Electrical Design
description
Transcript of Electrical Design
PTT PUBLIC COMPANY LlMiTED
BVW#7 COMPRESSOR STATION PROJECT
ELECTRICAL DESIGN MANUAL
TOTAL: 20 PAGES
DORSCH W CONSULT lngenieurgesellschaft mbH
M. Lebenyi
M. Lebenyi
M. Lebenvi APPROVED
0204 07 AREA CODE 4700
W. Horn
W. Horn
W.Horn CHECKED
PTT CONTRACT No PTTIGAS131113145
PTS PROJECT No Rev C
N. Hengen
0. Lorey
H. Fiedler PREPARED
PO-o20?0 C S 13\'\\#7
1-4-0104 0 7-4700-002
Final
For Approval
Issued for Comment REVISION
C B A
REV. NO.
24-Jan-2003
06-Jan-2003
16-Dec-2002 DATE
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Contents
SCOPE 3
REGULATIONS, CODES AND STANDARDS 3
GENERAL 4
SERVICE AND ENVIRONMENTAL CONDITIONS 4
AREA CLASSIFICA'TION AND EQUIPMENT' APPLICATION 5
ELECTRICAL SYSTEM 6
POWER SUPPLY 7
POWER DISTRIBUTION TRANSFORMER- 8
MOTOR CONTROL 8
MOTORS 9
WIRES AND CABLES, 9
INSTALLATION OF CABLES 11
LIGHTING 13
GROUNDING 15
ALARMS 17
FIRE FIGHTING SYSTEM 19
RECEPTACLES AND MOUNTING HEIGHTS 19
CONTRACTORS" DOCUMEN'TATION - 20
APPENDIX 20
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1 SCOPE
'This specification covers the general requirements, design, supply, installation and commissioning of complete electrical facilities of the compressor station BVW#7
For specific requirements not described in this specification, reference should be made to the Regulations, Codes and Specifications listed in section 2 of this specification and all construction drawings,,
The electrical system will include the following items: Electrical power distribution
Lighting systems
Grounding systems
D C System for Cathodic Protection and switchgear TripIClose actuation
2 REGULATIONS, CODES AND STANDARDS
The electrical materials and instruments shall conform to the latest edition of following regulations, standards and codes:
Recommendation for rotating electrical
machinery, motors and generators IEC 43 1
Recommended practice for electrical installations at the gas compressor station
Recommended practice for classification of location for electrical installation at gas facilities ANSllNEC C1
Safety rules for installation and maintenance of
electric supply and communication lines NEClANSIC2.2
Standard for cross linked polyethylene
insulated wire and cables IPCEAS-66524
Lighting intensities IEC
Lighting protection IEC
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0 National electric code I EC
Switchgear IEEE C37
Transformer IEC
Institute of electrical & electronic engineers IEEE
Electrical equipment and materials shall comply preferably with relevant international standards Electrical equipment and materials may comply with other national standards provided they are approved by recognised national certifying authorities of the country of origin and approved by the Company.
3 GENERAL
The scope of work of the supplier of the equipment includes the following as a minimum:
Design, engineering of the system and project management
0 Manufacturing
Factory acceptance test
Shipping
Supervision during installation of the system . Start-up, pre-commissioning and commissioning
Supply of commission spare parts
Documentation
4 SERVICE AND ENVIRONMENTAL CONDITIONS
Location
All equipment shall be suitable for operation in a hot, dusty and humid environment, subject to monsoonal rains
For basic design date refer to Specification E4 0204 07-4700-002 Rev 0
Design temperature for electrical equipment 52 "C
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Physical protection
Electrical equipment will be installed indoors or outdoors, above or below ground, with or without additional protection as further detailed in relevant specifications for various types of equipment,,
5 AREA CLASSIFICATION AND EQUIPMENT APPLICATION
Area classification shall be developed for installation based upon the requirements of "Recommended Practice for Classification of Locations for Electrical Equipment at gas compressors facilities", 199 xs or later edition Drawings shall be prepared indicating the classification and extent of each area and shall include reference to major structures and equipment contained therein All equipment which is considered a source of flammable liquid, gas or vapour shall be shown on the drawings Source shall be identified by equipment number, flammable materials handled, and
i atmosphere group as per NEC
All equipment installed in hazardous areas shall be certified for use in the appropriate area classification and shall bear permanent indication from either BASEEFA, CENELEC or an approved testing laboratory in the country of manufacture. In general the equipment shall be protected by one of the following methods:
- Ex i Intrinsically Safe - Exd Explosion Proof - Ex p Pressurized / purged Enclosure .. Ex m Encapsulation - Exe Increased safety
Equipment meeting these standards may be installed in classified areas as indicated in the following table:
Equipment protection methods
Standard industrial equipment having enclosures suitable for indoor or outdoor locations as appropriate may be applied in unclassified (safe) areas
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Ex e Area classif. Ex i Ex m Ex d Ex p
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Whenever feasible electrical equipment should be installed in safe areas
Equipment for installation in classified areas shall be suitably certified by one of the following authorities:
American Equipment U L (Underwriter Laboratories) German Equipment PTB ( Physikalische Technische Bundesanstalt ) British Equipment BASEEFA (British Approvals Service for
Electrical Equipment in Flammable Atmospheres)
French Equipment Le Ministre Du Developement Industriel et Scientifique
Equipment of other Countries Such equipment may be accepted provided it has been tested and certified by any one above listed authorities
6 ELECTRICAL SYSTEM
Single line diagrams shall cover all power and excitation circuits including metering and protective relaying One line diagrams shall be a separate set of drawings and may not be based on other types of drawings
The one line diagrams shall include:
Major Equipment Ratings
Generators V, kW, PF, Xd, Xd"
Power Transformers
Circuit breakers
Bus
kVA (ONANIONAF), V, Hz Phase, tap range, impedance BIL, (if arrestors), vector group, Connections, grounding
Continuous A, interrupting MVA or kA, momentary kA ( if different )
Continuous A, momentary kA, (Spec symmetrical or asymmetrical)
Arrestors kV opening
Neutral grounding devices A (limit)
Current and Potential Transformers Ratios, connectors
(
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Cable supplying power transformers Size and substation buses
Protective Relays Device number and number of Elements
Loads Size, service, number
The principal voltage levels shall be as follows:
Power Utilization
22 kV, 3 phase, 50 Hz, 3 wire Solidly Grounded Neutral 380 V, 3 phase, 50 Hz, 3 wire Solidly Grounded Neutral 220 V, 3 phase, 50 Hz, 4 wire Solidly Grounded Neutral 110 VDC 48 VDC, Ungrounded 24 VDC, Ungrounded
The electrical system shall be capable of handling the maximum expected plant loads continuously These expected plant loads shall be detailed in load summary schedules During starting of a motor, the voltage at its terminal shall not fall below
i 80% of motor rated voltage
Power cables shall be sized as per NEC requirements limiting the maximum voltage drop in the cable to 17% on motor starting, or 3% when running, whichever requires the larger cross section
7 POWER SUPPLY
i Electrical power for the facilities to be constructed may be derived from the existing 22 kV open air line via an additional transformer The dimension of this transformer rating shall be approx 80 % of the summary compressor station The whole equipment for connection to the existing 22 kV line shall be provided
Facilities unable to meet the requirements of Section 6 shall be provided with a new primary sub-station, power transformer and distribution switchgear The electrical sub-station shall be located in an area of the control building as close as possible to the plant area with which it is associated and shall comprise of the following :
Dead End Structure, Line Fuses and Protection
22 kVl380 V Distribution 'Transformer
380 V Distribution SwitchboardIMCC
220 V Lighting & Small Power Distribution Board
110 V Uninterruptible Power Supply
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All equipment should be suitable for continuous operation in a tropical environment, housed in a prefabricated, skid mounted, fully isolated, sheet metal enclosure (except transformers) complete with all necessary standard and emergency lighting, power outlets, air-conditioning and fire detectionlprotection equipment The enclosure will be designed to prevent the ingress of sand and insects and to provide a clean cool working environment
8 POWER DISTRIBUTION TRANSFORMER
Distribution transformers shall comply with Specification N o E3-020407-4700-112
Distribution transformers will be of indoor type for installation on concrete foundations (rolling tracks) in a suitable transformer room and inherent suitable personal protection
A separate oil pit shall be provided for each transformer Oil pits shall be filled with gravel and shall be of sufficient size to retain the quantity of oil in its associated transformer
