2495 000 JSS 1661 51 - B

NOTICE: THIS DRAWING HAS NOT BEEN PUBLISHED. IT IS THE SOLE PROPERTY OF ENPPI.
IT IS LENT TO THE RECIPIENT FOR HIS CONFIDENTIAL USE ONLY , AND UPON THE CONDITIONS AND AGREEMENTS FOLLOWING IN CONSIDERATION OF THE LOAN OF THIS DRAWING . THE RECIPIENT
PROMISES AND AGREE TO RETURN IT UPON REQUEST AND THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT, OR OTHERWISE DISPOSED OF DIRECTLY OR INDIRECTLY WITHOUT ENPPI WRITTEN CONSENT, NOR BE USED IN ANY WAY DETRIMENTAL TO THE INTERESTS OF ENPPI.
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E-STYRENICS
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Enppi Reference: 3688
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JSS 1661
300,000 MTA EB/SM PLANT EARLY WORKS PACKAGE

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ESTYRENICS Reference: ES-PRO-02
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ENGINEERING FOR THE PETROLEUM & PROCESS INDUSTRIES (Enppi) - EGYPT

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NOTICE: THIS DRAWING HAS NOT BEEN PUBLISHED. IT IS THE SOLE PROPERTY OF ENPPI. IT IS LENT TO THE RECIPIENT FOR HIS CONFIDENTIAL USE ONLY , AND UPON THE CONDITIONS AND AGREEMENTS FOLLOWING IN CONSIDERATION OF THE LOAN OF THIS DRAWING . THE RECIPIENT


E-STYRENICS
SUMMARY
1. SCOPE 5
1.1. General 5
1.2. List of Abbreviations 5
1.3. ENGINEERING COORDINATION 5
2. REFERENCE STANDARDS, CODES AND DOCUMENTS 5
2.1. General 5
2.2. Reference Documents 6
2.3. Compliance with EC (European Community) directives 6
2.3.1. Applicable directives 6
2.3.2. EC declaration of conformity and CE marking 7
3. GENERAL REQUIREMENTS 7
3.1. Application 7
3.2. Proposal 8
4. AMBIENT CONDITIONS 9
5. SYSTEM FREQUENCY AND VOLTAGE LEVELS 9
5.1. Frequency 9
5.2. Voltage 9
6. DEFINITIONS 9
7. TECHNICAL CHARACTERISTICS AND SUB-SYSTEMS 10
7.1. Power supply: 10
7.2. Clock Reference 10
7.3. Overall Synchronizing System 10
7.4. Load Shedding System 10
7.4.1. Power Load shedding (fast load shedding) 11
7.4.2. Under plant emergency condition 12
7.5. Operator Interface 12
7.6. SCADA System 12
7.7. Loss of communication 13
7.8. EMCS Interface with Other Systems 13
8. EMCS CONTROL AND MONITORING 13
8.1. Control management 14
8.2. Monitoring and Alarm Management 15
8.3. Monitoring of diagnostic and maintenance data shall include the following: 18
8.4. Trending 18
8.4.1. Historical 18
8.4.2. Trending Parameters 19
8.5. Design life and maintenance schedules 19

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8.6. Reliability 19

9. NAMEPLATES 20
10. ELECTRICAL IMMUNITY 20
11. PAINTING 21
12. INSPECTIONS AND TESTS 21
12.1. Inspections 21
12.2. Test procedure 21
12.2.1. General 21
12.2.2. Factory acceptance tests 22
13. BID INSTRUCTIONS 22
14. DOCUMENTATION 22
15. SUPPLIER'S RESPONSBILITY AND GUARANTEES 25
16. RECOMMENDED SPARE PARTS LIST 25
17. SHIPPING REQUIREMENTS 26
17.1. Documentation 26
17.2. Delivery 26
17.3. Specific requirements 26
18. SITE INSTALLATION ASSISTANCE, COMMISSIONING AND START-UP 27
19. HEALTH, SAFETY AND ENVIRONMENTAL MANAGEMENT 28

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1. SCOPE
1.1. General
This specification, together with the data sheet, defines the minimum requirements for
design, construction, painting, inspection, testing, documentation, preparation for
shipment, commissioning and start-up of a complete and ready for operation electrical
monitoring and control system for the 300,000 MTA EB/SM Production Facilities.
1.2. List of Abbreviations
The following abbreviations shall be used in the present specification:
IEC International Electro-technical Commission

ISO International Standards Organisation
BSI British Standard Institution
ANSI American National Standards Institute
API American Petroleum Institute
IEEE Institute of Electrical and Electronic Engineers
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
UL Underwriters Laboratories
SI Unit Metric System
ESR Essential Safety Requirements
EC Electromagnetic Compatibility
EMCS Electrical Monitoring and Control System
SNTP Simple Network Time Protocol
LSS Load Shedding System
AC Alternating Current
DC Direct Current
CB Circuit Breaker
DCS Distributed Control System
SCADA Supervisory Control and Data Acquisition for Power Distribution
GPS Global Positioning System
1.3. ENGINEERING COORDINATION
The supplier of the equipment covered by this specification shall be responsible for the
coordination and match-up of the parts of substation building which interface
mechanically or electrically with his work such as diesel and medium and low voltage
switchgears.
2. REFERENCE STANDARDS, CODES AND DOCUMENTS
2.1. General
The EMCS shall be designed, manufactured and tested according to the requirements
of the latest edition of the following codes and standards in order of precedence:

