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ENGINEERING SPECIFICATION FOR


Page
ELECTRICAL FACILITIES

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ENGINEERING SPECIFICATION FOR


ELECTRICAL FACILITIES

12-Dec-2014

REV

DATE

STATUS

Preliminary

MKS

TKW

SRL

DESCRIPTION

PRED

CHKD

APRD

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CONTENTS

1.

GENERAL

2.

AREA CLASSIFICATION

1.1
1.2
1.3
1.4
1.5
1.6
1.7

PURPOSE
SCOPE
CODE AND STANDARDS
AMBIENT CONDITIONS
UNITS, SYMBOL, AND IDENTIFICATION SYSTEM
LANGUAGE
SCREW THREAD

3.
DESIGN BASIS FOR POWER SYSTEM
3.1.
POWER SUPPLY AND DISTRIBUTION
3.2.
RATED VOLTAGE
3.3
SYSTEM GROUNDING
3.4
VOLTAGE DROP
3.5
POWER FACTOR
3.6
FAULT CALCULATION
3.7
EQUIPMENT SIZING
3.8
EMERGENCY POWER SUPPLY
3.9
110 VOLT DC CHARGER UNIT AND STATION BATTERY SYSTEM
3.10
UNITERUPTIBLE POWER SUPPLY (UPS)
4.

ELECTRICAAL CONTROL, PROTECTION, AND METERING SYSTEM

4.1
4.2
4.3
4.4
4.5

CONTROL SYSTEM
OVERCURRENT PROTECTION
GROUND-FAULT PROTECTION
UNDER VOLTAGE PROTECTION
TRIP AND ALARM SYSTEM

5.

MAJOR EQUIPMENT

6.

MOTOR CONTROL

5.1
5.2
5.3
5.4

6.1
6.2
6.3

7.
7.1
7.2
7.3
7.4
7.5
7.6
7.7

POWER AND DISTRIBUTION TRANSFORMER


HIGH VOLTAGE SWITCHGEARS AND MOTOR CONTROLLERS
LOW VOLTAGE SWITCGEARS
MOTORS

CONTROL CIRCUIT
LOCAL CONTROL STATIONS
MOTOR OPERATED VALVES

PAGE
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4
4
5
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6
6
7
7
7
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8
9
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9
9
10
10
13
13

14
14
14

WIRING
GENERAL
TYPE OF CABLE
CABLE SIZE
GENERAL WIRING METHOD
UNDERGROUND WIRING SYSTEM
ABOVE GROUND WIRING SYSTEM
CABLE RACK

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15
15
16
16
17
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7.8
7.9
7.10
7.11
7.12
7.13
7.14

8.
8.1
8.2
8.3
8.4

9.
9.1
9.2
9.3
9.4
9.5

10.
10.1
10.2

11.

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CONDUIT
CONDUIT FITTINGS
JUNCTION BOXES (APROX. 300 mm X 300 mm AND ABOVE) AND ENCLOSURES
CABLE TERMINATION AND IDENTIFICATION
SEALING
COLOR FOR IDENTIFICATION OF CABLES
POWER OUTLET (380 V, 3 PHASE) AND CONVENIENCE OUTLET (220V, 1 PHASE)

18
18
18
18
19
19
19

GRONDING AND LIGHTNING PROTECTION


GENERAL
GROUNDING OF SYSTEM NEUTRALS
GROUNDING OF ELECTRICAL EQUIPMENT ENCLOSURE
STATIC AND LIGHTNING PROTECTION GROUNDING

20
21
21
21

LIGHTING
GENERAL
ILLUMINATION LEVELS
EMERGENCY LIGHTING SYSTEM
STREET LIGHTING
OBSTRUCTION AND WARNING LIGHTS

22
23
23
23
24

COMMUNITCATION SYSTEM
TELEPHONE SYSTEM
RADIO COMMUNICATION SYSTEM

TESTING

24
24
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1. GENERAL
1.1

PURPOSE
This specification covers the general requirements for design, construction, and testing of electrical
facilities, within the battery limit of PT. Chandra Asri Petrochemical Tbk. (CAP) plant modification

1.2

SCOPE
The general requirement for the electrical facilities inside buildings such as substations, central
control buildings, and other offsite buildings is not included in this specification.
Electrical facilities which are supplied as component parts of a package unit are also excluded from
this specification. For these electrical facilities, the manufacturers standards or practices shall be
applicable provided that they have been used, proven and comply with the codes and standards
listed 2.1 below.

1.3
1.3.1

CODE AND STANDARDS


Unless otherwise specified, the electrical design, materials and equipment shall conform to the
applicable requirements of IEC (International Electrotechnical Commission) standards. Following
national codes and standards may be used as supplements to IEC;
France
Italy
Japan
F.R. Germany
England
USA

1.3.2

: NF, UTE
: CEI
: JIS, JEC, JEM
: VDE, DIN
: BS
: ANSI, NEC, NEMA, IEEE, UL

Electrical equipment for use in classified (hazardous) location must be labeled as approved for use
in that location approved equipment must be listed or certified for use in the particular hazardous
location by a internationally recognized testing organization.

1.3.3This specification shall be used in conjunction with the following relevant engineering
specifications.