Bus ducts shall not be used for secondary connection of transformers to motor control centres Such connections shall be by cables or in concrete trenches and entering the switchboard from below
Transformer sizing shall normally be 120% of the total motor operating load plus the lighting and electric heating loads, and shall also permit starting of largest motor with remaining normal connected load operating without secondary bus voltage drop exceeding 15% of normal
Transformers shall be provided with taps at: +I- 2,5% and +/- 5,0%
9 MOTOR CONTROL
Switchboard I MCC shall be of the metal enclosed cubicle with multi-tier starter units for 380 V motors and shall be housed as indicated in the relevant section of this specification,,
Switchboard I MCC shall comply with specification No E3-0204 07-4700-1 18-Rev 0
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COMPANY LIMITED 1 Electrical Design Manual
10 MOTORS
Motors shall comply with specification No. E3-020407-4700-119-Rev0
Motor windings shall be designed for the following voltages:
0,5 kW to 200 kW 380 V / 3 Phase ,50 Hz below 0,5 kW may be single phase motor
All motors shall have "lock-off' type emergency stop buttons located adjacent to the motor
11 WIRES AND CABLES
All power, control, lighting and instrument cables shall be manufactured in accordance with specification No -E3-0204 07-4700-120 and shall comply with the latest issue of the applicable IEEE or IEC specifications with respect to ratings and isolation All building or control wire must be constructed with 98% conductivity
( copper
Aluminium conductors shall only be used for overhead power installations Acceptable classes of conductor isolation are as follows: Moisture resistant thermoplastic for wiring 600 Volts and below, Moisture resistant cross linked polyethylene for wiring 600 Volts and below, and PVC jacketed cross linked polyethylene for wiring above 600 Volts
Mineral isolation, 600 Volt rated, if copper sheathed and PVC jacketed Minimum acceptable isolation thickness between conductors and between conductors on sheath shall be 1,5 mm (0 06 in)
Isolation shall be fully resistant against petroleum products, weak acids and all alkalis, intense sunlight, moisture and abrasion from wind driven sand Isolation shall be rated for handling at -5 "C and for operation at +90 "C or better
Cable armour shall be either galvanised steel or corrosion resistant aluminium containing less than 0,4 % copper Armoured cable installed outdoor or underground shall have an outer thermosetting or thermoplastic jacket
Cable jackets shall be colour coded, with tracers as necessary, for ease of identification Colour code shall be as follows :
Power, Lighting and Miscellaneous Cables black or grey Fire and Gas - Explosion Proof red Fire and Gas - Intrinsically Safe red / blue trace Gas Detection light blue / brown
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Flame Detection Heat Detection Smoke Detection C02 Dump System Controls Deluge Release Control Manual Fire Alarms Fire Pump Controls
light blue 1 orange light blue I green light blue 1 yellow red 1 orange red 1 brown red I yellow red 1 white
Use of coloured bands adjacent to the cable numbering, may be used as an alternative to coded jacketing
Wire and cable passing close to high temperature equipment and piping shall use isolation and jacket materials suitable for higher ambient temperatures expected
The maximum permissible voltage drop in cables for normal operation shall be as follows :
Feeders to area sub-station 1 % Motor branch circuits 3 % (continuous)
17 % (starting inrush) Lighting branch circuits 2 % (from panel to furthest outlet)
(
Single Core Power cables shall have nonmagnetic armouring, which shall be bonded to the grounding system and shall be installed in trefoil formation with clamps suitably rated to withstand the applicable short circuit bursting force
All cables shall be rated adequately, with suitable derating factors applied for :
Ambient air temperature
Grouping arrangement of cables on a tray or cable rack
Buried directly in the ground or ducts
Cable sizes for control and signal cables shall be as follows
- Control cables 14 AWG ( 2,5 mm2 ) - Signal cables 1 6 ~ ~ ~ ( 1 , 5 m m ~ )
Thermal short circuit rating shall also be taken into account, consideration being given to maximum applicable fault clearance time possible
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12 INSTALLATION OF CABLES
Cables mounted above the ground
The installation of cables above the ground requires the utmost attention to neatness to improve the aesthetic qualities of the final installation, and consequently much thought should be given to cable positioning to minimise the number of crossovers.
