Venezuela INVECEM

PROCESS CONTROL AND ELECTRICAL EQUIPMENT

Standard Design Criteria: June 2012

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PROCESS CONTROL AND ELECTRICAL EQUIPMENT

TABLE OF CONTENTS:

0. GROUP E00: GENERAL 1

0.1 Standard Design Criteria - Group Organization 1
0.1.1 Standards 1
0.1.2 Standardization 1
0.2 Electrical Data 2
0.2.1 Voltage and Frequency Levels 2
0.2.2 Operating Tolerances 2
0.2.3 Equipment Capacities 3
0.2.4 Power Factor Correction / Total Harmonic Distortion (THD) / Filters (1C) 3
0.2.5 Basic Power Distribution Design Philosophy 3
0.3 Electrical Panel Requirements 3
0.4 Electrical Room Requirements 4
0.5 Name Plates / Labels 4
1. GROUP E10: MAIN TRANSFORMER STATION 4
1.1 General Requirements 4
1.1.1 Loading and Spare Capacity 4
1.2 Equipment Selection 4
1.2.1 HV-Switchgear Selection 4
1.3 Main Transformer HV / MV (1T) 5
1.4 HV-Circuit Breaker (1Q) 5
1.5 HV-Isolating Switch 5
1.6 HV-Grounding Switch 5
1.7 HV-Insulators, Surge arrestors 5
1.8 HV - Power Distribution - Metering and Control Panel (2C / 2H) 5
1.9 HV - Control Power Supply / Battery Charger (2D) 6
1.10 General Requirements 6
1.10.1 Loading and Spare Capacity 6
1.11 Medium Voltage Power Distribution (1S) 6
1.12 Departmental Distribution Transformers MV / LV (1T) 7
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1.13 Circuit Breakers / Contactors (1S) 7
1.14 Power Factor Compensation 8
1.15 MV - Power Distribution – Metering, Monitoring & Control (2C / 2H) 8
1.16 Control Power Supply (2D) 8
2. GROUP E30: LV POWER DISTRIBUTION AND MCC 9
2.1 General Requirements 9
2.1.1 Loading and Spare Capacity 9
2.2 Low Voltage Power Distribution (1V) 9
2.3 Motor Control Centers (1M) 9
2.4 Control Voltage Supply 10
2.5 Uninterruptable Power Supply (E30-2A) 10
2.6 Control Interface with Process Control System 10
2.7 Low Voltage Power Factor Correction Equipment (1C) 10
2.8 Emergency Diesel Generator System (E30-EG) 11
3. GROUP E40: LIGHTING 11
3.1 General Requirements 11
3.2 Indoor Lighting (1F) 12
3.3 Outdoor Lighting (1F) 12
3.4 Traffic Lighting (1F) 13
3.5 Power Sockets, Plug Sockets (1U) 13
4. GROUP E50: PROCESS CONTROL SYSTEM (PCS) 13
4.1 General Requirements 13
4.2 Basic Design Criteria 14
4.3 I/O Devices (E50-2J) 14
4.4 Communication Networks (E50-2S) 15
4.5 Process Stations (E50-2P) 15
4.5.1 General 15
4.5.2 Hardware 15
4.5.3 Software 15
4.6 Operator Stations (E50-2H) 15
4.6.1 General 15
4.6.2 Operator Station Input Device 16

