Project Variations

Kuwait National Petroleum Company (K.S.C.) P4001NRP.00.10.64.001 New Refinery Project (NRP) REV B, 31-Jan-2006 KNPC Contract No. NRP/PMC-0001/CNSL Page 1 of 27 Fluor Project No. A1WR

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Project Specification ELECTRICAL SPECIFICATION FOR

PACKAGED MECHANICAL EQUIPMENT

B 31-Jan-06 Approved for Design

A 17-Oct-05 Approved for Design JRP SB BTD

O 19-July-2005

Issued for Approval HDV SB BTD

Rev. Date Description Orig. CHKD By Approved By Client

Approval

Kuwait National Petroleum Company (K.S.C.) New Refinery Project

Kuwait

Fluor Enterprises, Inc. Fluor Project No. A1WR

Sugar Land, Texas

CONTRACT NO. PROJECT SPECIFICATION NO. REV. NO.

NRP/PMC-0001/CNSL

P4001NRP.00.10.64.001

B


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Record of Revisions

Rev. No. Date Description

O 19 July 2005 Issued for approval.

A 17-Oct-2005 Approved fro design- Incorporated KNPC comments from transmittal X-1312. In addition the following changes have been included:

• Deleted appendices 1 and 2 from the table of contents and the text.

• Revised section 4.7 to include ingress protection for different areas.

• Revised section 5.1 to remove Holds on temperature class.

• Revised section 5.4 to add reference to DEP 33.64.10.10-Gen section 2.3.

• Revised section 6.5 to change 3.3 kV to 6.6 kV.

• Revised section 7.1 to include earthing requirements for skids with multiple modules.

• Revised section 8.2, second bullet to include auxiliary contacts for fuses for alarm and indication.

• The degree of protection in section 10.4 is now included in 4.7

• Section 10.15 is revised to include reference to PV 33.64.10.10-P4001NRP-00-PV.

• Revised section 11.4 to include reference to PV 33.64.10.10-P4001NRP-00-PV, appendix 15.

• Revised section 15.3 to include reference to PV 33.66.05.33-P4001NRP-00-PV.

• Added reference to specification Basic Engineering Design data P4001NRP.00.10.08.001 in section 10.0

B 31-Jan-06 Approved for design with the following revisions:

• Added section 19.0 – Documentation

• Revised Section No. 19.0 References to Section No. 20


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TABLE OF CONTENTS

1.0 SCOPE.......................................................................................................................................4

2.0 INTRODUCTION .......................................................................................................................4

3.0 CODES, STANDARDS AND SPECIFICATIONS ......................................................................4

4.0 SERVICE CONDITIONS............................................................................................................4

5.0 HAZARDOUS AREA CERTIFICATION OF ELECTRICAL EQUIPMENT AND MATERIALS...5

6.0 UTILIZATION VOLTAGES.........................................................................................................6

7.0 EARTHING ................................................................................................................................7

8.0 ELECTRICAL DISTRIBUTION ..................................................................................................8

9.0 CONTROL AND INDICATION...................................................................................................9

10.0 JUNCTION BOXES AND CONTROL PANELS.......................................................................11

11.0 WIRING AND TERMINALS .....................................................................................................13

12.0 INTERCONNECTING CABLES AND TERMINATIONS..........................................................15

13.0 LIGHTING ................................................................................................................................15

14.0 REMOTE CONTROL UNITS (RCU) AND OTHER CONTROL EQUIPMENT ........................15

15.0 MOTORS .................................................................................................................................16

16.0 ELECTRIC HEATERS .............................................................................................................16

17.0 ELECTRIC TRACE HEATING SYSTEMS...............................................................................16

18.0 NAMEPLATES.........................................................................................................................16

19.0 DOCUMENTS..........................................................................................................................17

20.0 REFERENCES .........................................................................................................................20


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1.0 SCOPE

This specification defines the requirements for design, manufacture, installation and testing of electrical equipment and materials forming an integral part of a mechanical package for the New Refinery Project (hereafter referred to as ‘the Project’) for KNPC near Kuwait City, Kuwait.

2.0 INTRODUCTION

This specification shall also be read in conjunction with all other specifications and data sheets attached to the material requisition. Specifically, reference shall be made to Procedural Specification “Instrumentation for Equipment Packages”, DEP 32.31.09.31-Gen., and associated NRP Project Variation 32.31.09.31-P4001NRP-00-PV.

3.0 CODES, STANDARDS AND SPECIFICATIONS

3.1 The electrical equipment and installation shall conform in design, materials and performance, except where otherwise specified, with the current issue and amendments of the Codes and Standards specified in Section 19.

3.2 Wherever possible, equipment, materials and services selected for use on the Project are to be readily available in Kuwait.

3.3 All conflicts between the requirements of this specification and other relevant documents shall be referred to the Company for resolution.

3.4 Under no circumstances does this specification replace or supersede the requirements contained in any standard or regulation that may be applicable, unless formal written dispensation has been provided by the Company.

3.5 All equipment shall be certified for the intended use in accordance with the requirements of the relevant Codes and Standards as listed in Section 19.

4.0 SERVICE CONDITIONS

4.1 All electrical equipment and materials shall be suitable for continuous operation under the service conditions specified in the equipment specifications, requisition and data sheets. Due consideration shall also be given to drifting sand and a near shore environment.

4.2 Electrical equipment and materials shall be located in a manner that facilitates easy access for routine operation and maintenance. Ladders and scaffolds shall not be required to access the equipment.

4.3 Electrical equipment and materials located outdoors shall be suitable for continuous operation in direct sunlight (black body exposure temperature of 85°C maximum), or it shall be provided by


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the vendor with a suitable protection or hood. Electrical components shall be suitable for continuous operation at the maximum temperature that can exist within the enclosure.

4.4 Ampacity of wiring, ratings of transformers, motor overcurrent protective devices and all other electrical equipment shall be based upon 50°C ambient for outdoor installations and 40°C ambient for indoor installations.