1.4

CBP-PRS-ES-001-00
CBP-ELE-ES-001-00
CBP-ELE-ES-004-00
CBP-ELE-ES-005-00
CBP-ELE-ES-006-00
CBP-ELE-ES-007-00
CBP-ELE-ES-008-00
CBP-ELE-ES-009-00
CBP-ELE-ES-010-00
CBP-ELE-ES-011-00
CBP-ELE-ES-012-00
CBP-ELE-ES-013-00
CBP-ELE-ES-015-00
CBP-ELE-ES-016-00
CBP-CIV-ES-005-00
CBP-ELE-017-00
AMBIENT CONDITIONS

Design Basis
Intensity Of Illumination
Motors
Transformers
Bus Duct
Storage Batteries & Charger
6 kV Motor Starter
Medium Voltage Switchgear
Motor Control Center
Low Voltage Switchgear
Uninterruptible Power Supply System
Control Switch Station
Inspection & Test Of Electrical Equipment
Inspection Of Electrical Equipment Installation
Building , Clause 2.6 Electrical
Diesel Engine Generator

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The electrical facilities shall be designed for safe and correct function under the following ambient
conditions.
(1) Altitude

1000m or less above sea level

(2) Temperature
:
Ambient Temperature (dry bulb)
- Maximum temperature on record
- Minimum temperature on record
- Average daily maximum temperature
- Average daily minimum temperature
Design temperature:
-

1.5

Indoor temperature
Outdoor temperature

36.5 C
0
18.3 C
0
31.4 C
0
22.7 C
Maximum
40 deg. C
40 deg. C

(3) Relative humidity :


Average daily maximum
Average daily minimum
Annual average

85%
77%
80.7%

(4) Rainfall

144 mm/day maximum

UNITS, SYMBOL AND IDENTIFICATION SYSTEM

1.5.1

The metric system shall be used for all design and engineering documents and drawings which
are listed in para.2 of measurement on the engineering specification for design basis (CBP-PRS001-00).

1.5.2

Graphical symbols for electrical equipment shall generally be in accordance with IEC Publication
60617-1 to 60617-13.

1.6

LANGUAGE
The English language shall be used for all design and engineering documents and drawings.

1.7

SCREW THREAD

1.7.1

The form of thread and diameters and associated pitches of cable glands shall be in accordance
with
BS-3643.

1.7.2

In case where NPT cable entries are required in hazardous location, only approved adaptors shall
be utilized.

1.7.3

Any rigid galvanized steel conduit installation, where required, shall be NPT thread.
The minimum degree of protection for the enclosures shall be IP2X as per IEC 60947-1.

2. AREA CLASSIFICATION
2.1

Area where volatile liquids, flammable gasses or combustible dusts are handled shall be classified
in accordance with the National Electrical Code (NEC) and as interpreted by API-500A.

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2.2

Area classification drawings Hazardous Area Plan shall be prepared to indicate the degrees of
hazard and areas.

2.3

Equipment installed in the classified area shall be suitable for the area.

3.DESIGN BASIS FOR POWER SYSTEM


3.1
3.1.1

POWER SUPPLY AND DISTRIBUTION


Power Supply (to be confirmed with network power)
Main power supply will be 20 kV, 3-phase, 50 Hz, 300 A, resistance grounded.
Frequency and voltage variation at the tie-in point shall be in accordance with standard utility
practice; i.e., 1% on frequency and 5% max. on voltage.
The symmetrical fault level at the tie-in point shall be 35 kA provisionally.

3.2

RATED VOLTAGE

3.2.1

The frequency of all alternating current system shall be 50 Hz.

3.2.2

Unless otherwise specified, the electrical equipments shall be designed for operation at the
nominal system voltages listed below.
Sr.
No.
1

Equipments

Rated Voltage

Motor, below 0.2 kW rating

(1)

Nominal System Voltage

220 Volts, 50 Hz;


single phase

380/220 Volts 50 Hz;


3-phase 4-wire

Motors, 0.2 through 150 kW


rating

380 Volts, 50 Hz;


3-phase

380 Volts, 50 Hz;


3-phase

Motors, above 150 kW rating

6000 Volts, 50 Hz; 3-phase

6000 Volts, 50 Hz;


3-phase

Circuit breaker control

110 Volts DC

110 Volts DC

Low-voltage
circuit

110 Volts, 50 Hz;


single phase

110 Volts, 50 Hz;


single phase

Lighting fixtures

220 Volts, 50 Hz; single-phase

380/220 V, 50Hz

Instrumentation
(1) UPS

110 Volts, 50 Hz;


single-phase
24 Volts, DC

110 Volts, 50 Hz;


single-phase
24 Volts, DC

110 Volts, 50 Hz;


single-phase

110 Volts, 50 Hz;


single-phase

motor

(2) General

Note

(1)

control

: For critical service, 380 V, 3 phase, 50 Hz shall be applied.

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3.3

ENGINEERING SPECIFICATION FOR


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ELECTRICAL FACILITIES

SYSTEM GROUNDING

3.3.1

20 kV system neutral shall be resistance grounded.

3.3.2

11 kV generator neutral shall be distribution transformer grounded.

3.3.3

6 kV system neutral shall be resistance grounded.

3.3.4

380 V/ 220 V system neutral shall be solidly grounded.

3.3.5

110 V DC system shall be ungrounded.

3.3.6

110 V AC and 24 V DC system for instrumentation shall be ungrounded.

3.4
3.4.1

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VOLTAGE DROP
The maximum allowable voltage drop in percentage of the nominal system voltage shall be as
follow;
Feeders
Motor feeders on full load
Motor feeders during starting
Lighting circuits i.e. from 380 Volt distribution board to the furthest lighting fitting

5%
5%
5%
5%

3.4.2

During starting of motor, either alone or in a group, the voltage drop on any bus shall not exceed
20% of the nominal system voltage.

3.4.3

Motor terminal voltage due to starting shall be, at all times, sufficient to produce the torque
required to accelerate the load to the rated speed.

3.5
3.5.1

3.6

POWER FACTOR
The plant overall load power factor measured at the 20 kV bus shall be 0.85 or greater at Plant
normal operation except during the large motor starting. Automatic power factor control shall not
be required.
FAULT CALCULATION

3.6.1

Fault current calculations to determine short-circuit RMS current shall incorporate all short-circuit
current source and all components of circuit impedance in the primary system, secondary system
and branch circuit.

3.6.2

The fault current shall be limited by design to values that can be withstood by the equipment
and/or the equipment shall be selected within the available fault currents.

3.7

EQUIPMENT SIZING

3.7.1

All transformers shall have enough capacity to cover the maximum demand of the plant normal
operation.

3.7.2

Transformer primary and secondary circuit breakers shall have a continuous rating at least equal
to maximum rating of the transformer.