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4.7 Control Desks (E50-2Z) 17
List of Engineering Units to be applied 17
5. GROUP E60: INSTRUMENTATION, SENSORS AND SUBCONTROLS 19
5.1 General Requirements 19
5.2 Basic Design Criteria 19
5.3 Field Control Devices for Safety and Maintenance 19
5.3.1 Rope Switches (Emergency Pull Cord) 19
5.3.2 Panic Stop Push Buttons 19
5.3.3 Local Start and Stop Push Buttons 19
5.3.4 Start-up Notice (Start-up Warning) 19
5.4 Field Control Devices for Machine Protection 20
5.4.1 Proximity Switches 20
5.4.2 Limit Switches 20
5.4.3 Belt Drift Switches (Misalignment Switches) 20
5.4.4 Temperature Sensors PT100 20
5.4.5 Vibration Sensors 20
5.5 Process Instrumentation 20
5.5.1 Level Sensors 20
5.5.2 Load Cells 21
5.5.3 Control Valves and Actuators 21
5.5.4 Solenoid Valves 21
5.6 Sub-Control Systems (E60-2C) 21
5.6.1 General 21
5.6.2 Specification of Sub-Control System (SCS) 21
5.6.3 Definition of Input and Output Circuits 22
5.6.4 Installation 23
5.7 Special Instruments 23
5.7.1 Pyrometers and Special Temperature Measurement 23
5.7.2 Pyrometer and Camera Systems (E60-2V) 24
5.7.3 Kiln Shell and Refractory Monitoring (E60-2I.T) 24
5.7.4 Gas Analyzer (E60-2K) 24
5.7.5 Emission and Dust Monitoring Equipment (E60-2N) 24
6. GROUP E70: BUILDING AUTOMATION / COMMUNICATION SYSTEM 25
6.1 Fire Detection 25
6.1.1 General 25
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6.1.2 Fire Detection and Alarming (2F) Design 25
6.2 Telephone System 25
6.2.1 General 25
6.2.2 Telephone System (2T) 25
6.3 General Plant View Cameras 25
7. GROUP E80: MOTORS AND DRIVE SYSTEMS 26
7.1 General Design Requirements for Motors 26
7.2 Specific Requirements for Medium Voltage Motors (1X) 26
7.2.1 General Motor Requirements 26
7.2.2 Liquid Rheostat for Slip Ring Motors 26
7.3 General Requirements for Power Cables (1H, 1L) 26
7.3.1 Loading and Spare Capacity 26
7.3.2 High-voltage (HV) - & Medium-voltage (MV) Cables (1H) 27
7.3.3 Low-voltage (LV) - Cables (1L) 27
7.4 Control and Communication Cables 27
7.5 Cable Installation 28
7.5.1 Loading and Spare Capacity 28
7.6 Grounding 28
7.7 Lightning Protection 29

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0. GROUP E00: GENERAL

The following Standard Design Criteria shall apply to all Process Control and Electrical Equipm
The given Stan dard Desig n C rite ria identi fy t he minimum Eq uipme nt requirem ent s. The fo
t e r m s a n d d e fi n i ti o n s w i l l b e u s e d i n t h e D e s i g n C r i t e r i a f o r P r
Equipment:
Cost Center: The manufacturing process is subdivided according to the IEC
Department: T hes ubdivision
o t m f phe a anufacturing
t C C a p rocess cc
line. It normally includes the corresponding auxiliaries as required to make the process operational.
Group: Is the subdivision of a main or pre-process department into start/stop sequences, normally
identified by the HAC in position 123. The group of an auxiliary department normally defines types
of Equipment.
D r i ve :I s t h e m o t o r u p t o t h e m e c h a n ic a l c ou p l in g , i n c l u d in g i t s s t a r ti n g - , c o n t r o l - a n d p ro
device(s).
Sensor: I st he
a onalog
d m r eigital i easuring
i t u lement
t c a ncluding
t
protect the machine or the process (Refer to paragraph 5 for more detail).

0.1 Standard Design Criteria - Group Organization

The S tandard
D C fesign
P C riteriaa E or E rocess a a ontrol
a tnd lec
the various Equipment types, called groups, and are coded E00 to E90.

0.1.1 Standards
All instruments shall be calibrated in the metric system.
Equipment shall generally be designed for a maximum altitude of <= 1000m above sea level, unless
otherwise s i C tated P I n( ontract
P D art a II S Owner’s
a t d roject
t e
S1, continuous operation, 8,000 service hours per year.