4.5 Electrical components for incorporation into electrical equipment shall comply with the relevant Codes and Standards specified in Section 19.

4.6 Reliability of all electrical equipment and materials to perform continuously in the service conditions specified is essential. Electrical equipment and materials typical of that being supplied by the Vendor shall have been in operational use elsewhere for a minimum of two years. Prototype or unproven equipment or materials will not be considered.

4.7 The minimum degree of protection against ingress of water and dust for electrical equipment, materials and control panels in accordance with IEC 60529 shall be as follows:

• Indoor, in air conditioned area: IP 44

• Indoor in non-air conditioned area: IP 54

• Outdoor; IP 65

The above IP ratings shall be used unless a lower rating is specifically allowed elsewhere in the DEPs.

4.8 Where electrical equipment or materials are subject to routine deluge testing or other powerful water jets, it shall have minimum degree of protection equal to IP66.

4.9 Electrical apparatus shall be protected against the harmful effects of short-circuits and earth faults.

5.0 HAZARDOUS AREA CERTIFICATION OF ELECTRICAL EQUIPMENT AND MATERIALS

5.1 Electrical equipment and materials located in a hazardous (classified) area shall be in accordance with the applicable requirements of IEC60079 (all parts). Electrical equipment in hazardous areas shall be certified for gas group IIA temperature class T3 (in areas where Hydrogen is not present). A more stringent classification may be required in some areas, as determined during detailed design, and as stated on the equipment data sheets. In areas where Hydrogen may be present in the atmosphere, Electrical equipment shall be certified for gas group IIC temperature class T3, minimum. In all cases, equipment and material shall meet the requirements for the hazardous location in which they are installed. Hazardous area certifications for electrical equipment shall apply over the full ambient temperature range applicable in Kuwait as indicated in Specification for Basic Engineering Data, specification number P4001NRP-.00.10.08.001


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5.2 Electrical and instrument equipment in hazardous (classified) areas shall be in compliance with ATEX Directive 94/9/EC.

5.3 Selection and construction of electrical equipment and materials shall comply with the requirements of the relevant parts of the Codes and Standards listed in Section 19, and this specification.

5.4 Electrical equipment and materials shall be certified for use in the highest classification of hazardous area in which they are installed. Certified electrical equipment and materials shall be explosion protection type per DEP 33.64.10.10-Gen, section 2.3.

5.5 All certified cable glands are to be dual-certified explosion protection type Exd/Exe. The entry thread of cable glands should preferably be ISO metric. Where ISO metric threads cannot be provided, certified ISO metric adapters shall be furnished with each gland.

6.0 UTILIZATION VOLTAGES

6.1 The Vendor shall select electrical equipment which is appropriate for use with the electrical system as specified on the material requisition and data sheets.

6.2 Where the Vendor has provided field electrical or instrument devices for connection to the Company’s motor control centers, the control voltage shall be 230VAC derived from the Company’s equipment, unless otherwise indicated on the material requisition or data sheets.

6.3 Where the Vendor has provided field electrical or instrument devices for connection to the Company’s process control system, the voltage should be 24VDC derived from the Company’s equipment. Current-to-current transducers (isolators) will be provided by the Vendor where Vendor supplied signals may not be directly connected to the Company’s process control system.

6.4 Unless otherwise stated, all electrical equipment shall be suitable for operation within the voltage and frequency variations stated below, without damaging effects:

• Voltage 5%

• Frequency 2%

6.5 Unless otherwise stated, prospective fault currents for the various voltage levels are in accordance with the following:

• 6.6 kV system 40 kA rms for 3 sec sym, 100 kA peak

• 400V systems 65 kA rms for 1 sec sym, 143 kA peak

6.6 Where the Vendor package includes field electrical or instrument devices connected to Vendor’s Control Panel, (i.e. not directly connected to Company’s equipment), Vendor shall provide the necessary 24VDC power supply units to condition the Company provided 230VAC power.


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6.7 The phase rotation of the main distribution system is counter-clockwise. Phase sequence identification is RED-YELLOW–BLUE, corresponding to phases A-B-C (U-V-W).

7.0 EARTHING

7.1 Packaged mechanical equipment shall be provided with a tinned copper earth bar, 50 mm wide X 6 mm thick, the length of the earth bar shall be as required to suit the number of earth connections. The earth bar shall be securely fixed to the side of the skid. Structural steel and the metallic enclosures of all electrical and non-electrical equipment shall be directly bonded to this packaged mechanical equipment earthing bar using individual green/yellow PVC insulated copper conductors. Skids with mutiple modules shall have an earth bar for each module. For large single skids or modules, multiple earth bars may be used with approval by the Principal.

7.2 Two M10 holes, complete with bolts, nuts and washers shall be provided on each earth bar for connection of the Company’s earth cables.

7.3 Tanks, vessels, exchangers, and other non-electrical process equipment located on the packaged mechanical equipment shall each be provided with an M10 earth stud and shall be bonded to the earth bar with a minimum 25mm² green/yellow PVC insulated copper conductors.

7.4 All structural elements of the packaged mechanical equipment are to be bonded to form a single conductive structure and connected to the packaged mechanical equipment earthing system. The fastening together (bolting, welding, or other metallic means of mechanical connection) of the various metallic components of the structure shall be considered to effectively bond the components, and as such, additional electrical bonding jumpers shall not be required to insure continuity between the various components of the structure. When fastening, care must be taken to provde an electrically continuous connection (e.g. coated parts do not constitue a bonding connection). Where expansion joints exist in a structure, the structure columns shall be bonded to the plant earth grid as near as practical to, and on both sides of, the expansion joints.

7.5 The minimum cross-sectional area of earth conductors connecting equipment and structures to the packaged mechanical equipment earthing bar shall be per the table below.

to metallic enclosures of HV electrical equipment 70 mm2

to metallic enclosures of LV electrical equipment, having a

supply cable cross-sectional area ≥ 35 mm2 70 mm2

to metallic enclosures of LV electrical equipment, having a

supply cable cross-sectional area < 35 mm2 25 mm2

to control panels, etc. 25 mm2


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to non-electrical equipment exposed to lightning, e.g., tanks, columns and tall structures

70 mm2

to other non-electrical equipment 25 mm2

7.6 All earthing terminations shall be made with compression cable lugs. Interconnections shall be made using compression connectors. All bolted connections in the earthing system (i.e., connections to equipment) shall be fully accessible.

