Vol IX - PG B209 - Electrical Works

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ENGINEER’S STAMP: CONTRACTOR’S STAMP:

C Issued for Tender Wilken 06.11.2020


Gasic Nyoundou
B Issued for Tender Shahab Nyoundou Wilken 22.07.2020

0 Issued for Tender Nyoundou Wilken 08.04.2020


Shahab
REV DESCRIPTION PREPARED CHECKED APPROVED DATE

KINGDOM OF SAUDI ARABIA ‫اﻟـﻤﻤـﻠـﻜــﺔ اﻟﻌــﺮﺑـﯿــﺔ اﻟﺴــﻌـﻮدﯾـــﺔ‬


‫اﻟﻤـﺆﺳــﺴــــﺔ اﻟﻌــﺎﻣــﺔ ﻟﺘﺤــﻠـﯿﺔ اﻟـﻤــﯿــﺎه اﻟـﻤــﺎﻟــﺤــﺔ‬
SALINE WATER CONVERSION CORPORATION
CONSTRUCTION OF SALES GAS SUPPLY PIPELINE TO YANBU
PLANT PHASE-3 PROJECT

FICHTNER GMBH & CO. KG

TENDER DOCUMENTS

LOCATION: TITLE:
Western Coast Volume IX PART PG-B209
PACKAGE: TECHNICAL SPECIFICATION

ELECTRICAL WORKS

SCALE: REV:
None Q A 1 0 - H - 0 4 0 9 C
SUBCONTRACTOR:
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TECHNICAL SPECIFICATION
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Disclaimer

The content of this document is intended for the exclusive use of Fichtner’s client and
other contractually agreed recipients. It may only be made available in whole or in part to
third parties with the client’s consent and on a non-reliance basis. Fichtner is not liable to
third parties for the completeness and accuracy of the information provided therein.

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TABLE OF CONTENTS
1. Scope of Work 7
1.1 Incomers 7
1.2 Electrical architecture 8
1.3 Starters and Feeders 8
1.4 Emergency power supply system 9
1.5 Electrical and Control Buildings 9
1.6 Other topics 10

2. Standards 11

3. Voltage Levels 12

4. Environmental Conditions: Enclosure Classification 13

5. Protective Coatings 15
5.1 Galvanizing 15
5.2 Painting 15
5.3 Duplex System 16
5.4 Underground Material 17

6. Electrical Installations 18
6.1 Lighting and Small Power 18
6.1.1 General 18
6.1.2 Service illumination levels, glare index 20
6.1.3 Lighting fittings 21
6.1.4 Emergency lighting 25
6.1.5 Distribution boards 26
6.1.6 Socket outlets and plugs 29
6.1.7 Cables 30
6.1.8 Cable support systems 30
6.1.9 Earthing and bonding 34
6.2 Earthing and lightning protection 34
6.2.1 Earthing and bonding system 34

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6.2.2 Lightning protection 39


6.3 Cathodic protection system 41
6.4 Cable and cable trays 44
6.4.1 Cable laying and routing requirements 44
6.4.2 General cable construction requirements 46
6.4.3 Medium voltage (MV) power cables 47
6.4.4 Low voltage (LV) power cables 47
6.4.5 Current carrying capacity and voltage drop of power cables 48
6.4.6 Measuring and control cables above 60 V/ instrument transformer
cables 48
6.4.7 Measuring and control cables below 60 V 48
6.4.8 Cable supporting structures 50

7. Requirements for local cubicles and local housings for e.g.


switchgear, control, measurement and signaling equipment 51

8. Low Voltage Switchgears 54


8.1 General 54
8.2 Construction Requirements 54
8.2.1 General 54
8.2.2 Switchgear components 56

9. Electrical Motors 64
9.1 Scope 64
9.2 Codes and standards 64
9.3 Environmental Conditions 64
9.4 General requirements 64
9.4.1 Selection of motors 64
9.4.2 Components and equipment 65
9.4.3 Duty 66
9.4.4 Dimensions 66
9.4.5 Noise requirements 66
9.4.6 Vibration 66
9.4.7 Units and scales 66

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9.5 Low Voltage Motors 67


9.5.1 Motor start and torque requirements 67
9.5.2 Insulation / winding protection 67
9.5.3 Method of cooling 67
9.5.4 Terminal boxes 68
9.5.5 Anti-condensation heater 68
9.6 Painting 68
9.7 Installation 69
9.8 Spare parts 69

10. Variable Speed Drives 70


10.1 Scope 70
10.2 Code and Standards 70
10.3 Environmental Conditions 71
10.3.1 Outdoor and overall site conditions 71
10.4 General Requirements 71
10.4.1 Components and equipment 71
10.4.2 Harmonics 71
10.4.3 Units and scales 72
10.5 Frequency Converter Unit 72
10.5.1 General 72
10.5.2 Wiring 73
10.5.3 Earthing 73
10.5.4 Overvoltage protection 74
10.5.5 Control voltage 74
10.5.6 Auxiliary voltage 74
10.5.7 Anti-condensation heaters 74
10.5.8 Feeder 75
10.5.9 Rectifier 75
10.5.10 Intermediate DC link 75
10.5.11 Inverter 75
10.5.12 Cooling 76

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10.5.13 Control unit 76


10.5.14 Operator panel 78
10.5.15 Emergency stop push button 79
10.6 Cabling 79
10.7 Painting 79
10.8 Spare Parts and Accessories 79

11. EMC measures 81

12. UPS Equipment 83


12.1 Scope of Works 83
12.2 Codes and Standards 83
12.3 Environmental Conditions 84
12.4 General Requirements 84
12.4.1 Components and equipment 84
12.5 Description of the system 84
12.6 Equipment Characteristics 85
12.6.1 Mechanical requirements 85
12.6.2 Electrical requirements 85
12.7 Wiring 90
12.8 Painting 91
12.9 Installation 91
12.10 Spare Parts and Special Tools 91

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1. Scope of Work
This section covers the design, supply, erection and commissioning of the
electrical installation and equipment for the Gas Regulation Station (GRS)
of Yanbu Power & Desalination Plant Phase 3 Project, further the Project.
This section should be read in connection with P-A3 "General Project
Requirements”, Part P-A5 “Inspection and Testing” and Part PG-C
"Annexes" and other sections of this specification as relevant.

The plant/equipment shall be designed to ensure continuity of operation


under all working conditions at the site and to ease inspection, maintenance
and repairing tasks. All reasonable precautions shall be taken in the design
and selection of equipment, in order to ensure personnel safety at all
moment.

Materials and equipment used in the project shall be provided with high
efficiency and high level of reliability, specially related to:

a) high ambient temperatures


b) dust storms
c) nearness to sea
d) fire risk
e) solar radiation

The minimum design power factor overall for the plant shall be PF= 0.95.

1.1 Incomers
The Project will be supplied, from the existing LV switchboard MV cables
in Yanbu plant.

New incomers capacity calculation and design should be based on the


electrical load list for the GRS project consumption, starting loads and safe
allowances, and shall consider the whole capacity of the Plant. New loads
incoming cables will be laid in cable trenches, filled with sand (or in cable
trays/ ladders when cables are running above ground.

New metering rooms and contained switchgears shall be designed fully in


accordance with SWCC design specifications.

Electrical calculations short-circuit and load analysis, as well as


coordination and setting of all relays for the whole switchgears considering
the new load list scenario shall also be included in Contractor’s scope.

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1.2 Electrical architecture


The main electrical boards (MV&LV switchgears) shall be provided with
single double busbar, coupled through a high-speed transfer system
providing a full redundancy.

MCC’s and auxiliary distribution boards shall be fed with redundant


incoming lines, protected by breakers with mechanical interlocks (1of2)

Main voltage levels in the plant are shall be 14,5 kV, 6.6 kV and 400 V.

High-pressure pumps or motors with rated power above 355 kW shall be


powered at medium voltage level (6,6 kV). All other consumers will be fed
at low voltage level, distributed in electrical boards according to motor rated
power:

Motors ≥ 75kW powered from LV Switchgear


Motors < 75kW powered from MCC’s

Within each facility, power shall be distributed through L V switchgears,


MCC’s and auxiliary distribution boards as per the single line diagram.

1.3 Starters and Feeders


Motor starting type will be, preferably, Direct On-Line (DOL) for all motors
except for those with special process or safety requirements.

LV switchgears and MCC shall be designed to withstand motor starting


peak currents for full load direct start with voltage drops on main busbar
lower than 5%.

Variable Frequency Drivers (VFDs) shall be used in pumps applications


where is required a variation of working point.

Specification for VFD and Motor Starter are described in "Technical


Specifications", in Section 13 of this document.

The use of Soft Starter requires SWCC engineer’s approval.

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1.4 Emergency power supply system


Secured power supply shall be considered for the following if provided:
At least following services shall be considered as critical:
· Flushing pumps,
· DCS system,
· Essential loads as per HCIS,
· Critical MOV’s, and
· Control supply for MV/LV switchgears and MCCs.

The contractor shall calculate the power required for above indicated
systems, considering a minimum capacity of 500 kVA. Final load
calculation shall be submitted for approval to SWCC engineers.

An UPS System to bridge the gap between plant back out and availability of
DG Power to ensure availability of control and monitoring systems shall be
foreseen in addition.

The contractor shall calculate the required power for the UPS System.

1.5 Electrical and Control Buildings


The electrical part of the Electrical and Control building shall be considered
to house electrical switchgears and equipment for the Project shall be as
follow:

· Main Electrical Building:


· Any new main switchgear shall be installed in Main Electrical
Building with any other associated LV panels and utilities systems and
UPS’s.
· Metering room:
· The scope of work of the Contractor shall also include the
construction of a metering room according to the design specifications
of SWCC. Metering rooms will be built outside the security fence of
each plant, accessible for electrical company personnel.

The main electrical building shall consist of a cable cellar, a ground floor
and at least the following rooms:

· MV switchgear rooms (14.5 kV and 6.6 kV in separate rooms)


· VFD room
· LV room
· UPS room
· Battery room

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The dimensions of the rooms shall be adequate to accommodate the


corresponding equipment.

All electrical equipment related to units like MV, LV switchgear, Safe AC


and DC system and electronic cabinets shall be located in separated
electrical rooms and separated cable basement.

All electrical buildings and rooms shall be provided with controlled


atmosphere (HVAC).

The connection from the main transformers to the main medium voltage
switchgears shall be by means of cables or busbars.

1.6 Other topics


The Contractor shall verify ratings of the equipment based on final loads.
Transformer and other Switchgear’s ratings shown in this document are
indicative.

The tenderer shall determine the size of the transformers based on his own
electrical demand considering 20% of spare capacity.

The complete electrical system shall be remotely controlled and monitored


by the DCS system described in Part PG-B210.

The Contractor shall perform, at least, the following electrical system


studies to prove the viability of the electrical design.

The study shall include, but shall not be limited to:


· Load calculation and flow studies,
· Insulation coordination,
· Short circuit calculations,
· Transient stability studies including:
· Simulation of operation of under-voltage protection and automatic
change-over,
· Motor start studies including voltage drop calculations, and
· Relay protection setting studies.

The Tenderer shall submit a detailed list of all studies he proposes to carry
out together with the description of the computer programs which will be
used for each study for approval by the Engineer.
All MV, LV and other switchgears in the Plant shall be of the same make.

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2. Standards
The design and manufacture of all electrical equipment shall comply with
the latest editions of the IEC Standards. Compliance with
ANSI/IEEE/NEMA standards will only be accepted in case no applicable
IEC standards are available.

In case an IEC Standard or ANSI/IEEE/NEMA standards do not exist or


cover the Scope of Works, National Standards, at least equivalent to
German VDE Standards or British (BS) shall be applied. In such a case, the
Tenderer shall provide the Engineer with two sets (official, complete,
unabridged and in the English language) of all relevant standard
specifications according to which the equipment is manufactured.

The requirements of the Saudi Arabian Grid Code shall apply.

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3. Voltage Levels
The following voltage levels are preassigned and shall be used in the
project.

ITEM VOLTAGE STAR POINT /


NEUTRAL
TREATMENT
Grid supply voltage 220 kV, 60 Hz, 3-phase solidly grounded
Power Distribution 14.5 kV, 6.6 KV 60Hz, 3- neutral point grounding
System-Medium Voltage phase to be decided during
detail design engineering
Power Distribution 400/230 V, 60Hz, solidly grounded
System Low Voltage 3-phase, + PEN or + N +
PE
Uninterruptable Power Output 400/230 V AC, 60 solidly grounded
Supply (UPS) Hz, 3-phase + N + PE

ITEM VOLTAGE STAR POINT /


NEUTRAL
TREATMENT
Instrumentation a) 230 V safe AC, 60 Hz a) solidly grounded
b) 24 V DC (20 to 30V) b) to be defined by
Bidder
Switchgear and Motor a) 230V safe AC, 60 Hz solidly grounded
Control circuits b) 220 V DC
Welding receptacles 400 V three phases, 60 solidly grounded
Hz
Socket outlets, small 230 V AC, 60 Hz, solidly grounded
power single phase +N + PE
Lighting 400/230 V AC, 60 Hz, solidly grounded
single phase + N + PE

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4. Environmental Conditions: Enclosure Classification


The electrical equipment shall be designed taking into consideration the
following ambient conditions:

Maximum design temperature (outdoor in the shade) +54°C


Maximum daily average ambient shade temperature +40°C
Maximum monthly average shade temperature +37°C
Maximum annual average shade temperature +30°C
Maximum design temperature of the electrical equipment
installed indoors in air-conditioned rooms +40°C
Maximum design temperature of the electrical equipment
installed in non-air-conditioned room +50°C
Maximum annual average shade temperature +30°C
Maximum annual average shade temperature +30°C
Minimum design temperature 0°C
Minimum Design Ground Temperature +40°C

Equipment enclosures for electrical equipment shall comply with IEC


60034, IEC 60079, IEC60439, IEC 60529, IEC 60947, IEC 62271 as
applicable.

Unless otherwise specified equipment enclosure classes shall be as follows:

Indoor location Outdoor


Equipment
location
Dry Damp
MV switchgears IP 41 --- ---
LV switchboards, distribution
IP 41 IP 54 IP 65W
boards, local control panels
MV and LV motors IP 55 IP 55 IP 65
Lighting - indoor IP 42 IP 55 IP 65
Equipment terminal boxes IP 55 IP 55 IP 65
Junction boxes;
IP 55 IP 55 IP 65W
Local Control Panels

UPS IP 32 IP 42 -------

VFD IP 41 IP 55

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The additional measures (e.g. “W”) shall consist of sunshades, protection


covers against splashing water, rainwater and sand, additional sealing,
special sea water or acid resistive coating etc., depending upon the particular
site conditions.

Electrical operational equipment which must be installed in areas exposed to


danger from explosions must have the required explosion-proof design
appropriate to the flash-point group classification of the explosive mixture
as laid down in IEC 60079 and IEC 61241. Attention must be paid to IEC
60079 and IEC 61241 or equivalent with respect to the use of electrical
operational equipment in workshops and storage premises exposed to the
risk of explosions.

In all rooms and areas where the local and operational conditions and
surroundings can lead to the accumulation of gases, vapours, mists or dusts
which, in combination with air, form explosive mixtures, the operational
equipment and installations to be used in these circumstances must be of
explosion-proof design. All operational equipment must be designed to
comply with the class of protection dictated by the ignitable mixture (e.g.
compression-proof casing, external ventilation, inherent safety, etc.).

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5. Protective Coatings
Unless otherwise specified, the equipment/material shall be adequately
protected from corrosion either by hot-dip galvanizing or painting or by a
combination of both (a duplex system). The duplex system wherever
required shall be specified and described in the relevant SWCC
specifications.