0.1.2 Standardization
The s ame m s ake, s a tandard
c f a izes
r end Eapacities e orf t ll equir
following:
 High voltage, medium- and low voltage Equipment, e.g. circuit breakers and transformers
 Control monitoring and metering Equipment, e.g. PLCs and electronic circuits
 Instruments, field control devices, valves, control switches and lamps, etc.
 Motors, including power electronics, starters and contactors
 Cables, cable color, cable numbering

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Sub-control p ( e anels c i.e.
s lectrical
s f s ontrol
s a r ystem b fi upplied
a i r c o n d i ti o n e r s , c r a n e s , e t c . ) s h o u l d b e a v o i d e d w h e n e v e r p o s s i b l e . R e q u i r e d
realized in the process control system. If this is not possible for reasons of guaran
hardware used has to be of the same make and type as used for the process control system.

0.2 Electrical Data

0.2.1 Voltage and Frequency Levels

Description Unit Value
Network frequency Hz 60

HV main power supply kV/3 ph 115

Grounding system of Infeed power supply specify isolated

(isolated; direct, low or high resistance grounded)

Short Circuit Current(HV) kA 31.5

MV-Distribution voltage kV/3 ph 6.6

Short Circuit Current(MV) kA 31.5

Grounding system of MV network specify low resistance

(isolated; direct, low or high resistance grounded) grounded

Low voltage power distribution (LVD) system V/3 ph+PEN 440

Short Circuit Current(LV) kA 50

Grounding system of LVD (TN-C / TN-S):

- For LVD/MCC specify TN-S
- For lighting and socket outlets specify TN-S

Voltage level of motors:

-Medium voltage motors (P ≥ 250 kW) V/3 ph 6600
-Medium voltage variable speed motors (P ≥ 1000 kW) V/3 ph 3300
-Low voltage variable speed motors (P ≥ 250 kW) V/3 ph+PE 690

-Low voltage motors (P＜250 kW) V/3 ph+PE 440

Control Circuit for HV+MV switchgear VDC 125

Lighting and socket outlets VAC 220/110

Maintenance Lighting Voltage VDC 24

Plug socket centers / Welding socket outlets V/3 ph+PE 440

MCC's contactor control voltage V/2ph VAC 220

consumers (< 2000VA) V/3 ph+N+PE 220/127

Solenoid valves (< 400VA) VAC 127

Sensors VDC 24VDC

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Description Unit Value
Digital Inputs And Outputs VDC 24VDC

Analogue field devices:

- Wired 2-wire 4 - 20 mA
- Bus DEVICENET

0.2.2 Operating Tolerances

A) Full performance of Plant with slow changing or steady deviations:
 Voltage ± 10 %
 Frequency ± 2 %
B) Uninterrupted service of kiln department and other important ser
network disturbance (EN 50160 = Supply voltage dips) of:
 Voltage - 100 % (for 0.5 seconds)

0.2.3 Equipment Capacities

The s izing
o e fE lectricali t quipment
r p a c ncluding s b d he b ated
t o
Contractor according to the requirements of the mechanical Equipment and shall include the spare
capacities as specified in this document. Sizing must also be consistent with industry standards.

0.2.4 Power Factor Correction / Total Harmonic Distortion (THD) / Filters (1C)
The Plant power factor may be corrected on MV and/or LV level in order to achieve the specifi
overall Plant power factor. The following possibilities shall be considered:
 Low v oltage
p d ower - c istribution
L s ompensation:
b c t V-Equ
a u t o m a ti c a l l y r e g u l a t e d r e a c ti v e p o w e r c o m p e n s a ti o n E q u i p m e n t s i t u a t
power d istribution,
T h h he
c igher
p b armonics
n E ontent
s b ro
eliminated at the source to guarantee a trouble free operati on of all Equipment within
ranges given by standards and the requirements of the Equipment.
 For large variable speed drives and MV fixed speed drives: variable speed drive systems and
fi x e d s p e e d d r i v e s s u p p l i e d f r o m t h e M V - b u s b a r s s h a l l b e c o m p e n
r e a c ti v e p o w e r c o m p e n s a ti o n E q u i p m e n t c o r r e c ti n g t h e p o w e r f a
harmonics generated by the various kinds of converters.
 The level of harmonic distorti ons at the point of common coupling with the uti lity company
shall be maintained during all operating conditions of the Plant and shall be in line with good
e n g i n e e r i n g a n d c o n s t r u c ti o n p r a c ti c e s a n d c o
standards.

