks are transported in one or several sections each. They are to be moved onto the installation spot section by section in accordance with the manufacturer's recommendations and drawings, lifting and pushing /pulling only at intended points using tools as recommended. Panels and cabinets can generally be tilted or laid lying for transporting through narrow passages. This is however to be done with greatest care, possibly so that plug-in units and cards are to be detached or secured and heavy floor mounted transformers and UPSs supported or taken out before it can be done.
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Placing, levelling and fixing to the floor and to other sections of the controlgear is carried out using recommended methods and tools. Each end of each section of modular constructions are normally fixed to the floor after the mechanical interconnections have been completed. Fixing to the floor is done by bolting or welding as prescribed by manufacturer.
6.5. DC-panels, batteries

Generally used d.c. panel types have internal lead-acid batteries. For this reason these panels should be stored and transported only in temperatures +5...+40C nor must the humidity be considerably high. DC-panels with internal batteries must not be laid lying or enven steely tilted during transportation. For larger systems or alkaline (NiCd-type) batteries the d.c. panel holds the charger and d.c. distributionboard only. Batteries are delivered separately to be located on a separate battery stand (generally supplied with the batteries) or in a separate battery cabinet. D.C.panel with chargers, internal batteries and d.c. distributing MCBs are generally located in an electrical room. NiCd batteries are generally to be installed in a separate, well ventilated battery room. Lead-acid batteries are of hermetically sealed type or they are delivered dry, battery acid in separate cans. Such batteries are filled in accordance with manufacturer's instructions when they or the d.c. cabinets containing the batteries have been installed on their positions. Sealed batteries are delivered factory filled and charged. If stored for a longer period, filled batteries are to be charged at an interval of about one month. Free standing batteries are interconnected and connected to the d.c. panel using prefabricated interlinking conductors, as short and well apart from each others as possible. Unfused battery cables from end units to the d.c.-panel are separate 1-pole cables laid in separate plastic pipes which are fixed to the wall >100mm apart from each other. Battery cables are entered into the d.c.-panel through a cable gland plate of nonconductive material. All required accessories such as density meter, funnels, anti-corrosive agents or pastes as well as the initial acid filling are supplied with the batteries and installed nearby batteries by the contractor.
6.6. Field mounted sensors, switches...

Process sensors in tanks, flanges, pipes, ducts are mounted in pockets or on flanges which are to be furnished by the mechanical contractor who will also furnish the sensor, transmitter and similar appliance itself - if required with assistance of the electrical contractor. Sensors, switches, junction boxes,amplifiers and similar which are not to be attached directly onto the process equipment are to be furnished by the electrical contractor observing any installation instructions issued by Wrtsil NSD or the manufacurer of the equipment.
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7. EARTHING / GROUNDING SYSTEM

Definitions: This chapter is using earthing for bonding of equipment and circuits to common plant earth electrode potential, protective earthing (PE) when this bonding is required for personal safety provisions grounding for interference suppressing bonding of screens, systems with ground level. A low-impedance earth bonding and equipotential grounding system is required for optimum internal safety and immunity against as well low- as high-frequency interference. For any circuits extending outside the equipotential bonded area of the power plant also the earthing resistance will be of importance. The primary intention is to provide a system for reliable low-impedance bonding of any two exposed parts of the installation including the earth (earthing electrode). This is achieved either by connecting equipment incorporating electrically powered appliances or electrically sensing/measuring instrument circuits to earth bus or earth line trunk conductors or directly to a mesh net earthing electrode. Each earthing connection is to be built as short and direct as possible. New independant installations are built for optimized earth bonding of any involved equipment and systems to one mesh net earthing electrode. The electrode bonding is secured and interference bonding improved using earth line conductors along cable routes where considered practical. This is of specific importance when Extended or Advanced control technology is applied. Local regulations or existing systems may however require separate earthing of high voltage equipment, of sensitive electronics etc. In those cases regulations or existing practice is to be followed. Instrument cable screens are to be connected for efficient grounding of any occurring electromagnetical interference using methods as they are described later in the part Cable terminations.
7.1. Earthing electrode

A mesh net earthing electrode is built to incorporate the entire furnished area and surrounding the foundations of buildings, tanks and other equipment. A meshed grid of bare cupper conductors is to be buried 0,5 - 1 m below grade onto or below bottom level of the escavation made for equipment foundations. Depths of 1,5 m or even deeper may be required to ensure soil drying or freezing will not increase the earth resistance of the earth electrodes. Low enough earthing resistance is to be reached during any expectable conditions.
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Earthing resistance value to be deemed acceptable is dependant of local regulations for maximum prospective touch voltage (between ground and conductive parts connected to the earthing system), of prospective maximum earth fault current values and durations but also of fault current detection requirements. As Wrtsil standard powerplants are built for direct bonding of any exposed part, earthing resistance will not generally form any part of local earth fault current loops. The total earthing resistance value has thus little significance from local restricted systems point of view where there is no possibility for earth current loops passing out of controlled area. Transmission voltage earth fault to station earth may however raise the high resistance station earth voltage to considerable values related to remote earth. Thus any low voltage system connecting the plant to distant locations may distribute dangerous voltages or be destroyed in such a situation. For this reason acceptable earthing resistance value is mainly dependant of connected transmission system requirements, not of local systems.
The meshed earth electrode structure is repeated for each building, switchyard and equipmentyard. Electrode conductors are laid on the bottom of each excavation either separately or as an extension of the area electrodes trough the excavation. As a rule, the earth electrode should be set in (or laid on) the natural soil, not in backfill materials, and if possible in damp earth on the same or below the level of underground drainage systems. Solid conductors are preferred as they are less subject to corrosion than stranded types. Connections between conductors are to be exothermically welded or connected by other means qualified especially for this kind of use. Separately laid electrodes are to be multiple-interconnected to constitute a larger meshed electrode especially where (telecommunication) systems may extend from one eartbound location to another. Bonding jumpers are to be brought up for connecting the electrode to larger concrete mesh reinforcements (fig. -3), as also earthing conductors connected for branching up to large steel structures and to electric assemblies and electrically powered process units (see chapter Earthing conductors).
Figure 7.1
Meeting electrode mesh conductors with : hermetic, exothermically welded connection, : bottom of escavation, : sorted backfill, : unsorted backfill
Figure 7.2
Clamped connection
Figure 7.3
Connection to reinforcement, exoth.welded, clamped and if connection is to be visible, detachable
Electrode conductor dimensions: Use bare cupper conductors of cross-sectional areas large enough to withstand the occurring mechanical and chemical stresses and having required current carrying capacity with respect to effective fault release time. Check required cross-sectional dimension using the table for earthing conductor dimensions. If the eart fault current will be spread into the earth electrode mesh into several directions from the point where the earthing
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conducter is connected, the current may be assumed split up into uneven paths thus making smaller cross-section areas sufficient
7.1.1. Substation
IEC 364-4-442 requires one earhing system to which shall be connected earth electrodes, the transformer tank, metallic coverings of low and highvoltage cables, earth wires of high-voltage systems, the exposedconductive parts of HV and LV equipment as also extraneous conductive parts. Mesh layout: One deep, continuing conductor is laid along or beyond the boundary fence. Crossing conductors are spaced 3 - 7 m along equipment foundations in a way that each apparatus or assembly to be installed can have two short ground connections to different crossing conductors (or to the boundary conductor). Crossing conductors are primarily for distributing earth connections and for keeping the potential gradients within the substation reasonable and does not require same depth. Each one of the crossing conductors is exothermic-welded, brazed or clamped (using for this purpose approved connector clamps and tools) both ends to the boundary conductor and to each crossing conductor. Dimensions: Cross-sectional dimensions are always to be checked for sufficient current carrying capacity with respect to maximum prospective earth fault current value and duration (transmission system earth fault current with the additional earth fault current supplied by genset & step-up transformers). Following recommendations are to be followed only where no data available might indicate needs for larger cross-sectional areas:
o For very small substation arrangements (one mod-
erate size step-up transformer, high voltage CB and isolator) a Cu 75 mm boundary wire or cable only is generally sufficient when it is extracting from the larger power plant mesh electrode which is providing the low enough earthing resistance required. medium size substations as also whenever there is risks for mechanical damages or chemically aggressive matters in the ground, a conductor sizing of 95 to 150 mm is to be used. Concentrations of current such as low impedance neutral to earth connection of transmission voltage (step-up) transformers require vertical rods bound to multiple distributing conductors or larger sized conductors. For protective doubled bonding of structures and apparatuses via mesh conductors to earth 50 - 70 mm is generally sufficient.
o For
Figure 7.1.1
o Large
substations may require even larger cross section areas to meet the requirements for current carrying capacity. Those are to be calculated with respect to grid capacities mainly.
The substation boundary conductor shall form an integrated part of the plant earth electrode being connected to the main electrode by conductors capable of carrying a major part of the prospective earth fault current i.e. at least the size of the boundary conductor.
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Where a low-impedance earth connection of the transmission voltage distribution system is required, either by connecting the step-up transformer neutral(s) to earth or by other means, this connection is to have specific attention. Where possible enhance the earthing electrode in this spot by using one or several vertical deep-driven earthing rod(s) penetrating all known underlying ground/soil layers and capable of carrying the total maximum prospective earth fault current for the release time required. Earthing resistance: The value to be deemed sufficient is dependant of maximum allowable step voltage (1 m), touch voltage (ground to earthed structures) and transferred voltage (remote earthed to locally earthed equipment, see previous chapter) in fault situations.
7.1.2. Power building

