J08086-FD-SPC-ENV-05 REV 0

Gama Güç Sistemleri Mühendislik ve Taahhüt A.Ş.

Disi‐Mudawarra to Amman Water Conveyance System Project

Specification for Cathodic Protection Equipment and Material

Doc. No: J08086‐FD‐SPC‐ENV‐05 REV 0 Page i of i

TOC Doc. No: J08086‐FD‐SPC‐ENV‐05 REV 0

TABLE OF CONTENTS

1. Introduction ................................................................................................................ 1

2. Technical Requirements .............................................................................................. 2

Appendix A: Transformer Rectifier and Solar Power Unit ................................................... 11

A1. Cathodic Protection Transformer Rectifier Unit ................................................................. 11

A2. Cathodic Protection Solar Cell Unit .................................................................................... 18




Doc. No: J08086‐FD‐SPC‐ENV‐05 REV 0 Page 1 of 26

Cathodic Protection Equipment and Material Doc. No: J08086‐FD‐SPC‐ENV‐05 REV 0

1. INTRODUCTION

1.1 Scope

This specification describes the requirements for the cathodic protection equipment and materials required for systems along the water conveyor, wellfield, and at Mudawarra, regulating tank, break pressure tank, Madaba Bridge, Abu Alanda and Dabuk sites.

1.2 Applicable Standards

NACE SP0286‐2007 Electrical Isolation of Cathodically Protected Pipelines

NACE SP0572‐2007 Design, Installation, Operation, and Maintenance of Impressed Current Deep anode Beds

NACE SP0169‐2007 Control of External Corrosion on Underground or Submerged Metallic Piping Systems

ASTM G 57‐95a Field Measurement of Soil Resistivity Using the Wenner Four–Electrode Method

ISO 15589‐1 Petroleum & Natural Gas Industries – Cathodic Protection of Pipeline Transportation Systems. On‐land Pipelines

BS 7361:Part1 Cathodic Protection, Code of Practice for Land and Marine

NACE RP0104‐2004 The Use of Coupons for CP Monitoring Applications

NACE TM0497‐2002 Measurement Techniques Related to Criteria for CO on Underground of Submerged Metallic Piping Systems

BS EN 50162 Protection against corrosion by stray current from direct current systems






DD CEN/TS 15280 Evaluation of ac corrosion likelihood of buried pipelines Application to cathodically protected pipelines

NACE SP0177 Standard Recommended Practice ‐ Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems

BS EN 12954:2001 Cathodic Protection of buried or immersed metallic Structures General principles and application to pipelines

2. TECHNICAL REQUIREMENTS

2.1 Cathodic Protection Systems

Cathodic protection for the water conveyor and wellfield piping shall be based on impressed current systems which shall have a 50 year design life from the completion of system commissioning.

The entire conveyance system including the wellfield piping system will be segregated into six independent sections. Each section shall be protected independently with a separate CP system. The extremities of each section shall be isolated from the above ground facilities utilising insulating flange kits.

The CP designs shall be based on the availability of ac power source along the conveyor and the wellfield area. Consequently, the cathodic protection stations shall be installed close to the conveyor inlet and outlet at the following sites:

Wellfield Mudawarra Regulation Tank Break pressure Tank Madaba Abu Alanda Dabuk Reservoir

Three other CP stations will be located remotely from the above stated sites (on the off‐road and highway section) in which solar units may be used in case the provision of ac power source is not possible. Actual location of each CP station will be stated in the final design drawings.






2.2 Environmental Conditions

Ambient air temperature range throughout the project are as follows,

Maximum ambient air temperature 50oC

Minimum ambient air temperature ‐10oC

2.3 Inspection and Tests

The Manufacturer shall make available all equipment and materials for inspection by the Employer and conduct all tests as necessary to show full compliance with the specification to the satisfaction of the Employer.

In the event that inspection is waived, then this shall not release the Manufacturer from an obligation to supply completely satisfactory materials and equipment.

2.4 Cable

Cable for DC service shall be multiple stranded conductors, single core copper XLPE/PVC 600/1000 volt grade to IEC 60502.

Cable for deep well groundbed service shall be single core, copper, Kynar/HMWPE 600/1000 volt grade to ASTM D‐1248.

Cable for AC power supplies to CP stations shall be three core, copper XLPE/PVC/SWA/PVC 600/1000 volt grade to IEC 60502.