3.7.3

Feeder breakers or incoming breakers supplying busses shall have a continuous rating at least
equal to the adjusted maximum demand of the total load supplied from the bus. For secondary

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selective sub stations adjusted maximum demand shall be determined with the bus tie breaker
closed one incomer open.
3.74

Bus tie circuit breakers in secondary-selective substation shall have a continuous capacity equal
to that of the main secondary circuit breaker.

3.7.5

In secondary selective substation the rating of each transformer shall be such that if any one
transformer is out of service the remainder transformer can meet the adjusted maximum demand
of the load.

3.7.6

Cable capacity shall be calculated by taking into account the derating factors for grouped
installation of the cables. Number and configuration of load carrying cables shall only be
considered to determine what group derating factor to be used for cables which contain carrying
and stand-by non-current carrying cables.

3.8

EMERGENCY POWER SUPPLY

3.8.1

In order to facilitate the safe shutdown of the plant an emergency 380 V, 3 phase, 4-wire 50 Hz
switchgear shall be provided. The switchgear shall supply all the essential loads and is supplied
from the normal power supply and emergency generator. The normal operation is supplied from
normal power however in case a power failure the switchgear shall automatically switch over to
the emergency generator.

3.8.2

Starting of the diesel generator shall be initiated upon failure of the normal supply detected at the
emergency bus in switchgear. If the normal source of supply has not been restored and the
generator is at acceptable voltage and frequency, then change-over to the generator source shall
be fully automatic
The generator, once started, shall continue to run until it is manually stopped or unless it is tripped
due to fault / trouble.

3.8.3
3.9

For further details refer to specification for Diesel Engine Generator CBP/ELE/017/00.
110 VOLT DC CHARGER UNIT AND STATION BATTERY SYSTEM

3.9.1

A 110 V DC charger unit and station battery system shall be provided for the followings;
- Switchgear Operation and Control

3.9.2

The system shall consist of one constant voltage/current limiting rectifier, one set of lead-acid
batteries sized for 30 minutes back-up and a DC distribution panel.

3.9.3

For further details refer to specification CBP-ELE-007-00.

3.10 UNITERUPTIBLE POWER SUPPLY (UPS)


3.10.1

A 24 V DC and 110 V AC UPS system with batteries shall be provided for instrumentation, which
shall generally with the recommendation contained in IEC publication 60439 and 60146.

3.10.2

The 110 V AC UPS system shall consist of one constant voltage/current limiting rectifier
connected to the inverter, one set of lead-acid batteries, a by-pass transformer and a
transfer switch providing no-break operation for load application and a distribution panel.
The 24 V DC system shall consist of one constant voltage/current limiting rectifier and one set of
lead-acid batteries.

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3.10.3 The batteries shall be sized for 30 minutes operation to supply the power to instrumentation with
full voltage.
3.10.4 A separate uninterruptible power supply system with batteries shall be incorporated in the fire
alarm system.
3.10.5 For further details refer to specification CBP-ELE-012-00.

4. ELECTRICAL CONTROL, PROTECTION, AND METERING SYSTEM


4.1

CONTROL SYSTEM

4.1.1

Switchgears except motor controllers, shall generally be controlled manually by a ON/OFF control
switch mounted on the front face of each switchboard.

4.1.2

The power for the control circuit shall be supplied from the 110 V DC unit with station batteries.

4.2

OVERCURRENT PROTECTION
The overcurrent protection shall be coordinated to ensure correct sequential operation between
incomers and feeders.

4.3

GROUND-FAULT PROTECTION

4.3.1

In the 6 kV system, each power feeder and motor controller shall be provided with a instantaneous
ground overcurrent relay (50G) which shall be coordinated with a time delay ground overcurrent
relay (51G) provided at the transformer neutral to ensure correct sequential operation incomers
and feeders.

4.3.2

In low voltage system, each power feeder and motor control unit shall be protected against ground
fault by the molded case circuit breaker (MCCB) or the fuses in each circuit, and coordinated with
time delay ground overcurrent relay (51G) provided at the transformer neutral to ensure correct
sequential operation between incomers and feeders.

4.3.3

Earth leakage relay may be provided in some motor control unit to trip the molded case circuit
breaker (MCCB) or the contactor where the ground fault circuit impedance is not sufficiently small
to trip the MCCB or the fuses.

4.4

UNDERVOLTAGE PROTECTION

4.4.1

All the low voltage motors will be tripped by the electromagnetic contactor drop out when
undervoltage occurs.

4.4.2

All the high voltage motors will be provided with a DC tripping coil in the controller, and shall be
tripped using an undervoltage trip relay when undervoltage occurs.

4.4.3

Auto-restart of motors following a voltage dip (a brief interruption of electricity) will be provided if
required process reasons.

4.5

TRIP AND ALARM SYSTEM

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4.5.1

The normally de-energized (Close to Trip) system by means of relay shall generally be applied for
the electrical trip system.

4.5.2

The normally energized (Open to Alarm) system shall generally be applied to the electric alarm
system.

4.5.3

Substation Alarms
Electrical equipment in the substation/Switchroom shall have the following alarms for annunciation
in the power control room, one dry contact for each.
(1) 20 kV trouble
(2) 6 kV trouble
(3) L.V. trouble
(4) Emergency generator troble
(5) D.C. 110 V trouble
(6) D.C. 24 V trouble
(7) A.C. 110V UPS trouble
(8) Air conditioning trouble

4.6

For further details of electrical control and protection refer to the following specification:
CBP/ELE/008/00 6 kV Motor Starter
CBP/ELE/009/00 Medium Voltage Switchgear
CBP/ELE/010/00 Motor Control Center
CBP/ELE/011/00 Low Voltage Switchgear

5. MAJOR EQUIPMENT
5.1

POWER AND DISTRIBUTION TRANSFORMER

5.1.1 Power and distribution transformers shall generally comply with recommendations contained in IEC
publication 60076.
5.1.2

Power and distribution transformers shall be of outdoor use, oil-immersed and self-cooled type.