7.7 Control panels shall contain a tinned copper earth bar, 6 mm thick X 50 mm wide along the full length of the panel, located on the inside rear face. All metallic non-current-carrying parts internal to the panel shall be bonded together and connected to this earth bar.

7.8 Control panel doors are to be bonded to the main panel enclosure by means of a flexible 2.5 mm² green/yellow PVC insulated cable arranged so that it cannot be trapped as the door is opened or closed.

7.9 Control panels shall be provided with external M10 earth studs to facilitate connection to the Company’s external earthing system at two points. Earth studs shall be bonded to the earth bar with minimum 25 mm² green/yellow PVC insulated cable.

7.10 Earthing and bonding of equipment and components within the panel shall be carried out so as to mitigate the effects of electromagnetic radiation and interference in accordance with the requirements of IEC 61000.

8.0 ELECTRICAL DISTRIBUTION

8.1 Unless otherwise specified, all electrical power distribution equipment shall either be mounted in a panel integrated with the control equipment or in a separate Company supplied motor control center. The selection of either system will be indicated in the material requisition.

8.2 Each control panel shall be provided with a suitably rated 4 pole switch, mechanically interlocked with the cubicle door so that access can only be obtained with the switch in the off position. The main incoming switch shall be provided with sufficient auxiliary contacts to isolate all incoming auxiliary voltages, where applicable. The operating handle shall have on/off indication and be padlockable in the off position. The switch shall comprise one of the following:

• Molded case circuit breaker (MCCB) shall be fault make load break, equal to “Utilization Category A” (as defined in IEC 60947-2). Where selectivity is required with other protective devices on the load side, the MCCB shall be equal to “Utilization Category B” (as defined in IEC 60947-2) fitted with an adjustable time delay element. Each phase pole shall be fitted with external adjustable thermal and magnetic elements. A magnetic trip indicator shall be provided.


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The MCCBs shall be provided with auxiliary contacts for use in indication/alarm circuits, with the number of auxiliary contacts indicated in the requisition.

• Fused switch shall be fault make load break, “Utilization Category AC23B” (as defined in IEC 60947-3). The fused switch shall be fitted with suitably sized fuse links of the high rupturing capacity (HRC) type (as defined in IEC 60269). The fused switch shall be provided with auxiliary contacts for use in alarm and indication circuits. The number of auxiliary contacts shall be per the requisition.

8.3 The live side of the incoming switch shall be fully shrouded to prevent accidental contact with live parts when the panel door is open.

8.4 Control circuit voltages within a control panel shall be derived from a control transformer(s) in accordance with the following requirements:

8.4.1 Control transformers shall be equal to the requirements defined in IEC 60186, double wound with an earth screen between the primary and secondary windings. The transformer rating shall be 150% of worst case load currentat design temperature.

8.4.2 The earth screen shall be brought out to a terminal connection adjacent to the transformer and connected to the main earth bar within the control panel. One side of the secondary winding shall be earthed.

8.4.3 The control transformer primary and secondary windings shall be protected by suitably rated fuses or miniature circuit breakers (MCBs).

9.0 CONTROL AND INDICATION

9.1 All control equipment supplied by the Vendor shall be mounted in the Vendor’s control panel, other than RCUs. RCUs may be mounted at the motor being controlled, or mounted in the Vendor’s control panel. See Section 14 for specific RCU requirements.

9.2 External devices shall be individually wired to the control panel. Looping of external circuits within the control panel is not permitted.

9.3 Control relays shall be of the heavy duty enclosed plug-in type fitted with bases suitable for “DIN” rail mounting (or equivalent) and providing the requisite number of suitably rated contacts. Coil voltage shall be rated for 24VDC, low energy type, suitable for operating in the range 80% to 110% nominal voltage. Alternately, DIN rail mounted type relays, such as Phoenix PLC-RELAY series (or approved equal), may be used.

9.4 Pushbuttons shall be of the manual momentary type (except for emergency stops, see 9.6) fitted with suitably rated contacts configured for the application. Pushbutton actuators shall be of the fully shrouded type and colored in accordance with the following table:


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Color Function Application

Red Stop Equipment stop, motor stop, equipment shutdown, etc.

Green Start Equipment start, motor start, etc.

White Reset Reset of trip lockout

Red Emergency stop Emergency shutdown of motor, equipment and etc.

9.5 Signal lamps shall be cluster type light emitting diodes (LEDs) , visible from a wide viewing angle and in all types of ambient lighting conditions (i.e. bright sun, mist, etc.).

The color of the lamps shall be as per IEC 60073 using Red for “ON”, Green for “OFF” and etc.,

Lamps shall have an integral lamp test feature or be part of a lamp test facility for the complete equipment/panel. Signal lamps shall have fully shrouded rear terminals and their lens color shall comply with the following table:

Color Function Application

Red On

Running

Energized

Motor running, equipment or device energized etc.

Green Off

De-energized,

Motor stopped, equipment or device de-energized

White Healthy

Ready

Power available

Yellow Tripped, warning, abnormal equipment status, abnormal system status, not ready

Fault Trip

Alarm

9.6 Emergency stop push-buttons shall be mushroom head type and supplied with a maintained type actuator/operator and protected to avoid accidental operation. Emergency stop push-buttons shall be padlockable in the depressed postion.


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9.7 Selector switch actuators/operators shall be of the rotary, key lockable type.

9.8 All control, protection, indication and other auxiliary circuits shall be protected by either suitably rated HRC control fuses (equal to the requirements defined in IEC 60269) or MCBs (equal to the requirements defined in IEC 60898).

