70A1READING

ELECTRICAL
SYSTEMS GROUP
FWUK OU 70A1 (READING)
ELECTRICAL ENGINEERING STANDARD PAGE 1 OF 25
STANDARD ENGINEERING REV 8
CONTENTS
1. SCOPE .................................................................................................................................... 3
2. BASIS OF DESIGN ................................................................................................................. 3
3. CODES AND REGULATIONS ................................................................................................. 3
4. EQUIPMENT AND MATERIALS .............................................................................................. 4
5. AREA CLASSIFICATION......................................................................................................... 4
5.1 General............................................................................................................................. 4
5.2 Zones ............................................................................................................................... 4
6. ELECTRICAL EQUIPMENT ENCLOSURES ........................................................................... 5
6.1 Enclosure ......................................................................................................................... 5
6.2 Hazardous Areas .............................................................................................................. 5
6.3 Non-Hazardous Area ........................................................................................................ 6
7. DISTRIBUTION SYSTEM DESIGN ......................................................................................... 6
8. RELAYING AND PROTECTIVE DEVICES .............................................................................. 8
8.2 Protection Schemes ......................................................................................................... 8
8.3 Protective Relay Study ................................................................................................... 10
9. POWER TRANSFORMERS .................................................................................................. 10
9.1 Power Transformers shall comply with BS EN 60076. .................................................... 10
10. SWITCHGEAR AND CONTROL GEAR ................................................................................ 11
10.1 High Voltage (HV) Equipment (1000V up to and including 52kV). .................................. 11
10.2 Low Voltage (LV) Equipment (1000V and below). .......................................................... 11
11. CONTROL AND INDICATION ............................................................................................... 12
11.1 General........................................................................................................................... 12
11.2 Control Stations .............................................................................................................. 13
12. INSTRUMENT POWER SUPPLIES ...................................................................................... 13
13. LIGHTING ............................................................................................................................. 14
13.1 Lighting Design ............................................................................................................... 14
13.2 Lighting Intensities .......................................................................................................... 15
14. WELDING AND CONVENIENCE SOCKETS ........................................................................ 16
14.1 Basis of Design............................................................................................................... 16
14.2 Socket Types .................................................................................................................. 16
15. CABLE INSTALLATIONS ...................................................................................................... 17
15.1 Cable Sizing ................................................................................................................... 17
15.2 Cable Construction ......................................................................................................... 18
15.3 Cable Installation ............................................................................................................ 19
15.4 Underground Cable Installation ...................................................................................... 19
15.5 Overhead Cable Installation............................................................................................ 20
70A1READING.docx UNCONTROLLED COPY © FWUK OU 2004
ELECTRICAL
SYSTEMS GROUP
16. EARTHING ............................................................................................................................ 21

16.2 Earthing for Safety to Personnel ..................................................................................... 21
16.3 Earthing for Protection against Static Electricity ............................................................. 21
16.4 Earthing for Protection against Lightning ........................................................................ 21
16.5 Earthing for Protection against Electromagnetic Interference ......................................... 22
16.6 Earth Network ................................................................................................................. 22
17. EMERGENCY POWER GENERATION ................................................................................. 23
18. SUBSTATION BUILDINGS AND SWITCHROOMS ............................................................... 23
18.1 Location .......................................................................................................................... 23
18.2 Design Requirements ..................................................................................................... 23
19. SITE TESTING OF ELECTRICAL EQUIPMENT & INSTALLATIONS ................................... 25
19.1 General........................................................................................................................... 25
20. ELECTROMAGNETIC COMPATIBILITY (EMC) .................................................................... 25
The following document has been revised and changes highlighted within the text. A
summary of the changes is provided on the appropriate Quality.net webpage.

ELECTRICAL
SYSTEMS GROUP
1. SCOPE
This Standard gives the basic requirements for the design, equipment and materials of
the Electrical Installation for a process plant and its associated facilities. This
Standard should be supplemented, as applicable, by other FW Standards.
2. BASIS OF DESIGN
2.1.1 The Electrical Installation shall be provide:
Safety to personnel.
Reliability.
Provision for future requirements if specified.
A graded system of protective devices.
Equipment with adequate:
Insulation levels.
Interrupting capacity.
Make Duty capability.
Through Fault capability.
Continuous current carrying capacity.
Control and indication.
Facilities for operation and maintenance.
2.1.2 The design shall be assessed with regards to health and safety during construction,
commissioning, operation and maintenance. Where practical, potential risks shall be
mitigated at source and incorporated into the design.
3. CODES AND REGULATIONS

The design and installation of materials shall comply with the latest edition of the
following:
BS 7671 Requirements for Electrical Installations (I.E.E. Wiring Regulations).

The Institute of Petroleum Model Code of Safe Practice, Part 15, Area
Classification Code for Petroleum Installations.
The Institute of Petroleum Model Code of Safe Practice, Part 1, Electrical Safety
Code.
Electricity Association G5/4 Engineering Recommendation
EMMUA Publication No 133 Specification for Underground Armoured Cables
Protected against Solvent Penetration and Corrosive Attack.
Electrical Research Association Report No. 69-30 for cable current ratings not
covered by IEC 60364-5-52

ELECTRICAL
SYSTEMS GROUP
British, European and IEC Standards.