Cable sizing shall comply with the following,

Items Minimum Cable Core Size

Magnesium anode, monitoring coupon, reference electrode cable tails:‐

6 mm2

Test/monitoring cables:‐ 10 mm2

Impressed current anode cable tails, zinc ribbon/electrode connection at casings:‐

16 mm2

Foreign crossing bonding station cable 16 mm2

AC and DC stray mitigation bonding, zinc electrode/ribbon connections for earthing, IJ surge arrestors cable tails:‐

25 mm2

Negative and positive DC supply, positive DC groundbed distribution cables , Interpipeline bonds and electrical continuity jumper

35 mm2

Cable colour coding shall comply with the following,

Items Cable Insulation/Sheath

Magnesium anode, foreign pipeline cables, zinc ribbon/electrode connection at casings:‐

red/red

Monitoring coupons:‐ blue/grey

Permanent reference electrodes:‐ brown/grey

Zinc electrode/ribbon connections for earthing:‐

green‐yellow

Positive DC supply, DC groundbed distribution cables:‐

red/red

Other cables black/black






2.5 Cable Joint Kits

Cable joint kits shall be purpose made epoxy filled plastic joint boxes. Each kit supplied with a suitably sized electrolytic tinned brass through‐joint cable connector.

2.6 Cable Identification Tags/Sleeves

Temporary cable identification shall be effected by using write‐on self‐laminating vinyl cable markers.

Permanent cable identification shall be effected by using slide on PVC Z–type and/or captive PVC oval cable markers.

2.7 Cable Termination Lugs

Cable lugs shall be electrolytic tinned copper crimp compression type, suitably sized to fit the cable to be terminated and the terminal connection.

2.8 Cable to Pipe Connections

All cable to pipe connections shall utilise threaded studs of M8 minimum size.

Studs shall be connected to the pipe by drawn arc braze. All connections shall comply with Project welding procedures.

Test/monitoring cables shall not utilise the same stud as current carrying or mitigation earthing cables.

2.9 Cable Marking for Burial

Cable tiles shall be pre‐cast concrete, baked clay or recycled polyethylene, minimum width 200 mm, marked `Danger Electricity'.

Cable warning tape shall be yellow polyethylene, minimum width 100 mm and marked `Caution Electricity Cable Below' every 500 mm.

2.10 Carbonaceous Backfill

Carbonaceous backfill shall be calcined petroleum coke meeting the following requirements,

‐ Fixed carbon: > 99%

‐ Specific gravity > 2.0

‐ Bulk Density: > 800 kg/m3






‐ Particle size range (dia)

i) horizontal & shallow vertical groundbeds:

0.1 to 10 mm

ii) deep well vertical groundbeds: 90% 1‐5 mm, max 12 mm

‐Resistivity: < 0.15 ohm.cm @ 10 Bar

‐ Ash content >0.20%

‐ Volatiles >0.60%

‐ Moisture content >0.60%

Backfill shall be supplied in sacks or drums. Individual containers shall not weigh more than 25 kg.

2.11 Groundbed Surface Markers

Posts for the marking of horizontal and shallow vertical impressed current groundbeds shall be reinforced concrete having a section approximately 100 mm x 100 mm and length of 1000 mm.

Cast into at least one face of the post shall be the inscription ‘GROUNDBED’.

2.12 Impressed Current Anodes

2.12.1 Silicon Iron Anodes

Anodes shall be of a cast high silicon iron and shall meet the requirements of BS 1591 Grade Si14 with a 14‐15% by weight silicon.

Anodes for horizontal and shallow vertical groundbeds shall be supplied with a 16 mm2 (7/1.70 mm) single core, copper, XLPE/PVC cable tail. The cable tail length shall not be less then 3 m.

The cable/anode connection shall be caulked lead or approved equivalent method. The cable connection shall be sealed and protected overall by a cast resin cap which shall encase the insulation and sheathing ends of the cable, a section of the anode head and any additional cable retaining fixings. The resin used shall be compatible with the intended use.

The cable/anode connection shall be provided overall with a heat‐shrink anode cap.






All anodes shall be generally free from shrinkage, porosity, blow holes and surface defects. Any surface defect having a penetration in excess of 6.5 mm shall render the anodes unacceptable.

Each anode shall be tested and certified as conforming to the following:

Ten amperes DC shall be passed through the cable and anode body and the initial volt drop across the cable/anode assembly, excluding the volt drop due to the cable resistance, shall not exceed five millivolts. The volt drop measured after 10 minutes continuous current flow shall not exceed the initial measurements by more than 10%.

The anodes shall be pallet packaged and suitably protected against damage for freighting to site.

2.12.2 Mixed Metal Oxide

Anodes shall be titanium core to ASTM B338 or B265 Grade 1 provided with a mixed metal oxide coating of IrO2 and Ta2O5.

Anodes for horizontal and shallow vertical groundbeds shall be supplied with a 16 mm2 (7/1.70 mm) single core, copper, XLPE/PVC cable tail. The cable tail length shall be not less then 3 m.

