E_C& I Standards GSR_rev03

IPRO Industrieprojekt GmbHClient: Star Trading CompanyProject: Golden Sugar RefineryProject-No.: 7048.09

E+I StandardsCurrent status: October 14, 2010

Sheet Description

1 Electrical standard list

2 Control & Instrumentation standard list

3 Electrical consumer list info

4 Control & Instrumentation Identification list

5 Control & Instrumentation IO - list info

6 Control & Instrumentation Instrument list

7 Specification of electrical motors

8 Specification of frequency converters

9 Color code of wiring in electro distribution boards

10 Cable standards

11 Hazardous areas

0. Electrical / Control & Instrumentation Standardization: Table of contents

printed:25.11.2010 / 23



General IPRO-ProposalHigh voltage main power distribution board:- Air-insulated - Gas-insulated SF6

Air-insulated

Circuit breaker: fix-mounted or truck-mounted For SF6 only fix-mountedPower compensation: power factor cos phi at the medium voltage transfer point (value required by the power supply company)

cos phi = 0,95

Transformators: Oil transformer or dry transformer (cast iron) Cast resin (dry) transformerDiesel emergency generator Max. 2.500 kW each at low voltageMotor protection in the motor distribution boards (MCC) By an electronic relay/

(e.g.: Siemens Simocode Pro)Motor controls:a. Manual by local On/Off switchesb. Automatic remote control by the process automation system

a. Manual by local On/Off switchesandb. Automatic remote control by the process automation system

Disconnection of the main power supply for motor drives:By local 3-pole maintenance switches installed near by the motor drives

By local 3-pole maintenance switches installed near by the motor drives

Motor protection by controlling of the motor winding temperature Realized by thermistor motor protectionMotor Control Center (MCC):a. Fix-mounted switch gears orb. In-line plug-in technic or c. withdrawble technic

c. Withdrawble technic

Protection of the motor starters:a. By fuses orb. Fuseless (by motor circuit breakers)

b. Fuseless (by motor circuit breakers)

Thermal overload protection If possible: electronic overload protectionInternal ProtectionGeneral degree of protection IP54Motors IP65Frequency converters IP54Transformators BrandDry transformer ABB/ SiemensOil transformer ABB/ Siemens/ Alstom/ HelmkeCable ducts (cable tray system) BrandCable trays RICO/ Niedax/ Stago Wibe (sendzimir galvanized)Cable ladders RICO/ Niedax/ Stago Wibe (sendzimir galvanized)Distribution boards/ switch gears BrandMotor starter Siemens/ ABB/ MoellerArrestor (lightning protection) Dehn/ PhönixPower meter for current/ voltage/ cos phi etc. Siemens SIMEAS P/ alternativ: single instrumentsPower compensation Siemens/ ABB / Schneider / MoellerProgrammable logic computers SPS Siemens/ ABB / Schneider / MoellerMain circuit breakers / Disconnectors Siemens/ ABB / Schneider / MoellerCircuit breakers for motor protection Siemens/ ABB / Schneider / MoellerAutomatic cut-outs Siemens/ ABB / Schneider / MoellerDC power unit/ 3 phase AC 400V/DC 24V Siemens/ ABB / Schneider / MoellerEmergency switch/ basic hardware Siemens/ 3TK 28..Terminal strips Siemens/ Phönix/ Weidmüller/ WagoMotor distribution boards MCCs Siemens/ ABB / Schneider / MoellerSwitch gears (contactors) Siemens/ ABB / Schneider / MoellerElectro panels RITTALFuses Siemens/ ABB / Schneider / MoellerMotor DOL direct on line Siemens/ ABB / SchneiderMotor Star-Delta operation Siemens/ ABB / SchneiderMotors 132 kW up to 250 kW with softstarter Siemens/ ABB / SchneiderThermistor relay for motor temperature control/ Thermal overload protection Siemens/ ABB/ Moeller

1. Electrical Standardization List

printed:25.11.2010 / 23



1. Electrical Standardization List

Installation materials BrandSwitches for lighting Siemens/ Jung/ GiraSocket outlets 230V/400 V Menneckes/ GifasSockets for explosion proof areas Menneckes/ GifasLocal Control switch for motor operation: automatic (remote) / manual (local) Siemens

Illuminats BrandHigh Pressure Sodium Schuch/ Siemens/ Beghelli/ NorkaMetal Halide Schuch/ Siemens/ Beghelli/ NorkaFluorescent lamp Schuch/ Siemens/ Beghelli/ NorkaEmergency lighting BrandDC/AC alternator/ centralized batteries CEAG/ PräzisaCentral unit with DC Batteries/ illuminats will be switched from AC to DC/AC alternated voltage

CEAG/ Präzisa

Frequency converters BrandFrequency converters Siemens/ ABB/ Schneider / Moeller / Control Technik/ Rockwell Electro motors BrandElectro motors Siemens/ ABB/ SchorchBattery bank BrandBattery bank Nickel cadmium or Lead Acid types

printed:25.11.2010 / 23



Process-Automation-System IPRO-Proposal / BrandAll instruments, valves and accessories shall have attached a shipping label showing the instrument tag-number and the purchase order numberAll instruments, cabinets and terminals, wiring, etc. shall have nameplates, labels or markers showing the Tag- or identification-numberControl system based on DCS-System with Fieldbus Siemens PCS7, Emerson DeltaV, Yokogawa Centrum or similarHMI-Software (Human Machine Interface)Fieldbus Profibus DP/PA or Fieldbus FoundationMotor protection control device Siemens Simocode or similarManagement Information System and / or Advanced Monitoring System