Local Laws and Regulations.
In the case of Projects located in countries where these are not accepted, then such
Specifications, Codes and Regulations shall be replaced with the equivalent local
Specifications, Codes or Regulations or as specified.
4. EQUIPMENT AND MATERIALS
4.1.1 Equipment and materials shall be provided which conform to British Standards,
European or IEC Standards.
4.1.2 Equipment and Materials, for use in a hazardous area shall be certified by an ATEX
Notified Body as complying product directive 94/9/EC (ATEX 95). The supplier shall
provide a Certificate of Conformity.
4.1.3 Equipment subject to EC Directives shall be CE marked to indicate compliance with

the Directives. The supplier shall provide a statement of compliance listing all EC
Directives applicable to the equipment supplied.
5. AREA CLASSIFICATION
5.1 General
5.1.1 The Area Classification shall be based on the Institute of Petroleum Model Code of
Safe Practice, Part 15, Area Classification Code for Petroleum Installations.
5.1.2 Only those potential sources of hazard within the Foster Wheeler Scope of Work, will
be considered unless Foster Wheeler is informed of any other relevant source of
hazard.
5.2 Zones
5.2.1 Plants areas that have potentially explosive gas atmospheres, shall be classified in
accordance with IEC 60079 as follows:-
Zone 0: in which an explosive gas-air mixture is continuously present, or present for

long periods.
Zone 1: in which an explosive gas-air mixture is likely to occur in normal operation.
Zone 2: in which an explosive gas-air mixture is not likely to occur, and if it occurs it
will only exist for a short time.

ELECTRICAL
SYSTEMS GROUP
5.2.2 Plants areas that have a combustible dust hazard shall be classified in accordance
with BS EN 50281 as follows:-
Zone 20: Area in which an explosive atmosphere in the form of a cloud of combustible
dust in air is present continuously, or for long periods or frequently.
dust in air is likely to occur in normal operation occasionally.
dust in air is not likely to occur in normal operation but if it does occur, will
persist for a short period only.
5.2.3 Areas of plant not classified as one of the above shall be designated as being
non-hazardous.
6. ELECTRICAL EQUIPMENT ENCLOSURES
6.1 Enclosure
IP ratings to BS EN 60529 shall be applied.
6.2 Hazardous Areas
6.2.1 For gas and vapour risk areas, electrical equipment and the types of protection for
enclosures shall comply with IEC 60079.
6.2.2 The requirements for construction of electrical apparatus for use in potentially
explosive atmospheres shall comply with BS EN50014/15/17/18/19/20/28/39).
6.2.3 Electrical Equipment for dust risk areas shall comply with BS EN 50281 Part 1-1 & Part
1-2 and in particular with Part 1-2 Sections 5 and 6.
6.2.4 The type of protection to be applied to the electrical apparatus relative to the area
classification zone shall be as follows:
Zone Type of Protection Degree of

protection of
ia ib d e p n o q enclosure
0 x Min. IP 54
1 x x x x x Min. IP 54
2 x x x x x x x x Min. IP 54

ELECTRICAL
SYSTEMS GROUP
Types of protections „s‟ and „m‟ may be considered dependent on the application and
on appropriate certification being available.
6.2.5 The maximum surface temperature shall not exceed the ignition temperature of the
gases, dusts or vapours involved. This shall be indicated by the T Class (T1-T6) of the
apparatus as defined in IEC 60079.
6.3 Non-Hazardous Area
6.3.1 Indoor Locations
Electrical equipment in a relatively dust free environment (e.g. Substation Building)

shall be standard industrial equipment.
Switchboards shall have a minimum degree of protection of IP 41.
Ancillary apparatus shall have a minimum degree of protection IP 31.
Electrical apparatus in dusty areas shall have a minimum protection of IP54.
The substation floor shall not be considered as part of the enclosure.
6.3.2 Outdoor Locations:
The minimum enclosure for electrical equipment shall be IP 54W.
Electrical equipment shall be suitable for the environmental conditions (e.g. dust,
moisture, snow or rain) with additional protection provided (e.g. rain shields, sun
shields) where required.
7. DISTRIBUTION SYSTEM DESIGN
7.1.1 Distribution systems shall be of the secondary selective type, unless the plant is of a
type or in a location where single radial or spot networks are standard practice. In
secondary selective systems, the rating of all equipment in the distribution system shall
be such that any one transformer, feeder, switchboard or MCC feeder can be taken
out of service without affecting the availability of the plant supplied. Transformer ONAF
ratings may be utilised for single ended operation of secondary selective systems.
Ratings shall be based as a minimum on the electrical load when the plant or unit is
operating normally at its designed throughput. Where turbine drives have electric
drives as spares, the rating of the system shall include the load of the largest such
electric drive. Ratings shall also consider single ended arrangements and specified
future allowances.

