SPECIFICATION PREFACE SHEET
DEPARTMENT:
Engineering / Electrical
AREA: Grundartangi Reduction Plant
SHEET
1
OF
SPEC No: 00/06/TS021
14
REV:C1
STANDARD TECHNICAL
SPECIFICATION
FOR
ELECTRICAL ENGINEERING DESIGN
EQUIPMENT INSTALLATIONS
EQUIPMENT IDENTIFICATION
ELECTRICAL PRE-INSPECTION COMMISSIONING
This Standard Technical Specification is subject to change without prior
notice. The most current issue will at all times be located on the Nordural web
site, www.nordural.is.
REV
C1
BY
TDS
DATE
2004-05-24
CHK’D
TDS
APPROVED
ÓJ
NORÐURÁL – ENGINEERING
REVISIONS
Issued for Construction
STANDARD TECHNICAL SPECIFICATION
NORÐURÁL
00/06/TS021
NORDIC ALUMINUM
CONTENTS
1
2
ELECTRICAL ENGINEERING DESIGN
1.1
GENERAL
1.2
ENGINEERING AND DRAWINGS
1.3
INSPECTION AND TESTING
1.4
IDENTIFICATION
1.4.1
Cable numbering system
1.5
FINISH AND WORKMANSHIP
1.6
FACILITIES ON SITE
1.7
AUXILIARY POWER
3
3
4
5
5
5
6
6
CONDUITS, CABLE LADDERS
6
2.1
2.2
3
CONNECTION BOXES
PANELS
JUNCTION BOXES
7
7
8
8
CONTACTORS AND PULSE RELAYS
BUSBARS
WIRE TERMINALS
8
8
9
9
WIRES AND CABLES
INSTALLATION OF CABLES
9
11
PROTECTIVE DEVICES
6.1
6.2
6.3
6.4
6.5
7
7
WIRES AND CABLES
5.1
5.2
6
6
7
MISCELLANEOUS EQUIPMENT
4.1
4.2
4.3
5
CONDUITS AND JOINTS
CABLE LADDERS
PANELS AND CONNECTION BOXES
3.1
3.2
3.3
4
3
11
EARTH-LEAKAGE CIRCUIT BREAKERS
MINIATURE CIRCUIT BREAKERS
ON-LOAD SWITCH FUSES
LOAD BREAK SWITCHES
SWITCH-FUSE DISCONNECTS
12
12
12
12
12
INSPECTIONS AND COMMISSIONING
12
7.1
GENERAL INFORMATION
7.2
TESTING OF INSTALLATIONS
7.3
ENERGISATION
7.4
INSPECTION
7.4.1
Insulation measurement
7.4.2
Earth fault measurement
7.4.3
Measuring equipment
7.5
INSPECTION FORMS
12
13
13
13
13
14
14
14
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TECHNICAL SPECIFICATION
1
1.1
Electrical Engineering Design
General
In this Document the following words and expressions shall have the meaning hereby
assigned to them except where the context otherwiserequires:
Engineer:
The Owner or any person or organisation employed or engaged at any time by
the Owner and authorised by the Owner, in writing, from time to time to act on
behalf of the Owner in the execution of the items covered by this Document, in
whole or in any part, for any or all purposes provided in this Technical
Specification.
Owner:
Norðurál hf (Nordic Aluminum Corporation Ltd.), an independent legal entity
owned by Century Aluminum.
The Contractor undertakes to perform all work specified in accordance with the
Contract Documents. The Contractor shall cover all costs for work and equipment
necessary to deliver the work complete according to the Contract Documents.
The specification contains general requirements for the supply, installation and test of
the electrical facilities. Included are supply of materials and labour and all fastenings
and connection material to complete the installation.
All electrical engineering, design, wiring, equipment and workmanship must be in
accordance with the relavant Icelandic and European standards (ÍST and EN) and,
consequently, the Icelandic Electrical Regulation.
