Electrical Installation

STAR RAFNER, A..
CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
CONSTRUCTION SPECIFICATION 2248-P-EE-0020001 2/60
FOR GENERAL ELECTRICAL DOCUMENT No.
INSTALLATION 000-P-EE-0020001
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TABLE OF CONTENTS
1. PURPOSE 5
2. SCOPE 5
3. DEFINITIONS 6
4. REFERENCES 9
4.1 OWNER SPECIFICATIONS and PROCEDURES 9
4.2 REGULATION and CODES 9
4.3 CONTRACTOR SPECIFICATION 13
4.4 Hazardous area Classification Drawings 14
4.5 Installation Details Drawings 16
5. HAZARDOUS AREAS 17
6. HAZARDOUS AREA CLASSIFICATION 17
6.1 Hazardous area equipment 17
6.2 Installation 18
7. SUBSTATION WORK 18
7.1 General 18
7.2 Clearances inside Substation 19
7.3 Preparation for Installation of Equipment 19
7.4 Checks and Confirmation Prior To Haulage 19
7.5 Installation of equipment 20
7.6 Sealing of Cable Entries 21
8. STEEL FABRICATION 21
9. CABLE INSALLATION 22
9.1 General 22
9.2 Cable trays and cable ladders 23
9.3 Cable laying configuration 24
9.4 Cable pulling and termination 26
9.5 BUS bar trunking installation 27
9.6 Supporting cables 27
9.7 Cable Jointing 28
9.8 Cable Glands 29
STAR RAFNER, A.. CONTRACT N
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9.9 Cable Connection General 30

9.10 Insulation tests 30
9.10.1 Insulation Resistance Test 30
9.10.2 Low voltage cables 31
9.10.3 Medium voltage cables 31
9.11 Steel Conduit, Fittings and Junction Box Installation 32
9.11.1 Steel conduits and fittings 32
9.11.2 Junction boxes 34
9.12 Cable Connections and Marking 35
10. INSTALLATION LIGHTING, SOCKET OUTLETS, ETC. 36
11. TRANSFORMER 37
11.1 Transformer Installation 38
11.1.1 Initial Inspection 38
11.1.2 Handling 38
11.1.3 Storage 38
11.1.4 Installation Location 39
11.1.5 Connections 39
11.1.6 Final Inspection 40
12. ELECTRIC MOTORS 40
12.1 L.V. (400 VOLT) MOTORS 40
12.1.1 Storage 40
12.1.2 Termination at motor terminal box 41
12.1.3 General 41
12.1.3.1 Connection by Means of Cable Lugs 41
12.1.3.2 Direction of Rotation 41
12.1.3.3 Installing and Entering the Cable 42
12.1.3.4 Earth Connection 42
12.1.3.5 Final Checks 42
12.1.3.6 Local Motor control station 43
12.2 MV Motors general 44
13. UPS UNINTERRUPTABLE POWER SUPPLY 44
13.1 UPS installation 44
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14. BATTERIES 44
14.1 Storage Location 44
14.2 Installation 45
14.3 Parallel Installation 45
14.4 Freshening Charge 46
15. BATTERY CHARGER AND BANK TESTING 46
15.1 Energization of the AC circuit as follows: 47
15.2 Energization of the DC Circuit as follows: 47
16. SWITCHGEAR AND MOTOR CONTROL GEAR 47
16.1 LV Switchgears / Motor Control Center 47
16.2 Join switchgear section. 48
16.3 MV Switchgear installation 49
16.4 GIS Installation 51
16.4.1 Assembly on the switch gear floor 51
16.4.2 Installation and assembly of equipment in lower frame 51
16.4.3 Installation of power cable 52
16.4.4 Assembly the switchgear cubicle on the lower frame 52
16.4.5 Installation of the support cubicle 53
16.4.6 Earthing 53
17. ELECTRICAL HEAT TRACE INSTALLATION 53
18. EARTHING 55
18.1 Electrical System 56
18.2 Electrical System - Substation /switch Room 56
18.3 Lightning and Static Systems 56
19. OPERATING REQUIREMENTS FOR TESTING 57
19.1 General criteria for electrical testing 57
20. DEVELOPMENT 58
20.1 Subcontractor responsibility 58
20.2 Manufacturer/Vendor Specialist Involvement 59
21. TESTING METHODS 59
21.1 General requirements 59
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1. PURPOSE
The purpose of this specification is to cover the installation and test requirements of electrical items
and equipment. This specification defines also minimum requirements of workmanship and materials
to be used during installation.
2. SCOPE
This specification defines mainly the installation requirements to be fulfilled by Construction

Subcontractor for the installation of electrical works. Special tests may be added, based on
instructions given by suppliers of equipment and materials or on the basis of the provisions of the
reference standards.
In case of discrepancies between this specification and vendors document in principle this
specification shall prevail over vendors documents unless otherwise specified and decided by
Contractor.
In case of discrepancies between this specification and Owners specification (STGPS-P1) Owners
specification shall prevail over this specification. Unless otherwise specified by Owner.
Dress up assembly and installation shall be performed in accordance with the relevant documents.
This document is additional to and shall be read together with all other applicable contractual
documentation.
The electrical installation shall be complete in all respects as defined in this document; the design,
installation & detail drawings; the Vendor Installation Operation & Maintenance manuals and
the contract documentation. As-built drawings are to be completed by the Sub-contractor as
part of the Electrical Installation subcontract.
2.1 Field of application

This document applies in general to all new electrical installation to be performed at site on existing
machines frames and structures; cathodic protection systems.
The installation and erection of electric systems and equipment shall be such to assure under all
operating conditions:
Safety of personnel;
Construction and operating reliability;
Possibility of future extensions.
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3. DEFINITIONS
OWNER: STAR RAFNER, A.. (STAR)

CONTRACTOR: Joint Venture between Tcnicas Reunidas (TR), Saipem, GS E&C and
Itochu
PROJECT: Means the Aegean Refinery (AR) Project, being executed by OWNER
or its affiliates
SUBCONTRACTOR: Organization(s), including its sub-subcontractors to whom any part of
the Works has been subcontracted by Contractor.
TPI Third Party Inspection - any organization, authority, person or persons,
to which Construction Subcontractor has subcontracted the execution of
inspection and or laboratory testing, related activities.
WORKS: Means the permanent new, revamped and refurbished facilities
constituting the Project, including all the construction services, materials
and equipment to be provided by Contractor/Owner to satisfy its
obligations pursuant to the Contract undertaken with the Owner.
ITP Inspection and Test Plan - The ITP shall provide references to
applicable procedures, acceptance criteria, documentation, quality
records and inspection attendance to be performed, in chronological
order, from initial inspection, throughout final inspections and
mechanical completion. ITP(s) and relevant inspection report forms
shall be enclosed in the QCP.
METHOD STATMENT Procedure developed by Subcontractor to be approved by Contractor /
Owner describing the various construction steps mentioning all the
safety requirements, the acceptance criteria for inspection and the
testing execution
NCR Non Conformance Report - Document recording a non-fulfilment of a
requirement.
NON CONFORMITY The non-fulfilment of specified requirements
SPECIAL PROCESS A process of the results which are highly dependent on the control of
the process or the skill of the operator and in which the specified quality
cannot be readily determined by inspection or test on the product
CALIBRATION Comparison of a measurement and test equipment with a reference
standard or with another one provided with better class and valid
certification in order to detect or to measure possible inaccuracies and
to document or eliminate them.
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RECORDING Systematic collection of test results evidencing the testing activities

carried out (material traceability, machinery preservation, weather
conditions monitoring, other).
INSPECTION AND TEST METHODS Logic and chronological sequence of actions, operations
and recording necessary to perform an inspection, a check or a test
(each method may include references to other checks and other tests).
PROJECT DOCUMENTATION The set of all technical documents containing data and
information governing the design, performance and testing of the
electrical equipment and systems of a specific project. The project
documentation basically includes the project specifications, equipment
and system data sheets, layout drawings, installation standards,
Manufacturer documentation, testing methods and other
data/information relating to the project.
ELECTRICAL INSTALLATION WORKS All works for the installation of electrical equipment and
systems, mechanical assembling and electrical connection in
accordance with the project design documentation. The testing of
electrical equipment, systems and components before they are
energized is part of the installation works.
ELECTRIC SYSTEM The whole electric circuits, equipment, operating and protective
devices, and user apparatuses electrically connected in order to satisfy
a required function or service.
ELECTRICAL FUNCTION UNIT A part of the electrical system designed, manufactured and
tested to perform specific functions, complying with the project
requirements, that includes the structure section with the relevant
electrical and mechanical equipment suitably mounted, assembled and
wired (motor starter fall within this definition).
ELECTRICAL EQUIPMENT A factory pre-assembled item that is part of an electric system or
functional unit able to perform a specific function, complying with the
standard requirements.
LIGHTING CIRCUIT Electrical circuit, fed from local distribution switchgear, arranged with a
suitable power cable and derivation junction boxes for supplying a
limited number of lighting fixtures or lighting receptacles in parallel
connection.
ELECTRICAL LIGHTING SYSTEM Electrical circuit, fed from local distribution switchgear,
arranged with a suitable power cable and derivation junction boxes for
supplying a limited
All the lighting equipment (circuits, fixtures, boxes, receptacles)
provided for the illumination of an area of the plant (process, storage,
parking areas, plant unit, road, forecourts, tanks, others). Common or
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different switchgear(s) can feed the lighting fixtures and the relevant
circuits.
AREA GROUNDING Underground grid arranged with bare conductor of suitable cross
system section to which all the metallic parts of a process area or unit
plant are connected or bonded for protection against electric shocks.
GENERAL GROUNDING SYSTEM All the area grounding system, each interconnected to
the adjacent one(s).
ELECTRICAL SUBSTATION Building, or closed room for the operation of electrical
installations and equipment, to which access is intended to be restricted
to skilled or instructed persons or to lay personnel under the supervision
of skilled or instructed persons, e.g. by opening of a door only by the
use of a key or tool, and which is clearly marked by appropriate warning
signs.
ELECTRICAL SWITCHYARD Open locations limited by fences for operation of electrical
installations and equipment to which access is intended to be restricted
to skilled or instructed persons or to lay personnel under the supervision
of skilled or instructed persons, e.g. by opening of a door only by the
use of a key or tool, and which is clearly marked by appropriate warning
signs.
XLPE CABLES Extra Low Density Polyethylene
Ex d Flameproof or explosion proof
Ex e Increased Safety
Ex n Non-sparking approved for use in zone areas
PVC Poli Vinyl Chloride
IP International Protection Marking
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4. REFERENCES
In case of any conflict between specifications, data sheets, enquiry documents, scope of work or
drawings, or any lack of clear definition as to the applicability of any specification or standard, Sub-
contractor shall obtain a written clarification from Contractor/Owner.
The order of precedence shall be as follows and design shall be based on the most stringent of them:
4.1 OWNER SPECIFICATIONS and PROCEDURES
STGPS P1 General Project Design Specification Electric Power and Lighting

STGPS A0 BEDD (Basic Engineering Detail Design)
STGPS - A2 General Project design specification

STGPS P2 Cabling and sizing criteria
STGPS N1 Painting
STGPS R6 Buildings
STGPS C - D3N General notes to vend doc
STGPS - X1 Spare part
STGPS - A13 Material classifications
STGPS - G1 Centrifugal pumps
STGPS - G2 Reciprocating pumps
STGPS - G3 Rotary pumps
4.2 REGULATION and CODES
Contractor shall meet or exceed the requirements of the latest edition of the following codes,
regulations and standards, except as superseded herein. In cases where more than one code,
regulation or standard apply to the same condition, the most stringent shall be followed. In the event
of a conflict between this specification and other standards or correspondence, the OWNER shall be
consulted and a ruling, in writing, shall be obtained before any work is started.
I. E.C. International Electro-technical Commission recommendations