ELECTRICAL
SYSTEMS GROUP
7.1.2 Short circuit levels for secondary selective systems with two transformers (i.e. normally
open bus-section), shall be based on one of the following. Selection depends on the
process requirements.
a) Mechanical or key interlocking of switchboard incomers and bus-section circuit

breakers, to prevent paralleling. There is a loss of voltage to one busbar during
manual switching, to transfer loads between transformer incomers. Secondary
short circuit level shall be based on the contribution from motors on both busbars
and one transformer.
b) No interlocking of switchboard incomers and bus-section circuit breakers, allowing
temporary paralleling of transformers, to permit manual make before break
switching, for load transfers between transformer incomers, without loss of
supplies to either busbar. Secondary short circuit level shall be based on the
contribution from motors on both busbars and both transformers.
c) Electrical interlocking of incomers and bus tie combined with a fast auto-transfer
scheme that allows momentary paralleling of incomers. Secondary short circuit
level shall be based on the contribution from motors on both busbars and both
transformers, unless Client practice allows the contribution from only one
transformer to be taken into account.
7.1.3 Three transformer secondary selective systems may be adopted where increased firm
capacity is required. In this case the two bus-sections shall be electrically interlocked,
in order that only one may be closed at a time. Switching and interlocking to allow or
prevent parallel operation of two transformers shall be provided in a similar way to that
outlined in section 7.2.
7.1.4 Short circuit calculations shall be based on IEC 60909
7.1.5 The design shall comply with Electricity Association G5/4 Engineering
Recommendation for harmonics at the point of common coupling.
7.1.6 Automatic load transfer and automatic staged motor re-acceleration and restarting
systems shall not be provided, unless requested by the Client. Use of re-acceleration
systems may be considered where the system can be exposed to short outages or
voltage dips. This may result from auto-reclose on grid systems or lighting strikes to
overhead lines.
7.1.7 Load shedding systems should be considered in case of in plant generation, and may
be used to optimise installed capacity and spinning reserve.
7.1.8 LV systems (400V or equivalent) shall have the neutral point solidly earthed. For
feeders that supply into Hazardous Area locations, neutral isolation (i.e. 4 pole, three
phase & neutral isolators) are required at the switchgear / MCC.
7.1.9 High voltage systems shall be resistance earthed. The value of the resistance shall
limit earth fault current to equal or less than rated phase current.

ELECTRICAL
SYSTEMS GROUP
7.1.10 DOL motors on LV systems shall generally be limited to 150kW and below. Motors of
less than 1kW may be energised from lighting or convenience outlet supplies via local
switches, however all such process motors shall be three phase.
7.1.11 For motors at 3.3kV and above the limiting rating shall be determined by Foster
Wheeler after fault level and other assessments have been made.
8. RELAYING AND PROTECTIVE DEVICES
8.1.1 Design requirements
8.1.2 A graded system of protective devices shall be applied as far as reasonably practical.
Devices shall be selected, and co-ordinated so that the circuit interrupting device
nearest to a fault operates first, and within the rating of the protected equipment.
8.1.3 The protective system shall provide, as far as possible, main and back-up protection.
8.1.4 The back-up protection for equipment shall be provided by the main protection of the
upstream equipment. The back-up protection shall clear faults, as far as possible,
within the rating of the equipment. This does not apply to feeder cables.
8.2 Protection Schemes

Protection Schemes that meet the requirements of Section 8.1 are:
Single HV Feeders Overcurrent (51)

Earth fault (51N)
HV/HV Transformer Feeders Differential Protection (87)

Instantaneous overcurrent (50)
Overcurrent (51)
Earth fault (51N)
HV/LV Transformer Feeders Instantaneous overcurrent (50)

Overcurrent (51)
Earth fault (51N)
HV/HV Transformer Secondaries Differential Protection (87)

Restricted Earth Fault (64)
Neutral Earth Fault (51N)
HV/LV Transformer Secondaries Neutral Earth Fault (51N)
Bus Section Circuit Breaker No protection to be applied

ELECTRICAL
SYSTEMS GROUP
Transformers Buchholz (63)

Fluid-filled conservator type: Oil Temperature (26)
.
Transfomers Loss of oil and gas accumulation
Fluid-filled sealed type
Transformers Winding Temperature (26)

Dry Type
HV Motor (Controlled by Circuit Motor Protection Relay - including:

Breaker) Thermal overload (49)
Instantaneous overcurrent (50)
Earth Fault (51N)
Load Unbalance/Negative Phase
Sequence (46)
Differential (87M) - Motors 2,000kW and
greater.
HV Motor (Controlled by HRC Fuses (BS EN 60282-1)

Contactors) Motor Protection Relay -including:
Thermal Overload (49)
Earth Fault (51N)
Load Unbalance/Negative Phase
Sequence (46)
LV Motors HRC Fuses (BS EN 60269).

Thermal overcurrent (with single-phase
prevention).
Motors above 37kW rating - with earth fault
relay.
LV Feeders HRC Fuses (BS EN 60269).

Earth leakage protection (with contactors)
where the fuse does not give adequate and
selective earth fault protection.
Generators and other Special Protective Devices to meet the criteria in

Equipment 8.1 shall be provided.

ELECTRICAL
SYSTEMS GROUP
8.3 Protective Relay Study

Foster Wheeler shall provide a Protective Relay study for the electrical system
supplied.
This Study shall consist of:
An explanatory narrative
A Protective Relay Setting Schedule.
Co-ordination Curves for the Protective Devices.
Manufacturer‟s data sheets
9. POWER TRANSFORMERS
9.1 Power Transformers shall comply with BS EN 60076.

