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NOTICE: THIS DRAWING HAS NOT BEEN PUBLISHED. IT IS THE SOLE PROPERTY OF ENPPI.
IT IS LENT TO THE RECIPIENT FOR HIS CONFIDENTIAL USE ONLY , AND UPON THE CONDITIONS AND AGREEMENTS FOLLOWING IN CONSIDERATION OF THE LOAN OF THIS DRAWING . THE RECIPIENT
PROMISES AND AGREE TO RETURN IT UPON REQUEST AND THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT, OR OTHERWISE DISPOSED OF DIRECTLY OR INDIRECTLY WITHOUT ENPPI WRITTEN CONSENT, NOR BE USED IN ANY WAY DETRIMENTAL TO THE INTERESTS OF ENPPI.
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E-STYRENICS
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Enppi Reference: 3688
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JSD 1600
300,000 MTA EB/SM PLANT EARLY WORKS PACKAGE

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ESTYRENICS Reference: ES-PRO-02
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ENGINEERING FOR THE PETROLEUM & PROCESS INDUSTRIES (Enppi) - EGYPT

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2495 000 JSD 1600 51 B 3/40

NOTICE: THIS DRAWING HAS NOT BEEN PUBLISHED. IT IS THE SOLE PROPERTY OF ENPPI. IT IS LENT TO THE RECIPIENT FOR HIS CONFIDENTIAL USE ONLY , AND UPON THE CONDITIONS AND AGREEMENTS FOLLOWING IN CONSIDERATION OF THE LOAN OF THIS DRAWING . THE RECIPIENT

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INDEX
1. INTRODUCTION 4
2. SCOPE 4
3. CODES AND STANDARDS 4
4. REFERENCE DOCUMENTS 5
5. DESIGN DATA 6
6. POWER SYSTEM 12
7. EARTHING AND LIGTHNING SYSTEMS 27
8. LIGHTING SYSTEM 31
9. ELECTRICAL HEAT TRACING 36
10. CATHODIC PROTECTION SYSTEM 36
11. SUBSTATION ARRANGEMENT 37
12. OPERATION CRITERIA 38

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1. INTRODUCTION
This job specification cover the general requirements for the equipment, materials and
design of the electrical installation for the operation of a process plant and attendant
facilities to be followed by the EPC contractor for the detail design and procurement of
Electrical Systems of new units involved for 300,000 MTA EB/SM PLANT.
It is intended that this job specification be supplemented by a one line diagram. Any
modifications, additions and/or qualifications, for specific job requirements, will be
described in the EPC Project Job Specification for Design.
During FEED stage, the use of this specification will be limited to the contractual
framework and scope of work of Feed
In case of discrepancies between the present specification and the other project
JSS’s and JSD’s, the present specification requirements shall prevail and have to be
applied.
2. SCOPE
The present specification lays down the principal rules to be followed in the design of
electrical systems. It does not apply for jobsite temporary installations.
The electrical system includes: power system, lighting system, heat tracing system,
cathodic protection system, earthing and lightning protection.
3. CODES AND STANDARDS
Unless otherwise specified, design and engineering shall conform, as a minimum, to the
applicable requirements of the latest edition of the following coded and standards, in
order of precedence:
 International Electro technical Commission (IEC) publication.
 CENELEC Standards.
 API RP 505
The following standard shall be applied if there is not cover by IEC standards:
 NFPA 70 (National Electrical Code)
 NFPA 111 (Stored Electrical Energy Emergency and standby power Systems)
 NFPA 850 (Recommended Practice for Fire protection for Electric Generating Plant
and High Voltage Direct Current Converter Stations)
 IEC 60529 Degree of protection for enclosures
In any case, local regulations shall be observed.

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Measure system is the SI metric unit system

Electro technical vocabulary, units and symbols used in the design shall be as per
following IEC standards:
 IEC 60050 International Electrotechnical Vocabulary
 IEC 60255 Electrical Relays
 IEC 60617 Graphical symbols for Diagrams
4. REFERENCE DOCUMENTS
The present design rules are complemented by the following general supply and design
rules:
2495 -000-JSD-1600-52 General design specification for electrical system of

packaged equipment
2495-000-JSD-1600-53 General Rules for Area Classification Basis
2495-000-JSS-1621-51 General supply rules for Electrical Power and Control

Cables
2495-000-JSS-1641-51 General supply rules for transformers
2495-000-JSS-1652-51 General supply rules for Medium Voltage Switchgear
2495-000-JSS-1654-51 General supply rules for L.V. Switchgears (≤1000 VAC)

and Bus ducts
2495-000-JSS-1661-51 General supply rules for Electrical Monitoring and

Control Systems
2495-000-JSS-1671-51 General supply rules for A.C. UPS Systems
2495-000-JSS-1672-51 General supply rules for D.C. UPS systems
2495-000-JSS-1684-51 General supply rules for Cathodic Protection System
2495-000-JSS-1691-51 General supply rules for LV induction motors
2495-000-JSS-1692-51 General supply rules for MV induction motors
2495-000-JSS-4123-51 General supply rules for Emergency Diesel Generating

System
2495-000-MS-1600-51 Technical Specification For Electrical Installation

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The electrical system will be installed according to the following set of Typical Installation
Standards:
2495-000-STC-1691-51 Electrical Earthing System Typical Erection Details
2495-000-STC-1692-51 Electrical Power System Typical Erection Details
2495-000-STC-1693-51 Electrical Lighting System Typical Erection Details
2495-000-STC-1695-51 Cathodic Protection System Typical Erection Details
The electrical system will be configured according to the following drawings and electrical
diagrams:
2495-000-DW-1652-501 Key Single Line Diagram
2495-000-DW-1652-502 M.V. Switchboard Single Line Diagram
2495-000-DW-1654-501 L.V. Switchgear Single Line Diagram (Process Area

Loads)
2495-000-DW-1654-502 L.V. Switchgear Single Line Diagram (Utilities Area

Loads)
2495-000-DW-1654-503 Emergency Switchgear Single Line Diagram
2495-000-DW-1671-501 220 VAC – UPS – Single Line Diagram
2495-000-DW-1672-501 110 VDC – UPS – Single Line Diagram
2495-000-DW-1600-502 Electrical / Instrument interface philosophy
2495-000-DW-1600-501 Electrical symbols and legend
2495-000-DW-1630-501 Lighting and convenience outlet block diagram (typical)
5. DESIGN DATA
5.1. Environment Conditions:
The design of the electrical system shall comply with the following environment
conditions:
5.1.1. Temperature
 Maximum design temperature for outdoor installation : + 45°C
 Maximum design temperature for indoor installation : + 40°C
 Minimum design temperature for outdoor installation : + 1°C

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5.1.2. Relative humidity

 Average minimum value (winter) 65 %
 Average maximum value (summer) 100%
 Normal relative humidity 80%
5.1.3. Air barometric pressure

 Absolute: 1.03 kg/cm² at 2.7m
above sea level
5.1.4. Wind
 Basic wind pressure: 160 kN/m2
5.1.5. Rainfall
 Maximum rainfall recorder in 24 hours: 75 mm
5.1.6. Earthquake
 Seismicity grade Zone 2A

The electrical system shall be suitable for typical tropical atmosphere of chemical plant or
refinery (dusty, marine and corrosive).
Note: for more details refer to project process design basis.
5.2. Frequency
If not otherwise specified, the frequency shall be 50 Hz.
5.3. Voltage Levels
If not otherwise specified, the following voltage levels shall be selected for the electrical
system at rated frequency of 50 Hz. Equipment shall be anyway suitable for continuous
operation with voltages variations ranging within ± 10% of rated values and frequency
variations ranging within ± 5% of rated values, combined frequency and voltage
variations shall be in accordance with IEC 60034-1, the selection of equipment voltage
shall be made according to IEC 60038: “Standard Voltages”.
A 15% transient voltage dip shall not affect equipment operation
(a) MV distribution system:
-up to 10 MVA : 10.5 kV