5.1 Galvanizing
Unless otherwise specified in the associated SWCC specification or
respective standard, the hot-dip galvanizing shall be in accordance with the
following standards:

· ASTM A123 for steel structures. The minimum average thickness of


Zinc coating shall be 0.086mm (equivalent to 61O g / m2)

· ASTM A153 for Hardware, fittings, caps of insulators and fasteners


(bolts, nuts and washers). The minimum average thickness of Zinc
coating shall be 0.086mm (61O g /m2) for hardware fittings/caps of
insulators. The minimum average thickness of Zinc coating for bolts,
nuts and washers shall be as follows:
· 0.053mm (381 g/m2) for fasteners over 9.52mm in diameter
· 0.043mm (305 g/m2) for fasteners of diameter 9.52 and under

· The galvanizing thickness shall be as per manufacturer ' s standard for all
other equipment such as circuit breakers, disconnect switch, etc

5.2 Painting
Painting shall be a combination of compatible paints comprising of primer,
intermediate coat (on as needed basis) and top coat(s) to achieve optimum
protective and decorative coating against atmospheric corrosions caused by
tropical climate conditions, windblown dust, sand, salt, high humidity and
temperature fluctuations.

For all equipment used in distribution substations or distribution network,


colour shall be pebble grey or RAL 7032 conforming to BS 381C/2660 or
ASTM D1535, respectively. Unless otherwise specified in the associated
SWCC specification.

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Manufacturer's standard painting system shall be acceptable provided that


the following SWCC paint performance requirements are met:

· The paint coating shall be deemed to last life of equipment/material or at


least 10 years whichever is less.
· The painting coating shall be capable of withstanding the effect of
ultraviolet rays or direct solar radiation at its installed location without
change in colour.
· When a paint-coated equipment /material is tested for abrasion, there
shall be no penetration through the paint coating to the substrate.
· When a paint-coated equipment/material is tested by impact, there shall
be no cracking of the paint coating nor any detachment from the
substrate.
· When a painted or coated equipment/material is tested by salt spray for
1000 hours per ASTM B117, there shall be no blistering, softening or
detachment of the paint coating. There shall be not more than 1.0mm of
corrosion creep from the scribed, equivalent to rating number 8, in
accordance with Table I of ASTM D1654.
· After the equipment/material has been washed with water and allowed to
dry for 24 hours, it shall be tested for adhesion using Method B in
accordance with ASTM 03359. The adhesion scale shall be 5B, wherein
the edges of the cuts are completely smooth and none of the square of the
lattice is detached, unless within 1.0mm of the scribed.
· When a paint coated equipment/material is tested for its resistance to
humidity, there shall be no blistering, softening or detachment of the
coating nor signs of corrosion of the equipment/material.

5.3 Duplex System


Duplex system for protection of equipment / material from corrosion shall
be a combination of hot-dip galvanizing and painting.

The duplex system shall deem to have a life at least 30 years or more.

The paint system shall comprise of one primer coat, intermediate coat(s),
and top (finish) coat(s). The thickness of zinc coating shall be a standard
thickness as per ASTM A123 whereas the thickness of paint shall be as per
manufacturer' s recommendations and subject to approval by SWCC.

In case the contractor adopts this system, complete details of the paint
system and procedures for application shall be submitted for review
and approval by SWCC.

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5.4 Underground Material


Unless otherwise specified, the manufacturer /vendor shall propose
appropriate corrosion protection measures, other than specified above, for
the application of material for underground installation for SWCC review
and acceptance.

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6. Electrical Installations

6.1 Lighting and Small Power

6.1.1 General
This specification covers the rating, design, equipment requirements,
supply, installation, inspection and testing of complete lighting and small
power for the Project.

All materials and equipment shall be provided as are required to make a


complete, properly functioning installation and shall conform to the highest
standards of engineering design and workmanship.

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The design and installation of lighting and small power shall be based on the
following Regulations/Standards:

IEC 60364-5-54 Electrical installations of buildings: Earthing


arrangements and protective conductors.
BS 546 Two-pole and earthing-pin plugs, socket outlets and
socket adapters for circuits up to 250 V.
BS 1363 Specification for 13 A fused plugs, switched and
unswitched socket outlets and boxes.
EN 40 Lighting columns
IEC 60598 Luminaries
IEC 61347 Lamp Control gear
IEC 60898 Electrical accessories – Circuit breakers for over-current
protection for household and similar installations.
IEC 60423 Conduits for electrical purposes.
IEC 60947 Low voltage switchgear and control gear.
IEC 60502-1 Power cables with extruded insulation and their
accessories; Part 1: Cables rated for voltages of 1 kV
and 3 kV.
IEC 60502-2 Power cables with extruded insulation and their
Accessories, Part 2: Cables for voltages from 6 to 30 kV.
IEC 60502-4 Power cables with extruded insulation and their
Accessories, Part 4: Test requirements on accessories
for cables from 6 kV to 30 kV.
IEC 60227 PVC - insulated cables (non-armored) of rated voltages
up to and including 450/75
IEC 60245 Rubber insulated cables (insulated flexible cords). The
Tenderer is required to make himself aware of all
relevant standards and regulations.

This specification provides a performance specification only. It is the


Tenderer's responsibility to develop this into a full working design meeting
the requirements and objectives as stated herein.

Before proceeding with any purchase of equipment of any installation work


the Tenderer shall obtain prior approval from the Engineer of his detailed
design. Tenderer shall submit adequate and full supporting documentation
(calculations, schematics, general arrangement drawings, technical and
descriptive manufacturer's data, his own text and/or samples, etc.), to the
Engineer.

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Location of the lighting and small power equipment shall be reviewed at site
before installation so that satisfactory co-ordination with pipework,
ductwork, power cables, and other plant can be assured.

Lighting shall be designed to provide visual performance, safety and


amenity. Visual performance shall be free of excessive stroboscopic effects
and flicker from discharge type lighting.

In control rooms where, visual display units are to be installed the design
shall take account of the need to avoid operator fatigue.

In areas with high ceilings high bay light fittings for main lighting shall be
provided.

Circuit design shall also ensure that operation of a circuit protective device
or failure of a circuit component shall result only in limited loss of
illumination. This requirement shall be strictly observed for large areas.

LED luminaries shall be used for all services and purposes. The design shall
ensure satisfactory operation over the life of the station.

The lighting design shall take full account of the drop-off in performance of
lamps and fittings over their working life.

6.1.2 Service illumination levels, glare index


The below levels shall be based on measurements being taken after lamps
have operated for not less than 100 hours. The method of measurement shall
be in accordance with International Commission on Illumination (CIE)
Publication No. 29. Measurements shall be taken 0.85 meters above floor
level in control and relay rooms, electronic equipment rooms, and offices.
Otherwise, measurements shall be taken at floor level.

L Single-pole local switches


PB Push-button for remote control PC Photocell.

Service
illumination Type of
Location
Glare Control
Lux
Index
Local control and technical rooms
Offices and first aid rooms 500 16 L
Workshop (General) 300 22 PB/L
Computer and electronic equipment 500/800 L

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Service
illumination Type of
Location
Glare Control
Lux
Index
rooms
Switch rooms 300 25 L
Battery rooms 200 25 PB
Building corridors and stairways 200 25 L
Toilets 200 25 L
Locker rooms 100 10 L
All indoor areas not specifically listed 200 25 L
Transformer bays 100 - PB/L/PC
Cableways and cable basements 100 - L
Outdoor plant areas not specifically listed 50 - PC/L
Roadways, vehicle yard and car park 30 - PC/L
Access road 30 - PC/L
Access ladders, stairways and platforms 50 - L
Local control cabinets 200 25 L

6.1.3 Lighting fittings


Illustrations and/or samples of all lighting fittings which the Tenderer
proposes to purchase shall be submitted to the Engineer for approval before
issuing any suborders.

Lighting fittings for interior and exterior use shall be manufactured and
tested in accordance with the IEC 60598 or equivalent and together with all
components shall be suitable for service and operation in the climate stated.

Lighting fittings for use in hazardous areas shall be designed and certified as
suitable for use within the area according to the Zone or Division
classification and the nature of the inflammable gas, liquid, vapor or dust
concerned.

The lighting fittings and accessories shall be suitable for the highly
corrosive environment due to chemical fumes, vapors and dusts.

Each fitting shall be complete with all lamps, control gear (if apply), internal
wiring, terminal block, earth terminal and reflectors or diffusers as required.
The design of each fitting shall be such as to minimize the effect of glare,
and such that the ingress of dust, flies and insects is prevented.

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Preference shall be given to fittings with low maintenance and high


efficiency. As far as possible, such fittings shall be selected for which
replacement fittings and their spare parts are available locally or by such
manufacturer who have local agents in Saudi Arabia.

Internal connections shall comprise stranded conductors not less than


0.75mm2 covered with heat-resistant insulation to IEC 60245 or equivalent.
All internal wiring shall be adequately cleated to the fitting casing with an
approved form of cleat. The finish of fittings for interior use shall have a
vitreous enamel, natural aluminum or galvanized finish according to the
manufacturer's standard product.

The lighting installations shall be designed to give the standards service


illuminations specified above table. Control and relay rooms, computer and
electronic equipment rooms and offices shall all have the service
illumination measured at 850 mm above a finished floor level. All other
areas shall have the service illumination measured at floor level.

The Tenderer should hand over to Employer software copy disc he will use
for the illumination calculations within three (3) month after being awarded
the Contract.

The installations shall also meet the limiting glare index requirements
specified.

The number of different types of lighting fitting shall be rationalized to keep


the total to a minimum. Following types might be used:

· LED – High bay lighting unit: 3500K-4000K, color natural white, PF


>0.95, IP65, Class I, lifetime > 50000 hours, case material aluminium,
100W 110-270VAC.

· Fluorescent LED – T8 Tube (type-A): 5000K-5500K, color day white,


PF >0.95, IP20 (tube), lifetime > 50000 hours, case material glass,
18W/36W 110-270VAC.

· Fluorescent LED – T8 Tube (type-B)- Emergency lights: 5000K-


5500K, color day white, PF >0.95, IP20 (tube), lifetime > 50000 hours,
case material glass, 18W/36W 110-270VAC.

· LED Industrial Floodlight unit – Fence lights: 2700K-3000K, color


yellow, PF >0.95, IP67, Class I, lifetime > 60000 hours, case material
aluminium, 270W 110-270VAC, IK08.

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· LED Street lights unit: 3000K-3500K, color warm white, PF >0.95,


IP67, Class I, lifetime > 60000 hours, case material aluminium, 270W
110-270VAC, IK08.

· LED ceiling panel lighting units: 5000K-5500K, color day white, PF


>0.95, IP65, lifetime > 50000 hours, case material aluminium, 40W 110-
270VAC.

6.1.3.1 Lamps
The Contract includes the supply and erection of all LED lamps necessary to
complete the installation, together with one complete spare set for the first
change.

LED lamps shall be manufactured and tested in accordance with IEC


standards and shall have natural color rendering for internal use and daylight
color rendering for external use.

All lamps should be of types and sizes available locally.

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6.1.3.2 Poles for roadway and general floodlighting


Lighting poles shall be of fiber glass (FRP), of octagonal shape and shall be
approved by the SWCC/Engineer.

Poles for roadway lighting shall support the lanterns at a normal 10 m above
ground level and poles for floodlighting may exceed 10 m. The maximum
spacing between poles shall be 50 m.

Hinged type poles for access to the light fitting shall be provided where
floodlights are required to be installed at high level.

Each pole shall be equipped with a weatherproof base section of sufficient


size to house an inspection trap, lockable door, fused cut-out, cable entry
and termination for both the incoming and secondary cables feeding the
light source. Facility shall be included for cable looping.

All fittings shall be adequately earthed and all earth termination and fittings,
fixing brackets and supports shall be included.

The Tenderer shall ensure that each pole is provided with foundations
suitable for the ground conditions existing at site.

6.1.3.3 Exterior installations


All exterior lighting shall be automatically switched by photo-sensitive
switches and have a time delay between groups of circuits to even out the
switching peaks. Manual override facilities shall also be provided.

All external doors of buildings including switch rooms and stores shall
have external lighting fittings installed adjacent to the doors to provide
illumination immediately outside entrances in addition to the requirements
for roadway and area floodlighting detailed in this specification.

6.1.3.4 Photocells
Photocells shall be mounted within a waterproof and dustproof enclosure to
IP 65 which shall be fully corrosion resistant.

Means shall be provided for adjustment of the ambient light threshold at


which the photocell actuates the lighting.

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6.1.3.5 Lighting switches


Switches for use in AC circuits shall be rated for 16 or 20 A and shall be
single pole type provided with an earth terminal.

Switches for use in areas designated for surface installation shall be quick-
make quick-break fixed grid industrial types mounted in sheet-steel
weather-proof boxes with protected dolly and arranged where necessary for
multi-gang switching.

Switches for use in areas designated for flush installation shall be micro-
break types fixed to white plastic cover plates and mounted in galvanized
steel flush type boxes.

Switches for external use shall be of the surface mounting 16 A rotary


quick-make quick-break pattern housed in a cast iron galvanized
weatherproof box to IP 65.

Push-button switches shall either be flush or surface types, contained in


galvanized steel boxes and be single pole rated for 5 A. Push-button shall be
made of non-hygroscopic material, be non-swelling and so fitted as to avoid
any possibility of sticking.

The terminals for all switches shall be adequate to accommodate 2


conductors, each 2.5 mm2 in area.

Lighting circuits shall be designated such that no individual light switch is


loaded to more than 50% of the nominal rating of the switch. Shower rooms,
toilets and toilet blocks shall have light switches mounted outside the
entrance doors.

Light switches shall be installed such that the operating dolly shall be
pushed up for OFF and down for ON. Similarly, rocker-operated switches
shall be installed such that the upper portion of the rocker is pushed for OFF
and the lower portion for ON.

6.1.4 Emergency lighting


A security lighting system fed from 230 V AC shall be provided to allow for
the safe movement of personnel at all times in the event of a failure of the
normal lighting system.

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Security lighting shall be used for illuminating escape routes and exit signs
and shall switch on automatically in case of fire detection and in case of
failure of normal lighting. Manual testing facility shall be also provided.
Anywhere on the center line of escape routes a minimum illumination level
of 1 lux to be ensured. Average illumination level shall not be less than 10.8
lux according to Life Safety Code NFPA 101 7.9.2.

In case of failure of normal lighting, emergency lighting fed from separate


230 V safe AC systems shall provide sufficient illumination to allow a safe
movement of personnel and operation of the plant in a safe manner. At least
10% of the lighting in the following area shall be essential lighting:
· Control rooms
· Electrical building
· Stairways, access ladders and platforms

Wiring systems for emergency systems shall be kept separate from the
normal wiring system.

A method of testing emergency and security lighting shall be provided.


Escape routes shall be clearly marked and lit to facilitate emergency escape
in safety.

Security lighting according to the “Security Directives for Industrial


Facilities- SEC-04” of the HCIS shall be provided. The AC power supply of
the security systems and devices shall comply with the “Security Directives
for Industrial Facilities- SEC-07” and local requirements.

6.1.5 Distribution boards


The distribution boards and all component parts shall be manufactured and
tested in accordance with IEC 60947 and be capable of withstanding
without damage the mechanical and electrical stresses set up by any fault
current for twice the period required to disconnect such fault on any circuit.

Each distribution board shall have a dustproof metal case of sheet steel with
an enameled finish and shall have hinged doors complete with gasket seal.