The power building is, when incorporating also high voltage power systems, to fulfil transformer sub-station requirements acc. to IEC 364-5-54 as referred to in previous chapter. Due to the control systems applied also EMC (Electromagnetic compatibility) requirements are to be met:
o Basic level control systems are built using appliances and circuits which
are not by their nature sensitive to electromagnetic interference. Thus the earthing system is mainly built for protection against overvoltages at any possible fault situation.
Lay one continuing earth electrode conductor below drainage level along the perimeter of the escavation made for the foundations of the building. Incorporate stack foundation escavations in this loop or connect branching loops around them. Arrange the outermost corners of the loop to be later accessable for additional branches or earthing rods. Add such branches and /or rods for increasing the electrode area when building the electrode if the location is already known to have high earth resistance values. Pick away sharp stones and other objects which might damage the conductor from soil coming in contact with the conductor. Bring up both ends of the electrode conductor separately (isolated from each other) to the location of the main earthing bar. Attach branches from the main electrode conductor to be connected to the concrete floor reinforcement steel rods at each corner of the building.
o Extended level control systems for monitoring only can be applied with a
Basic level earthing / eart electrode system especially where well protected (not rapid) PLC systems are used. by their nature more sensitive to high frequency interference. Such systems as also
o Extended level control systems which have controlling facilities are o Advanced
level distributed control systems with rapid multi-level bus communications require earthing systems with interference suppressing qualities. These earthing systems are to be built for low-impedance earth bonding of any equipment at any frequency.
Build an earthing electrode loop structure as described for Basic level applications. Add crossing conductors to have a meshed stucture not unlike what was described for the substation electrode. Best earth connection will be achieved by laying each conductor on the bottom of the escavation
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but to get shortest possible rising earthing conductors the better location is in the backfill especially when engine beds require deep foundations. Lay one conductor to pass the generator ends of the genset-beds from one side of the perimeter loop to the opposite side and lay another conductor passing the engine ends of the beds. Lay transverse conductors to pass along each engine-generator bed below the engine panels. Add conductors which overlap escavation (and perimeter conductor) wings and where required to have optimum (=short) earthing connections to each unit, panel etc. Connect all these meshing conductors to the perimeter conductor and in crossing points to each other usin exothermic welding or other approved method. Cross-sectional areas are to be checked to meet the current carrying capacity required by each involved system as also to have the mechanical and chemical strength needed. Use the highest one of any of the following system requirements. Main (perimeter) earthing electrodes taking part in the earthing of substation equipment are to have cross-sectional areas for the same current carrying capacity as has the interconnecting earth electrode conductor. Medium voltage systems in WD-P powerplants are generally restricted and designed for allowing a maximum earth fault current of 5 A per connected generator (10 generators will thus give a maximum of 50 A) which will not require more than minimum dimensions. Where other than resistor or earthing transformer system earthing methods are applied or where larger distribution of medium voltages are to be set up, a specific calculation is required. Low voltage distribution is generally built as TN systems where all exposed conductive parts are connected to the earthing system and to the neutral point of the supplying transformer. In the meshed electrode system electrode conductors may come to carry prospective earth fault currents limited and released by the overcurrent protection. They are thus to be sized according the rules for protective earth conductors but generally allowing the higher final temperature as described for earthing conductors. Main electrode conductors are to have the crosssectional area required by the overcurrent protection of the largest outgoing feeder (to a sub distribution switchgear, process unit or similar). This is provided station transformer and low-voltage switchgear fault current loops are restricted to properly dimensioned return conductors. Earth electrode conductors of cross-sectional areas less than 50 mm Cu should not be used neither as perimeter nor as meshing conductors. Stresses due to lightning are also to be observed. Earthing conductors from stacks should where possible be extended across the (connected) perimeter conductor to form a 5 to 10 m long direct discharge electrode into surrounding ground. Use similar arrangements also where a downconductor from a lightning protection system meets the earth electrode conductor.
7.1.3. Tank farm and other open air located equipment
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Meshed structure earth electrodes are to incorporate also tank farm, radiator farm and similar areas. Smaller areas are surrounded by one electrode conductor loop from which branches are built to all, or at least to diagonal corners of foundation reinforcement steel arrangements and earthing conductors to the tanks or structures. For larger areas the meshed pattern and short earth connections for lowest possible impedance may require crossing electrode conductors also for the equipment yard. Preferrably lay one interconnecting electrode conductor along pipelines to provide short earthing connections from each one of the pipe supports. Incorporate also the fuel unloading area including the lot intended for the vehicle which is being unloaded to provide low impedance binding of the surface (ground or floor), unloading equipment and storage tanks.
7.2. Main earthing terminals or bars

IEC 364-5-542.4 requires for every installation, a main earthing terminal or bar to which shall be connected; earthing conductors, protective conductors, main equipotential bonding conductors and functional earthing conductors where required. Install the main earthing bar (MEB) of a minimum cross-sectional area of 50 * 8 mm Cu on a wall of the electrical room for good access from underfloor cable routes and for short connections to switchgear assemblies, station transformers etc. Required length of bar is depending of the number of cable to be connected. Provide the bar with fixing holes (c-c 25 - 40 mm) for heavy duty ring type cable lug termination ( 8,5 - 10,5 mm). Fix it to a conductive fabric wall using insulation studs. Bring both ends of the perimeter earth electrode conductor (as earthing conductors) to this main earthing bar. Keep the rising earthing section of these conductors isolated from each other to enable later continuity checks.
o Basic type earthing systems are built for connecting the main earthing
conductors, every protective earthing and equipotential bonding conductor to earth through the main earthing bar. Also Noiseless earth-systems are connected to the main earthing bar.
Install Basic type earthing, protective and equipotential bonding conductors directly but segregated to the main earthing bar. For remote groups secondary earthing bars are built using these same principles to be bound to the main earthing bar using one common conductor. Distributed panels and process units can be connected to along main cable route laid main earthing conductors which are forming stretched out earthing bars.
o Advanced
type earthing systems are based on low-impedance earth binding of each essential machine, assembly, system and structure to the meshed earthing network by direct earthing conductors (see next chapter). This is required to achieve optimum suppression of high-frequency interference.
Use the main earthing bars also in these installations for low voltage (~400 V) system operational earthing, for terminating protective conductors to station transformer tanks, switchgear room assemblies and to other secondary systems like telecommunication, computer systems etc. Upper floor control room equipment is to be earthbound to the main earhing bar by a
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distributing main earthing loop as an extension of the meshed electrode earthing. Other equipment; switchgear assemblies, panels, process units and structures are earthbound via direct earthing conductors.
7.3. Earthing conductors

Earthing conductors are built to connect earthing terminals of panels, switchgear assemblies, equipment and structures to the earthing electrode. In Basic level controlled plants the earth connection may be built exclusively via the main earthing bar. Where higher degree of interference suppression is required, earhing conductors are to form a low impedance connection to the underlying earthing electrode. Connect these earthing conductors to nearest point of the earth electrode by the same means as is used for connecting electrode conductors; exothermic-welding, brazing or clamping. Earthing conductors are in general to be branched off the electrode as the conductor is being laid down before being covered under backfill and concrete. Select earthing conductor cross-sectional areas according currentcarrying capacitys required for each connection separately. Required dimension depends of fault release time and installation type, also requirements for mechanical strength and chemical resistance are to be considered: Bare earthing conductors embedded in concrete or in soil as also visible earthing conductors in electrical rooms (and restricted areas) are considered as laid fireproof if they will not cause damage to other installations or structures even when reaching a final temperature of ~500C. Bare earthing conductors in Normal locations (non-visible or in generally accessible locations) may reach a final temperature of ~200C and are thus to be laid no to damage other cables or installations at this temperature. Earthing conductors in locations where hazards are greater are to be dimensioned for a final temperature not higher than 150C. Do not use cross-sectional areas less than 25 mm for earthing conductors passing down to underlying electrode to maintain sufficient reliability. Earthing conductors are to be protected against mechanical damage by the location or by protecting arrangements. Protect conductors which are rising through the concrete floor by locating them beside rising structures, unit foundations or cable conduits. Where required a corrosion resistant steel conduit shall be fitted to protect the conductor from half way down the concreting to 1,5 m above level or protected by other means.
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25 mm2 2 35 mm 50 mm2 70 mm2 95 mm2 2 120 mm 2*70 mm2 2*95 mm2
fireproof 500C normal 200C 8 5 11 7 16 11 22 15 30 21 38 26 45 31 61 42
fire risk 150C fireproof 500C normal 200C 4 5 3 6 7 5 9 11 7 13 15 11 18 21 15 23 27 19 27 31 22 37 43 30
fire risk 150C 3 4 6 9 13 16 19 26
7.3.1. Substation
Earthing (down) conductors are to be connected to the earthing electrode mesh conductors to provide earthing paths for each supporting structure, frame and tank of an outdoor open frame assembly, for excessive voltage arresters, for the boundary fence etc. Each appliance should have two or more earthing conductors to different segments of the electrode mesh (for testing, fault current distribution, backup etc.) each one detachable for testing required. Some appliances, e.g. transformer tank with arresters, have a combined earthing terminal thus not requiring separate conductors. Every earthing conductor shall have a cross sectional area of not less than what is required for sufficient current carrying capacity but in no case less than 25 mm Cu.
Figure 7.3.1 Fence earhing conductor.
7.3.2. Medium voltage system

Generators are directly earthbound in at least one point. Install another earthing connection to the engine or to the common base frame. For Basic level earthing one earthing connection in conduit to electrical room main earthing bar and another to the main earthing loop is recommended. Generator neutral point (resistor) cabinets require each an earth connection to carry the constructive part of any generator voltage earth fault current. Switchgear assemblies are earthbound via protective conductors to the main earthing busbar. Where the MEB is located distant from the far end cubicle, it should have a direct earthing conductor. Station transformer tanks and room structures are recommended to have at least one direct earth conductor to underlying electrode though they are also to have a protective connection to the main earthing bar. This is to minimise earth current loops in any possible earth fault situation.
7.3.3. Low voltage distribution