5.1.3

Primary windings of transformers shall have four 2.5 % full capacity taps (2 above normal and 2
below normal voltage) controlled by an external hand operated on load tap changer.

5.1.4

Primary and secondary terminations shall be enclosed in air insulated terminal chamber or throats
suitable for cable connections.

5.1.5

Power transformers shall be connected delta-star to provide vector group reference Dy5, and shall
have the secondary star point brought out and terminated at an insulated bushing, enclosed in a
separate cable box.

5.1.6

For further information refer to specification CBP/ELE/005/00.

5.2

HIGH VOLTAGE SWITCHGEARS AND MOTOR CONTROLLERS

5.2.1 20 kV switchgears, 6 kV switchgears, and 6 kV motor controllers shall generally comply with the
recommendation contained in IEC publication 62271-200.
5.2.2
5.2.3

All switchgears shall be of the metal enclosed indoor type with draw-out circuit breakers
mechanical interlocked to prevent moving of circuit breakers while closed.
All switchgears and motor controllers shall be arranged to form single assembled
switchgear with common bus-bars.

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5.2.4

All circuit breakers shall be either SF6 gas circuit breakers or vacuum circuit breakers, and
operated by solenoid, and operated by solenoid or motor charged spring type stored energy
mechanism. The 6 kV motor controllers shall be draw-out type vacuum contactors with current
limiting power fuses.

5.2.5

All switchgears and motor controllers shall be provided with space heaters (panel space heaters)
rated 220 V AC with thermostat control at each vertical section. Power to the space heaters shall
be supplied from the 380 / 220 V distribution panel.

5.2.6

Control power for switchgears and motor controllers shall be of 110 V DC supplied from 110 V DC
distribution panel.

5.2.7

Each motor controller shall have a space heater control circuit to provide power to the space
heater in the motor.

5.2.8

20 kV switchgears shall be equipped with the following protection and meters;


Incomer

i)

Voltmeter suitably scaled and fitted with phase selector switch.

ii)

Ammeter suitably scaled and fitted with phase selector switch.

iii)

Inverse Definite Minimum Time Limit (IDMTL) relays for overcurrent and earth
fault protection, having instantaneous high set alarm.

iv)

Transformer fault relay activated by Bucholz and oil temperature, having contacts
arranged to trip both the incomer and the feeding breaker. (only for generator
transformer incomer)

v)

Transformer differential protection relay. (only for generator transformer incomer)

vi)

Power factor meter

vii) KWH and kW meter


viii) Space heater manual on-off switch
ix)

Facilities for inter-tripping

x)

Hand reset lock-out relay to be tripped by all protective devices.

Transformer or Power Feeder


i)

Voltmeter suitably scaled and provided with phase selector switch

ii)

IDMTL relay for overcurrent and earth fault protection, having instantaneous high
set element.

5.2.9

iii)

KWH and kW meter

iv)

Space heater manual on-off switch

v)

Facilities for inter-tripping

6 kV switchgear and motor controller shall be equipped with the following protection and meters;
Incomer

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i)

Voltmeter suitably scaled and fitted with phase selector switch.

ii)

Ammeter suitably scaled and fitted with phase selector switch.

iii)

Inverse Definite Minimum Time Limit (IDMTL) relays for overcurrent and earth
fault protection.

iv)

Transformer fault relay activated by Bucholz and oil temperature, having contacts
arranged to trip both the incomer and the feeding breaker.

v)

Transformer differential protection relay.

vi)

Power factor meter

vii) Space heater manual on-off switch


viii) The breaker is to be arranged to allow inter-tripping from the feeding breaker
ix)

Hand reset lock-out relay to be tripped by all protective devices

Transformer or Power Feeder


i)

Voltmeter suitably scaled and provided with phase selector switch

ii)

IDMTL relay for overcurrent and earth fault protection, having instantaneous high
set element.

iii)

KWH and kW meter

iv)

Space heater manual on-off switch

v)

Facilities for inter-tripping

Motor Feeder
i)

Ammeter suitably scaled and fitted with phase selector switch

ii)

Motor protection relay or equivalent, giving protection against overcurrent, earth


fault, and single phasing

iii)

Undervoltage trip

iv)

Facilities for connecting a remote ammeter

v)

Breaker/contactor auxiliary contact arranged to operate a motor space heater in


the event of the breaker opening or being removed

vi)

Space heater manual on-off switch

vii) Local/remote change-over switch, which is key lockable


viii) Breaker/contactor on-off switch, which works only when the breaker/contactor is at
test position and the above change over switch is at remote position.
ix)

Current transducer, where required for process / operation

5.2.10 For further information refers to specification CBP-ELE-009-00.


5.3
LOW VOLTAGE SWITCHGEAR
5.3.1

380/220 V switchgears, motor control center and distribution panels shall generally comply with
the recommendation contained in IEC publication 60439.

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5.3.2

The low voltage switchgears shall be metal enclosed, indoor type, free standing floor mounting
with circuit breakers. The switchgears will be of multi-tiered construction.

5.3.3

The incoming circuit breaker and the tie breaker shall be three pole draw-out type air circuit
breakers. Molded-case circuit breakers, which shall have sufficient interrupting capacity, may be
used as branch breakers.

5.3.4

All low voltage air circuit breakers shall be electrically operated 110 V DC or 220 V AC with stored
energy operating mechanisms.

5.3.5

Each low voltage incomer switchgear shall be provided with the following protection and metering;
i)

Voltmeter and phase selector switch

ii)

Ammeter and phase selector switch

iii)

Inverse Definite Minimum Time Limit (IDMTL) relays for overcurrent and ground
fault protection

iv)

The breaker shall be arranged to allow inter-tripping from the primary feeder
breaker

v)

Transformer fault relay (depending on the rating of transformers)

5.3.6

Motor Control Centers (MCC) shall be metal enclosed, free standing, with multi-tiered fully
withdrawable control units for motor starters. Control units for large motors may be of fixed type.