Anodes for deep well groundbeds shall be supplied with a 16 mm2 (7/1.70 mm) single core, copper, Kynar/HMWPE cable tail. The cable tail length shall depend on the depth of the anodes in the deepwell.

The anode cable connection shall be a proven factory made connection which shall be tested and certified as having a resistance of less than 0.001 ohms.

The cable/anode junctions shall be provided overall with a heat‐shrink sleeve.

The anodes shall be pallet packaged and suitably protected against damage for freighting to site.

The size of each anode, the number of anodes per string and the spacing between anodes shall be as detailed in the Bill of Quantities.

2.12.3 Linear Anodes

Linear anodes shall be made of copper‐cored mixed metal oxide anode (MMO) powered by a 10 mm2 copper cable insulated with an inner layer of halar and outer layer of high molecular weight polyethylene. The central MMO wire and cable shall be surrounded by factory prepackaged, high conductivity coke breeze, held in place by porous, woven acid‐resistant jacket.






The following test method shall be carried out and test results shall be provided by the Manufacturer to the Employer prior to supply:

Property Test Method Accepted Value Copper

Conductor

Dimensions ASTM B‐263 10 mm2

Coke Breeze Fixed carbon ASTM D‐172 99.5 % Resistivity @23°C, 10 bar <1 Ohm‐cm

Fabric Jacket

Weight ‐ Min. 200 g/m² Bursting strength ISO 3303 >500 N

Abrasion Resistance

ASTM D‐4157 200 cycles to fail

Fluid resistance Internal immersion test 6 months

pass

Chlorine resistance

Internal immersion test 6 months

pass

UV resistance ASTM G‐53 <50% tear strength loss

2.13 Magnesium Anodes

Magnesium anodes shall be to the following composition:‐

Manganese : 0.5 ‐ 1.3%

Aluminium : 0.01% max

Copper : 0.02% max

Iron : 0.03% max

Nickel : 0.001% max

Lead : 0.01% max

Silicon : 0%

Magnesium : remainder






Open circuit potential : ‐1.75 volts ref. Cu/CuSO4

Current efficiency : 50% minimum

Capacity : 1230 amp.hrs per kg

Melt analysis and test certificates certifying compliance with the above requirements shall be provided by the Contractor, with each batch of anodes, when directed by the Employer.

Each anode shall be fitted with a 6 mm2 (7/1.04 mm) single core, copper PVC/PVC or XLPE/PVC red/red cable tail, brazed to the steel insert. The cable connection shall be fully sealed to prevent moisture penetration.

Anodes shall be supplied pre‐packaged in a backfill of the following composition,

‐ Powdered gypsum: 75%

‐ Granular bentonite: 20%

‐ Anhydrous sodium sulphate:

5%

The backfill shall be contained within a cotton bag and the anode shall be centrally located within the backfill.

2.14 AC Current Monitoring Coupons

Monitoring coupons shall comprise a steel coupon set in a PVC housing complete with cable tail. Coupon/cable connection shall be fully encapsulated and be suitable for burial.

The area of exposed steel coupon shall be 1.0 cm2.

Cable tails shall be 6 mm2 (7/1.04 mm) single core, copper, PVC/PVC or XLPE/PVC blue/grey.

2.15 Solar Power Units

Solar power unit shall be utilised when cathodic protection station is located remote from ac power source. The solar power unit shall comprise of photovoltaic panels, charge regulator, CPCU and battery bank. Solar units shall be sized to endorse the operation of the SCADA system which shall provide output current, output voltage, pipe potential, and unauthorised access alarm transmitter for the unit.

Solar power units shall fully comply with the requirements detailed in Appendix A.

2.16 Test Post/Pillar Facilities

Test post/pillars shall be BigFink and FinkLet or equivalent which provides convenient and easy test /monitoring and full cable protection.






Cable connections in posts shall be a minimum of M8 brass or stainless steel bolt, nut and washer assemblies, fully insulated from the facility housing where the housing is metallic or of concrete.

Cable conduit shall be a minimum 75 mm diameter for the BigFink and 25 mm diameter for the FinkLet or equivalent test post.

Each test post shall be supplied fitted with marker plates to identify the pipeline location/sequence designation and facility type.

2.17 Junction Boxes

Positive and negative wall/frame mounting enclosures shall be manufactured from stainless steel plate of 1.5 mm thickness.

The enclosure shall be fitted with cable entry plate and a M8 threaded stud for earthing to base, door and mounting plate.

