Electrical Engineering Design

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  SPECIFICATION PREFACE SHEET

DEPARTMENT:

Engineering / Electrical

AREA: Grundartangi Reduction Plant

SHEET

1

OF

14

SPEC No: 00/06/TS021 REV:C1

STANDARD TECHNICAL SPECIFICATION FOR

ELECTRICAL ENGINEERING DESIGN

EQUIPMENT INSTALLATIONS EQUIPMENT IDENTIFICATION ELECTRICAL PRE-INSPECTION COMMISSIONING

This Standard Standard Technical Technical Specification Specification is subj subject ect to change without prior notice. The most cur current rent issue will at all times be locate located d on the Nordural web site, www.nordural.is.  REV C1

BY TDS

DATE 2004-05-24

CHK’D TDS

APPROVED ÓJ

 NORÐURÁL – ENGINEERING ENGINEERING

REVISIONS Issued for Construction

 

NORÐURÁL  

STANDARD TECHNICAL SPECIFICATION

00/06/TS021

NORDIC ALUMINUM

CONTENTS 1 

1.1 

GENERAL 



1.2  1.3 1.4 

 NGINEERING AND DRAWINGS   IE NSPECTION AND TESTING   IDENTIFICATION 

43  5 

1.5  1.6  1.7 

FINISH AND WORKMANSHIP  FACILITIES ON SITE  AUXILIARY POWER  

1.4.1 





7  7  8 

CONNECTION BOXES  PANELS  JUNCTION BOXES 



8  8  9 

CONTACTORS AND PULSE RELAYS  BUSBARS  WIRE TERMINALS 



9  11 

WIRES AND CABLES  I NSTALLATION OF CABLES 

11 

PROTECTIVE DEVICES

6.1  6.2  6.3  6.4  6.5  7 

6  7 

CONDUITS AND JOINTS  CABLE LADDERS 

WIRES AND CABLES

5.1  5.2  6 



MISCELLANEOUS EQUIPMENT

4.1  4.2  4.3  5 

5  6  6 

PANELS AND CONNECTION BOXES

3.1  3.2  3.3  4 



Cable numbering system

CONDUITS, CABLE LADDERS

2.1  2.2  3 



ELECTRICAL ENGINEERING DESIGN

12  12  12  12  12 

EARTH-LEAKAGE CIRCUIT BREAKERS  MINIATURE CIRCUIT BREAKERS  O N-LOAD SWITCH FUSES  LOAD BREAK SWITCHES  SWITCH-FUSE DISCONNECTS 

12 

INSPECTIONS AND COMMISSIONING

7.1  7.2  7.3  7.4 

12  13  13  13 

GENERAL INFORMATION  TESTING OF INSTALLATIONS  E NERGISATION  I NSPECTION 

7.4.1   Insulation measurement 7.4.2   Earth fault measurement 7.4.3   Measuring equipment 7.5  I NSPECTION FORMS 

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STANDARD TECHNICAL SPECIFICATION

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NORDIC ALUMINUM

 T E C H N I C A L S P E C I F I C A T I O N

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 item itemss covered by this Do Document, cument, 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 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 ttoo 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 t he 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 t he 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 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. 1.5

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 I EC Publication 60364-1, for supplies of 125 A and less. CONDUITS, CABLE LADDERS

Conduits and joints The conduits shall have ample cross cross section and wall thickness. Conduits shall have no sharp edges or discontinuities that can da damage mage the insulation. Included in the conduit supply shall be all necessary fastening and jointing materials including special  joints for the jointing of pipes and 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 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, wireofducts and internal for makingThe the400/230 cubiclesV system complete and for warranty a trouble-free andwiring safe operation. 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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STANDARD TECHNICAL SPECIFICATION

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NORDIC ALUMINUM

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 f or the intended components or equipment. Boxes are flush mounted in walls. All unused glands shall  be closed by means means of a lid of an aappropriate ppropriate 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 busbars shall be made of E-copper. Equipme Equipment nt 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 of E-copper otherwise wires shall be of plastic andmade the colour of the unless insulation shall bespecified. the sameInsulation for wires of 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 me methods. thods. 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 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

Black (or some other acceptable colour) Brown

L3  N PE

Black Blue Blu e (between green/yellow and 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 thefollowing: panels must be of type H07V-K or equivalent. The wire colours must be according to the For power circuits in the panel (TN-C or TN-S systems) L1 L2 L3  N PE

Black Black Black Blue 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

Black

 N PE

Blue 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 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

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.

6

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 have fuses type or equivalent. The switches shall haveswitch a fusefuses alarmshall indicator wiredofto"Neozed" 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 i n 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 ma materials terials 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 the installations Prior to 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 measurem measurements ents must be recorded and submitted 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 record all information as required on forms. All equipment must bbee checked for correct installation and connection. All protection systems for each circuit shall be checked against the electrical drawings for completeness and conformity. conformity. The equipment shall be check checked ed for compliance with specifications and Icelandic standards governing labeling, dimensions, compliance with “AS-BUILT” “AS-BUILT” drawings, door system system and earthing earthing.. All wiring of equipment and all busbar connections shall be checked for tidiness, completion,  position of current transformers, etc. The installation shall be cchecked hecked to see that 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 checked for continuity of the PE-wire. PE-wire. Short-circuit current for branches must be checked for correct operation of all protection equipment. The installation of all cables aand nd cable ladders m must ust  be che checke ckedd ffor or correc correctt insta installat llation ion.. 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 loop measurement Earth fault 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. equipment. The test results shall be recorded on an aapproved pproved 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 adv advance. ance.

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