I.E.C. 60079 Part 0 Explosive atmospheres - Part 0: Equipment - General requirements
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I.E.C. 60079 Part 1 Explosive atmospheres - Part 1: Equipment protection by flameproof

enclosures d'
I.E.C. 60079 Part 2 Explosive atmospheres - Part 2: Equipment protection by pressurized
enclosures 'p'
I.E.C. 60079 Part 4 Electrical apparatus for explosive gas atmospheres. Part 4: Method of
test for ignition temperature
I.E.C. 60079 Part 5 Explosive atmospheres - Part 5: Equipment protection by powder filling
'q'
I.E.C. 60079 Part 6 Explosive atmospheres - Part 6: Equipment protection by oil immersion
'o'
I.E.C. 60079 Part 7 Explosive atmospheres - Part 7: Equipment protection by increased
safety 'e'
I.E.C. 60079 Part 9 Electrical apparatus for explosive gas atmospheres
I.E.C. 60079 Part 10 1 Explosive atmospheres - Part 10-1: Classification of areas - Explosive
gas atmospheres
I.E.C. 60079 Part 10 2 Explosive atmospheres - Part 10-2: Classification of areas -
Combustible dust atmospheres
I.E.C. 60079 Part 11 Explosive atmospheres - Part 11: Equipment protection by intrinsic
safety 'i'
I.E.C. 60079 Part 13 Explosive atmospheres - Part 13: Equipment protection by pressurized
room 'p'
I.E.C. 60079 Part 14 Explosive atmospheres - Part 14: Electrical installations design,
selection and erection
I.E.C. 60079 Part 15 Explosive atmospheres - Part 15: Equipment protection by type of
protection 'n'
I.E.C. 60079 Part 16 Electrical apparatus for explosive gas atmospheres - Part 16: Artificial
ventilation for the protection of analyzer (s) houses
I.E.C. 60079 Part 17 Electrical apparatus for explosive gas atmospheres - Part 17: Inspection
and maintenance of electrical installations in hazardous areas (other
than mines)
I.E.C. 60079 Part 18 Explosive atmospheres - Part 18: Equipment protection by
encapsulation "m"
I.E.C. 60079 Part 19 Explosive atmospheres - Part 19: Equipment repair, overhaul and
reclamation
I.E.C. 60079-20-1 Electrical apparatus for explosive gas atmospheres, Part 20: Material
Characteristics for Gas and Vapour Classification
I.E.C. 60079 Part 25 Explosive atmospheres - Part 25: Intrinsically safe systems
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I.E.C. 60079 Part 26 Explosive atmospheres - Part 26: Equipment with equipment protection
level (EPL) Ga
I.E.C. 60079 Part 27 Explosive atmospheres - Part 27: Fieldbus intrinsically safe concept
(FISCO)
I.E.C. 60079 Part 28 Explosive atmospheres - Part 28: Protection of equipment and
transmission systems using optical radiation
I.E.C. 60079 Part 29 1 Explosive atmospheres - Part 29-1: Gas detectors - Performance
requirements of detectors for flammable gases
I.E.C. 60079 Part 29 4 Explosive atmospheres - Part 29-4: Gas detectors - Performance
requirements of open path detectors for flammable gases
I.E.C. 60079 Part 30 1 Explosive atmospheres - Part 30-1: Electrical resistance trace heating -
General and testing requirements
I.E.C. 60079 Part 31 Explosive atmospheres - Part 31: Equipment dust ignition protection by
enclosure "t"
I.E.C. 61241 Part 0 Electrical apparatus for use in the presence of combustible dust - Part
0: General requirements
1: Protection by enclosures 'tD'
I.E.C. 61241 Part 1 1 Electrical apparatus for use in the presence of combustible dust - Part
1: Electrical apparatus protected by enclosures and surface
temperature limitation - Specification for apparatus
IEC 61241- Part 2 - 1 Electrical apparatus for use in the presence of combustible dust - Part
2: Test methods
3: Classification of areas where combustible dust is or may be present
4: Type of protection 'pD'
11: Protection by intrinsic safety 'iD'
14: Electrical installations in hazardous areas (other than mines))
17: Inspection and maintenance of electrical installations in hazardous
areas (other than mines)
18: Protection by encapsulation 'mD'
I.E.C. 60050 International Electro- technical Vocabulary
I.E.C. 61850 Communication standard for electrical substation automation systems
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I.E.C. 60076 Power transformers

I.E.C. 60073 Basic and safety principles for man-machine interface, marking and
identification - Coding principles for indication devices and actuators
I.E.C. 60529 Classification of degrees of protection provided by enclosures for
electrical equipment
I.E.C. 60034 Rotating electrical machines
I.E.C. 60502 600/1000V, PVC Insulated Cables
I.E.C. 60840 Test methods and requirements for power cable systems
I.E.C. 61439 Low-voltage switchgear and control-gear assemblies
I.E.C. 62271 High-voltage switchgear and control-gear
I.E.C. 60292 Low-voltage motor starters
I.E.C. 60726 Dry-type power transformers
I.E.C. 60287 Calculation of the continuous current rating of cables (100% load factor)
I.E.C. 60364 Electrical installations of buildings
I.E.C. 60445 Identification of equipment terminals and of terminations of certain
designated conductors including general rules for an alpha numerical
systems
I.E.C. 60446 Identification of conductors by colors or numerals

I.E.C. 60885 Electrical test methods for electrical cables
I.E.C. 61035 Specification for conduit fittings for electrical installations
I.E.C. 61084 Cable trunking and ducting systems for electrical installations
I.E.C. 61537 Cable tray systems and cable ladder systems
I.E.C. 60060 High Voltage test techniques
I.E.C. 60071 Insulation Coordination
I.E.C. 60947 Low-Voltage Switchgear and Control-gear
I.E.C. 60255 Electrical Relays
I.E.C. 60439 Low-voltage switchgear and control-gear assemblies
I.E.C. 60567 Oil-filled electrical equipment - Sampling of gases and of oil for analysis
of free and dissolved gases - Guidance
I.E.C. 60811 Common test methods for insulating and sheathing materials of electric
cables
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I.E.C. 60694 Common clauses for high voltage switchgear and control gear
standards
I.E.C. 60540 Test methods for insulation and sheaths of electric cables and cords
I.E.C. 60538 Electric cables, wires and cords: Methods of test for polyethylene
insulation and sheath
API RP 540 Electrical installations in petroleum processing plants

ANSI STANDARD American National Standards Institute
NEMA STANDARDS Electrical Equipment and Medical Imaging Manufacturers associations
TSE Electrical Turkish Standards
NEC National Electrical Code
EEMUA Engineering Equipment and Materials Users Associations
IES Illuminating Engineering Society
ERA Engineering Research Association
ASTM D923 Test Method for Sampling Electrical Insulating Liquids
ISO 281 Rolling Bearings Dynamic Load Ratings and Rating life Low voltage
induction motors
ISO 281 Rolling Bearings Dynamic Load Ratings and Rating life Synchronous
machinery
API 670 Machinery Protection Systems - API 671 Special purpose couplings for
Petroleum, Chemical and Gas Industry services
4.3 CONTRACTOR SPECIFICATION
000-N -EE -0020002 Painting General (project Variation to STGPS N1)

000-A-EE-0190626 Preservation Procedure for Equipment and Materials
000 P-PE-0020002-2 Switch & Control-gear Assemblies up 52kV
000-P-PE-0020003-2 High Voltage Switchgear and Control-gear Assemblies (up to 52,5 kV)
000-P-PE-0020004-2 MCC's
000-P-PE-0020005-2 Oil Immersed Transformers
000-P-PE-0020006-2 VSDS
000-P-PE-0020007-2 Emergency Diesel Generator
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000-P-PE-0020008-2 AC-UPS
000-P-PE-0020009-2 Electrical Distribution Panels
000-P-PE-0020010-1 Neutral Earthing Resistor
000-P-PE-0020011-2 Interposing Relay Cabinets
000-P-PE-0020012-1 On Load Tap Changer
000-P-PE-0020013-2 E-Escada System
4.4 Hazardous area Classification Drawings
100 P EB 0147101 Hazardous Area Classification Layout Unit 100 Crude/Vacuum

Distillation
100 P EB 0147102 Hazardous Area Classification Layout Unit 100 Crude/Vacuum
Distillation
110 P EA 0144090 Hazardous Area Classification Drawing - Unit 110 and 410 Plan
110 P EA 0144091 Hazardous Area Classification Drawing - Unit 110 and 410 Sections
116 P EB 0147201 Hazardous Area Classification Layout Unit 116 Unsaturated Gas Plan
116 P EB 0147202 Hazardous Area Classification Layout Unit 116 Unsaturated Gas Plan
120 P EA 0140001 Hazardous Area Classification Drawing - Unit 120 (1 of 2)
140 P EA 0144093 Hazardous Area Classification Drawing - Unit 140 Plan
140 P EA 0144094 Hazardous Area Classification Drawing - Unit 140 Sections
190 P EA 0147301 Hazardous Area Classification Layouts - Unit 190 Delayed Coker
190 P EA 0147302 Hazardous Area Classification Layouts - Unit 190 Delayed Coker
415 P EB 0147401 Hazardous Area Classification Layout Unit 415 Unsaturated LPG Merox
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415 P EB 0147402 Hazardous Area Classification Sections Unit 415 Unsaturated LPG
Merox
420 P EA 0140001 Hazardous Area Classification Drawings - Unit 420/421/440/441/442 (1
of 2)
420 P EA 0140002 Hazardous Area Classification Drawings - Unit 420/421/440/441/442 (2
of 2)
430 P EA 0140001 Hazardous Area Classification Drawings - Unit 430 (1 of 3)
445 P EB 0147010 Hazardous Area Classification Layout Unit 445 Unsaturated Waste
Water Treatment
445 P EB 0147011 Hazardous Area Classification Sections Unit 445 Unsaturated Waste
Water Treatment
500 P EA 0140001 Hazardous Area Classification Drawings - Unit - 514-518 -520 -535 -
540 -545 -600 -655 (1 of 2)
500 P EA 0140002 Hazardous Area Classification Drawings - Unit - 514-518 -520 -535 -
540 -545 -600 -655 (2 of 2)
560 P EB 0147701 Hazardous Area Classification Layout Unit 560 CWS
560 P EB 0147702 Hazardous Area Classification Sections Unit 560 CWS
600 P EA 0144105 Hazardous Area Classification Drawing - Unit 600 Plan Zone 1
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610 P EA 0140001 Hazardous Area Classification Drawings - Unit 610
630 P EA 0140001 Hazardous Area Classification Drawings - Unit 630
643 P EA 0147501 Hazardous Area Classification Layout - Unit 643 Coker Handling and
Storage
643 P EA 0147502 Hazardous Area Classification Layout - Unit 643 Coker Handling and
Storage
660 P EA 0140001 Hazardous Area Classification Drawings - Unit 660 / 661 (1 of 2)
660 P EA 0140002 Hazardous Area Classification Drawings - Unit 660 / 661 (2 of 2)
662 P EA 0144114 Hazardous Area Classification Drawing - Unit 662 Plan and Sections
690 P EA 0144117 Hazardous Area Classification Drawing - Unit 690 Plan Tank Facilities
and Building
690 P EA 0144119 Hazardous Area Classification Drawing - Unit 690 Plan Jetty 1
690 P EA 0144120 Hazardous Area Classification Drawing - Unit 690 Interconnecting North
4.5 Installation Details Drawings
000 P EE 0117001 Electrical Installation Assemblies Typical Power Details