5.3.7

Each combination motor control unit in MCC shall be of the direct on line starting, and provided
with a molded-case circuit breaker to provide short circuit protection and disconnecting means,
and a magnetic contactor and a thermal relay to provide overload protection. A thermal overload
relay shall be arranged for hand reset.

5.3.8

Each combination motor control unit in MCC shall be arranged for remote push-button control
circuit energized at phase to neutral voltage. Contactor on (red), off (green) and trip (amber)
indicate lamps shall be provided on each unit. No on-off control switch shall be provided on each
unit.

5.3.9

Each feeder unit in MCC shall contain a molded case circuit breaker or fuses manual operation

5.3.10

380/220 V distribution panels, which shall be for lighting, space heaters and miscellaneous
purpose, shall be metal enclosed, free standing with multi fixed type feeders.

5.3.11

For further information refers to specifications CBP-ELE-010-00 and CBP-ELE-011-00.

5.4

MOTORS

5.4.1

Motors shall generally be of the squirrel cage induction type and comply with the recommendation
contained in IEC publication 60034.

5.4.2

Motors shall be suitable for normal starting and continuous operation at name plate kW rating, and
have sufficient starting torque and thermal capabilities to accelerate the connected machine to
maximum speed without injurious heating.

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5.4.3

Protection grade against water and dust for motors, installed where exposed to water jet, shall be
IP55 specified in IEC publication 60034-5/60529.

5.4.4

Space heaters shall be provided in motors of rated voltage 6 kV and above. Space heaters shall
operate at 220 Volt, AC.

5.4.5

For further information refers to specification CBP-ELE-004-00.

6.MOTOR CONTROL
6.1

CONTROL CIRCUIT

6.1.1

For high voltage motors, each motor controller shall include the necessary electrical interlocking
and interwiring between units and interlocking provisions to remotely mounted devices. Control
circuit voltage shall be 220 V AC derived from the main circuit phase and neutral.

6.1.2

For low voltage motors, each motor control unit shall include the necessary electrical interlocking
and interwiring between units and interlocking provisions to remotely mounted devices. Control
circuit voltage shall be 220 V AC derived from the main circuit phase and neutral.

6.2.

LOCAL CONTROL STATIONS

6.2.1

Motors shall generally be controlled from STOP-START control switch stations located at, or near
the motor.

6.2.2

STOP-START control switch stations shall be arranged so that momentary operating of the STOP
switch stops the motors.

6.2.3

Local control stations for motors having a rating of 37 kW and above and driving critical loads for
plant operation shall have ammeters. The ammeter shall be connected to a CT in the motor
controller, rated secondary current 1 ampere.

6.3

MOTOR OPERATED VALVES


Valve operators shall be complete with integral reversing contactor starter and overload, etc.

7.WIRING
7.1

GENERAL

7.1.1

The electrical wiring in the Plant, shall generally be carried out by armored cables.

7.1.2

Materials used for cable insulation, sheathing and serving must be suitable to withstand any
contaminating liquids or gases likely to be encountered in the area.

7.1.3

Cable and wire shall conform in all respect to the IEC standard. Armoring shall be in accordance
with the regulation of BS, VDE, JIS or equivalent.

7.2
7.2.1

TYPE OF CABLE
The following type of cables shall be used for power, lighting and grounding wiring system.
a) 20 kV and 6 kV system power cable
: N2XSRY-FL

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b)

380/220 V system and below power cable : N2XRY-FL

c)

Control Cable

: NYRY-FL

d)

Lighting Cable

: N2XRY-FL

Legends
1. N2XSRY

: 15of 24

: Cross-linked polyethylene (XLPE) insulated, copper shielded/screened for


each core, flame retardant PVC inner sheathed, single wire armored (SWA)
and flame retardant PVC outer sheathed copper conductor cable

Note (1) : The voltage ratings of the cables shall be as follows:


System Voltage
a. 6 kV
b. 20 kV

7.2.2
7.3

Rated Voltage
3.6/6 kV
12/20 kV

Cable Grade
Maximum Voltage
7.2 kV
24 kV

(2)

For single core cables, aluminum armor shall be applied instead of steel
armor.

2. N2XRY

: 600/1,000 volt grade cross linked polyethylene (XLPE) insulated, flame


retardant PVC inner sheathed, single wire armored (SWA) and flame
retardant PVC outer sheathed copper conductor cable.
For single core cables, aluminum armor shall be applied instead of steel
armor.

3. NYRY

:600/1,000 volt grade PVC insulated, flame retardant PVC inner sheathed,
single wire armored (SWA) and flame retardant PVC outer sheathed copper
conductor multi-core control cable.

In areas where cable installation is well protected from physical damage such as inside
substation, central control building, etc., cables without wire armor may also be used.
CABLE SIZE
The sizing of cables for consumers shall be based on their nameplate rating. The allowable
current in any conductor shall be calculated in accordance with relevant IEC publications. Cable
nominal size shall be 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 95, 120, 150, 185, 240, 300, 400,
500, 630; unit is square mm
Minimum size of cable and wire shall be as follows;
(1) 20 kv circuit
(2) 6 kV circuit
(3) Low voltage power circuit
(4) Control circuit
(5) Lighting circuit
(6) External CT circuit for transformer neutral

7.4
7.4.1

:120 mm
2
: 25 mm
2
: 2.5mm
2
: 1.5 mm
2
: 1.5 mm
2
: 2.5mm

Note: Wire size for small current circuit such as testing and measuring instrument circuit and
internal wiring of power board is not include in this list.
GENERAL WIRING METHOD
Electrical distribution cable from the substation to each load shall generally be installed in
overhead racks or tray. The racks or trays shall be hot dipped galvanized.

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7.4.2

Single cables leaving a main cable run to a motor, motor control station or lighting fitting may be
fixed to walls or columns by suitable spacer type saddle and/or cable tray.

7.4.3

3 cores power cable shall be used for motor power supply cable.

7.4.4

Distribution to offsite buildings, street lighting and other loads far from the process area shall be
with direct buried underground cable. Cable route markers shall be installed on the main
underground cable route.

