DEFENCE WORKS SERVICES
MINISTRY OF DEFENCE
Defence Works Functional Standard
Design and installation guide for
specialist works on petroleum
installations - electrical
JANUARY 1995
COMPILED BY AIRFIELDS & BULK FUELS GROUP
DEFENCE WORKS SERVICES
LONDON : HMSO
© Crown copyright 1995
Applications for reproductions should be made to HMSO
First published 1994
ISBN 0 1 1 772690 7
Amendments
Issue A, Rev 000
iii
Foreword
This document is for the use of Top Level Budget Holders (TLBHs) for application
by the Project Sponsors, Property Managers (PROM), Establishment Works
Consultants (EWC), Works Services Managers (WSM) and other parties involved in
the design, selection and installation of electrical equipment within petroleum
hazardous areas on the MOD estate.
The principal users of the document are expected to be EWC specifiers and WSM
designers, installers and maintainers for works which fall within the Property
Services remit; and Project Managers, designers and installers for projects.
The organisation of works on the MOD estate is determined by the value of the
project or task. Over a certain value work is conducted as a Project under the control
of a Project Sponsor, who directs the appointment of a Project Manager for all
aspects of implementation. For work below the project value, the EWC, acting on
behalf of the PROM, briefs the WSM who acts as Project Manager for the works.
When completed, the work is accepted by the Property Manager on the basis of
technical acceptance by the EWC. Maintenance tasks are conducted by the WSM,
and are subject to audit by the EWC.
The guidance given within this document is based upon British Standards,
Health and Safety Guidance and Institute of Petroleum recommendations.
Failure to implement the recommended practices given herein, could result in
sub-standard equipment and workmanship in petroleum hazardous areas. The
consequence of sub-standard equipment and workmanship is a very high
probability of fire, explosion and possible loss of life.
This Defence Works Functional Standard supersedes the following Department of
Environment (DOE)/Property Services Agency (PSA) Electrical Design
documentation, for petroleum hazardous installations :
a.
DOE/PSA Mechanical and Electrical Engineering Guide (MEG), Volume 3,
Section 24, (1990).
b.
DOE/PSA Standard Specification (M&E) No.1 - Electrical Installations,
(1985), Section 18.
This Functional Standard was prepared under the patronage of the Defence
Petroleum Distribution Committee (DPOLDC) for application to electrical
installations within hazardous areas at bulk petroleum installations on the MOD
estate.
Guidance is given on apparatus standards for electrical installations in hazardous
areas. In addition, general electrical standards which apply to both hazardous and
non-hazardous areas, are cited in this Functional Standard. Examples are lightning
protection, earthing and BS 7671: Requirements for Electrical Installations.
This Functional Standard is not specifically directed to motor transport filling
stations, however the electrical principles involved in this document afford guidance.
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The design of motor transport filling stations should be in accordance with British
Standards and Health and Safety Guidance documents. A DWS design guidance
document to cater for MOD requirements at such installations is planned.
Amendments to this Functional Standard will be advised by DWS Technical
Bulletin, issued to PROM and TLBHs Works Staff. It is the responsibility of the
user to check with the PROM or Project Sponsor if amendments have been issued. A
sheet is provided for recording amendments. In addition, there is a feedback sheet at
Annex B, for suggested changes or developments to the document.
Technical advice and assistance on MOD petroleum matters can be obtained from
DWS. Approaches may be through local DWS offices or directly to the petroleum
Technical Authority, (DWS TA):
Head of Bulk Petroleum Installations
Room 121
Airfields and Bulk Fuels Group
PO Box 1734,
SUTTON COLDFIELD,
West Midlands,
B75 7QB.
This DWS Functional Standard has been devised for use of the Crown and of its
contractors in the execution of contracts for the Crown and, subject to the Unfair
Contracts Tenns Act 1977, the Crown will not be liable in any way whatever
(including but without limitation negligence on the part of the Crown its servants or
agents) where the specification is used for other purposes.
Notwithstanding that this document sets out guidance for specialist works on
petroleum installations electrical, and is the MOD preferred solution, its use does
not absolve a Project Manager from any responsibility for the design, neither does
its existence constrain him from using alternatives, provided such alternatives can be
demonstrated to provide a result of equal safety, quality and cost effectiveness.
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Abbreviations
AP (POL)
APPET
AVCAT
AVGAS
AVTUR
BS
BASEEFA
CENELEC
CSP
DOE
DPOLDC
DWS
EEx
Ex
EWC
FSII
GRP
HSE
IEE
*IP
IP
JSP
MOD
PCP
PET
PM
POL
PROM
PSA
PVC
SR&P
LEL
UEL
TA
TLBH's
WSM
XLPE
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Authorised Person POL (current terminology)
Authorised Person Petroleum (new terminology,
to be introduced)
Turbine Fuel, Aviation: High flash type
Gasoline, Aviation: Grade 100/130
Turbine Fuel, Aviation: Kerosine type
British Standard
British Approval Service for Electrical Equipment in
Flammable Atmospheres.