The door shall be secured to the base by means of at min. two hot galvanized hinges and its angle of opening is at least 130°. The direction of turn of the door shall be left‐right and is reversible, and are closed by min. two locking system. The doors shall be sealed from any outer contaminants or dust using seamless polyurethane gasket.

The enclosure shall achieve a minimum protection degree of IP65.

2.18 Transformer‐Rectifier Units

Where ac power is available transformer‐rectifier units for CP stations shall provide a full wave rectified DC output from a single phase 230 volt, 50 Hz AC input supply. Units shall be variac controlled. Units shall be oil cooled and suitable for plinth mounting.

Transformer‐rectifier units shall fully comply with the requirements detailed in Appendix A to ensure minimum standards and harmonisation of units throughout the pipeline system.

2.19 Zinc Ribbon

Zinc ribbon shall be of diamond cross section cast Zinc to MIL‐A‐18001K, on a galvanised steel wire core.

Melt analysis certificates certifying compliance with the above composition shall be provided by the Contractor, with each batch of ribbon, when directed by the Employer.






Appendix A: Transformer Rectifier and Solar Power Unit

A1. Cathodic Protection Transformer Rectifier Unit

1. GENERAL

Transformer‐rectifier unit shall provide a full wave rectified DC output from a single phase 230 volt (+10%, ‐6%), 50 Hz (+ 2%) AC input supply.

The maximum dc output voltage shall not exceed 48 volts.

The unit shall be oil cooled and suitable for plinth mounting in the project environmental conditions.

2. OIL TANK AND CONTROL ENCLOSURE

The unit shall generally comprise a sealed oil tank and external control enclosure.

The oil tank shall be a welded steel construction and be so sized that adequate oil cooling is provided when the unit is operating continuously at full load.

The oil tank shall be provided with a silica gel breather, oil filler cap, oil drain valve, dial thermometer and pocket and oil level sight gauge and its complete filling of oil.

The control enclosure for the unit shall be mounted on the oil tank, have front access via a hinged, lockable door and shall be constructed from 3 mm minimum thickness steel suitably stiffened to form a rigid unit. All cables from the tank shall enter the unit via the base or rear of the enclosure. All external cables shall enter the enclosure via a removable gland plate in the enclosure base.

The control enclosure shall contain all controls mounted on a panel for easy and safe access. The enclosure shall conform to EN 60529 protection category IP65, proof against damage by dust and water.

The tank and control enclosure shall be painted to meet as a minimum ‘High’ durability in a ‘C3’ corrosivity category in accordance with EN 12944‐5. All paint coats shall differ in shade and the final paint coat colour shall be as advised by the Employer.

3. GENERAL CONSTRUCTION

All components within the oil tank shall be assembled on a common rack. The dimensions of the rack and equipment shall be such that it may be removed and installed within the enclosure as one or two complete assemblies with only external wiring disconnections.

The unit shall be constructed to facilitate ease of repair and maintenance






All hinges, fixings and items liable to fretting or mechanical damage of coatings during normal use, shall be either 18/8 stainless steel or non ferrous materials or galvanised mild steel.

All materials used in the construction of the control panel and internal fixings shall be made from non‐hydroscopic materials.

All equipment and wiring shall be fully insulated from the support frame, tank, control enclosure and if made of conducting material, the control panel.

When the outer door of the control enclosure is opened to gain access to the controls and meters, it shall not be possible to make contact to live terminals.

A viewing window shall be fitted in the front of the control enclosure door to enable all meters and the AC healthy light to be viewed with out the need to open the enclosure door.

4. MODE OF OPERATION

The Unit method of control shall utilise variac to provide infinite variable adjustment between minimum and maximum output of the unit.

Variac controls shall provide constant voltage utilising handgrip for manual control of output. All controls shall be mounted on the control panel.

5. ALARM TRANSMITTERS

The unit shall be provided with output current, output voltage, pipe potential, and unauthorised access alarm transmitters compatible with the pipeline SCADA system.

6. TRANSFORMER

The main transformer shall be in accordance with EN 60076 with separate primary and secondary windings on a common core with Class "F" type insulation. It shall be continuously rated at full current and voltage load at the maximum operating temperature.

An earthed shield shall be placed between primary and secondary windings of the main transformer.

The main transformer efficiency shall not be less than 95%.

7. RECTIFIER

The rectifier elements shall be connected for full wave rectification using a single phase bridge circuit in accordance with IEC 60747‐2. The bridge rectifier shall be continuously rated at the unit full load current and voltage at the maximum ambient temperature specified.






The bridge rectifier shall be rated to provide an adequate margin for over voltage and over current surges and the peak inverse voltage rating shall be 1.2 kV. Voltage protection circuits shall be provided to the bridge rectifier. High speed fuses shall be provided between the transformer secondary and the rectifier bridge.