Where cables are run above grade they shall be securely fixed to suitably supported robust perforated galvanised steel cable trays
Cable shall be grouped according to voltage, and in minor cable runs specific trays shall be used for each group
Power I Lighting control cables shall not be mounted on same cable trays or racks as temperature compensating cable or air supply lines
Cable racks and trays shall be attached to steel supporting structures of building,
i platforms or pipelines They shall not be supported from process piping
Cables shall be fixed in positions where they shall not be exposed to oil, direct sunlight or heat from other hot objects unless the cables and their accessories are specially designed to withstand the effect of exposure to oil and heat,
All cable racks and trays installed in open locations shall be fitted with sunshades to prevent overheating by direct sunlight
A minimum distance of 10" shall be maintained from all hot vessels, pipelines or other hot objects for all cable rack or tray,,
Cables shall be installed in such a manner as to minimise the effects in vibration of any equipment
Cables to individual consumers shall be installed on light duty cable tray, adequately supported between the main cable route and the consumer terminal box
Under no circumstances shall any cable be bent to a radius less than the minimum specified by the manufacturer, Straining of cables at cable glands shall not be permitted and cables shall run straight out of the gland for a minimum of 4" before beginning to bend,,
Each cable shall be individual as designated on the cable schedu!e, by means of unique identification markers Each cable shall be so identified at its point of origin and termination, at both sides of any penetration and at 30'0" intervals along its length
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Cable trays should be assembled type, hot-dipped galvanised steel construction - either robust perforated galvanised steel cable trays or ladder type
PTT PUBLIC COMPANY LIMITED
Cable tray fill shall not exceed 40 % of its cross-sectional area
Cables installed on top of horizontal tray shall be secured to it by means of nylon straps or equivalent material at intervals not exceeding 20 feet
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Electrical Design Manual
Where vertical trays penetrate the floor or ground they shall be provided with covers for at least 6 feet above the floor or ground elevation, unless waived on Contractor's I Client's drawings
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The cable tray system shall be grounded
Cable tray systems shall be electrically continuous and grounded at intervals not exceeding 75 feet
i
Cable Termination
All conductor terminations shall be by means of compression type solderless cable lugs, except control circuits and other small wiring which shall be wired to readily accessible clamp type terminal blocks
All cables shall be supported so as to ensure that no weight has to be borne by the terminations
Grounding conductors included within cables and metallic sheathing and armouring of cables shall be connected to the grounding system
Each terminal and connected wire or cable core shall be marked and identified with suitable plastic type ferrules, in accordance with relevant wiring diagrams
Terminal studs in transformer cable terminating boxes shall be wrapped with "Scotch" tape.
When the cables to motors are too large for the terminal box, they shall be terminated in a suitable junction box and a smaller cable used between the junction box and the motor as detailed in relevant cable schedules
Outdoor cable glands shall be provided with a seal to prevent the ingress of dust Glands in classified hazardous areas shall be of approved flameproof type
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Particular attention shall be paid to the phase sequencing of power cable termination since subsequent alternation is difficult and time consuming
13 LIGHTING
Scope
Two separate lighting systems shall be provided; a main system and an emergency backup system Main L~ghfing
i Supply 230 VAC, 1 Phase, 2 wire, 50 Hz ii Control - outdoors
General area flood lighting shall be controlled by a single photo-electric cell
i controlled multi-pole lighting relay The flood lighting can also be controlled manually
iii Control -. indoors
All indoor lighting shall be manually controlled with switches at convenient positions next to entrances of doors
Design
Lighting shall provide the following minimum illumination levels in service as measured on the horizontal phase :
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COMPANY LIMITED
Emergency Lighting
The emergency lighting shall be by fitting with self-contained battery units which shall automatically operate in case of mains failure and shall remain illuminated for a minimum of 60 minutes The number of fittings required shall be approx 25 % of the total fittings requirement for each of the respective areas and shall be located at manned control panels, exits, and areas which will cause personnel safety hazard on loss of main power The laws and standards of the country must be strictly adhered to
Electrical Design Manual
5 1
75 100 75 20
1.13. 1.14. 1.16. 1.16.1. 1.16.2. 1.16.3. 1.16.4.