9.9 A control circuit test switch shall be provided to enable the complete control circuit to be tested live with the main power circuits disconnected. Suitable interlocks shall be incorporated to ensure the main switch cannot be switched on with the test switch remaining in the test position.

9.10 Under no circumstances shall voltmeters or ammeters be directly connected. Voltmeters shall be connected to a suitably rated voltage transformer and fitted with a phase selector switch. Ammeters shall be connected to a suitably rated current transformer and fitted with a line selector switch.

9.11 All measuring instruments shall meet the requirements defined in IEC 60051. Meters shall be square flush mounting type and analog or hybrid meters shall have a scale movement of approximately 240°. All meters shall be mounted at a height of between 1500mm and 1750mm above operator’s floor or platform level.

9.12 All instruments and apparatus shall be capable of carrying their full load current without excessive heating. They shall not be damaged due to the passage of circuit fault currents. All instruments shall be back connected. Means shall be provided for zero adjustment of instruments without dismantling.

9.13 The minimum scale reading shall not be less than 20% of the full load reading. All analog meter facias shall be white and the scale pointers black. Indication shall be in actual values. An adjustable red pointer to indicate normal operating point shall be provided.

9.14 Unless otherwise specified, the accuracy of indicating instruments shall be equal to “Class 1” (as defined in IEC 60051).

9.15 Ammeters for motor shall have a compressed overload end scale of at least 5 times the motor full load current. Ammeters shall be operated from current transformers with a 1A secondary as defined in IEC 60044. The minimum accuracy of current transformers shall be equal to “Class 1”, with an overcurrent factor of 5 as defined in IEC 60044.

10.0 JUNCTION BOXES AND CONTROL PANELS

10.1 Separate junction boxes shall be supplied for instrument and electrical systems. In addition the following segregation shall be strictly maintained:

• Wiring of different voltage levels (e.g. 230VAC and 24VDC)

• Intrinsically safe (IS) and non-IS signals (e.g. Exi and Exd).

• Emergency Shutdown (ESD) signals shall be separate from all others.


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• Fire and Gas signals shall be separate from all others.

10.2 Junction boxes and control panels shall be fabricated of 3mm thick (minimum) stainless steel. 316L stainless steel shall be used in areas exposed to saltwater and 316L or 304 stainless steel shall be used in areas not exposed to salt water.

10.3 Control panel construction shall be of the self supporting, metal enclosed type suitable for floor mounting. Panels designed for wall mounting require Company approval. For floor mounted panels, the supporting floor shall not be considered as part of the ingress protection and a substantial steel channel sub-base frame complete with fixing down holes shall be provided. Outdoor control panels shall be provided with a sun shield.

10.4 Gaskets shall be silicon type and held in place mechanically (not dependent on glue). Foam rubber or polystyrene seals are not permitted.

10.5 The internal degree of protection provided by the enclosure against accidental contact with live parts and ingress of solid bodies, shall comply with IP21, according to IEC 60529 (when energized).

10.6 The enclosure structure, including doors, shall be capable of withstanding internal pressures created by faults within the structure (equal to the maximum fault current rating) without danger to the operating personnel. Interlocks and covers shall be provided to prevent incorrect or unsafe operation and to prevent access to live parts.

10.7 Hinged access doors shall not be be divided horizontally and shall not exceed 900mm in width. Individually hinged access doors shall be self supporting fitted with stainless steel lift-off type hinges and stainless steel lever type lockable handle(s). Doors shall have facilities provided allowing fixing in the open position. A document holder on the inside of the door shall be provided. A laminated copy of the relavent schematic and connection diagram of the panel/junction box shall be placed in the document holder by the seller.

10.8 If the control panel is located in a hazardous area, the enclosure and equipment contained within shall be designed and rated to operate at an elevated temperature. Forced ventilation from an air intake within the hazardous area is unacceptable.

10.9 Enclosure design and construction shall facilitate inspection, cleaning, repair and maintenance and ensure absolute safety during operation, inspection and maintenance. Pockets or ledges that could hold moisture or permit dust build up are unacceptable. The enclosure shall be provided with lifting eyes in accordance with the respective IEC standard.

10.10 Junction boxes and control panels shall be constructed, installed and located so as to allow safe and easy access for maintenance.

10.11 Cable access shall be via suitably sized removable undrilled gland plates located along the lower portion of each side (and the bottom for wall mounted junction boxes and control panels). Junction boxes and control panels located indoors in air conditioned areas may be provided with undrilled removable gland plates at the top. Adequate space shall be reserved around gland plates for Company’s cable entries.


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10.12 Junction box and control panel height shall not be greater than 2100 mm above operator’s floor or platform level. Externally operable devices shall be positioned to provide adequate clearance for cable entry. Recommended clearance between gland plate and interior devices or equipment shall be 300 mm minimum.

10.13 Where the control panel houses a PLC or other programmable control device, a pull-out shelf, suitable for supporting a laptop computer, shall be provided on the inside of the door or at some other accessible location within the panel.

10.14 If the control panel is larger than 500 mm in depth, interior fluorescent light fittings (with integral ballast and lamp guard) are to be provided. Each light fitting shall have a dedicated on-off switch mounted inside the control panel. The switch is to be accessible only with the door in the open position. Closing the control panel door will automatically deenergize the light fittings.

10.15 A convenience socket outlet complying with 33.64.10.10-P4001NRP-00-PV, section 4.10.6.1 shall be provided at an accessible location within the control panel.

10.16 A separate 230VAC, 1 phase, 50Hz supply shall be provided by the Company for control panel lights, convenience socket outlets, and anti-condensation heaters only. Dedicated miniature circuit breakers (MCB) are to be provided for each auxiliary component in a common accessible location. A warning label shall be placed on each control panel door indicating that remote circuit isolation is required. The location of power source shall be marked on the panel/junction box with paint.

10.17 The metal enclosures of control panels and junction boxes shall be cleaned, primed and painted light gray. The interior of the panel shall be painted white. The panel and junction box assemblies shall meet the requirements of project variation # 30.48.00.31-P4001NRP-00-PV - Painting and coating of new equipment and piping. Seller shall provide two 1-pint cans of touch-up paint for each color used on the panel and junction box assemblies.