Though each power supplying feeder cable is including a protective conductor, each larger size distributionboard, control panel, machine and process unit is to be earthbound also via an independant earthing conductor. Size the earthing conductors for the same current-carrying capacity as has the cable-PE (higher final temperature will admit smaller area) but in no case less than 25 mm Cu.
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Terminate and bolt the earthing conductors for good protection against mechanical damage and corrosion but still visible and detachable for continuity testing. Aim at achieving best, shortest possible earth connection for highfrequency interference which might reach any kind of electronics along cable shields, supply, protective conductor etc. A motor or heater capable of a large fault current should not be bonded on the same earthing conductor as sensitive electronics.
7.4. Protective (PE) conductors

Protective conductors are installed mainly or exclusively for providing protection against electric shock. To do so they are to connect exposed and extraneous conductive parts to the main earthing bar and thereby to earth electrode and earthed point of supplying transformer or generator.
7.4.1. Substation
A project specific documentation will be issued by the supplier of the substation equipment. This documentation includes specifications of any earthing/PE conductors required for earthing of all metallic appliances and structures within the switchyard area.
7.4.2. Medium voltage gear

The cubicles forming the main MV switchgear assembly are interconnected for good binding to a common ground level. Install two protective conductors, each capable of continuously carrying the maximum earth fault current to the earthing terminals of each end cubicle. Where the main earthing bar will be located distant from the assembly the earth connection from one end should be built as an earthing conductor directly to the nearest electrode conductor. Generator frames and engine frames should have one earthing conductor connection (to the nearest electrode conductor) each. Each conductor capable of carrying maximum earth fault current of the MV system but also meeting PE size requirements coming from the heviest LVsupply to any load (e.g. heater) on engine or generator.
7.4.3. Low voltage distribution

Each power supplying multicore feeder cable is to include a protective conductor. Power cable types required for power plants have either a green/yellow PE-core or a concentric Cu-braid with a cross section similar to phase core sections up to 16 mm and the phase core cross section from 25 mm and up. Single core cable system feeders require similarly dimensionned neutral and PE cables (higher final temperature will admit smaller area) but in no case less than 25 mm Cu.
7.5. Cable screen earthing

Cable screens are supposed to decrease the interfering effects of electrostatic (and magnetic) fields passing in to and out from currect carrying cores in the cable and equipment housings to which it is connected. They also provide controlled current paths for fault currents when occurring. Metallic conduit can be considered similar to an overall screen if built for good, durable connections.
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7.5.1. Power cables

Power cable screens (as also armours) are always to be connected to earth. Designers instructions for single or both end earthbinding is to be observed as free end voltage versus current carrying capacity of the cable will be affected. Observe requirements for controlling and measuring earth current paths e.g. for correctly detecting earth faults. Screen / armour shall be isolated from chassis, if required with the metallic cable ending box, and connected to earth via a conductor passing out through the window transformers window before being connected to earth.
Figure 7.5.1
7.5.2. Signal cables

Sensitive signals are connected from field instruments to panels and to control systems using interference screening cables only. For (low voltage level) binary signals from alarming contacts or proximity switches etc. overall screened cables give sufficient immunity. Analogue signals (4-20 mA, Pt100, thermocouples) require twisted pair, double screened cables. The overall screens of these cables shall be connected to earth/chassis in both ends. This is with the exception for any case where power distribution ground loop (stray) currents might come to flow through the screen. In such cases the outer end earth connection shall be made using a HV (high voltage), HF (high frequency) capacitor or left open if HF interference seems unlikely to occur. Twisted pair (low frequency) screens shall be isolated from chassis or other conductors outer end. Pair screens shall be separately connected through marshalling boxes and finally connected to a close screen earth terminal which can be easily disconnected from earth for easy outer end earth fault check.
Figure 7.5.2 Earthbonding of analoque signal cables.
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7.5.3. Panel arrangements

Figure Error! No text of specified style in document.1.5.3 Local Panel arrangements 1 ) Earthing conductor to electrode 2 ) Supply cable with PE cnd. 3 ) Earthing Bar 4 ) Motor and heater feeder cables 5 ) All cable glands of strain relief type 6 ) 110 VAC control circuit cable 7 ) Screen bar disconnectable from earth 8 ) Analoque signal cable (mA, Pt100,TC) 9 ) Binary I/O signal cable 10) Thermocouple cable 11) Overall screens eartbound in glands or connected to Earthing bar 12) Bonding of lid if it is carrying equipment.
Panels are built for low-impedance earth-bonding fulfilling both protective and EMC requirements. The Main Earthing bar being connected via an Earthing conductor to the electrode as also via the supply cable PE core to the distribution switchgear Main Earthing bar. Chassis and internal appliances including derived voltages are earthbond to this Main Earth. Where sensitive analoque circuitry is to be terminated, a disconnectable from earth Screen bar or terminal block is arranged for connection of signal cable pair screens only. Screen to earth bar connections, pair screens as well as overall screens, are to be as short as possible. See also Cable termination in cabinets figure in chapter 11.
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Wires, other than those specialized instrumentation wires (e.g. thermocouple leads) are categorized into four groups to be treated each considering their specific requirements. Power wires are high-amperage large gage wires against which instrumentation and data transmission wires generally need to be shielded; Control wires are medium gage wires used to carry 110-115 V ac/dc or 24 V dc control signals. Electronic wires which are low-voltage vires that normally are shielded and Fieldbus wires which are shielded wires and cables designed to protect and transmit high-bandwidth control signals. Wrtsil NSD wiring systems are mainly employing multi core cable types designed especially for each category, voltage and load for any connections outside factory-built assemblies and appliances.
8.1. Heavy main connections

Heavy main connections like feeders from power transformers to switchgear assemblies, generator feeders and similar are generally built using prefabricated busways or busbar trunking systems. Alternatively these connections are built as single core cable systems (see below) or parallel three-core cable systems. Busways are prefabricated - tailor made to fit more or less exactly for the intended interconnection. They are to be assembled and installed by the electrical contractor. Flexible joints are used to join busbars to transformer bushings or generator terminals but may also be required where long busducts are terminated to switchgear assemblies. The joints are provided with flexible cup springs under fastening screws or nuts to withstand strains due to temperature fluctuations caused by load changes. Recommended tightening torques are used for any joints and terminations. Single core cable systems are to always meet two essential requirements: 1. MINIMIZING OF STRAY FIELD so as to minimize transmission reactance and risks to have fields closing through nearby ferro-metallic structures therby causing losses which are heating the structure and possibly inducing secondary current loops. (Ferrometallic structures framing single or a part of the cables forming a group will devastate the operability of the connection.) 2. EQUALIZING CABLE REACTANCES so as to have equal reactances for all SAME PHASE cables to carry equal parts of same phase current.
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Part cables are to have dimensions according to the part carrying the highest current.
8.2. Power distribution and control systems

WNS installations are generally employing plastic insulated multicore cables laid on cable racks or pulled into dropout and sub floor conduit. Single core flexible or semi flexible plastic insulated wire is used inside panels and cabinets. Also, bus bars are often used for power distribution in enclosures and panels. A.C. power cabling shall primarily be made using heavy-duty cable types with a concentric protective earth conductor around phase carrying cores. Control cables carrying 110-115 V control circuits are built using 300/500 V or higher cable types. Separate source and separately fused circuits are basically to be arranged in separate cables unless specified by supplier of connected appliance to use one cable only. D.C. circuits must not use cores of cables which are carrying a.c. voltages. D.C. cables shall be laid clearly segregated from a.c. cables with a separating distance of minimum 200 mm at any part of the length except for 90 crossings. Electronic circuit carrying cables (e.g. mA and T/C cables) are to be even clearlier separated from any heavy and switched load cables.
8.3. Civil systems

Engine hall, electrical rooms, workshop installations should be made as exposed installations to highest possible extent making use of cable routes built for LV power cables. Telecommunication, detection system and similar cables located on signal cable trays/racks and ladders. Exposed /concealed installation is to be used for installations in control room and similar premises.
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'%&0) 6398-2+
Wide conduits or cable ducts in floor construction are used for main routes directly from underneath the electrical room or for branching routes from trenches to alternators, process units or panels. Other cables of different categories are mainly routed along racks and ladders on walls, under service platforms or in trenches or are they pulled into conduits laid under ground/concrete. Single cables are clamped onto the wall or ceiling or e.g. pulled into metallic conduits along steel structures. Cable-runs shall be selected so as to be as far as possible straight and accessible. Routes shall not unneccessarily pass through zones where fire hazard may occur. They are also to avoid locations where exposed to oil (splashes, spray or mist), condensed moisture or dripping water. Cables shall be distant or screened from sources of heat such as boilers, hot pipes, resistors etc. Routes shall be protected from avoidable risks of mechanical damage, or where this is not possible, suitable shields should be installed or other precautions taken. Within his scope of supply the contractor is free to select the most suitable and effective cable passages and raceways as long as they do not interfere with reservations for other cables, piping and ducts or existing installations. This is however with the exception that design properties must be checked if installation conditions are changed (e.g. power cables sized for installation in free air must not be installed in poorer conduit cooling conditions). Routing of different categories HV/power/analog signals etc. are to be well separated. Rack/ladder routes are built for separate cable racks and ladders for each category; one rack carrying instrumentation and signalling cables. Low-power control cables can be located with a clear internal distance on the same tray or rack. 300 mm apart from this, one or several racks carrying LV power cables and one or several racks carrying HV-cables at least 300 mm apart from signal (and LV-power) cable racks. For a low number of LV power-, control- and signal cables one single shelf rack or ladder is acceptable if different categories can be kept well apart from each other, low level signal cables 200 mm apart from power cables.
Figure 9.0
No cable rack or shelf should be mounted closer than 200 mm from the ceiling or lid on a trenche. Metallic cable conduits are
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equipped with plastic endings every place where the cable cannot be fixed not to move against the edge of the conduit. Junction boxes, transducer amplifiers and similar are mounted on the outer edge of or under a rack or shelf, - not among the cables.
9.1. Cable penetrations