European Committee for electrical standardisation
Chlorosulphonated polyethylene
Department of the Environment
Defence Petroleum Distribution Committee
Defence Works Services
European Standard Certification Mark
Health and Safety Executive Certification Mark
Establishment Works Consultant
Fuel System Icing Inhibitor
Glass Reinforced Plastic
Health and Safety Executive
Institution of Electrical Engineers
Institute of Petroleum
Ingress Protection
Joint Services Publication
Ministry of Defence
Polychloroprene
Petroleum
Project Manager
Petroleum, Oil and Lubricant
Property Manager
Property Services Agency
Polyvinylchloride
Safety Rules and Procedures
Lower Explosive Limit
Upper Explosive Limit
Technical Authority
Top Level Budget Holders
Works Services Manager
Cross Linked Polyethylene
Contents
AMENDMENT SHEET
ABBREVIATIONS
FOREWORD
CONTENTS
1
1
GENERAL REQUIREMENTS
INTRODUCTION
1.1
AIM
1.2
1.3
DEFINITIONS
1.4
REGULATIONS
1.5
STANDARDS
EQUIPMENT CERTIFICATION
1.6
1.7
TRAINING
1.8
DESIGN AND INSTALLATION CERTIFICATION
1.9
DRAWINGS, CALCULATIONS, MAINTENANCE AND
OPERATING INSTRUCTIONS
1.10 MATERIALS
2
APPROACH TO THE SELECTION OF EQUIPMENT
2.1
HAZARDOUS PROPERTIES OF PETROLEUM
2.2
CLASSIFICATION OF HAZARDOUS AREAS
2.3
PROCEDURES FOR SELECTING ELECTRICAL
EQUIPMENT
2.4
MARKING OF ELECTRICAL EQUIPMENT
3
21
ELECTRICAL WIRING SYSTEMS WITHIN HAZARDOUS
AREA
3.1
ELECTRICAL SUPPLIES AND WIRING SYSTEMS WITHIN
HAZARDOUS AREAS
3.2
WIRING SYSTEMS
4
EARTHING AND BONDING
4.1
GENERAL
4.2
ELECTRICAL INSTALLATIONS
4.3
LIGHTNING PROTECTION
4.4
EQUIPOTENTIAL BONDING
4.5
BONDING OF VEHICLES TO FIXED INSTALLATIONS
23
5
INSPECTION, TESTING AND MAINTENANCE OF
ELECTRICAL EQUIPMENT WITHIN HAZARDOUS AREAS
27
5.1
5.2
GENERAL
SAFE WORKING
ANNEX A - COMPLETION & INSPECTION CERTIFICATE
ANNEX B - CHANGE SUGGESTION FORM
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Section 1
General requirements
1.1
INTRODUCTION
DWS Functional Standard, Design and Installation Guide for Specialist Works on
Petroleum Installations - Electrical, affords guidance and direction on the design,
selection, and installation of electrical equipment within hazardous areas at fixed
petroleum installations on the MOD estate.
The Functional Standard guides the designer and installer of new facilities and the
modifier and maintainer of existing facilities, in the precautions necessary to prevent
ignition of an explosive atmosphere, caused by electrical equipment.
1.2
AIM
The aim of this Functional Standard is to:
a.
Provide the details of design and installation standards for electrical
equipment and associated works in fixed petroleum installations hazardous
areas, within one document.
b.
Give guidance in the selection and installation of equipment, once the
hazardous area has been defined.
c.
Provide a consistent approach in the selection of materials and
workmanship, which will ensure similar solutions being constructed
throughout the MOD estate.
d.
Provide the designer and installer with guidance to engineer safe and
economic solutions, whilst ensuring compliance with the requirements of
relevant British Standards and other applicable Codes of Practice.
The document also assists the designer in the selection of materials, such as cables,
which are used in non hazardous areas of petroleum installations.
1.2.1 Arrangement
The document is arranged in the following manner, to achieve the aim :
a.
Section 1 includes the applicable standards, equipment certification,
training of installation personnel, and the record information required for
installations.
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b.
Section 2 comprises guidance on the approach to the selection of equipment
for use in hazardous areas
c.
Sections 3,4 and 5 cover the detailed matters of electrical supplies and
systems, earthing and bonding, and inspection and testing.
1.3
DEFINITIONS
The terms used within this standard shall be read as having the definitions given
below:
Approval (and words derived therefrom): Shall mean qualified approval in writing
by the Project Manager (PM) or Works Service Manager (WSM), unless stated
otherwise, for the design or commodities concerned, at the time of consideration.
Any such approval shall be given without prejudice to the requirement that formal
acceptance of the Works shall be subject to such performance, testing and
commissioning, as may be specified, and being to the satisfaction of the PM or
WSM.
Apparatus Group: Certain electrical apparatus for use in hazardous areas is
allocated a group depending on its suitability for use with specific gases.
Contractor: The company employed to carry out installation work on a site.
Earth: The conductive mass of Earth, whose electrical potential at any point is
conventionally taken as zero.
Earth Electrode: A conductor or group of conductors in intimate contact with and
providing an electrical connection to Earth.
Establishment Works Consultant (EWC): The organisation responsible for the
provision of specialist examinations, surveying, scheduling, financial assessments
and overseeing services in support of the PROM of the Establishment.
Equipotential Bonding: An electrical connection maintaining various exposedconductive-parts and extraneous conductive parts at the same potential.
Explosive Atmosphere: A mixture with air, under atmospheric conditions, of
flammable substances in the form of gas, vapour or mist in such proportions that it
can be exploded by excessive temperatures, arcs or sparks.
Equipment Certification: Equipment for use in Hazardous Areas is certified by
one of a number of national testing authorities as meeting the requisite standard.
This certification is arranged by the manufacturer of the equipment.
Flash Point: The minimum temperature at which a material gives off sufficient
vapour to form an explosive atmosphere within the apparatus used for flash point
determination.
Hazardous Area: An area where flammable or explosive gas or vapour-air mixture
(often referred to as explosive gas-air mixtures) is, or may be expected to be, present
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in quantities which require special precautions to be taken against the risk of ignition.
Ignition Temperature: The lowest temperature of a flammable gas or vapour at
which ignition occurs.
Non-hazardous Area: An area in which an explosive atmosphere is not expected
to be present so that special precautions for the construction and use of the electrical
equipment are not required.
Project Manager (PM): An official of the MOD or commercial representative
responsible for the purpose of management and administration of the works covered
within this Functional Standard. For work within the remit of the WSM, the term
PM shall be read as WSM.
Property Manager (PROM): An MOD official responsible for conducting the
day-to-day property management business at the establishment.
Project Sponsor : The representative of the TLBH responsible for the delivery of
the project through all stages.
Preferred: This indicates the course of action to be pursued when there is a choice
between acceptable alternatives.
Technical Authority: Branch of DWS with responsibility for providing authorative
technical works advice.
Temperature Class: One of six values of temperature allocated to electrical
apparatus derived from a system of classification according to the maximum surface
temperature of the apparatus.
Types of Protection: Measures applied in the construction of electrical apparatus
to prevent the ignition of a surrounding explosive atmosphere by such apparatus.
Works: This covers design, procurement, manufacture, installation, and relevant
maintenance activities.
Works Services Manager (WSM): The organisation responsible to the PROM for
planning, organisation and managing operation, maintenance and repair of plant and
facilities, and the design and construction of new works up to a specific value on the
MOD establishment for which it is appointed.