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- International Electro-technical Commission (IEC) publications, and ISO

(International Standards Organization) standards
IEC 60439 Low voltage switchgear and control gear assemblies

IEC 60445 Identification of Equipment Terminals and Terminations of
Certain Designated Conductors Including General Rules for an Alpha-numeric
System.
IEC 60446 Identification of Conductors by Colors or Numerals.
IEC 60529 Classification of Protection provided by Enclosures.
IEC 60947 Low voltage switchgear and control gear
IEC 61000 Electromagnetic compatibility (EMC)
IEC 60793 Optical fibers,
IEC 60794 Optical fiber cables,
IEC 60870 Tele-control equipment and systems
IEC 60874 Connectors for optical fibers and cables
IEC 60875 Fiber optic branching devices
IEC 61131 programmable controllers
- In case none of the above standards would be available, additional standards might
be considered among those listed here below:
 ANSI American National Standards Institute
 API American Petroleum Institute
 IEEE Institute of Electrical and Electronic Engineers
 NEMA National Electrical Manufacturers Association
 NFPA National Fire Protection Association
 UL Underwriters Laboratories
In any case, local regulations shall be observed.
The listed Standards and Codes, together with their all parts and subparts, shall be
applied considering their latest applicable issue available.
The measurement system is the SI metric unit system.
2.2. Reference Documents
This General Supply Rules is complemented by the following drawing:
2495-000-DW-1600-502 Electrical/Instrument Interface Philosophy
2.3. Compliance with EC (European Community) directives
2.3.1. Applicable directives
Even if the equipment and material supplied are to be installed in Egypt, that is not a
member country of the European Union, it shall be supplied in accordance with all
applicable European Community directives.

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In particular, for the supply related to this specification falling within the scope and
applicability limits of each pertinent EC Directive, compliance shall be given with:
 2006/95/EC Low Voltage Directive
2.3.2. EC declaration of conformity and CE marking
When required from the applicable EC Directives, Supplier shall provide an EC

Declaration of Conformity indicating the following:
 Contact and reference information such as corporate name, location, etc.

 A list of all the European Directives that Supplier declares compliance with.
 A list of standards the supply complies with.
 A legally binding signature on behalf of the Supplier Company.
EC Declaration of Conformity shall be referred to the supply as an overall assembly. A

collection of certificates referred to single components of the supply cannot be
considered as the EC Declaration of Conformity of the supply. CE Marking shall be
provided for the overall supply alike.
By affixing, when required, the CE Marking, the Supplier ensures that the overall
supply meets all the safety requirements as per the CE Marking Directives as well as
that the appropriate conformity assessment procedures have been successfully
completed.
In regard to the CE Marking extent stated on the applicable CE Marking Directives, the
following documentation, within the limits of the Directive requirements, shall be
included in the scope of supply:
 Technical documentation.
 Essential Safety Requirements (ESR) check list.
 Self-declaration of conformity.
 Operating instructions.
 CE Marking nameplate.
3. GENERAL REQUIREMENTS
3.1. Application
Electrical Monitoring and Control System (EMCS) shall control and monitor defined
aspects of the power system of the plant in order to guarantee high level of availability.
EMCS’s operator interface will be composed by a number of dedicated graphic

displays.

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The main purpose of the EMCS is to be an aid to electrical operations and

maintenance. Furthermore, failure of the EMCS shall not stop operations of any part of
the distribution system.
The EMCS shall perform the following functions:

- Monitoring of the electrical distribution network within the substation
- Control of main HV and LV circuit breakers,
- Interface between the DCS and electrical equipment,
- Record of significant events and actions which occur in the power distribution
system,
- Discrimination between the faults
- Load shedding functions,
- Automatic transfer
- Control of back-up power sources (diesel generator)
- Intertripping/Interlocking will be achieved by means of hard wired links between
equipment, without EMCS action.
3.2. Proposal
Technical proposal, as a minimum, shall include the following:
- General description
- Overall system configuration
- Outline drawings of equipment, showing dimensions.
- Technical bulletins
- Schedule of maintenance training available for system proposed, including tuition

costs.
- List of all deviations and exceptions to this specification, including a description of

offered alternatives (such as vendor standard equipment suitable for specified
service and comparable to equipment herein specified).
The lack of any declaration and/or deviation will be considered as full compliance
with the specifications.
- Certificates.
- Delivery time from placement of order.
- List of commissioning spare parts and materials to be provided by manufacturer,

with relevant availability and cost.
- List of two years recommended maintenance spare parts and materials to be

provided by manufacturer, with relevant availability and cost.