Siemens/ Emerson AMS

MES-Software (Manufacturing Execution System) SAP/ R3Flow measurement IPRO-Proposal / BrandFloat type flowmeter (glas) Bopp & Reuter / KoboldFloat type flowmeter (metall) Bopp & Reuter / KoboldDam flap type flow meter HeinrichsVane type, cup type flow meter Bopp & Reuter / KoboldVolumetric flow meter Bopp & Reuter / KoboldLocal pointer type temperature measurement

IPRO-Proposal / Brand

Thermeowell as a set-in nozzle, DIN16179 WIKA / LabomThermowells Weld-in protection tube DIN Standard type BS , 1.4571 , for thermometer with fixed screw R1/2" , connection 11

WIKA / Labom

Bimetall pointer-type , R 1/2" thermometer every angle,1.4301, WIKA / LabomGas filled case bimetall pointer-type , R 1/2" thermometer every angle , 1.4301 WIKA / LabomBimetall pointer-type , R 1/2" thermometer throug long distance line , 1.4301 WIKA / LabomLocal pressure gauge and differential pressure gauge measurement IPRO-Proposal / BrandBourdon tube pressure gauge, G 1/2" , phenolic case, acrylic windows , stainless steel 1.4301 WIKA / Labom

Bourdon tube pressure gauge, G 1/2" , liquid filled case by pulsating service, phenolic case , acrylic window , stainless steel 1.4301

WIKA / Labom

Contact pressure gauge , R 1/2", phenolic case , acrylic window , stainless steel 1.4301 WIKA / LabomDifferential pressure measuring instrument , R 1/2",phenolic case , acrylic windows , stainless steel 1.4301Diaphragm pressure gauge, G 1/2" WIKA / Labom

2. Control & Instrumentation (C&I) Standardization List

printed:25.11.2010 / 23




Velocity- and mass flow measurement IPRO-Proposal / BrandInductive flow meter E&H / Krohne / RosemountNuclear density meter in screw conveyor and pipes not usedOrifices plates measurement venturis measurement Intra AutomationWeight rate of flow meter for bulk material E&H / RembeVortex shedding flowmeters E&H / Krohne / RosemountTurbine measurement Bopp & Reuter / KoboldBelt weigh beam system Bitzer / Rembe / Boekels / KuklaMass flowmeter with flanges (coriolis type) E&H / Rosemount Micro MotionLevel measurement IPRO-Proposal / BrandFlange-type-transmitter (DN 80) with integral indicator Siemens / E&H / Rosemount Flange-transmitter (DN 80) with tube and integral indicator Siemens / E&H / Rosemount DP-transmitter (R 1/2") with integral indicator , through long distance line, flanges DN 80 (flexiblecapillary)

Siemens / E&H / Rosemount

Ultrasonic level gauges Siemens / E&H / Rosemount RF capacitance measurement with high frequency probes and integral electronic, covering 316 SS or PTFE


Electro/mechanical level indicator for bulk materia Siemens / E&HFloat type level indicator KrohneLevel meter with pulsed radar Siemens / E&H / Rosemount Pressure and differential pressure measurement IPRO-Proposal / BrandDP-transmitter (R 1/2") with integral indicator , throug long distance line, flanges DN 80 (flexible capillary)


DP-transmitter (flange type DN 80) with integral indicator Siemens / E&H / RosemountDP-transmitter (miniature diaphragm G 1") with integral indicator Siemens / E&H / RosemountAbsolut pressure transmitter Siemens / E&H / RosemountTemperature measurement IPRO-Proposal / BrandRTD resistance temperature detector (PT 100) Siemens / E&H / RosemountRTD resistance temperature detector (PT 100) with integral transmitter (4-20 mA) Siemens / E&H / RosemountThermocouple element, Type K Siemens / E&H / RosemountThermocouple element, Type R Siemens / E&H / Rosemount

printed:25.11.2010 / 23




Density measurement IPRO-Proposal / BrandMicro wave density meter Harrer and Kassen / BertholdQuality mesurement IPRO-Proposal / BrandpH-measurement Yokogava / E&H / Knick / RosemountRedox-measurement Yokogava / E&H / Knick / RosemountConductivity-measurement Yokogava / E&H / Knick / RosemountFlame photometer for boiler feed water VenemaPurity measurement DR. Kernchen / Schmidt & Haensch / Mettler-ToledoProcess-refractometer DR. Kernchen / Schmidt & HaenschOxygen-analyzer Siemens / E&H / ABBCarbon-monoxide-analyzer Siemens / E&H / ABBCarbon-dioxide-analyzer Siemens / E&H / ABBDew point / humidity / moisture measurement Mütec / Mettler-ToledoSpeed measurements IPRO-Proposal / BrandSpeed counter IFM / Pepperl+FuchsSpeed switch IFM / Pepperl+FuchsGlobe control valves IPRO-Proposal / BrandControl valve , single seat , with spring return diaphragm actuator positioner (4-20mA) ARI / Arca / Chemat

with Sipart PS 2 PA PositionerControl valve , single seat , with 230V~ electrical multi turn actuator (4-20mA) ARI / Arca / Chemat / AumaControl valve , double seat , with spring return diaphragm actuator positioner (4-20mA) ARI / Arca / Chemat / Crane

with Sipart PS 2 PA or PMV D3 PositionerControl valve, double seat, with 230V~ electrical multi turn actuator (4-20mA) ARI / Arca / Chemat / AumaThree-way-valve , with spring return diaphragm actuator positioner (4-20mA) ARI / Arca / Chemat / Crane

with Sipart PS 2 PA PMV D3 PositionerThree-way-valve , with 230V~ electrical multi turn actuator (4-20mA) ARI / Arca / ChematButterfly control valves and open / close valves IPRO-Proposal / BrandOpen/close butterfly valve actuator single-acting , integral 3/2-way solenoid valve, fully open and close limit switches from IFM Typ IND