The lighting and small power distribution boards shall be rated 230/400 V,
60 Hz. Supplies shall be taken from corresponding LV boards or safe AC
supply boards.

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Different Local distribution boards shall be provided depending on the


service:
· Panel to feed all normal lighting circuits,
· Panel to feed all emergency lighting circuits, and
· Panel to feed all AC socket outlet circuits.

The panel for normal and emergency lighting shall be equipped at least with
following components:
· Four-pole incoming circuit breaker with residual current protection,
· Two-pole outgoing circuit breakers with residual current protection,
· Four-pole outgoing circuit breakers with residual current protection,
· Three-phase + neutral busbar system,
· Earthing bar, and
· Push-button, contactors, auxiliary relays time relays, etc. as necessary.

The panel for socket outlets shall be furnished with following components:
· Four-pole incoming circuit breaker,
· Four-pole outgoing residual current circuit breakers, and
· Two-pole outgoing residual current circuit breakers.

All normal and essential lighting distribution boards require residual current
protection on the incoming supply with tripping sensitivity 300 mA.

Outgoing circuits for socket outlets require residual current protection with
tripping sensitivity 30 mA and air conditioning equipment with 100 mA.

Approved type labels shall be fitted externally on the front cover of each
distribution board giving details of the points controlled by each circuit. The
circuit list shall be typed or printed stating the location of the equipment
served, rating of the protective unit and the circuit loading. The lists shall be
mounted on the inside of the cover door and shall be protected by an acrylic
sheet slid into a frame over the circuit list, the list and cover to be easily
removable to permit circuit modifications.

Each panel shall be equipped with 20% spare feeders.

All equipment for lighting and small power system shall be suitable for
50°C ambient temperature and 100% humidity.

6.1.5.1 Circuit breakers


Molded case circuit breakers (MCCB)s, disconnectors and miniature circuit
breakers (MCB)s shall be used as appropriate. They shall be designed and

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rated in accordance with IEC 60947 and IEC 60898 as appropriate for
expected symmetrical fault rating and shall be capable of breaking rated
load current.

Interlocking shall be provided to prevent access to the interior of the unit


unless in the off position. Padlocking facilities shall be provided to enable
the device to be locked in the off position and also where applicable in the
earth or test positions.

The position of contacts shall be externally visible. Alternatively, positively


linked externally visible mechanical indication for the on, off and where
applicable, earth positions may be provided subject to details having been
submitted and approved.

Fuse switches and switch fuses may be used only with the approval of the
Engineer.

6.1.5.2 Miniature and molded case circuit breakers


All molded case circuit breakers (MCCBs) and miniature circuit breakers
(MCBs) shall be constructed to IEC 60947 and IEC 60898.

Circuit breakers shall be of the high-speed fault limiting, thermal/magnetic


type with quick-make and quick-break trip free mechanisms which prevent
the breaker being held-in against overloads of faults.

Tripping arrangements shall ensure simultaneous opening of all phases.

6.1.5.3 Residual current circuit breakers


Residual current circuit breakers shall be of the sensitivity given in the
relevant sections. They shall comply generally with the requirements of IEC
60947-2 and shall be of the four-pole type or two-pole type as appropriate.

Where RCCB's are mounted remote from distribution boards. They shall be
complete with a suitably sized all insulated robust enclosure having entries
for conduit or armoured cable glands and a lift up transparent flap for access
to controls and test facilities.

An ON/OFF operating switch and a test push-button shall be provided on


each RCCB. Terminals shall be suitable for the size and type of cable being
installed.

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Every RCCB shall be thoroughly tested by the Tenderer and its operation
proved to the satisfaction of the Engineer.

6.1.6 Socket outlets and plugs


A system of switch socket outlets shall be installed throughout all buildings
and shelters, main equipment areas to provide power for office equipment
and portable tools.

The Tenderer shall supply, install and test all power outlets, conduit,
trucking and accessories to form a complete power installation.

These outlets shall be:


· 63 A, 400 V AC 3-phase and earth socket outlets in all plant areas for
connection to portable welding equipment.
· 16 A, 230 V AV single-phase, neutral and earth socket outlets for general
use.

All sockets installed in the plant areas and workshops shall be of the
industrial type. The Tenderer shall supply matching plugs for all types. The
quantity of matching plugs shall be equal to the number of plugs +20%.

Installation and/or samples of all socket outlets and plugs which the
Tenderer propose to purchase shall be submitted to the Engineer for
approval before using any suborders.

6.1.6.1 Welding outlets


The Tenderer shall supply and install welding socket outlets complete with
matching plugs at strategic points located on a nominal 50-meter grid so that
all parts of the plant supplied can be reached using a maximum cable length
of 35 meters.

Socket outlets shall be 400 V, 63 A, 3 phases and earth. They shall


incorporate a load disconnector switch and a residual current protection
device rated at 30 mA including MCB.

The socket outlets shall be plastic or metal-clad to IP65, weatherproof and


incorporate spring-return flap cover.

The plug and socket shall be interlocked such that the unit cannot be
switched on until the matching plug is fully inserted, nor can the plug be
withdrawn with the switch closed.

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Each unit shall be provided with the following:


· facility for incoming supply cable looping, and
· provision for padlocking the switch in the off position.

6.1.7 Cables
The cables for indoor / outdoor lighting and socket systems installed
between distribution boards and final connections shall be PVC or XLPE
insulated (1, 3 and 4 cores), with separate earth conductor Copper
conductor, PVC outer sheath, 0.6/1 kV.

Fire resistant cables shall be used for emergency lighting. The cables shall
be suitably protected if laid directly in the ground.

All cables shall include a neutral conductor and an earth continuity


conductor.

The cores of all cables shall be identified in accordance with IEE


regulations.

As minimum requirement, outer sheath for all cables shall be flame


retardant type to IEC 60332 standards.

6.1.7.1 Cable terminations


Terminations shall comprise compression type glands in accordance with
the requirements of type A2 to BS 6121 or equivalent. A watertight seal
shall be provided between the outer sheath and the gland.

Only one cable shall be terminated in each gland.

6.1.8 Cable support systems

6.1.8.1 Conduit
All conduits and conduit fittings shall comply with IEC 60423 and IEC
60614.
Open conduit systems will also be acceptable for indoor installation. For
outdoor installation, closed systems shall be provided.

Special attention to be paid for selection of materials for conduits, trunking


junction boxes, panels and cable trays in view of the highly corrosive
environment due to location near to seaside.

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Prior to erection all burrs and sharp edges shall be removed from the conduit
together with any dirt, oil or paint which may be present.

Bushes for use with conduits may be rubber, PVC or brass. Corners shall be
turned by means of hand-made bends or where this is impracticable by
means of conduit boxes. Factory-made bends, tees and elbows and
inspection tees and elbows where applicable shall not be used without
approval.

Conduits, boxes and accessories comprising a circuit shall be erected, before


any wires in such circuit are drawn in.

Conduits necessarily exposed to the weather during building operation shall


be protected against ingress of moisture either by means of suitable brass
stops or other means as the Engineer may direct, and have their threads
coated with petroleum jelly. Blockages occurring in conduits shall be
cleared. Conduits shall be swabbed through before commencing wiring.

Rusting of steel conduits occurring during building construction shall be


removed with abrasive paper and the conduit repainted.

Conduits shall not be installed in contact with plumbing and mechanical


services, a minimum separation distance of 150 mm being maintained
wherever possible.

Conduits shall be so arranged that it is impossible for water from


condensation or other sources to lodge at any point. When this is not
practicable, drain holes of 3 mm diameter shall be drilled at the lowest
points in the conduit runs of boxes or at any other points required by the
Engineer.

In conduit runs containing cables of size up to and including 4 mm2 a


standard draw-in box shall be included at approximately 8 m to 10 m
intervals. For cables of size above 4 mm2 suitably sized adaptable boxes
shall be installed in lieu of draw-in boxes to facilitate easy withdrawal of
cables.

Conduit runs between draw-in boxes or adaptable boxes shall contain not
more than two right angle bends.

Where conduits terminate at distribution boards, adaptable boxes, switch


and socket outlets, etc., the connection shall be made by means of a socket
screwed on to the end of the conduit and a smooth bore brass male threaded
bush.

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Surface conduits shall be made to harmonize as far as practicable with the


architectural features of the building. They shall be run only in vertical and
horizontal directions except where it is desirable to follow the line of a
constructional feature, in which case approval shall be obtained.

In multiple runs crossing of conduits will not be permitted. Where a surface


conduit turns through a wall, a back-outlet box shall be provided.

On flush installations conduit running from ceiling or roof positions to


positions on walls shall be connected by a solid coupling 300 mm below
ceiling level.

Conduits shall be installed in wall chases and ceiling voids in such a manner
that inspection and draw boxes are accessible. Draw boxes shall not be fixed
in plastered walls unless specified.

Extension rings shall be fitted to sunk conduit boxes to which lighting


fittings or pull switches are to be attached, if the distance between the
conduit box and the finished ceiling or wall surface exceeds 10 mm.

Boxes shall be erected so as to recess approximately 2 mm below the


finished wall or ceiling surface and in order that this requirement is met the
finished thickness of all walls and ceilings shall be verified on site.

On flush installations conduits running vertically on walls shall protrude at


least 50 mm into the roof space or floor void where applicable.

Conduits shall be installed in floor screed only when it is particularly


specified, and care shall be taken to ensure that runs do not foul the position
of any door spring boxes or other services.

Before any screed is laid the conduit shall be checked for rigidity and
mechanical damage.

Cables conduits and ducts which terminate in buildings shall be sealed with
a permanently plastic weatherproof sealing compound in conjunction with
hardwood bushes to prevent the ingress of water, foreign matter and vermin.
Any spare conduits and ducts shall be similarly sealed.

Cables under roads shall be run in conduits of either PVC or vitrified clay
having a plastic sleeve to form a push fit joint. The conduit shall have a
minimum diameter of 100 mm, bends to suit the cables and extend 1 meter
on either side of the road. Conduit mechanical protection shall be provided
where necessary. appropriate number, but not < 20% of spare conduits shall
be provided at the road crossings.

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Surface conduits shall be securely fixed to the building fabric by means of


distance saddles to give not less than 6 mm clearance between the conduit
and the walls.

Steel conduits shall be supported at regular intervals not exceeding 1.2 m


and the distance from either side of any box or bend to the nearest saddle
shall not be more than 150 mm.
Saddles and distance pieces shall have the same finish as the conduit for
which they are to be used, be single-way or multi-way as required and be
fixed by means of screws in metal or other approved plugs. Wood or fiber
plugs shall not be used.
Conduit boxes to which lighting fittings are to be attached shall be fixed by
substantial screws so that the weight of lighting fittings will not be carried
by the conduit.

Conduit runs in suspended ceilings shall be fixed to the building structure


and not to the ceiling.

Where ceilings are fixed and the ceiling void is inaccessible after
completion, the outlet boxes on the ceiling shall be supported from the
structure.

Where ceilings are of the demountable tile type and capable of supporting
module light fittings, the outlet box for the light fitting shall be fixed to the
structure with a cable connection from the outlet box to the light fitting via
3-pin plug-in ceiling rose. Where the light fitting is not of the module type,
the outlet box shall be brought to the ceiling surface in the same manner as
that for a fixed ceiling.

All boxes for other apparatus such as sockets and ceiling switches shall be
supported as specified for a fixed ceiling.

Conduit buried in plaster shall be fixed by crumpets or equal and installed to


allow a minimum depth of plaster of 10 mm over its entire length.

6.1.8.2 Flexible conduit


Flexible conduit shall be used for the final connection of rigid conduit
systems to the terminal boxes of machines and to semi-portable equipment
where a limited amount of movement is required for cleaning and
maintenance purposes.

Flexible conduit shall be watertight and oil-tight flexible metal conduit


having an overall PVC sheath complying with DIN EN 50086.

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Earth continuity shall be maintained by means of a separate stranded earth


conductor of not less than 2.5 mm2 and generally equal to the live conductor
and terminating at the first box on the conduit system. The earth wire shall
be attached to the box at each end by means of a sweated or compression
socket, screw and spring washers.

6.1.9 Earthing and bonding


All equipment being supplied under this section shall be effectively bonded
to ensure electrical continuity throughout the system. A separate earth
continuity conductor shall be included with all wiring in conduits. No
reliance shall be placed on metal-to-metal joints in conduits for earth
continuity. The earth continuity conductors shall as far as possible be in one
continuous length to the furthest part of the installation from the controlling
switchboard, the earth conductor connecting all metal cases housing
electrical equipment. The branches shall be connected to the main conductor
by permanently soldered-on mechanically clamped joints.

6.2 Earthing and lightning protection

6.2.1 Earthing and bonding system


The earthing and bonding system shall comply with the following standards:

IEC 60364-4-41: Electrical Installation of Buildings – Protection for


Safety: Chapter 41: Protection Against Electric Shock
IEC 60364-5-54: Electrical Installation of Buildings – Part 5-54: Selection
and Erection of Electrical Equipment - Earthing
Arrangements, Protective Conductors and Protective
Bonding Conductors
VDE 0101: Power Installations Exceeding 1 kV – Chapter 9: in
Buildings with Information Technology Equipment
VDE 0845, Part 1: Protection of Telecommunication Systems Against
Lightning, Electrostatic Discharges and Over voltages
from Electric Power Installations; Provisions Against
Over-voltages.
IEC 61643: Low-voltage Surge Protective Devices

For earthing, protective earthing, functional earthing, potential equalization


and lightning protection-potential equalization, a common system shall be
established.

The earthing system will mainly comprise an earthing grid directly buried at
a depth of not less than 1.0 m in the ground and a set of raisers connecting

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TECHNICAL SPECIFICATION
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all electrical equipment and all metallic frames to the earthing grid forming
an equipotential bonding system.

The earthing system shall fulfill the following requirements:


· Maintain a low overall resistance of the earth mass to limit the plant
potential rise and ensure protective relay operation in the event of an
external fault.
· Provide ground connections to all electrical apparatus enclosures and
structural steelwork adequate to carry prospective ground faults without
excessive heating or fire risk.
· Limit potential differences within the plant site in the event of earth
current, originating from within or outside the station. To ensure the
safety of personnel and eliminate interference or damage to sensitive
electronic circuits.
· The contractor shall provide a potential gradient control system for all
locations where dangerous surface voltage gradients should be limited to
less than 5 kV.

The Tenderer shall be entirely responsible for the earthing system and
connections to cover the whole area and for ensuring that all apparatus is
securely and safely connected to this system. The overall resistance of the
earthing system shall be 0.5 Ohm or less.

The earthing system shall be interconnected with the earthing system of the
existing Plant.

The outdoor earthing system consists of:


· Earthing grid,
· Vertically buried rods, etc.

The earthing grid made of stranded tinned copper conductors with a cross
section required to fulfill the conditions laid out as per above
Relevant calculations based on specific ground resistance and short circuit
calculations shall be submitted for approval.
The earth electrodes buried directly in the ground shall be arranged so as to
utilize fully the available site area. The spacing between conductors forming
the mesh system shall limit the maximum mesh potential to a value not
greater than the maximum tolerable contact potential.

The facilities most likely to supply or carry high current, such as the
transformer, shall always be connected to the grid with more than one
down-lead. The location of the grounding grid shall enable all items of
equipment to be connected to the earthing system via the shortest possible
route.

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The lightning installations for all the buildings, structures, etc., shall also be
connected to the earthing system.

Within all buildings, internal earthing rings/bars of copper shall be installed.


