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SWITCHBOARD AND SCADA INSTALLATION AT NYNGAN WTP 2016/4/Switch Board and SCADA

TECHNICAL SPECIFICATION SECTION C

SWITCHBOARD AND SCADA INSTALLATION AT NYNGAN WTP CONTRACT NO: 2016/4/SWITCH BOARD AND SCADA

Engineering Department 5/09/2016


Section C

ELECTRICAL SPECIFICATION SWITCHBOARD AND SCADA INSTALLATION AT NYGAN WTP


TABLE OF CONTENTS

C1.1 ENCLOSURES - GENERAL .................................................................................................... 1

C1.1.1 Switchboard ...................................................................................................................... 1

C1.2 CABLING .................................................................................................................................. 1

C1.3 FIELD WORKS ......................................................................................................................... 1

C1.4 REMOVAL OF REDUNDANT EQUIPMENT ............................................................................ 1

C1.5 ELECTRICAL CONTROL CONCEPTS.................................................................................... 1

C1.5.1 Switchboard ...................................................................................................................... 1

C1.6 ELECTRICAL ENCLOSURES ................................................................................................. 1

C1.6.1 Switchgear Cabinet Construction ..................................................................................... 1

C1.6.2 Equipment Compliance .................................................................................................... 3

C1.6.3 Power Cables ................................................................................................................... 3

C1.6.4 Busbars ............................................................................................................................ 3

C1.6.5 Busbar Jointing ................................................................................................................. 3

C1.6.6 Control Circuit Wiring ........................................................................................................ 4

C1.6.7 Equipment Mounting ......................................................................................................... 6

C1.6.8 Equipment Earthing .......................................................................................................... 6

C1.6.9 Testing and Inspections.................................................................................................... 6

C1.6.10 Delivery and Storage ........................................................................................................ 7

C1.7 SWITCHGEAR ......................................................................................................................... 8

C1.7.1 Motor Circuit Breakers ...................................................................................................... 8

C1.7.2 Settings ............................................................................................................................. 8

C1.7.3 Fuses ................................................................................................................................ 8

C1.7.4 Contactors ........................................................................................................................ 8

C1.7.5 Motor Protection ............................................................................................................... 9

C1.7.6 Relays ............................................................................................................................... 9

C1.7.7 Submersible Pump Supervision and Phase Failure Relays ............................................. 9

C1.7.8 Push Button and Indicators .............................................................................................. 9

C1.7.9 Voltmeters and Ammeters ................................................................................................ 9

C1.7.10 Current Transformers ..................................................................................................... 10

C1.7.11 Terminals ........................................................................................................................ 10

C1.7.12 Extra Low Voltage Transformers .................................................................................... 10

C1.7.13 Low Voltage D.C. Power Supplies ................................................................................. 11

C1.7.14 Earth Leakage Protection Equipment ............................................................................. 11

C1.7.15 Instrumentation Indicators .............................................................................................. 11

C1.7.16 Current to Current Converters ........................................................................................ 11

C1.7.17 Soft Starters .................................................................................................................... 11

C1.8 LABELLING ............................................................................................................................ 12

C1.8.1 Labelling of Electrical Equipment, General .................................................................... 12

C1.8.2 Labelling within or on a Switchboard or Cubicle ............................................................ 12

C1.8.3 Fixing - Indoor Cabinets ................................................................................................. 13

C1.8.4 Fixing - Outdoor Cabinets .............................................................................................. 13

C1.8.5 Switchboard Nameplate ................................................................................................. 13


C1.8.6 Module Nameplate ......................................................................................................... 13

C1.9 INSTRUMENTATION ............................................................................................................. 13

C1.9.1 General ........................................................................................................................... 13

C1.9.2 Field Instruments ............................................................................................................ 14

C1.9.3 Electromagnetic Flow Metering ...................................................................................... 14

C1.9.4 Level Transmitter (Pressure Type) ................................................................................. 14

C1.9.5 Level Switches – (Float Type) ........................................................................................ 14

C1.9.6 Level Switches – (Conductivity Type) ............................................................................ 14

C1.10 ELECTRICAL INSTALLATION ............................................................................................... 14

C1.10.1 Extent of Work ................................................................................................................ 14

C1.10.2 Material and Workmanship ............................................................................................. 14

C1.10.3 Supply Authority Liaison/Fees ........................................................................................ 15

C1.10.4 Certificate of Testing and Compliance ........................................................................... 15

C1.10.5 Electric Welding Construction Precautions .................................................................... 15

C1.10.6 Mechanical Protection .................................................................................................... 15

C1.10.7 Sealing ............................................................................................................................ 15

C1.10.8 Installation of Cable ........................................................................................................ 15

C1.10.9 Supporting, Mounting and Positioning............................................................................ 16

C1.10.10 Bolts, Nuts, Washers and Jointing Materials .................................................................. 17

C1.10.11 Field Panels, Junction Boxes and Local Operator Panels ............................................. 17

C1.10.12 Field Cabling ................................................................................................................... 18

C1.10.13 Earthing .......................................................................................................................... 22

C1.11 PLC AND RTU PROGRAMMING .......................................................................................... 23

C1.12 SCADA PROGRAMMING ...................................................................................................... 24

C1.13 ELECTRICAL/CONTROL TESTING ...................................................................................... 24

C1.13.1 General ........................................................................................................................... 24

C1.13.2 Submission of Certificates .............................................................................................. 25

C1.13.3 PLC and SCADA Software Factory acceptance Testing ............................................... 25

C1.13.4 Site Electrical Testing General ....................................................................................... 25

C1.14 FINAL DOCUMENTATION .................................................................................................... 28

C1.14.1 Red Pen Mark-ups .......................................................................................................... 28

C1.14.2 TESTING AND COMMISSIONING DOCUMENTATION ............................................... 28

C1.14.3 WORK-AS-EXECUTED DRAWINGS ............................................................................. 28

C1.14.4 SOFTWARE ................................................................................................................... 28

C1.14.5 TRAINING ...................................................................................................................... 29

Bogan Shire Council A.B.N. 68 886 242 083 1 Technical Specification


C1.1 ENCLOSURES - GENERAL

C1.1.1 Switchboard

Design, supply and install a new switchboard of sufficient height to ensure the new switchboard’s final position will be suitable for the new location. This is to ensure that a minimum number of cables require extending.

C1.2 CABLING

All new electrical equipment shall be installed in a position as directed by the Superintendent on site. All cabling shall be mounted at the required height and positioned to enable reliable operation whilst being clear of obstacles. They shall also be mounted in a position which enables easy access for maintenance personnel.

Where any cable requires extending to facilitate terminating, joints shall be done using approved proprietary jointing kits, the use of any other method shall require the Superintendent’s prior approval.

Cabling between switchboards and equipment shall be installed in cable ladders, cable trenches, conduits, etc. Where runs of cabling are required to extend out of the cable reticulation system, additional sections of flexible conduit shall be used.

All new power, control, instrumentation and communications cabling shall be separated throughout the cable reticulation system with the use of individual conduits, or by physical separation as far as possible. Physical barriers are to be installed within cable ladder to segregate power and control/instrumentation cabling.

C1.3 FIELD WORKS

The connection of all cables to the new switchboard, with the exception of the flow (chart recorders), is part of this scope.

Further works include the supply and installation of the following:

(a) All sundry items necessary for the completion of the switchboard replacement.

C1.4 REMOVAL OF REDUNDANT EQUIPMENT

The constructor shall disconnect/uninstall, remove from site and dispose of all redundant equipment associated with the works of this contract.

The Principal shall own all material and shall be given the first right of refusal prior to any equipment being removed from site or disposed of.

C1.5 ELECTRICAL CONTROL CONCEPTS

C1.5.1 Switchboard

The main purpose of a switchboard is to act as a link for the provision of power and control to individual motors and drives via motor starter cubicles.

A new PLC will be installed as part of the new switchboard. This will enable the partial automation of the plant, as well as enable the connection to SCADA.

C1.6 ELECTRICAL ENCLOSURES

C1.6.1 Switchgear Cabinet Construction

C1.6.1.1 Classification

Switchboards can be classed into the following two categories:

Indoor Switchboard – a switchboard that is installed within a designated electrical switchroom, or building that contains a non-corrosive and/or dry environment.

Outdoor Switchboard – A switchboard installed external to a building or within a corrosive and/or wet environment



Note any building area/room that contains pipework under pressure or is subject to hose downs, is deemed to be a wet environment.

C1.6.1.2 Material

Switchboards are to be constructed out of the following material:

Indoor Switchboards - Mild Steel, minimum 2mm thickness (powder coated)

Outdoor Switchboards - Stainless Steel grade 316, minimum 1.5mm thickness

C1.6.1.3 Construction

Any new switchboards/control panels must have their design drawings submitted to BSC for approval prior to placing orders or commencing manufacture. This requirement shall not absolve the constructor of any obligations to comply with this specification, or any BSC directive.

C1.6.1.4 Switchboard Base

Switchboards shall be mounted on a full perimeter base adequately fixed to the cabinet and fully self-supported from the existing building concrete slab. The base shall be manufactured from “C”- Channel that is 100mm (high) x 50mm (wide) x 4mm (thick) mild steel and be hot dip galvanised after construction.

The base shall be securely fixed to the cabinet, with the plinth orientation to be ‘toe out’.

C1.6.1.5 Lifting Facilities

Provide fixings in support structure, and removable attachments for lifting assemblies whose shipping dimensions exceed 1.8 metres high by 0.6 metres wide.

C1.6.1.6 Equipment Mounting Pans

Equipment mounting pans shall be bolted to supports within the enclosure. Suitable supports shall be heavy duty angles or plates welded to the cubicle sides.

C1.6.1.7 Cable Entries

Provide sufficient clear space within each enclosure, adjacent to the cable entries, to allow the incoming cables and wiring to be neatly run and terminated, without overcrowding. For cable entry and internal distribution, provide cable entries of not less than 100mm depth by the full width of cubicle space which is unrestricted by equipment or internal wiring.

C1.6.1.8 Gland Plates

Gland plates shall be provided in the top of each section of cable zones. The gland plates are required to provide access to both sides of the cable gland and to provide a means to facilitate pulling cables into cubicles.

Gland plates shall be manufactured from 4mm aluminium plate.

Gland plates shall be fitted with a gasket to maintain the nominated Degree of Protection (IP) rating of the switchboard.

For earth continuity a 6mm² minimum earth wire shall be connected from the main earth bar to each gland plate. Daisy chaining equipment or gland plates together is not acceptable.

A gland plate shall be provided in the end of the switchboard for the consumers mains to be terminated in the incoming mains compartment.

C1.6.1.9 Equipment Mounting on Doors

Equipment mounted on doors shall be arranged so that it does not foul on door openings etc. when the door or panel is swung fully open, and shall not restrict the door opening to its maximum angle and shall remain in place unaided.