Generally transformers shall be:
located outside (unless there is a specific Project requirement for them to be

located indoors).
three phase, oil-filled, self-cooled type (ONAN).
vector Group - Dyn11.
insulation Class - Class A.
Construction :
up to 3150 kVA: oil-filled hermetically sealed type.

above 3150 kVA: oil-filled conservator type (for high humidity locations - with a
membrane, in order to prevent “direct oil-to-air” contact).
cable connected to secondary switchgear.
9.1.1 Transformers shall have externally operated off-load primary tap changer with full
capacity taps +/- 2.5, +/- 5.0 %.
9.1.2 Indoor transformers shall be three phase, dry type (ANAN).
9.1.3 Synthetic fluid (e.g. silicone or Midel) shall be used instead of mineral oil in
applications where it is desired to reduce the risk of fire to a minimum, and dry-type
transformers are not wanted.
9.1.4 Use of busduct should be avoided due to the high positional tolerances required. Cable
secondary terminations to be used unless there is clear economical or technical
justification to do otherwise. Economic evaluation to include for support structure,
specialist installation contractor and additional design costs.

ELECTRICAL
SYSTEMS GROUP
10. SWITCHGEAR AND CONTROL GEAR
10.1 High Voltage (HV) Equipment (1000V up to and including 52kV).
10.1.1 HV Switchgear shall comply with BS EN 602981-1 (IEC 60298).
10.1.2 HV Motor Feeder Control Gear shall comply with IEC 60470.
10.1.3 HV Switchgear and Control Gear shall be indoor, metal-clad, withdrawable, single bus
and extendable at each end.
10.1.4 Circuit Breakers (Vacuum or SF6) shall be used for:
Incoming Feeder Units.

Bus Section Units.
Transformer Feeder Units (above 11 kV or above 400A).
Motor feeder units (above 11kV or above 400A).
10.1.5 Contactors (Vacuum or SF6) shall be used for:
Transformer Feeder Units (above 1000V, up to and including 11kV).

Motor Feeder Units.
10.1.6 Motor starter contactor units shall incorporate a three pole-isolating switch, HRC fuses,
electrically held contactor, and a motor protection relay.
10.1.7 Switchgear and Controlgear shall be provided with the Manufacturer‟s standard
accessories for:
Protective Relays.
Current and Voltage Transformers.
Auxiliary devices.
10.2 Low Voltage (LV) Equipment (1000V and below).
10.2.1 LV Switchgear and Motor Control Centres (MCCs) shall comply with BS EN 60947.
10.2.2 LV Switchgear and MCCs shall be indoor, metal-clad, withdrawable cubicle type,
extendable at each end.
10.2.3 LV Switchgear and MCCs shall have Form 4 internal separation by barriers or
partitions.

ELECTRICAL
SYSTEMS GROUP
10.2.4 Spare Circuit Breaker Units shall not be provided.
10.2.5 Incomer and Bus Section switches shall be Air Circuit Breakers
10.2.6 Motor Starter Units shall incorporate a three pole isolating switch, HRC fuses,
electrically held contactor, and an overload relay.
10.2.7 Switchgear and MCCs shall be provided with the manufacturer‟s standard accessories
for:
Motor Starter Unit components.

Fuse Switch Units.
Protective Relays.
Current and Voltage Transformers.
Auxiliary devices.
11. CONTROL AND INDICATION
11.1 General
11.1.1 To avoid having to operate HV distribution equipment directly at the unit, control and
indication shall be provided from a remote location (e.g. DCS, ENMCS or dedicated
control panel).
11.1.2 Control and indication of LV distribution equipment shall be provided at the equipment.
11.1.3 Control of process and utility consumers shall be limited to emergency stop at the
switchgear. Normal control will be from the process system.
11.1.4 Each substation shall have an annunciator marshalling all alarms from local distribution
equipment, with a common alarm being available to a remote control room, DCS or
manned area.
11.1.5 Motor control shall be designed for direct-on-line starting, except if system conditions,
or the Project Specification, dictate other starting methods.
11.1.6 The operating duties of motors that are paired for „running‟ or „spare‟ duty shall be
interchangeable.

ELECTRICAL
SYSTEMS GROUP
11.2 Control Stations
11.2.1 The normal method of control from the field shall be 3-wire with momentary 'start'
contact and maintained stay-put 'stop' contact. Motors which may be required to start
automatically under process, or other control, shall have 4-wire control with 'Off Auto
Manual' facilities.
11.2.2 Control Stations shall be mounted adjacent to, and within reach, of the controlled
motor (not on the terminal box side); except in the case of air fin exchanger fan
motors, when they will be located at grade, and with an additional stay-put stop button
located adjacent to the motor.
11.2.3 If ammeters have been specified to be incorporated in the control stations, they shall
be oriented, so as to be visible from the delivery valve, or similar, of the driven
equipment.
12. INSTRUMENT POWER SUPPLIES
12.1.1 Instrument Power Supplies shall be provided from a single AC Uninterruptible Power
Supply unit (UPS) when a no-break power supply is specified.
12.1.2 The UPS shall comprise of:
Rectifier/Charger Unit
Batteries
Static Transfer Switch
Maintenance By-Pass Switch
Bypass Transformer
12.1.3 Batteries shall be rated to supply the relevant loads for not less than half an hour.
12.1.4 Batteries shall be of the valve regulated type, i.e. requiring no topping up with
electrolyte and evolving negligible gas when operated properly.