These shall be linked by way of connection tags to the foundation earthing
and outdoor earthing system by minimum two connections. Earth bars shall
be of adequate size and suitably supported and braced to carry the rated
short-circuit current for the associated electrical circuits, for the rated short-
circuit current duration, without damage or excessive heating likely to
damage joints, associated or adjacent components.

No framework parts or other structural components shall be used as earth


bar.

All system and plant components which are to be earthed as well as


electrical components, like protection and control cubicles, sub-distribution
boards, control systems, motors and transformers, shall be connected to the
earthing rings/bars.

All steel structures within a welded section shall be connected to the main
earthing system.

At pipelines for flammable liquids or gases, earthing tags shall be provided


at each flange.

All bolted flanges shall be bridged using a flexible braided copper


conductor. Each pipe shall be connected at least once to the main earthing
system.

An earthing cable shall be included in all main cable runs.

Protective earthing and bonding of electronics cubicles, frameworks, racks


etc. shall be executed as follows:
· Earthing rings shall be installed in the I&C rooms as buses, to be
connected at several locations – at least two – to the earthing network.
· For each row of cubicles, at least two connections shall be made to the
earthing ring. Cubicles in a row shall all be connected by conductors to
each other.
· If cubicles are attached to raised platform flooring of steel structural
parts, it shall be ensured that these are electrically connected to each
other throughout the area. The raised floor shall be connected to the
earthing ring at several locations, and as a minimum at two corners of the
room.

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TECHNICAL SPECIFICATION
ELECTRICAL WORKS
Doc No.: Q A 1 0 - H - 0 4 0 9 Rev. C

6.2.1.1 Foundation earthing


All buildings, including those with a steel skeleton, shall be equipped with
foundation earthing. The foundation earthing shall be installed in addition to
reinforcement that is likewise connected together with braided conductors.

The foundation earthing shall be used in connection with the other earthing
systems like protective, operational, functional and lightning protection
earthing.

In addition to the closed ring of the foundation earthing system, a net of


mesh size around 10 x 20 m shall be embedded in the bottommost concrete
layer. The foundation earthing shall be connected to the reinforcement by a
braided conductor at intervals of about 2 m.

At intervals not exceeding 20 m, and with at least two in every room,


connection tags from the foundation earthing shall be foreseen for
connecting the internal earthing ring. Connection tags shall likewise be
foreseen for connection to the external earthing system and to the lightning
rods. Optionally, lighting rods can be connected to the external ring
earthing, with connections then made from this ring earthing to the
foundation earthing by way of the internal earthing ring at intervals not
exceeding 20 m.

6.2.1.2 Screening
The measures described in the following serve for screening and potential
control within (see VDE 0101 Annexes D, and E) and for lessening
overvoltage.
· For reinforced concrete buildings, at each corner of the building
including the bottom slab, an additional mesh of approximate mesh size
10 x 10 m, shall be provided at the topmost reinforcement. The meshes
shall be produced by welding.
· Within the reinforced concrete walls and ceilings of electrical and I&C-
rooms mesh size 5 x 5 m shall be provided. The size of the electrical
building shall be determined first. It may be the case that these rasters are
not applicable in case the building is of smaller size.
· At intervals corresponding to the mesh width, earthing wires from the
reinforcement shall be incorporated into the building pillars, rising from
the foundations to the roof, and so welded that they are continuous.
These earthing wires shall terminate at the roof parapet.
· For steel skeleton buildings, equivalent measures shall be taken.
· Framework sections shall be welded to make up a defined, electrically
conducting connection or shall be bolted together so that they are
electrically conducting.

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· Metal façades and coverings shall be preferred over non-conducting


materials and at their topmost and bottommost points shall be connected
at an adequate frequency to the lightning protection system.
· Reinforcement of cable ducts of reinforced concrete shall be connected to
parallel running earthing cables. These earthing cables shall be connected
to the screen of the building earthing system or to the foundation earthing
system.

6.2.1.3 Components requirements


Earth electrodes
Earth electrodes shall consist of a network of horizontally buried green/
yellow PVC earth conductors with vertically buried rods connected to the
horizontal conductors. The exact cross section of the main earthing grid
conductor shall be determined by calculation. in any event the cross section
shall not be smaller than 70 mm2.

Tinned stranded soft copper conductor shall be used for earth electrodes
(grid conductors).

The cross-section of earth electrodes shall be chosen by the Tenderer in


accordance with the Main technical data, with a cross section required to
fulfill the conditions as specified above.
Relevant calculations based on specific ground resistance and short circuit
calculations shall be submitted for approval
The size of tinned stranded soft copper conductors shall be uniform
throughout the area of the whole Plant as far as possible.
Earthing conductors
Bare copper bars shall be used for the ring inside the buildings on the walls
at each operational level.

Stranded soft copper conductor or copper tape shall be used for connection
of the equipment to the ring inside buildings.

Tinned stranded soft copper conductors or PVC insulated copper conductor


shall be used for all connections to earth grid.

Single connections between the equipment and the earthing system shall
carry the total fault current but the cross-section area of branch connections
may be reduced to 60 percent of corresponding single conductor to provide
for the current distribution in two or more conductors.

The earthing conductors shall be sized to carry for 1 sec the max. earth fault
current.

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TECHNICAL SPECIFICATION
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The minimum cross-sectional area of any earthing conductor shall be


16 mm2.

Earthing connections
All equipment within the station area shall be connected to the main grid
including but not limited to the following: steel structures, hoist and motors,
cranes and motors, control boards, generator frames, generators neutral
point, generator cubicles, excitation cubicles, MV switchgear, transformers
neutral point, transformer tanks, fences, cable trays and conduits, bus ducts,
overhead shield wires, AC switchboards, control panels, control desks, relay
racks, motor frames, lighting fixtures, lighting poles, housing of small
equipment, ladders, steel reinforcing bars where it is applicable or where it
is used in ground slabs for equipotential grading, etc.

All joints and welded connections shall be of cad weld type. The location of
all buried joints shall be identified on a drawing. Whenever dissimilar
materials are to be joined the necessary transition plates shall be inserted as
required to ensure that electrolytic action is avoided.

All electrical equipment shall be equipped with earthing hooks of sufficient


size and shall be earthed at the earth system by means of heavy-duty tinned
copper compression lugs.

Earth pits and rods


Earth pits shall be provided for connecting copper earthing rods with
earthing grid.

Earthing rods shall be minimum 16 mm diameter and of a length sufficient


to penetrate 3 m below the water table. Earthing rod shall be fitted with a
cable clamp. If the indicated diameter (too small) is not suitable for water
table located too deep in the ground say more than 20m, consideration shall
be given to use galvanized steel pipe with 50mm diameter pipe schedule 80.

Earth link pits shall be provided at all interconnection points with the
earthing system provided for the Plant.

6.2.2 Lightning protection


All buildings and structures shall be equipped with a lightning protection
system (LPS). Lightning protection level (LPL) 1 (one) according to IEC
62305 shall be considered for the design of the lightning protection system.

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TECHNICAL SPECIFICATION
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The building lightning protection system shall be executed according to:


· IEC 62305-1:2006
· IEC 62305-3:2006
· IEC 62305-4:2006

and alongside protection of human life, shall prevent damage not only to
buildings, but also to electrical and electronic installations.

All buildings and structures are to be protected against lightning strikes by


means of lightning collectors and conductors. The collectors are to be
arranged in such a way that, as far as possible they collect all lightning
strokes without these directly striking the parts to be protected. This
condition is considered to have been fulfilled if no point on the roof surface
is more than 5 m away from a collector.

Ridge conductors must be taken right to the end of the ridge. Moreover, roof
conductors should run as natural continuations of all main conductors.
Conductors at the gable extremities or eaves must be laid in the closest
possible proximity thereto. In the case of steel-framed structures the ridge
conductors must be connected to the roof supporting structure at least every
20 m. Lower level annexes are also to be provided with collectors.

Roof lines and other conductors are to be laid and fixed in such a way that
they can withstand the stresses expected from storms, lightning strokes, roof
work, etc.

One main conductor between the lightning collectors mounted on the top of
the building and the potential grading ring laid in the ground is to be
provided every 20 m of the before-mentioned lightning collector. The max.
spacing between conductor fixings may not exceed 1 m for horizontal runs
and 1.2 m for vertical runs.

6.2.2.1 LPS System components


The main components of the lightning protection system shall be as follows:
· Air terminations,
· Down conductors,
· Earth terminations, and
· Joints, bonds, test joints, etc.

All buildings and other high structures shall be fitted with rod-type air
terminals and shall be connected to earth rods. Down conductors shall be
bonded to adjacent metalwork and other earth conductors. All conducting
bodies having a plan area exceeding 1 m2 or a volume of 0.1 m3 shall be

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connected to a local ground rod, unless located entirely within a zone of


lightning protection from an adjacent structure. All surge diverters shall be
directly connected to earth rods. All earth rods shall be connected to the
main earth grid. The steelwork of ground slabs shall be used to form an
equipotential system bonded to the main earth grid, but the alternative of
using a separate earth mat bonded to the grid may be considered in some
areas.

The down conductor shall be designed to minimize the possibility of


flashover to adjacent metal objects. Particular care shall be taken to ensure
that the overall design is free from undue chemical and electrolytic effects.

Lightning earth rods shall be placed as near as practicable to the building


line of the protected structure.

Disconnection links shall be installed at strategic points in the lightning


protection system to all checking of the integrity of both the down conductor
and earth termination.

The Tenderer is bound to provide complete Works even if the equipment or


services to be provided are not mentioned specifically.

All necessary excavation and backfilling are included in this part of


Contract.

6.3 Cathodic protection system


Cathodic protection system shall be provided for:
· Submerged structures of screening section, and
· Underground metal structures (bottom external surface of tanks, buried
steel pipes, etc.).
The Tenderer shall furnish and install complete impressed current cathodic
protection system(s) consisting of anode arrays, cathodic protection
rectifiers, control equipment and devices necessary to maintain constant
metal-electrolyte potential and facilities as required to monitor system
performance.

Cathodic protection system shall be designed for safe and economic


performance, and ease of maintenance and testing. Materials and installation
shall be in conformance with applicable codes, regulations and standards.

The system shall be so designed that any adverse corrosive effects on the
nearby concrete and steel structures, equipment, pipes, cables etc. are
eliminated. Similar measures shall be taken to prevent stray currents and

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shielding effects from other sources. Occurrence of longline corrosion cells


shall be considered due to extreme variations in the soil resistivity.

The cathodic protection system shall provide unattended operation under all
operating conditions. It shall be capable of automatically maintaining a
constant potential at the locations monitored by its reference device or
devices under all operating conditions. It shall also be capable of restoring
and then maintaining the potential after periods of extended power outage.
System shall be self-regulating. Restoration of power after extended power
outages shall not in itself overload the system causing protective devices to
render the system inoperative. Capability of automatic restoration of
protective potentials after the power outage shall be accomplished without
reducing the effectiveness of automatic protective devices. System shall be
fully protected against conditions such as those which result from lightning
strokes, internal system short circuit, overloads or interferences from the
plant earthing system.

The rectifier output control shall protect the units from electrical faults but
shall not shut it down when system requirements exceed the rectifier output
rating. The output shall be controlled by the unit output reaching either full
rated voltage or full rated current whichever occurs first. When the system
voltage requirements exceed the nameplate voltage rating of the rectifier
unit, the rectifier output voltage shall rise to the full rated voltage level and
continue to operate at full rated voltage output until the system voltage
requirements decrease.

Manual tap adjustment shall not be required to maintain output of the


connected impressed current anode system through full rated output current
range of the potential control device.
The potential control device shall be so circuited that its measuring circuit is
sensitive only to the potential control device and shall be unaffected by I-R
drops caused by the flow of protective current through the various
components in the circuit between the anodes and the metal surface being
protected.

The rectifier units, the automatic controllers, as well as all other control and
monitoring equipment and instruments shall be housed in the control panels.
The control panels shall be provided with bug screens on all ventilation
openings.

The impressed current anode systems shall be the manufacturer's proven


design for permanent anode systems for service in seawater plants and shall
consist of platinized titanium anodes. Wire anodes shall be protected by
plastic tubes. The anodes shall be designed to provide a service life of at
least ten years.

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The reference electrodes shall be of the extremely pure zinc type and shall
be guaranteed to have a five years’ service life as a minimum.

The anode systems shall be so constructed and arranged that they will not be
damaged by water flow and/or waves.
The individual anode systems shall be designed to maintain a uniform level
of protection on all immersed metal surfaces.

Cathodic protection anodes shall be supported by the manufacturer's


standard support system.

Where pipelines are fitted with cathodic protection, motorized valves shall
be connected to the main ground grid and insulated from the pipeline with
insulated flanges. The two pipeline flanges shall be bonded across the
central insulated portion.

Cathodic protection shall not be applied to the copper earthing circuits


unless unavoidable because of the build-up of electrolytic products which
will tend to insulate buried copper from ground. If segregation of cathodic
protection and copper grounding circuits is impracticable a requirement to
re-test earthing connections after a 12-month period and install additional
electrodes as necessary shall be a mandatory requirement.

Potential measuring points shall be fixed by the Tenderer in a sufficient


number of each cathodic protection system and indicated on the drawings to
be submitted for approval.
When final adjustment of the cathodic protection system has been
completed all metal-to-electrolyte potential measurements, rectifier readings
and rectifier setting data shall be recorded and a report submitted to the
Engineer.

6.3.1.1 Cathodic protection components


The cathodic protection equipment shall include:
· Control and monitoring equipment,
· Transformer/rectifier units,
· Impressed current anodes and materials for ground bed,
· Measuring points,
· Reference electrodes (permanent),
· Junction boxes,
· Insulating joints, and
· Electrical interconnecting cables, etc.

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The cathodic protection rectifier units shall be as follows:

Input power 60 Hz, 400/230 V AC


Input protection Thermal-magnetic circuit breaker
Input transformer Fully automatic system
Output voltage rating According to the individual plant requirements
Output current rating According to the individual plant requirements
Stacks Nonaging selenium full-wave bridge
Cooling Convection or forced ventilation according to the
requirements of the equipment
Surge protection Output filter
Meters Voltmeter indicating input voltage; voltmeter indicating
rectifier output volts; ammeter indicating total rectifier
output amperes: ammeters indicating as required to
monitor rectifier output amperes to each metal-to-
electrolyte-potential control device.

6.4 Cable and cable trays

6.4.1 Cable laying and routing requirements


The Tenderer is responsible for cable routing in all plant and cable laying
has to observe a strict unit separation. The cables must be routed in different
cable trenches or trays, so that in case of fire or accident two units will not
be affected at the same time.

The following salient resources shall be used in cable reinforced concrete


trench for achieving the desired objective of minimizing fire risks:
· Water spray system
· Water drainage system
· Smoke extractor fans

Following standards, besides other, shall be observed for above


requirements:
Fire tests of Building Construction & Materials; (NFPA No.251-2006, also
BS Specification BS476: Part 20, 21, 22 and 23, (which basically addresses
test methods & performance criteria for materials used in building
construction) for power station cable; NFPA No. 80-2010 i.e. Standard for
the Installation of Fire Doors & Windows may also be referred in this
regard.

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On vertical cable risers, walls and ceilings the cables must be secured with
corrosion-resistant cable clips (e.g. cable clamps with cable protecting cable
sleeves).

Cable risers near gangways or in electrical rooms that are exposed to


possible mechanical damage are to be protected up to 1 meter from ground
by suitable metal cover.

All holes in ceilings, floors and wall made for cable routing must be sealed
fire-resistant, when the cables have been laid. This also applies to
switchgear panels and cubicles, passages between cable ducts, at vertical
risers etc. As there is an increased danger of fire during the construction
period the holes shall be fire-resistant sealed at that stage already. This
applies especially to vertical runs.