000 P EE 0117002 Electrical Installation Assemblies Typical Cable trays installation Details
000 P EE 0117003 Electrical Installation Assemblies Typical Lighting and Outlet Details
000 P EE 0117004 Electrical Installation Assemblies Typical Grounding and Lightning
Details
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5. HAZARDOUS AREAS
The Hazardous classification areas for electrical installations have been designed according to IEC
Standard Publications 60079-10-1 for flammable gases and 60079-10-2 for combustible dusts.
6. HAZARDOUS AREA CLASSIFICATION
As per the above the area classification designed by Contractor and approved by Owner identifying
the extent of all ZONE 0, ZONE 1 and ZONE 2, together with the gas groups and the temperature
classes involved, have been incorporated in the Hazardous Areas Layout identified in the chapter
4.3.
ACCEPTANCE CRITERIA FOR SEQUENCES OF INSPECTION
6.1 Hazardous area equipment
The reference standards for the execution of the inspections and for the tests on all apparatus,
components and installations for hazardous areas shall be as per the followings:
IEC 60079-0 ELECTRICAL APPARATUS FOR EXPLOSIVE GAS ATMOSPHERES - PART
0: GENERAL REQUIREMENTS
14: ELECTRICAL INSTALLATIONS IN HAZARDOUS AREAS (OTHER THAN MINES)
17: INSPECTION AND MAINTENANCE OF ELECTRICAL INSTALLATIONS IN
HAZARDOUS AREAS (OTHER THAN MINES)
IEC 61241-0 ELECTRICAL APPARATUS FOR USE IN THE PRESENCE OF
COMBUSTIBLE DUST - PART 0: GENERAL REQUIREMENTS
COMBUSTIBLE DUST - PART 14: ELECTRICAL INSTALLATIONS IN HAZARDOUS AREAS
(OTHER THAN MINES)
COMBUSTIBLE DUST - PART 17: INSPECTION AND MAINTENANCE OF ELECTRICAL
INSTALLATIONS IN HAZARDOUS AREAS (OTHER THAN MINES)
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All apparatus, components and installations for hazardous areas shall be verified as per following
checks with positive results.
6.2 Installation
The following installation criteria are to be followed:

The erection is to be in compliance with instructions and details.
When required, the flexible conduits, explosion-proof seals and three-piece unions to be
correctly installed, coupled in the right sequence and in compliance with the erection
instructions and details, according to the reference codes and design.
The sealing of joints, ducts, pipes and/or conduits is satisfactory and filled with suitable paste.
The stopper boxes and terminal boxes are correctly filled.
The integrity of conduit system and interface with mixed system is maintained.
The various apparatus coupled together must have the same safety execution (Ex-d with Ex-
d or Ex-e with Ex-e).
Ex-d cable glands must have at least 5 threads inserted.
Cables not in use are to be correctly terminated.
If gland applies with lock nut, IP washer shall be used in order to provide IP rating.
7. SUBSTATION WORK
7.1 General
The substation is a complex facility consisting of power receiving, transformation and distribution
equipment.
All electrical installations which are related to sub-stations will be realized according to either the
contractor's approved drawings/details or the vendor's drawings.
Should any accident or inadequacy occur even in a part of the equipment, it will involve hazards to
human beings and plant equipment, causing huge losses.
Hence, the substation work must be carried out carefully with consideration given to this point.
Since substation equipment are expensive, important and heavy, good care must be taken in their
installation and safety measures must be provided to avoid injury and damage to the equipment.
MFR/Vendor will be Participated of all SS tests (as full package supplier)
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7.2 Clearances inside Substation
Minimum clearances to be followed inside substations are:

Behind switchgear 90 cm
Between equipment ends or between ends and wall 90 cm
Between power control center and MCC 180 cm
Between Motor Control Centres 150 cm
Two exit paths shall be provided for working space at the front and back sides of switchgear and
motor control equipment. Back to back arrangement (or very low clearance) may be considered for
low voltage switchboards provided with front access only (i.e. Motor Control Centers).
A minimum 150 cm vertical clearance shall be provided above the highest equipment section
measured to the bottom of the lowest roof beam.
7.3 Preparation for Installation of Equipment
Equipment channel bases shall be checked to be installed as accurately with respect to the positions
and elevations as indicated on the drawing, prior to hauling the equipment to the location.
The channel base shall be checked to be installed so at the required elevation and to be capable of
withstanding the weight of the equipment and shocks and impacts during operation sufficiently in
accordance with vendor/supplier installation procedure.
Channel bases shall be checked for deformations.
Basic points will be marked by the building construction contractor.
Basic level lines and perpendicular lines shall be decided based on the basic points.
Channel bases shall be welded to the floor embedded plate at several points and shall be grouted
with mortar after level adjustment.
When chain blocks are to be used in the substation, they shall be triad set in position prior to the
work to confirm that their supports can be sufficiently placed.
7.4 Checks and Confirmation Prior To Haulage
Confirm the numbers of pieces of equipment to be delivered and where they should be received.
Check and confirm the scope of respective parties' unloading services.
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Check whether or not concrete covers and checker plates for cable trenches have been installed.
Provide haulage floors at doorways and cover substation floors with plywood boards or scaffolding
boards along haulage routes to protect them from injury.
Equipment packages shall be disassembled by removing top and side boards in order.
Confirm that electrical equipment and parts have not been damaged externally or internally.
Haulage of equipment shall be conducted by using lifting system or multi-wheeled bogies.
When rollers are to be used, if there is a possibility of injury or damage to the equipment frames, the
equipment shall be placed on a skid (or timbers), under which rollers shall be used.
When construction equipment is to be used, the following points shall be checked:
Construction equipment operators' licenses and safety education and training
Instructions on the haulage of equipment whose centroids are high
Crane lifting capacities and weights of equipment
Wire rope size and lifting methods
7.5 Installation of equipment
The routes of haulage shall be decided in advance so that they need not be changed in the course of
the haulage.
In general for earthquake requirements refer to design documents.
Equipment shall be installed accurately with respect to their positions, arrangement, directions and
elevations. Prior to installation commence, all civil activities must be finished inside the building.
In the haulage and installation, care shall be taken not to cause injury and damage to the equipment
and substation building.
Since low voltage motor controllers are of small depth with the centroids high, they require measures
for prevention of overturning.
Low voltage motor controllers shall be hauled by using skids or multi-wheeled bogies which
are of high stability.
Low voltage motor controllers, if hauled on rollers, shall be supported on both sides.
After completion of the installation the following points shall be checked, and corrections, if
necessary, shall be made:
Whether the levelness, perpendicularity and alignment with the adjacent panels are correct.
Whether the doors can be opened and closed normally.
Whether there is no injury to the paint coating.
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Protective covers and locks used on panel-to-panel joints shall be removed prior to installation.
Panel-to-panel bolting shall be tightened.
The bus-bar bolts shall be securely tightened and marks on the tightened bolts shall be checked.
Since bolts may have become loose during transportation, they shall be re-tightened.
Bus bar bolts shall be tightened by using torque wrenches to the required torque in accordance with
the manufacturer's instructions.
Bus bar connection portions shall be cleaned and coated with specified compound to prevent rusting.
Equipment-to-equipment wiring, if separately transported, shall be connected in accordance with the
drawing and marking.
Check whether or not protections have been provided for installed equipment. If needed to access to
the ceiling, after completion of panel/switchgear installation, it is strictly prohibition to step on the top
of equipment.
7.6 Sealing of Cable Entries
In cases where cables are to be led through the substation lower parts, the cable entries shall be
sealed by the following method:
The cable entries shall be sealed so that no gaps may form by means of mortar, unless
glands are applied.
Cable supports shall be provided, so that the cable weights may not rest on the cable
terminal. Typical drawing will be applied.
8. STEEL FABRICATION
New steel as primer painted shall be used. That which is deformed and/or excessively rusted, shall
not be used.
Steel fabrication shall be done by using such suitable tools and machines that neither stresses nor
strains may be caused.
Cut edges shall be sander finished.
Steel shall be economically used:
Scraps shall be minimized.
Welds made on steel members shall be completely cleaned of slag and all other foreign
matter and coated with rust inhibitive coating.
Steel to be used shall be of such proper size and material that the fabricated parts and
components will be a good in appearance and sufficient in strength.
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Support of trays/ladder welded to structure shall be painted according to

000NEE-0020002 Painting General
The following precautions shall be taken with respect to the welding of electrical steel members to
other facilities:
Electrical steel members shall not be welded to equipment bodies, such as towers, vessels
and heat exchangers.
Electrical steel members shall not be welded to process piping.
Electrical steel members shall not be welded to any such portions where they will pose
obstructions to maintenance and passage.
Electrical steel members shall not be welded to the supports of high temperature process
piping or equipment.
In cases where electrical steel members are to be welded to any facilities adjacent to
movable equipment, it shall be checked whether or not any inadequacy will occur.
Welding shall be electric as a rule.
Welds shall be completely cleaned of oil, paint oxides, water and all other foreign matter.
When no load support is installed, Hilti stud can be used instead of welding.
9. CABLE INSALLATION
9.1 General
The cables shall be installed as per the approved construction and details drawings showing the
also followings:
Separation and Segregation from types of cables.
Numbers of layers of cable inside trenches and per tray/ladder.
The cable shall:

Run underground in concrete trenches covered by concrete slabs that without sand-fill can
withstand the loads that may arise during future maintenance works
Run above ground on cable ladder racks (where width exceeds 300mm) or cable trays made
of mild steel type and galvanized.
The slabs covering the Electrical cables trenches shall be identified by red color.
Inside the battery limits of classified areas ZONE 1 and ZONE 2, all cable trenches shall be filled free
sand (cleaned of salt, acid, etc.).
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Cables running underground in unpaved areas to be laid in concrete trenches shall be protected by
filling sand.
Cables running underground to be laid directly in the ground shall be surrounded by a layer of sand
and protected by cable cover tiles with the tiles to be covered with a layer of sand before back-filling
(for earthing cable sand bedding to be provided).
The route markers shall be located at grade to identify the cable run.
Underground Cables if:
Entering in buildings shall enter by means of concrete encased earthenware ducts to be
suitably sealed.
Crossing roads etc. shall run in steel pipes (Heavy duty type PVC pipes can be used f they
are embedded in reinforced concrete and approved by Owner).
Final routing of underground cables from main trench to equipment may be by trench, conduit or duct
and attention is to be paid to the termination facilities at equipment where:
Cables rise up from trenches or floors are to be protected by adequately sealed galvanized
steel pipe sleeves which shall extend not less than 100 mm above finished level.
Cables that may be subject to severe attack due to saturation on ground or at trenches by
corrosive substances (e.g. acid) shall run above ground within the area suitably protected.
The point at which the cables leave and reenter the underground route shall be outside the
potentially corrosive area.
9.2 Cable trays and cable ladders
Cable ladder and cable trays is to be supported whenever possible from structures at intervals not
exceeding 1.5 m and on one side of and at a distance not exceeding 500 mm from a bend or
intersection with approved steel brackets.
Cable trays in case to be cut shall be cut along the plain line of metal, and not through the
perforation, all cut edges are to be prepared and treated with cold galvanized 99% rich zinc and de-
burred of any rough remaining metal works.
Cable trays are to be connected between adjacent lengths tee or bend pieces by butt joins, and
securely fastened by mushrooms head steel roofing bolts, connections are to be mechanically strong
so that no relative movement between the two lengths can occur and are to be efficiently and
adequately bonded.
A minimum clear space of 20 mm shall be left behind all cable trays wherever possible.
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Property expansion splice plate will be used to joint adjacent length of tray. Trays will not join
crossing a construction expansion joint. At these points the trays is to be bridged with a flexible
conductor.
Cable ladders will follow the same criteria as trays where applicable and shall be supported at
intervals of not more than 1500 mm on still works of adequate strength and rungs shall be slotted for
cable clamping or tying.
Where cables turn down MV or LV panels or switch boards, drop out accessories will be used with
each ladder to support the cables as shown in the construction details drawings.
Cable tray deflection shall not exceed 1/100 of a 1.2 m span at the mid-point of the span after cable
installation. The Manufacturers recommendations are to be followed.
Where cables are required to peel off a tray, a molded protective edging shall be fitted to the tray.
Cable ladder deflection shall not exced1/100 of the span at the mid-point of the center of the span
continuous beam after cable installation. The Manufacturers recommendations are to be followed.
9.3 Cable laying configuration
For what is concerning the installation of single conductor cables, the same should run in triangular
or square bundles containing one conductor of each phase.
Sheaths should be in contact throughout the run length.
The neutral conductor in four wires systems may be located within the bundle or run separately.
Cables are to be bounded using stainless steel adjustable bands or bandings kits or glass reinforced
PVC.
The electrical codes address the problem of ensuring balanced AC resistance in each conductor
comprising a phase group:
All conductors must be of the same length
All conductors must be of the same size and same material
All conductors must have the same type of insulation
All conductors must be terminated in the same manner
It is recommended that 3-foil arrangement conductor cables be installed with the following
configuration
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Note: The above picture is a typical 3-foil arrangement, the real position will be done in according to
contractors approved drawings/details or the vendors specification.
Individual cables or small multiple cables shall also run with small size cable trays:
Cable ladder shall be used where widths of 300 mm and above are required.
Cable tray shall normally be used for widths less than 300 mm.
Cable clips, saddles, cleat, etc., , used, on cable trays or ladders shall be of a plastic coated
Stainless Steel and shall be installed at distance each other of 1200 mm for horizontal cables and
600 mm for vertical cables.
The cleats can be stainless steel or GRP type, aluminum type cannot be used.
Minimum clearance to be maintained:
250 mm between cables / conduits and the surface of the thermal insulation of any hot
surface.
500 mm between uninsulated hot surfaces.
660 mm between power cable trays and instrumentation cable trays (in parallel configuration)
The cables are to be installed in one length, in case of splices, the same shall be made in suitable
junction boxes previous Contractor / Owner approval.
Attention is to be paid to the routing of cables with respect to intrinsically safe systems, electronic
instrumentation and communication systems and other similar low power systems to avoid
interference from cables of power systems.
Instrument cables shall not be run in power cable trenches.
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9.4 Cable pulling and termination
Transport and place the cable drum schedule as per the locations where space is agreed as
available by site supervision for working. The cable drum shall be placed on a certified jack &
spindle arrangement to ensure free rotation of the drum.
Erect scaffolding where required as per site requirement.
Cable rollers shall be placed under the cable during pulling over larger distances and standoff
rollers for acute bends, to ensure that cable is pulled with minimum effort and the cable outer
jacket is free for scouring lines.
The cable shall be pulled by using pulling means such as fish tape, rope and basket weave
wire/cable grips, so as not to damage cable or its containment system. Care will be taken to
ensure that the maximum pulling tension of the cable is not exceeded at any given time.
Cable should be free of any static load (for example to be placed side by side) parallel on the
cable trays or ladder. Any kind of dead weight on the cables is to be avoided
At all times the cable schedule and section drawings for the relevant area will be
referred to ensure proper location of cable on the required ladder and to ensure
compliance with project specification.
A pulling compound/ lubricant shall be used where necessary per site condition (for
example slabs and underground conduits), the lubricant used shall be a type that does
not deteriorate the cable insulation. Compound/lubricant shall be submitted for Owner
approval before purchasing. Detergent, grease or improper lubricant is strictly
forbidden.
The cable shall be secured to the containment system using approved cable ties for
horizontal runs and cable cleats for vertical runs.
All control cables shall be installed at a minimum distance of 100mm from power
cables unless otherwise agreed with consultant as per site conditions.
Earthing cable (green/yellow) shall be pulled along power cables.
At all times when pulling , work both power and earth cables in order to pair them on
both sides of connections ( for example at sending and receiving ends )
Before termination complete length and route of cable shall be inspected by QA/QC
engineer, after which an NFI shall be raised for Contractor approval. Cable shall be
caped and sealed at both ends after installation until termination is done.
Termination shall be done by using the approved termination materials that include glands,
lugs and other accessories part of termination kit, by using proper crimping tools. Matching
colour gland sheaths shall be provided.
Hole of cable lug cannot be much bigger than bolt or vice versa.
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All termination shall be provided with tight fittings covering sleeves.
Internal bending radius of power cable shall follow the manufacturers recommendation.
Each cable is to be fitted with a cable identification tag as per project standard documentation.
At each joint or termination, a nonferrous label is to be fixed to the cable giving size and identification
of the cable.
Reduction in the number of strands of a cable core is not allowed at a cable joint or termination.
Where a compression joint is made, the appropriate tools specified by the manufacturer of joint
connectors will be used. The compression joints will be made by inserting the cores to be jointed into
the opposite end of a compression jointing coupling.
Cable support bracket will firmly clamp the incoming cable at a suitable distance from the
termination.
MV cable terminations is to be carried out in strict accordance with the termination manufacturer
instruction leaflets and great care is to be taken to ensure that terminations and equipment remain
clean and free from contamination during the termination process.
9.5 BUS bar trunking installation
BUS bar trunking is to be installed as per the approved construction drawings and manufacturers
shop drawings and details.
BUS bar trunking support system has to maintain the trunking in both horizontal and vertical plane
without stress on the joints.
Both joints and final connections of trunking will be torque tightened as per the manufacturers
recommendations.
9.6 Supporting cables
Cables that are running underground shall be laid in trenches as shown on the underground cable
routing drawings. Where such cables pass through ducts (i.e. under path or road), the duct is to be
sealed as specified in standards for duct sealing.
Cables that are running above ground shall be adequately supported.
Sagging of cables between supports shall be kept to a minimum.
The maximum spacing between supports shall be:
600 mm in horizontal planes.
300 mm in vertical planes.
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The minimum bending radius of these cables shall be as specified by cable manufacturer.
Hardwood Cleats are not permitted in project.
The cables are to be supported in such way that no weight is to be taken on a joint and the cable
armoring is to be finished in such a way as to support the joint. All earth clamps, where provided,
must be fitted.
9.7 Cable Jointing
All cable jointing shall be carried out by competent personnel (certification for competent specialist
shall be requested) who have experience in cable jointing. Any jointing instructions issued by the joint
box manufacturers shall be strictly adhered to previous Owner approval.
Mainly heat shrinkable type joints shall be used just. Epoxy type joints can be used only with Owners
approval for HV and MV cables. If epoxy type cable joints are used compound shall be heated to the
correct temperature before pouring (Type of compound will be subject to Owner approval).
Temperature measurement shall be by means of suitable thermometer and care shall be taken in not
overheating the compound so as to avoid damage to cable insulation and compound. Topping up
shall only take place after maximum settlement of compound has taken place.
Heat shrinkable cable breakouts are used to seal the crutches of plastic. The breakouts are coated at
each end with a hot melt adhesive which seals onto the cable sheath and care insulation during
installation (the procedure shall be adopted only after Owner approval).
Junction boxes will be used only for the control cable, in according to approval drawings.
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Splice arrangement for cable
9.8 Cable Glands
Metallic, Flameproof type glands, shall be used for terminating at classified equipment including Ex n.
All cable glands applications shall be suitable for area zone definitions as per hazardous area layout
plans (For cable glands ATEX 95 equipment directive 94/9/EC shall be followed)
Metallic, flameproof glands shall also be used for terminating at unclassified industrial type
equipment.
All glands in outdoor locations shall be weatherproof type and protected with heat shrinkable, PVC
shrouds (For cable glands ATEX 95 equipment directive 94/9/EC shall be followed).
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The cutting back of cable serving or sheeting to make a joint or connection shall be kept to a
minimum and made good if necessary by use of heat shrinkable sleeves.
Connections to equipment installed in outdoor locations shall:
Where possible, be made at the underside of equipment.
Side entry connection may be used.
Top entry connections should be avoided.
Care shall be taken at all connections to ensure good mechanical and electrical contact between
parts.
Cable glands type shall conform to the hazardous areas classification and shall be verified for
correctness prior to installation.
9.9 Cable Connection General
All cables furnished with shielding tape shall be terminated with stress cones and grounded in
accordance with manufacturers recommendation.
Copper lugs shall be used for terminating cables.
HV and MV cable terminations shall be done by certified personnel.
Lug size shall be suitable for the cable size. Cable cross section reducing in order to use smaller
sized lugs shall not be accepted.
Only hydraulic operated crimping tools shall be used to crimp lugs.
If soldering is foreseen after crimping, 40/60 solder shall be used only after Owner approval.
Gap between end of the lug and the end of the stripped cable insulation shall be more than 1 mm.
Heat shrinkable insulators which cover round part of the lug and some length (about 2 D of the cable)
on the cable shall be used. A suitable heat gun for heat shrink process shall be used and supplied by
Subcontractor.
For the specific cable and cable gland sizes please refer to related area's/unit's approved cable list
as well as cable calculation report.
Bare flame shall not be used.
9.10 Insulation tests
9.10.1 Insulation Resistance Test
Set the megger meter to 1000 Volt DC for cables and 500 Volt for wires; IR value shall be
higher than 100M.
Take reading between phase, phase and neutral, phase and earth, neutral and earth.
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Note the core resistance reading, must not exceed 2 M unless otherwise stated in the
manufacturers supply documents.
Check and record the resistance readings as per specification and approved insulation
resistance test form.
9.10.2 Low voltage cables
As general rule, the insulation resistance measurement of low voltage cables shall be established at
least in any one of the following three different steps:
a) on the drum, at the warehouse, before unrolling: no record of the measured resistance value(s) is
required;
b) in the trench before its backfilling or on the cable trays, after laying no record of the measured
resistance value(s) is required;
c) before cable connecting; the cable shall be complete with terminations, with cable glands, with
lugs and with all required fittings and isolated both at the user and functional unit sides) The record of
the measured resistance value(s) is required.
If the result of measurement at one of the above steps is unsatisfactory, the cable and its installation
shall be carefully rechecked.
The measurement shall be repeated after the check. If the result is still unsatisfactory, only the power
cables shall be submitted to the high voltage tests, or to adequate tests, in order to identify the
breakdown point.
9.10.3 Medium voltage cables
As general rule, the insulation resistance measurement of medium voltage cables shall be
established at least at any of the following two different steps:
a) on the drum at the warehouse, before unrolling: no record of the measured resistance value(s) is
required;
b) in the trench before its backfilling or on the cable trays, after laying no record of the measured
resistance value(s) is required;
In case of the presence of underground joints, the high voltage test shall be always performed after
the insulation resistance measurement.
All cable joints of rated voltage higher than 1 kV shall be subject to the high voltage test.
c) before cable connecting (see ch 7.4); the cable shall be complete with terminations, with cable
glands, with lugs and with all required fittings and isolated both at the user and functional unit sides)
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The record of the measured resistance value(s) is required. In addition, after the insulation resistance
measurement, the high voltage tests shall be performed on the power cables with a rated voltage
level higher than 3/3.6 kV.
The cable shall be maintained isolated at both the user and functional unit sides. The high voltage
test shall also be carried out as an additional test in case the insulation resistance measurement is
unsatisfactory.
9.11 Steel Conduit, Fittings and Junction Box Installation
9.11.1 Steel conduits and fittings
All conduit and fittings throughout the electrical installations shall be screwed type and in accordance
with IEC. Thread Form shall be NPT (type threaded metallic cable glands shall be used ).
All cable trays shall be perforated mild steel type hot deep galvanized:
Cable trays 300 mm and above shall be heavy duty type.