ELECTRICAL
SYSTEMS GROUP
13. LIGHTING
13.1 Lighting Design
13.1.1 Light fittings shall be rated to operate from 230V single phase supplies.
13.1.2 Outdoor lighting shall be provided for all Process Areas and Maintenance Lay-down
areas. This includes all sections of the Plant to which access is provided by ladders or
platforms. For Offsites Areas, only street lighting shall be provided.
13.1.3 Design for outdoor facilities shall make the maximum use of floodlighting, the
remaining fittings shall be fluorescent type.
13.1.4 Local lighting, including that in buildings shall be provided by fluorescent fittings.
13.1.5 Circuits shall normally be switched from lighting distribution boards. The use of local
switches shall be kept to a minimum. Outdoor lighting shall be photocell controlled.
13.1.6 Distribution Boards shall be of 3 phase 4 wire type. Distribution Boards shall have the
provision for phase and neutral isolation for circuits in hazardous areas. Fuses or
MCBs shall protect each sub-circuit. Wherever possible, boards shall be located in
non-hazardous areas (e.g. Substations).
13.1.7 Process Areas shall have fixed Emergency Lighting to help with safe egress from
Plants. This lighting design shall be based on “silhouette,” or “exit target” techniques.
Emergency Lighting Fittings shall:
Have an integral Battery, rated for 30 minutes.

Have auto-charging.
Be part of the normal lighting scheme.

ELECTRICAL
SYSTEMS GROUP
13.2 Lighting Intensities
13.2.1 The Lighting scheme shall be designed for the levels of illumination tabulated below.
Initial lamp lumens shall be modified by a Maintenance Factor of 80% to allow for
deterioration in lamp output in service.
13.2.2 The illumination level is defined as the mean of the maximum and minimum values of
illumination calculated at points throughout the illuminated area.
Illumination
Location Level Elevation Max/Min
(Lumens/ Sqm) Ratio
Outdoor Pump Rows 100 Grade 4
Main Operating Platforms 100 Floor 2
Ordinary Platforms 50 Floor 4
Stairways & Ladders (frequently used) 50 Floor 4
Stairways & Ladders (other) 20 Floor 4
Furnaces 100 Grade 4
Compressor Houses 150 Floor 2
Yard Areas 2 Grade 10
Maintenance Areas 100 Grade 4
Control Rooms (general) 200 Floor 2

Control Rooms (console desk areas) 300 1.75m 1.5
Control Rooms (back of panel) vertical 100 1.2m 4

Control Rooms – Auxiliary Room 150 1.2m 4
Loading Racks (Loading point) 100 Point -
Loading Racks (general area) 30 Grade 4
Substations outdoor 20 Grade 4
Substations indoor 150 Floor 2
Switchracks 100 1.2m 2
General Indoor areas 50 Floor 4
General Outdoor areas 20 Grade 4

ELECTRICAL
SYSTEMS GROUP
Street lighting shall generally be in accordance with Group B of BS 5489.
14. WELDING AND CONVENIENCE SOCKETS
14.1 Basis of Design
14.1.1 Welding Sockets shall be located on the basis of reaching any point within each
Process Unit where welding will be performed, assuming the use of 45 metre
extension leads.
Welding sockets shall only be provided at grade.
14.1.2 Convenience sockets shall be supplied on the basis of adequate coverage of each
Process Unit assuming the use of 15 metre extension leads. They shall be installed in
operational Off Site Areas, on the basis of adequate coverage using 30 metre
extension leads. Substations shall have a minimum of two sockets.
14.1.3 Sockets shall be arranged in groups of not more than ten from each power distribution
board circuit.
14.2 Socket Types
14.2.1 Welding sockets shall be rated 400V, 63A, three wire, four pin. In Zone 1 and Zone 2
Areas welding sockets shall have type of protection EEx d, or EEx ed and an
interlocked switch. In non-hazardous areas welding sockets shall have standard
industrial, weatherproof, enclosures.
14.2.2 Convenience sockets shall be rated 230V,16A, two wire, three pin. In Zone1 and
Zone 2 Areas convenience sockets shall have type of protection EEx d, or EEx ed
together with an interlocked switch. In outdoor non-hazardous areas convenience
sockets shall have standard industrial, weatherproof, enclosures.
14.2.3 In indoor, non-operational areas, (e.g. Administration Offices, Workshops, etc).

convenience sockets shall be 230V,13A, two wire, three pin. They may be on ring, or
radial distribution systems.

ELECTRICAL
SYSTEMS GROUP
15. CABLE INSTALLATIONS
15.1 Cable Sizing
15.1.1 The allowable current carrying capacity of cables shall be in accordance with IEC
60364-5-52, ERA Report No. 69-30 or Cable Manufacturer‟s information.
The cable rating factors shall be based on BS 7671.
15.1.2 Feeders and sub-feeders shall be sized for the demand based on the operating kVA
required for normal design throughput of the plant except that feeders to transformers
shall be sized to suit the transformer rating.
15.1.3 Cables shall be sized to ensure that the following voltage drops are not exceeded:-
Feeders and Sub-Feeders 1% of supply voltage.
Motor Feeders (under motor rated conditions) 5% of the motor rated voltage under
run conditions.
15% of the motor rated voltage under
starting conditions.
Lighting 5% of the lamp rated voltage.
15.1.4 Feeders and sub-feeders, except for Transformers Feeders, shall be sized for the
design throughput of the Plant.
Transformer Feeders shall be sized for the Transformer rating.
15.1.5 The minimum size cable, for circuits above 1000 volts, shall be the smallest practical
size dictated, by either the short circuit level and the primary protection fault clearance
time or the circuit load current which ever is the greater.
15.1.6 The smallest core size shall be 2.5mm2 for lighting and power cables, and 1.5mm2 for
control cables.

