Electrical specification

for packages
______________________________________________________________________________________

Plant:

Mamu Gas Processing Plant

TECON-Project:

C259 - Mamu Plant FEED

PETROM-Asset. No.: 2 MAD

Electrical Specification for

Packages

03
02
01
00

1-6

7 - 14

15,16

Asset No.

Document No.

Rev.

2 MAD

N00-X013

01

Final Issue
First issue

Rev.:

Description:

C259-N00-X013

17,18

19-21

22,23

Installation Code

30

31

Pl. Or.

TECONID:

C 259

07.08.2009
12.05.2009

FWI TEC
FWI TEC

HLA TEC
HLA TEC

Date:

Prepared:

checked:

Mamu Gas Processing Plant FEED

80
F

approved PETROM,
Date:

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Electrical specification
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LIST OF CONTENTS
1

Introduction ...............................................................................................................................................4

Abbreviations ............................................................................................................................................5

Scope........................................................................................................................................................6

3.1

Laws, regulations and standards........................................................................................................6

3.2

Application of standards and specifications .......................................................................................6

3.3

Suppliers responsibility.......................................................................................................................6

3.4

Language and measurement of units .................................................................................................7

3.5

Information from Vendor.....................................................................................................................7

General Requirements .............................................................................................................................9

4.1

Operating conditions........................................................................................................................ 10

4.2

Life span and spare parts ................................................................................................................ 10

4.3

Tagging............................................................................................................................................ 11

4.4

Painting............................................................................................................................................ 11

4.5

Hazardous Areas ............................................................................................................................. 11

Mechanical and Electrical Requirements .............................................................................................. 14

5.1

General ............................................................................................................................................ 14

5.2

Integration of the Package Unit in the Main Electrical Network ...................................................... 14

5.3

Package Distribution Boards ........................................................................................................... 14

5.4

Motors.............................................................................................................................................. 19

5.5

Trace Heating .................................................................................................................................. 20

5.6

Other Heating .................................................................................................................................. 20

5.7

Lighting Fixtures .............................................................................................................................. 20

5.8

Cabling............................................................................................................................................. 20

5.9

Earthing ........................................................................................................................................... 22

Inspection and Tests ............................................................................................................................. 23

Specific Scope of Electrical Supply ....................................................................................................... 24

C259-N00-X013

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7.1

Electrical Contents of Tender .......................................................................................................... 24

7.2

Continuous Electrical Documentation.............................................................................................. 24

7.3

Final electrical Documentation ........................................................................................................ 25

APPENDIX : List of Applicable Standards............................................................................................. 26

C259-N00-X013

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Introduction

The purpose of this document is to cover the minimum technical requirements for the design,
manufacture, testing and supply of electrical items supplied as part of packaged units.
In this specification, a package unit is considered to be a prefabricated process or utility unit which can
operate on its own, is supplied as a whole and is normally a standard skid-mounted unit. A package unit
can be composed of interconnected elements including distribution and control boards within the
substation building.
The electrical extent of scope for the package unit is described in the associated PROJECT
SPECIFICATION of process or mechanical engineering, regarding the main equipment identified as a
package unit. In the following this paper is referred as PROJECT SPECIFICATION.
The equipment and all necessary ancillary equipment to provide a complete operating system shall be
supplied in accordance with this specification, the relevant data sheet(s), the purchase order and the
documentation listed in the material requisition document.

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Abbreviations

EDG

Emergency Diesel Generator

EMC

Electromagnetic Compatibility

ESD

Emergency Shut Down

FAT

Factory Acceptance Test

FC
HBC

High Breaking Capacity

HVAC

Heating, Ventilation and air conditioning

LV

Low Voltage

MCC
MCCB
MCB
MSO
MV

Medium Voltage

RCBO
RCD

Residual Current Protection

RTD
SAT

Site Acceptance Test

UCS
UPS

Uninterruptable Power Supply

VFD

Variable Frequency Driver

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Scope

3.1

Laws, regulations and standards

The design, manufacturing and inspection/commission of the electrical equipment part of the
package shall comply with the following Laws, Regulations, Directives and Standards in
order of their precedence. Latest revisions/editions apply.

3.2

Laws and Regulations for Electrical Power Supply and Application in Romania
Applicable EC Directives
Local Romanian Standards
European Standards (EN Standards)
International Standards (IEC Publications)
Other national Standards (DIN, VDE )

Application of standards and specifications

In general, all applicable standards shall be followed. The quote shall include a list
containing all deviations from project specifications or standards. In the absence of such a
statement, it will be assumed that the requirements of this specification are met without any
exception. Costs for any subsequent modifications necessary to comply shall be borne by
the supplier without detriment to the schedule.
If any deviations and/or contradictions amongst the individual standards and regulations of
the same type (e.g. EN standards) arise, the most stringent wording shall apply. In case they
are mutually exclusive, Romanian federal law has to be considered.

3.3

Suppliers responsibility
The implied warranty of fitness of this specification for the intended purpose is within the
Suppliers responsibility. Compliance by the Supplier with the provisions of this Specification
does not relieve him of his responsibility to furnish equipment and accessories of a proper
mechanical and electrical design suitable for the specified service and conditions
guaranteeing health and safety. In case of any objections to the specification, the vendor
has to inform the client in writing.
The Supplier shall be fully responsible for all aspects of the design, manufacture, inspection
and factory acceptance testing within his scope of supply. This shall include responsibility for
the coordination and control of contingent Sub-Supplier activities, and for ensuring that the
equipment meets the requirements of this specification, including the quality
assurance/control requirements defined. If applicable, the Supplier shall provide a complete
list of his preferred sub-suppliers with the bid.
The Supplier shall also be responsible for providing technical support during erection, precommissioning, commissioning and start-up.
The Supplier has further to guarantee the committal of all certificates, acceptance papers,
reports and test logs by delivery of the switchgears

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It is incumbent upon Suppliers to familiarize themselves with all requirements.