7.4.5

A distance of at least 600 mm shall be maintained in the main cable route between power cables
and low level signal cables for instrumentation except where the two types of cable cross each
other, in which case the minimum distance between the two types cable shall be 200 mm. All
crossings shall be at 90 degrees angle as far as possible.

7.4.6

Cables for fire alarm system will be installed in the instrumentation cable duct or in the electrical
cable ladder with barrier separation.

7.4.7

Cable shall be arranged to minimize the number of crossover.

7.4.8

Cables shall be installed according to manufacturers recommendation. In no case shall the


manufacturers maximum allowable pulling tension be exceed during cable installation.

7.4.9

Minimum cable bending radii, either during installation or in the final arrangement, shall never be
less those allowed by the manufacturer.

7.4.10

As far as practical all cable runs shall be continuous without splices.

7.4.11

Cable must be placed a minimum of 300 mm to the side of or 600 mm above any hot line, fitting or
o
vessel above 55 C unless an insulating barrier is provided.

7.5

UNDERGROUND WIRING SYSTEM

7.5.1

Armored cables shall be buried directly in the ground.


Minimum burial depth from the finished grade to the top surface of the largest cable shall be 600
mm.

7.5.2

The cable trench shall be of sufficient width to accommodate the cables installed in the manner
described in section 7.5.10 and 7.5.11.

7.5.3

The bottom of the trench shall be covered with 100 mm of sand.

7.5.4

Prior to laying of the cables all neutral soil which has fallen in the trench shall be removed.

7.5.5

After laying of the cables, the cables shall be covered with 100 mm of sand measured from the
top of the largest cable.

7.5.6

The sand shall be clean and free of organic matter.

7.5.7

Backfill material shall be free of all large stones and rocks. Backfill shall be compacted.

7.5.8

After installation of all cabling as described in section 7.5.5, 50 mm thickness of red concrete tiles
or red lean concrete shall be placed over the cables.

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7.5.9

Warning tape shall be placed in the cable trench. The tape shall be 150 mm wide yellow
polyethylene with legend caution buried electric lines continuously along the length.

7.5.10

Cables shall generally be laid in flat formation, touching. Long runs of power cables shall be
installed with adequate separation. Where high voltage and low voltage cables run in the same
formation, a minimum of 150 mm horizontal separation shall be maintained. Where the 150 mm
separation cannot be maintained, concrete separators are to be provided.

7.5.11

Cables other than high voltage main distribution cables running in the same trench may be
installed up to a maximum of two layers. If two layers of cables are installed 75mm of clean sand
shall be placed between them.

7.5.12

Cables crossing roads shall run in underground conduits or other approved raceways. For
crossing of pipes or other underground obstructions, cables can run in sleeves.

7.5.13

Cables entering or leaving the ground shall be protected from mechanical damage by placing the
cables in rigid galvanized steel conduits between 150 mm above and 300 mm below grade. The
upper opening of the conduits shall be fitted with a conduit bushing and sealed with soft
compound.

7.5.14

Where cables pass thru floors, protecting covers for groups of cables or conduits for single cables
shall be provided. In either case, the upper opening of covers or conduits shall be sealed with soft
compound.

7.6

ABOVE GROUND WIRING SYSTEM

7.6.1

All cables routed above ground shall generally be fixed to cable racks in the main cable route and
cable trays in branch cable routes.

7.6.2

High voltage cables shall be installed in a separate cable racks or tray from that for low voltage
cables, or separator in the same rack or tray.

7.6.3

Cables shall in general be installed side by side touching for 6 kV power in single layer, for low
2
voltage power cable size 95 mm in a maximum of two layers. Under no circumstances shall the
cables protrude above the side rail of the cable rack/tray. The total cable fill shall comply with the
NEC code articles 318-9 to 318-12.

7.6.4

Cables shall be secured to the racks or trays by means of clamps or nylon cable ties.

7.6.5

Individual cables which run above grade between adjacent items of equipment may be supported
directly on local steelwork.

7.6.6

Where cables enter a building above grade, the cable entry shall be sealed with water tight and
flame reatardative agent.

7.7

CABLE RACK

7.7.1

Cable rack and accessories shall comply with standard NEMA, VEI or equivalent standard.

7.7.2

Cable rack shall be of the heavy duty type with a minimum of 100 mm depth and 300 mm rung
spacing.
Cable rack shall be hot dipped galvanized. The coating thickness shall conform to BS 729 or
equivalent standard.

7.7.3
7.7.4

Accessories such as bolts & nuts etc. shall be of stainless steel.

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7.7.5

Cable rack fittings shall be designed with proper radius, which is no less than the minimum
bending radius of the largest cable to be installed.

7.7.6

Cable rack shall be provided with metallic covers where exposed to sunlight or where mechanical
protection is required.

7.7.7

Cable rack shall be adequately supported to prevent sag utilizing the manufactures recommended
spans.

7.8

CONDUIT

7.8.1

Conduit utilized outdoors, shall be rigid galvanized steel.

7.8.2

Conduit utilized indoors in non-classified areas where subject to clean, dry non-corrosive locations
only, shall be galvanized steel thin wall conduit (EMT).

7.9

CONDUIT FITTINGS

7.9.1

Conduit fittings shall comply with applicable IEC publications.

7.9.2

Fittings shall be of corrosion resistant materials such as copper free aluminum or hot dipped
galvanized iron or iron alloy.

7.10

JUNCTION BOXES (APROX. 300 mm X 300 mm AND ABOVE) AND ENCLOSURES

7.10.1

All junction boxes and enclosures shall comply with applicable IEC publications.

7.10.2

All junction boxes shall be properly sealed against the entrance of moisture and shall be equipped
with breathers and drains. Degree of protection for junction boxes shall be IP54.

7.10.3

Cable entry (gland) or conduit shall be preferably from the bottom. Side entry is acceptable. Top
entry should be avoided whenever possible. In sheet metal enclosures tight entry shall be made
using corrosion resistant conduit hubs.