1.2
Engineering and Drawings
All engineering design drawings shall be typical and show in general what is
included. The Contractor shall send all design drawings and technical information to
the Engineer for acceptance prior to manufacturing of equipment.
Graphical drawing symbols and designations shall be in accordance with the relevant
IEC-standards. However, it is permissible to use the relevant DIN-standard as basis
for design. The use of other engineering standards has to be approved in writing by
the Engineer in advance. All engineering units shall belong to the SI-system.
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All electrical drawings and descriptions shall be made in Icelandic or English. The
final documentation shall be in Icelandic or English. All documentation must fulfil
Icelandic and European regulations.
All drawings must be CAD generated. The preferred CAD system is AutoCAD
Release 2000 or later. The drawings shall be in paper format DIN-A4, DIN-A3 or
DIN-A1. Drawings prepared on CAD system other than AutoCAD must be converted
and supplied as “dxf” files. These shall be generated to provision of six (6) decimal
places of accuracy for floating-point numbers.
All electrical drawings files must be supplied on a CD-ROM disk.
The Contractor shall maintain one complete set of prints of the most recent drawing
revisions for marking any “AS-BUILT” changes. The marking shall be made in red.
At the end of the work the Contractor shall return a copy of the complete set of prints
to the Engineer showing in a legible manner any “AS-BUILT” alterations. The
Contractor shall also supply in the end a final set of documents marked “AS-BUILT”.
All nonconformities to Norðurál technical specifications, Icelandic and European
standards or the Icelandic Electrical Regulation will have to be rectified at the
Contractor’s expense, if not approved in advance.
1.3
Inspection and testing
Engineer will have a work inspector as its representative inspecting the work of the
Contractor during the design and construction period. The Contractor shall always
perform the work according to the Engineer’s or its work inspector’s decisions. The
Contractor shall submit all descriptions, significant drawings and calculations to the
Engineer or its work inspector for approval prior to the start of manufacturing. This
approval, however, does not exempt the Contractor from being responsible for
inappropriate workmanship and strict compliance with EN standards.
The Contractor shall test all equipment functionally prior to delivery (Factory
acceptance test). The Engineer shall be notified of the date of the factory acceptance
test two weeks (14 days) in advance so that the presence of the Engineer’s
representative is made possible.
The Engineer or its work inspector can and will have an accredited Inspection body,
according to EN 45004, to approve the work, according to EN standards and the
Icelandic Electrical Regulation issued by the State Electrical Authority (Löggildingarstofa).
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After the satisfactory completion of installation, commissioning and start-up, the
Contractor shall demonstrate that the system successfully performs the tasks described
in the specification. After the successful demonstration and adherence to any remarks
made by a certified inspector on behalf of the Engineer, the system shall be handed
over to the responsibility of the Engineer.
1.4
Identification
All equipment, including equipment within panels, and cables shall be neatly and
clearly marked as indicated on the schematic and wiring diagrams, to ensure a good
and clear understanding of the electrical connections. Cables shall be marked with
sleeve type engraved markings. The marking system and marking material shall be
subject to approval by the Engineer. Identification of the respective conductors shall
be in accordance with the requirements of IEC Publication 446. In cables having five
conductors or more, the individual conductors shall be numbered throughout the entire
length.
The Contractor shall in his documentation from the beginning use the equipment
identification system adopted by Norðurál, the AKS-Identification System for
Aluminium Smelters developed by VAO in Iceland and GABO AT + PM in Germany
(The AKS-Identifcation System is based on the KKS-Identificaton System, edited by
VGB Technical Committee on Technical Classification Systems and published by
VGB-Kraftwerkstechnik GmbH, P.O.B. 103932, D-4300 ESSEN, Germany). A
special AKS key used by Norðurál will be submitted after the Contract agreement.