8. OUTPUT RIPPLE

The unit shall be fitted with smoothing filter circuits to ensure the DC output does not contain more than 5% ripple.

9. ELECTROMAGNETIC COMPATIBILITY

The unit shall comply with EU Electromagnetic Compatibility Directive 89/336/EEC amended by 92/31/EEC, 93/68/EEC and EN 50082 for Conducted and Radiated Immunity and EN 50081 for Emissions.

10. METERS

The unit shall be provided with the following meters mounted on the control panel behind the viewing window:‐

a) One 3½ digit LED DC output ammeter with 11 mm LEDs and scaled from 0.01 to 199.9 amps.

b) One 3½ digit LED DC output voltmeter with 11 mm LEDs and scaled from 0.01 to 199.9 volts.

c) One 3½ digit LED DC potential voltmeter with 11 mm LEDs and scaled from ‐0.01 to ‐199.9 volts.

Fuses shall be placed in both leads of the voltmeter.

Beneath each meter, separate 4 mm sockets shall be provided on the panel so that measurements of current, voltage and potential can be made with a portable voltmeter.

11. AC/DC CIRCUIT PROTECTION

A two‐pole miniature circuit breaker (MCB) complying with EN 60898 shall be provided to interrupt the AC supply to the unit The MCB shall be capable of carrying the maximum transformer inrush current without tripping.

The MCB shall be accessible by opening the control enclosure door.

The total DC output current in the negative circuit shall be fused.

Suitably rated surge arrestors shall be fitted across the AC input and DC output.






12. AC AND DC TERMINALS

The AC terminals shall be suitably shrouded and a clear warning label shall be fitted immediately adjacent to the terminals.

The label shall carry the words ‘SWITCH OFF AT SUPPLY POINT PRIOR TO DISCONNECTING’. The lettering shall be red on white background.

The DC output terminals shall be sized and rated for 35 mm2 single core cables.

DC terminals shall be identified with white/black/white engraved labels 3 mm letter height, the negative bearing the inscription ‘‐ve pipe’ and the positive bearing the inscription ‘+ve groundbed’.

AC supply terminals shall have a distinct and clean separation of at least 150 mm from DC terminals and all terminals shall be located at a minimum height of 250 mm above the bottom of the enclosure.

13. CABLING

All internal wiring shall be PVC insulated with a glossy finish and shall be incapable of supporting combustion and capable of withstanding the temperatures to be met in service.

The cross‐section of copper conductors and cable terminations shall be such that the maximum rated current carried shall not cause excessive volt drops or temperature rise.

All cable terminations and terminal connections of components shall be of adequate cross‐section and shake‐proof.

All terminals and equipment operating at AC supply voltage levels likely to cause electric shock to operators shall be insulated or screened from accidental contact.

Cable shall be neatly bunched, properly supported where required and both ends of the cable will be marked with ferrules identifying the cables.

All wiring will be terminated with proprietary compression lugs and will be numbered at all terminations.

14. EARTHING

A minimum of 2.5 mm2 single core PVC insulated green‐yellow cable shall be used within the unit to earth all metallic components. The enclosure door, gland plates, terminal rails and similar metallic objects will be suitably grounded.

A brass M10 earth stud shall be provided on the external surface of the unit.






Earth terminals within the enclosure shall be identified by a label bearing the inscription ‘Warning – Electrical Earth’ in red lettering.

Pre‐insulated compression crimp tags will connect all earth wires and all earth terminals will be numbered.

15. LABELLING

The function of all instruments, switches, terminals, indicators and the like on the control panel shall be clearly and permanently marked, with lettering not less than 3 mm high. All terminals shall be clearly labelled in accordance with their designation. Labels shall be engraved; black letters on a white background except where red is required. The labels shall be secured with countersunk stainless steel screws.

The outside of the unit shall carry a manufacturers standard rating plate, showing the name of the manufacturer, the type of equipment, maximum operating temperature, input and output voltage and current, kVA rating, type and unique serial/identification number.

A white/black/white engraved label with 12 mm high lettering shall be fixed on the front of the enclosure of dimensions 150 mm x 100 mm engraved with the following:

CATHODIC PROTECTION SYSTEM

TRANSFORMER

RECTIFIER

Voltage warning labels shall be fitted to the outside of the enclosure and shall be clearly visible.

All components within the unit shall be given a unique identification number.

16. SUNDRIES

The transformer‐rectifier shall be supplied complete with all external fittings to facilitate transportation, installation, operation and maintenance.