Crane / Gefa / ARI / Keystone

Open/close butterfly valve actuator double-acting , integral 5/2-way solenoid valve, fully open andclose limit switches from IFM Typ IND


Open/close butterfly valve, 230V~ electrical actuator, with integral fully open/close limit switches from IFM Typ IND


Control butterfly valve actuator single-acting, positioner (4-20mA) Crane / Gefa / ARI / Keystonewith Sipart PS 2 PA or PMV D3 Positioner

Control butterfly valve actuator double-acting, positioner(4-20mA)

Crane / Gefa / ARI / Keystonewith Sipart PS 2 PA or PMV D3 Positioner

Control butterfly valve , 230V~ electrical multi turn actuator (4-20mA) Crane / Gefa / ARI

printed:25.11.2010 / 23




Ball control valves and open / close ball valves IPRO-Proposal / BrandOpen/close throttling ball valve actuator single-acting, integral 3/2-way solenoid valve, fully open and close limit switches from IFM Typ IND

Gefa / Chemat / Megafrance

Open/close throttling ball valve actuator double-acting, integral 5/2-way solenoid valve, fully open and close limit switches from IFM Typ IND


Open/close Throttling ball valve, 230 VAC electrical actuator, with integralfully open/close limit switches from IFM Typ IND


Control Throttling ball valve, actuator single-acting, positioner (4-20mA) Gefa / Chemat / Megafrancewith Sipart PS 2 PA or PMV D3 Positioner

Control Throttling ball valve, actuator double-acting, positioner (4-20mA) Gefa / Chemat / Megafrancewith Sipart PS 2 Paor PMV D3 Positioner

Control Throttling ball valve, 230VAC electrical multi turn actuator (4-20mA) Gefa / Chemat / MegafranceActuators IPRO-Proposal / BrandPneumatic Actuator with proximity switch from IFM Typ IND Norbro / Valbia / Ebro / Elomatic / PMV400 VAC electro multi turn actuator with proximity switch Auma SAKnife-gates IPRO-Proposal / BrandOpen/close knife-gate with pneumatic air-cylinder fully open/close limit switch from IFM Typ IND Erhard / Ebro

Iris diaphragm control valve IPRO-Proposal / BrandIris diaphragm control valve with positioner (4-20mA) EggerLimit - switches IPRO-Proposal / BrandFlow switch (in-line) spring opposed paddle type E&HFlow switch (in-line) thermal effect type for low and no-flow service E&HSolid level switch or similar paddle wheel type switch E&HLevel alarm switch (float) Bestobell MobreyLevel alarm switch (float) for chemicals Bestobell Mobreylevel switch (vibration) Siemens / E&H / VegaTemperature switch FanalPressure switch FanalProximity switch IFM / Pepperl+FuchsPull rope switch for belt conveyor KiepeMisaligment switch / Belt drift switch Kiepe

printed:25.11.2010 / 23




Fittings / MountingsOiler Festo / Parker Hannifin / NorgrenReducers Festo / Parker Hannifin / NorgrenFilter Festo / Parker Hannifin / NorgrenFilter - Reducer Festo / Parker Hannifin / NorgrenPipes for measurements points Standard MaterialStainless steel diameter 12 mm and 16 mm Standard MaterialPipes for pneumatic controls Standard Material with UV protectionStainless steel diameter 12 mm and 16 mm Standard MaterialCoupling out Festo / SertoBrass Festo / SertoStainless steel Festo / SertoValve blocks Klinger / Festo / BurkertControl plug valves Klinger / Festo / BurkertSolenoid valve Herion / Rexroth / BurkertTransducerElectro pneumatic measurement transducer Siemens / E&HPneumatic electro measurement transducer Siemens / E&HGalvanic Isolator (4-20mA) without power-supply Siemens / E&H / LabomGalvanic Isolator (4-20mA) with power-supply Siemens / E&H / Labomtemperature transmitter (4-20mA) with power-supply Siemens / E&H / Labom / Rosemount

printed:25.11.2010 / 23



MOTORRevision Legend: N=New C=Cancelled xx=Change LVEBExtern

MachineExternLVDB

VFCSC

Ru

nn

ing

No

.

Re

visi

on

MachineMachine-

No.

P(Installed

rated motorload for

MCCs)

[kW]

PStand-by[kW]

PEstimate

dPower

StatusU[V]

I[A]

Speed[1/rpm]

LF(Load

Factor)

S(Appeare

nt

Power)

[kVA]

Power Factor[cos phi]

Eta(Efficien

cy)[%]

Back-up Power

(EmergencyPower Supply)

[kVA]

SF(Simultaneous Factor)

Kind of

operation

Environment conditi

ons

Emergency

Switch

Th

erm

isto

r

OM MESP

OP[kW]

PSB

[kW]

POP

[kW]

PSB

[kW]

P[kW]

Location Level Axis RemarksPID

Drawing-No.