When the cables are no longer supported on cable trays or risers etc. the
power, DC and instrument transformer cables must generally be run singly
in high-strength plastic conduit, at ambient temperatures above 60°C in
galvanized steel conduit. With lighting cables, measuring and control cables,
several similar cables can be run in one conduit. Surface-mounted conduits
must be secured every 1.5 m.

The laying of cables outside of buildings should be preferably in reinforced


concrete trenches with heavy duty fiber glass covers. The installation of
cable directly buried is not acceptable.
Cable raceways might be considered in some locations, in that cases heavy
duty fiberglass cable tray will be considered for indoor locations while hot-
dip galvanized steel trays must be considered for outdoor locations

Inside the trench a layer of sand must be introduced. On the sand the cables
are laid separately from each other according to voltage systems. The cables
must be laid at a depth of 0.8 m at least. The trench shall be filled with sand
and covered with heavy duty lockable fiber glass covers. The thermal
resistance of the backfilling shall not exceed 150 Kcm/W. A ground
temperature of 40°C has to be considered. Where cables have to pass under
streets cable duct banks should be provided. The marking of cable routes by
cable warning tapes must be provided.

When laying the cables on cable trays, cable risers, cable channels, etc. care
must be taken to assure sufficient ventilation to avoid thermal overheating
or strain on the cables.

All the ends of the cables must be prepared according to the particular
requirements of the manufacturers and connected to existing terminal strips,
terminal screws, apparatus terminals, etc.

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Cables supplying power to redundant consumers shall be laid on different


cable trenches/trays.

6.4.2 General cable construction requirements


The medium and low voltage cables shall be plastic-insulated copper cables.
For cables that are exposed to ambient temperatures above 60°C Teflon or
silicone cables shall be provided.

The cables must be suitable to be laid indoors, in direct or indirect sunlight,


in ducts, on trays or underground. The cables must be resistant to solar
radiation, the effect of oil, seawater, bacterial action, insects and rodents.
Outer sheaths are to be manufactured from non- combustible or flame-
retardant material.

All cables must be provided labeled, at both ends, according to plant coding
system which shall be clearly visible, captive and unrottable. The individual
cores shall be numbered or identified by color-coding.
The cables must be laid to ensure that they can be replaced or renewed in a
simple manner.

6.4.2.1 Fire-resistant cables


Fire-resistant cables shall be provided for the feeders:
· Of auxiliaries required for safe shut down of unit including motors for
lubricating oil pump, turning gear, jacking oil pump, air pre-heater, fuel
line control valve and any other critical equipment for safe shut down not
mentioned herewith.
· For control of unit circuit breaker and turbine lockout.
· Between emergency diesel generator and associated switchgear.
· Fire-detecting and fire-fighting systems.

The cables for (a) to (c) purposes shall have fire resistance capability
according to BS- 6387 Categories B or IEC 60331. The cables for (d)
purpose shall be Mineral Insulated Copper Cased (MICC) and it shall be
overall sheathed with low smoke and preferably zero halogen material or
any other type of cable with equivalent or better capabilities than MICC.

The feeders for above indicated purposes shall be routed with particular
care. The Contractor shall obtain approval from Engineer for the type of
cables and their routing etc.

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6.4.3 Medium voltage (MV) power cables


The MV cables shall be screened, stranded copper conductors, single-core
or three-core cables with XLPE insulation. The cable shall be sealed with a
red, non-fading HDPE outer sheath. Three-core cables shall be provided
with individually screened cores.

The MV power cables must be designed for the thermal and short-circuit
characteristics of the electrical systems, taking into consideration the fault
clearing time of the associated protection relay and an additional safety
margin of 0,25 sec.

The cables must be terminated and connected to the indoor metal-clad


switchgear or the sealing ends are installed in cable connection hoods
mounted on the power transformers.

In the event of outage of the air-conditioning in the electrical buildings the


internal and external conditions will become the same. Therefore, terminals
kits to be used shall be suitable for the worst site conditions (outdoors).

6.4.4 Low voltage (LV) power cables


The low voltage power cables shall be standard single and multi-core cables
with copper conductor and XLPE insulation.

All low voltage power cables shall be provided with an additional earthing
conductor.

The minimum conductor cross-section for power cables shall be 2.5 mm2.If
3 1/2-core cables are used, minimal cross section for protective neutral must
have 16 mm2.

Depending on the site conditions the DC cables must be single-core, 2-core


or 4-core. Between batteries or rectifiers and the DC switchgear single-core
power cables should in general be used.

The LV power cables must be designed to withstand the dynamic and


thermal characteristics of the electrical system and to assure continuous
operation.

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6.4.4.1 Over sheath


The cable over sheath shall be made of PVC, black color, oil-resistant and
flame retardant. The outer sheath shall indicate the manufacturer's name, the
voltage levels Uo/U in kV and the cable type.

6.4.5 Current carrying capacity and voltage drop of power cables


The ratings for continuous loading of the cables shall be calculated
according to the relevant IEC regulations. The Contractor must submit
corresponding calculations for all cables to be used.

The voltage drop on various feeders shall not exceed the following specified
percentage limits as referred to nominal voltages:
· Main feeder cables to switchboards at rated current 1%
· At consumer terminals at rated current. 5%
· At motor terminals during DOL starting 5%
· Supply cables for lighting and fail-safe equipment 2%

6.4.6 Measuring and control cables above 60 V/ instrument transformer


cables
For voltages above 60 V the cables must have PVC insulation and a mini-
mum conductor cross-section of 1.5 mm2.

If they lead to outlying buildings, cables with a common core screen and
protection against induction must generally be used.

For instrument transformer cables the minimum conductor cross-section


must be 2.5 mm2.

The maximum voltage drop shall not exceed 2%.

6.4.7 Measuring and control cables below 60 V


For voltages up to 60 V, measuring and control cables shall have stranded or
solid copper conductors of minimum 0.8 mm diameter. Multi-pair control
cables with paired lay-up of the leads and lay-up of the pairs themselves
shall be used.

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Wherever necessary, e.g. for all cables leading outside the relay rooms
and/or control rooms, the control cables shall have a common screen (Al-
foil or Cu-foil).

Cables must generally have appropriate electrical protection against


inductive/resistive influences and lightning.

The required compensating wires for temperature measurements must be at


least 1.5 mm2.

The maximum voltage drop shall not exceed 2%.

The individual cores of the multi-pair control cables shall be identified by


numbers or a colour coding system.

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6.4.8 Cable supporting structures

6.4.8.1 Construction requirements


Basically, prefabricated cable trays, cable risers, hanger rods, screws,
clamps and fixing shall be used. If in certain sections the use of trays and
risers is not possible, cable racks are to be provided in such places.

All cable tray T-junctions, crossovers, vertical and other shelving, bends,
etc. must consist in prefabricated tray elements.

The cables laid on the trays must be carefully arranged and ordered. All
cable tray routings consisting of several individual cable trays that are
located outside buildings and exposed to the sunlight shall be provided with
sunshades made of the material as described for the cable tray equipment.

The trays and risers must be installed in such a way that in accessible
manways an escape route at least 800 mm wide by 1950 mm high is
available for the personnel.

For safety reasons the lower parts of the hanger rods and all other exposed
parts in manways and escape routes must be fitted with plastic covers.

In indoor installations with aggressive environment heavy duty reinforced


fiberglass trays and supports shall be used.

In all external areas or not completely closed buildings and in areas with
corrosive gas or steam, the hot dip galvanized steel used material shall be
provided with an additional coating according to DIN ISO 12944.

The cable trays must be designed to ensure that there is 15% spare space on
all trays when commissioning and handing-over is complete.

The fixing materials for the cable trays and risers must be corrosion-
resistant or at least be hot-dip galvanized. The rods, brackets and risers must
be fitted with appropriate support brackets to be fixed to anchor rails or
fixed by dowels and screws in walls and ceilings.

Welding to steel structures and the welding together of hot-dip galvanized


cable-laying accessories is not permitted.

After completion of the cable-laying work the maximum deflection of the


cable trays shall not exceed 2.5 mm per 1.5 m (specified distance between
two hanger rods).

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7. Requirements for local cubicles and local housings


for e.g. switchgear, control, measurement and
signaling equipment
Steel-clad cubicles and enclosures with fixed, integral switchgear and
apparatus at least of the PTTA type must be provided.

The switchgear cubicles must be partitioned off and incorporate a busbar


system, the necessary instruments, control switches, switch panels of the
individual switch and apparatus chambers. The main busbars are to be
installed on the rear face, top side of the switchgear cubicle in a lockable
shuttered compartment.

Connections to switching devices, MCB's fuses etc. are to be made from


these busbars. The lower part of the cubicle will house the terminal strips
and connecting blocks, the clamps for the cable terminals and, if required
parallel connection copper straps for the connection of more than 2 cables in
parallel. An adequate number of ball studs must be provided within the
switchgear cubicle suitable for earthing the main and distribution busbars as
well as the switchgear itself by means of portable earthing and short-
circuiting equipment (to be provided once per switchgear panel row).

The space in the interior of the cubicles must be divided into a section with
'live' parts, 'live' switching elements etc. and a section with control and
measuring equipment. The sections are to be separated by reinforced sheet-
steel.

Care must be taken that in the event of arcing hot gases will not escape to
the front of the cubicles (the operational side).

Ammeters are to be provided on the cubicle front panel for the cubicle
feeders and the supply outlets for motors higher than 55 kW or motors of
lower rating, but particularly important for the process. A single voltmeter
with 4-position voltmeter changeover switch must be provided for measure-
ment of busbar voltage between each phase and neutral. Measuring
instruments should, in general, be square in shape.

Special precautions shall be taken in the design of electronic devices for


protection and control systems housed in the cubicle in order to allow for
the specified ambient conditions.

Heating elements are to be provided generally in each local cubicle or


cabinet and shall be humidity controlled.

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It must be possible to disconnect power supplies to the cabinets by means of


manually operated power circuit-breakers (MCB's).

For easy monitoring and a rapid grasp of the operational state, colored
mimic diagrams with the required switch position indicators, apparatus
symbols and pilot lamps must be provided in every case on main process
cubicles and switchgear cubicles. Lamp test facilities for all indicating
lamps connected shall be provided. All indicating lamps shall be of LED
type.

All cubicles shall be provided with the required earthing screws.

Plastic-insulated, stranded conductors must be used for wiring within the


switchgear cabinets, which must be numbered at each end with special tabs
so that change by mistake is impossible.

Preferably plug-in type auxiliary relays are to be used. Apparatus being


sensitive to impact must be protected against shock and vibration.

On completion of hand-over the cubicles must contain at least 15% of fully


fitted spare terminal capacity and 15% of spare space for the future
installation of extra equipment. It shall be possible to replace indicating
lamps on the front panels of cubicle feeders and motor-supply outlets
without isolating the equipment concerned. Further-more the control system
must be designed in such a way that lamps operate at less than their rated
voltage in order to avoid their being overheated.

Incoming and outgoing cables have to be fixed by suitable metallic cable


glands.

All local control/switchgear panels and “black boxes” shall be provided


with duplicate Power supplies for control and alarm signaling purposes.
Such duplicate supplies shall be derived from separate power sources as far
as practical. Suitable arrangements for the changeover of supplies shall be
provided. The changeover arrangements shall be such that failure of one
supply shall not cause a loss or reduction in output. Where failure of one
supply could cause a loss or reduction in output than the changeover
arrangement shall be automatic (diode decoupling, changeover contactors,
etc.) and alarm shall be provided to indicate when loss of supply/changeover
has taken place. Where failure of one supply does not result in loss or
reduction in output, changeover may be by means of changeover switches or
links. Alarms shall be provided to indicate loss of supplies.

All cubicles, desks and panels shall be painted externally and internally with
a high gloss paint to an agreed color.

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The internals of all cubicles, desks and panels shall be painted matte white.
For the cubicle from hot deed galvanized material without paint will be
accepted if manufacturer standard construction.

All panels shall be mounted on an approved form of anti-vibration mounting


whenever necessary and where they are mounted on computer type flooring
suitable support frames from sub-floor level shall be provided.

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8. Low Voltage Switchgears

8.1 General
This specification covers the required 0.4 kV low voltage AC switchgears.

The LV system for symmetrically as well as unsymmetrical connected


power consumers shall generally be of the TN-S type, i.e. a five-wire
system. The separation of N and PE shall be carried out. Because of the
clear demarcation between the neutral conductor N, carrying operational
current, and the protective earthing conductor PE, which - under non-fault
conditions - carries no current, NO connection between either N and PEN or
N and PE is permissible beyond the point of separation of the PEN
conductor into PE and N.

The switchgears shall be designed to accommodate a five-busbar system


(L1-L2-L3-N-PE).

8.2 Construction Requirements

8.2.1 General
The 0.4 kV switchgear shall be designed as indoor switchgear installation of
sheet-steel-clad, compartmentalized type, with withdrawable breakers.

The switchgear shall comply, if not stated otherwise elsewhere to IEC


60439 and IEC 60947. The switchgear shall be a type-tested assembly
(TTA) according to IEC 60439-1, Form 4.

All low voltage switchgears will be fed by 2 x 100% transformers and shall
be split into two busbars. One automatic changeover system (Automatic
transfer system) shall be provided for coupling between the two busbars.

Each switchgear cubicle shall be divided into fully segregate compartments,


comprising a busbar compartment, a cabling compartment and a
compartment containing all switching and protective units.

The compartment for the switching devices shall be divided into fully
segregated compartments for each circuit breaker, contactor starter or fuse
switch.

All components shall be accessibly mounted in the switchboard and shall


not impede access to wiring or terminals.

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All equipment shall be constructed of non-hygroscopic and non-flammable


material.

The incoming feeders, coupling breakers, motor protection breakers and


outgoing feeders with rated current over or equal 800A shall be provided
with 230 VAC motor-driven air circuit breakers (ACB).

All remaining outgoing feeders with rated power below 800A might be
provided with molded case circuit breakers (MCCBs).

In general, for all incoming and outgoing feeders requiring more than two
parallel cables per phase the Tenderer shall install parallel connection bars
of copper. The copper busbars shall be equipped with an adequate number
of earthing studs.

The Tenderer must ensure that, after handing-over of the plant, a minimum
of 10% of fully equipped reserve spare feeders and 10% spare terminals are
available in each cubicle. Switchgears shall be able to be extended on both
sides of the board.

The switchgear rooms must be air-conditioned, with ambient temperature of


26±2°C.

In the event of failure of the air-conditioning system, any condensation must


be prevented by means of suitable heating systems arranged in the
switchgear and controlled by humidity control device. A single 230/400 V
AC electrical power supply for the heating systems shall be provided for
each switchgear. The power supply lines from heater to heater in each
switchgear board shall be provided by the Tenderer.

8.2.1.1 Installation
All switchgear cubicles must be installed on frames specially provided for
that purpose. The frames must be provided by the Tenderer. The
switchboards shall be designed so, that they can be erected in the room
freely. It is envisaged that, in general, the switchgear shall be erected in
single rows (not back to back).

The switchgear building will be provided with a cable basement. The


necessary devices and fixtures for the cable connection shall be provided
in the appropriate feeders.

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8.2.1.2 Bulkheading
The individual switchgear cubicles shall be isolated from one another by
sheet-metal bulkhead or equivalent material.

Inside the switchgear cubicles the following compartments shall be isolated


from one another by bulkheads:
· Functional unit from cable connection compartment,
· Functional unit to functional unit,
· Busbar compartment from functional unit compartment, and
· Cable connection compartment from busbar compartment.