11.0 WIRING AND TERMINALS

11.1 Cabinet wiring shall be carried out using stranded copper conductors for control and power wiring and solid insulated copper conductors for 24VDC (and below) analog and digital wiring. The wiring insulation shall be 600/1000V grade for power and control and 250/400V for other wiring. Wiring shall be sized to suit the individual load requirements with the following minimum sizes:

Analog and digital signal wiring, 24VDC and below

- 1.13mm (minimum diameter) (for single signal conductors) 0.8mm (minimum diameter) (for multicore signal cables)

Power, lighting and control wiring - 2.5 mm2

Signalling and indication wiring - 1.5 mm2

Current transformer wiring - 6 mm2


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11.2 Wiring between terminals shall be continuous and without joints. Wiring shall be configured to not be subjected to temperatures exceeding the insulation rating. Wiring at terminal strips shall be arranged with sufficient spare length to allow reconnection at any terminal within the terminal strip.

11.3 All wiring and trunking shall be of low smoke and low halogen emissions.

11.4 Wiring and cable color codes shall be as described in 33.64.10.10-P4001NRP-00-PV, Appendix 15.

11.5 Individual wires of cables terminating in fixed (non plug-in) components shall be identified by means of slip-on ferrules of insulating material marked in accordance with the manufacturer's drawing.

11.6 Wires shall be held in position by means of insulating tubes, preformed wire channels, cleats, or plastic strips, and shall be routed such as to avoid mechanical damage. Wiring between fixed portions and hinged doors shall be mechanically protected against abrasion or entrapment and shall not be carried over or around sharp edges. Wiring shall not be bent to a radius less than the permissible value given by the manufacturers.

11.7 Where possible, wiring shall run in trunking and shall have 25% spare capacity once installed. Trunking for Intrinsically Safe wiring shall be blue, other trunking shall be grey.

11.8 No more than one wire shall be inserted into any one terminal. Looping between terminals, when required, shall be carried out using purpose made top of block cross connections or comb type busbars.

11.9 Terminal blocks with spring loaded terminals Cat# ELMEX or approved equal shall be provided and mounted together to form terminal strips. Each terminal strip shall be individually numbered, the number shall be included on a label carrier mounted at the beginning of the strip. Terminal strips shall be supplied with end plates and partition plates. All terminals shall be consecutively numbered. Panels shall have an installed terminal spare capacity of 20%.

11.10 Intrinsically safe wiring shall terminate on blue color coded terminals.

11.11 Terminals associated with current monitoring signals shall be provided with easily removable clearly identified shorting plugs.

11.12 Terminal blocks shall be arranged and installed to facilitate accessibility for cable core termination and inspection of terminal identification numbers. The proximity of terminals and gland plates shall be such that ample space is available for terminating the cores of external cables. In general, at least 300 mm clearance shall be allowed between the gland plate and any internal equipment to permit easy cable installation and connection.

11.13 Terminal blocks shall be logically grouped, indelibly marked. Adequate segregation shall be provided between analogue signals, digital signals and AC power wiring. Wiring for power, analogue signals and digital signals shall be installed in separate trunking or wiring looms and


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shall be separated from each other as far as is practicable. Wiring for intrinsically safe signals shall be segregated in accordance with the requirements of IEC 60079.

11.14 Terminal blocks associated with voltages greater than 24V shall be fully shrouded with removable plastic shrouds and fitted with a danger warning label. The warning label shall be mounted on clear plastic. Warning labels shall use international standard warning signs. Terminal blocks associated with external sources of supply shall be fully shrouded and fitted with a danger warning label.

12.0 INTERCONNECTING CABLES AND TERMINATIONS

12.1 The Vendor shall provide adequate space for glanding and termination of Company’s external cables in motor terminal boxes, junction boxes, control panels etc.

12.2 In all cases, a protective earth conductor shall be a separate core within the low voltage power supply cable. The armour of the cable shall also be bonded to the PE conductor at each end of the cable via a suitable compression gland. Under no circumstances shall the cable armour be the sole protective earth conductor.

12.3 Cable glands shall be dual certified Exd and Exe and selected to suit the type of cable supplied. All vendor supplied cables shall be terminated with compression type cable glands provided with an earth tag. Effective earth continuity shall be ensured between the cable armour/braid and the earth terminal. Glands shall be provided with an inner and outer seal. Glands for company supplied cabling will be supplied by the Company.

13.0 LIGHTING

Unless otherwise specified, lighting, convenience and power socket outlet equipment and wiring shall be provided by the Company (except for lighting and power outlets in control panels).

14.0 REMOTE CONTROL UNITS (RCU) AND OTHER CONTROL EQUIPMENT

14.1 Electric drives shall be provided with a remote control unit (RCU) with an ammeter mounted within sight and near the motor. By means of this RCU, motors can be started/stopped and, in the "O" (neutral) position, automatically or remotely controlled. RCUs shall be provided with momentary contacts, and shall be spring return from the "off” or “on" position to the "O" (neutral) position.

14.2 The RCU ammeter is to have a 1A input, a compressed overload scale and be suitable to withstand the motor starting currents. Ammeter shall be class 1.5 accuracy.

14.3 The location of the RCU shall not be further away from the motor than 1.5 m and the operator should be able to see the ammeter when operating the (discharge) valve.

14.4 RCU cable access shall be bottom entry via ISO metric threaded entries or undrilled gland plates.


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14.5 An internal and external M10 earthing stud shall be provided to facilitate connection of remote control unit (RCU) to the main earth system.

14.6 Each remote control unit (RCU) shall be provided with an identification plate indicating the tag number and service description of the controlled equipment.

14.7 Motors that are mounted above grade, e.g., fin-fan cooler motors, and controlled from grade level for operational convenience, shall have safety switches, that can be locked in the stop position, located near the motors.