1.4.1
1.5
Cable numbering system
The cable number shall be marked on both ends of each cable. The markings shall be
made permanent. The marking material shall be prefabricated sleeves with numbers
printed on, or prefabricated numbers on a strip. Markings that are handwritten with a
pen on a sleeve or strip are and will not be accepted. The marking material must be
shown to the Engineer for approval prior to usage and installation. The cable number
shall in general consist of a row of 6 digits (Panel-ABCDEF) that indicate panel
identification followed by location within the plant, type of cable and cable number.
Finish and workmanship
Workmanship shall, as a minimum, conform to general descriptions as stipulated in
"Ákvæðisvinnugrundöllur rafvirkja- Fyrirsögn um vinnubrögð" and shall fulfil the
requirements described in this technical specification.
All work shall conform to requirements stipulated by the relevant EN standards and
the State Electrical Authority, and other official authorities, as appropriate.
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1.6
Facilities on site
All temporary electrical distribution facilities for installation purposes shall be in
accordance with EN standards and stipulations issued by the State Electrical Authority
(Löggildingarstofa).
The Contractor shall expect that other contractors are working on the site at the same
time, and he can expect that this will affect his own working schedule.
1.7
2
2.1
Auxiliary power
The Contractor has access to auxiliary power in temporary distribution panels. The
Contractor shall take care of the connection to existing sockets and panels and the
cable installation to his own preliminary distribution panels used during the
construction period. Norðurál will pay the cost of electricity as long as this is
considered reasonable for this type of work. The electrical system is AC three-phase,
50 Hz, 5 wire system 400/230 V, type TN according to IEC Publication 60364-1, for
supplies of 125 A and less.
CONDUITS, CABLE LADDERS
Conduits and joints
The conduits shall have ample cross section and wall thickness. Conduits shall have
no sharp edges or discontinuities that can damage the insulation. Included in the
conduit supply shall be all necessary fastening and jointing materials including special
joints for the jointing of pipes and boxes.
Embedded conduits shall be made of plastic material, generally PVC. Parallelembedded conduits shall be installed with a minimum 3-cm clearance between them.
This is critical where many conduits and big conduits are installed in parallel. The
work inspector shall inspect all conduit installations in walls before the concrete
moulds are closed at both sides and in floors before concerning. To avoid damage to
plastic conduits during the building stage, plastic conduits that exit floors in order to
enter for example walls shall terminate in foam plastic material at the upper surface of
the floor. Conduits that exit ceilings shall terminate flush with the ceiling in special
termination joints.
Non-embedded cabling not installed in trays or ladders shall be installed in hot-dip
galvanised steel conduits. For outdoor installations, the surface must additionally be
painted.
Base mounted fastening clamps, “krókspennur”, shall be used for fastening of steel
conduits. The clamps shall fix the conduit approximately 15 mm from the wall. The
distance between fastenings of surface mounted conduits shall be maximum 50 cm.
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All conduits must be fixed in a vertical or horizontal position. Diagonal planes shall
not be accepted. The embedded conduits shall be tied to the reinforcement bars; the
maximum distance between ties shall be 20 cm.
Surface mounted conduits shall be installed in straight sections. In bends and at the
connection to equipment the cable is therefore exposed. Fastenings shall be
approximately 10 cm from pipe ends.
2.2
Cable ladders
All cable ladders shall be fastened on cantilever arms, both for installation on walls
and ceilings. Prefabricated bends shall be used. The number of fastenings shall be in
accordance with instructions from producers. The Contractor shall supply a continous
metal dividing strip in all cable ladders for the separation of power cables and signal
cables.
The cable ladders shall be designed to allow the laying of the cables on the trays and
ladders from the side, without pulling the cables through.
All cable ladders and fixing material shall be hot-dip galvanised. All cable ladders
shall be properly grounded.
3
PANELS AND CONNECTION BOXES
3.1
Connection boxes
Connection boxes shall, if possible, be of galvanised steel with metallic Pg cable
glands of IP68 tightness. The boxes shall have ample space for the terminal blocks to
make connections accessible.