Cable trays below 300 mm shall be standard type.
Cable trays 450 mm and above shall be minimum thickness 2 mm.
Cable trays below 450 mm shall be 1.5 mm.
The trays shall be adequately supported and the maximum spacing of support shall generally be
1000 mm except for 300 mm tray and above which shall be 1200 mm.
Where cables pass over the edge of trays or through trays, the edges shall be turned down or slots
widened and smoothed to prevent abrasion or indention of cables.
Cable ladder racks shall be mild steel type and galvanized (minimum thickness is to be 2 mm).
Spacing of supports shall be at a maximum allowed by load requirements.
Steel supports for lighting fittings, cables, push-buttons, etc. shall be properly fabricated and installed
in accordance with the Contractor's standard methods approved by OWNER where applicable.
All rough edges shall be removed.
Welding of bracers to structures shall be the main fixing medium.
Pockets where water may be trapped shall be avoided.
Supports brackets shall have one coat of primer prior to installation and the full painting application
shall be as per Painting General Specification n. 000 N EE 0020002.
The sizes of steelworks to be used shall have a thickness of not less than 3 mm.
No electrical equipment shall be supported from fire-proofing but the supports are to be in position
prior to fireproofing application.
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Equipment of an alloy construction such a lighting fittings, which are supported directly on brickwork
or concrete shall be spaced of such brickwork or concrete by means of suitable mild steel washers to
a depth of approximately 3 mm.
Repairs to galvanized finishes such as that caused by cutting shall be performed applying a minimum
of two coats of zinc rich paint 99% immediately after.
All fixing items (i.e. screws, nuts, bolts, etc.), shall have a rustproof finish.
All spring washers shall be used at all bolted connections.
All raw plugs shall be of the White Bronze Type.
All fixings shall be adequate for their duty.
All conduit fittings in exposed locations shall be weatherproof type in addition to being suitable for the
applicable are classification requirement.
Conduit runs must be installed in a neat and well-planned arrangement and in a manner that will not
interfere with the access to the equipment or with the use of access ways.
Conduit shall run parallel to or at right angles to structures and pipe supports.
All conduit runs and conduit fittings under platforms shall be located so that they can be reached
either from the platform, or from the ladder or stairway providing access to the platform.
Conduit joints shall be set up tight and attention is to be paid to prevent ingress of water in to
conduits.
Runs shall be straight and through.
Elbows, offsets and bends shall be uniform and symmetrical.
All conduit ends shall be carefully reamed and be free of burrs and sharp edges (bushing shall be
installed on both ends for power cables, for earthing cables shall be installed only one bushing).
The whole of a conduit installation shall be erected and swabbed through before cables are drawn in.
Where several cables are pulled in a common conduit all cables shall be pulled in simultaneously
and care is to be taken in order to avoid that twists to occur during the pulling in.
Only the use of French Chalk is permitted to assist wiring and the pulling in of cables.
It is forbidden the use of graphite, grease, oil, any kind of soap or detergent as lubricant during
pulling cables.
All conduits are to be adequately supported and when is installed on the surface a distance type
saddles is to be used.
Approved drains for condensation removal shall be installed wherever moisture is apt to collect in the
conduit systems and always at switches, push-buttons and other connections located at the bottom
of a conduit whose total horizontal and vertical run is 15 m or more.
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In all situations where a run of conduit, irrespective of size, passes from an Hazardous Area (ZONE 1
and 2) to a safe area, a flameproof stopper-box (seal box) is to be inserted on the side remote from
the danger (i.e. where a wall provides the boundary between the areas, the stopper-box- shall be on
the safe side).
A similar arrangement shall also be provided where conduit passes from a ZONE 1 to ZONE 2 area
the seal being located outside the boundary of the ZONE 1 area.
Conduit connections to equipment installed in outdoor locations is to be made:
At the underside of the equipment.
Side entry connection may be used where former is not possible.
Top entry connections are to be avoided.
The foregoing applies also to other locations where there is risk of condensation.
9.11.2 Junction boxes
The JB is to be installed in a location defined as per the classified hazardous area and the approved
design documents.
The JBs are to be installed as ex-proof according to the classified hazardous area zone and as per
approved design drawings/ installation details in a location"
Where junction boxes are used and in particular Ex-e type the use of Screw it type connectors will
not be permitted.
The following instructions are to be followed:
Make sure that the cables are long enough to easily reach the junction box location.
Excess cable may be trimmed.
Route the component cables so they are not twisted.
Be sure they are protected from falling material.
The complete cable needs to be fed through the grommet hole.

The shield then needs to be wrapped backwards over the grommet and fed through the cord grip nut.
Insert the cable through the hole in the integrator enclosure so that the cord grip presses the shield
against the housing as the nut is tightened.
Connect the component cables as per the approved design documents to the component wire
terminals.
Properly rated and fixed non corrosive terminals shall be used of a type permitting one conductor per
terminal side and with purposes designed links to afford looping facilities.
Any unused entries on equipment shall be sealed with screwed stopper plugs (ATEX 95 equipment
directive 94/9/EC shall be followed).
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9.12 Cable Connections and Marking
Where cables pass through walls or concrete they shall do so via ducts or sleeves which shall be
sealed as specified in standards for duct sealing.
Other means may be used for the passing of cables such as cable transits and shall be as indicated
on drawings.
Should it be necessary to leave a cable open prior to making the joint, the cable shall be suitably
sealed to prevent the ingress of moisture.
Lugs for cable core connections to stud type terminals shall be of the mechanical compression type
except for major equipment where soldering type if provided with equipment will be acceptable.
Cable core connections to stud type terminals shall be made by an appropriate method (If direct only
with the approval of OWNER).
Install the tags/cables as per project specification and as per approved material submittals
Cables shall be identified at the feeders (for example the sending and receiving ends) about 50mm
below the gland. All cables shall be identified at the inside and outside of the feeders, boxes and
panels.
Identification labels shall be provided at all positions where cable change directions and each side of
the wall or floor slab and on straight runs each 25m.
Cables connecting control gear, thermostat, valves etc. will also be identified and shall be fitted with
identification sleeves bearing the same marking as the terminal of the apparatus to witch this are
connected.
For cables at Feeders, identification will be done as per specification of approved materials.
In addition, all underground cables shall be fitted with identification bands at all points where they
enter or leave cable ducts at road crossings, trench ducts etc.
The cores of cables shall be phase identified either by self-color or by means of heat shrinkable
sleeves at their termination and at any joints as follows:
A.C. Multiphase Brown (L1), Black (L2), Grey (L3), Light Blue (N, Neutral)
A.C. Single Phase Brown (L), Light Blue (N, Neutral), (Earthed Neutral)
A.C. Single Phase Brown (L)
(Unearthed system)
D.C.2 wire system Positive (Red), Negative (Black)
Protective Earth Yellow/Green
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The cores of control and instrumentation cables shall be self-numbered but shall be identified by
means of plastic cable ferrules at the terminating ends.
All single core cables used for sub-circuit wiring, control circuits, etc. shall be self-colored Red or
Black and suitably identified.
Cable trunking for intrinsically safe systems shall be blue or identified by painting on the body and lid
a band approximately 500 mm wide colored BLUE.
The bands shall be applied at points of entry to equipment and also at 2000 mm intervals
approximately of trunking run.
Conduit used for the same systems shall be similarly identified except that in plant areas, the band
shall be increased to approximately 1500 mm intervals.
10. INSTALLATION LIGHTING, SOCKET OUTLETS, ETC.
In general the positions of lighting fittings shown on layout drawings are approximate only.
Illumination levels and uniformity shall be ensured as particularly specified for each area, location or
room by proper measuring at site as per approved projects designs, standards and lighting
calculations.
Drawings shall be examined prior to installation to ensure that the following conditions are met:
A check is made of final location and mounting height prior to installation.
Where possible, the fittings in a given area shall be spaced symmetrically.
Location of lighting fittings outdoors shall favor landings of stairways, ladders, gauges,
indicating instruments, etc.
Since a large amount of the lighting work is to be done in elevated places, firm scaffolding shall be
provided and "safety" shall be kept in mind in the execution of the work.
The lighting work shall be executed after confirmation of the schedules for the items of work that may
interfere with the lighting work. It shall be carried out in coordination with the personnel for the other
works, so that to avoid losses, injuries and damages.
Lighting fixtures and junction boxes shall be installed with following considerations given to their
maintenance:
Junction box covers shall permit easy removal and inspection.
Lamps and other lighting fixtures shall be easily replaceable.
Passages and operating floors shall be effectively lighted.
All exterior lighting fixtures and their JBs shall be installed as ex-proof according to the
classified hazardous area zone as indicated in related projects
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If final light intensities are not satisfactory for proper operation, even installation has been performed
according to the approved drawings, new armatures shall be added.
The installed overhead lights mounting must not obstruct the walkways, stairways and platforms.
Lighting switches shall generally be mounted 1500 mm above floor level.
Socket outlets in offices, control room, amenities rooms, etc. shall be mounted 450 mm above floor
level. In other areas they shall be bounded 1500 mm above floor level or as dictated by the location
i.e. supported from hand-rails, etc.
Care shall be taken to ensure the correct polarities when wiring switches, socket outlets, lamp
holders, etc.
Switches, socket outlets, junction boxes, etc., on differing phases shall be located at least 2000 mm
apart. Where not possible the switches shall be of multi-phase type and boxes shall have phase
identification on both outside and inside.
400V, 63 A, N+E power outlet cables can be reached by use of 50 m of extension cable. 230V, 16 A,
N+E convenience outlets can be reached by use of 25 m extension cable. Sufficient 230 V, 16 A,
N+E Non-Industrial type convenience outlets shall be provided in all buildings.
The number of junction boxes used on lighting circuits shall be kept to a minimum. When junction
boxes are used they shall be located in easily accessible positions not more than 2.2 meters above
the working floor level, in-board of all platform edges and fitted with permanent labels denoting circuit
reference.
The locations of junction boxes shown on the construction drawings are approximate. Precise
location shall be determined on site by the Sub-contractor.
Where equipment of any sort is fed from distribution fuse boards care shall be taken to ensure that
the equipment is connected to the circuit called for on the relevant drawing.
11. TRANSFORMER
Subcontractor shall:
Verify that the elevation of the foundation and the parallelism of the rails where the equipment
is to be set.
Verify that the position of the equipment is checked in respect to one reference point and the
reference elevation in the four sides of the foundation is marked to avoid any trouble with the
bas duct entering in to the substation.
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11.1 Transformer Installation
11.1.1 Initial Inspection
Before unloading the transformer, make an inspection to detect any signs of damage or mishandling.
Locate any accessory parts that may have been shipped separately.
Inspection may include but not limited to :
Check if there is any indication of external damage
Check the painting finish for damage
Check if the attached fittings are loose or damaged
Check if there is any evidence of leakage on and around the tank
Check if any bushings are broken or damaged
The tank pressure may be positive or negative when received depending on liquid temperature. In
some cases, the vacuum pressure gauge may read zero, which could indicate a tank leak.
If any damage is detected or shortages are noticed a OSDR report will be issued.
11.1.2 Handling
Transformers should be handled in the normal upright position, but in no case tilted more than 15
from vertical, unless instructions have been given to the contrary.
For unloading, lifting hooks are provided near the top of the transformer tank. Cable pull angles
should not be over 30 from vertical. Otherwise, spreaders should be used to hold the lifting cables
apart to avoid any bending of the structure or lifting hooks.
If the transformer cannot be lifted by crane, it may be skidded or moved with rollers. When jacking a
transformer to insert rollers underneath it, insure that at least two jacks are used and that two
adjacent corners are raised simultaneously and evenly to avoid warping the base.
Jacks may be placed only at the corners of the transformer base.
Do not place jacks under cooler assemblies, valves, or sheet metal parts. Use rollers as many as
necessary to distribute the weight uniformly. To pull, attach pulling eyes to the holes in the base at
either end of the transformer.
Do not attach pulling lines to mouldings or other sheet metal parts of the transformer.
11.1.3 Storage
When storing the transformer, it should be completely assembled and pressure tested. Transformers
designed for indoor use must be stored indoors.
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Whenever possible, the transformer should be stored at its permanent location.