0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00

1 03 ES 020 M01 Drum prewasher 03S020 0,00 400 0.0 VFC 0003-0211

2 03 ES 020 M02 Drum prewasher 03S020 0,00 400 0.0 VFC 0003-0211

3 03 ES 030 M01 Drum type rock catcher 03S030 0,00 400 0.0 VFC 0003-0211

4 03 ES 030 M02 Drum type rock catcher 03S030 0,00 400 0.0 VFC 0003-0211

5 03 ES 040 M01 Belt type weed catcher 03S040 0,00 400 0.0 DOL MCU 0003-0211

3. Electrical consumer list 3. Electrical consumer list

OM=Operation Mode: DOL=Direct On Line SD=Star-Delta RL=Right/Left SO=Soft-Starter VFC=Variable Frequency Converter TS=Two Speeds SC=Static Converter REC=Rectifier loop control for DC Drive MES=Motor Electrical System MCU=Motor Control Unit OP=Operation SB=Stand by

0,00

TAG-No. delivered by

LVDB 1 LVDB 2 Building Location

For example only! For example only!

printed:25.11.2010 / 23



Code-letter 1st.letter Addition of a letter Following letters C&I assortment of electric equipment (DIN 40719)

A Fault reportB Signal converterC ControlD Density DifferenceE Electrical dimension Sensor function Power supplyF Flow RateG Position, amplitude Frequency converterH Hand High(upper limit)I IndicatorJ ScanningK Time/Sequence DisposableL Level Low(lower limit)M Humidity Disposable MotorNO Local measurement/indicatingP PressureQ Quality, analysis Integral, totalR Radiation rate RegistrationS Rotational speed, frequency Switching, sequence controlT Temperature Transducer, transmitterU Compound dimension Analog/digital transducerV Viscosity Positioner, actuatorW ScaleX VariousY Function Valve, (and) addition M (YM)Z Protection, emergency switch

4. Control & Instrumentation Identification

printed:25.11.2010 / 23



printed:25.11.2010 / 23



Leg

end

Unit Function Tag MSR Loop Tag CommentField

Electrical EquipmentSupplier Action of valve Type

ConnectionType

Control modeMotor electrical

system

Equipment location Number

Type MediumOperatingVoltage

Range Unit

01 W I 010 U01 W-01.010.01 Weighing scale for goods waggon

Electronic platform scale for train

QI 01A010 230 V 0...xxx t

N9 01 H S 040 B01 Signal unit for unloading or not

Pilot light (green or red light) 01T040 24 V on/off

9 01 L S 040 B01 L-01.040.01 Level Hopper for unloading train Line 1

Level switch / vibration principle

LS 01T040 24 V on/off




9 01 X A 040 B01 interval time for start warning

Signal-horn XS 01T040 24 V on/off

01 E S 050 M01 E-01.050.01 Discharge screw conveyor

Motor DOL MCU 01C050 - -

N1 01 S S 050 B01 S-01.050.01 Speed switch scraper chain conveyor

Inductive proximity switch (speed control)

AMF IFM IG500A 01C050 24 V on/off rpm






N9 01 H S 060 B01 Signal unit for unloading or not

Pilot light (green or red light) 01T060 24 V on/off







N9 01 X A 060 B01 interval time for start warning

Signal-horn XS 01T040 24 V on/off











01 E S 080 M01 E-01.080.01 Inclined screw conveyor for raw sugar


N1 01 G Z 080 B01 G-01.080.01 Misalignment switch belt conveyor left

Limit switch AMF LS Kiepe HES 011 01C080 24 V on/off

N1 01 G Z 080 B02 G-01.080.02 Misalignment switch belt conveyor right


N1 01 G Z 080 B03 G-01.080.03 Misalignment switch belt conveyor left


N1 01 G Z 080 B04 G-01.080.04 Misalignment switch belt conveyor right


N1 01 H Z 080 B01 H-01.080.01 Rope Switch Belt Conveyor left

Emergency Limit Switch AMF LS Kiepe HEN 001 01C080 24 V on/off

N1 01 H Z 080 B02 H-01.080.02 Rope Switch Belt Conveyor right

Emergency Limit Switch AMF LS Kiepe HEN 001 01C080 24 V on/off

Spec-N°.

C&I - List Rev.xxissued: dd-mm-yyyy

"Control mode"and"MotorElectricalSystem": OM=Operation Mode DOL=Direct On Line SD=Star-Delta RL=Right/Left SO=Soft-Starter VFC=Variable Frequency Converter VS=Variable Speed SC=Static Converter SR=Slip Ring"Legend": N=New ; C=Cancelled ; 4=Change

MSR-Nr. Process Medium Working Range

6. Instrumentation List (C&I)

For example only!

printed:25.11.2010 / 23



Client:xxxProject: xxx

Project-No.: xxx

Signal Process StationElectrical System

Adressing (1) Adressing (2) Adressing (3)Field EQP/

Pipe NumberPipe DN

ConnectionDN

PNFittinglength

Pressure( bar )

Temperatur( °C )

Density( Kg/m³ )

Flow( m³/h )

Flow( t/h )