Handles of module isolator/breakers shall be located as close as possible to the doors lock mechanism.

C1.6.1.10 Equipment within Modules

All equipment within a module shall be fully accessible for inspection and maintenance without the removal of other components.



C1.6.1.11 Shrouding

In addition to the above requirements, all wiring and connections on the line side of the protective device in each incoming and outgoing functional unit shall be shrouded or insulated so as to prevent the possibility of a line side fault developing or personnel contact.

All moulded case circuit breakers shall have proprietary interphase barriers installed between line side terminations.

C1.6.1.12 Interlocking of Doors

Main incoming panels, feeders and motor compartments shall incorporate a mechanical interlock on the main circuit breaker operating handle such that the door cannot be opened unless the switch is in the “off” position.

Cableway doors shall be hinged and secured at a minimum of three points. The cableway doors shall only be able to be opened with the use of a tool.

C1.6.1.13 Switchboard Access

Ensure adequate space requirements around switchboards in accordance with AS3000.

As a minimum, a horizontal clearance of not less than 600mm from any part of a switchboard, with doors opened, shall be provided.

Exit facilities shall be provided from the building where the switchboard is installed in line with the Building Code of Australia requirements. The contractor is to ensure BCA compliance of the existing filter house.

C1.6.2 Equipment Compliance

All equipment shall be selected in line with BSC’s preferred electrical equipment. Where suitable equipment is not available, full technical details shall be submitted to, and written concurrence received from, the Superintendent prior to the purchase and use of alternative items.

Proof of compliance with the relevant Australian Standards shall be provided if requested by the Superintendent. Such proof shall comprise a complete Test Certificate from an accepted independent Testing Authority or a Certificate of Suitability issued by an Australian Electricity Authority. Imported equipment shall also comply with the relevant Australian Standards.

All door mounted equipment shall have IP2X "finger proof" terminals, or be provided with either rubber boots or a clear insulated barrier for personnel protection.

C1.6.3 Power Cables

All main circuit wiring and busbars shall be arranged and colour coded Red, White, and Blue from left to right, top to bottom or front to rear as viewed from the front of the switchboard.

Cables shall be coloured red, white, blue or where such colouring is not possible, shall be colour coded at each end by coloured heat shrink sleeve for 200mm.

Each power cable shall be numbered as shown in the cable schedule.

All cables shall be terminated with crimp lugs.

C1.6.4 Busbars

Busbars shall be hard-drawn high conductivity copper. Square-edged busbars shall not be used.

Provide busbar supports to withstand the maximum prospective fault currents without damage to busbars or the switchboard.

Pre-drill the main busbar for future extension and extend busbar droppers to spare locations. Drill each dropper to suit connection of future equipment of the same type as that specified.

Busbars shall be identified as per the phase colours.

C1.6.5 Busbar Jointing

Busbar jointing shall maximise the copper-to-copper contact area under the “shadow area” of the bolt head and nut.

Bolt holes shall be round, square edged with a maximum bolt clearance of 1mm. Deburring shall be the minimum necessary to remove any projections.



Tinned or electroplated joints are preferred. Otherwise, copper surfaces shall be flat and deliberately roughened by sanding or draw filing in one direction immediately prior to making the joint.

Connections between all joints shall be made using minimum 10mm grade 8.8 high tensile nuts and bolts. These should be tightened in accordance with manufacturer’s specifications. A minimum torque of 25Nm shall apply. Spring washers are not to be used with busbar bolts.

For the purpose of joint inspection, a joint as nominated by the Superintendent shall be dismantled and reassembled during the factory inspection. Dismantling of the joint shall be carried out without removal of the rear panels, where the switchboard shall be installed without access at the rear.

Where busbars are bolted to proprietary equipment, the proprietary bolts and terminating methods supplied by the manufacturer are acceptable.

Supports shall be of adequate size and shall rigidly hold all busbars by being rigidly fixed to the cubicle where possible. Floating supports shall be kept to a minimum.

Busbars shall be coded by coloured bands at each end of not less than 500mm of coloured heat shrink sleeve.

C1.6.6 Control Circuit Wiring

C1.6.6.1 General

Control circuit wiring shall be flexible PVC, of minimum size 1.5mm2 copper conductors with 250V grade insulation and 0.75mm2 for Dekoron analogue cables. Where space limitations exist at PLC input or output terminals, control wires may be sized 0.5mm2 from individual I/O terminal to first point of termination, providing that any common wire sourcing more than one input or output shall be 1.5mm2.

All internal switchboard wiring shall be flexible multi stranded (i.e. not solid core). Cabling between interconnecting cubicles shall be orange circular. TPS cabling is not be used within the switchboard/installation.

A separate terminal shall be provided for every field cable core including spare cores. Each core within a cable shall be terminated into consecutive terminals.

C1.6.6.2 Colour Code

All wiring shall be colour coded as follows:

AC Power

3 Phase

Phase 1

Phase 2

Phase 3

Red

White

Blue

1 Phase

Active

Neutral

Brown

Blue

AC Control

240VAC

Active

Neutral

Grey

Black

ELV Control

12/24VDC

Positive

Negative

Blue/Red trace

Blue/White trace

ELV Control

12/24VAC

Positive

Negative

Brown/Red trace

Brown/White trace

Screened Analogue Positive

Negative

White

Black

Earth, Earth Screens and Equipotential Bonds

Green/Yellow



For analogue loop wiring, the wire connecting the DC supply negative or the transmitter source negative to the last load device, shall be classified as ‘negative’. All other wires shall be classified as ‘positive’.

Refer colour coding for voltages other than the above to the Superintendent for a determination prior to installation.

C1.6.6.3 Terminations

All switchboard wiring shall be fully identified at both ends of every wire with Grafoplast "Trasp" or Critchley "Multi-mark" type ferrules numbered in accordance with the circuit diagrams. Handwritten or dot matrix printed numbered ferrules will not be accepted.

All ends of all wires shall be terminated with a lug to suit the particular size of wire and type of terminal.

Control wiring shall be terminated with a pre-insulated crimp lug or cable crimp sleeve. Under no circumstances are there to be more than one wire per terminal, in such cases, bridging bar and multiple terminals shall be used.

All crimp sleeves and crimp lugs shall be crimped to the wire ends with a tool having a ratchet device to ensure full crimping before tool will release. Crimp tools without ratchet devices, pliers or similar blade tools shall not be used to secure sleeves or lugs to wires.

The entire metal surface of any crimp sleeve or lug shall be contained within the terminal shrouding and shall not be visible.

Pin type crimp lugs and blade type crimp lugs shall not be used in tunnel type terminals.

C1.6.6.4 Cable Identification

Each terminal strip shall be identified with the drive number it is provided for. Labels shall be white traffolyte and shall be fixed into the terminals with nylon screws or by fixed label support brackets similar to Klippon type SCHT5.

C1.6.6.5 Earth Terminals

Where Rail Mounted Earth Terminals are mounted on rails other than aluminium or copper, each terminal shall be individually bonded with a suitably rated copper conductor to the earth bar within the cubicle.

C1.6.6.6 Data Cabling

Data cables shall not be installed in wiring ducts or channels with wiring operating at voltages in excess of Extra Low Voltage. Data cables shall comply with the requirements of ACMA.

C1.6.6.7 Wiring Support/Cable Duct

Unless otherwise specified, install wiring within PVC wiring ducts. The total cross section of the wiring within any one duct, including allowance for outgoing connections, shall not exceed 80% of the duct cross sectional area. If wiring is not installed in ducts, neatly bunch, support in fibreglass cable stocking and lace it with PVC ties or strips as required. Provide protective insulation where bunched wiring or cables could come into contact with metal, or pass through cut-outs in sheet metal.

External circuit cables: If no provision is made in wiring ducts for external connecting cables, i.e. inside a cable zone, install a galvanised perforated cable tray between terminal blocks and cable entries, of a size, and with available access space, sufficient to permit ready installation of this external wiring.

C1.6.6.8 Segregation

Segregate electric circuits subject to potential interference. Also segregate terminations into groups according to voltage and function (ELV, control, power, etc.). Segregate data and power cabling in accordance with the requirements of AS2834.

C1.6.6.9 Intercubicle Wiring

Intercubicle wiring shall be effectively bushed at all partitions. Cable looms to hinged panels and doors to be effectively bushed where loom passes over mullion and door edges. All metal edges shall be bushed where cables pass across or along them.

Where control circuits interconnect between different drive cells, this cabling shall pass through an auxiliary contact of the main circuit breaker for that respective cell.



C1.6.7 Equipment Mounting

All items of equipment shall be mounted by metric zinc plated metal thread set screws, screwed into tapped holes. Small items such as relays and miniature circuit breakers shall be mounted on DIN35 mounting rail.

Terminal mounting rail, DIN35 mounting rail and plastic wiring duct may be secured by self-drilling/threading screws. Self-tapping screws shall not be used.

Self-adhesive equipment mounts (or ‘sticky backs’) will not be accepted. All equipment mounted to doors, walls and equipment pans shall be mechanically secured, or secured through the use of proprietary mounts.

To facilitate wiring, a minimum of 30mm shall be provided between the terminal side of all relays and equipment and the adjacent wiring duct or equipment.

No equipment shall be mounted in front of other equipment.

DC power supply units and AC transformers shall have terminals facing the front of the switchboard. Provide adequate support brackets for this purpose.

DC power supply units shall not need to have covers removed for access to mounting screws. Power supplies shall be mounted to allow free flow of air for ventilation and cooling.

All power wiring and terminals shall be physically segregated from control and instrumentation wiring and terminals. Terminals shall not be located within 250mm of the base of the cubicle or 300mm of the top of the cubicle. Mains and motor terminals shall be located such as to provide easy access to outgoing terminations with cable holes clearly visible.

C1.6.8 Equipment Earthing

All equipment with its own chassis, shall be individually bonded to the MCC earth bar with suitably rated copper conductors, in accordance with the manufacturer’s recommendations. This will include, but not be limited to:

(a) PLC Backplanes, (b) PLC Common Ground, (c) Touchscreen, (d) Enclosure vent fans, (e) RTU Equipment, (f) Communications Equipment, (g) Soft Starters, and (h) Cubicle doors.

All metal surfaces of equipment mounted on module doors shall be bonded to the earth bar.

One side of each current transformer secondary shall be bonded to the earth bar.

Looping of earth wiring between equipment is not to be used.

Each device shall be individually earthed by bonding directly to the earth bar.

C1.6.9 Testing and Inspections

C1.6.9.1 Routine Tests/Inspections

The equipment shall be inspected by the manufacturer’s Quality Assurance Inspector during manufacture and tested in accordance with AS3439, carried out at the manufacturer's works and repeated at the site. The electrical function test shall use externally connected simulated circuits and equipment at the works and be repeated after connection of the permanent wiring and equipment at the site. These tests shall be performed with the PLC, SCADA, RTU and Communications equipment configured to demonstrate that all equipment and configurations function correctly.