3.4

Language and measurement of units

All documentation on the specified Low Voltage Switchboards shall be in English language.
Units of measurement shall be in accordance with the International System of Units (SI
System). Preferred units are described in Electrical design architecture philosophy
(C259_N00-J001).

3.5

Information from Vendor

Following electrical information shall be provided by the vendor from the tender stage.

3.5.1

Consumer Data
Following electrical consumer data shall be supplied:

In case of package distribution boards: for the tender a consumer list with the estimated
overall active and reactive power consumption separated for the type of electrical supply
required (230 VAC UPS and 230/400 VAC).
In case of no package distribution boards: for the tender a preliminary consumer list
showing first data for all consumers including type of supply and required protection.
The lists shall be detailed after purchase order and give detailed information on each
consumer fed by either board. Especially for motors correct rated efficiency, current,
power factor and locked rotor current shall be given. For main consumers (e.g. large
motors) detailed data for all operating points shall be given.
The detailed lists shall show data for all feeder protective devices (tripping curves!) in
order to enable cable sizing by contractor.
The maximum electrical level of disturbance acceptable by the package distribution
boards and/or consumers.
The type and maximum electrical level of disturbance in the main electrical network
induced by package distribution boards and/or consumers.
Maximum allowed fuse for 230/400 VAC feeders to package boards.
Maximum allowed fuse or MCCB / MCB for UPS feeders to package boards.
Maximum allowed peak short circuit current for incoming 230/400 VAC feeder to package
boards (usually according to mechanical design of main busbar within the board).
230 VAC UPS loads are rated vital loads and do not allow for any interruption. 230/400 VAC
loads are in general divided in normal and essential loads. The latter will be backuped by a
diesel genset with an interruption of approximately 20 seconds. The vendor may ask for two
different feeders where one will be diesel backed up depending on his design.
After purchase order, a cable schedule connecting all equipment of the package scope shall
be delivered. Calculation of cross section for power cables is up to the contractor and will be
made available on basis of vendor layout.

3.5.2

Other Data
Following data shall be supplied:

Dimensions of all package boards, cubicles and panels

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Approx. heat dissipation of boards, cubicles, panels and other equipment located indoors
Maximum environmental and climatic ratings
Approx. weights for boards, cubicles and panels

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General Requirements
The following sections give contractor requirements regarding the vendors electrical scope of
work. Generally, the Electrical design architecture philosophy (C259_N00-J001_02) shall be
considered for all electrical installations.
The scope of supply shall include, but shall not be limited to design, fabrication, inspection,
testing, preparation for shipment, spare parts, special tools, supply of documentation and
manuals and other services as defined in the relevant requisition.
In general (except as indicated below for the motors etc.), each necessary power supply will be
made available as only one feeder up to an agreed interface point at the edge of the package
unit. The same principle will apply to the control cabling intended for remote indication,
interlocks, intertrips etc, for which a single interface point, generally a junction box or terminal
block within a cubicle, will be accommodated at the edge of the package unit. All connections of
the equipment, sensors, push buttons etc. shall be wired up to the corresponding interface point
by the vendor (e.g. a skid mounted junction box).
If the motor controllers / VFDs for the motors within the package unit are provided by vendor,
then the package MCC board will be located in the electrical substation remote to the package
unit. In such case, the power cables to the motors shall terminate directly on the motor junction
boxes. The power and control cables from MCC to motor shall NOT be provided by the vendor.
The vendor shall instead provide a complete cable schedule and connection overview
coordinated with the client. The overview shall indicate all items, junction boxes and cubicles.
Cabling and termination works will be in scope of the electrical subcontract of the client.
Common (trace) heating or lighting within packages may be fed by a package board or the
general facilities within the substation. In the latter case, the vendor has to supply a complete
list of groups for heating devices or light fittings and a connection overview showing all
consumers, junction boxes on the skid and the package feeder cubicles. For cabling, refer to
the paragraph above.
If there are any specific materials, related to the package unit, which need to be located in the
electrical substation, they shall be supplied by the vendor.
The interface points cover but shall not be limited to:

Control and signaling

All supply feeders
Lighting
Termination points for cabling (terminal blocks, junction boxes etc.)
(Trace) heating

All the electrical material and equipment within the battery limits shall be supplied, installed with
all accessories if any, wired, configured and tested by the vendor.
The vendor shall perform all internal cabling, lighting and earthing within the package unit.
Wherever requested in the requisition, the vendor shall supply the MCC, control boards and
other material to be located remote to the package unit, i.e. in the substation. The prices for
such items shall be indicated separately in the bid.
For applicable standards related to electrical equipment on package equipment please refer to
chapter 8 of this document.

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4.1

Operating conditions

4.1.1

Climatic and environmental conditions

The switchboards shall be designed and constructed for continuous operation at full load under
the climatic and environmental conditions at the mounted site (usually inside the substation
building). The following table briefs about determining parameters. The given values represent
extreme values following typical environmental site data:
Characteristics
min
max
Altitude of site (m above sea level)
165
165
Ambient temperature outside (C)
-27
39.2
Ambient temperature inside (C)
0
35
Wind speed (m/s)
0
15
Relative humidity (%)
5%
90%

4.1.2

Voltage supply and tolerances

It can be assumed that the supply voltage, frequency and their tolerances offered by the local
public supply grid will comply with limits for industrial environments as per EN 61000-2-4 and
EN 50160.
The following table briefs about all supply voltages and mains configurations for the designated
plant site.
Description
Voltage (V)
Mains configuration
Medium voltage supply (MV)
6kV ~
IT-system
Low voltage supply (LV)
400V ~
TN-S-system
Uninterruptable Low voltage supply
230V ~
IT-system
The voltage tolerances are detailed in the Electrical design architecture philosophy (C259_N00J001) and shall be accordingly respected.