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(b) Motors below 0,37 KW :230 V, 1 phase, 3 wires expect process

motor 400V 3 phase 3 wire or 4 wire.
(c) Motors sized 0,37 KW to 160 kW : 400 V, 3 phase , 3 or 4 wires
(d) Motors 200 kW and above : 6.6 kV, 3 phase, 3 wires
(e) Process heater / package units : 400 V, 3 phase, 3 or 4 wires
(f) Space Heaters : 230 V, 1 phase, 3 wires
(g) Electrical heat tracing panels : 400 V, 3 phase, 5 wires
(h) Cathodic protection panels : 400 V, 3 phase, 3 or 4 wires
(i) Instruments (critical supply from UPS) : 220 V, 1 phase, 3 wires
(j) Lighting fixtures : 230 V, 1 phase, 3 wires
(k) Convenience outlets : 230 V, 1 phase, 3 wires
(l) Welding outlets : 400 V, 3 phase, 3 or 4 wires
(m) HV and LV switchgear controls : 110 V DC
(n) L.V. Motor controls : 110 V DC
(o) General Service Boards & local Panels : 400 V, 3 phase, 5 wires
(p) Branch circuits / Lighting fixtures : 230 V ,1 phase, 3 wires
(q) HVAC Main Panel : 400 V, 3 phase, 4 wires
(r) Motorized Valves : 400 V, 3 phase, 4 wires
Total harmonic distortion (THD) of the supply network voltage will not exceed 5%.
Note: For reason of economy, or special equipment considerations, voltage levels (in 5.3 above) may
vary (subject to Owner approval) .
5.4. Neutral Status
If not otherwise specified the following neutral status will be selected:
- MV system 6.6 kV : the neutral will be earthed through

resistance limiting the current at 50A 10s.
- LV system 400 V : the neutral will be solidly earthed.
- 110 V DC system : Unearthed.

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- 220 V UPS system : Unearthed unless otherwise required by

Instruments
5.5. Electrical Equipment in Hazardous Area
5.5.1. Hazardous area classification
Areas will be classified in accordance to the standard IEC 60079.10, the API RP 505 as
required by the EPC Job Specification for Design and following the instruction given by
process department.
5.5.2. Equipment and material selection
The equipment and material selection will be in accordance the standard IEC 60079.
The mechanical characteristics of enclosures for electrical components and materials will
be as follows:
5.5.2.1. Rules for electrical apparatus installed in Zone 1
Electrical apparatus can be used in Zone 1 if it classified in Category 2 and if it is

constructed in accordance with the following type of protection:
- MV induction motor: Ex “d”

- LV induction motor: Ex “d”
- Control station: Ex “d”
- Socket outlet: Ex “d”
- Welding socket: Ex “d”
- Control panel: Ex “d”
- Lighting fixture: Ex “d”
- Junction box: Ex “d”
- Gauge level lighting: Ex “d”
- Switch: Ex “d”
Switchboards and power transformers shall never be installed in hazardous areas.
The use of electrical equipment in Zone 1 shall be minimised
5.5.2.2. Rules for electrical apparatus installed in Zone 2
Electrical apparatus can be used in Zone 2 if it classified in Category 2 or 3 and if it is

constructed in accordance with the following type of protection:
- MV induction motor: Ex “d” - Ex “de”

- LV induction motor: Ex “d” - Ex “de”
- Control station: Ex “d” - Ex “de”
- Socket outlet: Ex “d” - Ex “de”
- Welding socket: Ex “d” - Ex “de”

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- Control panel: Ex “d” - Ex “de”

- Lighting fixture: Ex “d” - Ex “de
- Junction box: Ex “d” - Ex “e”
- Gauge level lighting: Ex “d” - Ex “de” - Ex “e”
- Switch: Ex “d” - Ex “de”
5.5.2.3. Rules for electrical apparatus installed in Safe Area
For reasons of standardization, additional safety and to minimise reclassification of

equipment due to plant expansion, all electrical equipment located within the boundaries
of a process plant area, installed outdoors in a non-hazardous area shall have Ex “n” type
protection for motors and Ex“de” or Ex “e” type protection for remote control units, lighting
fixtures, junction boxes, etc.
Electrical equipment installed indoors and in a safe area shall be the standard industrial
type.
5.5.3. Wiring methods in hazardous area
If not otherwise specified the wiring system shall use armoured cables and wiring shall
comply with Standard IEC 60079-14. armoured cables shall be laid in cable ladders or
open conduits for mechanical protection.
Cable glands or cable seals suitable for the classification of the area where they are
installed will realize cable entrance to enclosures of electrical apparatus.
5.5.4. Certification of Electrical Apparatus for Hazardous Area
The equipment and materials furnished shall be labelled, listed, certified, accepted, or
otherwise determined to be safe for the use by a nationally recognized testing laboratory
(NRTL) (i.e. CESI for Italy, PTB for Germany, BASEEFA for England, LCIE or INERIS for
France, etc).
Equipment suitable for Zone 1 area are suitable for zone 2 area.
5.5.5. Ingress Protection (IP) degree
Degree of protection for all enclosures shall be in accordance with IEC 60529 as
follow:
- Indoor equipment : IP 41 (minimum)

N.B. Equipment requiring heat dissipation can
be accepted to be IP 31 (e.g. for DC / AC UPS
systems, VFD …etc
- Outdoor equipment : IP 55 (minimum)

For more details refer to “General rules for area classification basis Doc. No. 2495-000-
JSD-1600-53 clause 5.2

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5.6. Electrical Load Summary
The electrical load summary is the main input for the electrical design activities and
includes main information about electrical users such as motors, miscellaneous
consumers, DC supply, lighting and UPS instrument supply.
5.7. Electrical Calculations
The electrical calculations shall be performed according to IEC standards and include
the following:
(a) Load flow analysis

(b) Fault levels studies
(c) Motor starting & stability studies
(d) Electrical protection and coordination study
(e) Cable sizing
(f) Lighting illumination level calculation criteria (for indoor areas and when needed for
outdoor areas)
(g) Harmonic studies, If contractually required.
5.7.1. Fault Levels

Short-circuit studies shall be performed in accordance with IEC 60909, and shall show
maximum fault levels at each busbar.
Initial Symmetrical Short circuit current (I"k) is the rms value of the AC symmetrical
component of an available short circuit current applicable at the instant of short circuit if
the impedance remains at zero time value. This parameters is calculated and used to
select the suitable short circuit withstand for all power system equipment.
5.7.2. Motor starting & stability studies

Motor starting study shall be performed to determine the limits of stability of the power
system, in terms of voltage during starting of largest motor. The results shall be used
to:
- Ensure that When largest motor is started the voltage-dip limit is not less than
85% at the switchgear bus and at the loads terminal.
- Check the need of motor starting method to achieve the above mentioned
starting condition.
5.7.3. Electrical protection and coordination study
Studies shall determine correct settings for protection relays to ensure correct devices
operate on the occurrence of a fault (3 phase or 1 phase) so that the effect of the fault
is minimised and correct grading is always achieved. Particular care shall be taken to
avoid loss of primary busbar, unnecessary loss of plant and also to maintain grading
where backfeeds are possible. The study shall also demonstrate that proper back-up
function is assured in case of malfunction of the primary protection.