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0.2.5 Basic Power Distribution Design Philosophy
The e ntire
p d ower s istribution
( M a L s bystem
d t gHV, sV nd
f V)
i s o l a ti o n , i s o l a ti n g a f a u l t y c i r c u i t f r o m t h e r e m a i n d e r o f t h e e
eliminating unnecessary power outages.

0.3 Electrical Panel Requirements

All Low Voltage (LV) pan els shall b e in line with good eng in eering and con st ru cti on practi
conform to the applicable codes and standards, including the following:
 Protections and labeling according relevant safety standards
 Padlockable I I ncomingS w i solator i witch
t t a ith s w
nsulated
on electrical Equipment of the panel

0.4 Electrical Room Requirements

Cable cellars shall be applied for electrical rooms with a total installed power > 2MW, or more than
200 cables entering the room. Depending on the arrangement other rooms may be equipped with
false floor.

0.5 Name Plates / Labels

All electrical and control Equipment, shall be clearly labeled. Nameplates/labels shall
sized.

1. GROUP E10: MAIN TRANSFORMER STATION

1.1 General Requirements

All Equipment shall be in line with good engineering and construction practices and conform to the
relevant international codes and standards and the applicable local standards and regulations.

1.1.1 Loading and Spare Capacity

The incoming HV circuits and busbars shall be designed according to
authority.
Under actual nominal Plant performance conditions the maximum demand shall not exceed 90% of
the full transformer capacity in ONAN-operating mode.
The HV tap changer shall not exceed 1.25% voltage per step.
The nominal secondary current (MV) of the transformer shall not exceed 400
operating mode.

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1.2 Equipment Selection

1.2.1 HV-Switchgear Selection

Depending on the Plant layout, the available space and possible requirements of the authority, the
following types of HV-switchgear arrangement might be applied for the in
distribution station:
 Conventional type outdoor switchgear

1.3 Main Transformer HV / MV (1T)

Main t ransformer(s)
s b t p ahallo t oe i hree ( haseo S nd O f he il
t r a n s f o rm e r s sh a ll b e a p p l i e d (f or p ro v i si o n o f f u t u r e a d d e d p la n t c a p a c i t y i . e . t r a n s f o rm
must be based on ONAN configuration).
Transformers shall not contain any PCB.
Transformer f s eeders
n p t hould
o t ot b ass e hrough
t b wther a ransf
Equipment shall be independent. If this is not possible for technical reasons, fire protection (F120)
shall be applied.
Standard protection devices shall be included.
M a i n t r a n s f o r m e r s s h a l l b e e q u i p p e d w i t h a u t o m a ti c o n - l o a d t a p c h a n g e r
p r o t e c ti o n d e v i c e s , a u t o c o n t r o l a d a p t e d t o t h e f e e d i n g l i n e c o n d i ti o n s
condition monitoring .

1.4 HV-Circuit Breaker (1Q)

Circuit breaker shall be 3-pole, with 3-pole or single pole operati ng mechanism as required
shall i nclude
a s a ll s tandard
f f r nd c peciala s eaturesi a or w emote
the authority.

1.5 HV-Isolating Switch

3-pole, single throw horizontal break switch shall be used capable of either
electrical operation in accordance with the authority.

1.6 HV-Grounding Switch

Hand operated, electrically interlocked grounding switch

1.7 HV-Insulators, Surge arrestors

Basic insulation level (BIL) shall be as required for the specific application.
All insulators shall be executed for increased creeping path.

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Surge a rrestors
a s g nd/or
s b a park
a i apsl a hall a s e pplied
b a t nco
specifications. Arrestors shall include standard features for supervision and control.

1.8 HV - Power Distribution - Metering and Control Panel (2C / 2H)

A l l g e n e r a l m e t e r i n g a n d s p e c i fi c m e t e r i n g d e v i c e s f o r b i l l i n g p u r p o s e s , p r o t e
functions shall conform to Applicable Laws and Applicable Codes and Standards.
Check and quality metering shall be installed to suit the requirements of the cement Plant for th
con trol of u ti lit y compa ny billing and power q uality. Qu alit y m etering sh all include det ecti
reporting of voltage fluctuations, power dips and harmonics.