Borings for small penetrations through walls and floors are carried out by the installer. Larger openings are (in cooperation with the civil engineer) reserved on the construction drawings and moulding forms to be checked by the installer before the actual concrete mouldings are done. Penetrations through load bearing structures are made only with approval from the structural designer. Conduit or ducting arrangements are to be made for cables through cheramical fibre- or other thermal insulations. Cable penetrations through fire barriers, walls or floors, which divide the building in defined fire-sections, are sealed to maintain full integrity. This can be done using specially developed and approved transit systems (like Hawke, Brattberg or similar). Sealing can also be made filling up the passage by molding when all cables have been laid through it. This method means sealing the passage from one side using e.g. parts of a soft fibre board and filling it thoroughly from the opposite side, around and between every cable to full depth. The cast compound used can be concrete, gypsum or any special compound developed and approved for this specific purpose. Penetrations through ceilings, damp proof courses or waterproof floors are sealed using cable glands or special compounds which can survive actual ambient stresses and seal expectable water pressures. Penetrations through other walls and floors are sealed to prevent air draugt and overhearing through these openings. This is normally done by filling the openings around and between the cables and racks or ladders using shredded ceramic fibres. A tailored lid shall be fitted to protect this filling from being pulled out by animals or by draught.
9.2. Cable galleries and trenches

Elevated floors (galleries) and cable trenches are built by the civil contractor including roof/floor elements. The construction work shall be kept under observation by the electrical contractor to ensure problem free installability of switchgear assemblies, cable routes, branching conduits, tubes and ducts but also to see to that trays and racks are lifted in before routes are blocked.
9.3. Cable ladders, racks and trays

Switchgear room gallery, trench and under platform routes as any elevated main routes are built using corrosion protected or corrosion-proof premanufactured standard racks and ladders which meet any local regulations. These racks are dimensioned for ca 30% spare capacity and mounted / suspended or supported for no obvious tilting and a maximum depression of 1/200 of the distance between supporting points when used
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at full capacity. In areas exposed to quake shocks or in vibrating areas, these circumstances are met with heavier dimensions and attachments. Wall mounted or along structures mounted racks (as shown in Figure ) are the first choise where applicable. For distant from wall or structures routing T-shape supporting or pendulum arrangements as shown in Figure 9.3 are recommended. Instrumentation cables are laid one side, other categories on the other side of the suspension rod, but the load must be balanced or rigid enough to remain horizontal. Where heavy or single edge loading must be expected (or where in exceptional cases cable racks are used as maintenance access routes to light fittings, fire alarm sensors...) rigid racks are to be laid on beams which are suspended at their Cable ladders, racks, trays and cables are laid out and fastened in such manners that they will not harm any normal service activities, nor being led close to hot or oil carrying piping. Cable racks are generally installed after the process-piping and ventilation ducts have been installed to ensure future accessability to the route. This makes it possible to use the same routes and supports for cable racking as for piping. It also helps to keep cable routes apart from hot or wet equipment and not to prevent access to valves, transmitters and other inspectable equipment. The contractor shall see to that the necessary distance is maintained to piping and ventilation ducts. Cable racks, trays and ladders are to be cut at fire- or watersealed penetrations to be continued on the oher side of the barrier. Main route racks and ladders will pass unbroken through other than barrier walls and floors. Cable racks shall also be cut between flexibly supported machines and firm constructions, cabling is to be carried out with slacks to take the vibration- and swing-movements across a gap. All cables are fixed not to transmit these movements to the terminations. Minimum bending radius of installed cable type is also to be observed. Only standard elements made for the specific rack / ladder type are to be used. Sharp edges, assembling- or fastening screws etc which can cause damage to installed cables are to be covered or eliminated. Rack-types built of open (U) profiles are generally to be installed open side down. Wrtsil NSD-delivered equipment generally has cable inlet glands or other type sealing entries furnished at factory for all expected cables. Installer must rectify or make the supervisor aware of occasionally lacking or wrong size glands. For single-core cable entry arrangements, attention must be paid not to cause magnetic shortings around single phase paths (cable glands are to be made of non-magnetic materials etc). Separate inlets are to be used for each cable, mounted and tightened to take coming vibrations, moisture etc. Cable racks, ladders and shelfs along brick, stone or concrete ceilings or walls are generally attached using anchor or 'Hilti' bolts. When routed with piping systems, under service platforms and among steel supports, welding or bolting to steel structures is used.
Figure 9.3 both ends.
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Figure 9.4 Cable dropouts from cable rack
Dropouts to a branching ladder, rack, conduit or appliance should be made dropping downwards through the ladder - not over the edge. Alternatively the racks are built overlapping on different levels. Dropout conduits are fixed to the cable rack and to the machine, to steel structure, to wall, ceiling or floor in at least two points 600 mm apart from each other.
9.4. Underground Installations

Direct burial cables are used for outdoor lighting distribution, service cables to secondary buildings and similar purposes mainly. Also utility connections or factory service cables are built direct buried. Only shielded type cables are to be used for direct burial racing. See below for minimum burial depths and other requirements. Underground/sub-floor cables in pipe or conduit Underground cable installed under a building shall be in a raceway. Wide conduit/ rigid plastic pipe is used to provide raceways needed for MVcables from trenches or from underneath the switchgear to generators and transformers as also for power and control cables between electrical rooms and field located equipment. Metallic conduit is recommended for housing signal cables which might be sensitive to electromagnetic interference. Separate raceways on appropriate internal distances (similar to those defined in previous chapter) are required for each nature MV-, power- a.c. control / signal- and d.c. control / signal cables. Power feeders from generators to switchgear room are built using large size conduits or rigid plastic pipes embedded in concrete or, which is most commmon, in sand under the concreting. For high currents multi (singlecore) cable systems are to be applied. Using a separate conduit ( 75 - 110 mm) for each part cable a group configuration as recommended in chapter 10 can be obtained. Strictly observe to keep the group as compact and well as possible in intended order (also where bows are used), distant as possible from reinforcing bars and other metallic structures. Figure 9.4.11 Using larger conduit ( 180 - 250 mm) or similar rigid pipe for one of each phase (L1+L2+L3) cable group per pipe stray fields are more easily controlled. Cable pulling is easily done one at a time when using PVC-sheated cable types and large enough pipe diameters.
0 0 0
0 0 0
Figure 9.4.2
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' G
1,05 D/d >3,0 -- jamming impossible 1.05 D/d <2,5 -- jamming impossible but clearance to be checked 1,05 D/d between 2,8 and 3,0 -- serious jamming probable
Routing is to be made for fewest possible (sweeping) bends, no more than three bends are allowed between pulling points. Use plastic conduit made of a different polymer than is the sheath of the cable to be pulled in (i.e. polyethylene conduit for PVC cable and v.v.). When several cables are to be pulled trough one conduit the size of the conduit is to be selected so as not to cause jamming /pulling problems (see fig. 9.3:1). Steel bends can be allowed to withstand heavy pulls for (all phases) LV power cable only. Do not route conduit nor even a more rigid pipe to unnecessarily penetrate supporting beams - try to level raceways to pass under the beams. Secure both ends to the concrete as also to metallic bends etc.
Figure 9.4.3 Jamming/No jamming
Dig cable or conduit escavations 100 mm deeper than is the intended depth for the cable and make a controlled backfill of sand or similar to ensure the cable or conduit will not be laid on sharp rocks. The backfill must not contain large rocks, sharp objects or corrosive material. Minimum cover requirements (between a point on the top surface of any direct buried cable or conduit and the top surface of finished grade): (=NEC)
Circuit voltage Up to 600 V Direct cables buried Rigid Nonmet. Conduit
(Approved for direct burial)
Rigid Conduit
Metal
600 V -22 kV
above 22 kV
600 mm 750 mm 1100 mm
450 mm 450 mm 750 mm
150 mm 150 mm 150 mm
When raceways or cables are buried in freezing ground, they are to be buried deep enough to be below the freezing layers or they are to be arranged to prevent damage to the enclosed conductors when being frozen. Cables emerging from the ground shall be protected by enclosures or raceways extending from the minimum cover distance (table below) below grade to a point at least 2,45 m above finished grade or until protected by other structures. Upper ends of raceways (conduits) are to be sealed not to let oil or litter into the raceway. Raceways which are connecting rooms of different cathegories are to have moisture, gas or fire proof sealings as required. Note that both ends are to be anchored to the concrete as also steel bends well fastened to PVC piping. One slow bend only (generally for bringing up to floor level) is recommended per conduit, redirecting in horisontal level by slow sweeping bends. Remember to select power cable dimensions according to considerably reduced cooling properties when installing in plastic conduit embedded in dry sand.
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9.5. Cables to and onboard machines

Cables to and onboard machines like the genset, auxiliary units etc. are primarily to be installed in rigid steel conduit. Mild steel pipe material is generally used where the most reliable fixing can be done by welding. Fasten galvanized conduit using galvanized steel straps or clamps when such conduit is required. (Galvanized materials should not be welded.) Paint corrosive conduit materials for qualified protection level after fixing is completed but before cables are being inserted. Also cables routed from racks and ladders to remote process appliances are recommended to where applicable be pulled into conduit or mild steel pipes which are fastened to supporting metallic structures. Any cable routed lower than 1,5 m above floor or platform level (and less than 1 m aside) shall be protected by structures or by rigid metallic conduit or other well fastened profile.
Figure 9.5.1 Engine connections to local panel.
Use joint conduits where several same category cables are to be routed likewise but individual conduits for cables which might disturb other circuits or build up excessive temperatures. For multicore cable installations we recommend not to connect conduits or pipes to enclosed systems, not even to connect them in series for longer distances. Instead cut the pipe for steep bends which can be located to places where risks for mechanical damage is low,
Figure 9.5.2 Routing in pipes/conduits.
see Figure 9.5.2 Routing in pipes/conduits. This is to enable easy pulling in but also to enable cable securing (to avoid sliding due to gravity forces and vibrations). Cables must be secured not to come to rest against metallic pipe ends - use plastic end bushings (see Error! Reference source not found.) where needed.
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9.6. Civil systems