These shall include but not be limited to the following items:‐

a) An engraved schematic diagram of the equipment circuitry securely attached to the inside of the enclosure door.

b) A flush fitting lock fitted to the enclosure door and provided with three keys.






c) A spare silica gel cartridge

d) Two complete sets of all cartridge fuses located on the panel or on the inside of the enclosure door.

17. TEST AT MANUFACTURER'S WORKS

The following tests shall be carried out at the Manufacturer's Works in order to determine that the units comply with this specification. Unless otherwise specified, all electrical tests shall be carried out in a manner prescribed by the relevant standard or specification or where no standard or specification applies, in a manner approved by the Employer.

The unit shall satisfactorily pass the following tests and the test result shall be recorded and up to three copies of a test certificate setting out the result in an approved form made available to the Employer:‐

a) All circuits and apparatus shall withstand a power frequency voltage test in accordance with the requirements of EN 60439.

b) 500 volt megger insulation test comprising:

- Primary to Secondary

- Primary to Earth

- DC positive to Earth

- DC negative to Earth

c) The unit shall be connected up and run continuously for at least 24 hours at maximum current and voltage outputs. The 500 volt insulation test shall be repeated immediately on conclusion of the continuous 24 hour test run.

d) Performance tests to EN 60076. The ratio, polarity, no load current, no load losses, full load losses, volts and winding resistance shall be measured and recorded.











A2. Cathodic Protection Solar Cell Unit

In remote locations solar power units shall be used to power the CP system. The solar power unit shall consist of a Solar Power Supply Unit providing dc power to a Controller Unit. The solar power unit shall be a completely self‐contained installation incorporating the following main components:

support frame photovoltaic array (solar array) storage batteries charge regulator and controller (power distribution unit) CP controller unit

1. CODES AND STANDARDS

The Solar Power Supply equipment shall conform to the latest editions of the following codes and Standards.

IEC 60904 Photovoltaic Devices.

IEC 60947 Low Voltage Switchgear and Control Gear.

IEC 60157 Low Voltage Switchgear and Control Gear.

IEC 60158 Low Voltage Control Gear.

IEC 60185 Current Transformers.

IEC 60186 Voltage Transformers.

IEC 60269‐1 Low Voltage Fuses.

IEC 38 Standard Voltages.

IEC 60112 Methods of determining the comparatives and the proof tracking indices of solid insulating material under moist conditions.

IEC 60144 Degree of Protection for L.V. Switchgear and Control Gear.

IEC 60277 Definitions for Switchgear and Control Gear.

IEC 60337 Control Switches.

IEC 60364 Electrical Installations for Buildings.






IEC 60408 Low Voltage Air Break Switches, Air Break Disconnectors and Fuse Combination Units.

IEC 60439 Factory Built Assemblies for Low Voltage Switchgear and Control Gear.

IEC 60445 Identification of Apparatus Terminals and General Rules for a Uniform System of terminal marking, using alphanumeric notation.

IEC 60529 Classification of degrees of protection provided by enclosures

IEC 60664 Insulation co‐ordination with low voltage systems including clearances and creepage distances for equipment.

IEC 60896 Lead Acid Batteries

In the event of conflict between Standards, the most stringent shall prevail.

2. GENERAL DESIGN REQUIREMENTS

The power output from the Solar Power Supply Unit shall be sufficient to supply the required load including the operation of the SCADA system plus simultaneous charging of the storage batteries. The unit shall be capable of operating between zero and the full rated load. The load shall be maintained by means of standby batteries during periods of low light (‘no sun’ days) and during the hours of darkness.

The module shall be capable of operation for 24 hours (1 day) without sunlight.

The Solar Power Supply Unit shall be designed to operate on 8 hours sunshine per day based on the solar insolation values (ie the level of radiation received from the sun) as per Section 6.

The Manufacturer shall submit the proposed design and calculations for the Employer approval. The design shall include all interconnections and interfaces.






3. DESIGN DATA

The Manufacturer shall submit the following information for Employer approval prior to the commencement of detailed engineering:

1. Full material description of the solar modules.

2. The ratio of collecting area compared to the total area.

3. The life of modules and battery.

4. Conformance to hail‐stone test.

5. Charge/discharge controller particulars.

6. Tilt angle of the solar modules.

The following data shall be provided for the solar modules:

1. Number of solar modules.

2. Average output of each solar module under the expected operational and environmental conditions.

3. I‐V Characteristics.

4. Open Circuit Voltage (Voc).

5. Short Circuit Current (Isc).

6. Maximum Power Point (P max) and Operating Point under standard test conditions and also at 40°C and 60°C cell temperatures.