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5.7.4. Harmonic studies (if contractually required)
Studies shall verify harmonics on the system and equipment to be in accordance with
acceptable limits (i.e. max. 5 % of harmonic voltage on every system voltage) taking
full account of significant non-linear loads and variation of plant operating loads.
Harmonic levels shall not invalidate equipment certifications for hazardous areas.
Action shall be taken either by equipment over-sizing, increasing impedance or by
additional filtration to meet these limits.
5.8. Main One Line Diagram
The main one line diagram is done using IEC Standard Symbology, and shows major
itemized electrical equipment such as HV equipment, generators, transformers, HV and
LV switchgears, emergency supply for electrical system and instrumentation, and main
feeders. The main electrical characteristics such as voltage, frequency, current and/or
rating are usually indicated for each equipment.
6. POWER SYSTEM
Power system design and installation will be in accordance with the IEC standards and
in particular with the IEC 60364.
6.1. Power supply philosophy:
A power generation system synchronized and in parallel operation with the national
grid are dedicated to feed existing polystyrene project.
EB/SM plant shall be electrically fed via two existing feeders from the existing MV
switchgear of the polystyrene project within an available capacity of 6MW from the grid
and 4 MW from power generation plant (IPP).
Capacity of existing power generation plant can be increased by adding additional gas
engines (Styrenics scope of work / supply) to cover power requirements for the EB\SM
project and the grid power shall be considered as hot stand-by supply.
In case of power requirements exceed the capability of the grid, load shedding shall be
applied to limit power to 13MW.
New Diesel generator will supply an emergency switchgear dedicated to feed the
EB/SM plant emergency loads in case of main electrical power outage.
For detailed operation criteria refer to para. 12.
- Existing power supply configuration:

Voltage level: 10.5 kV
Rated current: 1250A
Short circuit level: 25KA/3sec

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Feeding sources:- National grid with total capacity of 13MW

- Gas engines power generation plant with total capacity of 11MW
Actual total power consumption: 7 MW (as defined by client)
Spare capacity: 6 MW form the grid and 4 MW from power generation plant (IPP)
6.2. Power Distribution
6.2.1. General
All power distribution equipment shall be suitable for continuous operation at full load
and shall withstand the thermal and electrodynamics stresses resulting from the
studies.
Loads shall be categorised as follows:
- Non critical service

- Normal service
- Critical service
- Vital
Non critical service (III category) equipment tolerates prolonged power failure without
causing plant shut down.
Normal service (II category) equipment tolerates short power failure; prolonged power
failure cause plant shut down.
Critical service (I category) equipment is that whose operation involves the safeguard
of an item of equipment/installation or the continuation of certain operations. In case of
shutdown, this equipment tolerates a short interruption of service, but it shall be re-
started through the control room DCS system or automatically restarted (if requested
from process) and re-fed by emergency sources.
Vital equipment (I category special) is that whose operation affects personnel safety
whether directly or indirectly. This equipment does not allow the power supply
interruption and shall be fed by UPS systems.
6.2.2. Distribution
All high and low voltage switchgears will generally be of the secondary selective type.
In secondary selective systems, the rating of all equipment in the distribution system
shall be such that each transformer, feeder, switchgear can be taken out of service
without affecting the availability of the plant supplied. Each transformer shall be fed
from one single feeder. In normal operating conditions, the bus tie circuit breakers of
switchgears shall be open to limit short circuit levels.
Low voltage distribution boards for external lighting, power outlets and MOV supplies
may be outdoor types.

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6.2.3. Automatic and manual transfer
An automatic transfer system shall be incorporated in all MV and LV switchboards. On

under-voltage on any half bus bar, not caused by incoming circuit breaker protection
trip or manual trip, shall cause the affected busbar to be automatically switched to the
healthy supply by closure of the bus tie circuit breaker. Switchboards with two incomers
and no bus-tie shall operate with one incomer open and auto transfer shall operate
between the two incomers.
Return to normal condition shall be manually initiated, and shall occur without supply
interruption when the incomers are in synchronism. A timer shall prevent incomers
being in parallel for more than 1.0 second.
Manual transfer facilities shall also operate for all incomer/bus tie configurations
without supply interruption when in synchronism.
6.2.4. Insulation
Insulation levels of the power system shall be co-ordinated in accordance with IEC.
Rated short duration power frequency withstand voltage and switching/lightning
impulse withstand voltage shall be specified for all equipment of MV levels, taking
account of system voltages and type of earthing.
6.2.5. System ratings
Transformers, with the exception of captive transformers for motors, shall have an Oil
Natural / Air Natural (ONAN) cooling rating to meet the expected load requirements.
Circuits to and from transformers shall be rated for the full transformer rating.
Tie line circuits feeding switchboards, which also have transformer incomers, shall be
rated equal to the transformer incomer.
Feeders dedicated to individual loads shall be sized for the continuous full rating of the
load.
All ratings shall be continuous at specified maximum ambient temperature.
6.2.6. Power transformers
Power transformer shall be designed according to 2495-000-JSS-1641-51.

The transformers shall be generally ONAN (up to 25MVA) suitable for outdoor
installation. They will be with oil conservator or sealed type according to their rating.
Generally, rating of HV/LV distribution transformers shall be limited to 3150 kVA for
400V; LV/LV transformers shall be dry type. Tanks, radiators, conservator shall be
externally and internally treated and/or properly painted for the specified project

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ambient conditions. The transformers, 11kV and below, shall be provided of suitable
terminal box adequate to receive the housing cable terminations. Separate terminal
boxes will be provided for auxiliaries and protective devices.
All transformer windings, joints and other winding connections shall be manufactured
as per Manufacturer standard. All windings shall have a uniform full insulation (except
for large transformers). Winding neutral point shall be brought out.
Transformers and their accessories shall be capable of delivering their rated output
continuously at the frequency and voltage in the specified range, and the project
design ambient conditions. Connections of secondary side to switchgear will be
performed by means of single core cables, cable buses or by bus ducts while the
connection of switchgear to primary side will be performed by means of single or three
core cables. Protective devices and additional accessories will be as per One line
Diagram.
If not otherwise specified Transformer group will be Dyn11. Insulation Class will be
Class A. Generally dry-type cast resin shall be used for indoor transformers to supply
general service boards and building power supply. Dry-type transformers cooling shall
be AN.
Transformer spare capacity shall be evaluated as follow:
 For 10.5/0.4kV Transformer 20% of calculated power demand connected.

 For 10.5/6.6kV Transformer 10% of calculated power demand connected if
below 10MVA and 5% of calculated power demand connected if equal or above
10MVA. In any case the spare capacity shall not be less of the connected
evaluated LV spare.
 For Main Transformer base power (ONAN) no Spare capacity will be
considered. It will be sized rounding up the calculated power demand to the first
commercial size.
The above calculated power demand will be the one determinate at detail design stage
of Electrical consumer list.
OFF-CIRCUIT TAP CHANGERS
-When Off-circuit tap changers are specified they shall be on the primary side and
manually operated with the transformer de-energized. The operating handle shall be
external and accessible, with spindle enclosed in an oil or grease filled chamber
(situated below cold oil level) to prevent gas or oil leakage. Tap changers shall have
provision for padlocking in all positions.
- Unless otherwise noted on the Data Sheet(s), the tapping range shall be ± 5% in 2.5%
steps.
- All tapping shall be rated for full capacity.

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- Off circuit tap changer will be arranged for Positive snap-action contact changing,
such that it is impossible for the contacts to be set in a position whereby the windings
remain open- circuited or partly short-circuited (i.e. an intermediate positioning between
two taps will not occur).
6.2.7. MV Switchgears
Switchgears shall be designed according to the following general supply rules:
2495-000-JSS -1652-51 General Supply Rules For Medium Voltage Swithgear.

The assembly of switchgear shall consist of free-standing, vertical, dead front steel
structure cubicles, the cubicle shall be of LSC2B (loss of service continuity) type as
defined by IEC standard 62271-200 and the high voltage parts are compartmented
using metal partitions (PM class) which are connected to earth (unless otherwise
indicated in data sheet), each cubicle shall be subdivided into circuit breaker / fused
contactor compartment, cable termination compartment, bus bar compartment and a
secondary circuit and relay compartment.
Unless otherwise specified in the data sheet and as per IEC 62271-200, The high
voltage switchgear shall be Internal Arc Classified (IAC AFLR 31.5 kA x 1 Sec).
Generally switchgears will consist of free standing units assembled together in single
row and suitable for indoor installation. The switchgears will be arranged for future
extensions at both ends.
Units will be equipped with necessary current and potential transformers devices,
instruments and other ancillary equipment. Potential transformer will have primary
current limiting fuses. Secondary circuits will be rated 110/√3 V. Current transformers
will have secondary circuits basically rated 5A.
The bus bar system will be copper bars conductor, insulated according to
Manufacturer’s standard.
The switchgears will be connected to the transformers by means of cables or bus ducts
/ cable buses.
Switchgears will have incoming feeders, bus-tie, transformer feeders and motor
controller cubicles equipped with circuit breakers. Circuit breakers will be truck-
mounted, draw-out type, electrically operated with adequate breaking capacity. One
circuit breaker compartment in each cubicle will be used for incoming and bus-tie. One
breaker compartments in each cubicle will be used for outgoing users.
Switchgear will be sized for the full capacity of connected transformer.
Spaces will be considered as a free space of one vertical section per side left in
substation for the expansion of each HV switchgear.
Equipped spares are cubicles equipped with circuit breaker and protection devices as
per one line diagram.