Remarks Status PID Nummer

4-20mA RIO AI CH... 01A010 Hold 0001-0211

0/1 RIO DI / DO CH... CH... Manual operation 0001-0211

0/1 RIO DI CH... 01T040 1" 0001-0211

0/1 RIO DI CH... 01T040 1" 0001-0211

0/1 RIO DO CH... 0001-0211

MCU 01ES050M01 - - - - - - - - - See motor list 0001-0211

0/1 RIO DI CH... 01C050 10-55 VDC; max. 250 mA

0001-0211



0001-0211

0/1 RIO DI / DO CH... CH... Manual operation 0001-0211

0/1 RIO DI CH... 01T060 1" 0001-0211

0/1 RIO DI CH... 01T060 1" 0001-0211

0/1 RIO DO CH... 0001-0211



0001-0211



0001-0211


0/1 RIO DI CH... 01C080 0001-0211

0/1 RIO DI CH... 01C080 0001-0211

0/1 RIO DI CH... 01C080 0001-0211

0/1 RIO DI CH... 01C080 0001-0211

0/1 RIO DI CH... 01C080 0001-0211

0/1 RIO DI CH... 01C080 0001-0211

6. Instrumentation List (C&I)

Automatic System / Process control system Process Process data

printed:25.11.2010 / 23



GeneralThe complete contract work for the three phase standard motors is based on an accepted quality assurancesystem which meets the requirements according to the respective norms and regulations, especially the following:IEC = International Electrical CommissionEN = European Norm

IEC/EN 60034-xxIEC/EN 60038IEC/EN 60072IEC/EN 60085DIN/ISO 10816

Technical specifications for standard motors IPRO - ProposalMotors are to be delivered according to the specification as follows (particular deviations will be separately emphasized):

Motor type:Induction Motors, 3 pase squirrel cageCooling: a. IC 411, totally-enclosed fan-cooled: Cooling air is blown over the totally enclosed motor surface by a fan mounted on the shaft. For this self-cooling the minimal speed (>40% of nominal motor speed) of the converter should be defined to guarantee the cooling. b. IC 416, external surface cooling:Cooling air is blown over the totally enclosed motor surface by a separately excited fan motor. If the desirable speed of the motor will be less than 40%, external cooling will be needed.

IC 411

Mounting type:a. B3, foot mounting b. B5, flange mounting

B3

Terminal box: Completely delivered with cable entry threads, rotable 180°Nominal voltage: appropriated for star delta start according to:

400/690 VAC ± 5%IEC 60034-1IEC 60085

Nominal frequency, according to IEC 60034-1: 50 Hz ± 2%Mode of operation, Duty-type to EN60034/VDE 0530:- S1 Steady state- Other duty-types if required.

S1

Cast-iron construction, standard metric frame, Enclosure: IP 65Insulation class / utilization: F / BPainting for wet areas; color: RAL....Operation with Frequency converters IPRO - ProposalThe motors have to be suitable for operation with a frequency converter at a nominal voltage of:

3ph 400 V

Heating IPRO - ProposalThe stator terminals can be used with 4-10% of the motor rated voltage as an anti-condensation heater.Classification coefficient of efficiency IPRO - Proposala. EFF1: (High efficiency motor), motor with high coefficient of efficiencyb. EFF2: (Improved efficiency), motor with improved coefficient of efficiencyc. EFF3: (Convential motors)

EFF2

7. Specification for electrical motors

printed:25.11.2010 / 23




Starting procedure IPRO - ProposalMotors are standard operating as direct starter (DOL - direct on line), up to:

30 kW

Motors are starting in Star-Delta (depending on the kind of mechanical drive) with a rated power output above:

30 kW

The definitive starting mode has to be determined in coordination with the supplier of the mechanical drives. Preferred methods are soft starter or frequency converter.Thermistor motor protection IPRO - ProposalThermistors for winding temperature have to be installed ready for connection in the motor terminal box:a. For controlling the winding temperature, the three phase-motors are to be supplied with PTC thermistors (PT100).b. Alternatively the motors vare to be equipped with:- PTC binary (3 thermistors) for warning- PTC binary (3 thermistors) for shut-offThe difference in temperature between warning and shut off has to be 15 K.

PTC binary (3 thermistors) for warningPTC binary (3 thermistors) for shut-off

Bearing current protection IPRO - ProposalMeasures against bearing current, caused by AC induction on the motor shaft could be the following:- sinusoidal filter- du/dt filter- moderate puls frequency- isolated bearing or isolated bearing seatCounter measures should be conducted at motor sizes above:

Needed for type/size 315 and above and converter feeded

Bearing temperature control IPRO - ProposalTo observe the bearing temperature, three phase-motors are to be supplied with PT100 to capture and to monitor the bearing temperature:

Should to be used for motors of 200kW and above

Vibration control IPRO - ProposalTo prevent for hazards coused by vibrations motor are to be supplied with a vibration control.

Required for centrifugals, vacuum pumps

printed:25.11.2010 / 23




Overview to explosion proof motors IPRO - ProposalEx- Zone operation has to be defined during detail engineering under consideration to the following standards:IEC 60079-0, IEC 60079-1, IEC 60079-7, IEC 60079-15, IEC 61241

Gas:Category: 1G: Zone 0:Not common

Not used

Category: 2G: Zone 1:Type of protection:EX de IIC; Temperature class T1-T4;Grade of protection: minimum IP55

Operation: mains-operated, converter-operated

Category: 2G: Zone 1:Type of protection:EX e II; Temperature class T1-T3;Grade of protection: minimum IP55

Operation: mains-operated

Category: 3G: Zone 2:Type of protection:EX nA II; Temperature class T1-T3;Grade of protection: minimum IP55


Dust:Category: 1D: Zone 20:Not common

Not used

Category: 2D: Zone 21:Conductive and nonconductive dust;Max. frame temperature 125°C; Grade of protection: minimum IP65