Segregation between compartments shall be made by means of earthed sheet


steel barriers or approved synthetic material to prevent faults in one
compartment from spreading to an adjacent compartment.

In case of bus section switchgear cubicles, Section A busbars shall be


segregated from Section B busbars and from the circuit breaker
compartment.

Care must be taken that in the event of arcing no hot gases escape to the
front of the cubicle (the operational side).
The bottom shall be covered with removable galvanized sheet steel,
provided with holes for cable entry. The cable entries shall be sealed after
cable laying. Furthermore, each cover sheet shall be equipped with a
grounding connection to the steel frame of cabinet.

8.2.2 Switchgear components


The switchgear installations must comprise at least:
· Steel-clad switchgear cubicles, bulk-headed design, the various
components are separated from one another, shutters made of insulation
material shall be fireproof.
· Different zones of individual boards shall be fully insulated from each
other.
· Insulated bus bars system preferably by PVC sleeve or equivalent,
subject to Employer/engineer approval.
· Busbar earthing studs including earthing fittings.
· Cable paralleling arrangements with auxiliary busbar systems,
connecting bars for all in-feeds and outgoing feeds which require more
than two parallel cables.
· Fireproof enclosures to the base of the switchgear panels for sealing the
outgoing power cables.
· Heating systems within the switchgear panels.

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· Padlocking arrangement as required by local safety requirements

The switchgear cubicles shall be fitted with the following main items of
equipment:
· Withdrawable units with for circuit breakers.
· plug-in units with motor contactors, hand-operated molded case circuit
breakers including all necessary monitoring, measuring and control
equipment.
· the busbar compartment with busbars safeguarded against accidental
contact.
· the necessary current transformers either fixed in the infeed panels or
mounted on the plug-in unit.
· the relay recess with the protection and monitoring relays, the complete
terminal strips, etc. in the infeed panel.
· in the bulk-headed cable connection compartment the necessary cable
connecting fittings safe against accidental contact.

8.2.2.1 Functional units


The switchgear shall be supplied with functional units which shall be
equipped essentially with the following units:
· Withdrawable circuit breaker for incomers, bus couplers, interconnectors,
and motors protection breakers. The switch position indicators, signal
and actuating equipment, mimic diagram, ammeters and voltmeters with
four-way selector and designation plate shall be arranged on the front
panel. For switch boards with non-transparent doors the equipment
specified above shall be accommodated on the front door of the infeed
panel.
· Plug-in units for motors (except circuit breaker), including contactor,
auxiliary relays, interface with the DCS, plug- and-socket control
connections, protection relay, 230 V AC control voltage mini circuit
breaker, etc. The position indications, signals, and the designation plate
shall be accommodated on the front panels of the plug-in units.
· Withdrawable units for outgoing feeders with hand or motor (230 VAC)
operated circuit breaker (MCCB). The hand operated drive for the circuit
breaker shall be arranged on the front panels

Withdrawal or engagement of units must only be possible with the power


circuit open. This requirement shall be through inbuilt guide rails screw type
mechanism. Necessary operating handles shall be provided for this purpose.

Each unit shall be equipped with a defined operating, test and inspection
position. In the test position the power contacts must be separated, so that

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safe testing of the remote and local control system is ensured. In the
inspection position the control circuits must also be interrupted.

Each motor plug-in unit is to be provided with a main switch to prevent


uncontrolled closure of contactors, and hence short circuits, in the event of
contactors sticking or vibration being caused when the units are being
plugged in.

Transducer and coupling relays required for remote measurement and


control are to be supplied, mounted and wired by the Tenderer.

Service hour metering of motor feeders shall be performed via the DCS.

8.2.2.2 Current transformers


The thermal withstand capability of the instrument transformers shall be
based on a disconnection time of 0.9 sec. in the outgoing feeders to
consumers and 1.2 sec. in the infeeds. In each case the current transformers
must be mounted on the plug-in unit. In the case of the infeeds of the main
distributions the current transformers can also be arranged in the fixed part
of the cubicle.

Accuracy for protection:


· Over current class 5 P 10
· Tariff metering class 0,2 S
· REF class 5 P 20 or PX
· Differential class PX

Cast-resin insulated, corona-free transformers shall be used. The current


transformers must withstand the dynamic and thermal short circuit stresses.

Separate cores for protection and measurement shall be provided.

8.2.2.3 Protection relay design


All protection relays shall be of the state of art technique totally digital,
programmable with displays of operating and set point values along with
self-test facility etc.
The relays shall be arranged for panel door installation. Indicating devices
shall be provided which enable it to be seen when a relay has operated
without the need to open the door.

Each switchboard shall be provided with:

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· Trip supply fail relay and one indicator lamp on front panel colored
white.
· Under voltage relay.

Each circuit breaker shall be equipped with a three-phase, overcurrent time


relay with continuously variable short circuit trip.

Following protection relays shall be used for auxiliary transformers:

· Restricted earth fault protection,


· Instantaneous neutral earth fault protection,
· Overcurrent (IDMTL) protection according to the requirements of the
relay grading, and
· Pressure relief/Buchholz protection, oil and winding temperature
monitoring as specified.

The power circuits for the protection relays are to be supplied from the safe
230 VAC system described elsewhere in this specification. All protection
relays have to be selective. The Tenderer may offer additional protection
devices if he sees them necessary. The same degree of accuracy of the
protection relays must be guaranteed for room ambient temperature up to
50°C.

8.2.2.4 Mimic diagram and local indications


In the front of the switchgear cubicle of each main distribution infeed a
mimic diagram shall be provided, with the necessary indications.

Control and monitoring of the low voltage switchgear is to be provided also


on the Central Control Room through the DCS.

8.2.2.5 Local indications


Each functional unit shall be equipped with individual signal lamps or
position indicators which show the following switching conditions locally:
· Switch unit ON.
· Switch unit OFF.
· Unit not available (not engaged/test).
· Unit OFF - due to fault.

The following signals shall be additionally provided in the incoming panels


of the main switchgear:
· Control voltage 230 VAC (main ring).

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· Lamp test facility - for the LV switchgear equipped with LED’s omission
of the lamp test facilities will be accepted.
· Trip circuit fault (for circuit breakers with trip coil).
· Voltmeters to read the individual infeed voltage of control supply.

All circuit breakers shall be provided with switching operation counters.


The counters shall be installed in the relevant cubicle compartment.

Necessary key operated selector switches to select test/operate and


local/remote mode shall be provided.

8.2.2.6 Circuit breakers control voltage


Control voltage for circuit breakers shall be 230 VAC from safe supply
board. The switches must be capable of satisfactory operation in the range
of 110 to 70% of nominal voltage.

It must be possible for each circuit breaker to be operated locally by means


of push-buttons CLOSE and OPEN which are covered in normal operation.
If the control voltage fails, EMERGENCY- OPEN actuation of the switches
must be possible. It must also be possible to operate the switches locally in
the test position.

For all switchgear two out of three breakers (2 No: Incomer and 1 No:
coupling) logic shall prevail in addition to the provision of automatic
transfer of load from one transformer to the other transformer without
affecting the running loads.

In each circuit breaker control voltage shall be protected by miniature circuit


breakers; tripping of the MCBs shall be indicated locally and with a
common remote alarm in the DCS.

In each case an additional potential-free miniature circuit breaker contact is


to be wired to the Central Control Room as a group signal. Miniature circuit
breakers shall be provided for:
· Local controls and interlocks,
· Local signals and fault indications, and
· Local power supply to motor-driven stored energy mechanism.

The circuit breakers of the switchgear installations shall be remotely


controlled from the Central Control Room. Therefore, interfaces with the
DCS are to be provided.

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In the test position it must be possible to operate the circuit breakers from
the Central Control Room through the DCS.

An undervoltage monitoring device for monitoring the busbar voltage shall


be provided in each distribution and each half-bar of the main switchgear.
The response value of the monitoring devices must be adjustable from 50 -
100% voltage, the delay time shall be adjustable from 0.5 to 15 seconds.

8.2.2.7 Motors Control Voltage


Control voltage for motor units shall be 230 VAC. Each motor control
circuit shall be protected by a mini circuit breaker, auxiliary change-over
contacts of these shall be wired for trip fault indication on the switchgear
and in the Central Control Room. The motor units are to be remotely
controlled from the Central Control Room through the DCS. Therefore,
interface devices are to be supplied, installed and wired by the Tenderer.

In test position it must also be possible to operate the unit from local
(switchgear). Necessary key operated selector switches local/CCR (Central
Control Room), test/operate shall be provided for this purpose.

The protective relays for the motor protection should have necessarily
following features:
· Short circuit protection (instantaneous),
· Locked rotor protection,
· Unbalance protection,
· Thermal replica/overload protection,
· Earth fault protection (it should be duly stabilized to avoid mal- operation
during starting condition,
· A feature with running load indicator shall be preferred, and
· Anti-stall protection for motors > 100 kW.

8.2.2.8 Local auxiliary relays and measuring instruments


For auxiliary relays fix mounted or plug-in type relays are applicable.
Measuring instruments and relays which are sensitive to shocks must be
protected against vibration.
For measuring instruments only square flush-mounting types class 1.5 shall
be used.

In the case of ammeters for motor outgoings the rated current of the
consumer shall be marked in red.

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As a minimum requirement the following local measurements shall be


provided:
· Triple current indication of all main incoming and outgoing feeders
· Single current indication on the units with outgoing feeders of 250 A
· Single current indication on the units for motors equal or greater than 55
kW
· Voltage indication with suitable 4-way voltmeter selector for
measurement of phase L1 - N, phase L2 - N, phase L3 - N, phase L1 - L3
in all infeed’s of the switchgear installations.

8.2.2.9 Remote indications and measurements


For remote indications in the Central Control Room the following
signalization shall be provided:

For each remote-controlled unit:


· Unit not available (in test position or withdrawn),
· Switch unit ON (for each direction of rotation and for each step of pole-
changeable motors),
· Switch unit OFF,
· Plug-in unit faulty, and
· Position of the local/remote selector switch.

For each main distribution half bar and each sub-distribution:


· No control voltage (as group signal),
· Protection activated (as group signal), and
· No busbar voltage.

For remote measurements the Tenderer has to provide current and voltage
transducers with an output signal 4 - 20 mA.

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8.2.2.10 Connection terminals


For motors with the following ratings, suitable connection terminals are to
be provided:
· Terminals at the contactor tee-offs for motors up to
· 5.5 kW must be suitable for cable cross-sections of 4 mm²
· Ditto, for motors of 7.5 - 11.0 kW = 10 mm²
· Ditto, for motors of 15.0 - 22.0 kW = 25 mm²
· Ditto, for motors up to 30.0 kW = 35 mm²
· Ditto, for motors of 37.0 - 90.0 kW = 185 mm²
· Ditto, for motors up to 160.0 kW = 2 x 185 mm²
· Ditto, for motors up to 200.0 kW = 2 x 240 mm².

The given sizes however to be confirmed by Tenderer calculations taking


into account the derating factors.

8.2.2.11 Reserve cubicles


At least 10% of the allocated cabinet units are to be provided as reserve
cubicles for each main switchgear and distribution.

The empty reserve cubicles shall be so fitted out as to permit the installation
of units at a later date safely, and without shut-down or long periods of shut-
down.

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9. Electrical Motors

9.1 Scope
This document covers the requirements for the design, manufacturing,
construction, installation, test and commissioning of electrical motors
for medium and low voltage for the Project.

9.2 Codes and standards


The design, manufacturing, construction, installation, test and
commissioning of electrical motors shall be in accordance with the
following codes and standards, at least. The latest revision of the
publication referred to shall apply.

IEC 60034 Rotating electrical machines IEC 60038


IEC 60072 Dimensions and output series for rotating electrical machines
IEC 60085 Electrical insulation - thermal evaluation and designation
IEC 60529 Degrees of protection provided by enclosures (IP Code)
ISO 15 Rolling bearings - Radial bearings - Boundary dimensions,
general plan
ISO 281 Rolling bearings - Dynamic load ratings and rating life

As far as the power supply authority (SWCC/SEC) and permits of


other authorities require additional codes and standards, respectively
impose additional requirements, these are also part of the contract.

9.3 Environmental Conditions


The electrical motors shall be designed and constructed for continuous
operation at full load under the climatic and environmental conditions
as described elsewhere in this specification.

9.4 General requirements

9.4.1 Selection of motors


In general, it shall be the responsibility of the driven equipment
manufacturer to select and coordinate the required motor type. This
includes the co-ordination of the performance data (motor speed, shaft
power and direction of rotation) as also the mechanical construction and
coupling requirements.

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The motors shall be designed as squirrel cage motor and shall be of


industrial type.
The electric motor must be manufactured to achieve the highest PF that can
be manufactured according to the approval of the engineer

If not specified otherwise the actual power output of the motors must be
selected to meet the required shaft power of the driven equipment at
its duty point, multiplied by a factor of 1.2 for motors up to 250 kW
and 1.15 for motors above 250 kW and using the next larger standard
motor size.
Motors shall be entirely suitable for outdoor installation without any
additional protection.

Lifting lugs, horizontal alignment screws and drain hole for


condensation shall be provided on all motors.

The motors shall be suitable to deliver rated power continuously at


· ±10% nominal voltage and rated frequency,
· Nominal voltage and ±5% of rated frequency,
· ±10% combined variation of nominal voltage and frequency, with
frequency variation ≤±5%.

The type of MV motors (fixed or variable speed) has to be specified.


In case variable speed motors are selected, speed control mode of
operation needs to be detailed.

The LV motors shall be premium energy efficient (IE3).

9.4.2 Components and equipment


The Contractor has to take care, that all components and equipment are
selected considering easy maintenance, simple and quick diagnosis and
long maintenance intervals.

All components and equipment shall be designed for continuous duty at


rated load and under the given climatic conditions. Standard industrial
high-performance systems and components of supplier’s standard lists
shall be used as far as possible. Components and equipment of same
kind and type shall be selected for equivalent functions. The
interchangeability must be guaranteed.

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9.4.3 Duty
The motors shall be designed for continuous running duty, S1
according to IEC, at the specified conditions.

Motors connected to electric / electronic speed control or start-up


equipment such as frequency converters or start-up transformers have to
be selected / matched to the special requirement of such duty.

9.4.4 Dimensions
All motors of the same size shall be interchangeable. The motor
dimensions shall be in accordance with IEC 60072.

9.4.5 Noise requirements


The sound pressure level of electrical motors shall not exceed 85 dB
(A)@ 1 m under no load conditions.

9.4.6 Vibration
Vibration Grade
The motors shall be designed to fulfil the requirements of vibration
grade A according to IEC 60034-14, Tables 1 and 2.

Monitoring
Motors with ball or roller type bearings shall be provided with suitable
adaptors for shock plus measurements of bearing conditions while the
motor is in operation.

For motors with sleeve type bearings provisions for installation of


vibration probes shall be mounted.

9.4.7 Units and scales


The metric system on basis of SI-units shall be used for all scales and
indications.

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9.5 Low Voltage Motors

9.5.1 Motor start and torque requirements


The motors shall be designed for direct on-line starting at full load. For
motors of 132 kW shaft power and above, the starting current should
not exceed 5.5 times the rated current.

The motors shall not break out if during normal operation the voltage at
the motor terminals remains greater than 0.8 U N, but the operation at 0.8
UN shall be limited to 10 seconds.

The motors shall be designed to allow 4 starts successively from


cold (max. ambient temperature) or 3 starts successively from hot
service temperature without tripping of any protection device.