ELECTRICAL
SYSTEMS GROUP
15.2 Cable Construction
15.2.1 Cable Types shall be in accordance with the following:
System Utilisation Voltages of 1000 and below.
Voltage Grade 600/1000 V.
Distribution cables
Cross-linked polyethylene (XLPE) insulated, Non-Hygroscopic Fillers, Extruded

Polyvinyl Chloride Bedded, Single Steel Wire Armoured and Polyvinyl Chloride
Sheathed, (XLPE/PVC/SWA/PVC), in accordance with BS. 5467.
Transformer Secondaries
XLPE insulated, Aluminium Wire Armoured and Polyvinyl Chloride Sheathed,

(XLPE/AWA/PVC) to BS 5467.
a) System Utilisation Voltages of 3300V.

As a) above except for 1900/3300 Volt Grade.
b) System Utilization Voltages of 6,600 up to 33,000 V.

Voltage Grade 3,800/6600 V.
Voltage Grade 6,350/11,000 V.
Voltage Grade 19,000/33,000 V.
Distribution cables
XLPE Insulated, Screened, Extruded Polyvinyl Chloride Bedded, Single Steel Wire
Armoured and Polyvinyl Chloride Sheathed, (XLPE/Screened/ PVC/SWA/PVC), in
accordance with BS 6622.
Transformer Secondaries
Single core, XLPE insulated, Aluminium Wire Armoured, and Polyvinyl Chloride
Sheathed, (XLPE/AWA/PVC) in accordance with BS 6622.
15.2.2 Cables shall have stranded copper cores.
15.2.3 Cables installed underground and subjected to solvent penetration and corrosive
attack shall have a lead sheath. These cables shall in addition to complying with the
British Standards referenced in para. 15.2.1 a), b), c), also comply with EEMUA
Publication No 133 Specification for underground armoured cables protected against
solvent penetration and corrosive attack.

ELECTRICAL
SYSTEMS GROUP
15.2.4 Cables installed in aboveground enclosed areas shall be fire retardant and have non-
propagating, self-extinguishing characteristics in accordance with IEC 60332.
15.3 Cable Installation
15.3.1 Cable terminations shall use compression type glands.
15.3.2 Non magnetic cable glands and gland plates shall be used with single core power
cable.
15.3.3 Single core cable should be installed in trefoil formation to reduce circulating currents.
Cable derating shall consider the effects heating if the cable armour is earthed at more
than one point. Particular attention should be given to the connection of cable armour
and shields to earth for double point bonded systems as the circulating currents can be
significant. Where separable connectors are used for cable termination (i.e. as used
with Gas Insulated Switchgear), a proprietary cable earthing system should be utilised.
Installation drawings shall provide specific detail on the size and type of bonding and
equipment to be used.
15.3.4 Where long runs of single core high voltage cables are required, an evaluation of the
installation shall be carried out to determine if intermediate cross-bonding of armouring
is required to avoid the heating effect of sheath losses. Note that if single point
bonding is selected, then further evaluation is required to determine if Sheath Voltage
Limiters need to be installed to protect against high standing or short circuit induced
voltages.
Outside of process areas, in well defined cable trenches, the use of HDPE outer
sheath should be considered instead of copper or aluminium armour for single core
cables.
15.4 Underground Cable Installation
15.4.1 Cable shall be installed as follows:-
Location Method Minimum Cover

Offplot and Unpaved Direct Buried 450mm
Areas
Onplot Paved Areas Formed Trenches 450mm
Under Roads In Ducts 750mm
15.4.2 Cables shall be installed in up to three layer formation, spaced, or touching, as

appropriate to the derating applied.
Running, spare and control cables shall be interleaved to obtain the equivalent of
spacing when determining derating factors.

ELECTRICAL
SYSTEMS GROUP
Power cables shall be segregated where necessary from signal, and other sensitive
installations.
15.4.3 Cable tiles and polyethylene warning tape shall be installed.
15.4.4 Markers shall be provided to show the location of cables in unpaved and offplot areas.
The markers shall be located at:
50 m intervals,
changes to the cable direction
road and pipe crossings
entrances to buildings
all joint positions
one side only in cable formations 2m wide and under
both sides in cable formations above 2m wide.
15.4.5 The bottom of cable trenches shall be backfilled with a 75 mm layer of sand or sifted
fill. Cables shall be laid and the trench backfilled with sand or sifted fill to a level 75mm
above the top of the cables.
15.4.6 Cables shall be installed in one length where possible. The use of underground joints
shall be kept to a minimum.
15.4.7 Cables shall be mechanically protected to 150mm above grade where they leave the
ground.
15.5 Overhead Cable Installation
15.5.1 Cables shall be supported by galvanised cable trays, or racks, which shall be fixed,
where practical, to the main structures. Individual cables may be fixed directly to the
main structures.
15.5.2 Cable shall normally be supported every 450mm on horizontal runs and every 750mm
on vertical runs.
15.5.3 Power cables shall be separated from signal cables by a minimum separation of
600mm on long parallel runs.
15.5.4 Power cables shall be installed to a maximum depth of two layers.