3.2
Panels
The cubicles shall be complete with feeder units, busbars, terminal blocks for entering
cables, safety devices, wire ducts and internal wiring for making the cubicles
complete and for warranty of a trouble-free and safe operation. The 400/230 V system
shall be solidly grounded, type TN according to IEC Publication 60364-1.
The panels shall be made of steel and be of improved design. The panels shall have
base frames and be fastened using concrete bolts to wall and floor. Others will furnish
the electrical rooms with raised floors. The panels must be supplied with foundations.
In a pocket on the rear side of the panel door there shall be a legible list on a
prescribed sheet showing all branches according to drawings. This list shall be plastic
coated and securely stored in the data pocket.
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Wires shall be neatly and logically arranged and fastened and be of colours as
specified. All wires extending from the panel shall be connected to terminal blocks as
indicated on drawings. Wires shall be laid in closed wire ducts made of plastic with
ample space for future additions. All wires shall be flexible. When connecting wires
under screws, pressed end sleeve lugs or other approved methods shall be used.
Shields shall be used to secure against the accidental touch of energised parts in the
panel. All doors shall be earthed using a 6 mm² flexible yellow/green wire. All metal
parts, which are normally not energised, shall be securely connected to the PEN busbar.
The panels shall be standardised modular designed panels, equipped with a sliding
base for the fastening of incoming feeders. The panels shall be made according to
drawings or otherwise prescribed. Panel meters shall be flush mounted in the door.
Spare space shall be provided in the panel and arranged in such a way that it shall not
be necessary to make amendments for future extensions. Fastenings and mounting
plates shall be included in the spare space.
3.3
4
Junction boxes
Junction boxes shall generally be metallic and shall be of ample size for the intended
components or equipment. Boxes are flush mounted in walls. All unused glands shall
be closed by means of a lid of an appropriate type, intended for this purpose.
MISCELLANEOUS EQUIPMENT
4.1
Contactors and pulse relays
The Contractor shall install contactors and pulse relays for the control of equipment.
The control voltage of contactors shall be 230 V AC or 110 V AC. Across each relay
and contactor there shall be mounted a noise suppression RC element sustaining 20 %
harmonic voltage distortion. In case of a 24 VDC control, a bypass diode across relays
secures noise suppression.
4.2
Busbars
N and PE busbars shall be made of E-copper. Equipment shall not be mounted directly
on the busbars. N busbars shall be insulated as required. N busbars and PE busbars
shall be arranged as required. If the Contractor chooses to use the support strip of the
terminals as a PE conductor he shall follow the stipulations of Icelandic and European
regulations. The connection point of a PE conductor to the support strip shall be at the
middle of the strip or at both ends. A special PE wire shall be connected to each
support strip for each branch from the FI-breaker. Main busbars in panels shall be at
least 3 x 250 A.
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Busbars shall be safe against voltage exposure. The main busbars short circuit
capacity level shall be for at least 50 kA - Ith (1 s). Short circuit interrupters must be
capable of instantaneous disconnection of a three-phase fault of minimum 35 kA.
Rated current of busbars shall be at least as shown on drawings.
4.3
5
5.1
Wire terminals
The Contractor shall connect wires terminating in junction boxes using wire terminals.
All wires extending from panels shall terminate in terminal blocks. Terminal blocks
shall be at least 4 mm2. Terminal blocks shall be located in the bottom section of the
panels, as the cables in general enter the panels from below. If space is restricted,
terminal blocks in 2 or 3 layers can be used.
WIRES AND CABLES
Wires and cables
Conductors shall be made of E-copper unless otherwise specified. Insulation of wires
shall be of plastic and the colour of the insulation shall be the same for wires used for
the same purpose. The cross-section of the conductor shall not be smaller than 1,5
mm². For the controls and instruments the cross-section may be smaller, subject to the
approval of the Engineer.