14.8 Local isolating switches shall be provided for electric process heaters, motor operated valves (MOVs), trace heating systems, cathodic protection equipment, etc., and shall be located near to the equipment or on the appertaining control panels. Where automatic control is required for such equipment and its controlgear is located in the substation, then this shall be accomplished with an RCU similar to those used for motor control.

15.0 MOTORS

15.1 Cage induction motors shall comply with 33.66.05.31-P4001NRP-00-PV, Electrical Machines - Cage-Induction Types

15.2 Synchronous motors shall comply with 33.65.11.31-P4001NRP-00-PV, Synchronous AC Machines.

15.3 Electrical variable speed drives shall comply with 33.66.05.33-P4001NRP-00-PV.

15.4 The main power supply cable termination box on all motors shall be adequately sized to allow termination of the cable type and size specified by Company.

16.0 ELECTRIC HEATERS

16.1 Electric process heaters shall comply with DEP 33.68.30.33-Gen.

16.2 The main power supply cable termination box on all electric process heaters shall be adequately sized to allow termination of the cable type and size specified by Company.

17.0 ELECTRIC TRACE HEATING SYSTEMS

17.1 Electric trace heating shall comply with DEP 33.68.30.32-Gen, Technical Specification - Electrical Trace Heating.

18.0 NAMEPLATES

18.1 Labels shall be provided for all electrical equipment.


P4001NRP.00.10.64.001_B.DOC

18.2 Warning labels shall be provided in all locations where necessary to warn personnel of potential danger from electric shock.

18.3 Labels shall have black characters on a white background, except warning labels which shall have black characters on a yellow background.

18.4 Labels shall be machine engraved laminated plastic material and shall be attached with stainless steel screws; adhesive or self tapping screws are unacceptable.

18.5 All components incorporated within electrical equipment shall be indelibly marked with the circuit component reference. Hand written stickers or tape labels are unacceptable.

18.6 Where fuses are provided, labels shall be provided indicating the fuse rating.

18.7 All control panels and distribution boards shall be provided with an external label indicating:

- Vendor

- Year of manufacture

- Nominal voltage

- Nominal current

- Control voltage

- Vendor’s and Company ‘s purchase order numbers

- Short circuit withstand ratings

18.8 Distribution Boards shall additionally be provided with a circuit directory.

19.0 DOCUMENTS

19.1 All documents shall be marked in the right hand corner with the Principal’s order and item number together with the Seller’s reference numbers. All documents shall be in English.

19.2 Schematic diagrams shall include the following information as a minimum.

(a) Complete schematic diagram with item numbers corresponding to bill of materials.

(b) Cross reference to bill of materials and other drawings.

19.3 Seller’s drawing and Data requirements shall be as indicated in the table:


P4001NRP.00.10.64.001_B.DOC

With Bid

(A)

For Approval

(B)

Final Certified

(C)

As Built

(D)

Description

X X X Detailed bill of material

X X X X Motor and other electrical load information

X X X Motor Motor time-current and speed- torque curves, thermal

withstand curves and other motor data indicated on the motor data sheets.

X X X X General layout of equipment, showing all dimensions,

weights, location, and outline drawings showing the final assembled configuration

X X X Detailed installation drawings showing sizes and locations

of all cable connections, details of all cable routing, cable supports and hardware, details (including sizes and locations) of all terminations and junction boxes.

X X Hazardous area certification

X X Shipping description ( number of sections, type of protection of equipment in shipping)

X X X Control schematic and connection diagrams for all electrical equipment.

X X X Single line and three line diagrams

X Certified test reports

X (1) Installation, operation and maintenance manual

X Final as-built drawings

X X Recommended priced spare parts list

A. Bidder shall furnish these documents with proposal

B. Seller shall furnish these documents for Buyer’s review and authorization to proceed before fabrication

C. Seller shall furnish these documents as part of the final certified document submittal.

(1) Equipment shall be shipped with one (1) set of installation, operation, and


P4001NRP.00.10.64.001_B.DOC

maintenance manuals.

D. As built drawings within two weeks following shipment.

Note: Seller shall provide one (1) reproducible set of drawings plus the specified number of copies of all documentation and operating manuals as indicated on the data sheet. Reproducible drawings shall be CAD.DXF electronic format.


P4001NRP.00.10.64.001_B.DOC

20.0 REFERENCES

In this DEP reference is made to the following publications:

NOTE: Unless specifically designated by date, the latest edition of each publication shall be used, together with any amendments/supplements/revisions thereto.

SHELL STANDARDS

Index to DEP publications and standard specifications

DEP 00.00.05.05-Gen.

Index to standard drawings DEP 00.00.06.06-Gen.

Standard forms (binder) DEP 00.00.10.05-Gen.

Preparation and microfilming of technical drawings DEP 02.00.00.10-Gen.

Utility data – electrical DEP 05.00.10.80-Gen.*

Summary of electrical engineering (electrical equipment summary sheets)

DEP 05.00.54.84-Gen.*

General data/requisitioning sheets DEP 30.10.00.94-Gen.**

Requisitioning (binder) DEP 30.10.01.10-Gen.

Symbols and identification system – mechanical DEP 31.10.03.10-Gen.

Heating, ventilation and air conditioning for plant buildings

DEP 31.76.10.10-Gen.

Electrical engineering guidelines DEP 33.64.10.10-Gen.

Electrical network monitoring and control system – application

DEP 33.64.10.11-Gen.

Electrical network monitoring and control system – specification

DEP 33.64.10.32-Gen.

Electromagnetic compatibility (EMC) requirements DEP 33.64.10.33-Gen.

Packaged unit A.C. generator sets DEP 33.65.11.32-Gen.

Power transformers DEP 33.65.40.31-Gen.

Static D.C. uninterruptible power supply (DC UPS) units

DEP 33.65.50.31-Gen.

Static A.C. uninterruptible power supply unit (static AC UPS)

DEP 33.65.50.32-Gen.

Electrical variable speed drive systems DEP 33.66.05.33-Gen.