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6.2.8. Neutral Earthing Resistor
6.2.8.1. General
The neutral earthing resistors are intended to limit the earth fault current magnitudes to
reduce damage during earth faults.
The resistor shall be housed in a freestanding metal enclosure suitable for outdoor
installation under conditions as specified on the data sheet. The enclosure shall be
suitable for installation on a concrete foundation.
The enclosure shall be equipped with self-regulated, thermostat controlled,

anti-condensation heaters of sufficient capacity to prevent the formation of
condensation within the enclosure under the service conditions specified in data sheet.
Neutral earthing resistor shall be capable of carrying the design current (as specified in
data sheet) without exceeding the temperature of 500 degrees C for duration of not
less than 10 seconds and for a number of interventions per hour not less than three.
The value of the resistance shall be selected to allow sufficient current for earth fault
relays operation to clear the earth fault currents and isolate the faulted circuit.
Neutral earthing resistor shall be capable of carrying a continuous current equal to 10

% of rated current.
The rated voltage of the neutral earthing resistor shall be equal to the system rated
phase to neutral voltage.
The insulation voltage of neutral earthing resistor shall be sized for transformer
secondary insulated voltage. Graded insulation shall not be accepted.
The neutral earthing resistor shall be complete with and enclose resistance elements,
mounting insulators, cable boxes, current transformers etc.
When specified on data sheet current transformer(s) shall be provided to energize the
back-up earth fault protection relay (installed with the switchgear) as shown on the one
line diagram. Current transformer(s) shall be installed in the neutral side terminal
chamber.
A separate marshaling box for current transformer secondary circuits and space heater
termination shall be provided.
All terminal boxes enclosure shall have a minimum mechanical degree of protection
IP55.
6.2.9. LV Switchgears
Switchgears shall be designed according to the following general supply rules:

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2495-000-JSS-1654-51 General Supply Rules for L.V. Switchgear (≤1000

VAC) and Bus Ducts
Switchgears will be sized for the full capacity of connected transformer.
Spaces will be considered as a free space left in the substation for the future
expansions of the Switchgears. Free space of the dimension of one vertical section
from each side taking into consideration the available spaces inside the substation
building.
Equipped spares are drawers equipped with circuit breaker and protection devices as
per one line diagram.
The switchgear are to be of the standardized metal enclosed multi-tier cubicle type
construction comprising the equipment as detailed on the One Line Diagram, consumer
list and data sheets
The degree of protection for indoor installation in enclosed buildings shall be IP 41 for
the switchboard assembly and IP 20 for the exposed parts inside the switchboards.
Cubicles including doors shall be capable of withstanding the internal pressure created
by faults within the structure (equal to the maximum fault current rating) without danger
to the operating personnel.
Each individual starter or radial feeder compartment shall be fully partitioned from its
neighbour. Switchgear construction shall be form 4b, type 6 according to IEC (60439-1)
unless otherwise specified in datasheet.
Incomings and bus-tie compartments will be equipped with withdrawal air circuit
breakers electrically and manually operated.
Switchgear shall generally have two sections operating independently with two 100%
rated incoming feeders and with bus coupler open having facility for changeover in the
event of failure of either of the incoming circuit breakers.
The units will be equipped with the necessary current transformers, relays, instruments
and other necessary equipment.
Switchboard will be connected to transformers by means of power cables/cable

bus/bus ducts.
Outgoing feeders shall be provided with draw-out moulded case circuit breakers,
electrically operated, fitted with direct acting relays and earth fault relay.
The motor starters (generally equal or less than 160 kW) will be housed in individual
fully withdrawable units equipped with moulded case circuit breaker, air contactor,
direct acting overload relay with grounding fault relay.

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Protective relay current transformers shall have an accuracy of 5P20. Accuracy shall
be as necessary as is satisfactory to operate the relays over their design range.
Differential Protection current transformers shall have an accuracy class X or
equivalent.
VTs accuracy class shall be 0,5 for metering and 3P for protection.
Motor starters will be equipped with current limiting moulded case circuit breaker, air
contactor, overload relay, grounding fault relay (for motor 30 kW and above only).
Motor feeders will be equipped with Indicating lamps for motor running, stopped,
tripped and with reset button for thermal relay will be as indicated in single line
diagram.
Motor 7.5kW and above shall be equipped with space heater.
Motors operating equipment with same function will be fed from two different bus-bars.
Protective relays shall be microprocessor based, drawout type complete with front
accessible connection plugs. Protective relays shall be for operation from instrument
transformers having nominal 5 ampere, or 1 ampere for current relays or 110 volt
secondaries for voltage relays. Auxiliary supply shall be 110 VDC from separate DC system
unless otherwise specified on data sheet. Relays shall be provided with communication
ports (Modbus RTU- RS 485) for communication with other relays, EMCS...etc.
6.2.9.1. Auxiliary Supply Panel Boards and local boards
Auxiliary Supply Panel Boards, local motor controllers, motor operated valve panels
and so on, suitable for indoor or outdoor installation, will consist of self-supporting
structure, metal enclosed with fixed mounted equipment.
Equipment in separate or common compartment will consist of on-load switches and

HRC fuses combination or circuit breakers depending on the required interrupting
capacity. Ground fault relay will be foreseen for each outgoing feeders if any.
Dry type isolating transformers for lighting section will be provided of suitable rating
whenever necessary.
Outgoing feeders to lighting circuits, street lighting and lighting sockets will be equipped with
automatic moulded-case circuit breakers or miniature circuit breakers.
6.2.9.2. Bus Ducts
Bus duct shall be provided for Switchgear incomer feeders as specified in single line
diagrams.
Bus ducts for transformer connection shall be metal-enclosed, non-segregated phase

type having insulated bus bars. Outdoor enclosure section of the bus ducts shall be

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non-ventilated, weatherproof and dust-tight (IP 68 minimum). Indoor section may have
general purpose ventilated enclosures (IP 41).
The bus duct shall have gasket removable covers where required for assembly or
inspection purposes.
Flexible connectors (enclosure and bus-bars) shall be provided at the connections to

transformers and at switchgear side to allow metal expansion and to compensate
vibration. Splicing plates and bolting, gasket, miscellaneous hardware and screened
breather/drains shall be provided along outdoor enclosure. All pieces and bus duct
section shall be clearly identified in accordance with the assembly drawings.
A weather proof wall flange and all the necessary fittings to adjust the crossing shall be
provided where bus ducts pass through the wall opening.
Bus duct shall be equipped with a vapour and fire barrier (1 hour rated) at wall
penetration flange.
The sequence of the phases and neutral bars location shall be the same provided for
the Switchgear.
The space heater system of the bus-ducts will be fed from relevant switchgear, wiring
between switchgear and bus-duct will be supplied by Vendor.
Thermostatically controlled anti-condensation heaters shall be provided with adjustable

thermostat and shall have hermetically sealed contacts.
The bus-duct connection to the transformers shall be suitable for the transformers
flange and terminals.
Internal and external supports shall be hot dip galvanized.

All enclosure metal parts shall be suitably treated to prevent corrosion and paint
deterioration.
6.2.10. A.C. and D.C. UPS Systems
Uninterruptible power supply and Rectifier battery D.C. supply shall be designed
according to the following general supply rules:
2495-000-JSS -1671-51 A.C. UPS Systems

2495-000-JSS -1672-51 D.C. UPS Systems
6.2.10.1. AC System (AC UPS)
Generally Uninterruptible AC power System shall be located in dedicated room in

Control Room to supply the main instrument power panels installed within instrument
building and/or Control Room.