1.4
REGULATIONS
All work in and around petroleum hazardous areas must be carried out in
accordance with the applicable MOD safety rules and procedures for work
on petroleum installations. The current procedures are DOE/PSA Mechanical and
Electrical Engineering Guide, Volume 8, Sections 51 and 53, which will be replaced
by MOD Safety Rules and Procedures.
When required by the MOD Safety Rules and Procedures, (SR&P), a covering
Permit to Work (Petroleum) must be obtained from the responsible AP PET prior to
the commencement of any work on or near a petroleum installation which either
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contains, or has previously contained, petroleum products. Notwithstanding the
receipt of a Permit to Work (Petroleum) in such cases, it shall be the responsibility
of the contractor to ensure that the requirements for safety specified in the MOD
SR&P are strictly complied with at all times.
The completed work, and all aspects of the execution thereof, shall comply with all
relevant latest enactments, statutory instruments, regulations and codes including the
following where applicable:
a.
Factories Acts and Regulations made thereunder.
b.
Health and Safety at Work Act and Regulations made thereunder.
c.
Control of Pollution Act and Regulations made thereunder.
d.
Petroleum (Consolidation) Act and Regulations made thereunder.
e.
Home Office Model Code of Principles of Construction and Licensing
Conditions for Premises Licensed under the Petroleum (Consolidation) Act
1928-Parts I and II.
f.
Standards listed in clause 1.5.
g
HMSO Publication 'Standard Fire Precautions for Contractors Engaged on
Crown Works'.
1.5
STANDARDS
The Works shall comply with the latest editions of appropriate standards including :
a.
4
British Standards:
BS308
Engineering drawing practice.
BS 3429
Specification for sizes of drawing sheets.
BS 3939
Graphical symbols for electric power, telecommunications
and electronics diagrams.
BS 4533
Section 102.51, Specification for luminaries with type of
protection N.
BS 4568
Parts 1 and 2: Steel conduit.
BS 5000
Part 16: Rotating electrical machines with type of
protection N.
BS 5000
Part 17: Machines with flameproof enclosures.
BS 5070
Engineering diagram drawing practice.
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Section 1 - General requirements
BS 5345
Code of practice for selection and maintenance of electrical
apparatus for use in potentially explosive atmospheres
(other than mining applications or explosive processing
and manufacture).
Part 1: General recommendations.
Part 2: Classification of hazardous areas.
Part 3: Installation and maintenance requirements for
electrical apparatus with type of protection
Flameproof
enclosure.
Part 4: Installation and maintenance requirements for
electrical apparatus with type protection 'i'. Intrinsically
safe electrical apparatus and systems.
Part 5: Installation and maintenance requirements for
electrical apparatus protected by pressurisation 'p' and by
continuous dilution, for the pressurised room.
Part 6: Installation and maintenance for electrical
apparatus with type of protection
Increased safety.
Part 7: Installation and maintenance requirements for
electrical apparatus with type of protection
Part 8: Installation and maintenance requirements for
electrical apparatus with type of protection 's'. Special
protection.
BS 5467
Specification for cables with thermosetting insulation for
electricity supply for rated voltages up to and including
600/1000V and up to and including 1900/3300v.
BS 5501
Electrical apparatus for potentially explosive atmospheres.
Part 1: General requirements (EN 50014).
Part 2: Oil immersion V (EN50015).
Part 3: Pressurised apparatus "p" (EN50016).
Part 4: Powder filling "q" (EN50017).
Part 5: Flameproof enclosure "d" (EN50018).
Part 6: Increased safety "e" (EN50019).
Part 7: Intrinsic safety "i" (EN50020).
Part 8: Encapsulation
(EN50028).
Part 9: Specification for intrinsically safe electrical systems
"i" (EN50039).
Note: EN numbers given in brackets are the European
standard identical to the BS.
BS 5958
Code of practice for control of undesirable static
electricity.
BS 6121
Part 1: Mechanical cable glands - specification for metallic
glands.
BS 6207
Specification for mineral insulated copper sheathed cables
with copper conductors.
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BS 6231
Specification for PVC insulated cables for switchgear and
control gear.
BS 6346
Specification for PVC insulated cables for power supply.
BS 6480
Impregnated paper insulated lead/lead-alloy sheathed
cables for rated voltages up to and including 3300V.
BS 6651
Code of practice for protection of structures against
lightning.
BS 6656
Guide to the prevention of inadvertent ignition of
flammable atmospheres by radio frequency ignition.
BS 6941
Specification for electrical apparatus for explosive
atmospheres with type of protection
BS 7361
Cathodic protection.
BS 7430
Code of practice for earthing.
BS 7671
Requirements for electrical installations. Formerly the IEE
wiring regulations sixteenth edition.
BE EN 60529 Specification for degrees of protection afforded by
enclosures (IP code).
b.
MOD Standards:
JSP 317 Joint service safety regulations for the storage and handling of
fuels and lubricants.
Def Stan 01-5
Fuels, lubricants and associated products.
DWS Functional Standard 05 Specification for specialist works on
petroleum installations - Mechanical.
DWS Functional Standard 07 The inspection, maintenance and testing of
equipment installed at petroleum installations - Mechanical & Electrical.
MOD Fire Standards.
c.
Institute of Petroleum (*IP) Model Code of Safe Practice for the Petroleum
Industry:
*IP Part 1
*IP Part 15
Electrical Safety Code.
Area Classification Code for Petroleum Installations.
Where there is a discrepancy between either the requirements of this document and
those listed in clauses 1.4 and 1.5 herein, or between the documents listed in clauses
1.4 and 1.5 themselves, such discrepancy shall be referred to the PROM or WSM
for resolution.
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It should be assumed that the resolution will be in favour of the most onerous
requirement.
1.6
EQUIPMENT CERTIFICATION
Equipment installed in petroleum hazardous areas must be certified in accordance
with the relevant standard listed in clause 1.5.
Equipment shall have a certification mark of a recognised testing authority; this
verifies that the equipment is compliant with the relevant standard.
Under no circumstance shall equipment which does not comply with clauses 1.4 and
1.5 be installed in petroleum hazardous areas.
The Contractor shall provide current certificates of compliance for the equipment
when so required by the PM or WSM.
1.7
TRAINING
In order to satisfy the requirements of BS5345, Part 1, para 28:
"The inspection, maintenance, testing and repair of apparatus, systems
and installations should be carried out by persons whose training
includes instruction on the various types of protection involved.