Lighting Distribution boards
" "
Separators General Areas Unit and Central Control House ( or rooms ) Console desk area Panel front Panel interior
Generally, lighting distribution boards shall be suitable for 230 V, 3 phase, 4 wire 50 Hz operation, Branch ( outgoing ) circuits shall be of the single pole, phase protected by fuses or miniature type circuit breakers rated at 15 amps One spare branch circuit shall be provided for every five circuits used Each circuit shall be loaded only up to approx 10 Amps to leave at least 25% spare capacity
Normally, lighting distribution boards shall be installed in control rooms
Where it is necessary to locate lighting distribution boards out door they shall be installed in safe areas They shall be of the weatherproof type and be under a sun canopy
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Lighting Fixtures
Fixtures shall be of the type specified below :
General Area Lighting ( Outdoors )
On-plot high pressure sodium floodlighting must be supplemented by fluorescent lights where necessary
General Lighting ( Indoors )
Fluorescent fittings must be ceiling mounted All fittings installed outdoors shall be of a weatherproof type and suitable for use in the respective hazardous areas
Fittings shall be spaced to provide uniform illumination as far as possible
Illumination shall be provided for all non-self-illuminating gauges and instruments
Lamps that are adversely affected by transient voltage disturbances shall be kept to
( a m~nimum If used for main lighting, they shall be adequately interspersed with lamps that are not affected They shall not be used for emergency lighting Discharge type lamps in operating areas which incorporate rotating equipment shall be supplied from more than one phase to minimise stroboscopic effects
Installation
Fittings shall be so connected and located that the maintenance and the replacement of lamps can be achieved safely and conveniently by one man
A common grounding system is necessary All connections and links shall be of connector type,, The neutral of all power systems shall be solidly grounded at the transformer secondary For further details please refer to "Cabinet Grounding Diagram", J-3- 0204 07-4700-007,
Equipment Grounding
All non-current carrying metallic parts of the facility shall be directly grounded by connection to the grounding system
The main grounding system shall be bonded to the 380 Volt system
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neutral grounding electrodes
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COMPANY LIMITED
All structures, vessels, tanks, etc shall be connected to the main grounding system
The resistance of grounding system to the general mass of earth shall be as low as feasible, but shall never exceed 2 ohm at any point on the grounding system,,
- BVW#7 Compressor Station Project
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Main plant grounding system shall be least one ring system of 210 - AWG (70 mm2) minimum PVC sheathed stranded copper grounding conductor connected to the existing grounding equipment Branch connections to motors or small equipment shall be 4 - AWG (16 mm2) min green PVC sheathed stranded copper conductor,
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Ground rods shall be % " diameter copper clad steel ground rod of suitable length to achieve the desired resistance to earth
Lighting and static earthing
i Grounding and bonding for lighting and static protection shall be in accordance with the recommendations of ANSI C 51, API and NEC Main ground system may be utilized for grounding and bonding required for lighting and static grounding
Installation of grounding system
The grounding system shall be designed on the ring principle with interconnection of conductors to equipment as necessary The ring shall be connected to the main ground system via earth bars and shall be green PVC insulated stranded copper min, 210 AWG ( 70 rnm2 ), branch conductors to equipment shall be a minimum of 4-AWG ( 16 mm2),
In general, grounding conductors shall be run on main cable routes All underground cable connections to the ground ring shall be of the thermo weld type or similar, and each joint shall be taped Vessels shall be provided with lugs for ground connection Ground cables shall be bolted to lugs with solderless connectors Vessels having cathodic protection at the bottom shall not be connected to the main ground system to avoid affecting the efficiency of the cathodic protection system Electrical equipment grounding shall be by means of bolted connections Equipment holding down bolts shall not be used at the grounding points Cable armour shall not be used as the only means for the return of ground fault currents and shall nevertheless be grounded through the gland connection to the grounded equipment
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Connections between main grounding systems and electrodes shall be arranged so that easy inspection, maintenance and testing of individual electrodes will be possible Cable armour of single-core power cables shall be grounded at both ends and at any splice
15 ALARMS
Sub-station Alarms
Bus tie alarms shall be provided as follows:
For each secondary-selective substation, to give abnormal indication whenever the breaker is closed or not in the operating position