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4. AMBIENT CONDITIONS
The design of the equipment and of its components shall comply with the following
environmental conditions:
 Altitude : < 1000 m a.s.l.
 Pollution level : Heavy
 Design maximum ambient temperature outdoor : 45 °C

indoor : 40 °C
 Maximum relative humidity at 40°C : 100 %

 Minimum relative humidity : 60 %
 Earthquake Seismicity grade zone 2A
The equipment covered by this specification shall be suitable for installation in an air
conditioned switchgear room. However the equipment must be designed for safe and
reliable operation in the absence or failure of air conditioning system.
5. SYSTEM FREQUENCY AND VOLTAGE LEVELS
5.1. Frequency
The frequency of the electrical system is 50 + 5% Hz .
5.2. Voltage
Rated voltage levels are:

AC : 230 V, 1P+N or 400 V + 10%, 3P+N
DC : 110 V
6. DEFINITIONS
EMCS is the acronym for Electrical monitoring Control and is a group of systems
necessary to manage the 300,000 MTA EB/SM Production Facilities (no upgrading /
connection to the existing system is foreseen)
This group, as minimum includes:

- an Electrical Control and Monitoring system Supervising the 300,000 MTA EB/SM
Production Facilities Plant;
- a Load Shedding system (LSS)
- an Event Disturbance Recording system( if any )

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7. TECHNICAL CHARACTERISTICS AND SUB-SYSTEMS
7.1. Power supply:
Redundant power supplies shall be provided for Hot/Stand-by PLC’s to provide back-
up in the event of the loss of power to one supply or a power supply module failure.
The system shall be supplied via 220V AC from the UPS system.
EMCS system shall include the following spare and space capacities:
• 20% of equipped spare,
• 20% available space.
7.2. Clock Reference
When required, an independent GPS (for stand alone time stamping) will be supplied
as part of the EMCS.
Time stamping of events shall be carried out at multifunction relay level and to all the
intelligent devices without assigning a new time stamping.
All devices shall incorporate a Simple Network Time Protocol (SNTP) for time
synchronization over the network with the common clock.
7.3. Overall Synchronizing System
The following synchronizing functions shall be carried out by the EMCS:
o Supervision and activation of all operations necessary for the synchronization.
o Dedicated graphic/video page(s) and relevant equipment shall be dedicated for the
overall synchronizing system in order to monitor all electrical parameters and the
synchronizing sequences.
o EMCS will perform the synchrocheck function with the desired bus bar (upon
selection of the circuit breaker either on bus bar A or B) by measuring both sides of
the circuit breaker and giving the closing command only if the preset conditions as
to magnitude, phase and frequency difference are fulfilled (e.g. 1/10 Hz difference
between the sources).
7.4. Load Shedding System
The Load Shedding system shall be capable to disconnect some load in order to keep
alive the electrical network in case of overload. The Load Shedding System (LSS) will
have the following minimum characteristics:

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(a) The system in object will be activated in the following cases:
(i) if power demand exceeds the generation capability (fast load shedding)
(ii) Under plant emergency condition
(b) The output of the system consists of disconnecting commands that will be driven to the
outgoings of the switchgears feeding the various plant loads in order to open the
supplying breakers.
(c) Load Shedding System shall be able to be configured or adjusted from the EMCS
video terminals. Authorized Operators shall be able to Enable/Disable (ie. to bypass)
any “Load” as required.
7.4.1. Power Load shedding (fast load shedding)
EB/SM plant is electrically fed through a power generation system in parallel operation
with a national grid connected to a MV 11kV bus.
Based on the defined calculated spare capacity given from the existing upstream
system:
- In case of the generator’s outtage, in order to maintain the plant in operation, LSS
shall evaluate the load quantity that has to be shed in order to restablish the system
within the limits of the national grid’s remaining positive spare capacity.
Power load shedding will evaluate, periodically (about once every 5sec to 10secs)
in case of a generator’s outtage, the remaining positive spare capacity. In case of
negative balance, LSS shall evaluate the load quantity that has to be shed in order
to restablish the system within the limits.
- In case of the national grid outage, in order to maintain the plant in operation, LSS
shall evaluate the load quantity that has to be shed in order to restablish the system
within the limits of the generator’s remaining positive spare capacity. (Available
positive spare capacity for the EB/SM project shall be made available from the
existing system as an input to the new ECMS).
This calculation sets a dynamic cause/effect matrix including the loads to be shed
according to the network configuration and to the priority assigned to each load.
Provision shall be made to assign a priority level to each sheddable load. Selected
loads identified as sheddable will be sequentially tripped as per the pre-determined
priority until the shortage of power is cancelled.
Load shedding actuation will occur as soon as one of the trip/openings happens on the
generators or incoming line breakers.