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The electrical power supply system shall be designed so as to ensure, at all times,
continuity and steady voltage for all critical instrumentation.
AC UPS system shall be dual type and consist of the following:
- Microprocessor based controlled scheme for protection, metering and operation

- Two 100% battery charger capable of supplying the required load, and maintaining
the battery set fully charged
- Two Static inverters.
- Static and manual by-pass switches with related transformer for maintenance to
connect the load on the by-pass line
- Dual Sealed lead batteries
- Steel PVC coated racks (Acid resistance).
- EEx-d Battery Circuit Breaker Box.
- One voltage stabilizer..
- Interconnecting DC cables between UPS and the batteries
- Separate A.C. distribution panel
In case of power failure, uninterrupted power to such instrumentation shall be ensured

for a 60 minutes by VRLA batteries installed on Acid resistant battery racks in a separate
room. The rectifier-inverter unit shall include a continuous supply line with a
transformer, one rectifier-battery charger and one inverter. UPS will also have back-up
mains with a transformer and stabilizer. The quality of output power of this system shall
meet the requirements of the loads.
Mains input cables to UPS will come from different sources. When the both inverter
fails and/or output voltage of the inverter is lower than allowable value, the static switch
shall transfer the load automatically from the continuous supply line to back-up main,
with an allowable time limit, which permits the supplied systems to continue their
normal operation. UPS will be designed for high reliability even in case of spikes of
supply voltage.
6.2.10.2. D.C. Systems (DC UPS)
The direct current distribution system is generally composed by one D.C. distribution
board with two incomers, dual chargers and dual battery banks.
The D.C. distribution system will feed control, signal and protection circuits of MV
switchgear including spring loading motors and control circuit of low voltage incoming
and outgoing circuit breakers.
All D.C. circuits will be protected by automatic circuit breakers, with auxiliary contact for
remote alarm.
The battery panel will be charged by battery chargers and will be switched
automatically to supply the 110 V DC to the distribution panel in case of main failure.
The rectifiers and the battery chargers will be included in the same DC panel.

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Batteries will be sealed lead (VRLA) batteries installed on Acid resistant battery racks in
a separate room rated for 1 hour of autonomy (unless otherwise specified).
6.3. Protection
6.3.1. General
Protection systems shall be implemented to:
- Ensure safety of personnel.

- Maintain stability and integrity of the power system.
- Maximize continuity of power supply to non-faulted equipment.
- Minimize damage to equipment and systems due to faults.
- Assist with identification of faulted equipment and type of fault.
Protection shall include requirements of the typical protection schemes.
The protection system shall be based on the philosophy of overlapped zones. If

protection nearest the fault fails to operate, the preceding upstream protection shall
operate to clear the fault within the rating of the failed equipment.
The protection system shall be properly co-ordinated to ensure selective operation by

use of time/current devices with a wide range of settings, curve shapes and facilities
which shall include all requirements found necessary during the system studies.
Protective relays shall be matched to the equipment to be protected, to ensure
maximum utilisation of the equipment while limiting the consequential damage due to a
fault.
Protection relays shall operate reliably at both maximum and minimum prospective
fault levels at each location. Relay arrangement, speed of operation and fault
clearance times shall be sufficient to match equipment fault ratings and to ensure
system stability as determined by the studies.
Consistent protection schemes shall be applied for similar equipment, especially where
they are of identical rating and voltage.
Minimum grading interval between each time/current relay shall be 0.25 second,
subject to type of interrupting device and its fault clearance time.
Protection relay shall be multifunction electronic type as minimum.
6.3.2. Inter-tripping
Inter-tripping shall be provided between associated equipment to correctly isolate

faulted items and to leave the system in a predictable orderly state after operation of
protection devices. Inter-trip circuits shall be hard wired normally without repeat relays.

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Operation of any transformer buchholz or overpressure/gas evolution protection shall

trip the transformer feeder circuit breaker and shall inter-trip the associated
downstream circuit breaker.
Opening of any feeder circuit breaker, by protection operation or manual opening, shall
inter-trip the associated downstream circuit breaker.
6.3.3. Interlocking
Interlocking shall be provided to prevent mishandling of equipment.
Feeder circuit breakers shall be electrically interlocked with the associated downstream
circuit breaker such that closure of the downstream circuit breaker is prevented if the
feeder circuit breaker is open or isolated. Interlocks shall be hardwired normally without
repeat relays.
Closure of any HV incoming or outgoing circuit-earthing switch shall be prevented

unless the associated circuit breaker is withdrawn.
It shall be always the operator's responsibility to confirm that the associated "cable
side" circuit is dead prior to closing the earthing switch. Anyhow, when feasible,
mechanical and electrical interlock shall be provided.
Paralleling of transformers and busbars shall be prevented unless they are in

synchronism beforehand.
Access to transformer bays shall be fitted with padlock facilities.
It shall be the responsibility of the operator to ensure that transformers are on the same
tap prior to paralleling.
6.4. Consumers
6.4.1. Motors
Motors shall be designed according the following general supply rules:
2495-000-JSS -1691-51 LV Induction Motors

2495-000-JSS -1692-51 MV Induction Motors
Motors shall be of the squirrel cage induction type unless otherwise specified. As a
general rule, motors up to 160 kW should be Low Voltage, and High Voltage above 200
kW. Generally insulation class of motors will be “F” with temperature rise class “B” at
design temperature 40 °C. When required by process, the motors will be asynchronous
variable speed fed through a frequency converter (VSD). Generally the motor and
adjustable frequency drive shall be specified as a package, if this is not possible, there

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shall be documented liaison between the motor and adjustable frequency drive
suppliers about the application of the equipment.
Motors rated 400 kw and above shall be started through soft starters built-in inside 6.6
kV medium voltage switchgear, motors less than 400 kw shall be suitable for direct on
line starting …. for more details refer to medium voltage single line diagram drawing.
doc number 2495-000-dw-1652-502 page 2 of 2.
6.4.2. Welding outlets
Welding outlets will be 32A or 63A rated, 400 V, 3 phase and earth; they will have
mechanical protection degree IP 55 and be suitable for the classification of the area
where they will be installed. Number and location of power outlets will be defined in
order to reach every operating point of the plant area by about 50 m of cable length.
6.5. Cables
6.5.1. The cables shall be designed according to the applicable code and the following notes:
The following calculations/verifications are taken into consideration for cable sizing:
- Ampacity
- Voltage drops in both normal operating and starting conditions
- Maximum short-circuit conditions
- Minimum short-circuit conditions
- Protection against the indirect contacts.
The cable ampacity calculation is based on the value defined by the IEC standards
keeping into account the present laying conditions and ambient temperature.
Conductors shall be compacted and having continuous length.
The Minimum cross sectional areas shall be:
 Low voltage control cables: 2.5 mm2 and for control cable internal to
Control panels and switchboard can be
reduced to 1.5 mm2
 Low voltage power cables: 4 mm2
 Lighting circuit: 2.5 mm2
 Medium voltage power cables: 35 mm2
The Maximum cross sectional areas shall be:
For Low Voltage power feeders:

 240 mm2 for three-core cable either armoured or not armoured,
 500 mm2 for single core cable.

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For Medium Voltage power feeders:

 240 mm2 for three-core cable either armoured or not armoured,
 630 mm2 for single core cable
6.5.2. Voltage drops
The voltage drop in A.C. cables up to the terminal of end user shall not be more than
the following values based on rated voltage:
 11kV and 6.6kV feeders 1 % at rated load

 6.6kV motor feeders 2 % at full load current in normal operation,
10 % during starting time
 6.6kV power feeders 2% at rated load
 400V switchboards main feeder 1 % at full rated current of upstream

cables or bus ducts transformers
 400V motor feeders 5 % at full load current in normal operation,
15 % during starting time.
 400V power feeders 2% at rated load
 Lighting and local switch 3 % between substation and lighting panel

3 % for sub-circuits
 Small power socket outlets 3 % between substation and power panel and
3 % for sub-circuits.
 Welding socket outlets 5 % between substation and the most distant
welding socket.
DC UPS system
 steady state conditions : 1%
 on transient load changes: 10 %
AC UPS system
 steady state conditions: 1%
 on transient load changes: 5%
6.5.3. Underground cabling
The following laying situations are generally present in the industrial plant:
- unpaved area
- paved area
- streets/roads/railways crossing.
In the first case the cables shall be directly buried.
In the second case the cables shall be laid in concrete trenches filled with sand.