Appropriate refresher training should be given from time to time."
and the Memorandum of Guidance on the Electricity at Work Regulations 1989,
Regulation 6, para 19:
"the maintenance and repair of explosion protected equipment is a
specialised field and should only be undertaken by those who have the
necessary training."
It is a requirement that only competent, suitably trained contractors and workers,
undertake electrical works within petroleum hazardous areas.
The PM or the WSM must judge the competency of the proposed contractor or
worker prior to the work commencing.
The PM or the WSM must also ensure that the applicable safety rules and
procedures for electrical works on petroleum installations and general works on
petroleum installations are brought to the attention of the contractor and worker.
The electrical Contractor shall demonstrate that the worker proposed to conduct the
work has a considerable appropriate knowledge, both theoretical and practical, of
electrical equipment for hazardous areas and the associated risks. As part of the
assessment of competency, and as a minimum, the worker shall have attended a
course that covers the following main areas relating to electrical hazardous area
works:
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a.
Ignition sources.
b.
Methods of protection.
c.
Earthing and bonding.
d.
Inspection and testing.
e.
Cable glanding.
f.
Safe working practices.
Appropriate standards
Certification of attendance and successful completion must be provided by the
contractor to the Project manager or WSM.
1.8
DESIGN AND INSTALLATION CERTIFICATE
Prior to handover and use of the installation the PM or WSM shall be in receipt of a
suitably completed design, inspection and test certificate, as follows:
a.
The Completion and Inspection Certificate as detailed in BS 7671,
Appendix 6. The Particulars of the Installation sheet, Appendix 6, is
modified and included for use as Annex A of this Functional Standard.
Note: Part 1 of Annex A is to be completed by the designer.
Part 2 of Annex A is to be completed by the contractor /installer.
Part 3 of Annex A is to be completed by the test/commissioning
engineer.
Part 4 is to be completed by the designer/contractor.
b.
Electrical design calculations, As-Installed drawings, test certification and
operation and maintenance manuals. The number of copies of design
calculations and certificates shall be determined by the PM or WSM.
Alterations to existing installations must comply with BS 7671, Chapter 72. The
procedure detailed in clauses 1.8.a and l.8.b above must be complied with, and a
new certificate must be raised for the part of the installation affected by the
modification. The new design must comply with this Functional Standard and the
standards referenced within.
1.9
DRAWINGS, CALCULATIONS, MAINTENANCE AND
OPERATING INSTRUCTIONS
The Project Sponsor or the EWC, on behalf of the PROM for works within the
Property services remit, determines the drawing, calculation, maintenance and
operating instruction requirements. The timescale for submission of drawings,
calculations, maintenance and operating documents will be determined by the PM or
WSM.
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General layout drawings shall be drawn to a scale of 1:100 and more detailed
drawings shall be to scales of 1:20; 1:10, 1:2 and 1:1, as appropriate.
1.9.1 Installation Drawings
Detailed design drawings shall be produced by the designer. For a traditional
contract where the installation contractor is responsible for procurement, the
installation contractor shall carry out the necessary modifications to the design to
accommodate the actual equipment purchased.
a.
b.
The drawings as modified by the installation Contractor shall show the
details of the contractor's proposals for the works and shall include
everything necessary for the following purposes:
(1)
To illustrate in detail the arrangement of the various sections of the
works and to identify components.
(2)
To integrate the works with the detail of the building and other
installations works.
(3)
To show that the proposed installation and equipment is safely and
adequately rated for duty.
The installation drawings and documents shall include as appropriate:
(1)
General layout drawings showing the location of all equipment
including cables, cable trays, conduits, trunking, ducting and earth
electrodes.
(2)
Detailed layout drawings showing the location of all equipment
including cables, cable trays, conduits, trunking and ducting in
switchrooms and plant rooms.
(3)
Assembly drawings of factory built equipment and site built
assemblies.
(4)
Detailed layout drawings showing the connection of cables,
conduits and trunking to equipment.
(5)
System diagrams, circuit diagrams and wiring diagrams for all
installations and equipment.
(6)
Hazardous area classification drawings. (See clause 2.1).
(7)
Calculations of short circuit levels and circuit protection settings.
(8)
Calculations of cable sizes and developed cable schedules.
(9)
Calculations of illumination levels and luminaire selection.
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1.9.2 As-Installed Drawings and Documents
10
a.
These shall show the information necessary so that the installation can be
safely operated, maintained, inspected and tested. The drawings shall
incorporate the information necessary for the identification of the devices
performing the functions of protection, isolation and switching, and their
locations. The values of short circuit current and earth fault loop impedance
shall be recorded on the appropriate system diagram/drawing.
b.
The drawings shall detail the items specified in clause 1.9.1 and 1.9.2.
c.
Circuit details including loading, origin, route, destination and where buried,
the depth below finished ground level, shall be shown for each cable,
conduit, trunking and ducting. Conductor size, material and the type of
insulation of all cables shall be shown together with the number of cores in
each cable or the number of cables in each conduit, trunking or ducting.
Where identification is by colour of insulation or sheath, this shall be
shown. Joints in draw boxes shall be shown.
d.
All earthing conductors, main equipotential bonding conductors, main
earthing terminal, protective conductors and supplementary equipotential
bonding conductors shall be identified with function, origin, route
destination, conductor size and material, type of installation where buried
and the depth below finished ground level. The test points and subsequent
test readings shall be indicated.
e.
Earth electrodes shall be identified as to their type, dimension, material and
depth below finished ground level. The nature of the soil and any treatment
that has been given to it or special fill that has been used in the installation
shall be identified.
f.
Details of each item of equipment including luminaires, shall include
electrical characteristics, classification, degree of protection against ingress
of solids and water, hazardous area classification, class of protection against
corrosion, and manufacturer's name and reference.
g.
Drawings of the lightning protection system shall include identification of
those elements of the building fabric used as air terminations and down
conductors. Details of connections to structural steelwork or to the
reinforcement of a concrete structure shall be included. Details of the earth
electrodes are required.
h.
Each As-Installed drawing shall be suitable for micro-filming and shall be
on durable translucent material, other than paper. The words "AS
INSTALLED" shall be placed in 19mm block letters adjacent to the title
block of each drawing together with the name of the site and the section of
the works, the title of the installation, the date of completion of the works,
the Authority's contract number and the name of the contractor.
i.