Within three (3) days of the completion of any inspections, the contractor shall submit to the Superintendent a report verifying compliance of the equipment with the specification and drawings.

These inspections are intended to maintain construction standards and are not intended, unless otherwise arranged, as functional tests. Therefore, the manufacture of the switchboard shall not cease during these inspections and the presence of the Superintendent at such inspections shall not absolve the contractor from their contractual obligations.



C1.6.9.2 Inspection

The Superintendent shall be notified a minimum of three (3) working days before the following inspections shall be carried out, in the manufacturers workshop;-

(a) First inspection MCC assembled and equipment laid out – not fixed (b) Final inspection MCC complete and functionality demonstrated

C1.6.9.3 Precaution

During testing, special precautions shall be taken to ensure that PLC modules with transistor or triac outputs are not "bridged out". Output cards with transistor or triac outputs shall be "forced on" by software programming to simulate their operation.

C1.6.9.4 Shop Drawings

Drawings shall be submitted to the Superintendent for comments.

These drawings shall include:

(a) The general arrangement including detailed layout of all equipment, busbars and connections,

(b) Structural and enclosing elements including sheet metal and sealing details, (c) Type and rating of equipment items, (d) Terminal block layouts and identification, and (e) Details of labels and engraving.

C1.6.9.5 Certificate of Electrical Testing and Safety Compliance

The switchboard manufacturer shall complete a Certificate of Electrical Testing and Safety Compliance form after testing of the switchboard and prior to delivery.

The completed form (Local Electricity Distributor/Local Supply Authority copy) shall be placed in a clear plastic A4 sized envelope or pocket and affixed to the metering panel or MCC with tape for forwarding by the Electrical Installation Contractor upon completion of the installation.

The Customer Copy of the Certificate of Electrical Testing and Safety shall be forwarded to the Superintendent.

C1.6.10 Delivery and Storage

C1.6.10.1 General

Following satisfactory final inspection, the equipment shall be prepared for transport. All switchboards shall be protected against mechanical and water damage.

All batteries shall be disconnected from control circuits prior to transportation or storage.

All costs associated with this shall be at the contractor’s expense.

C1.6.10.2 Lifting Facilities

Lifting of the switchboard shall only be effected by providing lifting rods inserted through the lifting holes/loops in the switchboard plinth or by lifting lugs specifically provided for lifting. If a crane is used to lift the switchboard special care shall be taken to ensure that there is no damage to the switchboard.

Any equipment weighing more than 25kgs shall be supplied with suitable lifting apparatus. Lifting facilities shall comply with the requirements of AS4991.

All costs associated with this shall be at the contractor’s expense.

C1.6.10.3 Protection

Prior to transportation all equipment likely to be effected by shock or vibration shall be secured, where necessary. Sensitive items shall be removed and packed separately.

Where equipment is delivered in two or more sections, timber framework shall be provided to protect any protruding portions of equipment.

All equipment shall be adequately and effectively protected against damage from moisture, brinelling, handling or other cause during transportation and delivery.

C1.6.10.4 Tools

Supply and deliver to site, two (2) complete sets of any special tools required for the maintenance, overhaul and operation of the electrical equipment supplied under this Contract.



C1.7 SWITCHGEAR

C1.7.1 Motor Circuit Breakers

Circuit breakers shall comply with AS3947 and be coordinated with their upstream circuit breakers by means of Cascading. Grading calculations shall be submitted to the Superintendent for evaluation at least seven (7) days prior to switchboard energisation.

Mount the circuit breakers so that the "ON-OFF" and current rating indications are clearly visible with the cover or escutcheon in position (allowing access by non-qualified operations personnel) and so that arc discharges from the circuit breakers are directed away from live metal and insulation. Align operating toggles in the same plane.

Identification of the contact positions shall be clearly marked on the circuit breaker in a contrasting colour.

Horizontally mounted circuit breakers shall be capable of successful operation under full load and short-circuit conditions.

Interphase insulating barriers as supplied by the breaker manufacturer shall be installed on the line side of all multiphase circuit breakers.

Each drive circuit breaker shall feature an external pad-lockable operating handle, which will prevent the motor starter module door from opening whilst the circuit breaker is in the closed position. Drive circuit breakers shall include auxiliary contacts for control and indication.

C1.7.2 Settings

The contractor shall produce all circuit breaker settings ensuring compliance with AS3000 discrimination rules, and provide a copy of them to the Superintendent for evaluation at least seven (7) days prior to switchboard energisation.

C1.7.3 Fuses

Fuses shall comply with AS60269.

Fault current limiter fuse links shall be held in proprietary holders, and shall be mounted for withdrawal directly towards the operator. Holders for open blade type fuses shall have suitable fixed insulating barriers between adjacent phases to prevent inadvertent electrical contact by a foreign object.

Fuse links shall be high rupturing capacity (HRC), mounted in a fuse carrier with ‘fuse blown’ indication which is visible when the fuse link is fitted to the carrier.

Where fuse extraction handles are required, they shall be clipped inside the switchboard cubicle adjacent to the fuses. Where the fuses are located behind more than one cover, one handle shall be provided behind each cover.

In the application of control circuit fuses with voltages 24VAC/DC or less, G type fuse links incorporated in rail mounting, tunnel type, disconnect terminal block housings are acceptable.

Identify, by clip on markers, each fuse terminal. Include letter "F" as the prefix to identification number, as shown on the electrical drawings.

Provide separate fusing to each individual equipment item including each PLC I/O module, each power supply unit, each instrument, etc. such that a fault on any one individual item of equipment does not affect any other individual item of equipment.

C1.7.4 Contactors

AC contactors shall comply with AS3947.

The following details and minimum features shall apply:

(a) Block style electromagnetic, double break, air break type chatter free and operate without discernible noise and generally from the one manufacturer,

(b) Utilisation category "AC-3" minimum,

(c) Short circuit co-ordination shall be type 2,

(d) Contact life of 1 million operations at AC-3, and

(e) Series or parallel contacts shall not be used to achieve the required ratings.



Contactors shall be mounted with sufficient clearance to other equipment and the enclosure to allow full access for maintenance, removal, as well as the replacement of coils and contacts without the need to disconnect or remove other equipment.

C1.7.5 Motor Protection

All motors shall include overload protection.

The protection equipment shall operate in the event of:

(a) Overloading in continuous or intermittent service,

(b) Extended acceleration times,

(c) Failure of one phase resulting in two phasing, and

(d) Mechanical seizure of the rotor.

Electronic motor protection devices shall be manual reset and shall not reset on loss of power supply. These devices shall not indicate a fault on very short duration power faults.

C1.7.6 Relays

Contacts shall have a minimum rating of 10A at 240VAC.

All relays connected to 24VDC circuits shall include surge suppression diodes and LED indication.

Plug-in types shall be latched to the receptacle base by a captive clip which may be applied and released without the use of tools.

C1.7.7 Submersible Pump Supervision and Phase Failure Relays

Contacts shall have a minimum rating of 4A to AC11 at 240V AC.

The contractor shall submit all selections to the Superintendent for review. The period of review will be a minimum of 7 days.

C1.7.8 Push Button and Indicators

All signalling control devices shall be oil-tight with heat resistant plastic or glass components, all of the same manufacture and series, suitable for mounting in a 22.5 mm diameter hole.

All terminations shall be by screw terminals accessed from the rear of the unit.

Contacts shall be rated for 10A to AC1 and 3A to AC11 all at 240V AC

Indicating lamps shall be press to test.

Lamps shall be LED type. Indicators connected to voltages in excess of extra low voltage shall be fitted with an inbuilt transformer.

C1.7.8.1 Latched Stop and Emergency Stop Push Buttons

Each drive shall feature a red mushroom-head type latched quick stop pushbutton, wired into the control circuit of the drive which will immediately stop the motor (or where necessary due to load, decelerate the motor safely).

Drives requiring additional emergency stop functionality shall also have emergency stop pushbuttons connected to proprietary emergency stop relays. Emergency stop pushbuttons shall be located directly on or adjacent to the drive or item of equipment, with a reset pushbutton provided on the local motor control panel.

Latched stop and emergency stop push buttons shall be self-latching, "Twist to Reset" type. Instructions for releasing shall be included either on the face of the button or by label/legend.

The pushbuttons shall incorporate a mechanical latching facility such that the button latches out when the button is depressed and cannot be reset until the locking ring is released.

All Emergency stop pushbuttons shall be failsafe type.

C1.7.9 Voltmeters and Ammeters

Meters shall comply with AS1042 and the following details shall apply:

(a) Flush mounting,

(b) Accuracy class 1.5 (minimum),

(c) Impact resisting anti-glare face,



(d) Meters shall be a minimum 72 square bezel with 90 degree quadrant scale. All meters shall be of the same style and size,

(e) Meter scales shall be direct reading, and

(f) Ammeters on motor starters shall be selected so that full scale is not less than the motor MCR and motor running current is not less than 70% of meter scale.

Ammeters subject to motor starting currents shall be over scaled a minimum of five times.

C1.7.10 Current Transformers

Current transformers for Local Electricity Distributor’s/Local Supply Authority equipment shall comply with the requirement of the Local Electricity Distributor/Local Supply Authority.

All other current transformers shall comply with the following:

(a) Current transformers shall be resin encapsulated window type and shall comply with AS 1675,

(b) Rated primary current shall have a current rating equal to the maximum current rating of the frame size of the controlling device,

(c) Secondary windings of measurement current transformers shall be rated at 5A. The burden shall be 0.4ohms (10VA) minimum and the accuracy shall be class 2 minimum, and

(d) Secondary windings of protection current transformers shall be 5A rated, shall be suitable for the burden and shall be of the protection class.

Current transformers shall be capable of withstanding the indicated switchboard fault level for the appropriate time of duration and shall be suitable for operation in an ambient temperature

of 40oC with a temperature rise of 75

oC.

Where fitted on busbar systems each CT shall be fitted on removable links to allow easy removal from the switchboard. Where fitted over cables, CT's shall be installed to allow easy removal from the switchboard.

C1.7.11 Terminals

Extra Low Voltage control cables shall enter or exit their respective starter via terminals located within the cable zone.

Cables of voltages >110volts shall terminate within their respective MCC cubicle and Motor connections may terminate directly onto their relevant switchgear.

Terminals shall be rail mounted, flexible style, fully enclosed with no exposed, live parts. The terminal strips shall be mounted in a location to provide easy access to the terminal screws.

Terminals shall be screw tightened & non-flammable suitable for the insertion of the 4.5mm blade width of an electrician's standard screwdriver or No 2 Phillips screwdriver. Spring clamp type terminals shall not be permitted. All bars or links connecting various terminals shall be insulated.