The insulating liquid should be at its proper level and the gas space pressurized to approximately two
psig. Then it should be tightly sealed so that no moisture or air can enter the tank. Periodic inspection
should determine that the pressure gauge does not remain at zero, and proper liquid level is
maintained at all times.
The transformer should not be stored in the presence of corrosive gases (e.g., chlorine). Exterior
surfaces of the transformer should be maintained against rust and corrosion.
11.1.4 Installation Location
Transformer must be placed on a foundation of sufficient strength to support the weight of the unit.
The foundation must be level within one half inch per 100 inch base.
If the unit is not level, the liquid may not circulate through all the cooling tubes and cause over
heating that will shorten transformer life. When a transformer is designed to be energized while tilted,
the degree of maximum tilt will be noted on the transformer nameplate. The location of the
transformer should provide for adequate accessibility, ventilation, and ease of inspection for the unit.
To assure proper air circulation for cooling, the transformer coolers should be at least 24 inches from
any obstruction. Location in areas of corrosive chemicals should be avoided.
For each transformer the Sub-contractor shall ensure the transformer bay concrete base, cable or
bus-duct entry positions are all in a suitable state of completion before starting the installation.
Do not open the transformer in an area unprotected from weather during precipitation or in an area
where the air may contain dirt or other particles. Either of the above could cause a transformer
failure. If the transformer is opened, the openings should at all times be protected against entry of
foreign matter into the transformer tank.
11.1.5 Connections
After positioning, and where applicable, the Sub-contractor shall ensure correct alignment with the
bus duct, then transformers shall be fastened directly to the base foundation strictly in accordance
with the instructions on the vendors installation drawings. This may be a vendor supervised
activity.
Connections must be made without placing undue stress on the bushing terminals. Conductors
should be securely fastened in place and supported properly, with allowance for expansion and
contraction. Make sure that the tap connection is proper for the required voltage.
Safely verify that there is no voltage present at the terminals.
A secure and effective low resistance ground is essential for protection. The transformer must be
grounded permanently by connecting a heavy ground cable to the ground pad located at the bottom
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of the tank. If the transformer is designed for operation in a solidly grounded neutral system, the
neutral connection should be solidly and permanently grounded with minimum resistance.
Lightning arresters are recommended for every transformer installation.
11.1.6 Final Inspection
The final inspection can be done in three major steps: Electrical, Internal and External.
Electrical inspection should determine that:
All external connections have been made properly (phasing of connections to terminal
bushings, etc.).
All connections are tight and secure.
All accessory contact circuits are operational.
Current transformer circuits, if supplied, have secondary either shorted or connected through
their load.
Tap changer is operative and properly positioned.
The correct transformer ratio exists for units furnished with internal terminal board.
There is no grounding of windings that are not intended to be grounded. A 1000-volt megger
test is recommended.
Windings are in good condition. A polarization index (PI) test will be conducted.
There is continuity in all windings.
DGA and humidity analysis of the insulating material will be performed to verify the condition
of the transformer before energization.
The neutral and ground connections have been properly made.
12. ELECTRIC MOTORS
12.1 L.V. (400 VOLT) MOTORS
12.1.1 Storage
Motors should be raised by their eyebolts and never by their shafts. It is important that high rating
three-phase motors be raised by their eyebolts. Raising and lowering must be steady and jolt-less,
otherwise bearings may be harmed.
When motors are not immediately installed, they should be stored in their normal upright position in a
dry even temperature place, free of dust, gases and corrosive atmosphere.
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Other objects should not be placed on or against them.

Insulation resistance fluctuates widely with temperature and humidity variations and the cleanliness
of components. When a motor is not immediately put into service it should be protected against
moist, high temperatures and impurities, thus avoiding damage to insulation resistance, according to
its maintenance manual and vendor instructions.
12.1.2 Termination at motor terminal box
12.1.3 General
Ensure that the power supply agrees with the rating plate data.
The supply cables should be matched to the rated current and plant-specific conditions (e.g. ambient
temperature, method of cable installation, etc.).
Connect the supply-cable conductors.
Connection cables and cable ends must not exert any bending or torsion forces on the connection
bolts.
12.1.3.1 Connection by Means of Cable Lugs
The size of cable lugs must be matched to the size of the supply cable. Use appropriate units with
sufficient current-carrying capacity.
12.1.3.2 Direction of Rotation
When the power supply phase conductors L1, L2, L3 are connected to terminals U, V, W
respectively, the motor will rotate in a correct direction. If the connections to any two terminals are
reversed, i.e. if lines L1, L2, L3 are connected to terminals V, U, W (or U, W, V or W, V, U)
respectively, the motor will rotate in a reverse direction.
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12.1.3.3 Installing and Entering the Cable
The following steps are recommended for split entry:

Cut the sealing insert so that its opening is some millimetres smaller than the cable diameter.
Introduce the cable into the cable gland. In the case of a very small cable diameter, the cable
diameter should be increased by applying insulation tape at the securing point to ensure
concentric positioning of the cable in the sealing insert.
Provisionally attach the terminal box cover in order to check whether perfect sealing is achieved both
at the flange surfaces and at the entry point with sufficient pre-stressing. If this is not the case
enlarge the sealing insert cut out or adjust the cable diameter by means of insulation tape. The
securing bolts should then be tightened alternately in steps.
Unused entry openings always must be closed off by suitable plugs.
These must:
be of permissible resistant material,
conform to degree of protection IP55,
be tightened so that they can be removed only by means of a tool.
12.1.3.4 Earth Connection
An earth terminal for connecting the cable earth conductor is provided in the terminal box.
The minimum connection cross-section of earth connections should be selected according to IEC 34-
1 with reference to live conductors.
Make sure in any case of installation and maintenance work that the equipotential bonding is
maintained.
12.1.3.5 Final Checks
Before closing the terminal box, check the following:

Conductor connections and, if applicable, the circuit connections have been made correctly.
Interior of the terminal box is clean and free from remainders of cable material.
All terminal screws and the appropriate cable entry parts are firmly tightened.
For the clearance in air please will be maintained as per approved drawings and installation
details.
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Remove any projecting wire ends

Connection leads are not subject to strain and the insulation cannot be damaged.
Unused entry openings are closed off by suitable plugs.
All seals and sealing surfaces are in perfect condition. If sealing of the joints is affected by metal-to-
metal joints only, the surfaces should be cleaned and thinly re-greased.
Entry glands fulfil all requirements concerning degree of protection, conditions of installation,
permissible lead diameter.
12.1.3.6 Local Motor control station
The control station installation indicates when the line is energized and the motor is running.
Due to this prior to connect it to the system the following activities are to be carried out:
Insulation test on equipment
Insulation resistance and continuity test on cables
For the mechanical execution of the electrical installation after the cable connections the following
activities are to be checked and properly inspected:
Verification of the correct installation of the control station with the complete assembly of all
the accessories as per the project design and manufacturer instructions.
Completeness of the electrical connections as follows:
o Power connection termination with cable gland and shroud.
o Verification that the earthing connection, after having cleaned the surface thoroughly,
has been properly tightened.
o Verification that the Bonding connection connected to earth bar with flexible earthing
bonding link has been tightened.
o Verification of all electrical wire connections properly tightened.
The Verification of the efficiency of all the auxiliaries devices composing the control station to be
performed by specialized personnel listed underneath:
Selector switch
Instrument signal (amperometer)
Start /stop push button
Emergency stop push button.
Interlock system
The mechanical functionality of all the axillaries devices:

Selector switch
Instrument signal (on / off signal)
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12.2 MV Motors general
The same philosophy of the LV motors applies to the MV motors.
13. UPS UNINTERRUPTABLE POWER SUPPLY
13.1 UPS installation
Fork Lift or Crane, pallet mover with capacity & arrangement in line with the Manufacturer
recommendations and as required at site.
Ensure all civil works are completed for the area of installation and released / cleared by civil section
to proceed on with the installation of UPS Panel. Concrete bases should be prepared as per the
approved specifications and drawings.
Installation works shall be carried out only with respect to approved shop drawings of latest revision.
UPS panel and batteries shall be shifted to its location without causing any damages.
Installation of ups panel shall be carried out as per manufacturer recommendations Access around
ups panel shall be checked for any maintenance works.
All batteries shall be charged fully arranged and connected as per manufacturer recommendation
Incoming and outgoing cable connections shall be done as per approved shop drawing with suitable
cable gland cable lugs etc., Clean earth shall be provided for UPS panel as per approved shop
drawing.
Bypass arrangement shall be provided to operate the ups panel in case of any failures.
All components of the UPS panel such as breakers, relays, fuses, meters, contactors, and terminals
etc., shall be verified against the approved material for correct rating and size.
UPS panel shall be covered and protected until the time of commissioning
14. BATTERIES
The Battery units shall be made available at site in dry charged condition with electrolytic in separate
bottles with a complete set of tools including hydrometer, thermometer and accessories required for
maintenance of the battery shall be supplied.
14.1 Storage Location
Batteries are to be stored indoors in a clean, dry and cool location. Storage at higher temperatures
will result in accelerated rates of self-discharge and possible deterioration of battery performance and
life.
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The maximum storage time from shipment to initial charge is six months for batteries stored at
ambient temperatures no warmer than 25C. For storage temperatures greater than 25C, the battery
is to be recharged one month sooner for every 3C increase above 25C.
If storage time exceeds the storage time recommended by Manufacturer, give the battery a
freshening charge before the end of the recommended storage interval.
The batteries are to be charged always in the horizontal position, charging in vertical position could
damage the battery and void the warranty.
The freshening charge is to be repeated for each additional storage interval until the battery is
installed for a maximum total storage time prior to installation of two years or as per manufacturer
instruction.
Storage at higher temperatures will result in accelerated rates of self-discharge and possible
deterioration of battery performance and life. Storage times exceeding the above may result in plate
sulfating, which may adversely affect electrical performance and expected life
If storage time is likely to be exceeded, make advance preparation to have an adequate charger
available and adjacent to an appropriate AC supply voltage. Positioning of the cells to accept
temporary intercell connectors is another consideration of to be planned in advance.
14.2 Installation
Unless otherwise stated by manufacturer the following are to be verified:

Ventilation Usually No special battery room or special ventilation is required but they are not to be
installed in an airtight enclosure.
Grounding - All the modules or racks are to be grounded in accordance with NEC and/or local codes.
Floor Shimming, unless otherwise stated by manufacturer, is to be up to 6 mm maximum to the
battery level front to rear and side to side and must be capable of supporting the weight of the battery
as well as any auxiliary equipment.
Anchoring - All the installations are to be floor anchored. Anchoring should meet industry standards.
Proximity to Electronic Equipment Unless otherwise stated by manufacturer the batteries may be
installed next to electronic equipment, unless it generates heat.
14.3 Parallel Installation
If it is necessary to connect the battery system in parallel to obtain sufficient capacity, cable
connections to each of the parallel strings are important.
If parallel connection is required, do NOT exceed five strings in parallel.
In order to obtain:
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Proper load sharing on the discharge

Satisfactory recharge
The same float voltage for each string
Cables from the batteries to the load must be:
As short as possible (equal to the longest intercell connector).
Of equal lengths to the load.
Of sufficient ampacity (cable ampacity should not be exceeded).
14.4 Freshening Charge
It is to be performed as per manufacturer instruction.