Drafts of each As-Installed drawing shall be submitted to the PM or WSM
for Approval.
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j.
The number and format of final As-Installed drawings will be advised by
the PM or WSM.
1.9.3 Maintenance and Operating Instructions
For each electrical installation, system and equipment forming part of the works, the
maintenance and operating instructions shall include:
a.
Certification and electrical design information as required by clause 1.8.
b.
A copy of inspection certificates and test records.
c.
Comprehensive instructions for switching on, operation, switching off and
isolation.
d.
Instructions for maintenance, including frequency and spares required, to
maintain the equipment/installation in a safe reliable condition.
Maintenance, inspection and testing schedules shall be provided in the
format indicated in DWS Functional Standard 07, unless otherwise
specified.
e.
The names and addresses of equipment manufacturers and suppliers shall
be provided together with the type, model reference, serial number, duty
rating and the order number and date.
Maintenance and operating instructions shall be indexed and contained in ring
binders with stiff covers. The name of the site, Authority's contract number, and
appropriate title shall be printed on the front cover and on the spine. A suitable
index and reference to As-Installed drawings shall be provided within the binder.
Copies of manufacturer's data may be incorporated in the binder to supplement the
descriptions and instructions.
Draft Operation and Instruction manuals will be submitted to the PM or WSM for
approval.
The number of final copies and timescale for handover will be advised by the PM or
WSM.
1.10
MATERIALS
Only new materials in accordance with the relevant BS shall be used unless
otherwise specified. Where the PM or WSM directs the use of existing materials,
these shall meet the specification for new materials.
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Section 2 - Background for the selection of equipment
Section 2
Background for the selection of equipment
2.1
GENERAL
The classification of the hazardous area shall be completed by a suitably qualified
and experienced engineer. The classification should be in accordance with JSP 317,
which is based on the more detailed *IP Model Code of Safe Practice for the
Petroleum Industry, Part 15, Area Classification.
The Contractor will not be tasked to undertake the area classification, with the
possible exception of design and construct contracts. In such circumstances the
hazardous area classification shall be completed by a suitably qualified and
experienced engineer.
Once the area classification is complete and the area classification drawings have
been produced, the design and selection of the electrical equipment can proceed.
Clauses 2.2 and 2.3 offer elementary guidance on the hazardous properties of
petroleum and the classification of hazardous areas. JSP 317 and *IP Part 15 are
essential references for the area classification process. Clauses 2.4 and 2.5 deal with
the selection and marking of electrical equipment.
In some cases an installation is designed to accommodate Class I petroleum products
even though only Class II petroleum products are to be stored. This is done to
provide future flexibility.
2.2
HAZARDOUS PROPERTIES OF PETROLEUM
Petroleum products produce flammable vapours which when mixed with air in
certain proportions form a flammable atmosphere which will ignite if exposed to a
source of ignition. A flammable/explosive atmosphere exists when the proportion of
petroleum vapour in the air is between the Lower Explosive Limit (LEL) and the
Upper Explosive Limit (UEL).
Petroleum products are classified according to their minimum flash point. The
classifications are in accordance with * IP Part 15, Appendix A. See Table 2.1.
Class II and Class III petroleum products may be further sub-divided. The subdivision is dependent upon the temperatures at which the products are handled and
stored. Class II(1) and Class III(1) refer to petroleum products stored and handled
at temperatures below their flash point. Class II(2) and Class III(2) refers to
petroleum product stored and handled at temperatures above their flash point.
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Section 2 - Background for the selection of equipment
TABLE 2.1 - Institute of Petroleum flash point classification of petroleum products
For countries where ambient temperatures are high enough for the handling and
storage temperatures of petroleum products to rise close to, or above, the product
flash point, then petroleum products which fall into Class II(2) or Class III(2),
should be treated as Class I.
Based upon Clause 2.1 above, the fuels commonly handled on the MOD estate are
detailed in Table 2.2.
TABLE 2.2 - MOD Fuel data
Note 1: It is possible that in certain circumstances, including hot climate
installations, AVTUR could be stored at above its flash point, leading to a
Class II (2) designation.
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Note 2: Although Class III products are not likely to reach their flashpoints in
normal circumstances and thus do not give rise to a flammable vapour,
they are treated as hazardous products in accordance with IP Part 15,
Clause 2.12.3 in that the inside of the tank and an area around the vent
are classified as hazardous zones.
Specific guidance on petroleum characteristics are given in MOD, Defence Standard
01-5/Issue 10 (November 1993); Fuels, Lubricants and Associated Products.
Further information is available from the DWS TA.
2.3
CLASSIFICATION OF HAZARDOUS AREAS
Hazardous area classification zones are defined in BS5345 and presented in Table
2.3.
TABLE 2.3 - Zone definitions (BS 5345)
Zone 0
Zone in which an explosive atmosphere is continuously present, or present for long
periods
Zone 1
Zone in which an explosive atmosphere is likely to occur under normal operation.
Zone 2
Zone in which an explosive atmosphere is not likely to occur in normal operation, and
if it occurs will only exist for a short time.
2.4
PROCEDURES FOR SELECTING ELECTRICAL EQUIPMENT
The selection of electrical equipment for use in petroleum hazardous zones is
dependent upon the four following criteria:
2.4.1
The Selection of Equipment Suitable for the Particular
Hazardous Zone
BS 5345 determines that there are nine accepted types of protection for electrical
apparatus. The relationships between the type of protection and zone are given in
Table 2.4.
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Section 2 - Background for the selection of equipment
TABLE 2.4 - Types of hazardous area protection (BS5345)
0
Intrinsically safe, category
in Zone 0)
Special Protection (specifically certified for use
1
Intrinsically safe, category 'ia' or
Flameproof enclosure 'd'
Pressurised apparatus
Special protection 's'
Increased safety
2
Intrinsically safe, category 'ia' or 'ib'
Flameproof enclosure 'd'
Pressurised apparatus 'p'
Special protection
Increased safety 'e'
Type 'N'
Oil immersion 'o'
Powder filling 'q'
The preferred types of protection, for use on MOD estate hazardous areas are:
a.
Zone 0: In general, electrical equipment is not allowed in Zone 0 areas. In
some cases intrinsically safe instrumentation is used in the vapour
space of tanks, a Zone 0 area.
b.