Exposed installation shall utilize available power and signal cable routes for process equipment. Where branched off from these routes cables are using steel or Al-conduit, or where there is little risk for damage, clamped using plastic clips. Previously described method for using metallic pipe or conduit is recommended also for civil system cable installations. Concealed installations make use of steel or plastic conduit approved for electrical installations and accessories (adaptors, boxes, fittings, lids etc.) made and approved for conduit type used.
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10. CABLE PULLING AND INSTALLATION

All cables listed in main (not in process unit internal) cable lists, as (depending of scope) also any cables required for lighting, HEvAC and maintenance power distribution, fire and/or gas detection, telecommunication etc. systems included in the scopeof supply shall be pulled, installed and properly terminated by the electrical contractor who is also responsible for installing cable routes required for these cables. All installed cable types are to be manufactured and have necessary certificates for the actual rated voltages and fused currents as also to withstand the environment whereto installed; actual ambient temperatures, mechanical stresses, diesel fuels etc where so needed. Only recommended terminating accessories, tools and methods are used for each type. Cables are to have dimensions sufficient for expectable load conditions, for the type of installation and use as recommended by the manufacturer. Cable sealing boxes are selected for good compatibility with cable type, enclosures and ambient conditions. Cables along main routes are laid on category dedicated cable shelfs and racks as far as possible, - HV cables on separate racks, LV power cables on power cable racks and instrumentation and control cables apart in separate groups onto own racks. In control rooms, workshops, storage, social and office rooms etc cables are installed on or under plaster and run either vertically or horizontally. Any cables are to be laid avoiding hazardous areas (fire, explosion, heat etc). Installations are made in a manner which allows cables to be added for future needs. Cables are generally entered into switchboards, panels, cabinets and boxes from the bottom side, through factory made cable entries and for shortest possible internal routing to where they are terminated. Segregation of cable categories is to be observed also at entries and inside the assembly. In locations where there are obvious risks for a cable to be damaged, cables are screened using steel profiles or metallic conduit or alternatively armoured cable types are to be used. Cables passing through floors are always protected to 1,5..2 m above the floor level if not rising protected by piping, machines or other equipment. Cables on machines are to all their extents laid on and fixed to shelfs, racks or ladders or laid in metallic conduit. Free slacks between fixing points in bends or at entrys are 15 * cable diameter. When necessary also these slacks are protected by flexible conduits or covered e.g. by shielding profiles.
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Control and signal cables are preferably grouped for analoque signal cables / control bus cables and on/off signal cable in separate cathegory groups. A secondary grouping is for common destination. A.C. control or PT/CT secondary signal carrying cables should be laid with LV power cables rather than with mA and T/C -signal carrying instrumentation cables. Figure 10.0.4 a) b) c) Power cables dimensioned for optimal current carrying capacity are to be laid with a cooling gap = cable diameter (min.20mm) between cables = a) in figure above. Normally dimensioning margins admit laying of power cables side by side without cooling gap = b) alternatively clamped in groups of four ensuring enough cooling surface being exposed of each cable = c). Cables having insulating materials with different maximum permissible conductor temperatures shall not be bunched in a common clip, gland, conduit trunking or duct. High voltage cables are always to be laid with cooling gaps, single core cable alternatively to form a triangle. Single core cable systems (LV or HV) are to be laid and firmly fastened to keep a specific configuration for largest possible portion of the interconnection. In the installing of two or more single-core cables forming respectively single-phase circuits, three-phase circuits, or three-phase and neutral circuits, the cables shall as far as possible be in contact with one another. In every case, the distance measured between the external covering of two adjacent cables shall be not greater than one cable diameter. Connections using three single-core cables are recommended to be built arranging phase cables in trefoil formation, but for cable fixing and optimized cooling a spread-out arrangement may be more practical.
In order to equalize to some degree the impedance of (not trefoil) three-phase circuits of considerable length (> 30 m) consisting of single-core cables of a conGORSE NK CABLES ductor cross-section of 185 mm or over, a transposition of the phases shall be effected at TWO cables intervals not exceeding 15 m. Most essential is per phase, to not use flux short-circuiting ferrometallic 2 alternatives clamping (or similar e.g. reinforcing bars) and to keep them on a distance from other cables THREE caand metallic structures. bles In circuits involving several single-core cables per phase in parallel per phase, all cables shall follow the stacked or same route and have the same cross-sectional alternatively area. Further, the cables pertaining to the tied same phase shall be as far as practicable alternated with those of the other phases so that FOUR cables unequal division of the current is avoided. per phase Manufacturers recommendations for grouping SIX cables part cables (> 1 per phase) are developed to per phase meet these requirements as well as possible without deeper understanding. If specified internal positions are not held cable loading caTable 1: Recommended by mfg grouping pacity will be lower.
Figure 10.0.2
Figure 10.0.3
= L1, = L2, = L3
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10.1. Cable pulling

Cable pulling is to be made during controlled circumstances only. Cable temperature is not to be below -15C (-5C for some HV cable types). Observe that cable on a drum will warm up very slowly when brought in from cold storage. Pulling should be made using guiding rollers or a trained electrician at each bend. Minimum pulling radii given for each cable type are to be observed. Maximum pulling forces each type are also to be observed and pulling route carefully controlled not to endanger the cable oversheath from being damaged by sharp edges. Pulled out cable is to be immediately marked for correct cable identification code and cable ends protected not to be damaged before terminated. Perform any cable pulling with greatest care so as not to damage the cable construction: Never exceed pulling forces and ambient and cable temperature limits stated by the manufacturer. In colder environments, cables should be stored in a warm location for at least 24 hours before installation. Arrangements should ensure minimum bending radii are observed and sharp edges, rough surfaces etc. will not endanger cables during pulling nor when being fixed to the raceway. Clean the conduit/raceway/cable tray before beginning the pull. (Waste removal can be done by pulling a mandrel or plug through the conduit and removing any foreign matter dislodged at condulets or pullboxes. Pulling a clean cloth/swab to wipe out any remaining debris complete the procedure.) Locate the cable drum to the raceway/conduit end where the entering bend is located and pull from the strightforward end. Make sure there are no twists, bends or kinks in the cable. When possible without increasing the risks for cable damages, the cable could be laid out for one or two hours before installation to dissipate any stress remaining from cable storage. When pulling multiple cables, the pulling eye or basket should be equipped with a swivel to allow free rotation. Stranded steel lines should be used only for pulling into steel raceways as it can saw into bends of aluminium or nonmetallic raceways, leaving sharp edges that can damage the cable. Nylon ropes which stretch will result in uneven pulling tension and erratic cable surges. Lubricate, lubricate, lubricate: Apply a lubricant continuously and liberally throughout the pulling process to reduce friction between the cable jacket and cable tray. The grease used for lubricating the cable sheath must not be of a kind which affects the polymer of neiher the cable nor the conduit/tray. Neither should it transform to cement the cable into the conduit. The pull should be planned so that a continuous, nonstop pulling rate is maintained. Stopping in mid-pull should be avoided. For long, difficult pulls two-way radios are required to communicate between the feed and pulling points. Each cable is recommended primarily fixed to its position along the route to be finally fixed when all cables have been pulled out. Cables laid on horizontal racks are generally strapped or lashed to the racks but clamped if
Figure 10.1
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needed to keep the position as always in vibrating or quake areas. All cables are clamped to vertical or rising racks and ladders. This is generally done fixing with 1 or 2 bow-clamps to the top rungs of the ladder and below that to every third rung.
10.2. Identification of pulled out cables

Cables should have a marking for unabiguous identification as soon as pulled out to be connected for a specific use. They are either to have a temporary marking or the final cable label for having identification number according to the cable list as soon as they are cut to the length required. See chapter 11.1 for cable labelling instructions.
10.3. Cable clamping

Cables shall in general be so installed that the tesile stress applied to them either by reason of thir own weight or for any other reason, is minimized. These precautions are particularly important for cables of small cross-section and for cables on vertical run, or in vertical pipes. All cables in combustion engine power plants are generally to be fastened to racks and ladders laid along. This is to ensure distances between different category cables are sufficient along all the route, but also to ensure power cables will have cooling as designed for. Positions of unfastened cables may change due to vibrations occurring especially where resonances evolve. Cables laid on horizontal (or slowly rising) cable racks are generally strapped or lashed to the racks, but clamped in quake- or vibrating areas. All cables are clamped to vertical or rising racks and ladders. This is generally done by fixing with 1 or 2 bow-clamps to the top rungs of the ladder and below that clamping to every third rung. Drop-outs from the rack to machine units, pumps, transmitters etc are led via ladders or conduits whitch are fixed to the cable rack and to wall, ceiling or floor. Power cables are laid and/or fastened ensuring that the space between the cables or group of cables (depending of sizing for cooling) remains about as large as the diameter of the larger cable. In situations where cables must cross, they should be fixed by clamps or cable ties at 90 to each other to minimize electrical interference caused by the magnetic flux. Fastening of the cables is done using bow-type cable clamps on racks and ladders, on other places using corrosive proof metal or plastic clamps and screws dimensioned for the cable to fasten. Proper clamping and glanding at entries to panels and enclosures must ensure that the cable cannot cause stress to the termination points. The cable must be secured at the cable entry, either by the gland if this is strain relief type, or by clamping immediately inside or outside the entry. Cables of all kinds are to be fixed properly also inside panels and in cable compartments and starter modules of the assemblies. Cables are generally dismantled at the terminal blocks to which the major part of the cable parts are connected. Single-core cables (e.g. transformer to LV-swg) are subject to effects of electrodynamic forces developing on the occurrence of a short circuit.
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Special precaution is to be taken to ensure that no closed ferromagnetic circuit is formed around single core cables laid in any formation, or around any cable liable to carry unbalanced load currents. Clamps which fix them should include all the phases, unless they are of nonmagnetic material. Heavy single-core cable-systems are recommended to be clamped using factory made System Clamps for the specific cable dimension, keeping the cables in specified configurations. System Clamps are to be used on c-c distances as prescribed to take occurring forces. Please note: Engine-generator-sets are vibrating during normal use and spring mounted sets are making swinging movements especially during start and stop procedures. When the set is mounted on air bellows/dampers, these slower movements may be rather large. If dampers are mounted under an engine-bed, also the bed vibrates and swings with the engine. All cables onto the engine or generator, especially generator power cables are to be laid and fastened to allow these movements without laying excessive stress to cables or terminals. Cables, conduits and light apparatus are fastened to walls or ceilings using screws and plastic or metallic plugs drilled into concrete, brick or stone - heavier loads using anchor bolts. Onto metallic structures are fastenings attached by welding or screws, to which the conduit or cable is clamped.
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11. CABLE TERMINATION