The following data shall be provided for the storage batteries:

1. Load pattern.

2. Battery chargers factor (efficiency).

3. Acceptable maximum Daily Depth of Discharge (DDOD).

4. Calculated maximum DDOD.

5. Calculated average DDOD.

6. Acceptable minimum state of charge.

7. Calculated minimum battery back‐up time.

8. Calculated average battery back up time.

9. The maximum time taken to fully charge the battery at the end of the back‐up time.






10. The maximum, average, and minimum terminal voltage supplied to the equipment during day and night.

System losses and de‐rating factors due to the following shall be stated:

1. Charging efficiency of the batteries

2. Ageing

3. Dust deposit

4. Environmental conditions (temperature, wind, sandstorms, hail)

5. Insolation variation due to normal year to year statistical changes

6. Current consumed by control equipment, metering and alarm system

7. Losses in control equipment, wiring, fuses, diodes and circuit breakers

The Manufacturer shall submit evidence of satisfying the basic requirements by means of a design and system simulation taking into account all parameters mentioned above.

4. AMPERE HOUR DESIGN REQUIREMENTS

The size of the system shall be such that the energy requirements of the load can be met by the battery during ‘no sun’ days.

The battery shall have sufficient capacity to meet the back‐up time required for the loads, with the batteries at the maximum DDOD and with minimum or insufficient insolation during the intervening days, considering a minimum state of charge of the battery of 20%.

From the minimum state of charge level, the system shall also, under conditions of minimum daily average insolation, recharge the battery to full charge level, while at the same time supplying rated power output to the load.

The solar module rating shall be such that at any moment the battery charge factor shall be 1.2 minimum, and the DDOD shall not be more than 15% of full capacity, depending on type of battery and ambient temperature of the battery location.

If the solar modules are installed at a significant distance from the load and/or battery, attention shall be given to the selection of the output voltage and the cross‐sectional area of the cabling to avoid unacceptable losses.

Site and panel temperature must be taken into account for the performance of the solar modules.






Electrical connections shall be made to a junction in which two by‐pass diodes shall be incorporated to prevent hot spots. Each diode shall have a minimum direct current value of three times the short circuit current of the array on which it is installed.

5. INSOLATION DATA

The Manufacturer shall be responsible for obtaining insolation data for the project location from internationally recognized sources and use the same for the design of the Solar Power Supply Unit.

The Manufacturer shall submit to the Employer detailed information on his source of insolation data together with his design of the Solar Power Supply Unit. These shall be submitted to Employer for approval before implementing the design.

6. SOLAR MODULES

The solar modules shall be mounted on a frame suitable for installation at site.

The support frame shall be constructed from corrosion resistant, heavy extruded aluminium alloy designed for the climatic conditions and the whole installation capable of withstanding the wind and storm conditions.

This frame shall be designed for tilting to the optimum angle for absorption of energy and also for creating a self‐cleaning washing of the module surface when it rains.

The frame shall be supplied with holes or slides for mechanical attachment. Should vandal protection be required adequate allowance shall be made for the shielding of solar radiation from the panels.

7. BATTERY

Batteries shall be the deep‐cycle, long‐life, maintenance‐free, and sealed type design, proven for solar power system use. The effects of site temperatures on available capacity and lifetime expectancy shall be taken into account in the selection of the battery type and its housing.

The expected service life shall be stated for the service conditions stated herein and shall have the following features:

1. They shall not degrade more than 20 percent of full capacity over their service life.

2. Storage capacity shall be calculated to allow the load to operate continuously for a minimum of one (1) ‘no sun’ days.






3. Battery capacity shall not be allowed to fall below 20 percent of full capacity during operation.

4. The self discharge rate shall be <2% per month at 20ºC.

Cooling of the batteries shall be by natural air flow and good design practice only, forced cooling shall not be used.

The batteries shall be arranged to facilitate access for maintenance purposes. Inter cell connectors shall be provided.

Batteries shall be of minimum five years lifespan.

8. POWER DISTRIBUTION UNIT

Each solar power supply unit shall have a power distribution unit (PDU). The PDU shall be of modular design for ease of component replacement and maintenance and shall ensure proper charging and discharging of the batteries through the following functions:

1. Dual voltage regulation to cater for boost and float operation.

2. Overcharge protection of the batteries by switching off the solar array from the system if the battery is already fully charged.

3. Battery protection by switching off the load from the system if the voltage drops below a voltage limits and alarm contact for warning of low battery voltage.

4. Temperature compensation maximum charge voltage.

5. Prevention of overnight discharge of the batteries through the solar array.

6. Protection against over voltage from the solar module output.

7. Protection against overload and short circuit conditions in the connected load.

The PDU shall include a voltmeter and ammeter and LED Indications for all battery alarms etc. As a minimum the following shall be provided to indicate system status:

1. Battery voltage below minimum voltage.

2. Battery voltage above maximum voltage.

3. Voltage free contacts for remote indication of battery low voltage.

The PDU shall incorporate a SPDT (Single Pole Double Throw) contactor which is actuated on battery low voltage. The contactor rating shall allow for the inductive load during switching. A local programmable module with display panel shall be provided.