Zone 1 Increased safety 'e'
Flameproof enclosure 'd'
{preferred first choice}
{preferred second choice}
c.
Zone 2 Type 'N'
Increased safety 'e'
Flameproof enclosure 'd'
{preferred first choice}
{preferred second choice}
{preferred third choice}
The most economical solution that satisfies the requirements for safety should
be chosen.
2.4.2
The Maximum Surface Temperature of the Equipment in
Relation to the Ignition Temperature of the Petroleum
Vapours/Product
The maximum surface temperature of equipment (the temperature classification)
selected must be below that of the ignition temperature of the petroleum product that
the installation is designed to handle. Details of temperature classification for
equipment are given in BS 5345 Part 1. Details are summarised in Table 2.5.
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TABLE 2.5 - Temperature classification (BS5345)
T1
T2
T3
T4
T5
T6
450
300
200
135
100
85
Reference to BS 5345 Part 1 Table 7 gives the following temperature classifications:
a.
Kerosene - T3 (AVTUR, AVTUR/FSII, AVCAT/FSII).
b.
Gasoline (Petroleum) - T3 (AVGAS 100LL)
BS 5345 does not give guidance for diesel fuel; this is treated as classification T3 as
for the other fuels, based on *IP Part 15.
Thus the "T" class for all equipment associated with all the fuels listed shall be "T3"
or better, ie T4, T5 or T6.
2.4.3
The Apparatus Grouping
The designations Group I and Group II are employed to differentiate between
electrical equipment installed in mines and that installed in all other locations.
Consequently, electrical apparatus for use on petroleum hazardous areas on MOD
estate will be Group II.
Within Group II, preferred protection type flameproof 'd' is sub-divided into groups
IIA, IIB and IIC.
Reference to BS 5345 Part 1 Table 7 gives the following equipment groups:
a.
Kerosene - IIA.
b.
Petroleum - IIA.
BS5345 gives no guidance for diesel fuel; this will be treated as petroleum.
All flameproof 'd1 equipment associated with all the fuels listed shall be
Class IIA.
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Section 2 - Background for the selection of equipment
2.4.4 The Environmental Conditions at the Installation
Electrical equipment installed within hazardous areas shall be suitable for the
environmental conditions to which it is exposed. This will include protection
against:
a.
Ingress of solid bodies, water or liquids, BS EN 60529 (IP Number).
The degree of ingress protection afforded by the enclosure is denoted by
the letters IP followed by two numbers. Details of IP classification are given
in Table 2.6.
TABLE 2.6 - IP protection (BS EN 60529)
0
1
2
3
4
5
6
X
No protection
Entry up to 50mm
Entry up to 12.5mm
Entry up to 2.5mm
Entry up to 1mm
Dust proof
Dust tight
Characteristic numeral not required
0
1
2
3
4
5
6
7
8
X
No protection
Drip proof
Rain proof up to 15° from vertical
Rain proof up to 60° from vertical
Splash proof
Jet proof
Cascade proof
Proof against temporary immersion
Proof against permanent immersion
Characteristic numeral not required
For outdoor locations, the degree of protection shall not be less than IP 55.
For indoor locations, the degree of protection shall not be less than IP 52.
b.
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c.
Effects of exposure to the petroleum product.
d.
Effects of heat from adjacent plant.
2.5
MARKING OF ELECTRICAL EQUIPMENT
The explosion-protection markings of electrical apparatus permits visual
confirmation of the correct selection of suitable equipment for the hazardous zone.
The markings are defined in the relevant BS and include the following details:
a.
The name of the manufacturer or his registered trade mark.
b.
The manufacturer's type identification.
c.
The symbol Ex or EEx, which indicates that the electrical apparatus
corresponds to one or more of the types of protection as required by the
appropriate standards. (See clause 2.5.g. below).
d.
The symbol for the type of protection used, either
e.
The symbol of the group of electrical apparatus, for protection type 'd',
either IIA, IIB or IIC.
f.
The symbol indicating the temperature class.
g.
The number of the certificate and name or mark of the certifying authority.
'e' or 'N'.
Note: If the type of protection complies with a British Standard, which
mirrors a European Standard, for example BS5501 part I, and equivalent
BS EN 50014, then the prefix to the type of protection code becomes
'EEx'.
The Registered mark for the British Approval Service for Electrical
Equipment in Flammable Atmospheres (BASEEFA) are the letters 'Ex'
are located within a crown. Similarly equipment certified by Sira
Certification Service would be marked with 'SCS'.
h.
Any other particular information, for example, IP protection or electrical
rating.
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Section 3 - Electrical supplies and wiring systems within hazardous areas
Section 3
Electrical supplies and wiring systems within
hazardous areas
3.1
ELECTRICAL SUPPLIES
The electrical supply to a petroleum hazardous area shall be via underground cables
except where cables necessarily have to exit the ground to reach above-ground
equipment. When the installation is supplied via overhead circuit this shall terminate
outside of the hazardous area and be routed via underground cable to the
installation. Overhead conductors are not permitted within the hazardous area.
Underground cables shall be protected against mechanical and environmental
damage. LV cables shall be installed to a minimum depth of 500mm in open ground
and under footpaths and 800mm under roadways unless otherwise specified by the
PM. Warning tape shall be placed above each cable route mat is laid directly in the
ground, at a depth of 300mm below finished ground level. Where ducting enters
hazardous areas the cable ducts shall be sealed with a suitable petroleum resistant
material to prevent the ingress of hazardous vapour or product.
The petroleum installation electrical supply shall generally be 240V 50Hz, singlephase and neutral or 415/140V, 50Hz, 3 phase and neutral with the neutral solidly
earthed at source.
The electrical supply shall be TN-S or TT as defined in BS 7671.
TN-C, TN-C-S and IT systems are not acceptable in classified hazardous
areas.
When the petroleum installation is fed from a dedicated substation or a feeder pillar
feeding other installations, the new installation shall be constructed sufficiently far
away from the electrical supply so that the electrical supply equipment is outside of
the hazardous area.
As a matter of good practice and economics, whenever possible, the electrical
equipment should be located outside of the classified hazardous area.
Standby power supplies, when provided, shall be located outside the hazardous area.
The standby power supply shall be provided with suitable changeover and isolation
facilities.
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Section 3 - Electrical supplies and wiring systems within hazardous areas
3.2
WIRING SYSTEMS
Cabling wiring systems for classified hazardous area installations shall be, in order
of preference:
a.