Not more than one wire shall be terminated at each side of a terminal.

No live components shall be accessible to any personnel.

Minimum size terminals shall accept is a 4mm2 cable.

C1.7.12 Extra Low Voltage Transformers

Transformers shall comply with AS60044.

The following features shall be incorporated:

(a) The primary and secondary windings shall be brought out at opposite sides of the transformer case,

(b) Terminals shall be accessible from the front of the unit,

(c) The output loading shall not exceed 80% of the transformers continuous rating. Note that such ratings shall take account of the degree of ventilation and ambient temperature of the transformer and supplied load, and

(d) The secondary (load) side of each transformer shall be earthed.



C1.7.13 Low Voltage D.C. Power Supplies

Switched mode power supplies shall be used on all of the following applications:

(a) Instrumentation, and

(b) PLC Equipment.

The power supply shall meet the following specifications:-

(a) Supply shall operate successfully and at selected voltage at no load,

(b) Input to output isolation of 3000V AC,

(c) Isolation of output to case exceeding 500V AC,

(d) Line regulation better than 0.4%,

(e) Load regulation better than 0.8%,

(f) Ripple and noise better than 150mV peak to peak,

(g) Temperature drift less than 1% for temperature range 0o to 55

oC,

(h) Overcurrent protection to operate at 105% of rated current with automatic recovery,

(i) All connections shall be accessible from the front of the unit, and

(j) The secondary (load) side of each power supply shall be earthed.

C1.7.14 Earth Leakage Protection Equipment

Earth leakage protection equipment shall be current-operated (RCD) type to AS3190.

Each single and three phase outlet shall be RCD protected. Rated leakage trip current shall be 30mA.

All equipment associated with an individual earth leakage circuit section shall be grouped together in a regular and logical manner.

C1.7.15 Instrumentation Indicators

Where required, indicators shall be digital, loop powered type meters suitable for flush panel mounting.

The indicator shall be enclosed in a panel mounting case with screw type terminals mounted on the rear. Zero and span adjustments shall be accessible without removing the indicator from its case.

Input range shall be 4-20mA DC with a loop loading not exceeding 250ohms. Display to be three and one half (31/2) digits, 10mm LCD scaled in engineering units for the individual loop.

Accuracy and repeatability shall be better than 0.1%.

C1.7.16 Current to Current Converters

Converters shall be fully solid state capable of receiving 4-20mA. They shall be provided for current isolation and as a source of power for repeating a 4-20mA current signal.

Converters shall be loop powered and shall be capable of supplying 20mA into a loop resistance of 1000ohms.

Converters shall be provided wherever the loop impedances of load devices exceed the source device capabilities.

Accuracy +/- 0.15% of span

Repeatability +/- 0.1% of span

Input impedance 50ohms

Auxiliary voltage for input loop 22Volts at 25mA

C1.7.17 Soft Starters

Soft Starters shall be included for any drive as shown in the schematics. They shall comply with AS3947.4, include a bypass contactor (internal/external) and be rated as follows for the required kW output of the motor.

By-pass operation 12 starts



per hour

Without By-pass operation (i.e., under test operation)

10 starts per hour

Soft Starter equipment shall be selected from the BSC’s preferred electrical equipment.

Soft Starters shall include voltage/current/torque control in all 3 phases. Include snubber networks for dv/dt suppression and MOVs for overvoltage protection of the thyristors controlling phase current to the motor.

Thermal protection devices shall be supplied and connected to stop the drive upon excess temperature rise of power switching transistors/thyristors.

The disturbance to the electrical supply system when using soft starters shall not exceed the limit set down in AS61000.3.7.

To reduce the possibility of radio interference the soft starters chassis and cubicle shall be bonded to earth with a larger than normal earth conductor - minimum of 20% above nominal size, based on the active conductor sizing and AS3000 Table 5.1.

Acceleration times shall be adjustable between 5 and 120 seconds.

During pump deceleration, the Soft Starter shall control the motor speed to a lower limit adjustable between 50% and 90% of speed over an adjustable time of 5 to 120 seconds. Control settings for deceleration shall be independent to those for acceleration.

All solid-state starters shall comply with the Australian C-tick EMC requirements as defined in the following standards AS/NZS4251 & AS/NZS4252. The manufacturer shall provide full instructions for the correct installation of filters. Where filters are not required initially, adequate space shall be provided to retrofit filters on both input and output.

C1.8 LABELLING

C1.8.1 Labelling of Electrical Equipment, General

Supply and install labels to identify all electrical equipment as shown on the drawings. Labels shall be in a readily discernible position.

All labels outside of the switchboard shall be of engraved stainless steel not less than 3mm in thickness and 50mm high. Characters shall be block letters, a minimum 5 mm high.

Labels shall be fixed to the mounting pan adjacent to the main body of the equipment they are identifying, with 316 stainless steel screws and nuts or tapped holes and screws. Self-tapping screws will not be acceptable.

Labels shall be fixed so that they may be conveniently read when equipment is in the installed position and shall not be attached, so that they are not discarded with equipment is replaced.

All of the manufacturer’s name plates shall be visible from the access position.

Light switch and power outlet identification shall include the distribution or panel board name and/or location together with the respective circuit or circuit breaker number at which the circuit may be isolated, e.g. General DB, CB6.

C1.8.2 Labelling within or on a Switchboard or Cubicle

Every item of equipment within or on a switchboard or control cubicle shall be clearly and accurately labelled.

Equipment mounted in the cubicles and modules shall be identified as per the schematic diagrams. The identification of the equipment mounted on doors and panels shall also include a description of the equipment function e.g. ‘Stop’ pushbutton, ‘Control Switch’, ‘Plant Inlet Flow – I.L.****’ etc.

A label shall be mounted adjacent to each HRC fuse base, engraved with the fuse element rating.

Labels shall be engraved laminated plastic or photo anodised rigid aluminium and shall comply with the following requirements:

(a) Except where otherwise required, labels shall be fixed adjacent to, but not on any item of equipment. Labels shall not be fixed to wiring duct or duct lid,



(b) Engraved lettering shall be black on a white background, except that the label for a main switch shall have red lettering on a white background, and warning and caution labels shall have white lettering on a red background and shall comply with AS1319,

(c) Under no circumstances is double backed tape to be used, and (d) The minimum height of lettering shall be 3mm and of sufficient definition to allow easy

reading.

Self-threading or self-tapping screws shall not be used to secure labels.

C1.8.3 Fixing - Indoor Cabinets

Labels on indoor cabinets shall be fixed by the following methods:

(a) On external surface of doors and covers - by metal thread screws, (b) On external surface of internal doors and covers - by metal thread screws, or (c) On equipment mounting plate - by metal thread screws.

C1.8.4 Fixing - Outdoor Cabinets

Labels on outdoor cabinets shall be fixed by the following methods:

(a) On external surface of exterior doors - by rivets or stainless steel metal thread screws, (b) On external surface of internal doors - by metal thread screws or rivets, or (c) On equipment mounting plate - by metal thread screws.

C1.8.5 Switchboard Nameplate

A nameplate complying with AS3439 shall be fixed to the front of indoor switchboards.

The nameplate shall include details listed in the standard and shall include the following;

(a) manufacturer’s name, (b) year of manufacture, (c) rated voltage, (d) rated amps, (e) fault rating, (f) AS standard and Form, and (g) site name or Job number e.g. Nundle Water Treatment Plant.

C1.8.6 Module Nameplate

Each module shall have a label fixed to the door engraved, and including the following:

(a) motor plant number (PU*** , numbers as per schedules and P&I drawings), (b) motor description, and (c) motor rating (kW).

Lettering shall be minimum 5 mm high.

C1.9 INSTRUMENTATION

C1.9.1 General

Supply all instrumentation and associated devices supplied under the Contract, and as detailed in the equipment list and drawings.

Instruments shall be such that the replacement of any parts may be rapidly executed to minimise non-availability of any control or measuring loop.

All instruments and associated devices supplied shall be fully supported by spare parts and technical service.

All instrument transmitters shall operate from 24VDC supply, where available.

All instruments shall have solid state circuitry of robust design. Analogue signal transmission shall be linear, 4-20mA DC proportional to the range of measured variable.

All indicating transmitters and output devices shall be capable of working into instrument loop impedances of up to 1,000ohms.

All instrument loops shall perform reliably under the site conditions at the plant.

Earth electrodes shall be installed at the location of each field instrumentation enclosure for surge protection. An earth bar shall be installed in each instrumentation enclosure for the connection of all earths and the earth electrode.

A means to isolate the power supply shall be provided within each instrumentation enclosure.



All indicating transmitters shall be provided with adjustable signal damping, and non-interacting span and zero adjustment over 50% of the range.

Instrument Calibration Certificates shall be submitted to the Superintendent for all installed instrument devices establishing the overall accuracy of the devices from primary element to the output signal (4-20mA current).

Calibration Certificates shall also be submitted for all test and measurement equipment used to calibrate the field instruments.

The instruments shall also comply with the requirements for the individual instruments as detailed in the following clauses.

C1.9.2 Field Instruments

Procure, works test (as applicable), deliver to site, install, site test and commission all field instruments as required. Where instrumentation is required below ground level, install within a suitably sized concrete pit including isolation, to allow maintenance. Direct buried units are unacceptable.

Field instruments required for process control shall comply with the requirements detailed in the following clauses. All field devices shall have a form of UV protection enclosure.

C1.9.3 Electromagnetic Flow Metering

Refer to the Mechanical Specification for technical requirements for electromagnetic flow metering.

C1.9.4 Level Transmitter (Pressure Type)

The level sensing units shall be hydrostatic pressure sensing types complete with remote transmitter.

The units shall have the following minimum specification:

Accuracy of ± 1% of span,

Rated for 1 bar (103.43kPa) or 2 bar (206.85kPa) ranges for most applications or as otherwise specified, and

Overpressure protected to 200% of rating,

C1.9.5 Level Switches – (Float Type)

The switch shall be provided with sufficient length of heavy duty flexible cable to allow a generous adjustment of the operating level. The cable length allowed for adjustment shall be neatly coiled and tied.

C1.9.6 Level Switches – (Conductivity Type)

Conductivity level switches shall consist of an electrode (or probe), and an electronic signal converter.

An earth electrode (or probe) shall be provided as necessary for correct operation.

Where more than one electrode (or probe) is suspended at the same point provide insulators at suitable spacing to maintain an acceptable clearance at all times.

The sensitivity of the switch shall be suitable for the application.

The electronic signal converter shall be mounted either in the head of the probe or mounted separately within a suitable panel.

C1.10 ELECTRICAL INSTALLATION

C1.10.1 Extent of Work

Supply all labour, tools, material and equipment necessary to complete the electrical installation, including the installation, field testing, commissioning and setting into operation of equipment supplied and installed by the Contractor as detailed in this Specification.