Low-voltage switchgear and controlgear assemblies DEP 33.67.01.31-Gen.

Schedule for LV switchboard DEP 33.67.01.80-Gen.*


P4001NRP.00.10.64.001_B.DOC

Schedule for lighting distribution switchboard DEP 33.67.01.81-Gen.*

Schedule for a.c. instrument distribution switchboard DEP 33.67.01.82-Gen.*

Schedule for d.c. instrument distribution switchboard DEP 33.67.20.80-Gen.*

Schedule for HV switchgear and controlgear assemblies

DEP 33.67.51.80-Gen.*

Electric heating system for frost heave prevention of refrigerated hydrocarbon storage tanks

DEP 33.68.30.31-Gen.

Electrical trace heating DEP 33.68.30.32-Gen.

Electrical process heaters DEP 33.68.30.33-Gen

Navigational aids for offshore structures DEP 33.80.00.30-Gen.

Minimum requirements for design and engineering of buildings

DEP 34.17.00.32-Gen.

Field commissioning and maintenance of electrical installations and equipment

DEP 63.10.08.11-Gen.

NOTE: * Standard Forms, see DEP 00.00.10.05-Gen.

** Data/Requisition sheets, see DEP 30.10.01.10-Gen.

KNPC NRP STANDARDS

Project Variation to Shell DEP 33.64.10.10-Gen., Electrical Engineering Guidelines

33.64.10.10-P4001NRP-00-PV

Project Variation for Shell DEP 33.64.10.33-Gen., ELECTROMAGNETIC COMPATIBILITY (EMC) REQUIREMENTS

33.64.10.33-P4001NRP-00-PV

Project Variation to Shell DEP 33.65.11.31-Gen., SYNCHRONOUS AC MACHINES

33.65.11.31-P4001NRP-00-PV

Project Variation to Shell DEP 33.65.40.31-Gen., Power Transformers

33.65.40.31-P4001NRP-00-PV

Project Variation for Shell DEP 33.65.50.31-Gen., STATIC DC UNINTERRUPTIBLE POWER SUPPLY (DC UPS) UNITS

33.65.50.31-P4001NRP-00-PV

Project Variation for Shell DEP 33.65.50.32-Gen., STATIC AC UNINTERRUPTIBLE POWER SUPPLY UNIT (STATIC AC UPS UNIT)

33.65.50.32-P4001NRP-00-PV

Project Variation to Shell DEP 33.67.01.31-Gen., LOW-VOLTAGE SWITCHGEAR AND

33.67.01.31-P4001NRP-00-PV


P4001NRP.00.10.64.001_B.DOC

CONTROLGEAR ASSEMBLIES (AMENDMENTS/SUPPLEMENTS TO IEC 60439-1)

Project Variation to Shell DEP 33.67.51.31-Gen., High voltage switchgear and controlgear assemblies above 1 kV and below 52kV (Amendments/Supplements to IEC 62271-200)

33.67.51.31-P4001NRP-00-PV

Project Variation to Shell DEP 30.48.00.31, Painting and coating of new equipment and Piping

30.48.00.31-P4001NRP-00-PV

Specification for basic engineering design data P4001NRP.00.10.08.001

STANDARD DRAWINGS

Electrical and instrument cable trenches in concrete paved areas

S 19.001

Cable routing in unpaved, brick-paved or tiled areas and crossing roads

S 19.002

Electrical symbols (additional to IEC 617) S 64.000

Schematic diagrams of control circuits for LV motors

S 67.004

Typical instrument electricity supply systems with static components

S 67.006

Single line diagrams of LV switchboard panels S 67.019

Single line diagram and control circuits for lighting distribution switchboards

S 67.022

Schematic diagram and control circuits for A.C. instrument distribution switchboard

S 67.024

Schematic diagram of D.C. distribution switchboard for process control and safeguarding systems

S 67.025

Schematic diagrams of control circuits for HV motors (contactor starters)

S 67.028

Typical HV single line diagram, motor controlled by contactor

S 67.045

Typical HV single line diagram, motor controlled by circuit breaker

S 67.046

Typical HV single line diagram, large synchronous motor

S 67.047


P4001NRP.00.10.64.001_B.DOC

Typical HV single line diagram, motor with unit transformer

S 67.048

Typical HV single line diagram, HV/LV transformer 1600 kVA, controlled by contactor

S 67.049

Typical HV single line diagram, HV/LV transformer 1600 kVA, controlled by circuit breaker

S 67.050

Typical HV single line diagram, HV/LV transformer including feeder cable 250 m

S 67.051

Typical HV single line diagram, HV/LV transformer including feeder cable > 250 m

S 67.052

Typical HV single line diagram, parallel plain feeder S 67.053

Typical HV single line diagram, single plain feeder S 67.054

Typical HV single line diagram, generator directly connected (voltage 11 kV)

S 67.055

Typical HV single line diagram, generator with unit transformer (voltage > 11 kV)

S 67.056

Typical HV single line diagram for variable speed drive system (VSDS) with synchronous motor

S 67.057

Typical HV single line diagram for submerged motors (contactor starter)

S 67.058

Typical HV single line diagram, overhead line circuits (33 - 132 kV)

S 67.059

Typical HV single line diagram for grid supply incomer with on site generation

S 67.060

Typical single line and schematic diagram of control circuits for LV emergency generator

S 67.070

Schematic diagram of control circuits for HV motors (circuit breaker starters)

S 67.071

Typical instrument electrical supply systems with d.c. ups units

S 67.080

Typical arrangements of cables in trenches in plant areas

S 68.009

Clamps for unarmoured single core cables, EPR insulated, PVC sheathed (3800/6600 V grade)

S 68.021

Typical earthing arrangements for substations, control buildings and field auxiliary rooms and associated typical mounting details

S 68.030

Typical earthing arrangements for offshore S 68.031


P4001NRP.00.10.64.001_B.DOC

installations

Typical drawing for electrical substation S 68.040

Construction and fastening of lamp post for fluorescent lighting fittings

S 69.001

Typical lighting details S 69.003

NOTE: The latest editions of standard drawings are identified in DEP 00.00.06.06-Gen.