Depending on storage time, a battery may require a freshening charge and the constant voltage is
the ONLY charging method allowed.
Usually during charging the battery temperature is to be monitored and if the cell/battery temperature
exceeds 40C, the charge is to be immediately stopped in order to allow that temperature decreases
below 32C. Failure to follow this warning may result in severe overcharge and damage to the
cell/battery.
The battery is considered fully charged when the current to the battery starts to decrease and
stabilize.
Than when the current level remains constant for three consecutive hours, the state-of-charge is
approximately 95 to 98% and the battery is considered fully charged and ready for use.
15. BATTERY CHARGER AND BANK TESTING
The following Visual, electrical and mechanical inspection activities are to be performed on a battery
charger:
Test of the incoming AC and the outgoing DC terminals for voltage.
Identification of the type and the rating of the components installed with the parts list.
Inspection for visual damages.
Checking of the battery bus link integrity.
Verification that the room is clean and well ventilated.
Verification that the rack is properly grounded.
Verification that the batteries terminals are covered with a protective base.
Checking that the correct set of batteries is provided.
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Prior to energization, verification that the polarity of the batteries is correct in relation to the charger is
to be performed.
15.1 Energization of the AC circuit as follows:
Checking for any shorts and grounds before turning the AC power on.
Turn on the AC to the battery charger with no load connected.
Checking that the fans are operational.
Checking of the input voltage
Configuration of the battery charger voltage and current
Restarting of the battery charger after configuration.
15.2 Energization of the DC Circuit as follows:
Checking for any shorts and grounds before turning the DC power on.
Measuring of the system charging voltage and each individual battery voltage before and
after energization.
Verification that the charger is inspected and properly adjusted as per manufacturers
specifications.
Leave the charger unit on, to let the batteries fully charge.
At this stage connect the battery bus bar and increase the load until the battery charger is running at
full capacity without exceeding the battery charger rating.
The battery charger running is to be left at full capacity for the set amount of time recording the
values.
16. SWITCHGEAR AND MOTOR CONTROL GEAR
16.1 LV Switchgears / Motor Control Center
Check the cable trenches and supports are painted and ready for permanent installation of the said
equipment.
Move the panels from the storage area to their designated room. Fully crated switchgear or panels
shipped on a timber sub-base shall be lifted under the sub base.
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When moving the fully crated panels from the storage area to the switchgear room using fork lifts, the
mast must be as close as possible to the face of the crate and forks must be fully projected under the
crate. Lift the fully crated switchgear squarely.
Uncrate, unpack and remove the switchgear from its timber base. Care must be taken to protect the
panels from unnecessary scratches or bents on the panels.
Move in the switchgear using steel pipe rollers to its final location. Care must be taken to ensure that
the panel does not over balanced while being moved to its final locations.
Align the panels horizontally and vertically.
16.2 Join switchgear section.
Jointing of section must be done under the direct supervision of the manufacturer representative and
shall be done in accordance to their standards. Ensure that the bus bars are properly aligned and
shall be tight as per manufacturer recommended torque setting.
Secure the switchgear assembly and ensure that it is fixed properly on its base, according to vendor
recommendations.
Remove all unused bolts, nuts, washers and clean the panel. Panel side covers and doors shall be
put back, ensuring that it is properly tightened.
Conduct insulation resistance test on the switchgear to ensure that all joints are properly insulated.
Raise Notification for Inspection for switchgear installation.
Conduct on-site testing on the equipment such as insulation test, Di-electric test at 2.5kV for the LV
switchgear, CT ratio test and simulation test for protection and relay setting in accordance to
manufacturer recommendation and project specification.
Main Distribution and Motor Control Centers will be installed as stand-alone type and sub-distribution
boards according to their vendor design could be installed as wall-mounted or stand-alone as per
vendor drawings.
Checks the locations where in the panel boards are installed were accessible and ready for
permanent work installation and left enough minimum space behind and in-between panels
according to regulations for maintenance (refer to electric switchboards placement plans for each
substations).
Mark the location of the panel on the wall. Wall-mounted panels shall be installed 1800mm A.F.F.L.
from the top of the panel.
Install the uni-strut channel supports on the walls. Make sure that the support is rigidly and securely
fixed.
Fix the panel on the supports. Ensure that the panel are rigidly fixed in its supports and vertically and
horizontally aligned.
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Remove unnecessary foreign materials and unused bolts, nut and washer inside the panel. Fix panel
cover and protect with plastic sheet.
Dress and terminate properly the wires and cables inside the panels.
Gland the cable (power and earthing) on the non-magnetic glanding plate of the panel and terminate
properly.
Tighten the connections as required.
The access around the panel is to be checked for future maintenance.
Ensure the services contains water is away from the panel or properly protected against the any
accidental leakage.
Identification of panel and outgoing breaker are to be verified against approved drawings.
Incoming and outgoing cables are to be marked / identified as per approved drawings.
All components of the panel such as MCCB, MCB, Relays, fuses, meters, CTs,Terminals, etc., shall
be verified against the approved panel drawings for correct rating and size.
Any internal connections / modification is to be carried out by the manufacturer of the particular
switchgear
All breakers (incoming and outgoing) shall be in OFF position and to be locked to prevent
mishandling.
After installation the panel is to be properly cleaned and protected to prevent dust and contamination.
16.3 MV Switchgear installation
On receipt of MV panel and accessories at site, precaution shall be taken for unloading, shifting and
storage as follows:
Material is to be stored in a covered and dry space at all time
All materials received at site are to be inspected to ensure that the materials are as per the
approved material.
Any discrepancies, damages, found are to be notified and reported for further action
Prior to start the installation the following is to be done:

Ensure that the work area is ready and safe to start the installation of panel
Ensure the installation of MV panel are carried out in accordance with manufacturers
installation recommendations, requirement of applicable standards and in accordance with
recognized industrial practices and specified in the project specification to ensure that the
installation complies with the requirements.
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Prior to start the installations refer to the approved shop drawings related to the area of
installation and ensure that the required materials are available at site as per approved
material submitted.
Ensure the materials are stored properly and there is not mark of damage or deformity of any
kind before issuing the materials from site store. All materials and accessories should be free
of dust, scale, or oil.
The installation procedure for switchgear panel shall follow as follows:
All components such as relays, fuses, CTs contactors meters, breakers size, bus bar sizes,
is to be verified against the approved material.
All installations shall be carried out according to the approved shop drawings construction for
the panels.
Ensure that the surface is ready with base frames grouted on the open trenches inside the
HV room to install the MV panel.
Minimum clearance of 800 mm is to be maintained from rear side of the panel so that easy
access for termination of cables and other maintenance works can be carried out.
MV panel is to be installed in accordance with the manufacturers recommendations and
approved site layout.
All knockouts made on the panel covers are to be filed and provided with grommets to avoid
sharp edges and unused knockouts are to be covered.
The connections of bus bar trunking with MV panel are to be done rigidly with proper
supports.
Cable bending radius should not be less than 12 times the cable diameter in line with the
manufacturers specifications.
Cable pulling, termination, and crimping are to be done as per point 10.1.
Termination cable is to be done by using approved materials for cable gland and lugs.
Glanding and connections should be done only by competent technicians.
Switchgear is to be provided with proper earthing connections as per approved shop drawing.
Manufacturers recommendations are to be followed for all relays and other breakers current
settings as per the total connected loads.
Identifications labels of approve type is to be fixed on the MV panel.
Ensure that all cable entry and other openings of Electrical/Floor are HV room, wall/Floor are
to be carried out with proper sealant.
Ensure that adequate A/C provided to MV panel room and the Unit of the A/C shall not be
installed inside
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16.4 GIS Installation
16.4.1 Assembly on the switch gear floor
Measure and mark out the low frames (switchgears) position in the room on the floor sections as per
the manufacturers drawings.
Make any holes required for cable lead-through and fit any embedment frames or metal sleeves
following the instructions provided by the manufacturer of the sealing system.
Fit the anchoring brackets on the lower frame.
Adjust the frame's support feet so that the lower frame stands horizontal.
Check using a spirit level that the frame is flat.
Mark out the position for the anchoring bracket holes in the floor and drill the holes for the bolts.
Bolt the lower frame to the floor sections. Check that the anchoring hooks are turned so that they
lock against a floor profile.
Tighten the locking nuts on the feet.
Tighten the nuts on the anchor bolts.
16.4.2 Installation and assembly of equipment in lower frame
For efficient installation work, it is recommended to install and assemble all equipment in the lower
frame before the switchgear cubicle is put in place. This means savings in time as well as a
comfortable working position, but most important of all, the quality of the work will be better.
The following should be carried out before the switchgear cubicle is lifted on the lower frame:
Install the power cables including anchoring.
Insulate and fit the cable screens with cable lugs for connection to the earth rail.
Assemble and install conventional cable current transformers of a ring core type (if these are
to be included).
Seal the cable holes according to the approved fire seal class.
A dummy assembly should be used to install the power cables. The dummy assembly has cable
glands in exactly the same positions as on a switchgear cubicle and ensures that the cable
installation will fit when the switchgear cubicle is lifted in position.
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16.4.3 Installation of power cable
Route the cable in the lower frame.

Insert the cable through any cable transformers.
Terminate the cable according to the manufacturers instructions.
Check that the cable screen is long enough to be routed to the cubicles earth rail. The cable screen
can be jointed if necessary with a conductor that has at least the same cross-section as the screen.
The cable screen must be insulated with a plastic sheath, fitted with a cable lug and connected to the
cubicles earth rail.
Ensure that the distance between the cables in the same phase is at least 30 mm.
Secure the cables in the cable bracket.
Secure the cable transformers.
The cables earth conductor must be returned insulated through the transformer and connected to
the cubicles earth rail.
16.4.4 Assembly the switchgear cubicle on the lower frame
Check the identity of the cubicle carefully before assembly. Start the assembly process with one of
the outer cubicles to the left or right of the switchgear line. It does not matter from which end you
start.
Remove the packaging around the cubicle (straps and plastic cover).
The sensor cables must be removed from the sensors in the cable connectors before the cubicle is
lifted on the lower frame. Reconnect the cables as soon as the cubicle is in position.
Check that the right sensor cable has been connected to the right sensor and on the right
connection.
Place the switchgear cubicle on the service trolley.
Drive the service trolley to the lower frame, directly in the centre where the switchgear cubicle is to
be fitted.
Check that the beam, with the earth rail on the front edge of the lower frame, is removed.
Lift so that the lower edge of the switchgear cubicle is a few centimetres above the frame top beam.
Drive the service trolley so that it is only a few centimetres from the front edge of the lower frame.
Slide the switchgear cubicle into position on the lower frame. The cubicle weighs 400-550 kilograms
and can slide into position.
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Bolt the cubicle to the lower frame and join the bus bar with tubular bus bar joint. When assembling
one switchgear cubicle the bus bar is joined between this and the cubicle assembled immediately
before.
16.4.5 Installation of the support cubicle
The support cubicle is fitted to the lower frame in the same way as other switchgear cubicles. A floor
plate must be fitted for the battery carriage to assist movement of the carriage. The floor plate is
supplied with the battery carriage.
Fit the floor plate in the lower frame.
Fit the rear and side plates on the lower frame.
Connect the ribbon cable for the display unit in the connection box to the connector on the battery
carriage.
Connect 110 V DC cables to the fuse protected terminals.
Connect the alternating current for maintenance charging to the appropriate terminals.
Slide in the battery carriage in the support cubicle.
16.4.6 Earthing
When all the switchgear cubicles have been assembled, the cubicles earth rails need to be
connected to each other. The vertical cubicle earth rail should be placed between the horizontal earth
rails. The earth conductors and screens should be connected to the earth rails. All earth conductors
and screens connected to the earth rail shall be fitted with cable lugs for 12 mm connection bolts.
The switchgears earth rail should be joined with the installations earth line network (earthing point)
via a secure earth connection. The connection to the installations earth line network should be made
from the earth rail in a cubicle located as close to the centre of the switchgear line as possible.
Alternatively an earth connection can be placed at each end of the switchgear line.
17. ELECTRICAL HEAT TRACE INSTALLATION
For elevated work, proper scaffolding and sufficient safety measures shall be provided.
Splicing and termination of heat trace equipment and materials shall be made by qualified personnel.
The electric heat tracing cables are used for freeze protection or temperature maintenance of piping,
tanks and instrumentation.
At the arrival the heat cable is to be visually inspected for any damage incurred during shipment.
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The test voltage for polymer insulated heating cables be 500 Vdc. Minimum resistance should be 20
meg-ohms or as per Manufacturers instruction.
The heating cable is to be stored in dry location and before Installation ensures that:
All piping and equipment to be traced is completely installed and pressure tested.
The surface areas where heat tracing is to be installed must be reasonably clean. (Remove
dirt, rust and scale with a wire brush and oil and grease films with a suitable solvent).
The installation is to be done as follows:
Locate the cable on the lower quadrant of the pipe at the 4 or 8 oclock position. If
accessibility is a problem the cable may be installed at the 10 or 2 oclock position.
Temperature sensor should be located at least 90 from all heating cables.
Begin temporary installation at the proposed end-of-circuit location and lay out heating circuit on the
pipe, allowing extra cable for the power connection and for any splice
Make heating cable allowances for valves, flanges, elbows and supports as per the applicable
drawings.
When the Installation is terminated, the final cable attachment is to be done by securing the end-of-
circuit termination kit and working back toward the power supply, end-off circuit termination kit (end
cap) shall be marked after completion of insulation works
The flexible heating cables are to be installed using attachment tape. Circumferential bands of tape
should be installed at (30 cm) intervals to keep the cable in proper contact with the pipe (it is
prohibited to apply PVC tape or binding wires).
Complete splice connections (if required) in accordance with the installation instructions provided
with the splice kit by Manufacturer.
The heating cable is to be tested to ensure the electrical integrity with at least a 500 Vdc megger
between the heating cable bus wires and the heating cable metallic braid.
The cable is to be visually inspected for any damage incurred during shipment as follows:
1. Connect the positive lead of the megger to the cable bus wires.
2. Connect the negative lead of the megger to the metallic braid.
3. Energize the megger and record the reading. Readings between 20 meg-ohms and infinity
are acceptable. Readings below 20 meg-ohms may mean the electrical insulation has been
damaged.
Recheck the heating cable for physical damage between the braid and the heating element; small
cuts or scuffmarks on the outer jacket will not affect the megger reading unless there was actual
penetration through the braid and dielectric insulation jacket.
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Once the installation is complete, but prior to installation of thermal insulation, recheck the heating
cable with at least a 500 Vdc megger between the heating cable bus wires and the heating cable
metallic braid. The test voltage for polymer insulated heating cables is 2500 Vdc should be 20 meg-
ohms.
After the thermal insulation is installed, the meg-ohmmeter test should be repeated. Minimum
resistance should be 5 meg-ohms.
After the thermal insulation is installed and the power supply is completed, the following is to be
done:
Ensure that all junction boxes, temperature controllers, cable glands, etc. are properly
secured.
Set the temperature controller (if applicable) to the manual setting and apply rated voltage to
the heat tracing circuit(s) for 5 minutes.
Measure and record the circuit(s) voltage and current.
Insulation, heat losses are generally too high to be offset by a conventional heat tracing system.
In addition to piping and in-line equipment such as pumps and valves, all heat sinks must be properly
insulated. This includes pipe supports, hangers, flanges and, in most cases, valve bonnets.
Regardless of the type or thickness of insulation used, a protective barrier should be installed. This
protects the insulation from moisture intrusion, physical damage and helps ensure the proper
performance of the heat tracing system. Seal around all penetrations through the thermal insulation.
After the installation of the thermal insulation and weather barrier but BEFORE ENERGIZING THE
HEATING CIRCUIT, the meg-ohmmeter test should be repeated. This should call attention to any
damage to the heating cable that may have occurred during the insulation installation.
Complete splice connections (if required) in accordance with the installation instructions provided
with the splice kit by Manufacturer.
18. EARTHING
Subcontractor shall pay attention to the following:

All metal parts, with the exception of that already part of an electrical circuit, shall be bonded
together.
All electrical motors shall be earthed separately.
All Transformers shall be earthed separately.
For cable sizes refer to STGPS-P1
DCS control System shall be earthed separately (clean earth)
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18.1 Electrical System
The enclosures of major electrical equipment such as switchgear, transformers, lighting boards,
floodlight towers or poles, control panels, etc., and metallic frameworks for supporting the same, shall
be directly connected to the earthing system.
Frames of motors shall be directly connected to the earthing system.
Other apparatus such as lighting systems shall be connected to the earthing system via cable
armoring provided the completed system earth loop impedance permits operation of the circuit
protective device.
18.2 Electrical System - Substation /switch Room
All earthing within sub-stations and switch rooms, including the connections to main equipment, shall
be carried out using tin coated copper tape of a minimum size of copper tape shall be 50 mm x 3
mm.
Earthing conductors to auxiliary apparatus such as battery chargers shall be 35 smm2 PVC tin
coated cables. These connections may be made either at the earthing bus bars or directly to the
main earthing ring.
Earthing conductors from bus bars to substation earth electrodes located externally shall be stranded
tin coated copper conductor P.V.C. sheathed and of size to suit requirements.
The metallic sheaths of single core cables between a transformer and a switchboard shall be bonded
together and earthed at the transformer end, the sheaths lightly insulated throughout their length and
insulated from each other and from the switchboard at their connection to the switchboard.
Neutrals of power transformers (34.5, 11, 6.3 kV) shall be low resstance grounded. Earthing shall be
connected to separate earthing electrode systems.
As minimum there will be two inter-connections between the sub-station earthing system and the
plant earthing system.
18.3 Lightning and Static Systems
Lightning and static earthing protection shall be provided by connecting steel structures, towers,
vessels, tank, etc. to the earthing system, as per approved lightning drawings/calculations and
installation details
Down conductors in reach of human shall be insulated from any contact.
Tall steel structures such as process towers or structural columns shall be considered inherently
protected against lightning by their connection to the earthing system provided they are electrically
continuous; the connection to the earthing system shall be direct to an earth electrode, complete with
Ground bar, located close to the base.
REV 0 1 2 3
Electrically continuous structural columns shall be used as down conductors by means of which the
earthing conductor of elevated tanks, vessels, etc., shall be connected to the earthing system.
Joints other than welded type in structural columns used as down conductors shall be bonded to
ensure electrical continuity.
Separate lightning protection systems shall be provided for tall masonry stacks and other tall
masonry or concrete structures. Down conductors or other parts of the systems shall not be used for
earthing electrical equipment. The systems shall be electrically and mechanically bonded to the
general earthing system at the final connections to lightning protection earth electrodes. Down
conductors and all other parts of the system shall be tin coated.
Radioactive type lightning system shall not be used.
Flanges of metallic pipelines that have insulated linings shall be bonded across to ensure electrical
continuity. The flange bolts shall be used to secure the bonding conductor. A bond shall also be
applied at the equipment connection. Flanged joints and other types of joints in other metallic
pipelines shall be considered inherently electrically continuous.
Pipeline itself shall only be, directly, connected to the earthing systems where they enter and leave
the battery limits. Between two end points, sleepers shall be grounded.
Earthing connections to equipment shall be by properly provided termination. Anchor bolts shall not
be used.
Where the driven equipment is not mounted on a common bed plate with the motor, it may be
connected to the earthing system directly or via the motor earthing connection.
Lightning safety should be practiced by all people during thunderstorms. Preparedness includes: get
indoors or in a car; avoid water and all metal objects; get off the high ground; avoid solitary trees;
stay off the telephone. If caught outdoors during nearby lightning, adopt the Lightning Safety Position
(LSP). LSP means staying away from other people, taking off all metal objects, crouching with feet
together, head bowed, and placing hands on ears to reduce acoustic shock.
19. OPERATING REQUIREMENTS FOR TESTING
The complete electrical installation including cables shall be subject to inspections and tests for
compliance with Owners specification. All inspections and tests shall be recorded as per QCP and
ITP.
19.1 General criteria for electrical testing
In general electrical testing activities shall be carried out initially on power service systems
generators, incoming supply lines), then on primary distribution systems (in particular main
switchgears which are the most vital parts), then on secondary distribution systems and finally on
supplies of individual users.
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After mechanical completion, all electrical system shall be checked and tested at the job-site for the
safety, satisfactory installation and proper operation of electrical equipment prior to the complete
energization and integration to electrical system.
Inspections and tests shall be carried out just after the completion of relevant installation work and all
the test devices must have proper calibration certificate.
The Manufacturer/Vendor Specialist representative shall be involved in the inspection and testing
activities if requested.
When the Manufacturer/Vendor Specialist is on site, he shall be involved in inspection and testing
activities as per criteria of the following item 13.2.
20. DEVELOPMENT
20.1 Subcontractor responsibility
Subcontractor shall:
Prepare and update any other necessary QCP(s) and ITP(s) and relevant forms and
procedures to include all inspections, examinations and tests required to verify the quality of
the Works. The above documents shall be timely submitted to Contractor for review and
approval in order to ensure their availability in approved status prior to starting of the activities
related to electrical works.
Perform and record all inspections, examinations and tests required and shall carry out all the
works necessary for the preparation of inspections, examinations and tests, including
adequate scaffolding for safely witnessing the inspection.
Provide, for the execution of testing, inspection and measurements all necessary equipment,
tools and shall make available the applicable international Standards and Codes.
Issue inspections, examinations and tests reports immediately after the completion of each
inspection activity. All reports shall be approved and signed off by Subcontractor authorized
personnel prior to submission to Contractor for review or approval, as appropriate.
Provide qualified and experienced personnel to carry out tests on electrical systems and
standards. These specialists shall have a thorough knowledge of International and of local
Codes and standards. They shall also have good knowledge of electrical materials and
installation both in substations and in field hazardous areas.
Contractor or other Parties signature on inspection, examination and test reports does not release
the Subcontractor from his responsibilities.
Inspections and tests required by local regulations are out from the scope of this specification.
However, they shall be strictly adhered to and documented by Subcontractor.
When local regulations are less stringent than the applicable design codes, the latter shall prevail.
REV 0 1 2 3
20.2 Manufacturer/Vendor Specialist Involvement
MFR Involvement Equipment to be tested:

Witness on all equipment to be tested Transformers - over 3.15 MVA
Switchgears - over 1 kV
A;C and DC System
M.V. Variable Speed Drive System
M.V. Motors - over 3 MW
Synchronous Motors
ECMS Cables - over 100 kV
Witness on one sample for each type of equipment to be tested:

Transformers up to 3.15 MVA
Switchgears - up to 1 kV
M.V. Motors up to 3 MW
L.V. Variable Speed Drive System
Heating System
Bus Ducts
21. TESTING METHODS
21.1 General requirements
Subcontractor shall develop:

All necessary test procedures taking in account all safety requirements,
Construction schedule,
Contractual requirements and Contractor acceptance criteria for inspections and testing
All detailed inspection and check lists are to be indicated in the CDQ forms.
Subcontractor test procedures shall include:
Testing methods, as provided by the reference applicable Codes, Standards and Project
documentation
Manufacturer/Vendor specific instruction and recommendations.
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In all cases, the Subcontractor shall be fully responsible for the correctness and reliability of testing
methods proposed in test procedures.

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STAR RAFNER, A..

9.9 Cable Connection General 30

This specification defines mainly the installation requirements to be fulfilled by Construction

2.1 Field of application

OWNER: STAR RAFNER, A.. (STAR)

RECORDING Systematic collection of test results evidencing the testing activities

4.1 OWNER SPECIFICATIONS and PROCEDURES

STGPS P1 General Project Design Specification Electric Power and Lighting

STGPS - A2 General Project design specification

4.2 REGULATION and CODES

I. E.C. International Electro-technical Commission recommendations

I.E.C. 60079 Part 1 Explosive atmospheres - Part 1: Equipment protection by flameproof

I.E.C. 60076 Power transformers

I.E.C. 60446 Identification of conductors by colors or numerals

API RP 540 Electrical installations in petroleum processing plants

4.3 CONTRACTOR SPECIFICATION

000-N -EE -0020002 Painting General (project Variation to STGPS N1)

4.4 Hazardous area Classification Drawings

100 P EB 0147101 Hazardous Area Classification Layout Unit 100 Crude/Vacuum

600 P EA 0140006 Hazardous Area Classification Drawings - Unit 600 (6 of 6)

4.5 Installation Details Drawings

000 P EE 0117001 Electrical Installation Assemblies Typical Power Details

6. HAZARDOUS AREA CLASSIFICATION

ACCEPTANCE CRITERIA FOR SEQUENCES OF INSPECTION

6.1 Hazardous area equipment

The following installation criteria are to be followed:

7.2 Clearances inside Substation

Minimum clearances to be followed inside substations are:

7.3 Preparation for Installation of Equipment

7.4 Checks and Confirmation Prior To Haulage

7.5 Installation of equipment

7.6 Sealing of Cable Entries

Support of trays/ladder welded to structure shall be painted according to

Separation and Segregation from types of cables.

Numbers of layers of cable inside trenches and per tray/ladder.

The cable shall:

9.2 Cable trays and cable ladders

9.3 Cable laying configuration

9.4 Cable pulling and termination

All termination shall be provided with tight fittings covering sleeves.

9.5 BUS bar trunking installation

9.6 Supporting cables

9.7 Cable Jointing

Splice arrangement for cable

9.8 Cable Glands

9.9 Cable Connection General

9.10.1 Insulation Resistance Test

9.10.2 Low voltage cables

9.10.3 Medium voltage cables

9.11 Steel Conduit, Fittings and Junction Box Installation

9.11.1 Steel conduits and fittings

Cable trays 300 mm and above shall be heavy duty type.

9.11.2 Junction boxes

The complete cable needs to be fed through the grommet hole.

9.12 Cable Connections and Marking

10. INSTALLATION LIGHTING, SOCKET OUTLETS, ETC.

11.1 Transformer Installation

11.1.1 Initial Inspection

Whenever possible, the transformer should be stored at its permanent location.

11.1.4 Installation Location

11.1.6 Final Inspection

12. ELECTRIC MOTORS

12.1 L.V. (400 VOLT) MOTORS