4.1.3

Electromagnetic Compatibility (EMC)

Concerning electromagnetic compatibility, the impact on other systems by alternating magnetic
fields (radiated emission and susceptibility) shall be respected. Consequently, the related
regulations and standards shall be followed (mainly EN 61000). All electrical equipment shall be
constructed in order to allow electric and electronic industrial devices with a generic radiated
and conducted immunity at least as per EN 61000-6-2 to operate properly without any
functional constriction for typical industrial arrangements.
It is incumbent on the supplier to guarantee, that the offered electrical equipment will not
interfere with other devices subject to the typical conditions at the intended place of installation.
Any kind of low radiation design offered by some manufacturers is not required.

4.2

Life span and spare parts

The electrical equipment has to correspond to the standard of most modern technology and
should have been operated in comparable reference assets for at least two years. A reference
list of those assets is to be attached to the offer giving at least five examples. Suitable spare
parts must be available for at least 20 years after installation of the equipment.

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4.3

Tagging
All equipment of the package unit, including control panels, distribution boards, motors,
switches, control devices, indicators, junction boxes etc. shall be fully and clearly identified in
accordance with the drawings.
A label shall include the item tag-number of the equipment according to the vendor's drawings.
The labels shall be made from non decomposing material with durably UV- and weather-proof
black inscription on bright background. It is recommended to use engraved resopal plates or
approved equivalent.
Labels shall be attached to non-removable parts using corrosion proof screws, rivets or non
plastic cable ties, adherence is not permissible.
Nameplates shall describe push buttons, indicators etc. on the front side of control panels or
package boards.
Dymotape lettering or means of a similar kind shall not be used for permanent installations
except for inside cubicles.
Cables shall be fitted at both ends with cable markers showing the cable number stated in the
cable schedule.
For all inscriptions the character size shall be at least 8 mm. For smaller devices 6 mm may be
tolerable. The font shall be ARIAL standard.
The language of the inscription shall be English and Romanian. Directly after the TAG-Number
the CE-marking shall be placed.
Any electrical symbols used on the equipment should comply with IEC 60417.

4.4

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. The RAL code of
color for the switchboards will be given on the data sheets or shall be coordinated with the
client. An additional painting at location of installation is not allowed.

4.5

Hazardous Areas
Areas will be classified in accordance to the standard IEC 60079-10 (non hazardous area, zone
0, zone1, zone 2). The selection of electrical equipment and material shall take place with
respect of the standard IEC 60079 and with the European Directive ATEX 94/9/EC. The
mechanical characteristics of enclosures for electrical components and materials have to be as
follows.
The decision of the temperature rating (T1-T6) and gas group (IIA, IIB, IIC) according to IEC
60079-0 will be given by process safety department of TPGY.
For any package units or parts of package units installed outside process areas no EX-proof
design is required (e.g. instrument air supply, HVAC, EDG).

4.5.1

Induction Motors
Regardless of their location within the process area all LV motors and their junction boxes shall
have the following type of protection:
II 2G EEx de
II 2G EEx e

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4.5.2

Lighting Fixtures
Regardless of their location within the process area all lightning fixtures shall have the following
type of protection:
II 2G EEx de

4.5.3

Welding and Socket Outlets

Regardless of their location within the process area all outlets shall have the following type of
protection:
II 2G EEx de

4.5.4

Trace Heating
Regardless of their location within the process area all trace heating shall have the following
type of protection:
II 2G EEx e

4.5.5

Other Heating
All other heating within the process area shall have the following type of protection:
II 2G EEx d
or
II 2G EEx de
or
II 2G EEx dm
Outside of hazardous areas a non-EX design may be considered to reduce costs (e.g. electrical
heating within the diesel genset container).

4.5.6

Junction and Control Boxes

All junction and control boxes (e.g. for trace heating or lighting fixtures in package containers)
within the process area shall have the following type of protection:
II 2G EEx e

4.5.7

Switches
All switches (e.g. for trace heating or lighting fixtures in package containers) within the process
area and the well sites shall have the following type of protection:
II 2G EEx de
II 2G EEx e
(local control box)

4.5.8

Cabling in Hazardous Areas

The methods shall comply with standard IEC 60079-14. If cabling to an interface junction box
within zone1 is up to the vendor, the mechanical protection is also within his scope (usually all
factory assembled, skid mounted).
Cable glands suitable for the classification of the area where they are installed shall realize
cable entrance to enclosures of electrical apparatus. For flame proof (EEx d) glands and
junction boxes the use of armored cables is mandatory (gas tight!). As a consequence EEx d
boxes shall be avoided. The vendor must point out any need for armored cables at tender
stage.

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4.5.9

Certification of Electrical Apparatus for Hazardous Area

Electrical apparatus suitable for use in classified areas shall be provided with test certificates by
a Notified Body. The certificates shall be delivered according document schedule. Regardless
of the schedule, the papers for standard equipment shall be available on demand within one
week. A list shall summarize all EX-proof consumers and related certificates.
The equipment suitable for zone 1 area is suitable for zone 2 and non hazardous area.