Cables connected to panels and/or boxes shall be identified with a cable number. It
shall, from the identification, be possible to see at both ends of the cable what it is
used for. Connection of cables shall be by use of special clamps intended for that
purpose, pressed end sleeve lugs or other approved methods.
The cross-sectional area of wires shall be in accordance with the schematic terminal
layouts and installation drawings. Where cables enter boxes, fixtures etc., Pg metallic
cable glands or other approved method shall be used for the proper fastening of the
cable. Where tensile force acts upon the cable gland, IP68 tightness shall be applied.
Arrangement of cables in cable ladders and girt ducts shall be neatly and securely
done. Fastening of cables in vertical cable ladders shall be by means of special clamps
intended for that purpose, “krókspennur”. Where cable ladders are horizontal, plastic
strips of ample strength shall be used. Cables in girt ducts shall not be fastened, but
due attention must be paid to risk of damage during installation and later cladding
repairs by gun nails.
All electrical cables and wires must be in accordance with Icelandic regulations and
according to the following requirements regarding wire and cable core colours.
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All power cables used in the industrial areas must be of type NYY-J or equivalent. The
core colours must be according to the following:
3-core cable
L
N
PE
Black (or some other acceptable colour)
Blue
Green/Yellow
4-core cable
L1
L2
L3
PE
Black
Brown
Blue (or some other acceptable colour)
Green/Yellow
5-core cable
L1
L2
L3
N
PE
Black (or some other acceptable colour)
Brown
Black (between green/yellow and blue)
Blue
Green/Yellow
All control cables used in the industrial areas must be of type NYY-JZ or equivalent. Prior
to installation the Engineer must approve any other type of control cables. The core
colours must be according to the following:
X-core cable
All cores
PE
Black with numbers on, from 1 to xx
Green/Yellow
All wires used within the panels must be of type H07V-K or equivalent. The wire colours
must be according to the following:
For power circuits in the panel (TN-C or TN-S systems)
L1
L2
L3
N
PE
Black
Black
Black
Blue
Green/Yellow
For control circuits in the panel;
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•
If the control voltage (230 V AC) is taken between phase and neutral in the
TN-S system:
L1
N
PE
Black
Blue
Green/Yellow
•
If the control voltage is produced with an isolation transformer, 230 V AC,
110 V AC or other lower AC voltage:
L1
Red
N
White
PE
Green/Yellow
•
If the control voltage (DC) that is produced with a DC-power pack, usually
isolated, 24 VDC:
Plus
Minus
PE
Brown
Grey
Green/Yellow
All analog wires in the panel shall be:
Analog
PE
Violet
Green/Yellow
All wires within the panel that are for volt free contacts, external use, control or alarms that
will be routed to other panels and are supplied with voltage from other panels and routed
to terminal blocks shall be:
To contacts
5.2
6
Orange
Installation of cables
All cables shall be installed on cable ladders, trays or racking, in ducts, cleared to
steelwork, in conduits laid in concrete trenches or directly buried in the ground. No
joints shall be allowed in any cable run unless approved by the Engineer. No cables
are to be laid in ducts or trenches with other services such as oil pipes, air pipes,
water pipes etc.
PROTECTIVE DEVICES
Earth-leakage circuit breakers, miniature circuit breakers and circuit breakers shall be
equipped with auxiliary contacts. The Contractor shall connect in series all auxiliary
contacts of protective switches to terminals.
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6.1
Earth-leakage circuit breakers
Earth-leakage circuit breakers shall be four-pole, with rated current 63 A and rated
earth fault current 30 mA according to IEC 61008 and IEC 60947-2, if not otherwise
specified. Earth fault breakers shall only be applied in specific cases and situations,
and an approval from the Engineer is needed.