All installed cables (as also any pre-installed cable connections, unor disconnected for the transportation) are to be terminated by the contractor in accordance with Wrtsil NSDs and equipment supplier's drawings, diagrams and instructions. Segregation of power from instrumentation circuits is to be observed as well outside as inside enclosures and proper grounding of screens and shields must be made to minimise the risks for interfering with signals in sensitive circuits.
Figure 11.0.1
Instrument / signal cable screens shall have shortest possible (low-impedance) connections to cabinet earthing provisions. Equipment installation instructions are always to be followed but fullowing general rules apply: Low frequency (pair) screens shall be brought close to I/O terminals and terminated to a bar which can be easily disconnected from ground. This provision is enabling quick checking that no connected pair screen has forbidden ground connections. (See chapter 7.5.2;) Pair screens of signal cables are generally to be isolated from earth or signal cores at sensor/transmitter end. Where signal paths are run via marshalling boxes, pair screens shall be individually continued through insulated from earth terminal blocks (see fig 7-7). High frequency (cable) screen shall have a reliable earth connection in or immediately after the gland or latest at another earhing bar intimately connected to cabinet housing. The lenght of the cable screen from entering the cabinet until terminated to earthing bar and cabinet ground level shall be as short as possible. Cabinet main earthing bar shall have a close connection to plant earth level. Connect outer cable end overallscreens to earthing terminals whenever the connection can be found reliable not to carry stray currents, but isolate them or connect them to earth via HF capacitors when not. Power supply cables to cabinets housing electronics shall be terminated shortest possible way to surge arrester devices when such are applied.
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CABLE ENTRIES into panels, assemblies and appliances shall always be made using separate cable glands or bushes for each single cable. A suitable selection of glands are normally furnished by the manufacturer of the panel. Glands and bushes are generally having plugs which are to be removed before cable is inserted but all other elements; sealing grommet, washers and nuts must be used as intended (see Figure 11.0.2) - tightening nut first loosened to allow cable to be pushed through and > 10 mm inside the panel, thereafter tightened to lock and seal cable as well as possible. Too large or too small glands are to be changed to correct dimension for ensuring proper sealing. Cables should be fixed within 15 * outer diameter from the cable entry unless the gland is of strain relief type or fastening is arranged inside the assembly or panel. Figure 11.0.2 facturer. Where single-core cable systems pass through steel plates, all the conductors of the same circuit shall pass through a plate or gland, so made that there is no magnetic material between the cables, and the clearance between the cables and the magnetic material shall be not less than 75 mm, unless the cables belonging to the same a.c. circuit are installed in trefoil formation. High voltage cables are clamped to cable supports in the bottom of the cubicle, but observe that when a window transformer is applied for earth fault detection, the cable screen must not get in contact with earthed structures until brought to the outer side of the transformer, see chapter 7.5.1 and Error! Reference source not found.. Only adequate equipment and methods are to be used; heavy duty crimp terminals for correct core and bolt hole diameter and crimp tools as recommended for terminals applied. Stranded cable cores are terminated using crimp tool terminals. Stranded cores can be terminated without crimp terminals, bootlace ferrules or wire pins only in terminals designed for direct termination of stranded wire. Always use recommended compression forces. H.V.cable endings are made using standard end kits applicable for the cable type, size and environment where used. Ending kits are assembled by contractors skilled personnel only. The termination will be accepted only if the insulation reading, 24 hours after making off, is more than 100 M using a standard (1000V or higher) megger. Where required (by client or circumstances) a high d.c. voltage tester shall be available for final validation. All screened H.V.cables are generally grounded at both ends. Cable cores are to be carefully checked not to lay stress to the terminals. Especially heavy, rigid cables which are terminated to transformer bushings, current transformer terminals, main circuit breaker terminals or similar must be reliably fixed to assembly frames and cores must be precisely cut and terminated not to lay forces to the terminals. Also warming up (of cable and appliances), vibrations, machine movements on flexible supports and risks for grabbing, hitting exposed parts of the cable must be observed not to transfer forces to the terminals. The distance between unisolated live parts and frame is also to be checked to meet regulations and standards and touch protection screens are to be reassembled when the termination work is finished. Where specific requirements are in force; e.g. at entries into EMCqualified cabinets, in Ex-classified zones, cable glands of classified types only shall be used in accordance with instructions issued by the manu-
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Special care is taken to the connection of correct phase-sequence visa shaft rotation wherever rotating machines are employed. Clockwise rotation (seen from motor coupling end) giving the phase sequence U,V,W (A,B,C). Note that for counter clockwise rotation as has the major part of the Wrtsil NSD generator sets the phase sequence is W,V,U (A,B,C). Before starpoint connections are made, the insulating resistance of the windings are checked in accordance with manufacturers instructions (to be not less than 1k*/V of normal working voltage with a minimum of 500k*). Cables to field instruments are to be cabled with a loop. This is to provide the slack needed for local calibration / spare needed when terminated core-ends are worn out from demountings for regularly made maintenance and calibrations. This is required also anywhere else where cables are terminated into equipment expected to be regularly disassembled for maintenance or repair especially when the cable is of considerable length or not easily to be replaced. (Most of this type of instruments are readily installed on the various process units.) Metallic cable conduits are to be provided with plastic endings whenever the cable is not prevented from moving onto the edge. See Figure 11.0.3. Core termination is always to be done in accordance with latest revision documents. Three-wire connecting of two-point terminated (Pt100) sensors is to be made according to Figure 11.0.4 unless other instructions have been given. Figure 11.0.4
Figure 11.0.3
11.1. Core codes

Delivered low-voltage cable types have colour coded cores or numbered cores. Power cables are generally coded by colours while numbers are mainly used for identification of cores in control and secondary circuit cables. In documents (connection diagrams and tables) cores are generally referred to using numbers also for presentation of power cable connections. Instrumentation cables are of the twisted pair type where each pair is identified by a number and pair cores generally have a colour code e.g. blue and red. This code is referred to in documents as - core a (for the core having the more negative) and - core b (for the core having the more positive potential). Cables are generally to be terminated applying following rules for combining carried phase, colours and numbers. Note that differing national or clients rules generally overrule this WNS-praxis. Also differing cable types may re-
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4S[IV 4PERXW ;(%%% 19-Aug-1999 <<
POWER CABLES Distr. cables Motor cables
quire specific rules for how document core-identifications are to be interpreted. Neutral Phase L1 Phase L2 Phase L3 PE INSTRUMENTATION CABLE CORES LT BLUE BLACK BLACK/W BROWN YEL/GRN blue red BLACK LT BLUE BLACK/W BROWN YEL/GRN BLACK 3 3 BROWN YEL/GRN 4 highest nr 5 4
+ b
NUMBERED CABLE CORES e.g. 5-core e.g. 4-core
1 1 1
... 2 2
Table 11-1: Cable core code compatibility
11.2.Cable marking
/ /
X3
W133 ;
Each cable end shall have a cable identification marking. This marking shall identify the cable using the cable identification code which is used in cable lists and connection documents; generally a letter W followed by a series of numerals or numerals only. These markings are to be clear and durable enough to withstand the environmental stresses at the location where installed and still maintain sufficient readability after decades maybe in wet, oily and dusty circumstances. Marking labels can be made as engraved or printed plastic or metal labels or using sleeve markers for building up the code marking. Hand writing and paper labels are not accepted, not even when inserted in a plastic pocket. They are tied along the unpeeled cable close as convenient to where the cable is entering an appliance or where the outer sheath is cut inside a panel or assembly. Location must be such that the marking is still readable when the installation of all cables have been completed without undoing any cable clamping.
Figure 11.2 Cable cores are to be marked up with the code of the terminal to which the core is connected (reconnection marking). This is intended to enable quick replacement of a faulty device, to enable easy reconnection of appliences which are de- and remounted for maintenance and recalibration etc. Phase carrying cores as also PE and N-cores are marked L1..L3, PE and N correspondingly when terminated to bars or screw terminals lacking identification markings. Also core markers are to be durable enough to remain there identifying the core in an expectable hot and oily environment. Sleeve type stackable or heat shrinkable cable markers are recommended. Cable marking equipment is either supplied by Wrtsil NSD or by the contractor or by the owner of the plant. Cable marking is made by the contractor.
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12. LIGHTING, HEATING, AIR COND. & MAINT.PWR DISTRIBUTION