ELECTRICAL
SYSTEMS GROUP
16. EARTHING
16.1.1 A common earthing and bonding system shall be installed for:
Safety to personnel
Protection against static electricity
Protection against lightning
To limit the voltage on a circuit when exposed to a higher voltage than its design
voltage.
Protection against electromagnetic interference.
16.1.2 Earthing and bonding shall be designed to BS 7430 and BS 7671.
16.1.3 Computer, Instrumentation and DCS Installations shall have earthing systems
connected to the common earthing system at a single point.
16.2 Earthing for Safety to Personnel

All exposed conductive parts of all electrical equipment shall be bonded to the earth
network. If there is no nearby network, they shall be connected to one or more earth
rods or equivalent.
16.3 Earthing for Protection against Static Electricity
16.3.1 Tanks, piping and process vessels and equipment containing flammable liquids or gas
shall be earthed by a connection to the earth network, or by bonding to an earthed
metal structure.
16.3.2 Metal enclosures in intimate contact with the ground (for example, tanks) may be
considered to be adequately protected without additional bonding.
16.3.3 Bonding straps shall be applied across in-line insulating devices on lines handling
materials which give rise to significant amounts of static.
16.4 Earthing for Protection against Lightning
16.4.1 Earthing for Protection against Lightning shall be comply with BS 6651.
16.4.2 Any structure or equipment less than 20m high is adequately shielded against lightning
if it is within a protection cone with and earthed metallic tip. The angle between the
side if the cone and the vertical at the tip shall be not greater than 45 degrees.
Between two or more vertical conductors, spaced at a distance not exceeding twice
their height, this angle may be relaxed to 60 degrees.
ELECTRICAL
SYSTEMS GROUP
16.4.3 For structures greater than 20m in height, the rolling sphere method from BS.6651
shall be applied.
16.4.4 Self-conducting structures such as metal-framed structures shall not be provided with
air terminations or down conductors. If they are not shielded in accordance with
16.4.2, they shall be earthed on at least two sides, by connection to the earth network,
or by other means if there is no nearby network.
16.4.5 Steel columns and other structures on reinforced concrete foundations shall be
earthed by bonding the foundation reinforcing and the anchor bolts to the column or by
connection to the earth network
16.5 Earthing for Protection against Electromagnetic Interference
16.5.1 Bonding straps shall be as short as possible. They shall have now resistance and
inductance.
16.5.2 Bonding straps shall be resistant to corrosion, shock and vibration
16.5.3 Cable armour shall be bonded at both ends
16.5.4 Equipment suppliers published recommendations shall be also be applied.
16.6 Earth Network
16.6.1 An earth network shall be installed around Substations, Process Units, Structures,
Switchracks and other Electrical Installations. The Earth Network shall consist of a
main cable loop with bonds to earth rods.
16.6.2 Earth cable shall be stranded copper.
16.6.3 Earth conductors shall be laid directly in the ground, preferably without breaks or
joints. Any underground joints shall be brazed, or welded. Main earth bars shall be
provided above ground on the earthing network to attach bonds to equipment. Where
possible, the earth bars shall be attached to the steel of structures.
16.6.4 Equipotential bonds to primary electrical equipment shall be based on the short time
rating of the associated switchgear.
16.6.5 Earthing Conductors shall be selected and sized to BS 7430, but the minimum cross-
sectional area for a main loop shall be a minimum of 70mm2.

ELECTRICAL
SYSTEMS GROUP
16.6.6 The interval between earth rods shall not exceed 25m. Each earth rod shall have a
disconnection/inspection facility.
16.6.7 Electrical equipment shall be directly connected to the earth network. Luminaries shall
be earthed by the cable armour or a separate core within the supply cable.
17. EMERGENCY POWER GENERATION

Emergency power generation shall not be provided unless it is specified in the Project
Specification.
18. SUBSTATION BUILDINGS AND SWITCHROOMS
18.1 Location
18.1.1 Substation Buildings shall preferably be located in non-hazardous Areas.
18.1.2 If the Substation is in a Zone 2 Hazardous Area, then the installation shall be designed
in accordance with IEC 60079-13 and the Institute of Petroleum Model Code of Safe
Practice Part 15. The interior of the building shall have pressurisation with continuous
circulation of air (positive pressure ventilation) to ensure that the interior is
non-hazardous.
Air intakes should be located as far as possible and at least 1 metre outside hazardous
areas. The location shall be selected after considering the effects of:
Air contamination with flammable material.

Any additional safety systems, e.g. equipment trips on detection of flammable
material in the air intakes.
18.2 Design Requirements
18.2.1 Substation Buildings shall not have windows. They shall have at least one personnel
door and one equipment door. Doors shall preferably be located at opposite ends of
the Substation Building. They shall be fitted with quick release bolts.
The equipment door opening shall be big enough to accommodate the largest
assembled unit of equipment. They shall use standard size doors with removable
panels above (if required).
18.2.2 The Substation Building layout shall provide space for the extension of:
HV Switchboards at each end by one semi-equipped Panel.

LV Switchboards at each end by one semi-equipped M.C.C. Cubicle.