Thermoplastic or XLPE insulated, lead alloy or thermoplastic sheathed,
single steel wire armoured with polyvinylchloride (PVC), chlorosulphonated
polyethylene (CSP) or polychloroprene (PCP) overall sheath - first.
b.
Mineral insulated copper sheathed cables - second.
c.
Paper insulated, lead/lead alloy sheathed, steel wire armouring and
PVC/CSP/PCP overall sheath - third.
d.
Cables drawn into conduit - fourth.
Where there is a possibility that cables may come into contact with product,
they shall be lead alloy sheathed with either CSP or PCP overall sheath.
All cables shall have copper conductors.
Compression cable glands shall be brass or brass plated, weatherproof type, with
inner and outer cable sheath seal and overall protective PVC boot. They shall be
provided with a separate earthing tag that is secured with the gland fixing. Glands
shall have metric fixing threads.
Where compression glands are used with lead sheathed cables, the glands shall
incorporate an internal lead sealing ring.
For apparatus protection types "d" and
cable glands shall be certified EEx "d" or
For apparatus protection type "N", cable glands shall be either weatherproof or
certified EEx "d" or "e".
Conduit fittings for use in Zone 1 hazardous areas shall be certified enclosure
protection type "d".
Steel conduit and fittings shall be heavy duty, galvanised with metric threads.
Conduits shall be threaded to the full length of the tapped entry on apparatus
protection type "d".
Conduits shall be sealed in accordance with BS 5345 Part 1, clause 16 where they
enter apparatus protection type "e".
Where paper insulated cables are used, terminated cable cores shall be sealed with
heat-shrink sleeving that also seals the cores into the cable.
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Section 4 - Earthing and bonding
Section 4
Earthing and bonding
4.1
GENERAL
Flammable atmospheres found in the vicinity of petroleum installations necessitate
special earthing and bonding procedures which by correct design and installation
must provide adequate protection against fire and explosion. The employment of
earthing and bonding can generally be sub-divided into three categories, those
associated with the:
a.
Electrical installation.
b.
Protection against lightning.
c.
Equipotential bonding of structures, storage tanks, plant, pipelines and
other non-electrical metallic parts.
Details of potential causes of incendive conditions and the relevant precautionary
guidance documentation are given in the Table 4.1.
4.2
ELECTRICAL INSTALLATION
The design of the electrical system and installation shall be in accordance with BS
7671, BS 7430 and IP Part 1.
As noted in clause 3.1 above, the electrical distribution system shall be TN-S. This
requires a protective conductor(s) to connect the main source earth to the various
items of electrical equipment.
For all wiring systems, a separate dedicated protective conductor shall be provided
as part of the wiring system and shall comprise:
a.
Copper conductor incorporated in an armoured flexible cable.
b.
Separately insulated copper conductor.
The protective conductors shall be sized in accordance with BS 7671 Chapter 54.
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Section 4 - Earthing and bonding
TABLE 4.1 - Causes of incendive conditions
Electrical equipment that is incorrectly selected
for the hazardous environment, incorrectly
installed, defective, incorrectly operated or poorly
maintained
BS7671
BS 7430
Static discharges between objects at different
potentials
BS 5958
Lightning discharges, direct or indirect
BS6651
Stray electric currents eg cathodic protection
systems
Cathodically protected pipelines have
an insulating flange at each end to
prevent current loss to other
installations.
In a petroleum hazardous area
exposed insulating flanges should be
fitted with protective covers to avoid
the risk of sparking. It is preferable to
have insulating flanges sited in nonhazardous areas
BS 7361
Radio frequency induction
Structures that are constructed from
conductive materials, for example,
tanks, pipelines, metal gantries etc,
can have a potential as a result of
radio frequency induction.
A potential difference between
equipment can occur, which may
result in incendive sparking and
fire/explosion
BS 6656
4.3
LIGHTNING PROTECTION
The design of lightning protection systems is covered by BS 6651 and IP Part 1.
a.
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Although it is recognised that steel storage tanks and vessels are by their
method of installation normally effectively earthed through their general
contact with the mass of earth, extraneous piping, and cable connections,
they shall be provided with lightning protection earth electrodes.
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Section 4 - Earthing and bonding
b.
To facilitate the earthing of a metal storage tank, earthing bosses shall be
welded onto the tank. The number and approximate positions are
determined by the type, shape and size of the tank. Typical details are given
in Table 4.2.
TABLE 4.2 - Storage tank earthing bosses
The earthing bosses shall be fabricated from flat carbon steel bar, 75mm x
30mm x 8mm drilled with an 8mm hole for connection of earth cable lug.
Each boss shall be connected to either a dedicated earth electrode or an
earthing grid as determined by die Contractor's design.
If the storage tank is fitted with a cathodic protection system, for
example, for tank bottom protection, then the tank earthing system
shall comply with BS 7361, Section 4.5.
4.4
EQUIPOTENTIAL BONDING
All non-current carrying conducting parts of an installation shall be effectively
bonded together and to the main earth system to ensure that:
a.
The electric potential of one mass of metal cannot rise to dangerous levels
with respect to another mass of metal, due to either wiring system faults or
lightning strikes.
b.
Potentially hazardous static electric charges are safely dissipated.
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Section 4 - Earthing and bonding
4.4.1
Examples
Examples of metallic, conducting non-current carrying equipment that requires
bonding together and to the earthing system are:
a.
Pipework.
b.
Tanks.
c.
Stairways, ladders, pipetrack bridges.
d.
Lighting columns and towers.
e.
Firefighting foam solution tanks, fire monitors.
f.
Cranes and hoists.
The resistance to Earth at any point of any metallic, conducting non-current carrying
equipment must be less than 10 ohms (Q). Pipelines that are connected by screwed
joints or bolted flanges do not generally require bonding across the flange or joint.
Bonding would only be required if the pipeline resistance to earth is greater than 10
Q, and this is due to high resistance across the bolted flange or screwed joint.
Exceptionally however where long runs of pipe are needed they may require earthing
at intervals to ensure that the resistance to earth of any part of the system of
pipework does not exceed 10Q.