9.5.2 Insulation / winding protection


The motors shall have tropicalized insulation. The motors shall be
designed for class F insulation, thermal utilization of the motors shall be
for class B only.

The stator winding shall be insulated by high quality modern


synthetic resin insulation system based on mica-glass tape. After
insertion of the coils into the stator core the whole winding shall be
vacuum impregnated with epoxy resin, free from any solvent.

The motors shall be designed for re-acceleration against 100%


residual field at phase opposition.

Motors of a rated power of 90 kW and above shall be equipped


with winding protection by means of embedded positive temperature
coefficient thermistors. Two thermistors per phase (one set service –
one set spare) shall be provided and wired to the auxiliary terminal box.

9.5.3 Method of cooling


Motors shall be totally enclosed, and fan cooled by ambient air,
equivalent to cooling code IC0141 or IC0151 according to IEC 60034
part 6.

Self-cooled sleeve bearings are acceptable, too. Sleeve bearings shall


be equipped with an oil ring lubrication, the bearing housings shall have
an oil level indication.

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External lube oil systems for LV motors will not be accepted.

9.5.4 Terminal boxes


Terminal boxes shall be provided and fitted with terminals and cable
glands for the connection of the actual number and type of cables.
Dimension of cable glands as per requirement.

If required, auxiliary terminal boxes with terminals and cable glands


for instrumentation and anti-condensation heater connection shall be
foreseen.

All terminal boxes shall be IP55 enclosure type.

9.5.5 Anti-condensation heater


Motors with 90 kW rated power and above shall be equipped in
general with electrical anti condensation heaters, to be switched on if the
motor circuit breaker is off.

The voltage level for the anti-condensation heater shall be 1 x 230 V AC,
60 Hz.

9.6 Painting
The painting shall be as per the approved manufacturer standard at
least consisting of:
· One coat of two-component epoxy zinc chromate rust-inhibiting
primer,
· One intermediate coat of two-component epoxy primer, and
· Two top coatings for two-component resin, color as per the
approved color code schedule.

Total thickness of dry protective paint coating shall be at least 120 µm.
All paint coatings shall be resistant against temperature conditions up
to 140 °C and intermittently up to 180 °C.

Damages, caused by transport, installation, cabling or commissioning


shall be repaired in a way, that the original quality is restored.

An additional painting at location of installation is not allowed.

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9.7 Installation
Installation and alignment shall be carried out in accordance with the
instructions and recommendations of the manufacturer and with due
regard to the requirements of the driven machine.

9.8 Spare parts


The Contractor shall deliver all spare parts, which are necessary for
commissioning and two years operation time (see “General Description
of Project and Works”).

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10. Variable Speed Drives

10.1 Scope
This specification covers the requirements for design, manufacturing,
construction, installation, test and commissioning of the variable speed
drives and soft starters accordingly for the Project.

10.2 Code and Standards


The design, manufacturing, construction, installation, test and
commissioning of Variable speed drives shall be in accordance with the
following codes and standards, at least. The latest revision of the
publication referred to shall apply.

IEC 60034 Rotating electrical machines


IEC 60038 IEC standard voltages
IEC 60044 Instrument transformers
IEC 60071 Insulation co-ordination
IEC 60072 Dimensions and output series for
rotating electrical machines
IEC 60076 Power transformers
IEC 60085 Electrical insulation - thermal evaluation
and designation
IEC 60255 Electrical relays
IEC 60265 High-voltage switches
IEC 60270 High-voltage test techniques – partial
discharge measurements
IEC 60871 Shunt Capacitor for AC Power
Systems
IEC 60146 Semiconductor converters
IEC 60529 Degrees of protection provided by
enclosures (IP Code)
IEC 60664 Insulation co-ordination for equipment
within low voltage systems
IEC 61000 Electromagnetic compatibility
IEC 61800 Adjustable speed electrical
power drive systems
IEC 62271 High voltage switchgear and control gear

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10.3 Environmental Conditions


The variable speed drives shall be designed and constructed for
continuous operation at full load under the climatic and environmental
conditions described elsewhere in this specification.

VFD shall preferably be located in electrical rooms with controlled


atmosphere.

10.3.1 Outdoor and overall site conditions


All equipment and materials provided for outdoor installation shall
be resistant also against sand, sandstorms, strong sun radiation and
salty air (in shoreline areas). In general, all outdoor equipment shall
have suitable rain and sun protection cover or shed.
Design temperature (maximum metal temperature in the sun) for all field
mounted instruments shall be +85°C.

10.4 General Requirements

10.4.1 Components and equipment


All components and equipment shall be selected considering easy
maintenance, simple and quick diagnosis and long maintenance
intervals.

All components and equipment shall be designed for continuous


duty at rated load and under the given climatic conditions. Standard
industrial high-performance systems and components of manufacturer
standard lists shall be used as far as possible.
Components and equipment of same kind and type shall be selected for
equivalent functions. The interchangeability must be guaranteed.

10.4.2 Harmonics
The speed regulation systems shall meet the international requirements
for voltage and current harmonic distortion according to IEEE 519-
2014 (limited to 5% of THD with each individual harmonic limited to
3%) and The Saudi Arabian Grid Code.

If requirements for harmonic distortion as stated above cannot be met


active harmonic filters shall be provided.

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10.4.3 Units and scales


The metric system on basis of SI-units shall be used for all scales and
indications.

10.5 Frequency Converter Unit

10.5.1 General
The converters shall be provided as medium voltage variable frequency
units with intermediate voltage circuit and shall guarantee, that the
connected medium voltage motor can be well operated about the
whole speed range. The characteristic and the power of converters shall
be adjusted to the motors.

Start and speed adjustment of the connected motor shall be carried


out with nominal current.

The converter shall consist of the following main units:


· Feeder
· Rectifier
· Intermediate DC link
· Inverter
· Output sine filter
· Cooling
· Motor and transformer protection
· Control unit, and
· Operator panel.

All units shall be installed in metal enclosed, self-standing cabinets


with hinged and lockable doors, with lifting lugs and cable entries
from the bottom. Power equipment and devices for control, operation
and monitoring shall be placed in different cabinets or shall be clearly
separated. The doors of cabinets for rectifier, intermediate DC link and
inverter must be locked during operation using integrated safety locks.

The converter units shall be suitable for indoor installation inside


electrical rooms on cable cellar or raised floor. For design of entries
through the floor the Supplier shall submit the foundation plan of the
converter together with weights and the information about necessary
distances between the converters and between converters and other
equipment, walls, ceiling, etc.

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10.5.2 Wiring
The wires shall be selected according to load, insulation level, function
and operating requirements. The wires shall be adequately rated and
equipped with fuses/circuit breakers of adequate size.

The wiring shall be carried out solid and safe against damages. Wires
shall be bundled and fixed. The wiring shall be laid inside of wiring
channels, preferably. If wiring in channels will be used, a spare of 20 %
shall be foreseen.

All circuits shall be terminated on terminal strips. If wires with different


potential will be terminated on one terminal strip the respective
terminals shall be separated by means of isolating plates. The
termination of multiple stranded wires has to be carried out by means of
multiple core cable ends.

Terminals shall be marked durable and easily readable, corresponding to


the drawings. Wires shall be marked on the termination of each wire
with the number of the corresponding connection point.

10.5.3 Earthing
All exposed conductive parts likely to be accidentally charged shall be
joined together by an earthing circuit. For this purpose, a minimum 100
mm² cross section bare copper earthing bus shall be installed. This
earthing bus shall be connected to the general grounding system by
means of conventional cable connection terminals.

For the removable panels, electric continuity shall be ensured by


fastening screws and bolts. The opening type panels, assembled on
hinges shall be bonded to the enclosure by a tinned copper braid, or
hinges shall be certified for this purpose.

The following shall be also connected to the earthing circuit:


· Secondary windings of the instrument transformers,
· Neutral point of the potential transformers,
· Armors or screens of cables,
· Operating handles, mounting plates, doors, etc.

In addition, both ends of the complete converter assembly shall be


terminated to the general grounding system by separate cables.

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10.5.4 Overvoltage protection


The converters shall be designed and rated in a manner such that
overvoltage caused by switching and flashes, do not impair the safety in
operation of the units.

The converters shall be equipped with the necessary devices against the
effect of overvoltage, caused by switching or flashes. The supplier shall
deliver a respective protection concept for approval.

10.5.5 Control voltage


The control voltage supply will be carried out from a 230 V AC, 60 Hz
power supply. The converter will be provided with one supply, protected
by means of a miniature circuit breaker situated in the UPS 230 V AC
power supply distribution board. The sub-distribution of control voltage
shall be carried out selective from the main supply to the different
consumers.

All other necessary control and signal voltage levels shall be generated
inside the converter.
For sizing of 230 VAC power supply, the Supplier shall submit the
power consumption for the control voltage consumers of the converter
and the recommended circuit breaker size for feeder line.

10.5.6 Auxiliary voltage


The auxiliary devices inside the converter will be fed from the 230/400
V, 60 Hz level via one feeder. The sub-distribution of auxiliary voltage
shall be carried out selective from the main supply to the different
consumers.

For sizing of feeder, the Supplier shall submit the power consumption of
converter auxiliaries and the recommended circuit breaker size for
feeder line.

10.5.7 Anti-condensation heaters


The converter shall be equipped with anti-condensation heater(s), which
shall also be fed from the 230V, 60 Hz level. Heaters shall only be
operated if the main circuit of converter is switched off and shall be
controlled via hygrostat or thermostat.

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For stand-still heater of motor the respective auxiliary circuits shall be


provided, too. The heater shall be supplied via a miniature circuit
breaker and controlled via contactor.

A failure of heater circuits shall be indicated on indicator board/operator


panel and wired in the summary alarm for transfer to the DCS system.

10.5.8 Feeder
The converters shall be switched from a medium voltage circuit breaker,
located in a MV switchgear. If additional fuses for inverter protection
will be necessary, they are part of the converter.

For termination of main power cables removable bus stubs or bolt


terminals shall be used.

10.5.9 Rectifier
The rectifier shall be equipped with a 24-pulse diode or diode/thyristor
bridge.

10.5.10 Intermediate DC link


The intermediate DC link shall be equipped with capacitors.

10.5.11 Inverter
The inverter shall preferably be equipped with a 6-pulse semiconductor
bridge, to allow a three-line connection with the motor. For
semiconductors the Insulated Gate Bipolar Transistor (IGBT) or
Integrated Gate Commutated Thyristor (IGCT) type shall be used.

For reducing the harmonic content of the output voltage sine filters shall
be installed. With this filter the voltage waveform applied to the motor
shall be kept nearly sinusoidal.

For termination of main power cables to the motors’ removable bus


stubs or bolt terminals shall be used.

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10.5.12 Cooling
VFD shall be preferably air-cooled design.

For all components which cannot be cooled directly by air the respective
internal fans shall be provided. The cooling system shall be dimensioned
in a manner such that the waste heat can be carried off in each case,
without any overheating of the units and devices.

If the converter will be equipped with air intakes respective air filters
shall be provided in order to prevent dust and particles from entering
into the converter. It shall be possible to replace the filters from outside
while the drive system is in operation, preferably.

10.5.13 Control unit


The control unit, housed in a separate cabinet or in a clearly separated
part of the inverter, shall include all facilities for operation, control and
supervision of converter transformer, converter and motor.

The following functions shall be fulfilled from the control unit:


· Switching of the motor via circuit breaker, which is located inside
of a MV switchgear,
· Speed variation of motor,
· Speed monitoring of motor,
· Supervision of converter and signalization of operation modes and
failures,
· Output current supervision,
· Protection of the speed regulation system components,
· Supervision of converter transformer and motor,
· Supervision of internal cooling system, and
· Transfer of all signals to the station control system.

Control and monitoring of the frequency converter shall be possible


from the operator panel and from control system, dependent of the
location of control responsibility.

For control and monitoring from station control system the following
signals shall be transferred.

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Commands from station control system to converter:


· Pre-start (if necessary),
· Motor start,
· Motor stop,
· Speed set point value, and
· Emergency stops.

Messages/alarms/values from converter to station control system:


· Ready for charge of capacitors (if necessary),
· Ready for operation (speed control active),
· Feedback of the commands, listed under a),
· Motor is running,
· Actual speed,
· Overcurrent/short circuit,
· Overvoltage/undervoltage,
· Motor current outside the limits,
· Phase undercurrent of motor,
· Locked rotor,
· Failure converter,
· Failure control voltage,
· Failure auxiliary voltage,
· Failure internal cooling system, or overtemperature transformer or
overpressure tran sformer,
· Low oil level transformer
· Variable speed drive switching off, caused by transformer
overtemperature/overpressure,
· Variable speed drive switching off, caused by transformer release
of transformer sudden pressure or Buchholz relay, and
· Variable speed drive switching off, caused by motor,
· Summary alarm.

For switching the speed regulation system via MV switchgear the


following signals shall be transferred:

Commands from converter to switchgear:


· Circuit breaker On, and
· Circuit breaker Off.

Messages from switchgear to converter:


· circuit breaker open,
· circuit breaker closed, and
· circuit breaker released.

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The signal transfer between converter and station control system, with
exception of the signals “failure control voltage” and “emergency
stop”, which will be hardwired, shall be carried out via serial link
(via Profibus, Modbus, etc.). If necessary, a respective bus
adapter/coupler shall be installed inside of converter.

The signal transfer between converter and MV switchgear shall be


performed hardwired via digital inputs and outputs.

For the digital inputs and outputs, the necessary floating contacts or
couple relays shall be provided.

The devices of the control unit shall be protected against overvoltage by


means of suitable measures.

10.5.14 Operator panel


The operator panel shall be placed in the hinged door of the control
cabinet. The panel shall consist of a multilingual alphanumeric display
with user menu and the respective operation elements.

In minimum the following operation elements shall be provided:


· Variable speed drive On/Off,
· Speed higher/lower,
· Reset of alarms,
· Deletion of messages,
· Request of command power, and
· Return of command power,

and all elements for operation of the menu.

All messages, measuring values and alarms, which will be transferred


to station control system, shall be indicated on the display.

In addition, the following messages and values shall be indicated, at


least:
· Operating hours,
· Power factor,
· DC link voltage,
· Voltage, current and frequency of motor,
· Command power at converter, and
· Failure message.

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The failure message shall be indicated as a common alarm. On an


additional display or by means of the user menu the kind of failure shall
be indicated.

In addition, it shall be possible to adjust the parameters from the


operation unit. Adjustment of parameters and operation shall only be
possible with input of a user code.

10.5.15 Emergency stop push button


Each converter shall have one emergency stop push button, mounted on
the front door.

10.6 Cabling
The delivery, laying and termination of all cables to and between
the components of the speed regulation systems shall be carried out by
others.

The delivery, laying and termination of all cables to and between the
harmonic filter and MV Switchgear shall be carried out by others.

The Supplier shall submit a block diagram for cabling and a cable list
with the recommended cables and cable sizes and if necessary, with
the type of special cables.

10.7 Painting
All components and devices shall have a resistant, long term stable,
high quality painting.

Damages, caused by transport, installation, cabling or commissioning


shall be repaired in a way, that the original quality is restored.

10.8 Spare Parts and Accessories


The Supplier shall deliver all spare parts and consumables, which are
necessary for commissioning, start-up and two (2) years operation.

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All necessary accessories for operation and maintenance shall be


supplied for each station location where variable speed drive units
will be installed, at least consisting of:
· One (1) set of all special tools and handles required for
operation and maintenance,
· One (1) set high voltage fuse tongs (if any),
· Key set for doors and locks,
· One (1) set magnetic labels "HIGH VOLTAGE – ATTENTION
DANGER FOR YOUR LIFE" in sufficient number.