ELECTRICAL
SYSTEMS GROUP
Future additional equipment should be accommodated by extending the Substation

Building.
18.2.3 Minimum clearance around equipment shall be as follows:
Behind switchgear requiring rear 750 mm

access.
Between equipment ends, or between 750 mm

equipment ends and wall.
Operating aisle (between switchgear 1500 mm (or manufacturers

and other equipment). minimum recommendation)
18.2.4 A minimum vertical clearance of 450mm shall be provided. The clearance shall be
measured between the highest equipment section and the bottom of the lowest roof
beam, air conditioning duct or overhead cable support system.
18.2.5 Switchgear batteries and charging equipment should be installed in the same room as
the switchgear, and should be a minimum of 1500mm from other equipment.
18.2.6 Battery racks installed on raised floors, whether the cells are sealed (valve regulated)
or conventional, shall have drip trays installed at floor level.
18.2.7 Substation Building floors shall be level and smooth. Channel inserts shall be provided
for the mounting of Switchgear and Equipment, and shall be installed level with the
finished floor.
18.2.8 Oil filled Transformers shall be located outside the Substation Building and arranged to
minimise the length of secondary cable.
Minimum clearances shall be:
Between the Transformer and the building wall - 750 mm

Between Transformers - 1000mm
Oil filled Transformers, Reactors and Neutral Earthing Resistors, shall be mounted on
concrete pads.
The entire Transformer area shall have a 200 mm wide perimeter curb. The void
between the kerb and equipment pads shall be filled with graded stone of sufficient
depth to accommodate the oil.

ELECTRICAL
SYSTEMS GROUP
19. SITE TESTING OF ELECTRICAL EQUIPMENT & INSTALLATIONS
19.1 General
19.1.1 Site Testing of Electrical Equipment & Installations shall be performed, before
energising the electrical system, as a check that:
Equipment has not suffered deterioration since works testing.

Electrical connections on site are satisfactory.
19.1.2 Routine tests as specified in the Equipment Standards and re-calibration of

instruments, or relays shall not be repeated as part of site testing.
19.1.3 Site Testing shall be performed in accordance with Engineering Standard “Site Testing
of Electrical Equipment and Installations” (Std. No. 70A5 (Reading))
20. ELECTROMAGNETIC COMPATIBILITY (EMC)
20.1.1 Equipment and Systems shall comply with the BS EN 61000 Series Standards (IEC
61000 Series).
20.1.2 In order to achieve EMC compliance for Power Drive Systems (i.e. combination of
VSD, power cabling and motor) or UPS systems, the Supplier installation
recommendations shall be strictly adhered to.

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ELECTRICAL

16. EARTHING ............................................................................................................................ 21

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2.1.1 The Electrical Installation shall be provide:

3. CODES AND REGULATIONS

BS 7671 Requirements for Electrical Installations (I.E.E. Wiring Regulations).

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British, European and IEC Standards.

4. EQUIPMENT AND MATERIALS

4.1.3 Equipment subject to EC Directives shall be CE marked to indicate compliance with

Zone 0: in which an explosive gas-air mixture is continuously present, or present for

Zone 1: in which an explosive gas-air mixture is likely to occur in normal operation.

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6. ELECTRICAL EQUIPMENT ENCLOSURES

6.2 Hazardous Areas

Zone Type of Protection Degree of

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6.3 Non-Hazardous Area

6.3.1 Indoor Locations

Electrical equipment in a relatively dust free environment (e.g. Substation Building)

Switchboards shall have a minimum degree of protection of IP 41.

Ancillary apparatus shall have a minimum degree of protection IP 31.

Electrical apparatus in dusty areas shall have a minimum protection of IP54.

The substation floor shall not be considered as part of the enclosure.

6.3.2 Outdoor Locations:

The minimum enclosure for electrical equipment shall be IP 54W.

7. DISTRIBUTION SYSTEM DESIGN

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a) Mechanical or key interlocking of switchboard incomers and bus-section circuit

7.1.4 Short circuit calculations shall be based on IEC 60909

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8. RELAYING AND PROTECTIVE DEVICES

8.1.1 Design requirements

8.2 Protection Schemes

Single HV Feeders Overcurrent (51)

HV/HV Transformer Feeders Differential Protection (87)

HV/LV Transformer Feeders Instantaneous overcurrent (50)

HV/HV Transformer Secondaries Differential Protection (87)

HV/LV Transformer Secondaries Neutral Earth Fault (51N)

Bus Section Circuit Breaker No protection to be applied

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Transformers Buchholz (63)

Transformers Winding Temperature (26)

HV Motor (Controlled by Circuit Motor Protection Relay - including:

HV Motor (Controlled by HRC Fuses (BS EN 60282-1)

LV Motors HRC Fuses (BS EN 60269).

LV Feeders HRC Fuses (BS EN 60269).

Generators and other Special Protective Devices to meet the criteria in

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8.3 Protective Relay Study

This Study shall consist of:

9.1 Power Transformers shall comply with BS EN 60076.

located outside (unless there is a specific Project requirement for them to be

up to 3150 kVA: oil-filled hermetically sealed type.

9.1.2 Indoor transformers shall be three phase, dry type (ANAN).

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10. SWITCHGEAR AND CONTROL GEAR

10.1 High Voltage (HV) Equipment (1000V up to and including 52kV).

10.1.1 HV Switchgear shall comply with BS EN 602981-1 (IEC 60298).

10.1.4 Circuit Breakers (Vacuum or SF6) shall be used for:

Incoming Feeder Units.

10.1.5 Contactors (Vacuum or SF6) shall be used for:

Transformer Feeder Units (above 1000V, up to and including 11kV).

10.2 Low Voltage (LV) Equipment (1000V and below).