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7.4.2. Under plant emergency condition
In case of main power supply outage, emergency diesel generator will feed emergency
loads and non-emergency power feeders and motor starters shall be tripped through a
load shedding signals.
7.5. Operator Interface
The man/machine interface will be implemented by server, monitors and keyboards

plus printer, mouse.
Redundant servers shall be provided for monitoring/controlling workstations
EMCS will be operated and monitored by dedicated graphic displays built on the
operator interface.
The operator interface will be based on Vendor standards in terms of symbols, colour
coding and structure of the display.
At least the following graphic displays and messages will be provided:
o Single line diagrams provided in sufficient quantity to allow an adequate

monitoring of the network. Dedicated “push buttons” nearby the equipment
symbol in the mimic or similar functionality will be provided to allow fast
visualization of metering or events/alarms relevant to each monitored
equipment
o Load margins calculation and load start inhibition
o Load shedding
o Messages/warnings relevant to load shedding/load reduction
o Messages/warnings relevant network interconnecting status
o Message/warnings relevant to the engagement or disengagement of automatic
operations
o Detailed single line for MV and LV switchgears
o General arrangement of EMCS system including miscellaneous equipment
(servers, Power Supply, I/O cards, communication cards, …) EMCS
architecture
7.6. SCADA System
The Plant Electrical Engineer will be able to perform several tasks such as:
o EMCS system diagnostics and troubleshooting;

o System Upgrade;
o Events & Alarms logs and Trends data acquisition and visualization;
o Energy and Power consumption balance reports acquisition and visualization.
o Reports such as average power consumption, energy consumption, voltage
current, power factor, etc., for particular processes and drives shall be prepared
periodically and printed at the engineer workstation.

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7.7. Loss of communication
In case of loss of communication with an electrical device, the EMCS shall clearly show it
on its display. Status shall be frozen to their last value. A loss of communication shall Never
block an automatic sequence. If the device shall be controlled, EMCS shall raise an alarm
and continue the sequence if it is possible. If it is not possible, it shall raise a sequence
failure alarm message. Status and displays shall be refreshed as soon as the
communication is restored.
Any communication failure must not stop operation of any part of the power distribution
system and cause unwanted automatic tasks such as intertripping,
7.8. EMCS Interface with Other Systems
a. EMCS will interface through redundant serial links with DCS in order to exchange data
only and commands for process users must be Hard wired including but not limited to
as the following:
- Start
- Run feedback
- Stop
- Stop feedback
- Electrical fault
- Drawer isolation
b. EMCS’s control functions will be limited to items not involved in process control.
c. When needed, a list of signals to be exchanged will be provided in a document named

Electrical – Instrument Interface. As for now, the data shall be made available to the
DCS.
d. ESD (Emergency Shut Down) is an independent system, and it shall not be considered
part of the EMCS.
e. Motor reacceleration is part of the process control and shall be through hard wired
signal
8. EMCS CONTROL AND MONITORING
Access to monitoring and control shall be limited by a password protection system. Specific
access levels shall be as specified in the requisition. As a minimum, access shall be
restricted to the following three levels :
o monitoring,
o monitoring and remote control for protective devices.
o monitoring and overall control.

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8.1. Control management
a. In normal operating conditions, the EMCS shall allow the operator to control the
electrical network through EMCS workstation.
b. Upon request, in addition to function control on Switchgear Front panel, the electrical
network control can be carried out through EMCS workstation
c. Controls shall be carried out in parallel as follows:
o For Medium voltage switchgears:
Incomers / tie circuit breakers, manual transfer with momentary paralleling shall be
performed from:
- Manually in the Switchgear Front panel by means of push button/selector

- EMCS system workstation
Outgoing feeders, control (open/close) shall be carried out in parallel by:

- Remote from EMCS system workstation
Outgoing motor starter, control (start/stop) shall be carried out in parallel by:
- Field push button/selector (Motor control station) located beside the motor
- Automatic from DCS (through hired wires)
Incomings / tie and outgoings’ motor starter & power feeder, changing protection
settings shall be carried out in parallel by:
- Manually in the switchgear front panel through the relay

- Remote from EMCS (System workstation)
o For low voltage switchgears:

Incomers / tie circuit breakers, manual transfer with momentary paralleling shall be
performed from:

- EMCS system workstation
Outgoing motor starter, control (start/stop) shall be carried out in parallel by:

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- Field push button/selector (Motor control station) located beside the motor
- Automatic from DCS (through hired wires)
Incomers / tie circuit breakers, changing protection settings shall be carried out in
parallel by:
- Manually in the switchgear front panel through the relay

Outgoing motor starter & power feeder, changing protection settings shall be carried
out in parallel by:
- Local by LCU (service laptop)

d. Control maneuvering shall be safe in order to avoid errors by the operator. Interactive
control sequences are required i.e. operator will be guided step-by-step, with
confirmation that the right commands have been accepted, or that wrong commands
have not been accepted.
e. All given commands shall be filled in a historical Data Base; the filling shall be complete
with date/time in which the command was given.
f. In order to guarantee the commands, even when the feasibility conditions determined
by the field signals do not arise, the supervision systems shall have a field-signal
“forcing” facility.
These "forcing" facilities, used to cut out the control of a field sensor, shall be useful
during maintenance in order to temporarily cut out a wrongly received signal. Access to
this facility shall be possible only through a “high level” password.
8.2. Monitoring and Alarm Management
(i) In addition to data shown on Switchgear Front panel, Monitoring and Alarm shall be
displayed on EMCS workstation (as required)
(ii) Monitoring and Alarm shall be as follows:
o For Medium voltage switchgears
EMCS system shall have facility to calculate the total electrical power consumed for
the plant. This should be done as the summation of the (MWH) of main feeding
circuit breakers.
The following metering data shall be transferred / shown on the EMCS system:
- Voltage between phases and between phase and neutral (V).