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11. EMC measures


All EMC measures shall ensure that during subsequent operation, no
impermissible malfunctions or damage to equipment occurs due to violating
electromagnetic compatibility.

The description of the measures is not limited to this chapter, but also forms
a part of other chapters, in particular “Protective measures", "grounding and
lightning protection” and “Cabling”.

The EMC requirements are set out in the following paragraphs.

Under consideration of the conditions and constraints, the equipment used


shall emit the lowest interference signals and exhibit the highest immunity
to interference.

All equipment items shall operate properly when connected to networks


with a power supply corresponding to the maximum permissible tolerances
as laid down in EN 50160 (as regards, harmonics, voltage fluctuations etc.).

Priority is given to reducing sources of interference.

Additionally, by means of high-quality screening, generation of over-


voltages due to inductive or capacitive coupling shall be reduced.
Influencing by electrical and magnetic fields shall be lessened.

Earthing and potential equalization systems designed for low impedance


shall reduce generation of over-voltages due to ohmic coupling.

If EMC resulting from the measures named above is still not adequate,
further measures shall be taken within buildings, for example by isolation
and suppressor circuits.

Thanks to the lightning protection and screening measures taken at the


buildings, within them an EMC protection zone is formed.

All installations penetrating this protection zone, that is where they pass
through the external walls of buildings, shall be incorporated into a
lightning protection-potential equalization system as close as possible to the
points of entry and exit of the building. This applies also for conductors
carrying a potential. At entry or exit, these shall be included in the lightning
protection-potential equalization system by way of suppressor circuits.

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Cable runs to outdoor plant components and between buildings may also be
screened by appropriate measures, and so form a part of the protection zone.
If this is done, the suppressor circuit can be dispensed with.
A suppressor circuit shall be provided at all low-voltage main distribution
boards.

Overvoltage protection shall be foreseen within the power supply for both
central and distributed power supplies to electronic cubicles.

All conductive parts of the structures and installation within the scope of the
contract must be connected to the main earthing system.

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12. UPS Equipment

12.1 Scope of Works


This document covers the requirements for the design, manufacturing,
construction, installation, test and commissioning of a redundant
uninterruptible power supply system (UPS) for AC consumers.

12.2 Codes and Standards


The design, manufacturing, construction, installation, test and
commissioning of uninterruptible power supplies shall be in
accordance with the following codes and standards, at least. The latest
revision of the publication referred to shall apply.

IEC 60051 Direct acting indicating analogue


electrical – measuring instruments and
their accessories
IEC 60076 Power Transformers
IEC 60085 Electrical insulation - thermal
evaluation and designation
IEC 60146 Semiconductor Converters
IEC 60255 Electrical relays
IEC 60269 Low-voltage fuses
IEC 60439 Low voltage switchgear and
assemblies
IEC 60529 Degrees of protection provided by
enclosures (IP Code)
IEC 60896 Stationary lead – acid batteries. Vented
types, general requirements and
methods of test
IEC 60947 Low-voltage switchgear and control
gear
IEC 60989 Separating transformers,
autotransformers, variable transformers
and reactors
IEC 61558 Safety of power transformers

As far as the power supply authority (SEC) and permits of other


authorities require additional codes and standards, respectively impose
additional requirements, these are also part of the contract.

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12.3 Environmental Conditions


The uninterruptible power supplies shall be designed and constructed for
continuous operation at full load under the climatic and environmental
conditions specified elsewhere in this specification.

The UPS’s shall be installed in rooms of the electrical buildings. The


rooms will be equipped with air conditioning.

12.4 General Requirements

12.4.1 Components and equipment


The Contractor has to take care, that all components and equipment are
selected considering easy maintenance, simple and quick diagnosis and
long maintenance intervals.

All components and equipment shall be designed for continuous duty at


rated load and under the given climatic conditions. Standard industrial
high-performance systems and components of supplier’s standard lists
shall be used as far as possible. Components and equipment of same
kind and type shall be selected for equivalent functions. The
interchangeability must be guaranteed.
Units and Scales
The metric system on basis of SI-units shall be used for all scales and
indications.

12.5 Description of the system


The UPS system shall be design as a fully redundant system, 2x100%
(including batteries bank). Units output shall be 400V 3F+N 60Hz.
Rated power shall be calculated by the manufacturer according to real
loads and submitted for approval to SWCC, in any case, minimal power
rate to be consider for each unit shall be 50kVA.

Each uninterruptible power supply unit (UPS) shall consist of the


following main parts:
· Isolation transformer,
· Rectifier,
· Battery bank,
· Inverter,
· Static bypass,
· Manual bypass, and
· One distribution board (common for both redundant units).

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TECHNICAL SPECIFICATION
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During normal network conditions the AC consumers will be supplied


via both rectifier/inverter circuits, which work in half-load operation
mode. At the same time the battery bank will be trickle charged. In case
of interrupt on one feeder or failure of one rectifier/inverter circuit the
other circuit takes over the supply of all consumers. If both feeders are
without voltage the consumers shall be fed via the battery. After return
of the feeders the rectifiers take up the operation automatically, feed the
inverters and charge the battery. In case of overload or UPS failure the
consumers shall be fed via the static bypass. For maintenance a manual
bypass shall be provided.

12.6 Equipment Characteristics

12.6.1 Mechanical requirements


The uninterruptible power supplies shall be industrial type, metal
enclosed factory assembled with self-standing cabinets and with fix
mounted units and devices.

The cabinets shall be suitable for back-to-back installation or installation


against the wall. The cabinets shall only be accessible from the front.
The hinged front doors shall be swinged out more than 90°.
The cabinets will be mounted on cable cellar. The bottom of cabinets
shall be covered with galvanized steel sheets. If necessary, for air
circulation holed steel sheets can be used.

The cable entries shall be designed in a manner such that a sealing after
cable laying is possible without any problem. Further, each cover sheet
shall be equipped with a grounding connection to the steel frame of
cabinet.

All nuts for fixing of components shall be welded on the steel structure
or threads will be cut in the steel structure. The use of loose nuts or self-
cutting screws shall be avoided as for as possible. Screws, nuts and
washers shall be galvanized or tinned.

12.6.2 Electrical requirements

12.6.2.1 Rectifier
The UPS’s shall be equipped with full wave rectifiers. Each rectifier
shall be suitable to supply all connected consumers. An additional

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ELECTRICAL WORKS
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charging and floating of the battery banks must be possible (also


applicable, if the battery was drained prior to start of charging).

The rectifiers shall be designed for operation with natural air cooling,
preferably. If forced air-cooling is required, then 2 x 100 % fans with
monitoring and alarm signal (local and remote) shall be provided.

Each rectifier shall mainly consist of the following:


· Fully-controlled semi-conductor bridge with current and voltage control,
· Filters to limit the AC components of output,
· Moulded case circuit breakers for AC and DC,
· Miniature circuit breakers for control circuits,
· Devices for overvoltage protection, and
· Indicator board for all signals of the system (mounted in the door).

For the indication of the signals one indicator board for both
rectifiers can be used.

Battery manufacturer’s specification regarding charging voltage,


maximum voltage ripples, etc. shall strictly be observed, as well as
values given in their data sheets.
The rectifier shall be equipped with the following supervisory
devices:
· electronic network supervisory (switching off at 85 % voltage;
switching on at 90 % voltage),
· overvoltage supervisory with switching off the rectifier,
· over-discharging supervisory with disconnection of the battery,
· supervisory of battery circuit interrupt and short circuit of battery
cells, earth fault supervisory on DC side.

The response of the mentioned supervisory devices shall be indicated


on the indicator board.

12.6.2.2 Inverter
The UPS’s shall be equipped with full electronically inverters. The
inverter of one rectifier/inverter circuit shall be located in the cabinet of
the respective rectifier. Each inverter shall be suitable to supply all
connected consumers.

The inverters shall be designed for operation with natural air cooling.
Each inverter shall mainly consist of the following:

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· Self-commutating solid-state static inverter unit with voltage


regulation,
· Filters for wave form stabilization,
· Voltage peak limiting,
· Synchronization device,
· Molded case circuit breakers for AC,
· Miniature circuit breakers for control circuits, and
· Indicator board for all signals of inverter (if not part of indicator
board of rectifier).

The inverters shall be sized in a manner such that the largest circuit
breaker for consumers located in distribution board will trip without any
difficulties and that with one (1) inverter in operation and without
support from bypass.

The inverter shall be equipped with the following supervisory devices:

· Input voltage supervisory,


· Electronic inverter supervisory,
· Output voltage supervisory, which initiates a switch over to static
bypass,
· Overload supervisory, and
· Frequency supervisory.

The response of the mentioned supervisory devices shall be


indicated on the indicator board.

12.6.2.3 Bypass
For the inverters an electronically change over device shall be provided.
The device shall enable the automatic, uninterrupted, synchronous
switch-over to the consumer bus bar in case of failure. The change-over
device must be able to carry such a current that the largest circuit
breaker for consumers located in the distribution board will trip without
problems and that without support from the inverters.

The change-over device provided shall be equipped with thyristor


switches, control electronics and a check-out-system. The check-out
system must make it possible to test the correct functioning of the unit
without disturbing the operation of the consumers.

For change-over in case of maintenance an additional, manual bypass


shall be provided. The switch-over shall be carried out with overlapping,
that means without interrupt, too.

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The operation of bypass shall be indicated on the mimic panel, a


summary and fault alarm on the indicator panel of inverter.

The automatic and manual bypass shall be fed via a common isolation
transformer, which will be supplied from the normal network.

12.6.2.4 Measuring instruments


The UPS shall be equipped with the following measuring
instruments:
· AC input voltage (per rectifier and for bypass),
· Battery current (charging / discharging),
· Battery voltage, and
· AC output current.

The measuring instruments shall be mounted in the front door.

12.6.2.5 Mimic panel


For the uninterruptible power supply, a mimic panel shall be provided.
The mimic panel/diagram shall show the main power circuit with all
necessary switch positions, device symbols and important alarms.
All measuring instruments shall be allocated to the respective symbols
of devices and bus bars.

The signals which are incorporated in the mimic panel may not be
indicated on the indicator boards.

12.6.2.6 Remote monitoring


For remote monitoring to station control system the following signals
shall be wired on terminal strip:
· Failure feeder of rectifier (for each rectifier),
· Failure feeder of bypass,
· Over-discharging of battery,
· Summary alarm per rectifier/inverter unit, and
· Summary alarm bypass.

The transfer of the mentioned signals shall be carried out via potential
free contacts.

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TECHNICAL SPECIFICATION
ELECTRICAL WORKS
Doc No.: Q A 1 0 - H - 0 4 0 9 Rev. C

12.6.2.7 Batteries
The batteries shall be from the valve-regulated lead-acid type and
maintenance-free. All batteries shall be clearly marked to show
manufacturers name, type, voltage, capacity, etc.

The sizing of battery system shall be made in a manner such that in case
of loss of power the complete consumer loads will be supplied from the
batteries continuously for a duration of minimum one (2) hours and it
shall be guaranteed that the cell voltage of any single cell will not fall
below 1.8 V during at the end of the minimum back-up time. The Ah
capacity calculation shall be performed for maximum load demand at
ambient temperature of 25 °C. During on-site battery test the above-
mentioned performance data shall be proved.

Manufacturer to confirm that minimum life expectancy of batteries will


not be less than 15 years after commissioning of the same at site.

The batteries shall be placed inside an air-conditioned battery room on


rack.

Between batteries and rectifier/inverter cabinets a respective fuse box


shall be installed. The fuse box may be placed either inside the battery
room or inside the neighboring room on the wall to the battery room
(preferred solution). The cables between battery and fuse box shall be
laid short circuit proof.

12.6.2.8 Distribution Board


For each uninterruptible power supply, a distribution board shall be
provided.

The distribution board shall be located in a separated part of one


rectifier/inverter cabinet. If the cabinet is not sufficient for distribution
board installation or if inside of the cabinet is no space, a separate
cabinet shall be foreseen.

The distribution boards shall be equipped with 2-pole or 4-pole


miniature circuit breaker, sized according to the requirements and with
the respective terminal strips. Further, an earth fault supervision unit
shall be provided. For future extension each distribution board shall have
at least 20 % full installed spare and further 20 % spare place to install
additional devices.

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In addition, the bus bars of distribution boards shall be equipped with the
following measuring instruments:
· Voltmeter, and
· Frequency meter.

The measuring instruments shall be mounted in the front door. The


response of the earth fault supervision shall be shown on the indicator
board of the rectifier.

For remote monitoring the summary alarm of moulded case circuit


breaker tripping shall be wired on terminal strip.

The transfer of the mentioned signal shall be carried out via potential
free contact. The terminals shall be located beside the terminal strips for
remote monitoring of rectifier/inverter unit.

12.7 Wiring
The wires shall be selected according to load, insulation level,
function and operating requirements. The wires shall be adequately
rated and equipped with fuses/circuit breakers of adequate size.

The wiring shall be carried out solid and safe against damages. Wires
shall be bundled and fixed. The wiring shall be laid inside of wiring
channels, pr eferably. If wiring channels will be used, they must be from
halogen-free type and a spare of 20 % shall be foreseen.

All circuits and auxiliary contacts shall be terminated on terminal


strips. Terminal strips shall have at least 10 % spare terminals. If wires
with different potential will be terminated on one terminal strip the
respective terminals shall be separated by means of isolating plates.
The termination of multiple stranded wires has to be carried out by
means of multiple core cable ends.

Terminals shall be marked durable and easily readable,


corresponding to the drawings. Wires shall be marked on the
termination of each wire with the number of the corresponding
connection point.

12.7.1.1 Overvoltage protection


The UPS shall be designed in a manner such that overvoltage’s caused
by switching and flashes, do not impair the safety in operation of the
units.

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ELECTRICAL WORKS
Doc No.: Q A 1 0 - H - 0 4 0 9 Rev. C

The incomers of UPS and the bus bar of the distribution boards shall be
equipped with additionally surge arrestors. The electronic devices shall
be separately protected against overvoltage’s.

12.8 Painting
All components and devices shall have a resistant, long term stable, high
quality painting. At least two layers have to be applied.

Damages, caused by transport, installation, cabling or commissioning


shall be repaired in a way, that the original quality is restored.

An additional painting at location of installation is not allowed.

12.9 Installation
The delivery, installation and commissioning of the UPS equipment
shall include, but not limited to the following items:
· transport to location of installation (if necessary, storage), and the
complete mounting,
· cable connections between the different parts of UPS equipment,
· grounding and potential equalization for the parts, including
connection with the next grounding bus bars,
· termination of all cables at the UPS equipment,
· commissioning of the functioning UPS equipment, and
· briefing of the operation personnel in operation and maintenance
during installation and commissioning phase and during a training on
site.

The installation and as well the tests and the commissioning shall be
carried out with Contractors own staff and with own tools and
measuring/test devices.

12.10 Spare Parts and Special Tools


The Contractor shall deliver all spare parts, which are necessary for
commissioning and two years operation time (see “General Description
of Project and Works”).

All necessary special tools for operation and maintenance of the UPS
equipment shall be supplied for each location, at least consisting of:
· One (1) set of all special tools required for operation and maintenance of
UPS equipment,
· One (1) set fuses (6 fuses of each used size),

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Doc No.: Q A 1 0 - H - 0 4 0 9 Rev. C

· Key set for cabinet doors and locks,


· Magnetic warning labels in sufficient number, English and Arabic,
· Software for special equipment (if any),
· One (1) IC pro-programming kit (suitable for all IC in the system).

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