Indoor & outdoor lighting systems, electrical indoor heating systems and area & indoor distribution of power for maintenance and repair outlets are to be installed in accordance with Wrtsil NSDs drawings. Main low voltage power cable routes are to be used to highest possible extension, cables fastened similarly to power cables, branching single or few cables being fastened using plastic clamps or steel / aluminium conduit fixed by welding, bolting or clamping. Hanging rack for main lights in the engine hall is to be fastened to the roof beams above the crane(s). Similar rack installation is recommended for switchgear rooms while other light fittings are fastened to the building structures, all exact locations to be decided on site as well as mounting type. Lighting control and distribution panel(s) is to be installed according to drawings, if needed on frame(s) supplied by the contractor. Supplies for internal lighting, heating and maintenance outlets integrated within process units, switchgear cubicles etc. are to be installed according to unit / assembly drawings. Emergency lighting is generally established using luminaires with built in batteries. These luminaires shall be used only at those very locations pointed out in drawings. The exact location shall be determinated in cooperation with Wrtsil NSDs supervisor for best possible access for the testing and maintenance required. Light fittings and heaters must not be installed so that the beam/radiation/air flow is blocked by structures, piping, cable raceways etc. Locations indicated in drawings must be adjusted to avoid any obstacles which might reduce intended efficiency or maintenace of the appliance or even overheat blocking elements. Air conditioning equipment is delivered as ready for use fan-filter-damper units with required internal installations made. They can also be lacking any power and control installations. Power distribution board and control panel with designed supply, feeder and control cables are to be installed on locations pointed out by WNSs supervisor. When required safety switches, temperature sensors and similar appliances are also to be installed by the electrical contractor.
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Telecommunication (including intercom and telephone) systems, fire detection and gas detection systems are, when included within the scope, to be installed by the electrical contractor in accordance with Wrtsil NSDs drawings. Ordinary cable raceways (trays for control or signal cables) shall be used where convenient. Especially unscreened cable types shall be routed and laid to avoid interference with power or signal cables. A connection to the local telephone network is generally built to include one or several control room jacks for conventional telephone sets, for modem connection to the digital control system and in some cases for remote alarm connections. Such extensions of an existing telephone system are to be built in close cooperation with the local telephone network owner, strictly following rules and regulations set up by him. The contractor shall clear out such requirements and himself apply for the connection in cooperation with WNSs Site Manager or plant operator. Internal telephone or intercom systems are built to fulfil operational needs for internal communication between locations within a larger power plant installation. System manufacturers instructions are to be fullowed for selecting cable types, routes, locations of jacks and phone sets and for the installation and programming of these. Site Manager or electrical Supervisor are to be consulted whenever decisions on locations or affecting appearance or reliability are to be made. Fire detection systems and gas alarm systems, security systems and similar shall be installed in accordance with manufacturers instructions and with system designers drawings. When approval by local authorities or ensurance company is required before the system can be installed and accepted for use, the contractor shall contact such instances and hand them any document copies required for assessment and approval. Detecting sensors shall be installed at the very locations indicated on issued drawings. Smoke or gas collecting boards of durable enough material must be applied where they are required. Locations shall be such that detectors/sensors can be inspected and tested/calibrated in the operating power plant. Where doubts arise they are to be cleared out with the designer and supervisor. Each sensor shall be checked to be classified for installation in actual environment before it is installed; e.g. IP-classification as required, lower temperature detectors in cooler environment, higher temperature detectors close to heated or exhaust gas systems. Note that circuits and detectors having (E)Exi (intrinsically safe for installation in hazardous zones) character shall be installed to meet requirements for separation of these from other, non-Exi circuits.
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4S[IV 4PERXW ;(%%% 19-Aug-1999 <<
Security system components shall be installed so that exposure of cables and sensors for damage, sabotage etc. is minimized. Armoured cable may be required where exposure cannot be avoided.
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Inspections of the equipment are made when packings are opened and immediately after the erection work is finished. Damages caused to painted surfaces, isolators or other apparatus are repaired immediately when observed or in any case before covered during proceeding work. The inspection of erected assemblies includes trimming of the positions, movements, interlockings and limitswitch-functions of compartment-doors, withdrawable equipment etc. Installation including termination and afterwork or other work made as any modification or temporary dis/re-assembly of equipment is to be properly finished, cable routes and interiors of the assemblies cleaned from all dust, dirt and installation debris and all of the installation to be assessed to meet client expectations. When appropriate, insulation and conductivity is to be tested by contractors chief engineer prior to energising. Contractor bearing full responsibility for equipment and installation works within his scope of supply, will also have the resposibility for performing verifying/validating tests required to ensure that his installation conforms to operative aspects of user needs and requirements: Assemblies, distributionboards and panels with connected external circuits shall be operationally tested for correct functions as soon as energising is possible and needed. Fuse links (generally delivered with the switchgear assembly) or MCCB trip settings shall be checked correct for cable and load, thermal protection relays to be adjusted for expectable loads etc. Systems not integrated within the power production process (like lighting, heating, telecommunication and security systems) are to be tested fully operable by the contractor. Wrtsil NSDs and system suppliers commissioning engineers will test and adjust delivered auxiliary system, engine and main power distribution controlling systems. These pre-commissioning tests require power distribution to be established in order to enable test-running of each section/system at its time.
14.1. Insulation tests

Insulation tests including some part of WNS-delivered equipment shall be performed in cooperation with WNSs supervisor or commissioning engineer. Site insulation tests shall be made in accordance with IEC 4391 (equipment rated up to 1000 VAC):
(8.3.4 Verification of insulation resistance) For partially type tested assemblies which have not been subjected to a dielectric test acc. to IEC 439-1 8.2.2 or 8.3.2, an insulation measuring device at a voltage of at least 500V shall be carried out. In this case, the test is deemed satisfactory if the insulation resistance between circuits and exposed conductive parts is at least 1000/V per circuit referred to nominal voltage to earth of these circuits.
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4S[IV 4PERXW ;(%%% 19-Aug-1999
By exception, items which according to their specific requirements are current-consuming apparatus (e.g. windings, measuring instruments) at the application of the test voltage or which are not designed for the full test voltage shall be disconnected as appropriate. (These apparatus shall be disconnected at one of their terminals unless they are not designed to withstand the full test voltage, in which case all terminals may be disconnected. Anti-interference capacitors installed between live and exposed conductive parts shall not be disconnected and shall be capable of withstanding the test voltage. (8.3.2.1 General))
Any larger circuitry like the power distribution in every panel and switchgear assembly is to be included in these site insulation tests even though they have been tested by the manufacturer before being shipped. Acceptance value as above mentioned is for a lone standing assembly integrated circuitry. A minimum value of 1 M should however be obtained under average conditions for any circuit or part thereof. Electrical motors are tested with their feeder cables. The motors shall be measured in warm conditions, immediately after running with nominal load when practicable. Insulation resistance must be at least Ri > 20 * Un / (1000 + 2Pn) M at 25 C nominal motor voltage and power. where Un, Pn =
Test the insulation on motor and feeder cables including the termination in switchboard / panel and also local controller or safety switch. Make sure the supply breaker is open. Open the motor termination box and disconnect star or delta connecting strips to separate the phases but leave the cable connected to the motor. After the test, the star / delta connection must be remade checking that connection for the actual voltage is correct. High voltage installations may require verification by dielectric tests according to applicable standards.
14.1.1. Procedure
Measure each circuit from each phase or pole to earth and between phases/poles. The elements may be connected to include a complete circuit for one measuring, or they can be measured one at a time. In general, a test/metering voltage of 500V is used for testing of controlgear circuitry (rated voltages 24V...220V). Power distributing switchgear, cables, motors etc. are tested using a test voltage of 1000V. For testing of MV and HV circuitry, rated voltage >5 kV, a metering voltage of 5000V is recommended. The test/metering voltage is applied for 1 minute or until the measured value has stabilised.
14.2. Other tests

Contractor must check and test distribution systems and connected panels and loads to have correct phase sequence order. Starters and motor operation are tested when installations are finalized and the system is ready for test runs. This is to ensure the correct direction of motor rotations and to see that power and control circuits are faultfree and settings correct. Excessive vibrations, noisy equipment and protection trippings must be observed and reported. Where appropriate motor currents shall be checked not to exceed nominal values. Reasons for relay trippings are immediately cleared out.
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4S[IV 4PERXW ;(%%% 19-Aug-1999
Protective bonding circuits are to be inspected for proper connections. In European installations injection tests are to be performed for machines or parts of these which have not been subject to such tests by the manufacturer. Injecting a 10 Amp. current for 10 sec. from various earthed points to PE-terminal a maximum voltage drop of 2,5V/1,9V/1,0 V is allowed for 1,5/2,5/4 mm branches respectively. When it is considered that the voltage of a consuming device may be unduly low, tests shall be taken to verify that the allowable voltage drop has not been exceeded. Signal cable interference screening shall be checked to be in proper condition. Circuits incorporating electronics, especially those carrying high frequency signals, shall be checked to be implemented fully according to equipment manufacturers instructions. Control circuitry shall be checked complete and connected according to diagrams and, where practicable, tested to be operable etc. Lighting, heating systems, telecommunication, detection systems as also service electricity distribution are to be connected, tested and powered up by the contractor who is also responsible for having the required board, authority and ensurance company approvals and certificates. Lighting / lux-values shall be measured and recorded for highest and lowest values in each essential area. Fire-, gas-alarm and similar system Test certificates shall be made and signed to prove full operability according to system requirements. When backfilling of escavations has been completed and the ground has settled so that final ground conditions can be assumed established, an earhing resistance test is generally to be performed. This measurement shall be made in cooperation with WNSs superviser / commisioning engineer using an earth resistance meter and method suitable for required earthing resistance values.
14.3. Verification test records