1.9 HV - Control Power Supply / Battery Charger (2D)

T h e H V - d i s t r i b u ti o n s y s t e m s h a l l b e c o m p l e t e w i t h t h e r e q u i r e d u n i n t e r r u
supply, f t oor he c peration,
a m o tontrol
H d nd onitoring
s U p f he
AC or DC Equipment, which includes battery rack, charging Equipment and a distribution panel shall
be located in a separate room and be designed according authority req
charging E quipment
( fl a r c for i oat
ac nde apids b harging)
i A n o
shall be provided for loss of AC supply, charger fault, and low DC voltage.Group E20: M
Distribution and Transformers

1.10 General Requirements

T h e p o w e r d i s t r i b u ti o n s c h e m e s h a l l c o m p l y w i t h t h e p r o c e s s r e q u i r e m e n t s .
departments s r d hall peceives a edicated
d I ower
p d upply nd
are determined by HAC.
The medium voltage power distribution switchgear shall be located in electrical rooms.
Following terms and definitions will be used:
Busbar l ine-up:
All E quipment
m i a ounted
M p a n d djacent
c w Vt s anels
busbar.
Section: A freestanding panel (part of a busbar line-up) containing one or several compartments
Compartment: Metal casing containing electrical / control Equipment

1.10.1 Loading and Spare Capacity

T h e M V c i r c u i t s a n d b u s b a r s o f t h e m a i n s u b s t a ti o n s h a l l b e d e
transformer(s) maximum load in ONAF operation.
The nominal secondary current (LV) of the transformer shall not exceed 4000A.
Every MV busbar line-up shall be equipped with one spare feeder.

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1.11 Medium Voltage Power Distribution (1S)
The following basic requirements shall be met:
 All MV-switchgear shall be of the metal enclosed / metal clad
switchgear and controlgear.
 IEC b usbar
l s ine-up
c t I hall
F a Aonform
b l os ACb a rLR nd
t NSI
2B respectively
 All busbars shall be made of copper.
 Anti-condensation heating maybe used as required by local climatic conditions.
 All Equipment shall be readily accessible for maintenance and for easy replacement

1.12 Departmental Distribution Transformers MV / LV (1T)

Transformer capaciti es shall have a maximum of four standard sizes between 500kVA and approx.
2 0 0 0 k V A . E x c e p ti o n s f o r s p e c i a l t r a n s f o r m e r s f o r v a r i a b l e
technically required.
The transformer room design (sheltered) shall allow for uti lizati on of full rati ng of transformers b
natural air draft cooling.
Transformer feeders should not pass through other transformer bay; each transformer bay with all
Equipment shall be independent.

1.13 Circuit Breakers / Contactors (1S)

Ci rc ui t b re a ke rs an d con t a ct ors sh a ll b e of t h e d ra w -ou t t yp e p rov id e d w it h au t om ati c sh
separate compartments of the metal clad section. The circuit breakers shall be capable of local and
remote control (electrically) and emergency off at local (mechanically).

Safety measures shall include:

 Lockable in off, racked-out and grounded position
 No-voltage release
 Interlocks to prevent movement of circuit breaker in closed position
 Allow closing of circuit breaker in defined positions only
 Grounding switch

Other standard features shall include:

 Trip coil / closed coil monitoring
 Switching status indicator
 Operation counter
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 Panel door locking device (identical key for all doors)
 Undervoltage coil required for motor feeders
The o perating
m s echanism
b s ( halle eF mpring-loadedp c stored
breakers / contactors shall be operable in racked out/test position.