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In the third case the cables shall be laid in PVC sleeves in concrete bank.
In general the cables will be copper XLPE insulated, armoured and PVC flame
retardant resistant to hydrocarbon.
Single core cables shall be installed in trefoil formation (where possible).
PVC duct banks shall have 10% of spare space for future cables.
Unless the cable lengths exceed the maximum delivery ones, joints shall be avoided.
A cable presence warning system made of plastic strips shall be provided above the
top level of all cables run direct buried.
Joint markers indicating joint position shall be installed above grade.
Electrical cables shall not be laid in the same trench with the instrument and
communication cables excepted in congested area provided that a minimum distance
of 500mm between them is guaranteed.
Leaving the ground, cables shall be protected by a stub-up pipe sealed with
compound.
Cables shall be identified with corrosion resistant cable strips, showing the cable item,
every 40m, at road crossings and when cable changing routing direction.
Unpaved areas cable trench markers will be provided at grade over the cable trenches
to show clearly the extent and the run of the cables.
6.5.4. Above grade cabling
Cables will be laid on hot-dip galvanized cable trays ladder type and/or in open PVC or
galvanized steel conduit system.
Trays will be bolted to steel structures and walls or to adequately sized tray supports.
Cable trays will be provided with covers where subject to direct sunlight or where there
is a high risk of mechanical damage during normal operation or maintenance periods.
Cables will be fixed on trays by adequate ties. Interval of clamping shall be as per
installation standards requirements. Single core cables shall be installed in trefoil
formation. Non-magnetic clamps or ties shall brace single-core cables.
Cables leaving trays to reach equipment will be individually protected by open conduit
system or mounting profile.
LV power circuit and its associated control circuit shall normally be laid in the same
cable way.
Lighting branch circuits may run in common conduit.

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Control, metering, interlocking, and signal circuits may be grouped in common cable
way/conduits provided all cables are insulated for 500 V or more.
D.C. circuits shall not run in the same conduit with A.C. circuits.
Instrument cables shall not run in the same conduit with electrical cables.
All outside power and control cables shall be max 2 layers and 4 layers inside
substation cellar.
Cables shall be marked with corrosion resistant cable strips, every 30÷40 m, showing
cable item.
Unless the cable lengths exceed the maximum delivery ones, joints should be avoided.
6.6. Control Stations
Motor control shall be carried out by local control stations, installed close to the motor
and complete with:
- Local manual start-stop device (with the device padlockable in the stop position).
- Remote control facility from DCS, if applicable.
- Ammeters for motors rated 30kw and above.
Control stations will have protection degree IP 55 and shall be suitable for the
classification of the area where they are installed.
7. EARTHING AND LIGTHNING SYSTEMS
7.1. Earthing System
Grounding and bonding for protection of the electrical system circuits and equipment
shall be installed to minimize damage in case of ground faults by providing low fault
impedance, thereby limiting the voltage to ground and facilitating the operation of the
overcurrent devices.
The earthing system design and installation will be in accordance to the IEC Standards
and in particular with IEC 60364-4-41 and IEC 60364-5-54.
The earthing system shall protect the electric network and assure personal safety in
case of an electric failure and against static charges.
The following equipment shall be connected to earth:
- Non-current carrying metallic parts of electric equipment,

- Neutral impedance, lightning arrestors and conductors,

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- Metallic structure of building and metallic reinforcement of concrete building,

- Tanks, vessels, exchangers, pipes,
- Lorry tanks during loading, if necessary.
The earthing system shall consist of ground rods driven in earth and embedded ground
cable connected to the ground rods. Individual pieces of equipment shall be connected
with jumpers to the ground loop.
Underground and above grade connections shall be made using compression type
cable connector.
Earthing cable connections to equipment shall be made using compression type lugs.
7.2. Main Equipotential Bonding
Main equipotential bonding shall consist in:
One main earthing grid around all plant, consisting in buried bare or insulated copper
conductor, earthing rings relevant to each unit or building, connected to the main
earthing grid through minimum two earthing connections at opposite sides,
the main grid can be connected to earth rods if necessary, through earthing
connections,
The value of loop earthing resistance, all networks connected, shall be recorded.
EB/SM grounding network shall be connected to existing network.
Branch derivation shall consist of compression type connection. Thermoweld

connection can be used in alternative.
7.3. Connection to Earth
7.3.1. Electric equipment earthing (Protective earthing)
7.3.1.1. Switchboards
Each electric switchboard shall be connected to the substation-earthing loop through

two insulated copper branch conductors, connecting each end of the switchboard-
earthing bar. Local distribution panels will be earthed to the unit-earthing ring either
locally by a branch conductor connected to the earthing loop, or through the protective
conductor of the supply cable.
7.3.1.2. Power transformer, welding sockets, MV motors and junction boxes.
All exposed conductive parts of this equipment shall be connected to the earthing ring.

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7.3.1.3. LV motors
The LV motor are connected to the earthing system by means of:
(a) a specific earthing conductor connecting the motor earthing terminal to the
earthing ring,
(b) the protective conductor of multicore cable (PE), if any, connected to the earth bus
bar of the relevant MCC and earthing bolt inside the motor box.
The control unit shall be connected to earth by means of a second earthing conductor
connected to the motor earthing.
7.3.1.4. Lighting fixtures, junction boxes, convenience sockets
The conductive parts of the above mentioned equipment shall be earthed by means of
the protective conductor of the supply cable connected to the earth bus bar of the
lighting panel.
Lighting pole earthing terminals shall be directly connected to the earthing loop through
branch conductors.
7.3.1.5. Cable trays
Cable trays shall be connected to earth; their electric continuity can be achieved by
means of bonding straps between each section or by means of a bare cable running all
along cable trays and connecting each section, if electric continuity is not assured by
the fixing devices.
7.3.1.6. Cables
Cable armour, if any, shall be connected to earth at both sides (at the user side by
means of cable glands) with the exception of single core cable that will be earth at
source side only. HV cable armour/shields earthing will be specifically analysed and in
any case the solidly earth will be done only at one side (source side).
7.3.1.7. Electric room - Substation
A bare tape or insulated cable loop running above ground within each electric room
and substation (cable rooms or compartment) shall connect all equipment requiring
Protective earthing (switchboards, transformers, … etc).
A bare or insulated cable loop running underground around the substation shall
connect all parts requiring static earthing such as concrete reinforcement, doors,
fencing, etc. The loop shall be connected to the main earthing grid through minimum
two connections at opposite side.

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Both loops shall be interconnected through minimum two earthing connections at

opposite side.
In case of control room or technical room and where required by sensitive equipment,
electronic equipment shall be connected to a dedicate “electronic earthing loop”,
connected to the plant earthing grid in only one common point through two insulated
earthing cables.
7.3.2. Non–electric equipment (Equipotential bonding)
7.3.2.1. Vessel, tanks
Exposed conductive parts of these elements shall be connected to the unit-earthing

ring.
The electric continuity of this equipment shall be assured at manufacturing stage.
7.3.2.2. Metallic building structure
Metallic building structure shall be connected to the unit-earthing ring.

Important metallic structures may require multiple earthing connections to the unit
earthing ring, or a dedicated surrounding earthing loop connected to the earthing grid
or to the unit earthing ring through minimum two connections at opposite sides.
7.3.2.3. Pipes
Pipes shall be connected to the unit-earthing ring when they enter the unit from the
interconnecting pipe rack.
Inside the units and where insulating flanges prevent the natural earthing continuity to
be assured, straps shall be installed to restore the electric continuity.
7.3.2.4. Loading area
Loading area and lorry’s tanks shall be connected to earth if required by process or
safety.
7.3.2.5. Note – Miscellaneous
Are considered as connected to earth:
Non-current carrying equipment connected mechanically with suitable electric

continuity with earth equipment,
Non-current carrying equipment with an earth resistance below 20 ohms.