Record the inspection and performed testing of each installation, producing a report which includes; date, performers name and underwriting, type of test equipment used (Megohm-meter, Ammeter, Luxmeter etc.) and calibration date of meters, inspected, tested installation/gear and tested circuit (or group of circuits) and the extents, insulation test voltage and other variables applied (for tested entity), critical measurement results like lowest measured isolation value (M) - phase or pole to earth and between phases / poles, checking of phase sequence order, earthing connections/conductivity and checking of anti-LF-interference screen isolation, comment; equipment not included, reasons for low values etc. and describe actions caused by bad test results.
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Higher metallic exhaust gas stack(s) will provide a basic shield against lightning provided a good conductive connection to ground potential is ensured. For this standard level protection two lightning down conductors (50-95 mmCu) are built from each stack to, without any sharp bends, pass over the edge of the concrete foundation down into surrounding soil. At a depth below that of the common earthing electrode they continue in horizontal direction in e.g. 60 angle 20-30 m away from the powerhouse, one to left - the other to right side of radiator farm or cooling tower foundations - this rule having to be applied to each case specifically with respect to routes available, lengths (and amounts) depending of soil resistivity. We recommend to build connections between these down conductors and earthing electrode systems at the crossing points to decrease the possibilities for capacitive and inductive connections between systems and structures to build up potential differencies able to damage sensitive systems. A larger protection system for conducting lightning surges to ground is generally to be built when heavy lightning conditions are supposed to cause harm to the operation of the powerplant. The system is designed to protect the power building, switchyard and in some cases cooling towers and tank farm.
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IEC, national or other agreed regulations for equipment and installations in classified areas are to be strictly observed when potentially explosive atmospheres are indicated by the contract or by zone classification drawings or by other means. Potentially explosive zones are always created around fuelling equipment in gas powered plants but also in oil fuelled plants depending of the type of fuel oil and oil handling used. The inside of (especially heated) oil piping and tanks and their vent openings as also sludge pits should always be considered hazardous zones though no classification drawings are made. Base the installations on Zone Classification drawings made up by the process designer. These drawings are also indicating ignition temperatures and explosion grouping of gases or vapours involved. No equipment which might be located outside a Zone should be installed inside Zone limits without justifying reasons - and then always in the least hazardous area. See to that any installations or equipment used inside a Zone fulfils the requirements for that Zone but also comply with the appropriate standards and recommendations for installations in nonhazardous areas (IEC 364).
17.1. Equipotential bonding

Join any metallic parts and structures which might charge spark energy to the earthed structural ground by equipotential bondings. This requires bonding jumpers to be added across isolating bellows, from one cable tray element to another etc. but also across valves, strainers etc which might be detached while the area is hazardous. Every structure is to be connected to the structural ground and earth potential by a conductance corresponding to at least 10 mm of copper. Potential equilization is always required for installations in Zone 0 and Zone 1 but is adapted whenever considered necessary (or required by adapred regulations) also for Zone 2. The installation methods are to fulfil the same requirements as for earthing/grounding system installations described in chapter 4. Note that this equipotential bonding - earthing is not replacing the protective earthing (PE) provided with the power cable. Classified motors and instruments have internal grounding terminals for the PE brought with the cable and external terminals for equipotential bonding and both are to be used.
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17.2. Electrical equipment

Check that electrical equipment to be used is selected observing as well the zone it will be located in as also the explosion group and temperature class built and equipped for. As a breif concentation of these criteria based on IEC 79 (1995) and European applications following tables can be used however with reservations for diverging specifications in national or other standards agreed. A: Selection with respect to Zone
Zone 0 Ex ia Ex S z.0 Zone 1 Ex ia Ex ib Ex d Ex e Ex m Ex p Ex q Zone 2 Any electrical apparatus for Zone 0 or Zone 1 Electrical apparatus with pressurized enclosures for Zone 2 Electrical apparatus designed specifically for Zone 2 (e.g. Ex n) Electrical apparatus complying with the requirements of a recognized standard for industrial electrical apparatus which does not in normal serviceproduce arcs or sparks or ignitioncapable hot surfaces. This el. apparatus requires no special marking, but shall be assessed by a competent person
B: Selection w. respect to explosion group / minimum igniting current ratio

- Group II electrical apparatus for all places with an explosive gas atmosphere other than mines. Apparatus type ia,ib or d require an additional grouping (A/B/C)with respect to igniting energy or gas properties Classif. of gases and vapours... GROUP IIA (Propane) > 180 J GROUP IIB (Ethene) > 60 J GROUP IIC (Hydrogen) > 20 J Apparatus allowed IIA or IIB or IIC IIA or IIB IIA Note
Natural gas (Methane) is mainly Hydrogen
C: Selection with respect to temperature class

Temperature class of app. T1 T2 T3 T4 T5 T6 Max. surface temperature 450C 300C 200C 135C 100C 85C Ignition temperature of gas or vapour 450C (Hydrogen) 300C 200C 135C 100C 85C Apparatus allowed with such gas or vapour T1, T2, T3, T4, T5 or T6 T2, T3, T4, T5 or T6 T3, T4, T5 or T6 T4, T5 or T6 T5 or T6 T61
17.3. Cable routing

Install no cables which carry external circuits (which are not to be connected to apparatus in classified areas) into a Zone and do not route cables to any apparatus through another Zone especially not a Zone characterized by a lower number (higher hazard). Try to minimize routing within classified areas. Route cables in hazardous area for optimum protection from any mechanical, chemical, temperature or other kind of damage. Any place where the cable is not protected due to the location or construction of the cable or circuit, additional protection should be used. Do not use any cables in Zone 0 without additional (mechanical, etectrical or environmental) protection. Conduit systems for flameproof enclosures (acc. to IEC 79-14 chapter 9.3) are recommended be applied.
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Wiring to type p and n appliances: When cable wiring systems are used, the cable entries shall avoid excessive leakage of the protective gas, and prevent the escape from the enclosure of sparks or incandescent particles. Cable entries to Ex nR (for restricted breathing) enclosures are to be sealed for practically no lekage in of hydrocarbone vapours occosionally surrounding the enclosure. When conduit systems are used, all conduit entries to an enclosure should be sealed unless the conduit is being used as a duct for supplying the protective gas. Intrinsically safe type ia or ib circuits Intrinsic safety of these circuits is based on techniques for limiting the energy of the circuit to values below what is needed for igniting an explosive atmosphere. The intrinsic safe portion of the circuitry is thus fully dependant on its capability not to catch or to carry any excessive energy. For this reason any part of intrinsic safe circuits shall be installed well apart from any equipment distributing or using higher energies so that no phenomena or fault, inside or outside the hazardous area, should be able to transfer igniting energies onto the intrinsic safe circuit.
Intrinsically safe circuit cables are not allowed to carry any non-intrinsically safe wiring of any kind. They are to be routed on separate trays or physically separated from non-intrinsically safe cables by a mechanical barrier. Common and pair screens of these cables are connected to the isolated ground bus of the safety barrier only, which in turn is connected to earhed structural ground using one low-impedance connection. Instrument sensor to amplifier cables are connected strictly according manufacturers instructions. Wiring to amplifiers or safety barriers inside a control cabinet are to be separated by a panel or by a gap of at least 50 mm from any non-intrinsically safe circuits. Where intrinsically safe circuits may be exposed to disturbing magnetic or electric fields, special attention should be given to transposition or shielding so that these fields do not adversely affect the intrinsic safety of the circuit.
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;VXWMP 27( *MRPERH Doc no: Date: Page: Status: Made/Approved: Project: Name: Subject: WECS projects
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19-Aug-1999 1 (1) WORK Kari Ahven / KW
Instructions to site personnel WECS INSTRUCTIONS

The circuit boards of the WECS contain parts sensitive to damage by electrostatic discharge (ESD). Other unidentified failures have also been reported. ESD protective procedures and some simple instructions must be followed to protect sensitive equipment when working with the WECS engines. Following precautions can significantly reduce the risk of system failure or malfunction on the WECS engines: - MCU, DCU,SMU, KDU and CCU cabinets have to be protected for water and uncleannes by water-proof covering during transportation and when stored at site. If moisture occured inside the cabinets, careful dehydration must be done. - Communication cables between the engine and control panels are to be located far away, minimum 300mm, from power- and high voltage cables. If this is not possible, the communication cables are to be pulled in earthed steel conduits. More detailed information about earthing methods can be found in Electrical Installation Guide. - The engine has to be well earthed, unconnected to the external systems or WECS unpowered before installation work close to the engine, especially before electrical welding work to avoid circulating currents to damage the equipment. More detailed information in Electrical Installation Guide. - In generally an instrumentation cable shield is earthed to earthing bar and pair shields are to be connected to screen grounding bars in the PLC panel. The shields should not be earthed at the other end of the cable. Profibus cables are earthed only in a cabinet where the termination resistors are located. Project related design should be observed. - All the terminations in all units have to be checked and tightened before first start of engine. The unused terminal screws are to be tightened too. - The cabinets should be kept closed and opened only, if absolutely necessary. - Touching the circuit boards or the connector pins should be avoided. - The use of RF-equipment nearby units should be avoided during running.
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Electrical Installation Guide

Electrical Installation Guide for WNS Power Plants

Electrical Installation Guide

Electrical Installation Guide for WNS Power Plants

2.1. General project information

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Installation of equipment supplied by Wrtsil NSD

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Installation including equipment

Installation and equipment partly supplied by the client

2.3. Technical documentation

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2.4. Permits, certificates, licences..

Electrical Installation Guide

Electrical Installation Guide for WNS Power Plants

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3.1. Power distribution

Electrical Installation Guide

Electrical Installation Guide for WNS Power Plants

4. SITE RESPONSIBILITIES AND ACCOMMODATION

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4.4. Safety at Site

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Figure 4.4 Danger: electricity

Electrical Installation Guide

Electrical Installation Guide for WNS Power Plants

5. STORAGE AND TRANSPORTATION OF EQUIPMENT

5.1. Wrtsil NSDs equipment

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5.2. Contractors equipment

Electrical Installation Guide

Electrical Installation Guide for WNS Power Plants

6.1. Arc welding

6.2. Generators and power transformers

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6.3. Auxiliary units

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6.4. Switchgear and controlgear assemblies

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6.5. DC-panels, batteries

6.6. Field mounted sensors, switches...

Electrical Installation Guide

Electrical Installation Guide for WNS Power Plants

7. EARTHING / GROUNDING SYSTEM

7.1. Earthing electrode

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