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Mechanical and Electrical Requirements

5.1

General
The package units shall be designed to ensure the safety of personal during all operating
conditions, inspection and maintenance. They are suitable for operation and utilization
according to EN 50110.
The degree of protection for all enclosures shall be in accordance with IEC 60529:
Indoor equipment:
IP 21 (minimum)
Outdoor equipment:
IP 55 (minimum)
All equipment shall be tagged in accordance with vendor's drawings and identified with
nameplates.
It is to be remarked that, if not otherwise specified, the package unit shall be considered
as one machine in view of EC machinery directive 2006/42/EG. A new edition will be
available per 29.12.2009. Especially IEC 60204 for electrical equipment of machines is to
be respected.
Standard equipment shall be used whenever possible. All material and equipment shall be new,
unused and of a good proven quality.
All equipment and ancillaries will be installed in dust and industrial environment and shall be
corrosion resistant or effectively corrosion proof.
Electrical installation in the package unit shall be laid out with adequate access for convenient
operation and maintenance. Process equipment, piping, etc, shall not obstruct the access to
electrical equipment.

5.2

Integration of the Package Unit in the Main Electrical Network

The vendor shall indicate all items within the package unit likely to be responsible of electrical
disturbance in the main electrical network.
The electrical disturbance can be:

Voltage depression
Overvoltage
Wave disturbances such as harmonics
Overcurrents
Electromagnetic disturbances

The vendor shall indicate the type and level of disturbance likely to occur and shall propose a
corrective action in order to be in accordance with the IEC standards and project specifications.
For limits reference is made to IEC 61000-2-4.

5.3

Package Distribution Boards

The panels may include the package unit control system (UCS) as well as the motor starters
and the distribution feeders as required in the project specification.
The objective shall be to guarantee one common design throughout the whole project also for
distribution boards. The boards may contain specific FCs, thyristor controllers or other devices
which shall be embedded into the general design.
Whether distribution boards are within vendors scope or not shall be detailed on the associated
project specification of process or mechanical engineering. The specification will also indicate

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which package consumers shall be supplied by the boards. If required, the boards and their
feeders supplied with the package unit shall comply with the following.

5.3.1

General
Protection and control devices of package unit electrical equipment (heaters, lighting, motors
etc) shall be grouped in package panels supplied by the vendor completely pre-wired. All
devices within the boards shall be completely set.
Power distribution and control shall be installed in 2 separate sections of the panel.
The main power supply shall be disconnected by means of a load switch, padlockable in the off
position. Load switches shall be fault make, load break type. This device shall break all poles of
the supply, including any neutral (4 poles for 3 phases and neutral, 2 poles for 1 phase and
neutral and for DC supply).
For UPS feeds, load switches shall be foreseen within the cubicle. 230 VAC UPS has to be
marked clearly as an external voltage, as it is not switched off by the main supply
disconnector.
Conductors and electrical apparatus shall be protected against overcurrents by means of fuses
or MCB/MCCB/MSP/RCBO rated for the prospective fault level at the installation location and
taking limiting fuses prior to the device into account. In general, the vendor shall respect short
circuit levels of all incoming feeders and must design the equipment accordingly. If required, the
vendor shall make use of backup fusing to match the short circuit breaking capacity of
MSP/MCB/RCBO devices incorporated.
All protective devices within the boards shall be fully coordinated to ensure selective operation
within the rating of the concerned equipment.
The boards shall comply with IEC 60439 for partially type tested assemblies.
Distribution boards shall preferably be located at a convenient position within the LV room of
the plant substation. In case of package containers or dedicated unit buildings, it may be
considered to place boards outside the building, locally in the dedicated housings (local
panels). Outdoor installation shall be avoided. Anyway, an installation within hazardous areas
shall not be allowed, as this asks for EX-proof design and will drastically increase costs.
It shall be allowed to locate small panel boards for control etc. within classified areas. In this
case the design must meet the area classification.

5.3.2

Mechanical Cubicle Design

All LV distribution boards including those of package equipment shall be of same size and
layout to guarantee a continuous design and easy switch room layout. The cubicles/boards
shall mechanically comply as a minimum with the following requirements:

Add-on-design usually without baffles and factory assembled for easy on site installation
H x B x T = 2000 x 800 x 600 mm
Base 200mm
Color for cubicle and base RAL 7035
Ventilation per raised floor and air outlet on top of the cubicle (for ambient indoor
conditions)
Cable entry from bottom with ingress protection IP00 for cable terminals to raised floor
(no gland plate due to ventilation)
Two-way key bit locks for each door and rotary handle
Lighting fixture with socket outlet fed by 230 VAC UPS and door contact (double
terminals for loop in and NO protective device; protective device is within feeder cubicle)
20% mechanical spare space for possible future extension within the panel
Completely accessible from front side so that they can be placed against a wall or
installed back to back

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5.3.3

No space heaters are required for indoor installation; 230 VAC space heaters for outdoor
installation mandatory with own incoming feeder (main feeder switch off does not affect
anti condensation heating; to be included in consumer list.
Design allows cables to be safely connected to outgoing circuits without the necessity of
de-energizing the distribution board

Electrical Cubicle Design

For electrical design of the boards refer to the following points. It is to be pointed out that all live
parts and busbars shall be protected against inadvertent contact by design or by isolated
barriers (EN 50110 shall be supported).