7.10.4

Terminal blocks when required shall be installed in such a manner as to allow ample wiring
around the terminals.

7.11

CABLE TERMINATION AND IDENTIFICATION

7.11.1

Cables shall in general be terminated by means of compression type cable glands. The cable
gland shall be of brass construction and shall be suitable for the type of armoured cable used.

7.11.2

Cable lugs, where used, shall be crimp/compression type and shall be installed with ratchet or
hydraulic crimping tools utilizing the proper dies.

7.11.3

Terminal blocks shall in no case be used to terminate more than two wires, one per side. If
multiple connections are required, terminal block jumper bars shall be utilized. Wire shall be left
with sufficient spare length to enable wiring modifications to be made. Spare cores shall be left
with sufficient length to terminate at the furthest terminal from entry.

7.11.4

Each power and control cable shall be clearly marked with PVC markers. The markers shall be
secured with nylon ties. A cable marker shall be installed at both end of each cable. Direct buried
cables shall be marked every 10 meters maximum with lead markers giving cable number.

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7.12

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Conductors of all control cables shall be identified at both ends with a suitable wire marker. There
wire markers must correspond to the wire numbering shown on the electrical drawings.
SEALING

7.12.1

Sealing shall be installed in accordance with applicable IEC publications.

7.12.2

In division 1 and 2 locations seals are required:


-

In every cable run entering any of enclosure containing arcing devices


At the terminating ends of cables crossing division 1 location applicable shall be so
constructed not to transmit gases or vapors.

7.12.3

Sealing fittings should be accessible during and after installation.

7.12.4

Sealing fittings shall only be mounted in the position for which they were designed.

7.12.5

Approved sealing compound and fibre shall be used, and the manufacturers instructions should
be followed in preparation of dams, the preparation and pouring of sealing compound.

7.13
7.13.1

COLOR FOR IDENTIFICATION OF CABLES


The color for identification of cable shall be as follows;
(1) Overall sheath
(a) H.V. power cable -------------------- Black
(b) L.V power and control cable------ Black
(2) Core
(a) H.V. power cable
Single core -------- Red
3 cores ------------- Red, Yellow, Blue
(b) L.V. power cable
Single core --------- Red
2 cores -------------- Red, Black
3 cores -------------- Red, Yellow, Blue
4 cores -------------- Red, Yellow, Blue, Black
(c) Control cable
Individual cores shall be identified by number 1,2. Printed on the cores at some interval
throughout the length.

7.14

POWER OUTLET (380 V, 3 PHASE) AND CONVENIENCE OUTLET (220V, 1 PHASE)

7.14.1

Power outlets and convenience outlets shall be installed at convenient points to serve the plant
area. Power and convenience outlets shall in general be located so that the total plant area can
be served with 100 meters cords from power outlet, and 50 meters cords from convenience outlet.

7.14.2

Branch circuits supplying the power and convenience outlets shall server no other equipment and
not more than six outlets shall be supplied by one circuit. Each branch circuit shall be protected by
thermal magnetic moulded case circuit breaker of suitable current rating or fuses, located in the
380/220 volt distribution panel.

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GROUNDING AND LIGHTNING PROTECTION

8.1

GENERAL

8.1.1

The grounding arrangements shall provide for:


(1)
(2)
(3)
(4)

Grounding of system neutrals


Grounding of electrical equipment enclosures
Static protection grounding
Lightning protection grounding

8.1.2

Grounding of system neutrals and electrical equipment enclosures shall be by means of


interconnecting conductors to the bellow grade ground grid.

8.1.3

Static, system and electrical equipment grounding shall be integrated to form a common
grounding network.

8.1.4

Grounding system around the flare stack area will be independent from that in the plant area.

8.1.5

An independent grounding system shall be provided for all electronic equipment.

8.1.6

The conductor used for the grounding system shall be stranded copper wire with green yellow
PVC insulation.

8.1.7

All buried or concealed connections in the grounding system shall be made by thermoweld
connection. Bare metal at taps shall be covered with one layer of self-adhesive tape and two
layers of insulation tape.

8.1.8

All screw, bolts, nuts, clamps, and connectors shall be compatible with the grounding material
being used.

8.1.9

Equipment that is located remotely from the main grounding network may be grounded by means
of individual grounding conductors and grounding electrodes.

8.1.10

Underground grounding conductors shall be installed at least 460 mm below grade.

8.1.11

Grounding conductors leaving the ground shall be protected by rigid galvanized steel conduit
between 150 mm above grade and 150 mm below grade.

8.1.12

Armor of cables shall be electrically grounded at both ends, unless otherwise specified.

8.1.13

All conveying line/resin transport lines shall be electrically continuous and properly bonded and
grounded.

8.1.14

Grounding electrodes shall be 20 mm (3/4) diameter X 3000 mm (10 FT) long carbon steel copper
clad rod.

8.2
8.2.1

GROUNDING OF SYSTEM NEUTRALS


Each power transformer or generator neutral shall be grounded (solid via resistor or distribution
transformer) by means of driven ground rods which are interconnected below grade with a ground
grid. In the substation / switchroom a copper ground loop or bar of sufficient size shall be provided

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to enable termination of all electrical equipment grounds. The loop or bar shall be connected to
the main ground grid with a minimum of two ground conductors.
8.2.2

Ground conductors shall be rated for the prospective fault current and shall be sized in
accordance with the applicable IEC publication.

8.2.3

The ground resistance value for system neutrals shall not exceed 4 ohm as a loop or grid.

8.3

GROUNDING OF ELECTRICAL EQUIPMENT ENCLOSURE

8.3.1

Non current carrying parts of electrical equipment shall be grounded. In general, a separate
ground conductor shall be attached to each item for which grounding is required, except for
equipment that shall be considered as satisfactorily grounded when the structural steel on which it
is supported is grounded.

8.3.2

The ground grid shall generally be installed below grade. The main grid shall be 70 mm stranded
copper conductor PVC insulated. The grid shall interconnect all driven ground rods as detailed in
8.1.14. All equipment requiring grounding shall be connected to this grid minimum wire size 16
2
mm (for mechanical protection).