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7.4. Cross-section of Earth Conductors
Cross-section of earth conductors shall be calculated according to IEC 60364-5-54. If

calculation lead to a non-standard cross-section the nearest bigger standard cross-
section shall be used.
The cross-sectional area of branch conductors connecting equipment and structures to

the unit earth ring shall be (as minimum):
- Main ground ring: 120 mm2

- Ground ring connection: 120 mm2
- Motors: 35mm2
- Motor Control Station: 35mm2
- Cable tray: 35mm2
- Welding receptacles: 35mm2
- Convenience outlet: 16mm2
- street lighting poles: 16mm2
- Lighting poles: 16mm2
- Lighting fixtures: 6mm2
- Instrument terminal boxes: 6mm2
- To metallic enclosures 30 mm²
- To control panels, etc : 35 mm²
- To other non-electrical equipment: 16-35 mm²
7.5. Lightning System
Lightning protection shall conform to IEC 61024 or UL 96A and/or to local standards.
Early streamer lightning protection system shall be to be in consistence with the
existing polystyrene system.
8. LIGHTING SYSTEM
The lighting system shall be designed utilizing the minimum number of fixtures
consistent with the average initial illumination values specified below illumination level
table. The lighting design and installation will be in accordance to IEC Standards and in
particular with IEC 60364.
8.1. Principle of Design
8.1.1. Power supply
Unit lighting circuits shall be fed from dedicated lighting distribution boards.
Substation lighting distribution boards will feed local lighting panels through a 3 phase
+ neutral supply.

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Lighting fixtures will be supplied through the local panel provided at suitable location.
8.2. Lighting Distribution
8.2.1. Building and Unit lighting
The lighting circuits from local panel to the lighting fixtures shall be single phase with 3
wires cables (phase + neutral + earth).
The load of lighting circuits shall be balanced over the 3 phases, as much as possible.
Outgoing branch circuits will be protected by 20 A circuit breakers.
Each branch circuit should not be loaded over 2 kW and in any case not feed more
than 20 lighting fixtures per phase (if incandescent), 50 (if fluorescent) and 24 for the
other type (HPS).
Adjacent lighting fixtures shall not be supplied from the same circuit.
8.2.2. Street and fence lighting
Unless otherwise specified, street lighting shall consist of 250 W high-pressure sodium
lights spaced by 40 m and mounted on 10m poles.
If special security fence lighting is required and unless otherwise specified, a floodlight
installation shall be designed based on HP discharge lighting with a minimum
illumination of 5 lux at any point in the area between the fence and 5 m outside the
fence.
Street and fence lighting can be controlled by means of the following device:
- Push-buttons located in substation or control room,

- Photoelectric cell,
- Daily timer.
8.2.3. Emergency Lights
- A convenient number of lighting fixtures are to be used as emergency lighting

and shall be provided for all the areas.
- Emergency lighting level shall reach at least 30% of the normal illumination level
for process area and building while for control room, Substation and Rack Room
shall be 50% minimum.
- Emergency lighting circuits originate their supplies from the substation

emergency distribution boards.

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8.2.4. Safety lighting
A convenient number of lighting fixtures will be provided as safety lighting to allow the
operation of the substation, control room and the safe escape from the building. They
will be equipped with internal emergency source (built-in battery).
8.2.5. Convenience outlets
The convenience outlets circuits from local panel or main junction boxes shall be single
phase, 3 wires cables (phase + neutral + earth).
Convenience outlets will be 16A rated, 230V, single phase. They will have protection
degree IP55 and suitable for the classification of the area where they will be installed.
Number and location of convenience outlets will be defined in order to reach every
point of operating plant area by about 25 m of cable length extension.
8.2.6. Gauge glass lighting
Gauge glass lighting from convenience panel shall be single phase, 3 wires (phase +
neutral + earth).
8.2.7. Aircraft warning lights
Aircraft Warning lighting shall comply with ICAO Standards- International Civil Aviation
Organization.
Platforms shall be provided to guarantee accessibility for Aircraft Warning Lights

system according to ICAO on the top of stack (if required).
Stack shall consider all the provision necessary for the installation of Aircraft Warning
Lights in accordance with ICAO norm
Aircraft warning lights are provided if required in the contract and by local safety
requirements.
If there is no availability of emergency power supply, aircraft warning lights shall

include an autonomous power supply unit.
8.3. Illumination Levels
If not otherwise specified the outdoor and indoor illumination levels will be in
accordance with the following paragraph 8.3.1.
Indicated levels are average over the considered area, and should be measured one
meter above grade.

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8.3.1. Illumination levels are indicated in LUX (1 LUX= 0.1 foot candles)
8.3.1.1. Outdoor Process Data
- Furnaces, heat exchangers, cooling towers ............................................................ 50

- Pumps, operating platforms, instruments, valves, manifold .................................... 50
- Package operating zones ........................................................................................ 50
- Stairs and ladders .................................................................................................... 30
8.3.1.2. Outdoor Non Process area
- Tank (stairs, ladders, and gauging area) ................................................................. 20

- Tank (general area) ................................................................................................. 10
- Manifold area ........................................................................................................... 20
- Loading area .......................................................................................................... 100
- Pump area................................................................................................................ 50
- Control panels area................................................................................................ 100
- Street lighting .............................................................................. Ref. to § 8.2.2 above
- Fence lighting .............................................................................. Ref. to § 8.2.2 above
- Parking area ............................................................................................................. 10
8.3.1.3. Control, Communication and Auxiliary Rooms
- Front of Panel......................................................................................................... 300

- Back of Panel ......................................................................................................... 150
- General .................................................................................................................. 100
- Emergency ............................................................................................................... 30
8.3.1.4. Substations/Machinery Rooms
- Outdoor switchyard .................................................................................................. 20

- Front of Switchboard .............................................................................................. 150
- General .................................................................................................................... 50
- Generator, machine room ...................................................................................... 200
- Transformers ............................................................................................................ 20
8.3.1.5. Building
- Offices (administration, technical).......................................................................... 500

- Laboratories ........................................................................................................... 500
- Warehouses ............................................................................................................. 50
- Workshops ............................................................................................................. 300
- Services (change, toilets, smoke room) .................................................................. 50
- Dining room, canteen, recreation room, kitchen.................................................... 150
- Sleeping room .......................................................................................................... 50

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8.4. Principle of Installation
8.4.1. Street and fence lighting
Refer to § 8.2.2 above.
The lighting fixtures supply ballast shall be incorporated in the lanterns. Lanterns are
supplied between phase and neutral. A fuse on the phase wire and a plug on the
neutral wire protect them. Fuse and plug are located in the lantern or in the pole base
at ground level.
The street and fence lighting fixtures will be supplied from the substation normal
lighting distribution board or field distribution boards. The supply cable runs along
roads to the junction box of the lamp post and supplies each fixture by means of a
branch cable.
Branch cable inside the lamp post, between junction box and light consists of 3 x 2.5
mm² conductors (phase + neutral + earth).
Fixture supply is balanced between each phase (1 fixture out of 3 per phase).
8.4.2. Lighting inside process plant
Cables from substation lighting distribution boards to the local lighting panels are
routed together with power cables.
Each local lighting panelboard is provided with an enclosure, whose type of protection
corresponds to the area classification, housing a 4-pole busbar to which the different
outgoes are connected.
In case of maintenance of the lighting panel itself, main disconnection and lock-off is
made at the supply side on the substation distribution board. Single-phase outgoing
circuits from the lighting panelboard consist of 3 pole cables (phase, neutral, and
earth) with a 2.5-mm² minimum cross-section.
Depending on the installation possibilities and illumination levels to be obtained,

lighting fixtures are equipped with:
- Incandescent lamps sized 100W, 150W, 300W to be limited with application as

per SN RK 4.04-19-2003.
- Fluorescent tubes sized 1 x 18W, 1 x 36W, 2 x 18W, 2 x 36W, 4 x 18W
- HP sodium lamps sized 100W, 150W, 250W, and 400W.
- Mercury Vapour Type sized 125W, 250W, and 400W.
Lighting fixtures shall be complete with all necessary accessories such as ballast,
capacitor, globe, guard, reflector and junction box.
The ballast shall be rapid start type.