For each spot network substation, to give abnormal indication whenever the bus sectionalizing device is open or not in the operating position,,
For the two incoming circuit breakers or each spot network substation, a single alarm shall be provided, giving abnormal indication whenever either breaker is open or not in operating position Transformers rated 500 kVA and larger shall be provided with an alarm as follows:
The alarm shall be actuated by contacts in the liquid temperatule thermometer and shall give abnormal indication whenever the transformer reaches its maximum self cooled operating temperature as indicated by the thermometer
An alarm for each transformer with 2 float Buchholz relays is to be actuated by slow gas accumulation
Transformer alarms shall also be provided for differential relaying Switchgear control alarms shall be provided as follows:
Control battery charger alarms as listed below for each sub-station control battery o Loss of an AC battery charger The detecting device shall be
connected to the load side of the protective device or switch closest to the charger in the supply circuit
o Low battery charger DC output voltage o High battery charger DC output voltage o Low battery voltage
Ground fault alarm actuated by contacts in the control power system
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ground detector
One alarm relay shall be provided to monitor the trip circuit for each DC controlled circuit breaker not controlling a motor
All alarms shall conform to the following:
Plaster units and relays used in annunciator cabinets shall be of plug-in type,
Alarm systems shall be fail-safe type and utilizing normally closed alarm contacts
Annunciators may be of solid state type and of modular construction
Acknowledge and lamp test switches shall be provided for each annunciator cabinet
Motor alarms
Motor alarms shall be provided as shown below, Alarms shall be located in the control room unless specified otherwise,
L
I Alarm function I Alarm rew i red for motor I Alarm actuated by 1 having
Bearing high temperature
Winding high temperature
Winding high temperature
Winding high temperature ~ -
Air ( or Gas ) low pressure
Motor winding high temperature alarms shall be set to operate when the normal or anticipated motor load is exceeded and before the overload relay setting is reached
Bearing temperature relays or detectors
Resistance temperature detectors Winding temperature detectors (thermistor) Alarm thermal relay in motor
Motor - off
Operating sequence of "motor off' alarm shall be:
Bearing temperature relay contacts ( A single alarm can be provided to actuate if either or both relays operate ) Contacts in winding temperature indicating controller Winding temperature detector contacts
Alarm thermal relay contacts controller Pressurized motor enclosure, or pressurized commutator or slip rina enclosure
Motor running - light off and horn silent Motor shutdown - light on steady and horn silent Motor shutdown by other means - light on or flashing and horn sounding
Pressure sensing device located on high pressure side if air ( or gas ) supply line ( as close to the ~ressure reducina device as -
When specified
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- practical ) Auxiliary contact of motor contiol ( A second contact of motor stop button shall prevent operation of alarm when the motor is shut own at its control station )
BVW#7 Compressor Station Project I PTT PI I R I IC Bidding Documents
Alarm for emergency valve motor actuators
An alarm shall be provided for each remote bus supplying motor actuators for block valves used in emergency isolation or shutdown and liquid pull down or vapour blow down service The alarm shall supervise bus voltage and shall be actuated by contacts of a normally energised supervisory relay at the valve bus and shall operate on loss of voltage The alarms shall be located in the control room
16 FIRE FIGHTING SYSTEM
The fire fighting system shall come into play when the fire alarm system has been activated The fire alarm system and the fire fighting system installed by the Contractor shall work effectively and in conjunction with each other,
17 RECEPTACLES AND MOUNTING HEIGHTS
Receptacles or convenience outlets in process buildings shall be provided, enabling a 10 m extension cable to provide coverage in all areas as approved by the owner
Receptacles on convenience outlets shall be provided adjacent to all outdoor coolers
Receptacles or convenience outlets in non-processing buildings shall be provided to give adequate coverage in all areas as approved by the owner
Receptacles or convenience outlets above the counter in a kitchen area shall be split receptacles fed from a dedicated double pole lighting panel circuit
Mounting Heights
The mounting height of equipment and I or components shall be from finished floor level to the centre of the equipment and 1 or components
Light and control switches for building or room auxiliary devices shall be located on the latch side of the door
I
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I Consultancy Services for 1 1
18 CONTRACTORS' DOCUMENTATION
All CONTRACTOR correspondence, documents, certificates and drawings shall be in the English language Fur further details refer to "General Specification for Electrical, SCADA, Instrumentation and Telecommunication", Chapter 10
19 APPENDIX
"Cabinet Grounding Diagram" : J-3-0204.07-4700-007
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