Generally metallic conducting non-current carrying equipment which is cathodically
protected must not be earthed. Special precautions may have to be taken to protect
against earthing through cable armours to actuators and instruments, and conducting
paths through pipe supports etc. Special earthing requirements for cathodically
protected equipment are given in BS 7361.
Concerning equipment fabricated from non-metallic materials, such as GRP, each
case has to be considered on its merits, and guidance on earthing is given in BS
5958.
For such equipment, the resistance to earth shall not exceed 106Q, but conducting
metallic parts of such equipment shall have a resistance to earth of less than 10Q.
4.5
BONDING OF VEHICLES TO FIXED INSTALLATIONS
Fuel dispense and receipt points shall be provided with a bonding cable. The
bonding cable shall be connected to the fixed earthing network, which in turn will be
connected to the dispense/receipt pipeline. The resistance from the end of the
bonding cable to earth shall be less than 10Q.
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Section 5 - inspection, testing of electrical equipment within hazardous areas
Section 5.0
Inspection, testing and maintenance of electrical
equipment within hazardous areas
5.1
GENERAL
Inspection, testing and maintenance of electrical equipment shall be undertaken in
accordance with DWS Functional Standard 07.
5.2
SAFE WORKING
All work on petroleum installations is controlled under the delegation of the
Operating Authority, by the Authorised Person, AP (POL)/AP PET. Permits to
work are issued by the AP (POL)/AP PET.
Electrical permits are issued by the Authorised Person (Electrical) in coordination
with the AP (POL)/AP PET.
5.2.1
Competent personnel
Inspection, maintenance and testing in petroleum hazardous areas should only be
undertaken by competent personnel who are :
a.
Familiar with the MOD Safety Rules and Procedures for Works on
Petroleum Installations, and are familiar with the MOD Safety Rules and
Procedures - Electrical.
b.
Experienced in inspection, maintenance and testing within petroleum
hazardous areas.
In addition, electrical personnel should be trained and experienced in:
c.
The principles and details of the various types of explosion protection.
d.
Related installation practice.
e.
The general principles of the selection of equipment for installations in
hazardous areas.
Earth fault loop impedance tests, high current continuity tests and prospective
short circuit current tests are not to be carried out in hazardous areas. Such
tests can introduce current and/or voltages in parts of the installation
they might not be expected, due to bonding of extraneous conductive parts and
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Section 5 - inspection, testing of electrical equipment within hazardous areas
lightning protection systems. This could result in incendive sparking in areas
or parts of the installation not covered by the permit to work.
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Annex A - Design, contractor installation and inspectiont test certificate
Annex A
Design, contractor installation and inspection\test
certificate
Electrical design certification - completed by electrical designer.
Installation certification - completed by the contractor /installer.
Test/commissioning certification - completed by test/commissioning
engineer eg contractor/designer.
Installation particulars - completed by the designer/contractor.
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Annex A - Design, contractor installation and inspection\test certificate
PART 1 - DESIGN CERTIFICATION
Client:
Address:
DESIGN
I/We being the person(s) responsible (as indicated by my/our signatures below) for the Design of the
electrical installation, particulars of which are described in part 4 of this form CERTIFY that the said work
for which I/we have been responsible is to the best of my/our knowledge and belief in accordance with the BS
7671, Regulations for Electrical Installations published by the Institution of Electrical Engineers, 16th
Edition, amended to (date.......), and any other relevant standards particular to the installation, except for the
departures, if any, stated in mis Certificate.
The extent of liability of the signatory is limited to the work described in part 4 as the subject of this
Certificate.
For the Design of the Installation:
Name (In Block Letters):
Position:
For and on behalf of:
Address:
Signature:
30
Date:
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Annex A - Design, contractor installation and inspection\test certificate
PART 2 - INSTALLATION CERTIFICATION
Client:
Address:
CONSTRUCTION
I/We being the person(s) responsible (as indicated by my/our signatures below) for the Construction of the
electrical installation, particulars of which are described in part 4 of this form CERTIFY that the said work
for which I/we have been responsible is to the best of my/our knowledge and belief in accordance with the BS
7671, Regulations for Electrical Installations published by the Institution of Electrical Engineers, 16th
Edition, amended to (date.......), and any other relevant standards particular to the installation, except for the
departures, if any, stated in this Certificate.
The extent of liability of the signatory is limited to the work described in part 4 as the subject of this
Certificate.
For the Construction of the Installation:
Name (In Block Letters):
Position:
For and on behalf of:
Address:
Signature:
Date:
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petroleum installations
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PART 3 - TEST/COMMISSIONING CERTIFICATION
Client:
Address:
INSPECTION AND TEST
I/We being the person(s) responsible (as indicated by my/our signatures below) for the Inspection and Test of
the electrical installation, particulars of which are described in part 4 of this form CERTIFY that the said
work for which I/we have been responsible is to the best of my/our knowledge and belief in accordance with
the BS 7671, Regulations for Electrical Installations published by the Institution of Electrical Engineers, 16th
Edition, amended to (date.......), and any other relevant standards particular to the installation, except for the
departures, if any, stated in this Certificate.
The extent of liability of the signatory is limited to the work described in part 4 as the subject of this
Certificate.
For the Inspection and Test of the Installation:
Name (In Block Letters):
Position:
For and on behalf of:
Address:
I RECOMMEND that this installation be further inspected and tested after an interval of not more than
years.
Signature:
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Annex A - Design, contractor installation and inspection\test certificate
PART 4 - PARTICULARS OF THE INSTALLATION
A full record of the details of the installation should be made including :
A description of the installation.
The earthing system adopted for electrical equipment and the results of the earth resistance
measurement taken.
Characteristics of the supply, short circuit currents, protective measures, overcurrent devices and
circuit breakers.
Details of the equipotential bonding system and the size of conductors installed.
Details of any departures from the Wiring Regulations or other relevant standards.
Hazardous area details.
note:
Part 4 is initially completed by the designer and amended by the contractor to reflect any changes that
may have occurred during the construction/installation process.
Number of additional pages
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Annex B - Change suggestion form
Annex B
Change suggestion form
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Annex B - Change suggestion form
Date:
Originator:
Ref:
Section:
Page:
Change Detail:
Continuation Sheet included ? Y
N
Continuation Sheet included ? Y
N
Reason:
Ref:
Action:
Action Date:
Approved:
Actioned:
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Printed in the United Kingdom for HMSO
Dd. 298037 C35 3/95 59226