- Currents through phases and neutral (A).
- Current demand (A).

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- Frequency.
- Power factor.
- Active power (kW).
- Active power demand (kW).
- Reactive power (kVAr).
- Apparent power (kVA).
- Active energy (kWb).
- Reactive energy (kVArh).
- Apparent energy (kVAh).
Incoming and outgoing power feeder / motor starter status shown on EMCS is
including but not limited to the following:
- Circuit breaker open / close / trip status / available.

- Earth switch open / close / trip status.
- Selector status local/remote/off
Emergency shutdown initiated by the ESD shall generate an alarm for each motor
that had not previously been stopped by the DCS.
Alarm logging shall allow identification of “first in time” event.
Each alarm shall appear in a dedicated alarm window on the EMCS operator’s
terminal. Alarms require acknowledgment by the EMCS operator.
All incomers and outgoing power feeder / motor starter alarms shown on single line
diagram shall be displayed on the EMCS workstations.
o For low voltage switchgears:
The following metering data shall be transferred / shown on the EMCS system:

- Current demand (A).
- Frequency.
- Power factor.
- Active power demand (kW).
Incoming and outgoing power feeder / motor starter status shown on EMCS is
including but not limited to the following:
- Circuit breaker open / close / trip status / available

- Circuit breaker position draw out/drawing/test position
- Contactor status

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- Selector status local/remote/off
emergency shutdown initiated by the ESD shall generate an alarm for each motor
that had not previously been stopped by the DCS.
Alarm logging shall allow identification of “first in time” event.
Each alarm shall appear in a dedicated alarm window on the EMCS operator’s
terminal. Alarms require acknowledgment by the EMCS operator.
All incomers and outgoing power feeder / motor starter alarms shown on single line
diagram shall be displayed on the EMCS workstations.
o For low voltage diesel generator set:
Metering data to be transferred / shown on the EMCS systems is including but not
limited to the following:
- Active Power (kW);

- Reactive Power (kVAr);
- Active Energy (kW-h);
- Reactive Energy (kVAr.h);
- Frequency.
Status to be shown on EMCS is including but not limited to the following:
- Running time (hours);

- General Alarm/Trip.
- Generator status running/stop
o For UPS systems:
- AC and DC voltage
- Current
- General Alarm/Trip
o For variable speed drives:
- Voltage

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- Currents
- Frequency/speed.
- VFD status running/stop

- Running time (hours)
- VFD Alarm/Trip.
o Transformer (trip and alarms) due to protection devices such as transformer but
not limited to buchholz or overpressure/gas-evolution, winding temp. oil temp shall
be monitored on the EMCS
(iii) All generated alarms and events shall be filed in a historical Data Base saving on
hard disk; the filing shall be complete with date/time in which the alarms were
acknowledged, switched off and normalized
8.3. Monitoring of diagnostic and maintenance data shall include the following:
- Number of operating hours.
- Number of contactor or circuit breaker operations.
- Number of contactor operations during last hour
- Starting current and time (for motor starters only).
- Trip current L1,L2, L3.
- Trip indication.
- Time to trip
- Time to reset
8.4. Trending
8.4.1. Historical
All defined measurements are logged onto hard disk each 5 seconds.
The logs older than one month to be stored in a dedicated folder on the hard-disk
automatically.
After opening any of the distribution system components windows, the associated trend
can be displayed. Desired parameter groups can be made visible by selection. Trend
variables will be displayed grouped by Current, Voltage, Power and energy.
Historical trends stored on hard-disk can be viewed, zoomed and viewed statically for a
defined period of time within the scope of the stored data.

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The zero offset, lower limit and high limit of the Y-axis can be adjusted as desired. At zoom
in and zoom out the default offsets will be adopted.
When Zooming in fixed steps, the X- and Y-axis will be zoomed using the same zoom ratio.
The zoom factor and viewed range is set to default whenever the trend page is activated.
It should also be possible to get trending for the whole electrical power consumption of the
plant (kWH). This will include the (kWH) of main feeding circuit breakers.
8.4.2. Trending Parameters
Shall include but not limited to The following parameters for trending.
Low voltage outgoing motors and feeders Current (I)

Voltage (V)
Power (P)
Medium voltage outgoing motors and feeders Current (I)

Voltage (V)
Power (P)
Medium and low voltage incomers Current (I)

Voltage (V)
Power (P)
Plant main incomer feeders Current (I)

Voltage (V)
Power (P)
Total energy for main feeding circuit breakers
8.5. Design life and maintenance schedules
Equipment shall have a design life of at least 20 years and a periodic maintenance
interval (excluding periodic visual inspections and routine recording) greater than:
- 3 years for relay calibration and functional tests

- 5 years for other electronic equipment adjustment
8.6. Reliability
The hardware of the EMCS shall be suitable for the temperatures that will occur in the
switchboard. This should be achieved by de-rating all electronic components and
suitable burn-in of the PCB's of all the units to prevent failures.