Category: 3D: Zone 22:Non conductive dust;Max. frame temperature 125°C; Grade of protection: minimum IP55


Brands IPRO - ProposalStipulated motor brand name (depending on local possibilities):

Siemens, ABB

Requirements for the supplier:- Service has to be customized, world wide, according to international standards. - Specific solutions according to the clients requirements- Experience for extrem environmental conditions (explosion zones, flammable atmosphere, high humidity)

printed:25.11.2010 / 23



General requirementsLine voltage:a. 3ph. 380…480V ACb. 3ph. 660…690V ACc. Medium voltage

3ph. 380…480V AC, others depending on motor list and power consumption

Line frequency: 47…63Hz, possible frequency slew rate > 2% fLN /sec according to EN61800-3

Output voltage: 0 … Line voltageOutput frequency: 0…100HzRated putput power according to motor list: See motor listOverload capacity: 10% minimumGrid configuration / earthing system:a. TN-Cb. TN-S

TN-S

Degree of protection:a. IP20 at conditioned indoor installationb. IP54c. IP 65

IP 54

Motor type:Induction Motors, 3 pase squirrel cageAmbient temperature:-10°C …40°CGeneral:PC tool for engineering, tool for start-up and tool for communication with the PLC-controlled drives, local support for distribution and serviceTechnological functionsContro technique:a. V/f open control loopb. Vector control

V/f open loop control, others depending on permormance and start up torque

Dynamic functions:a. Flying restartb. Automatic restartc. Kinetic bufferingd. Compound brakinge. DC brakingf. Dynamic (regenerative) braking

Flying restart especially for long slow-down time, dynamic (regenerative) braking is essential for centrifugal drives

Safety functions:a. Safe torque offb. Safe operating stopc. Safe brake controld. Safe stop 1 (category 1, EN 954-1)e. Safe stop 2 (category 2, EN 954-1)f. Safe speed limitation

Safe operating stop, safe stop 1 and 2 (category 1 and 2), safe torque off, safe speed limtation

Protection:Undervoltage, supply and DC Link overvoltage, phase loss, drive overload, Instantaneous overcurrent, over temperature, short circuit, ground fault, thermal motor protection, watchdogBypass circuit:As an optionInterface: Digital, analog, serial (RS232/RS485), Profibus DPMinimal input/output configuration:Digital input: On, interlockDigital output: Failure 2x, readyAnalog input: SetpointAnalog output: free configurable for actual values (current, speed, …)Front end converter:a. 6 pulse diode or thyristor bridgeb. 12 pulse diode or thyristor bridgec. Active front end IGBT converter

The system has to meet the following criteria: - The EMC requirements: THD, Harmonics, … (see electromagnetic compatibility)- The dynamic functions: Dynamic (regenerative) braking (see dynamic functions) if required according to process

Filtering:a. Mains reactorb. Output reactorc. dv/dt-filterd. Sine wave filtere. Radio interference suppression filter class A

Preferred mains reactor and dv/dt-filter, suppression filter class A

8. Specification for Frequency converters

printed:25.11.2010 / 23



8. Specification for Frequency converters

Electromagnetic compatibility (EMC)Compliance with:

EN 61000-2-2 Environment - Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems: Environmental Class 2 -> THD-u = 8%, ...

EN 61000-2-4:Environment - Compatibility levels in industrial plants for low-frequency conducted disturbances:Environmental Class 2 -> THD-u = 8%, ...

EN 61000-6-2: Generic standards - Imunity for industrial environments

EN 61000-6-2: Generic standards - Emission standard for industrial environment

EN 61800-3: Adjustable speed electrical power drive systems - EMC requirements and specific test methods

BrandStipulated brand names depending on local possibilities Siemens, ABB, Reliance, Klöckner or equal

printed:25.11.2010 / 23



First Phase Black [BK]Second Phase Black [BK]Third Phase Black [BK]

Neutral Light-blue [BL]Protection Earth PE Green-Yellow [GN/YE]

Main circuit Phase L01 / 230V AC Black [BK]Main circuit Phase L02 / 0V AC Neutral Light-blue [BL]

Switch circuit L01 230V AC RedSwitch circuit L02 230V AC Red

Control Voltage 24V DC for Instruments and DIO Line Orange [OR]

Control Voltage 0V DC for Instruments and DIO Purple [VIO]

External voltage OrangeDigital In-/Output-signals to the PLC BrownAnalog In-/Output-signals to the PLC Purple

9. Color code of wiring in electro distribution boards

printed:25.11.2010 / 23



Type Cores Features ApplicationNYM-J - 1x1,5 to 1x16

- 3x1,5 to 3x10- 4x1,5 to 4x35- 5x1,5 to 5x25

- Solid,- Coloured single core,- Without shield,- Three cores and more with PE

Lighting,General power installationindoors (outdoors only with protection against sun light)

NYY-J - Multi core cable - 3x1,5 to 3x240- 3x35/16 to 3x300/150- 4x1,5 to 4x240- 5x1,5 to 5x35- 7x1,5 to 61x2,5

- Colour coded cores according DIN VDE 0293-308.- Different type of conductors as follows:Multi wired cables: 1,5mm² to 16mm² solid round conductor, 25mm² round conductors, multiple wired, 35mm² to 240mm² stranded, sectional core conductor

Motorcabel, power cable, general purpose

NYY-0 Single core cables andmulti core cables withoutPE core

- Single core- 1x4 to 1x16 round conductor single wire - 1x25 to 1x630 round conductor, multiple wire

Earthing potential, equalization, in- and outdoor applications

NYCWY - Single core- 2x10/10 to 2x16/16- 3x6/6 to 3x240/120- 4x10/10 to 4x240/120

- Solid for cores until 10mm², - Single round wire, colored, up to 25mm²- Sector formed wire from 35 up to 240mm²- WScreened, resistant for inand outdoor applications.