Failure of the PDU shall not result in catastrophic failure of the whole system.

The charge controller should be able to operate at various system voltages (12V, 24V, 36V and 48V.

9. CP CONTROLLER UNIT

The CP controller unit (CPCU) shall regulate the voltage and current output to the cathodic protection system to a manually set level (i.e. the CP load). The dc output shall be controllable from any value between zero and maximum, the output current shall be electronically limited to the rated maximum of the unit.

The CPCU shall be specified and supplied to the following requirements:

1. The CPCU shall be suitably rated for the requirements of the CP system.

2. The unit shall be protected against induced over‐voltages.

3. The unit shall have a CP load MCB (miniature circuit breaker) with trip alarm.

4. Display meters shall be provided for: the CP output voltage, the CP output current and the reference cell potential.

5. Synchronized Interrupt timer compatible with those fitted in the transformer rectifiers

Separate analogue meters shall be provided for the continuous display of the output voltage, output current and the pipeline drain point potential. The meters shall be flush mounted on the control panel and visible through the enclosure door.

Meters shall have scale settings of 20% greater than the maximum output rating of the CPCU with a red line to show the maximum output value.

Each controller unit shall incorporate a synchronized GPS current interrupter similar to that fitted in the transformer rectifiers.

The CPCU shall incorporate RTU designed to collect the DC output , AC input and pipeline potential data and transmit it using GSM text messaging to cell phone on a daily and weekly basis in addition to alarm messaging in case inadequate protection arise during normal operation.. The RTU shall be supplied with data management software for data display and interpretation.

Terminals shall be provided on the CPCU panel for termination of the DC supply cables to the groundbed , pipeline, and the potential monitoring cables.






All controls, switches, fuses, meters and cable entry glands shall be easily accessible.

10. AUXILIARY EQUIPMENT

Separate enclosures shall be provided for the PDU and the CPCU. As a minimum the enclosures shall be constructed to EN 60529 protection category IP65, proof against damage by dust and water.

The enclosures shall be provided with DC circuit breaker protected terminals for the design loads and cable glands appropriate for the installation cables.

The interconnection between the solar array and the PDU shall be made by means of a DC circuit breaker to facilitate the electrical isolation of the solar modules from the system for repair or replacement.

The interconnection between the battery bank and the PDU shall also be made by means of a DC circuit breaker to facilitate the electrical isolation of the battery from the system for inspection and maintenance purposes.

11. INTERCONNECTION CABLES

All interconnection cables between the solar modules, the solar array, the storage batteries and the control equipment enclosures shall be supplied.

All cables shall be 600/1000 V grade, copper conductor, PVC insulated, PVC sheathed, steel wire armoured with PVC outer sheath (PVC/PVC/SWA/PVC).

12. EARTHING

M8 earth studs shall be supplied on all cabinets and enclosures.

13. TESTS

The complete solar system complete with all interconnecting cables shall be tested at the Manufacturer’s works in accordance with applicable codes and manufacturer’s standard testing procedures. Comprehensive test for the solar system shall be carried out throughout each process along the project. The Manufacturer shall submit copies of the subject test certificates to the Employer.

Testing shall include the following:

1. Visual inspection.

2. Insulation test on all cables.

3. Functional testing of the complete system.






4. Load testing of complete installation (under maximum CP load).

5. Battery discharge test.

6. Measurement of typical values of solar module short circuit current and open circuit voltage.

14. DOCUMENTATION

The Manufacturer shall supply installation, operation, maintenance manuals for each piece of equipment supplied and other documents as required defined in an approved Supplier Data Requirement List (SDRL), and including the following documentations to be submitted to the Employer for review and approval;

− Track record of materials and equipment. − Materials certificates for anodes to BS EN 10204 Type 3.1.B. − Certificate of compliance for hot dip galvanizing. − Coating materials certificates. − Product/Equipment/Material specifications, Manufacturer’s product data sheets

and drawings including, where appropriate, statements of manufacturing tolerances.

− Quality plan covering manufacture, inspection and testing of sacrificial anodes. − Detailed instrument and spare parts list. − Batch analysis for all sacrificial anodes supplied against the specification. − Factory test report of tests of dimensions, casting quality and cable connection

resistance. − Operating and instruction manuals. − As‐built drawings. − Spare lists.

Documents

J08086-FD-SPC-ENV-05 REV 0