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When lamps require the use of ballast, condenser, etc., these items are installed in the
lighting fixtures or separate housings.
In high buildings, such as compressor houses, maintenance and lamp changing shall
be possible using the overhead crane.
Lighting fixtures are provided with a class of protection corresponding to their

classification area. Their attachment fittings are selected depending on local facilities
(Hanger, console, lamppost, etc.).
Floodlights are preferably installed on structures. Should floodlights be installed on

poles, these shall be galvanized.
Branch connections are made through junction boxes housing the power and earthing
terminals; their class of protection is selected depending on the classification area.
Entrance of cables in lighting panelboard, junction boxes and lighting fixtures is by

means of cable glands suitable for the equipment on which they are installed.
Lighting cables are generally unarmoured and will be installed as follows:
Aboveground;
One or two cables will be installed in open conduit system, fixed on the structures.
More than 2 cables will be installed in perforated sheet galvanized steel cable trays.
Underground;
The cables will be installed with the same method as power underground cable system.
9. ELECTRICAL HEAT TRACING
Where required by process or other reasons, a heat tracing system shall be provided
and it shall be designed according to the project specification.
All heating cables and the ancillary materials shall be suitable for installation in a
classified area shall be approved for the purpose by an authorized laboratory.
Verification of maximum sheath temperature of heater cables in classified areas shall
comply with relevant temperature class. (T3,T4, etc.). Heating cables shall be
thermostatically controlled. Thermistors or high temperature limiters can also be used.
Heat tracing systems shall be generally supplied from their own distribution panel
boards.
10. CATHODIC PROTECTION SYSTEM

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Where required, a cathodic protection system shall be provided and it shall be

designed according to the following general supply rules:
2495-000-JSD-1684-51 General Design Rules for Cathodic Protection
11. SUBSTATION ARRANGEMENT
11.1. General
Substations normally include:
(a) A switchroom housing the HV and LV Switchgears, the auxiliary switchboards and
equipment (e.g. battery chargers, lighting distribution boards, capacitors, DC UPS,
etc.).
(b) Dedicated boxes separated by firewalls to house the power unit transformers and
their associated equipment (earthing resistors, inductance, etc). Do not apply to
main distribution Transformer with primary side feed by HV overhead line.
(c) A cable room under the switchroom to safely route and raises the cables up to the
switchroom electrical equipment.
11.2. Construction Requirements
Refer to civil building specification 2495-0000-JSD-2000-01
11.3. Installation Requirements
All cable entry holes in the substation floor or walls shall be suitable sealed.
The single line diagrams shall be mounted on the wall of substation in suitable frames.
Each substation switchroom shall be provided with:
- Wall mounted key cabinet

- Wall mounted electrical safety equipment including gloves and insulated tools.
- Insulated step ladders
- Isolation padlocks.
Substation building shall be sized to accommodate equipment according to clearances

specified in the following table and including a reasonable space for future expansion.
To this purpose space for at least one vertical panel or section should be provided at
the ends of each power switchgear.
The clearances from the electrical equipment will be respected as per electrical
equipment suppliers’ recommendations.

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Power transformers shall be located in the dedicated boxes in such a way as to

minimize the length and bends of secondary connections.
One access door shall be provided for each transformer. A clearance of 1m will be left
around each transformer.
12. OPERATION CRITERIA
12.1. NORMAL OPERATION (TWO MAIN INCOMING FEEDERS ARE AVAILABLE)
For medium voltage and low voltage switchgears, normal operation will be with the
main incoming breakers closed while the bus-tie breaker is open.
12.1.1. Loss of one main incoming feeder (automatic transfer)
Normally, the ATS selector switch must be always at “AUTO” position, If one of the
main incoming feeders is lost due to under voltage; its breaker will be automatically
tripped and the bus-tie will be immediately closed (provided that this incoming breaker
has not been tripped by fault clearing operation).
12.1.2. Return of lost main incoming feeder (manual transfer)
- Switch the ATS selector switch to “MANUAL” position.

- Switch the trip selector switch to “TRIP TIE C.B.” position.
Relay “25” shall check synchronizing between the returned feeder & the connected
feeder.
If the system is within the synchronizing limits, then breaker of the returned incoming
feeder shall be closed manually; this will result in momentary paralleling of both main
incoming breakers and the tie breaker, followed by the automatic opening of the bus tie
breaker.
12.1.3. Load transfer from one section to the other (manual transfer)
- Switch the ATS selector switch to “MANUAL” position.

- Switch the trip selector switch to “INC.1” or “INC.2” position.
Relay “25” shall check synchronizing between the two incomers.
If the system is within the synchronizing limits, the bus tie breaker shall be closed
manually; this will result in momentary paralleling of both main incoming breakers and
the tie breaker, followed by opening of the selected incomer.
12.2. Emergency operation (loss of the two main incoming feeders)

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Emergency operation shall be carried out in case of power loss due to under voltage
on emergency low voltage switchgear’s main incoming feeders and shall be inhibited in
case of power loss due to fault clearing operation on switchgears.
12.2.1. Loss of main incoming feeders on L.V. switchgear tagged 1-ESWG-3-1 (automatic
transfer)
Normally, the ATS selector switch on the generator control panel must be always at
“AUTO” position, if Incomers of emergency low voltage switchgear will be tripped due
under-voltage / inter-trip, consequently, under voltage will be sensed on the emergency
low voltage switchgear bus bars.
A start signal to the diesel generator will be initiated from emergency switchgear and
upon reaching generator’s nominal frequency and voltage, the diesel generator control
panel shall inhibit closing the switchgear’s incomers (1-ESWG-3-1-INC.1 and 1-ESWG-
3-1-INC.2) and signals (1-ESWG-3-1-INC.3 and 1-ESWG-3-1-TIE) to close.
Diesel generator 1-EDG-3-01 will supply the emergency power feeders while the DCS
(in control building) will automatically start the emergency motors, and other manually
operated emergency motors (if-any) shall be started manually from field control station.
12.2.2. Return to normal operation (restore one or two main incoming feeders) on emergency
low voltage switchgear tagged 1-ESWG-3-1 (manual transfer)
In case of restoring of one main incoming feeder, manually synchronizing of diesel

generator incoming feeder circuit breaker (1-ESWG-3-1-INC.3) with the restored main
incoming feeder shall be carried out through the generator control panel.
If the system is within the synchronizing limits, a closing signal to the restored incoming
circuit breaker will be initiated from the generator control panel, this will result in
momentary paralleling of the restored main incoming breaker (1-ESWG-3-1-INC.1 or
2), tie breaker (1-ESWG-3-1-TIE) and diesel generator incoming feeder (1-ESWG-3-1-
INC.3) followed by automatic opening of the of the bus tie breaker(1-ESWG-3-1-TIE)
and diesel generator incoming feeder (1-ESWG-3-1-INC.3) and stop signal to the
emergency diesel generator (1-EDG-3-1).
N.B. in case of restoring of both main incoming feeders of the emergency low voltage
switchgear, steps carried out in item 12.2.1 above shall be followed by steps in item
12.1.2 above.
12.2.3. Emergency load transfer to diesel generator
- Start emergency diesel generator manually.

- Switch the generator control panel selector switch to “MANUAL” position.
- Adjust the emergency switchgear as per item 12.1.3 above.
Manually synchronize the diesel generator incoming feeder (1-ESWG-3-1-INC.3) with

the selected incomer (1-ESWG-3-1-INC.1 or 2).

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if the system is within the synchronizing limits, a closing signal to the diesel generator
incoming feeder (1-ESWG-3-1-INC.3) will be initiated from the generator control panel,
this will result in momentary paralleling of the selected main incoming breaker (1-
ESWG-3-1-INC.1 or 2), tie breaker (1-ESWG-3-1-TIE) and diesel generator incoming
feeder (1-ESWG-3-1-INC.3) followed by automatic opening of the of the selected
incoming feeder.

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NOTICE: THIS DRAWING HAS NOT BEEN PUBLISHED. IT IS THE SOLE PROPERTY OF ENPPI.

300,000 MTA EB/SM PLANT EARLY WORKS PACKAGE

ESTYRENICS Reference: ES-PRO-02

ENGINEERING FOR THE PETROLEUM & PROCESS INDUSTRIES (Enppi) - EGYPT