Motorcabel when shielded (cable required e.g. for VFC), power cable, general purpose

NYCY - single core- 1x10 RE/10 to 1x25 RM/25- 2x1,5 RE/1,5 to 2x6 RE/6- 3x1,5 RE/1,5 to 3x6 RE/6- 4x1,5 RE/1,5 to 4x6 RE/6- 5x1,5 RE/1,5 to5x6 RE/6- 7x1,5 RE/2,5 to 7x6 RE/6- 8x1,5 RE/2,5 to 8x2,5 RE/4- 10x1,5 RE/2,5 to 10x2,5 RE/4

- Solid for cores until 10mm²- Single cores, coloured, if more than colour black and numbered- Cables are shielded- Resistant against normal acid chemicals applicable for in- and outdoor

Motorcabel, power cable, general purpose

- 12x1,5 RE/2,5 to 12x6 RE/6- 14x1,5 RE/2,5 to 14x2,5 RE/6- 16x1,5 RE/4 to 16x2,5 RE/6- 19x1,5 RE/4 to 19x2,5 RE/6- 21x1,5 RE/6 to 21x2,5 RE/10- 24x1,5 RE/6 to 24x2,5 RE/10- 30x1,5 RE/6 to 30x2,5 RE/10- 40x1,5 RE/10 to 40x2,5 RE/10- 52x1,5 RE/10 to 52x2,5 RE/10- 61x1,5 RE/10

H07RN-F - Single core cable- 2x1,5 to 2x4- 3x1 to 3x16- 5x1,5 to 5x35- 7x1,5 to 24x2,5

- Flexible wired cores without shield, - Resistant against normal acid chemicals- Applicable for in- and outdoor

Motor cabel from the safety switch to the motor

Ölflex -110 - Twisted cores- 2x1,5 to 100x1,5- 2x2,5 to 100x2,5- 2x4 to 12x4- 3x6 to 7x6 - 3x10 to 7x10- 3x16 to 7x16- 3x25 to 7x25- 3x35 to 5x35- 3x50 to 4x50- 3x70 to 4x70- 3x95 to 4x95- 4x120

- Flexible cores,- Twisted and numbered without shield- Mostly resistant against oil andchemicals- Three wires and more: with PE

Oil resistant, applicable for indoors

(N)HXH E 90 - Twisted- 3x1,5RE to 12x2,5 RE

- Halogen-free and flame retardend,- Power cable, safety operation E90- Safety isolation, FE 180 according to DIN VDE 0472

Installation for Fire protection equipment

JE-H(ST)H...BDE 90 orange

- Twisted- 2x2x0,8 to 52x2x0,8

- Halogen-free and flame retardend- Twisted pairs, numbered, shielded, without PE

Installation for Fire protection equipment, control cable, indoors (outdoors only with protection against sun light)

YSLY-JZ/-OZ - Twisted- 2x0,5 to 100x0,5- Other core cables identicalto Ölflex-110

- Flexible, - Twisted and numbered, without shield- with PE (OZ without PE)

Control cable, indoors (outdoors only with protection against sun light)

10. Standard Cabels (IEC-Standards)

printed:25.11.2010 / 23



Type Cores Features Application


CON-V1-02 - Control Cable- 2x1 to 50x1mm²- Available until 2,5mm²

- PVC insulated- Overall shielded - Tinned copper drain core for PE

Control cable, white cores, nummerical identification, especially South Africaapplicable

CON-V2-02 - Control Cable- 2x1 to 50x1mm²- Available until 2,5mm²

- PVC insulated- Steel wire amouring- Tinned copper drain core for PE

Control cable, white cores, numerical identification, especially South Africaapplicable

H05VV5-F - Twisted- 2x0,5 to 61x0,5- 2x0,75 to 27x0,75

- Flexible- twisted and numbered- without shield

Control cable

LiYCY(JZ) - Twisted- 1x0,14 to 100x0,14- 1x0,25 to 100x0,25- 1x0,34 to 100x0,34- 1x0,5 to 100x0,5- 1x0,75 to 100x0,75- 1x1,0 to 100x1,0- 1x1,5 to 100x1,5- 1x2,5 to 12x2,5- 2x4,0 to 7x4,0- 2x6,0 to 7x6,0- 2x10 to 7x10

- Flexible- Twisted wires up to 0,75mm² coloured,- More than 1,0mm² numbered- With PE (non-fused earth conductor)

Control cable, indoor applications

LiYCY-0 Twisted pairs - Flexible, - Twisted pairs,- Shielded and headlabeled wires regarding DIN 47100.- Without PE core


LSYCY - Twisted- 2x0,75 to 30x0,75

- Flexible- Twisted cores, colored, shielded- Without PE core


NLSCY-JZ - Twisted- 2x0,75 to 30x0,75

- Flexible,- Twisted wires, numbered, shielded- With PE core


LSPYCY - Twisted- 2x2x0,14 to 20x2x0,14- 2x2x0,25 to 16x2x0,25- 2x2x0,5 to 16x2x0,5- 2x2x0,75 to 16x2x0,75- 2x2x1 to 12x2x1