C1.10.2 Material and Workmanship

All equipment support frames, brackets and installation accessories shall be constructed from either marine grade aluminium or 316 grade stainless steel, as detailed in this specification.

The use of alternative materials for specific applications shall be subject to prior approval by the Superintendent.



C1.10.3 Supply Authority Liaison/Fees

Obtain all necessary permits from, pay all necessary fees to, and arrange all inspections and tests required by the Local Supply Authority.

Additionally, the Contractor is required to perform all Local Supply Authority liaison requirements.

C1.10.4 Certificate of Testing and Compliance

Submit Certificate of Testing and Compliance/Safety forms, covering all electrical installation work. Submit with the Compliance/Safety forms, test reports completed by the person who conducted the tests on the electrical installation and certification of who carried out the work.

The provision of copies of the Certificate of Testing and Compliance/Safety forms and associated documentation to the Principal’s representative shall be a condition of Practical Completion.

C1.10.5 Electric Welding Construction Precautions

Ensure that no welding currents pass through any power or earthing conductor connected to any part of the structure, plant or electrical apparatus during the installation.

During welding, all possible parallel or series conductor paths shall be isolated, if necessary by disconnection, from the part being welded.

Instrument type low voltage cables shall be disconnected and isolated before welding commences in every instance.

C1.10.6 Mechanical Protection

Supply and install approved mechanical protection on all electrical equipment and in particular under the following minimum conditions:

(a) All conduits for a distance of 500mm above any floor, walkway or concrete surface,

(b) Where subject to damage during normal plant operation and maintenance, and

(c) On which scaffolding and/or planks may be placed, or which may be used as means of access for abnormal plant maintenance.

Sheet metal covers installed to provide mechanical protection of electrical equipment shall be constructed to withstand the shock loading likely to occur in the area. Covers shall be constructed of a minimum of 5mm aluminium.

Sheet metal covers installed to provide mechanical protection of electrical equipment shall be constructed so as to enclose such electrical equipment and associated conduits but provide adequate ventilation.

Any device installed for the mechanical protection of conduits and/or cables shall be free of burrs and sharp edges. Additional bushing or sleeving shall be provided to prevent conduit and/or cable damage.

C1.10.7 Sealing

Effectively seal all openings, conduits, ducts, trenches, cable ways or the like. The seal should adequately prevent the ingress of fire, water & vermin and the like. Supply details of the proposed methodologies for Superintendent approval. Where a conduit contains an individual cable, (where no space exists for future cable installation) this shall be sealed by means of a cable gland.

Silicon rubber or pressure pack foam is not acceptable for sealing of openings or conduits.

Ensure that all spare conduits and ducts are effectively plugged and sealed.

Ensure that all openings in electrical equipment mounted in locations exposed to the weather are made weatherproof, by the installation if necessary of flashing and/or rain hoods to prevent the entry of water, driving rain and/or water seepage.

Ensure that all cable entry to cubicles and panels are sealed to that of the cubicle and panel specification.

This includes sealing of cables through internal/external walls of buildings.

C1.10.8 Installation of Cable

Supply and install all cable routes and related materials, e.g. cable trays, ladders, conduits and the like necessary for the overall cabling of the plant and associated sites.



Process, Power and Control Cabling in the switchroom shall be neatly arranged in cable trays or ladders and shall be segregated from one another.

Additional sections will be required to provide access to equipment. Any exterior runs shall be fitted with peaked lid as well as a vented rear cover to protect from UV radiation and still provide air flow, as required.

Cables throughout the site shall be segregated into conduits allocated to the following groups.

(a) Power - sub mains, (b) Power - motor cables, (c) 240VAC control cables, (d) 24VDC control cables, thermistor cables etc., and (e) Instrumentation cables, potentiometer cables, PLC data cables etc.

Field cable distribution from the main cable routes shall be along the shortest route to the field termination and/or pull boxes.

Distributed field cabling shall follow orientation of process pipe routing where possible.

Cable routes mounted along or across access ways shall not present a hazard to vehicular traffic, cranes or personnel using these access ways.

C1.10.9 Supporting, Mounting and Positioning

Supply and install, where necessary all supports, brackets and plates for the mounting and positioning of all electrical equipment, such as cubicles, panels, power outlets, light fittings, field instruments, switches, hand stations, isolating switches, conduits, cables and the like. Such supports and mountings shall be 6mm aluminium as a minimum.

All electrical equipment shall be mounted and positioned so that it is readily accessible for operation, inspection, replacement, modification and maintenance.

All independently mounted equipment shall be mounted onto fixed structures. Where no fixed structure is available, provide a prior approved structure for the mounting of such equipment.

All mounting supports, brackets, plates and the like used for the mounting of electrical equipment shall be so constructed to prevent vibration due to wind, operation of adjacent equipment or any other dynamic forces likely to be present within the immediate area.

Explosive or impact power tools shall not be used for placing mounting studs and the like.

All electrical equipment, such as isolating switches, hand stations, light switches, power outlets and the like shall be positioned and mounted a minimum of 1 metre above operating floor or platform.

All electrical equipment shall be positioned and mounted to allow bottom entry of conduits and/or cables.

All cables, cable trays, cable ducts, conduits, fixings and supports etc., shall be installed in locations that do not interfere with the normal operation and maintenance of the plant.

Supply and install all necessary non-corrosive metal packers, shims and grouting to ensure correct levelling and alignment of equipment installed under this Contract. All floor mounted equipment shall be packed as required and grouted. Shims, packers etc., shall be stainless steel.

Isolation washers/shims shall be interposed between bolts and equipment of dissimilar materials to prevent electrolytic corrosion.

Where three or more conduit or cable runs are grouped together, they shall be mounted on suitable sized cable trays and ladders. Single or double runs may be fixed directly to walls, structural members and the like. Holes shall not be drilled through the flanges of RSJs, channels or structural members.

Conduits and cables shall be supported by saddles, cleats or other prior approved means so that there is no weight taken by the conduit termination or cable gland and such that no force is exerted on core terminations.

Saddles shall be double sided Grade 316 stainless steel, they shall be fixed with Grade 316 stainless steel screws. Single sided, electroplated zinc steel saddles, or spring clip saddles will not be acceptable.

Special care shall be taken when saddling ‘single core cables’ or ‘conduits containing single core cables’. Ferrous saddles shall not be used when fixing such cables or conduits. In particular, care shall be taken with ‘single core cables’ or ‘conduits containing single core



cables’ when run on cable trays or conduit racks to ensure that steel support brackets do not form a magnetic path around such cables or conduits.

Cleats, wooden or otherwise, used for clamping conduits and cables shall firmly clamp, without causing distortion or damage, to such conduits and cables.

Saddles shall be fastened using plastic plugs for up to No. 8 size screws. For larger fastenings, Grade 316 stainless steel Dyna bolts or Loxin anchors or other prior approved fixings shall be used. Screws securing saddles shall be Grade 316 stainless steel.

Sufficient length of waterproof flexible conduit and cable shall be provided, to permit the following:

(a) positional adjustment of electrical equipment without electrical disconnection, for example, adjustable floodlights, no-flow proximity and/or limit switches etc.,

(b) removal and/or positional adjustment of driven equipment without electrical disconnection of the motor, and

(c) full motor travel adjustment without straining or chaffing conduits and/or cables or electrical disconnection of the motor.

Flexible conduit shall be limited to a maximum length of 500 mm.

C1.10.10 Bolts, Nuts, Washers and Jointing Materials

Bolts, nuts, washers and other demountable fastenings shall be Grade 316 stainless steel and shall remain unpainted. Isolating washers shall be fitted between dissimilar metals.

Anti-seize type lubricant shall be used on all nut/bolt combinations to stop binding of the two items.

Electro-galvanising, nickel, cadmium, chromium or any other plating process, will not be acceptable.

Fixing into concrete shall be by chemical anchors with Grade 316 stainless steel studs.

All bolts and nuts shall have metric threads to AS1111 and AS1112.

All exposed boltheads and nuts shall be hexagonal and the length of all bolts shall be such that when fitted with a nut and tightened down the threaded portion shall fill the nut and not protrude from the face thereof by less than half a bolt diameter and not exceeding 1 bolt diameter.

C1.10.11 Field Panels, Junction Boxes and Local Operator Panels

Field panels shall be located adjacent to their respective primary element or sensor. The enclosure shall be mounted with the indicator at 1.5m (or as agreed on site) from the finished walkway surface.

Boxes shall be weatherproof, with a degree of protection of IP65 minimum and suitably sized to accommodate conduits and rail mounted terminals.

Boxes shall be manufactured from marine grade aluminium or 316 grade stainless steel with sufficient strength to withstand all electrical, mechanical and thermal stresses of all site conditions. All cover screws that are tapped into aluminium shall be lubricated with silicon grease before insertion. All screws bolts and fixings shall be Grade 316 stainless steel.

Boxes shall be fixed to concrete structures with Grade 316 stainless steel chemical anchors.

Bolts, nuts, washers and other demountable fastenings located outdoors shall be Grade 316 stainless steel and shall remain unpainted. Isolating washers shall be fitted between dissimilar metals.

Local operator panels shall be mounted a minimum of 1.2m from the finished walkway surface. The panel shall be located within reach of the drive motor and driven device with controls visible from the device.

Submit construction and layout drawings of each type of local panel to the Superintendent prior to construction.

Field Panels, Junction Boxes and Local Operator Panels shall be located as agreed with the Principal’s representative.



C1.10.12 Field Cabling

C1.10.12.1 General

All cables and/or conduits shall be neatly placed, even and parallel and all supports, brackets, saddles and expansion joints installed at suitable intervals particularly in exposed locations to prevent sag due to expansion in sunlight.

All cables and/or conduits shall be grouped as far as possible and all supports, brackets, saddles and clips spaced to ensure that the runs remain straight and in any case shall not exceed 1 metre between centres.

Cables on ladder trays shall not exceed two layers.

Any Contractor initiated cable selection shall require calculations to be submitted for Superintendent comments prior to procurement. These calculations shall take into account all applicable de-ratings.

Cables in access floors or in concrete trenches shall be laid on cable ladders.

Care shall be exercised when laying cables in ducts, cable ways, trenches and ladder trays, they shall be neatly placed and run parallel, bunching will not be acceptable, crossovers shall be confined to cables entering and leaving the medium.

Where power cables and instrument cables share the same cable tray, a barrier strip shall be installed to separate power cables from other cables. The barrier strip shall be of the same material as the cable tray and secured to the cable tray.

Cable runs on cable trays shall be fixed with outdoor nylon cable ties at a maximum of 1 metre intervals. All cable ties shall be neatly trimmed.

All wiring, junction boxes, terminal boxes and the like, shall be arranged so that there is ample access for replacement, modification and maintenance.