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The whole EMCS system hardware components shall be capable to withstand an

ambient temperature of 45°C.
9. NAMEPLATES
Nameplates shall be provided to identify all circuits entering or leaving the EMCS.
These shall be attached to the external surfaces of the assembly. Nameplates
minimum size shall be 125 mm by 30 mm.
Nameplates shall also be provided to identify wiring, indicating lights, instruments,

control switches, circuit breakers, the internal power, control and protective
components and cards, etc. These components shall be identified in accordance with
their identification on the power and control schematics. Nameplates shall be sized
according to the space available for mounting.
Compartments which contain accessible permanently live terminals shall be provided

with warning signs, advising personnel of this fact.
Nameplates shall be laminated plastic with engraved black letters on white

background.
Nameplates shall be attached using a minimum of two (2) stainless steel screws per
plate. Adhesive type nameplates are not acceptable.
Inscriptions shall be in the English language
10. ELECTRICAL IMMUNITY
All Equipment shall be able to generally withstand the impact of the imposed electrical
tests as defined in referenced me.
DISTURBANCE IMMUNITY The entire system shall be suitably screened to optimize

electromagnetic compatibility (EMC).
The complete EMCS shall be type tested in accordance with IEC 61000 part 4, level 3 -
typical industrial environments, as detailed below:
IEC 61000-4-2- Electrostatic Discharge -level3- 8kV air discharge.

IEC 61000-4-3- Radiated Electromagnetic Field (RFI) - level3-10 V/m.
IEC 61000-4-4- Electrical Fast Transient - level3- 4kV common mode.
IEC 61000-4-5- Surge- 2 kV line- earth and 1 kV line -line.
The manufacturer shall provide type test certificates from a recognized testing
authority to verify that the complete EMCS is effectively screened against EMC in line
with the applicable IEC standards.

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11. PAINTING
The enclosures shall be thoroughly cleaned free of scale, sand, rust and grease, both
internally and externally. The cleaned surfaces shall be given one priming coat of paint
and two top coats and otherwise made corrosion resisting. The exterior final paint finish
shall be manufacturer's standard.
12. INSPECTIONS AND TESTS
12.1. Inspections
During the manufacturing period, the equipment could be subject to inspection by

Contractor inspectors or by others appointed purchaser.
Accessory material could be subject to inspection too.
The Manufacturer shall allow the free access of inspectors to the workshop, shall give
all information required and shall make available all copies of internal orders to other
sub-suppliers.
OWNER /CONTRACTOR reserves the right to inspect all EMCS system at the
MANUFACTURER's premises prior to shipment to prove compliance with
specifications
12.2. Test procedure
12.2.1. General
The tests should be carried out in Vendor workshop at his care and expense.
Even in case Contractor or Owner waives to witness the tests, the Vendor shall draw
up the certificate of the tests carried out containing a full report and all results and the
measures of the tests.
The tests shall be carried out in accordance with the requirements of applicable codes
and of the Inspection and Test Plan.
Routine tests shall be conducted on each item and/or assembly in accordance with the
requirements of IEC / ISO codes and of the Inspection and Test Plan.
Type tests are for the purpose of proving the characteristics of equipment design.
Evidence of valid type tests covering the equipment offered together with tests
certificate from an Independent testing station, or recognized manufacturer testing
station, shall be submitted with the tender. The type tests shall encompass the
requirements listed in the Inspection and Test Plan.

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12.2.2. Factory acceptance tests
The following tests shall be carried out on the PMS System:
Hardware Tests
- Visual check
- Dimensional check
- Equipment check
- Painting check
- Insulation Resistance measurement
- Earthing circuits checks
- Initial system start-up
- System accuracy and resolution
- Surge protection tests
- Auxiliary control unit test
- Analogue / digital I/O Functions
- System Power Failure/Restart
- Central Control unit checks
- Communications Link Terminations and Data Transmission Media
- Storage Backup
- Redundancy check
- Communication with DCS
Software Tests
- Software Validation and development

- Command Software
- System Timing Tests
- Remote terminal unit software tests
13. BID INSTRUCTIONS
The base quotation shall be in strict accord with this specification and the applicable
data sheet. Alternate quotations may also be submitted if deviations from these
specifications or data sheets are clearly stated and a base quotation is offered.
Service-proven designs shall be offered. If a design is offered that has not been proven
in service for at least two years, proposals shall indicate which parts of the equipment
are affected and the extent of experience with these parts. Equipment designs
scheduled for supersede shall not be used.
14. DOCUMENTATION
Documentation shall be provided and shall give, as minimum information:

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- a general description of the unit including installation and maintenance

instructions; manuals shall describe EMCS system in sections pertaining to
description, installation, theory of operation, operational procedures, maintenance,
and troubleshooting techniques;
- sufficient reproducible detailed installation drawings, circuit diagrams, wiring
diagrams, electrical interconnect diagrams, electrical schematics, panel layouts
and descriptions of operation;
- recommendations for maintenance/replacement intervals on all components;
- a list of standards applied;
- the test reports;
- the compliance certificates with the applicable standards.
Full documentation shall be submitted for review and approval in accordance with the
material requisition and its attachments. The information shall reflect 'as-built' situation.
All drawings shall be produced in AutoCAD format, release 14 or higher, suitable for an
lBM PC. Any special fonts, symbol or menu files used to generate the drawings that
are not part of the standard AutoCAD release other than through configuration shall
also be supplied. All manuals/documents shall be produced in Microsoft Word for
windows XP or later. All drawing and system documentation will be provided in hard
copy as well as CD-ROM.
Following order placement the supplier shall provide for purchaser approval the
functional design specification which shall present the supplier proposal in detail to
enable the purchaser to verify that the system design meets the project requirements.
The functional design specification shall include as a minimum:
- Detailed planning network showing all hardware/software production and test

activities.
- System hardware broken down to each type of unit.
- Interface details including connections.
- I/0 allocations.
- Configuration details
- Graphic display details.
- Data link development, software production and testing plan.
- Expected performance figures.
- Availability I reliability analysis.
- System constraints and limitations.
- Details of the physical design of the cabinets and console.
- Details of the components within the scope of supply.
- Details of the operator interfaces.
MANUALS
As a minimum the following documents will be supplied with the system:
- Site preparation and installation manual.
- System maintenance and troubleshooting manual.
- System operation manual.

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- System configuration manual.
The manuals shall include all relevant documentation together with full system and
user interface descriptions and procedures appropriate to the manual function.
Manuals shall be available for factory test. The versions shall be in an advanced draft
stage requiring amendment only as a result of changes found necessary during the
test.
All documentation shall be supplied in English.
For sequence control manuals shall include detailed flow sheets, documented with all
relevant
(cross) references and clarification notes.
SYSTEM PREPARATION AND INSTALLATION MANUAL

The site preparation and installation manual shall contain all data necessary for safe
installation of the delivered system. It shall cover comprehensively all the required
tools and utilities and describe the detailed installation procedures.
SYSTEM MAINTENANCE AND TROUBLESHOOTING MANUAL The maintenance

manual shall contain all data necessary for the maintenance of the delivered systems.
It shall cover comprehensively all predictive, preventive and corrective maintenance
tasks and detailed procedures required to allow on-site company personnel to maintain
the specified availability.
SYSTEM OPERATION MANUAL

The system operation manual contains:
- General information about control and monitoring system.
- Simple (step-by-step) operating instructions.
- Background information concerning the facility
SYSTEM CONFIGURATION MANUAL

The system manual will be used by the system engineers and shall be the relationship
between the various parts of the delivered system, engineering instructions and
software and hardware descriptions from system and packages.
Typical design information, which should be covered:

- System description, including standard/optional function blocks, applications,
programs.
- System communication links characteristics including communication speed,
protocols, access/control principles, error detection/recovery, network logging,
failure identification / repair, back-up principles.
- Configuration documents
DRAWINGS
All the drawings required for the design, manufacturing, installation, maintenance and
operation of the delivered systems shall be provided, i.e. as a minimum:

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- Functional design specification.

- Certified dimensional drawing of all cabinets, operator station and peripherals.
- Lay-out drawings of all cabinets, with location details for field I/O terminations.
- Power distribution drawings with interconnection details.
- Earthing lay-out and connections.
- System cable schedule.
- Configuration data.
- System interconnection drawings.
- Hardwired panel lay-out and construction drawings.
- Factory acceptance test documents.
- Man/machine interface and supervisory controls System architecture, including all
interfaces with sub-systems.
- Loop diagrams and logic diagrams.
- Ladder diagrams (if any).
15. SUPPLIER'S RESPONSBILITY AND GUARANTEES
The supplier is responsible for complying with all codes which apply to the equipment.
Any special certification requirements or inspections by other authorities arising from
the above shall be arranged by the supplier and the costs for the same shall be
included in his quotation.
The equipment to be provided by supplier must be in complete compliance with this

specification and reference codes. Any exception or deviations, if any must be listed
separately with the quotation for owner approval. Any exception which is not listed
shall not be considered.
A complete set of tools for service and maintenance shall be supplied in a box suitable
for wall mounting for each system.
16. RECOMMENDED SPARE PARTS LIST
Vendor shall provide a system(s) recommended spare part list.
Spare parts list shall describe part, function, manufacturer’s part number, vendor’s part
number, price, and delivery for each recommended spare part.
The following spare parts shall be included in suppliers' quotation:
- COMMISSIONING SPARE PARTS

Commissioning spare parts shall be supplier responsibility but supplier shall submit
a detailed list with his quotation.
- TWO YEARS SPARE PARTS

The supplier shall submit for the system a detailed list of two years spare parts
with his quotation.