5.3.4

Signal lamp RED, with test push button (approx. 2 x 2cm) in the door centre, to indicate
any unusual operating condition = COMMON ALARM (e.g. tripping of protective
devices); shall be supplied by external 230 VAC UPS feeder to maintain function even
when regular AC supply of cubicle is cut off
Voltage monitoring relay if the package cable feeder from LV main switchboard is not
supervised (overvoltage, undervoltage, phase failure, symmetry); necessity shall be
detailed on the associated project specification
Main load switch for 230/400 VAC incoming feeders with door handle and padlock-able;
for UPS feeds load switches within the cubicle
No incoming feeder fuse or MCCB (also not allowed for UPS); the main LV busbar of the
package board will be protected by MCC cable feeder within the LV main switchboard
The manufacturer must indicate the maximum allowed fuse ratings and peak short circuit
current of the LV busbar on the type plate of the package board (also for UPS)
Voltage metering (switchable if applicable) for all incoming feeders 96x96 mm; range
500V for 400V and 400V for 230V.
Type II/C monitored surge protection for AC boards except for UPS (goes to common
alarm of board)
Power distribution per main busbar with sufficient thermal and mechanical design

Motor feeders
If required in the project specification, motor starters for all motors within the package unit will
be designed and supplied by the vendor. They shall be located in a package distribution board.
All components shall be rated to withstand short circuit stresses and temperature applicable at
the appropriate point.
All motor starters shall be provided with:

MSP (thermal overload, short circuit and phase failure protection) appropriately sized to
protect the motor; monitored by auxiliary contact
Instead above, an MCB for short circuit protection and an additional thermal relay (e.g.
digital motor management with current transformer) may be used
MSP combined to groups with one fuse per group snapped up on the main busbar
Monitoring of group fuses is usually not necessary as a tripping of one phase causes
MSP to trip
Contactor (IEC 60947-4-1 shall be respected: classification 2 for fault clearance by MSP
prior to any contactor damage); monitored by auxiliary contact
Control circuits per MSP protected control transformer 230 VAC and one MCB per motor
feeder
Facilities for remote control by means of start/stop local control stations located adjacent
to the motors in the process area
Earth fault relays shall be foreseen for all motors

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All equipment relevant to specific operation, such as speed variation, 2 speed motor,
reversing motor, break motor, etc.

Any FCs shall be of DC voltage link pulsed type which requires no adaption to the motor. A bus
link may be preferred to enable control and monitoring by the packages control. Depending on
cable lengths output filters shall be foreseen (sinus or du/dt motor filter). Cable lengths will be
supplied by the client together with the results of the cable calculations. Attention shall be paid
that the motor isolation is suitable for all expected peak voltages. For high frequency - EMC
issues IEC 61800-3 shall be respected. The environment shall be rated C3. If necessary HF
filters shall be foreseen in the supply. For low frequency harmonic line currents input filters may
be considered to comply with IEC 61000-2-4.
FCs shall be protected by MSPs either directly attached to the main busbars or, for smaller
ratings, combined to groups with group fuses. Usually the FC offers an alarm when the power
supply fails. Thus a monitoring for the feeder is not necessary.
FCs or soft starters may be required by client instead of direct on line starting of larger motors
(change order). The client will calculate voltage drops according to vendors consumer data and
check against the allowed limits.
For ESD shutdowns each feeder must be equipped with a certified relay interrupting the control
circuit for the contactor.
PTC temperature monitoring and anti condensation heaters (if required) will also be part of the
motor feeder. The anti condensation heaters are automatically switched on when the contactor
stops the motor. PTC devices interrupt the control circuit of the feeder.
It shall not be possible to energize the contactor when the MSP is turned off.
Variable Frequency Drives (VFDs) above 250kW and all other motor feeders exceeding 160kW
shall not be fed by LV, but by 6kV medium voltage. Any need for this power range shall be
clearly indicated by the vendor on tender stage, as this requires enhancement of planned
electrical power supply levels.

5.3.5

Other feeders
For personnel safety, residual current protections (RCDs) shall be provided on all other circuits
feeding package equipment such as lighting or trace heating. The feeders shall be combined to
groups with one three phase fuse per group snapped up on the main busbar. The group fuses
shall be monitored.
For trace heating each feeder shall be designed for single phase and equipped with a RCBO
B16 in order to improve selectivity. The trace heating shall be grouped according to package
layout, each group switchable on the front panel of the board.
Other heating shall be fed similarly and will receive individual feeders of either one or three
phase design.
If possible, it should be considered to feed heating by the main heating board within the
substation or, for larger heaters, directly be controlled contactor feeders of LV main
switchboard.
Only locally switched lighting within package containers or housings (normal and assigned
emergency) shall be fed by a package board and comparable to trace heating. No group
switches are required and for standard florescent lighting within packages B6 or B10 RCBOs
are sufficient. Emergency lighting will require an own 230 VAC UPS feeder to the board.
Outdoor lighting fixtures on package equipment are usually fed by the main lighting board.

5.3.6

Distribution Board Wiring

For all boards a common code for wiring colors, marking and other principles shall be defined
by the client. The following table shall be considered a basic guideline.

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Power circuits (L1, L2, L3)
black
Neutral conductor (N)
blue RAL 5015
Protective conductor (PE)
yellow/green
Analog signals
green
DC control +24V
grey
DC control +0V
blue RAL 5012
AC control (L1)
red
AC control (N)
red/blue
UPS voltage (L1)
brown
UPS voltage (N)
blue RAL 5010
DC external control
orange
(e.g. interlock)
Dry contacts to terminals
yellow
Intrinsically safe circuits
blue RAL 5015
AC voltage 24V (L1, N)
rosy
(e.g. HVAC)
Conductors not available in listed color and required conductor size shall be marked by shrink
tubes at least at both ends.
For internal wiring PVC isolated stranded conductors shall be used. The calculation of cross
section shall be according to the standard. It is not allowed to use cross sections below 2,5mm
for power and 1,0mm for other wiring. Bundles of single core cables shall be routed neatly in
vertical or horizontal plans.
Package boards shall be supplied by vendor completely pre-wired to terminal blocks mounted
at the bottom of the panel.