BRITISH STANDARDS

Engineering recommendation S.34 A guide for assessing the rise of earth potential at substation sites

S.34

Issued by: Engineering and safety division The Electricity Association 30 Millbank, London SWIP 4RD United Kingdom.

IP Model Code of Safe Practice Part 15: Area classification code for petroleum installations

IP 15

International safety guide for oil tankers and terminals ISGOTT

Issued by: Institute of Petroleum 61, New Cavendish Street London W1M 8AR United Kingdom

Current rating standards for distribution cables ERA 69-30

Issued by: Electrical Research Association Cleeve Road Leatherhead, Surrey KT22 7SA United Kingdom

EUROPEAN STANDARDS

Safety rules for the construction and installation of lifts and service lifts

EN 81

Electrical apparatus for potentially explosive atmospheres:

General requirements EN 50014

Pressurised apparatus 'p' EN 50016

Flameproof enclosure 'd' EN 50018

Increased safety 'e' EN 50019

Intrinsic safety 'i' EN 50020


P4001NRP.00.10.64.001_B.DOC

Intrinsically safe electrical systems 'i' EN 50039

Voltage characteristics of electricity supplied by public distribution systems

EN 50160

Issued by: CENELEC, 2, Rue Brederode B-1000 Brussels Belgium

Copies can also be obtained from national standards organizations

Directive 94/9/EC on the approximation of the laws of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres

ATEX Directive

Issued by: The European Commission Website: http://europa.eu.int/comm/enterprise/atex/

INTERNATIONAL STANDARDS

Annex 14 to the Convention on International Civil Aviation Aerodromes

ICAO July 1990

Issued by: International Civil Aviation Organisation ICAO International Aviation Building 1080 University Street, Montreal Canada.

Rotating electrical machines

Part 1 - Rating and performance IEC 60034-1

IEC standard voltages IEC 60038

International electrotechnical vocabulary IEC 60050

Insulation co-ordination IEC 60071

Power transformers IEC 60076

Part 5 - Ability to withstand short circuit IEC 60076-5

Electrical apparatus for explosive gas atmospheres IEC 60079

Part 1 - Construction and verification test of flameproof enclosures of electrical apparatus

IEC 60079-1

Part 2 - Electrical apparatus type of protection 'p IEC 60079-2

Part 7 - Increased safety 'e' IEC 60079-7

Part 11 - Construction and test of intrinsically safe and associated apparatus

IEC 60079-11

Part 13 - Construction and use of rooms or buildings protected by pressurisation

IEC 60079-13


P4001NRP.00.10.64.001_B.DOC

Part 14 - Electrical installations in explosive gas atmospheres (other than mines)

IEC 60079-14

Lightning arresters

Part 1 - Non-linear resistor type arrester for a.c. systems

IEC 60099-1

Dimensions of ball and socket couplings of string insulator units

IEC 60120

Polyvinyl chloride insulated cables of rated voltages up to including 450/750 V

IEC 60227

Electrical relays IEC 60255

Plugs, socket-outlets and couplers for industrial purposes IEC 60309

Tests on electric cables under fire conditions

Part 3 - Tests on bunched wires or cables IEC 60332-3

Electrical installations of buildings IEC 60364

Part 3 - Assessment of general characteristics IEC 60364-3

Tests on insulators of ceramic material or glass for overhead lines with a nominal voltage greater than 1000 V

IEC 60383

Characteristics of string insulator units of the long rod type IEC 60433

Low-voltage switchgear and controlgear assemblies

Part 4 - Particular requirements for assemblies for construction sites (ACS)

IEC 60439-4

Degrees of protection provided by enclosures (IP Code) IEC 60529

High-voltage fuses for the external protection of shunt power capacitors

IEC 60549

Graphical symbols for diagrams IEC 60617

Vented nickel-cadmium prismatic rechargeable single cells IEC 60623

Guide for the selection of insulators in respect of polluted conditions

IEC 60815

Shunt power capacitors of the self-heating type for a.c. systems having a rated voltage up to and including 1 kV

IEC 60831

Shunt capacitors for a.c. power systems having a rated voltage above 1 kV

IEC 60871

Shunt Capacitors for A.C. Power Systems Having a Rated Voltage Above 1 000 V - Part 4: Internal Fuses

IEC 60871-4

Stationary lead-acid batteries. General requirements

Part 11 - Vented types IEC 60896-11

Part 21 – Valve regulated types IEC 60896-21

Shunt power capacitors of the non-self-healing type for a.c. systems having a rated voltage up to and including 1 000 V Part 3: Internal fuses

IEC 60931-3

Low voltage switchgear and controlgear IEC 60947


P4001NRP.00.10.64.001_B.DOC

Parts 1 - 8 - Circuit-breakers IEC 60947-1 through 8

Electromagnetic compatibility (EMC) IEC 61000

Parts 1 through 6

Preparation of Documents Used in Electrotechnology IEC 61082

Round wire concentric lay overhead electrical stranded conductors

IEC 61089

Safety of Power Transformers, Power Supply Units and Similar

IEC 61558

Protection Against Electric Shock - Common Aspects for Installation and Equipment

IEC 61140

Electrical apparatus for use in the presence of combustible dust IEC 61241

High-voltage switchgear and controlgear IEC 62271

High-Voltage Switchgear and Controlgear - Part 100: High-Voltage Alternating-Current Circuit-Breakers

IEC 62271-100

Issued by: Central Office of the IEC, (Sales Dept) 3, Rue de Varembé 1211 Geneva 20 Switzerland


Galvanized coatings on fabricated iron and steel articles ISO 1461

Quality management and quality assurance standards - guidelines for selection and use

ISO 9000

Issued by: Central Secretariat of ISO 1, Rue de Varembé 1211 Geneva 20 Switzerland


NOTE: The DEPs and most referenced external standards are available for Shell users on the SWW

(Shell Wide Web) at address http://sww.shell.com/standards.