8.3.3

Each H.V. and L.V. switchgears shall be connected to the grounding network with two copper
ground conductors one at each end of the single assembled switchgear sized in accordance with
the applicable IEC publication.

8.3.4

Low voltage cables shall have a protective conductor which size shall be selected on a below
basis.

Cross-sectional area of phase conductor of


the installation S (mm2)
S 16
16 < S 35
S > 35

Minimum cross-sectional area of the


corresponding protective conductor S0 (mm2)
S
16
S/2

8.3.5

Lighting panels shall be connected directly to the grounding systems with a separate grounding
2
wire of 16 mm .

8.3.6

Street lighting poles shall be grounded by a wire of 16 mm .

8.3.7

The cable racks and tray shall be grounded at intervals of approximately thirty (30) meters.

8.3.8

The armoring of cables interconnecting the equipments may be considered as one of grounding
path where electrically connected to the equipment.

8.4

STATIC AND LIGHTNING PROTECTION GROUNDING

8.4.1

Process equipment containing hazardous materials and located in hazardous area, shall be
grounded to prevent static discharges.
2
Each equipment shall be connected to the main grounding loop by means of 25 mm branch wire.

8.4.2

The tallest structures, columns and stacks in each area shall be grounded for the protection
against lighting.

8.4.3

Lighting protection shall be in accordance with NFPA78-Lightning Protection Code. Lightning


protection shall generally be connected with any other grounding system in the direct vicinity, and

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shall take the form of cone protection. The cone protection system shall smart at the tallest
structure within the plant and shall be continued until complete plant protection is achieved.
8.4.4

Any structure within a cone of protection shall be considered adequately shielded against lightning
and shall not require further protection.

8.4.5

The resistance to ground for lightning protection shall not exceed 7 ohms.

8.4.6

Where the lightning protection system is installed close to any other grounding system, they shall
be interconnected at convenient points.

8.4.7

The pipes, generating static electricity, on the pipe racks/sleepers shall be grounded at the
boundary of hazardous area or at interval of approximately thirty (30) meters in order to minimize
potential differences.

9.

LIGHTING

9.1

GENERAL

9.1.1

Sufficient lighting shall be provided to enable operators to circulate freely and safely within the
accessible area of the plant and perform whatever duties are required.

9.1.2

General illumination of outdoor area shall be provided by suitably located floodlights. Where
supplementary lighting is required for items such as instruments, gauge glasses, etc. , individual
fixtures shall be used. Sodium vapor lamps shall generally be used.

9.1.3

Armored cables specified in Par.7.2 shall, in general, be used for the lighting circuits.

9.1.4

Floodlights shall generally be mounted on structures, pipe support or poles of hot-dip galvanized
steel or concrete.

9.1.5

Lighting supply shall be at 220 V volts single phase and neutral, obtained from local lighting
distribution boards installed at convenient location in the plant. These boards shall receive 380
volts, 3-phase 4-wire supply from a contactor feeder unit, controlled by photo electric cell with
manual override control in the distribution panel located in the substation. The local emergency
lighting distribution boards shall be similarly controlled but fed from the emergency power
distribution panel in the substation.

9.1.6

Branch circuit breakers in each local distribution panel shall be of 20 amperes, initially loaded to a
maximum of 80% of the breaker rating.

9.1.7

Minimum lighting levels as listed in 9.2 shall be attained when the light output for the lamps have
dropped to 70% of the initial rated value.

9.2

ILLUMINATION LEVELS
Illumination levels shall not be less than the values listed below in average (measured in above
grade):

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Area

Average Intensity in Lux

Process Plant
Tank Yard
Sea Water Intake
Cooling Water
Air Supply
Nitrogen Supply
Water Treatment & Fire Fighting
Waste Water Treatment
Ware House
Control Room & Laboratory
Work Shop General Area
Machine & Lathe Work
Fine Work
Instrument Work
Other Office
Substation
Steam Generation
Unloading Platform
Street Lighting

50/20 *
10
50/20 *
50/20 *
50/20 *
50/20 *
50/20 *
50/20 *
100
500
400
550
1000
1500
400
150
50
10/20/100 **
10

A: Around Rotating Machine


B: Around Tank and Vessel

* A/B/C A: Access Way


B: Cat Walk
C: Unloading Point
9.3

EMERGENCY LIGHTING SYSTEM

9.3.1

Emergency lighting shall be provided throughout the plant at all essential operating points and
shall give adequate lighting for the safe movement of personnel during emergency conditions
when production operations are still being affected. It shall be separated in every way from the
normal lighting system, and supplied from the 380V emergency power distribution panel and thus
subject to change over to emergency supply in the event of normal power outage.

9.3.2

The emergency lighting fixtures for the process areas shall be of incandescent type or fluorescent
type. All incandescent fixtures shall be of screw-in type.

9.4

STREET LIGHTING

9.4.1

Street lighting will be as follows;


(1) Fixture
(2) Fixture mounting height
(3) Pole type
(4) Pole spacing
(5) Wiring

9.4.2

Circuits for street lighting shall be energized during night by normal power source.

9.5
9.5.1

--- Sodium vapor


--- Approx. 10 m above finished grade
--- Galvanized steel or concrete
--- Approx. 50 m
--- Underground direct burial cable

OBSTRUCTION AND WARNING LIGHTS


The obstruction and warning lights shall generally be installed as per the International Civil
Aviation Organization (ICAQ) requirements.

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Circuits for obstruction and warning lights shall be energized during night by emergency lighting
power source.

10. COMMUNICATION SYSTEM


10.1 TELEPHONE SYSTEM
Telephone system will be provided to cover central control building sub-stations. Paging system will
not be provided as radio communication system is provided

11. TESTING
Electrical equipment shall be subjected to routine shop test to ensure that they are free from electrical or
mechanical defects, and that they meet design specifications. Engineering Specification (CBP-ELE-01500) shall apply to the inspection and test for each electrical equipment.

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