C1.10.12.2 Cable Glands

Provide approved cable glands for entry into enclosures, terminal boxes etc. Glands to have protection rating equal to the enclosure, terminal box etc.

Where cables are not enclosed in conduit where they enter a switchgear and control gear assembly or local field control or instrument panel, they shall be glanded using PVC type compression cable glands of suitable size. Cable glands above 32mm diameter shall be metallic. Glands shall be mounted in a logical position.

Cable glands shall be tight fitting and shall grip the cable sheathing to ensure the cable cannot move. The cable sheath shall be continuous through the gland.

Cable glands shall not be fixed into miss-matched threads or holes with adhesives or epoxy. Provide suitable adaptor fittings as required.

All cable entries shall be machine-cut (holesaw) and free of burrs and sharp edges. Cutting of holes by burning methods is not acceptable.

All cables shall be continuous throughout their route length. No ‘through joints’ will be permitted.

Cables shall not be bent in a radius less than twelve (12) times their outside diameter.

Correct phase colours, orientation and rotation shall be maintained, at all terminations of cables throughout the installation.

Any cable, which suffers abrasion or damage to the insulation during installation, shall be replaced.

C1.10.12.3 Variable Speed Drive Power Cabling

Power cabling from all Variable Speed Drives shall be screened, in accordance with the supplier recommendations. The factory fitted power cable for variable speed driven submersible pumps and mixers, shall be suitably screened.

Cables shall be earthed at the source using appropriate cable glands. The earth screen shall be continuous from the earth at the switchboard to the motor frame.

C1.10.12.4 Low Voltage Sheathed Cables

Sheathed cables for circuits operating at voltages above ELV shall be circular, 0.6/1 kV rated, PVC insulated, orange PVC sheathed cable with stranded copper conductors.

The minimum size of conductors shall be as follows:



(a) power circuits: 7/0.67 (2.5 mm2) copper, (b) light circuits: 7/0.50 (1.5 mm2) copper, and (c) control circuits: 7/0.50 (1.5 mm2) copper.

C1.10.12.5 Instrumentation Cables

All multicore instrumentation cable shall have individual twisted pairs screened and overall screened.

The cables to be used shall be PVC insulated and sheathed with an aluminium Mylar screen and base copper drain wire.

The cable shall be similar in all respects to the Dekoron Electronic Instrument Cable type IEC-2 or ASC Cable-Aid type B50 and shall consist of twisted pairs of seven (7) strands of minimum size 0.30mm copper conductor with a PVC insulation not less than 0.38mm thick. Cable outer sheath shall be black.

Cable pairs shall be twisted and be identified either by colours or numbers embossed on the PVC insulation.

Analogue signals shall not be run in instrument cables used for digital signalling.

C1.10.12.6 Control Cables

The cables to be used shall be PVC insulated and PVC sheathed and have a minimum of seven (7) strands of minimum size 1.50mm copper conductor, insulation shall be rated at 0.6/1kV.

These cables shall be used for digital I/O, motor control & solenoids.

C1.10.12.7 Network Cables

Cables for communication between racks and peripheral equipment shall be CAT5E shielded, structured cabling and shall be compatible with all communication modes required by the PLC interface modules.

All communication cabling running externally to a building, shall be run in fibre optic cable.

C1.10.12.8 Above Ground Conduits and Fittings

All cables installed external to buildings or service trenches shall be enclosed over their full length by conduit except where cables pass through cable pits.

All rigid conduits installed outdoors in locations exposed to the weather or sunlight shall be Halogen free, Fire resistant, Temperature and Ultra Violet light stabilised. All fittings, saddles and terminators shall be manufactured from the same material. Conduit to be Clipsal HFT or approved equivalent.

Final cable connections to motors, valve actuators, solenoids, proximity and/or limit switches, field devices and sensors etc. shall be enclosed in black, heavy duty water tight, spiral reinforced, non-metallic flexible conduit. Each end shall be terminated with screwed conduit terminators supplied from the same manufacturer as the conduit and sealed to IP56 minimum.

Flexible conduit and terminators shall be heavy duty Ultraflex 170 series Rhino or approved equivalent.

All conduit reducers/adaptors shall be of the same material as the conduit used with threadform identical to the mating threads.

Conduit terminators shall not be fixed into miss-matched threads or holes with adhesives or epoxy. Provide suitable adaptor fittings as required.

After installation, all metallic conduit components and saddles shall be painted with Amercoat No. 62 or approved equivalent over the full surface.

C1.10.12.9 Below Ground Conduits

Particular care is to be taken when installing underground conduits. All conduits shall be installed in accordance with AS3000 Section 3.11 for a Category A wiring system.

All cables installed below ground shall be installed in heavy duty rigid conduit.

Below ground conduits shall:

(a) be straight, maintain minimum spacing as detailed on pit conduit entry layouts and not cross over,

(b) be accurately located using route markers placed at intervals of not more than 10 metres for straight distances, at changes of direction, at terminations and entry points to buildings,



(c) be fitted with bellmouths at the entry to the switchroom and all pits/penetrations, (d) drain to electrical conduit pits which then shall be drained where located adjacent to a

suitable drainage point as detailed on the electrical pit and conduit general arrangement drawing,

(e) be identified with marker tape over each individual conduit in accordance with AS3000 Section 3.11,

(f) be provided with draw wire in all conduits. A 1000mm length of draw wire shall be left securely fixed at the ends of each run. The draw wire proposed to be used by the Contractor shall be approved by the Principal prior to installation,

(g) be installed in clean sharp sand, and (h) all excavations to be backfilled and adequately compacted.

A concrete “collar” is to be formed around all conduits that protrude above natural ground. The collar is to extend a minimum of 100mm above and below finished surface level. All conduits shall protrude above the top of concrete by a minimum of 300mm.

The following inspections are to be allowed for by the Contractor:

(a) Prior to backfilling of all trenches there is to be an inspection by the Principal to ensure the requirements of this specification are being met,

(b) During backfilling the Principal is to be present to witness and verify the correct installation of marker tape above the conduit runs, and

(c) Prior to the final grouting of conduits within all cable pits, there is to be an inspection by the Principal to ensure the requirements of the specification are being met. During this inspection the Principal shall be checking particularly that the minimum cover requirements identified in AS3000 are being adhered to for all conduits leaving the cable pits.

C1.10.12.10 Cable Pits

Supply and install all cable pits in accordance with the contract drawings. Pits shall be pre-cast concrete.

Cable pits installed where vehicular traffic exists shall be selected and installed to withstand vehicle loading. Provide pits with the Gatic covers to suit traffic loading – Class B.

Where cable pits are installed in non-trafficable areas, their lids shall be Aluminium checker plate and constructed with a lip of minimum 30mm.

All lids to be labelled with "ELECTRIC CABLES".

Pits shall sit 50mm proud from top of the finished surface level.

All pits installed within a concrete slab are to sit flush with the top of concrete.

Pit dimensions shall be adequate to facilitate ease of cable installation and withdrawal, as specified on the Contract drawings.

All pits shall be drained to either adjacent pits or directly to a drainage system.

All conduits are to be fitted with bell-mouths within the cable pits. All conduit penetrations shall be sealed by epoxy grouting following installation to ensure there is no ingress of water into the pit via the penetration.

C1.10.12.11 Control Boxes, Junction Boxes and Connection Boxes

Boxes shall be weatherproof, with a degree of protection of IP65 minimum and suitably sized to accommodate conduits and rail mounted terminals.

Boxes shall be manufactured from marine grade aluminium or 316 grade stainless steel with sufficient strength to withstand all electrical, mechanical and thermal stresses of all site conditions. All cover screws that are tapped into aluminium shall be lubricated with silicon grease before insertion. All screws bolts and fixings shall be Grade 316 stainless steel.

Boxes shall be fixed to concrete structures with Grade 316 stainless steel chemical anchors.

Bolts, nuts, washers and other demountable fastenings located outdoors shall be Grade 316 stainless steel and shall remain unpainted. Isolating washers shall be fitted between dissimilar metals.

C1.10.12.12 Cable Draw-In Boxes

Cable draw-in boxes shall include any enclosure, provided to interface flexible conduits from electrical equipment with the conduit system. All cable draw-in boxes and enclosures shall be constructed to the same requirements as for boxes in 1.15.11.



C1.10.12.13 Cable Ladders

At the completion of the upgrade works, all redundant cables and redundant cable ladder shall be removed by the contractor and all penetrations sealed by grouting. Expansion foam shall not be used.

Cable ladders, including their covers, shall be heavy duty aluminium, or stainless steel. The offered material shall be subject to acceptance by the Superintendent.

Supply and install all cable ladder with all the necessary bends, risers, reducers, expansion joints and other fittings as required. Use Grade 316 stainless steel fixings in all joins in cable tray. The requirements of 1.12.9 shall be adhered to.

Cable ladder tray shall be with continuous ventilated base and fixed non-ventilated lid. The cable tray lid shall be screw fixed with parallel clamps along both sides every 600mm. Self-tapping screws, self-threading screws or rivets are not approved. Rung spacing shall not exceed 300mm. Cables smaller than 13mm OD installed on cable ladder shall be run on perforated tray or ducts installed on the ladder. This requirement does not apply where the rungs of the ladder form a continuous base.

Cables shall be fixed to the ladder by outdoor plastic cable ties. All cable tie ends shall be neatly trimmed.

Supply and install support brackets and accessories for supporting the cable ladder trays. Support brackets shall be manufactured from marine grade aluminium or stainless steel, to match the tray installed with Grade 316 stainless steel bolts, nuts and fixings.

All cable ladder shall be continuously connected to the main earth bar. A 16mm2 earth wire shall be connected across any gaps or joints that are not continuous.

Where cable tray is not mounted in a horizontal plane with the lid uppermost, or not mounted vertically against concrete walls, the tray shall be fitted with a full width back cover, of the approved material, to exclude all sunlight from the enclosed cables.

All cables installed above ground level and external to buildings shall be installed in cable ladder tray with final connection to equipment in flexible conduit.

Cables shall leave the cable tray or ladder in such a manner that no cable shall be in contact with the side rails. In general, cable shall leave the tray or ladder in conduit, which shall be securely anchored to the tray or ladder.

C1.10.12.14 Cable Support Stockings

All submersible pump and mixer cables, level regulator cables, suspended level probes etc. shall be supported at the top of the structure or well with cable stockings. A maximum of one cable shall be installed in each stocking.

The stockings shall be woven mesh type sized to support the cable without slipping.

Cable support stockings shall be manufactured from Grade 316 stainless steel and shall be complete with a Grade 316 stainless steel ferrule. Copper ferrules will not be accepted.

Fix cable support stockings to the structure or well top with Grade 316 stainless steel brackets and 6mm diameter, Grade 316 stainless steel expansive fixings.