5.3.7

Terminals
All terminal blocks shall be equipped with a spare of at least 20% for future extension. Different
voltage levels within a terminal block shall be separated by strips. Stranded conductors shall be
equipped with cable compression lugs. Each termination point shall only serve one
interconnection. In case of multiple connections terminals with internal connection clamp shall
be used. Control and metering circuit terminals shall be designed as disconnect terminals for
metering purposes.
Terminal sizes shall be according to the cable schedule.
A free space of at least 200 mm in height shall be available between the lowest cable terminal
and the bottom plate of the panel.

5.3.8

Conduits
Wires within the boards shall be held within insulated channels in order to avoid mechanical
damages.
The conduits shall be sized for at least 20% spare capacity. They shall be closed and easily
accessible for further enhancement. The wiring for voltage levels below and above 50V should
be separated if possible. Intrinsically safe wiring must be separated and laid in BLUE conduits.
In case of inevitable crossing of other conductors protective wrappers shall be used.
Wiring between cubicle and devices on door shall be protected against mechanical damage by
the use of flexible conduits.

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5.3.9

Installation devices
The following points shall be respected for all other live parts installed within the cubicles of the
package boards:

Control voltage transformers if necessary (fusing primary and secondary side; secondary
fusing may be omitted if instantaneous tripping of primary fuse is guaranteed for all fault
locations on secondary side)
No N-PE link within the cubicle, TN-S supply by LV main switchboard
Special attention to be paid on the required safety margins to intrinsically safe signals
(blue cable ducts and blue cabling!)
Special attention to be paid on minimum clearances of equipment according to
manufacturer instructions
All MCB rated class III with a breaking capacity of >= 10kA, neutral switched and
monitored by auxiliary contact
All RCD or RCBO to be of type A (pulse current sensitive) and G or K (lagged and peak
current proof); monitored by auxiliary contact
Fuses shall be monitored if required (e.g. necessary for group fuses but not necessary
for single fusing of MSP)
All interposing or control relays shall be of pluggable design

For different devices a specific type/brand may be stipulated by the client in order to stick to one
plant design. A list with allowed vendors may be supplied in addition to this specification.
One complete set of fuses shall be provided for all fusible equipment furnished or installed by
the supplier as part of his work.
Fuses shall be high breaking capacity (HBC) type, general purpose with time characteristics in
accordance with IEC 60269-2, with an interrupting rating greater than or equal to expected fault
current.
IEC 60947 is to be pointed out as the major standard for low voltage switchgear and control
gear.
Devices mounted in the control panel shall be easily accessible for maintenance.

5.4

Motors
This chapter represents an overview for LV motors. For details refer to the Specification of LV
motors (C259-N00-X010 Specification for LV Motors) or MV motors (C259-N00-X011
Specification for MV Motors). For DOL or softstarter motors above 160kW and for VFDs above
250kW medium voltage 6kV shall be used.
All LV AC motors shall be of three phase squirrel cage induction type. For fraction power
motors a one phase induction design may be used.
A typical local control for motors if within the package scope shall be made up as follows.
The design may be adapted by specific package vendors needs.
For local control a manual switch within a control box next to the motor shall be foreseen in the
process area, linked to the feeders digital control device within the drawer. The local switch
shall offer the following positions:

ON
to ESD
OFF
REMOTE

Motor ON regardless of package UCS but secondary

Motor OFF regardless of package UCS
Motor control is up to package UCS

The box shall be rated IP 55 minimum and be connected by one control cable.

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The local controls shall be installed on structural steelworks, against walls or piles. If not
possible the vendor shall provide an adequate support.
Motor control stations shall be installed in such a way that the relation between the control
station and the corresponding motor is clear and without any doubt.
No intermediate junction boxes are allowed for motors within packages. The feeder directly
connects the motor terminals to the distribution board.

5.5

Trace Heating
Electrical trace heating may be in the scope of the package supplier as indicated in the package
specification. Self regulated, self limiting trace heating shall be foreseen if required by process
design.
Special attention shall be paid on isolation tests after mounting according to manufacturer
directives. The tests shall be recorded and prepared for authority attestations.

5.6

Other Heating
If required by process, other heating may be fed by a package board (e.g. in case a thyristor
controller is planned). Any heaters exceeding 160kW shall be indicated clearly by the vendor in
order to respect the electrical system design.

5.7

Lighting Fixtures
Area lighting is not in the package vendor scope, but local lighting fixtures inside a package
(e.g. enclosures, control panels, containers, process racks, structural steelwork) shall be
designed and installed by the vendor.
The vendor shall supply and install the complete package unit lighting system including:

Lighting fixtures with supports

Cables and conduits up to terminal boxes
Electrical feeders including protection devices of lighting circuits if required
Switches and/or push buttons

Only locally switched lighting shall be supplied by a package distribution board. All other lighting
fixtures will be supplied by the common lighting board not in scope of the vendor.
Lighting shall be based on the use of 1 or 2 x 36W or 58W fixed to structural steelwork by
means of hangers. The fixtures shall be complete with all necessary accessories such as
electronic ballast, globe, guard, reflector and wired/cabled to junction boxes. The junction boxes
are the interface to cabling in scope of client.
The vendor shall submit to client prior approval, the lighting levels used for calculation and the
selected type of lighting fixtures to be installed, according to the required area classification as
described in the Electrical design architecture philosophy (C259_N00-J001).
Emergency lighting within the battery limits shall also be in the scope of the vendor and
installed and separately wired/cabled to junction boxes.