- Flexible- Twisted pairs, colored- Without PE core

Indoors (outdoors only with protection against sun light)

H05VVG4V5-k andNYLLCYÖ-J

twisted2x0,5 to 50x0,52x0,75 to 61x0,75

- Flexible- Twisted wires, numbered- With PE core

Indoors (outdoors only with protection against sun light)

Ölflex-440 P - Twisted- 2x0,5 to 41x0,5- 2x0,75 to 41x0,75- 2x1,0 to 41x1,0- 2x1,5 to 41x1,5- 3x2,5 to 12x2,5- 7x4,0- 7x6,0

- Flexible- Twisted wires, numbered- Without shield- Oil-und chemical resistant- With PE

Control cable for in- and outdoorapplication

Li2YCY (TP) - twisted- 2x2x0,22 to 10x2x022- 2x2x0,34 to 10x2x0,34- 2x2x0,5 to 10x2x0,5

- Flexible- Twisted pairs, colored, shielded- Without PE

Control cable

Li2YCYv (TP) - Twisted pairs- 2x2x0,22 to 10x2x022- 2x2x0,34 to 10x2x0,34- 2x2x0,5 to 10x2x0,5

- Flexible- Twisted pairs, coloured, shielded- Without PE


JE-LiYCY...Bd Si

- 2x2x0,5 to 40x2x0,5 - Flexible- Twisted pairs, coloured, shielded- Without PE


Profibus-DP02Y(ST)CY 2x0,64

- twisted- two wire line 1x2x0,64

- Solid- Twisted, colored, shielded- Without PE

Control cable for bus installation, indoor applications

Ölflex-EB CY - twisted- 2x0,75 to 25x0,75- 2x1,0 to 25x1,0- 2x1,5 to 25x1,5

- Flexible- Twisted wires, numbered, shielded- Without PE

For intrinsically safe circuits, indoor applications, cable colour blue only for intrinsically use

printed:25.11.2010 / 23



Type Cores Features Application


Ölmass-EB CY - Single- 3x1,5 to 7x1,5

- solid- single cores- up to 5 wires: coloured, from 7 to … wires numbered- shielded- without PE

For intrinsically safe circuits, indoor applications, cable colour blue only for intrinsically use

UNITRONIC-BUSAS-i

- Flat wired cable, yellow - 2x1,5mm²

- Flexible- Outer jacket oil resistant

Data communication and energy feeding

Profibus-PATyp: 02Y CY

- Twisted- 1x2x1,0/ 2,55-100

- Flexible- Shielded and twisted pair

Bus cable for field bus installation in the process area according to IEC 61158-2

ProfibusDP02YY (ST) CY

- Twisted- (1x2x0,64); Unitronic Bus DP

- Total shielded- Shielded and twisted pair cable

Bus cable for indoor application

LWL A-DQ(ZN)2YOptical waveguide

Four Fiber glass cores For industrial areas, in- and outdoor applicable

EthernetJ-02YSCY

2x2x0,64/1,5 PIMFF - ITP-Standard cabel (Industrial Twisted Pair)- Four wires twisted; each wire separate shielded - Cable over all shielded

Field bus installation in the process area

Pneumatic tubeTyp: PA 12 W

Diameter 6, 8, 10, 12 mm; - Black coloured- Ultra-violet resistant

Pneumatics

printed:25.11.2010 / 23



11. Hazardous areas and equipment categories

Hazardous area classification is used to identify places where, because of the potential for an explosive atmosphere, special precautions over sources of ignition are needed to prevent fires and explosions. Hazardous places are classified in terms of zones on the basis of the frequency and duration of the occurrence of an explosive atmosphere. In details the places will be defined after HAZOP study for the whole technology, folowing the description below.

For gases, vapours and mists the zone classifications are:Zone 0 A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances in the form of gas, vapour or mist is likely to occur in normal for more than 1000hrs per year.Zone 1 A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances in the form of gas, vapour or mist is likely to occur in normal operation between 10-1000hrs per year.Zone 2 A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances in the form of gas, vapour or mist is not likely to occur in normal operation but, if it does occur, will persist for less than 10hrs per year.

For dusts the zone classifications are:Zone 20 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is present continuously, or for for more than 1000hrs per year.Zone 21 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur in normal operation between 10-1000hrs per year.Zone 22 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but, if it does occur, will persist for less than 10hrs per year.Electrical Equipment for Hazardous AreasHazardous Area Zone 0Ex ia - Intrinsically SafeEx s - Special protection, must be certified for use in Zone 0Hazardous Area Zone 1Any equipment suitable for Zone 0EX d - Fame ProofEx p - Pressurised or PurgingEx q - Powder filledEx o - Oil Filled/immersionEx e - Increased SafetyEx ib - Intrinsically SafeEx m - EncapsulationHazardous Area Zone 2Any equipment suitable for Zone 0 or Zone 1Ex n - Certified that the equipment is not capable under normal operation of igniting a surrounding explosive atmosphere.Temperature ClassificationT1 - Surface temperature must not exceed 450°CT2 - Surface temperature must not exceed 300°CT3 - Surface temperature must not exceed 200°CT4 - Surface temperature must not exceed 135°CT5 - Surface temperature must not exceed 100°CT6 - Surface temperature must not exceed 85°C

printed:25.11.2010 / 23

E_C& I Standards GSR_rev03

Documents

Transcript of E_C& I Standards GSR_rev03