C1.10.12.15 Power Outlets and Switches

Power Outlets, (both single and multiphase) and lighting switches mounted external to buildings and in the pump house, shall be Clipsal 56 series for single and Clipsal 2000 series for Multiphase.

All outlets shall accept Clipsal 56 series plugs and sockets without the use of adaptor units or adaptor leads.

All multiphase outlets shall be 5 pin.

Motor local isolating switches shall be mounted in hose proof, weatherproof, lockable type enclosures having degree of protection IP56 to AS1939.

The switch unit shall be high fault rated for application as a motor isolator and safety switch complete with three (3) poles and an ‘early break - late make’ fourth (4th) pole. All isolators shall be pad lockable in the off position.

C1.10.12.16 Cable Installation in Access Floor Areas

All cables installed below access flooring shall be installed on the approved cable ladder. Cable ladders below access floors do not require lids.



All cables installed in below floor concrete trenches shall be installed in the approved cable ladder with lid.

Cables to lay in an orderly fashion on cable trays with a minimum of cross-overs. Fix all cables to cable tray with cable ties.

All cables shall be easily accessible for replacement. Cables or cable ladder/tray shall not be laid under areas designated for future MCCs.

C1.10.12.17 Cable Terminations

Each core of every cable shall be terminated in individual, fixed terminals. Cores within each cable shall be terminated in adjacent terminals in numerical sequence - i.e. cores 1, 2, 3, 4 etc.

Both ends of each wire shall be terminated with a crimped lug to suit the particular size of wire and type of terminal.

Every control cable core shall be terminated with a pre-insulated cable crimp sleeve.

All crimp sleeves and crimp lugs shall be crimped to the wire ends with a tool having a ratchet device to ensure full crimping before tool will release. Crimp tools without ratchet devices, pliers or similar blade tools shall not be used to secure sleeves or lugs to wires.

Where cable cores terminate in tunnel type terminals, entire metal surface of the crimp sleeve or lug shall be contained within the terminal shrouding and shall not be visible.

No more than one cable core shall be terminated in any tunnel type terminal.

Pin type crimp lugs and blade type crimp lugs shall not be used in tunnel type terminals.

XLPE cables shall be terminated in accordance with the recommendations of the cable manufacturer.

Where lugs are fitted, each wire shall have sufficient length to permit replacement of a lug.

At all terminations of power cable cores, correct phase to phase relationship and phase rotation shall be maintained.

All spare cable cores shall be terminated on terminal strips and identified as spare ‘(SP)’.

C1.10.12.18 Cable Identification

Each end of every cable shall be identified with a numbered cable tag in accordance with the cable schedule. The cables shall be identified with a prefix according to their function and a suffix representing the cable number i.e. ****-P1 for power cables, ****-C1 for control cables, ****-I1 for instrumentation cables, ****-D1 for data cables.

Identifying cable tags shall consist of numbered ferrules mounted on a tag bar designed such that when attached to the cable, the ferrules cannot be removed from the tag bar. The identifying tag shall be fixed to the cable with black nylon cable ties.

All power cable cores shall be identified at each termination by the appropriate red, white and blue phase colour and black for the neutral.

Every cable core shall be fully identified at both ends with stainless steel labels and numbered in accordance with the circuit diagrams.

All earth conductors shall be identified at each termination by the colour green/yellow. Other colours will not be acceptable.

C1.10.13 Earthing

C1.10.13.1 General

All new portions of the installation shall be considered as an ‘Earthed Situation’, and all exposed metal of equipment shall be earthed in accordance with the requirements of AS3000 and those of the Local Electricity Distributor/Local Supply Authority.

The earthing system shall comprise the MEN system.

Install earthing to all low voltage electrical equipment and exposed metal on which electrical equipment is mounted.

Install an earthing system in accordance with the requirements of Section 5 of AS3000.

Earth electrode(s) shall be installed in a suitable and accessible position. The cable to the electrode shall be enclosed in HD UPVC conduit.

Earth electrodes shall be ALM-Dulmison Grade 316 stainless steel sleeved steel type and shall be driven to a minimum depth of 2.5 metres.



The connection at the top of all earth electrodes shall be installed in approved earthing boxes such as ALM-Dulmison.

All earth electrodes shall be provided with an accessible removable type connection or link or other prior approved means to enable resistance tests to be carried out.

Bare earth conductors shall not be used.

Supply and install an earth bond conductor between the main earth bar and the incoming water main.

Screened signal cables shall have their earth screens connected to earth at the switchboard end only, (unless specified otherwise).

The earth loop resistance for each system shall not exceed 1ohm as required by AS3000 Part 1 at the worst point and the system earth loop resistance test shall be carried out at the point in the system specified by the Superintendent. If the earth loop resistance exceeds this value additional earth electrodes shall be installed until the required resistance is achieved.

Notwithstanding some provisions of AS3000 regarding use of constructional bolts or studs for earthing or earthing terminals, all metal to be earthed shall be connected from an approved earth terminal directly to the earth bar or link with an electrically continuous copper conductor.

C1.10.13.2 Equipotential Bonding

Provide equipotential bonding to all new areas of plant. Equipotential bonding shall include:

(a) Earth bar at each area of plant, with 35mm2 earthing cable connection to the main switchroom earth bar

(b) Reinforcement in concrete footings or structures connected to the earth bar via “Dulmison - Type C70” earth bonding system at a maximum spacing of 20 metres.

(c) Each individual section of external handrail and metallic building structures shall be electrically bonded using a minimum 35mm2 earthing conductor.

(d) Each individual section of cable ladder shall be electrically bonded using 16mm2 earthing conductor.

(e) Pipework, miscellaneous metallic support stands and equipment shall be bonded using a minimum 6mm2 earthing conductor.

C1.11 PLC AND RTU PROGRAMMING

The copyright for all PLC configured code is to be the property of the Principal. The PLC code is to be provided to the Principal at the completion of commissioning for their records.

The PLC program shall be programmed using the following IEC1131 programming languages:

Function Block Diagram (FBD)

Structured Text (ST) and

Sequential Function Chart (SFC).

The PLC program and user defined Function blocks shall not include any Instruction List (IL) or Ladder Logic (LL) programming.

The main body of the PLC program shall be predominantly programmed using Function Block Diagram (FBD). The use of Structured Text (ST) or Sequential Function Chart (SFC) elements in the code in the PLC program shall be minimised wherever possible.

Function blocks shall be used for repeated control elements within the program such as drives, valves, pump queues etc. to simplify the program and improve readability. Comments shall be provided within user defined function blocks to ensure easy diagnostics. Also with in the comments shall exist the history of changes and versions of the block development until the end of the commissioning phase.

Plant process sequences shall not be included within Function Blocks i.e. sequences shall be coded in the main program body as Function Blocks and/or Sequential Function Chart with the resulting sequence output provided as inputs to the relevant drive function blocks. Where sequences rely on a specific order of steps or stages then the current step must be indicated on SCADA. In addition to this, if the next step is determined by a timer then the countdown to the next step must be displayed.



The PLC program and associated function blocks shall be fully documented within the code. Comments shall be provided for sequences and logic within the code. The comments shall describe the purpose of each section of code and the functionality of each sequence, logic element or control action for the relevant section of code.

Individual variable comments should be constructed such that the function and purpose of the point is clear from the comment. If the Boolean state descriptions of a point are not precise opposites then the comment will include a description of each state. If an analogue point has a short list of possible integer states then the comment will list all states and state values.

Variable names must be meaningful to easily identify the asset/device and function of the variable.

Addressing ranges must be organised and without gaps within a sequential range to avoid messy gaps. Correct data types should be used for different variable types/functions. For example, pump hours should be a real variable and pump starts should be an integer variable.

C1.12 SCADA PROGRAMMING

The copyright for all SCADA configured code is to be the property of the Principal. The SCADA code is to be provided to the Principal at the completion of commissioning for their records.

The supervisory control and data acquisition (SCADA) system software will be designed for onsite control and monitoring of the plant.

The scope of works associated with the new control system shall be undertaken in accordance with the Contract, and includes the following:

1. Configuration and commissioning of a Schneider CitectSCADA system to meet the requirements of the Functional Specification. All SCADA pages are to be designed in accordance with the provided standard graphics and genies included within the BSC WTP project. The page layouts shall be developed in line with the P&IDs and shall be submitted to the Superintendent for approval.

2. SCADA Security shall be configured to ensure only authorised users can access the server and database. User permissions must also be configured within the database to limit controls and popup access to authorised security groups.

C1.13 ELECTRICAL/CONTROL TESTING

C1.13.1 General

Provide the following general electrical testing /checks once the switchboard is installed and relevant circuits terminated. This testing is required as if this were a new installation and any results found “out of spec” shall be referred to the Principal for further action.

(a) Checking electrical circuit continuity in accordance with drawings;

(b) Checking electrical insulation integrity in accordance with the design and statutory requirements;

(c) Checking electrical earthing integrity in accordance with design and statutory requirements;

(d) Checking calibration and ratings of safety devices such as circuit breakers and overloads;

(e) Checking calibration of measuring and indication equipment such as instruments, signal converters, meters etc.;

(f) Checking operational integrity of controlled equipment;

(g) Checking operational integrity of safety devices such as isolators and interlocks;

(h) Checking the direction of rotation of rotating electrical equipment;



C1.13.2 Submission of Certificates

Submit for review by the Principal, examples of Inspection and Test Plans and Factory Acceptance Test certificates. Factory Acceptance testing shall be witnessed by the Superintendent prior to equipment delivery.

Submit Certificate of Testing and Compliance/Safety forms after completion of all testing in accordance with statutory requirements.

C1.13.3 PLC and SCADA Software Factory acceptance Testing

The tests performed shall include the following:

(a) Confirmation of logic operation via software simulation in accordance with the Functional Specification including all system sequencing, PID controls and alarming,

(b) Response to power failure and system failure, and

(c) SCADA display and control interaction.

If the system fails during the test the fault is to be rectified and the test repeated.

One (1) copy of the test results shall be submitted to the Principal, five (5) working days, prior to dispatch from the suppliers works.

C1.13.4 Site Electrical Testing General

Ensure, before carrying out any tests, that all equipment likely to be damaged by such tests has been removed from the circuit under test or has been isolated and earthed. For example, thermistor circuits, electronic components and the like.

On completion of all checks and tests, ensure that all equipment disconnected and/or removed to enable such checks and tests to be carried out has been replaced and/or reconnected. For example, verify that all links have been closed and tightened, all fuses replaced, all terminations made and tightened, components replaced and/or reconnected, and all covers and the like replaced.

For all interfaced components of the MCCs and Process Control and Instrumentation System, complete continuity checks shall be carried out to establish the correct physical interconnection of the various individual components and their isolation from one another and earth.

All system voltages shall be checked to verify that their magnitude and type is compatible with the interconnected components.