6.2
Miniature circuit breakers
Miniature circuit breakers rated 50 A or less shall have a breaking capacity of at least
10 kA according to IEC 60947-2. These in turn must be protected by an interrupter of
at least 35 kA capacity. In case of overcurrent in one phase of a three-phase unit, the
respective breaker shall operate.
Miniature circuit breakers shall have both overcurrent and short-circuit protection.
Miniature circuit breakers shall be of B-type for lighting and C- type for individual
equipment.
6.3
On-load switch fuses
On-load switch fuses shall have fuses of "Neozed" type or equivalent. The switches
shall have a fuse alarm indicator wired to the terminal.
6.4
Load break switches
Load break switches shall be three- or four-pole, with a breaking capacity according
to IEC 60947-3.
6.5
Switch-fuse disconnects
All switch-fuse disconnects shall be approved by the Engineer.
7
7.1
INSPECTIONS AND COMMISSIONING
General information
The Contractor shall perform all electrical pre-inspection (“inspection”) and precommissioning (“commissioning”) of all electrical installations and systems, (low
voltage installations (400 V and other low voltage systems) or high voltage
installations (above 1000 V voltage systems)) as specified in the Contract Documents.
As part of the Scope of Supply, the Contractor shall cover all costs for work,
equipment, licenses and/or fees necessary to deliver the work complete according to
the Contract Documents and this specification.
The specification contains general requirements for the testing of the electrical
facilities. As part of the Scope of Work, the Contractor shall supply all materials and
labour needed to complete the commissioning and electrical inspection.
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All work and installations shall conform to requirements stipulated by EN standards,
the State Electrical Authority and other official authorities, as appropriate.
7.2
Testing of installations
Prior to the energisation of any electrical equipment (panel, low voltage or high
voltage), the Contractor shall visually inspect the equipment and make all required
measurement tests. All measurements must be recorded and submitted to the
Engineer on an approved form.
7.3
Energisation
Prior to the energisation of any major power panel or high voltage equipment the
Contractor shall obtain written approval from the Engineer and Norðurál’s Senior
Electrical Engineer, or authorized deputies.
7.4
Inspection
The Contractor shall fully inspect all electrical installations (panel, low voltage or
high voltage), and record all information as required on forms. All equipment must be
checked for correct installation and connection.
All protection systems for each circuit shall be checked against the electrical drawings
for completeness and conformity. The equipment shall be checked for compliance
with specifications and Icelandic standards governing labeling, dimensions,
compliance with “AS-BUILT” drawings, door system and earthing. All wiring of
equipment and all busbar connections shall be checked for tidiness, completion,
position of current transformers, etc. The installation shall be checked to see that the
Contractor has provided sufficient spare terminals and room for additional cables.
The installation must be checked for phase rotation. All installations must be checked for
continuity of the PE-wire. Short-circuit current for branches must be checked for correct
operation of all protection equipment. The installation of all cables and cable ladders must
be checked for correct installation.
Also, the Contractor shall demonstrate and verify that equipment is in accordance
with the layout specifications, fixing screws/terminations are tight, necessary and
insulating shields are in position, component sizes/duty ratings are as specified, and
meter scales are correct.
7.4.1
Insulation measurement
Insulation measurement of the electrical installation (panels, low voltage cables and
high voltage cables) shall be made by measuring the resistance between a phase and
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the PE-wire. The measurement value must be at least 1000 Ω for each voltage value
on the system. The result shall be recorded on an approved form.
7.4.2
Earth fault measurement
Earth fault loop impedance must be measured for circuits/branches for the secure
operation of protection systems. The measurement shall be made on the end farthest
from the protection equipment. The test results shall be recorded on an approved
form.
7.4.3
Measuring equipment
All test equipment used must be recorded on an approved form.
7.5
Inspection forms
The Contractor shall provide all applicable information requested and needed on
approved forms. Applicable inspection forms used in Iceland are published by the
State Electrical Authority (Löggildingarstofa). The use of other types of forms has to
be approved in writing by the Engineer in advance.
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