5.8

Cabling

5.8.1

General
Power and control cables interconnecting separated package boards (e.g. a control and a
distribution board) and going from separated package boards to process equipment shall not be

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in vendor scope. Interconnections between adjacent boards (arrays) shall be within the scope.
Cabling on skids or within containers shall be provided up to the interface points as defined in
the project specification. An interface point may be given by the terminals of a junction box, a
local board or control panel (terminal blocks within the boards). An example for a local board
would be a cubicle within housing on a skid.
For all cabling connected to package items the vendor shall

provide all terminating facilities and cable glands complying with the type of cable and the
area classification.
supply a complete system connection overview for all cabling.
provide a complete cable schedule based on the cable types given by client and
indicating the scope of the cable (vendor or client). The list will be reviewed and cross
sections for power cables as per calculation will be added together with lengths. Lengths
and cross sections for package cables on skids etc. shall be preliminary given by the
vendor
supply tripping curves or data on protective devices for outgoing feeder cables of
package boards to allow calculation of cross sections

All terminals and terminal boxes shall be sized for the calculated conductor cross sections. All
cable glands are within the vendors scope and shall be sized according to the cable diameters.
Data sheet of cable manufacturers will be supplied by client.
All cabling requiring interconnection to the general network (power or control) shall be provided
with junction boxes or terminal blocks in panels, etc, located at convenient positions, agreed by
contractor, along one side of the package unit battery limit.
Power cables will be supported within the package unit up to the interfacing terminal boxes or
terminal blocks.
Within the package unit, all cabling and wiring between electrical equipment shall be adequately
supported and fixed within cable trays or conduits up to the terminal boxes.

5.8.2

Cables and Cable Laying

All types for cables within the scope of the vendor as defined above shall be conform to
Electrical design architecture philosophy (C259_N00-J001_02). Generally following points shall
be considered:

mechanical protection by conduits or clads

laying and protection in hazardous areas rated zone1
supports by trays, ladders, conduits or clamps
cable marking
separation of cable types
fixing by clamps or similar

Main issues for cable laying are:

Cables shall be provided with mechanical support and protection by the use of hot dip
galvanized cable trays or heavy-duty hot dip galvanized conduits
Cabling shall not be supported by process piping, nor shall they be fastened directly to
structures
When 3 or more cables are routing paralleled, they shall be installed on cable trays or
cable ladders
Unless otherwise specified, cable trays and cable ladders shall be only 75% occupied at
the moment of completion of the installation
Cables for different voltage levels (High Voltage, Low Voltage, instrumentation) shall be
installed in separate trays or conduits

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The conductor color coding and minimum cross sections depending on the application is
defined within the specification.
The calculation of cross sections for package cabling (e.g. for a lighting fixture to a common
junction box or within a package container) shall be done by vendor and according to laying
conditions following the national Romanian standard. In case of a local supply board within the
package also voltage drop and short circuit tripping as per above specification is to be
respected for definition of package cables.
For long package cabling directly connected via client cables to a separated (package) board,
the client may ask for a larger cross section in order to guarantee voltage drop tolerances or
short circuit tripping for most distant faults. This may prevent an upgrade of the feeder cable
within his scope of supply.

5.9

Earthing
Earthing within the package shall be according to the Electrical design architecture philosophy
(C259_N00-J001). Although lightning protection is covered by the specification it shall be in the
scope of others and not considered to be up to the vendor.
The specification shall also be considered in view of external interfaces. This means that
earthing connections to skids, containers etc, which are not in the scope of the vendor, shall be
prepared in form of tags, termination points etc.

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Inspection and Tests

All electrical equipment, including sub-supplier equipment, shall be subject to inspection by the
contractor or appointed representative.
The vendor shall provide a witness testing schedule and the tests procedure for the vendor to
review by contractor at least 2 weeks before the proposed test date. The schedule shall reflect
all necessary electrical issues. It shall further include all final factory and site acceptance test
(FAT, SAT) in an electrical point of view.
Testing of electrical equipment within the package shall verify satisfactory operation in
accordance with the relevant inspection and test plans required by the project specification.
The vendor shall provide all facilities to carry out these tests. All test equipment and meters
used during tests shall have a valid calibration certificate issued by an independent authority.
The vendor shall provide to contractor the test reports within 2 weeks after testing.
From an electrical point of view, the package supplier shall in particular be responsible for:

Isolation tests on all cables within his scope

Initial electrical loop tests for all package consumers supplied by package boards within
the suppliers scope, regardless of the scope of the feeder cables (measuring loop
impedance; RCD check; verification of short circuit tripping)
Motor startup tests (rotary field check; MSP setting and optimizing etc.) for all motors fed
by package boards within the suppliers scope
Signal and control testing for all consumers fed by package boards within the suppliers
scope (e.g. local control switches or local protective RTDs)
All tests for package boards according to IEC 60439-1, -2

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Specific Scope of Electrical Supply

7.1

Electrical Contents of Tender

The offered package has to comply with all requirements of this electrical specification and all
other electrical and mechanical purchaser supplied data on the attached data sheet etc. The
bidder is asked to fill out all empty fields on the data sheet and has to guarantee the fulfillment
of all stipulations. Empty fields offer a free choice for the vendor within the constraints of this
specification including all referenced laws, regulations, standards, papers etc.
The tender letter, for electrical items of the package, has to be completed by following papers
as a minimum. Incomplete tenders may not be respected:

7.2

Index sheet for all electrical attachments to the tender letter

First vendor information
General layout and arrangement drawing showing electrical items
Electrical connection/system overview drawing
General brochures and flysheets for major items
List of major sub-suppliers (e.g. motors, distribution board, lighting fixtures, VFDs)
List with deviations to this electrical specification
Filled out data sheet for motors etc.