C1.13.4.1 Wiring Point to Point checks

Undertake Point to Point checks on all power, control wiring and instrument wiring. Power shall not be switched on to an area of plant until all cabling in that area has been tested, verified and properly terminated. Record all point to point checks in a format acceptable to the Principal.

C1.13.4.2 Insulation Resistance Level Tests

Insulation resistance tests shall be carried out on all motors, LV cable, MCCs, LV distribution panels and auxiliary equipment as follows:

(a) The test voltage shall be applied to each conductor for one minute and the resistance recorded,

(b) Voltage rating of insulation testers shall be 500 V for LV equipment, and

(c) Acceptable resistance value for LV cables and busbars is greater than 1 Megaohms as per AS3000 8.3.6.2.

Unacceptable resistance values shall necessitate:

(a) Cables to be rejected and replaced,

(b) Machines to be dried out and subsequently re-tested, and

(c) Busbar and wiring systems to have faults localised and corrected.



C1.13.4.3 LV and Control Cable Tests

(a) LV cables - carry out insulation resistance test on all LV cables. The final insulation resistance test shall be carried out after terminations are completed,

(b) Control cables - carry out insulation resistance test on 0.6/1 kV grade cables. Control cables shall be insulation resistance tested between earth and each core and between each conductor. Screened instrument cables shall not be tested, and

(c) Check that the cable size to be installed to the equipment as installed complies with the requirements of AS3008.1.1, AS3000 and the Rules of the Local Supply Authority.

C1.13.4.4 Installed Cabling and Circuit Tests

(a) Check all relays, contactors, selector switches, pushbuttons for operation, installation, adjustment, rating and labelling,

(b) All circuit breakers, fuses, type and rating shall be checked against the drawings,

(c) Cable installations shall be inspected and sizes shall be checked against the drawings, and

(d) Cabling shall be checked and tested against the schematic diagrams. If the circuit is interlocked with other drives or equipment, the logic of these interlocks shall be checked.

Particular care shall be taken in circuits which may contain semi-conductors to ensure that they are not damaged during testing.

(a) Check that all safety and field devices and auxiliary equipment are installed, connected and set for correct operation. Check tightness of cable terminations, and freedom of operation of pushbuttons, limit switches, and the like. Check correct labelling of all cables, cable cores and termination strips,

(b) Complete all tests as detailed in AS3017 “Electrical installations – Testing and inspection guidelines”,

(c) With control circuits only energised, verify that each field device and associated relay(s) operate correctly, and that they prevent contactor closing or cause tripping etc. Repeat for each motor in the installation commencing with auxiliaries and finishing with the main drive,

(d) Energise lighting and general purpose outlet circuits one at a time. Check that each unit is in the correct circuit in accordance with the drawings. Check that lamps operate, replace lamps as necessary. Check power outlets for voltage and correct rotation of active neutral and earth pins. Check all switches for correct function, and

(e) Complete a C/B / circuit schedule for each distribution panel and insert within panel in storage provided.

The drawings used in these tests shall be the latest issue.

C1.13.4.5 Earthing Installations

Check continuity of static earthing throughout all steelwork within the installation.

Earth resistance testing using an approved test instrument shall be carried out in accordance with the requirements of AS 3000 Part 1 before and after the installation is bonded to the grid. Resistance readings shall be recorded and shall not exceed one ohm for the earthing system.

C1.13.4.6 Drive Checks

For Each Drive, submit to the Principal a Test Sheet summarizing the results of the following site checks & tests:

Initial Checks

(a) Motor Nameplate details,

(b) Main Circuit Breaker/Fuse details,

(c) Motor Overload details,



(d) Variable Speed Drive/Soft Starter set up parameters,

(e) Motor ‘Megger’ Readings,

(f) Cable ‘Megger’ Readings,

(g) Earth Continuity check, and

(h) Labelling check.

C1.13.4.7 Instrument Checks

Each instrument and each instrument loop shall be separately tested to prove the calibration, repeatability and where appropriate, the control response. Instruments shall be tested at 0, 25, 50, 75 and 100% FSD with both rising and falling signals. All necessary test equipment shall have been calibrated prior to the tests commencing. A NATA certificate of accuracy for all test equipment shall be available for inspection on request.

Tests shall verify the guaranteed accuracy, repeatability and drift of the equipment as specified for the particular instrument and/or instrument loop, and shall verify the specified functional requirements of the overall Instrumentation System.

For each instrument, submit to the Principal a Test Sheet summarizing the results of the following site checks:

(a) Instrument Loop No

(b) Instrument Details (Manufacturer, type etc.)

(c) Range

(d) Calibration report (minimum 5 point calibration)

C1.13.4.8 Fibre Optic Cabling Checks

For Fibre Optic Cabling, submit to the Principal a test sheet summarising the results of the following site checks:

(a) Details of test instrument & method,

(b) Identifying number of the cable and fibres,

(c) Measured length of fibres, and

(d) Loss in dB.

C1.13.4.9 PLC input and Output Checks

Ensure the PLC input and output signals are in accordance with the Electrical Drawings and Specifications by simulating the operation of all input and output field devices.

C1.13.4.10 Variable Speed Drives/Soft Starters

Provide for a technical representative of the manufacturer or technician accredited by the manufacturer who is fully versed in the programming of the supplied equipment to be present on site to carry out the required testing and commissioning.

Following successful commissioning of the equipment the drive configuration files shall be provided (electronically) for inclusion in the Operational & Maintenance Manuals.

C1.13.4.11 SCADA System Testing

Confirm that:

(a) Each analogue and digital point is correctly displayed,

(b) All operator controls are fully functional,

(c) System functionality is confirmed in accordance with the Functional Description,

(d) All alarms are functional by simulation of each individual fault (at both the plant and off site SCADA systems),

(e) All events are logged,

(f) Operator logins and access levels are in accordance with specified requirements,

(g) Remote notification systems are configured in accordance with the Principal’s requirements and are fully functional, and

(h) Data trending views are functioning correctly.



C1.14 FINAL DOCUMENTATION

C1.14.1 Red Pen Mark-ups

At all times a legible and marked-up set of working drawings shall remain on site.

C1.14.2 TESTING AND COMMISSIONING DOCUMENTATION

Prepare testing and commissioning sheets to record all inspection, testing, calibration and commissioning work. All completed sheets shall be neatly bound in loose leafed (plastic sleeved), hardback (4 ring ‘D’ type) binders at ISO A4 size and appropriately labelled, indexed and divided.

Testing and commissioning sheets shall include:

(a) Results of all tests and site data,

(b) Date of test/check, and

(c) Name and signature of person performing the test/check.

Submit testing and commissioning standardised sheets to the Principal for approval a minimum of two weeks prior to commencement of the testing and commissioning.

Provide two completed bound copies of the Testing and Commissioning Manuals for each site

after completion of all testing, commissioning and process proving stages.

C1.14.3 WORK-AS-EXECUTED DRAWINGS

The electrical drawings in electronic (.dwg) and (.pdf) formats will be forwarded to the Contractor on Contract award.

Submit work as executed (WAE) information prior to Practical Completion. All drawings shall be updated to include all modifications made during the construction and commissioning stages.

A complete drawing register is to be provided at the front of the volume which includes the following:

(a) Drawing Number,

(b) Drawing Title,

(c) Revision Number, and

(d) Revision Date.

The Contractor shall provide the drawings in electronic (.dwg) and (.pdf) formats submitted on a CD or DVD. Electronic drawing (*.dwg) files shall be compatible with AutoCAD 2013 format or later.

Provide the following copies of WAE drawings:

(a) One bound copy of all electrical, control and instrumentation drawings shall be housed inside the PLC compartment of the MSB,

(b) One bound hard copy of all electrical, control and instrumentation drawings, and

(c) Two CD/DVD copies of all drawing files in both Autocad and PDF format.

If it is established that the marked up WAE information furnished by the Contractor is incorrect, all costs associated with the determination of the correct WAE information will be the responsibility of the Contractor.

C1.14.3.1 Programmable Device Configurations

Provide two (2) CD/DVD soft copies and hardcopies as part of the Operation and Maintenance Manuals of the configured parameters for all programmable devices such as Soft Starter’s, Variable Speed Drives, etc. associated with the Contract.

C1.14.4 SOFTWARE

C1.14.4.1 PLC Software

Provide two bound hard copy printouts and two CD/DVD soft copies of the following PLC documentation for each site.

(a)

(b) The Functional Specification document, updated to reflect any modifications to

the control procedures included in the PLC program.

All documentation and information shall be presented in the English language.

Provide two CD/DVD soft copies of the operational version of PLC programs associated with the Contract.



The submission of the complete package of information relating to the PLC and the PLC Programs is a condition of achieving Practical Completion.

C1.14.4.2 SCADA Software

Provide two CD/DVD soft copies of the operational version of all SCADA system configurations associated with the Contract.

C1.14.4.3 Proprietary Software Packages

Provide original software packages and licenses for all licensed software provided under the contract.

The software packages shall include:

(a) All PC operating systems,

(b) All SCADA systems and associated packages,

(c) All device configuration software.

Provide a complete list of all software packages provided.

C1.14.5 TRAINING

Separate ‘Operations staff’ and ‘Maintenance staff’ training sessions shall be provided. The maintenance staff may also attend the ‘Operations Staff’ training.

The training shall take the form of both ‘classroom’ and ‘on-site inspections’ to highlight equipment controlled and also to reinforce the classroom content.

C1.14.5.1 Operations Staff

The Operations Staff training shall consist of the following as a minimum;

(a) SCADA Description and Operation,

(b) SCADA Navigation,

(c) The use of Pop-ups,

(d) Trend and report Operation,

(e) Setpoint adjustment, and

(f) Alarm handling and operation (including the meaning of the different levels of severity).

Specific ‘SCADA Instructions’ shall be developed by the Contractor for the Principal’s staff to allow them a written reference for all SCADA operations.

These Instructions shall also form part of the Operation and Maintenance Manuals.

C1.14.5.2 Maintenance Staff

The Maintenance Staff training shall consist of the following as a minimum;

(a) Incoming power supply source/route/location and isolation procedures,

(b) Main switchboard familiarisation and operation,

(c) New switchboard familiarisation and operation,

(d) Cable routes emanating from the all Switchboard’s,

(e) Submain isolation procedures,

(f) Equipment familiarisation and operation,

(g) Equipment isolation procedures,

(h) Control system functionality, and

(i) Communication system layout, overview and functionality.

Specific ‘Maintenance Instructions’ shall be developed by the Contractor for the Principal’s staff to allow them a written reference for all Maintenance activities, including what to do in the event of a PLC/SCADA/Telemetry failure.

These Instructions shall also form part of the Operation and Maintenance Manuals.



[END OF ELECTRICAL SPECIFICATION]

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