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17. SHIPPING REQUIREMENTS
17.1. Documentation
Supplier shall, on order award, advice and gives to Purchaser all supporting
documentation relevant to any commodity contained in the supply subject to
governmental Export/Import License, so that all necessary actions can be promptly
taken in compliance with the related rules or regulations in force.
Supplier shall provide to Purchaser, by fax, the preliminary packing list 4 weeks after
the purchase order. All shipping documents (invoices, packing lists, FCR, B/L and
others), shall be in English language.
17.2. Delivery
At least 7 days prior to delivery, supplier shall give fax binding confirmation of the
actual Ex-works delivery date of the goods. Supplier shall be fully liable for any dead
freight and demurrage caused by his failure to deliver the goods within the confirmed
date.
Supplier shall deliver the goods only after receipt of purchaser/forwarder’s written
instructions. If requested, supplier shall provide free storage of the goods in a covered
area, for a period previously agreed upon with the purchaser.
Supplier shall provide, free of charge, all handling devices (crane, fork lifts, etc.), labor
and materials (i.e. wooden boards, struts, wedges, ropes, etc.) needed for loading,
stowing and lashing the equipment on conveyances or into containers.
The purchaser reserves the right to verify, by opening the packages at the erection site
or delivery point, that the quantities indicated in the packing list correspond with those
effectively contained in the packing. If, according to the sole judgment of purchaser, the
materials do not match with the quantity and/or types specified in the purchase order
and/or packing list, supplier shall, upon written notification of the irregular supply,
provide for prompt replacement at his own care and charge up to delivery at site.
17.3. Specific requirements
If required for transportation, all equipment with shall have transport locking devices
installed.
Provisions shall be taken to protect the equipment properly against water, salt spray,
moisture, rust and vibration damages of the equipment.
The units shall be shipped at the maximum preassembly extent.
The Supplier should state the maximum storage time limits based on temperature.

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E-STYRENICS
Receiving location shall be notified two working days in advance so that handling
equipment will be available.
18. SITE INSTALLATION ASSISTANCE, COMMISSIONING AND START-UP
When required as per the material requisition, Manufacturer shall provide a specialist
for construction commissioning and start-up supervision.
Construction supervision shall include but not limited to the following:

- Visual inspection to check compliance with the requirements and quality of the
materials and fabrication. This shall include the check of the conformity of the
drawing and the diagrams, the quality and quantity of all components and
accessories and presence of the required nameplate and marking.
- Check and supervision of all mechanical installation.
- Check of alignment, assembly, inter-wiring connection of the various units shipped
separately and interconnection wiring with other supplier in order to assure that the
EMCS is ready for connection and operating.
SITE ACCEPTANCE TEST (SAT)
The function of the SAT is to prove that the system has not been damaged in transit,
equipment has been installed correctly, and is fully functional. A full functional test as
for the FAT with connection to live external system shall be completed as a minimum.
After the system has been installed at site, the Supplier shall supervise the initial
power-up of the system. The Supplier shall perform hardware testing to ensure that the
system is fully operational. In addition, all I/0 signals shall be tested to ensure full
functionality of all system components.
PRE-COMMISSIONING The Supplier shall:
- Test all functions of the EMCS system including tests as specified in the Contract,
standard test procedures and diagnostic routines.
- Verify system program and data load and restart facilities.
- Test and commission the communications network between locations.
- Test and commission all data transmission between locations.
- Simulate, test and commission all input functions from the incoming terminals at
the cabinets through to the operator interface.
- Test and commission the complete database.
- Test and commission the facilities and operator interface including all displays,
reports, application programs, backups and archiving etc.
- Test and commission all maintenance and diagnostic facilities
FINAL COMMISSIONING, INCLUDING PLANT START-UP The Supplier shall assist in

commissioning all field input and output devices to EMCS including:
- Commissioning from the field device to the operator interface.

- Reconfiguration and rewiring of the system where necessary.

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- Start-up and shutdown of the system.

- A Site Acceptance Test (SAT) to demonstrate that the EMCS functions correctly in
combination with plant subsystems.
- Start-up assistance is required from Supplier for the following activities:
- To check whether system installation is conform to Supplier specifications.
- To install system configuration.
- To power-up the system and run diagnostic programs to ensure hardware integrity.
19. HEALTH, SAFETY AND ENVIRONMENTAL MANAGEMENT
The supplier shall consider the impact on the environment of his products during
different process (e.g. designs, manufacturing, .... etc), and shall develop
environmentally friendly products and manufacturing processes such that the supplied
equipment will be safely, efficiently and in ways that conserve energy and other natural
resources.
The electrical equipment and products shall cover (in design, engineering,
manufacturing and testing processes) any emergency, abnormal and upset conditions
which would be met during equipment operation to prevent the following:
- Environmental damages.
- Equipment or product damages.
- Plant operation losses.
- Health effects.
- Loss of public & customer trust.

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NOTICE: THIS DRAWING HAS NOT BEEN PUBLISHED. IT IS THE SOLE PROPERTY OF ENPPI.

300,000 MTA EB/SM PLANT EARLY WORKS PACKAGE

ESTYRENICS Reference: ES-PRO-02

ENGINEERING FOR THE PETROLEUM & PROCESS INDUSTRIES (Enppi) - EGYPT