Continuous Electrical Documentation

A list with required electrical deliverables will be included in the tendering papers. The delivery
schedule will be stated in the purchase order for each type of deliverable. The delivery dates,
as part of the contractual schedule, are subject to penalties in the event of delays. The papers
will be subject to client approval or review and have to be prepared in English language.
The continuous electrical documentation shall include but in respect of the list of deliverables
is not limited to the following documents:

Detailed information according to chapter 3.5

Detailed layout and arrangement drawings showing all electrical items
Electrical connection/system detailed drawings
Layout drawings for all major electrical equipment
All equipment data sheets (e.g. motors, electrical panels, transformers, converters,
cables)
Detailed wiring diagrams for all electrical panels and boards
Cable list for all cables
Cable routing on skids, in containers etc. (drawings)
Cable sizing calculation notes for package cabling
All characteristics of the motors (current, torque, efficiency, power factor, locked rotor
conditions data) with the associated resistant torque
For main consumers (e.g. large motors) detailed data for all operating points
Terminal block diagrams and/or junction box drawings for all external connections with
suitable numbering
Test certificates for electrical material to be used in hazardous areas and list showing all
equipment plus certificate number
Inspection and test schedule and procedures according to chapter 6
Reports on electrical loop tests, cable isolation tests, motor startup and signal & control
check
Reports on convenient progress, kickoff meetings etc. covering also electrical issues

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7.3

Final electrical Documentation

Complete documentation of the electrical part shall be provided for the design, manufacturing,
testing, commissioning, start-up, operation and maintenance. All final documentation shall be
written in English language and should agree with typical national and international standards
for documentation (especially for drawings in digital form and used symbols according to IEC
60417 and IEC 60617). Preliminary papers for acceptance and review may only be supplied in
English Language.
The final electrical documentation shall include, but is not limited to, all papers of the continuous
documentation (as built status) and shall include:

Overall package instruction manual with respect of electrical issues

Operation and maintenance manuals for electrical items of package
Operation and maintenance manuals for all electrical auxiliaries
Outline drawing for the electrical items indicating all dimensions, weights
Outline drawing for the electrical auxiliaries indicating all dimensions
All technical data sheet for the electrical package items
All technical data sheet for auxiliary electrical items
All routine test reports for the electrical equipment (motors, boards, panels etc.)
Reports on factory and site acceptance tests (FAT, SAT) of the package equipment
manufacturer reflecting electrical issues
Separate list of used electrical equipment, auxiliaries, materials and their manufacturers
Assembly and mounting instructions for electrical equipment
Declarations of conformity for equipment (especially EC machinery directive 2006/42/EG
for the whole package)
Any other electrical declarations of the manufacturer or his sub-suppliers
Any electrical calculation notes
Priced spare parts list including major electrical items

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APPENDIX : List of Applicable Standards

Code

Description

IEC 60079

Electrical apparatus for explosive gas atmospheres

IEC 60034

Rotating Electrical Machines

IEC 60072

Dimension and output series for rotating Electrical Machines

IEC 60364

Low-voltage electrical installations

IEC 60439

Low-voltage switchgear and control gear assemblies

IEC 60529

Degrees of protection by enclosures

IEC 60204

Safety of machinery Electrical equipment of machines

IEC 60947

Low-voltage switchgear and controlgear

IEC 61000

Electromagnetic compatibility

IEC 61800

Adjustable speed electrical power drive systems

IEC 60269

Low voltage fuses

IEC 60417

Graphical symbols for use on equipment

IEC 60617

Graphical symbols for use on circuit diagrams

IEC 60445

Basic and safety principles for man-machine interface, marking and

identification

IEC 60059

IEC standard current ratings

IEC 60073

Basic and safety principles for man-machine interface

IEC 60445-60447

Basic and safety principles for man-machine interface

IEC 61140

Protection against electric shock

IEC 61496

Safety of machinery - Electro-sensitive protective equipment

IEC 62061

Safety of machinery - Functional safety of safety-related electrical,

electronic and programmable electronic control systems

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IEC 60598

Luminaries

IEC 60968-60969

Self-ballasted lamps for general lighting services

IEC 61347

Lamp control gear

IEC 62035

Discharge lamps

IEC 60898

Circuit-breakers for overcurrent protection for household and similar

installations

IEC 61008

Residual current operated circuit-breakers without integral overcurrent

protection for household and similar uses (RCCBs)

IEC 61009

Residual current operated circuit-breakers with integral overcurrent

protection for household and similar uses (RCBOs)

IEC 61095

Electromechanical contactors for household and similar purposes

IEC 61643

Low-voltage surge protective devices

IEC 61238

Compression and mechanical connectors for power cables for rated

voltages up to 30 kV

IEC 60228

Conductors of insulated cables

IEC 60146

Corrigendum 1 - Semiconductor convertors - General requirements and

line commutated convertors

IEC 61204

Low-voltage power supply devices, d.c. output

IEC 62041

Power transformers, power supply units, reactors and similar products EMC requirements

EN 50110

Operation of electrical installations

EN 50288

Multi-element metallic cables

communication and control

EN 50300

Low-voltage switchgear and controlgear assemblies. General

requirements for low-voltage substation cable distribution boards

EN 50274

Low-voltage switchgear and controlgear assemblies - protection against

unintentional direct contact with hazardous live parts

used

in

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analogue

and

digital

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