1.14 Power Factor Compensation

Every medium voltage busbar line-up shall be equipped with at least one dedicated reactive power
c o m p e n s a ti n g E q u i p m e n t . I t s h a l l b e a u t o m a ti c a l l y c o n t r o l l e d a n d e q u i p p e d
guarantee the quality of the plant network with respect to volta
transformer tab changer), power factor and harmonics.
The capacitor banks shall be sized to achieve a power factor at full load operati on. In any case
overall plant power factor in accordance with the requirements of the authority shall be achieved.
The switching sequence (rotati ng load) and the capacitor unit size shall be selected in accordan
with the expected loading and shall not disturb or be disturbed by any electronical
Equipment.
All c omponents
( r capacitors,
r s b eactance’s,
i i t M r esistors)
o i as hall
room nearby the medium voltage distribution.

1.15 MV - Power Distribution – Metering, Monitoring & Control (2C / 2H)

A p o w e r d i s t r i b u ti o n m o n i t o r i n g a n d c o n t r o l s y s t e m s h a l l b e s u p p l i e d . I t s h a l
medium power distribution from its incoming and the outgoing feeders down to the respective LV-
i n f e e d c i r c u i t b r e a k e r s . T h e s t a t u s o f a l l s w
and the transformer and bus ti e-breaker shall be controllable from there and from a local con
panel. The control shall contain all relevant interlocking, alarm/annunc
medium voltage Equipment. Motor feeder circuits shall be started remotely only from the Pla
central control room.
All controlled Equipment shall have a standardized interface for the sign
process control system. Such signal interface of each individual Equipment
shall be arranged either
as c onventionals e i ignal ( xchange
f c nterface
a o a potential
v 4 ree
(2-wire system) or with the Plant-field-bus.
All terminal or plant-field-bus-connection arrangements for remote control and monitoring shall be
separately arranged in the individual compartments so as not to interfere with the internal cabling
and to allow easy access.

1.16 Control Power Supply (2D)

The M V-distribution
s E s ystem
b c quipment
w t r c hallp se omplete
f o r t h e o p e r a ti o n , c o n t r o l a n d m o n i t o r i n g o f t h e M V - p o w e r d i s t r i b u ti o n s y s t e m . D
w h i c h i n c l u d e s b a tt e r y r a c k , c h a r g i n g E q u i p m e n t a n d a d i s t r i b u ti o n p a n e l s h

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separate r A oom. c utomatic
E ( fl harging
a r c quipment
i ac e for oat
shall be included for each MV-switchgear room. Alarming shall be provided for loss of AC su
charger fault and low DC voltage.

2. GROUP E30: LV POWER DISTRIBUTION AND MCC

2.1 General Requirements

The p ower
d sistribution
s c w cheme
t p a hallr oincide I pith he
departments shall be supplied from individual power supplies and distributions. Individual process
departments are determined by HAC.
Applicable codes and standards:
 Low voltage switchgear and control gear: IEC 60947 or equivalent
 Construction design: IEC 60439 or equivalent
The required concept for the Low Voltage Distribution (LVD) and Motor Control Centers (MCC) may
depend on the installed loads as well as of the Plant layout. If required and technically feas
c o m b i n e d a r r a n g e m e n t o f L V D p a n e lms a w y i bt he ia np tpel gi er ad t. e Fd o M
r Ct
arrangements please refer to the typical arrangement drawings

2.1.1 Loading and Spare Capacity

T h e r e q u i r e d s h o r t c i r c u i t b r e a k i n g a n d l o a d i n g c a p a c i t y a t o p e r a ti n g v o l t a
Equipment shall be based on Contractor’s calculation according the relevant Standards.
The main LVD busbar shall be rated according to the transformer secondary current.
A m aximum o 7 d ifferenttf o Mypes
m sf bCCu t codulest e r hall o L em sed
capacities.
A maximum of 9 different types of On-load local isolator switches (LIS) circuit breakers / contactors
shall be used to cover the entire range of LV motor capacities.

2.2 Low Voltage Power Distribution (1V)

The l vow p oltagef f tower
d eed
t rom s he s istribution
s b c t ransform
the LVD panel either by cables or enclosed bus, depending
arrangement and distance. The connecti on and components shall be sized for the full transformer
capacity.

2.3 Motor Control Centers (1M)

The MCC shall contain motor control Equipment for a safe remote control of the different process
groups (HAC).

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A MCC shall comprise one or several process groups of a cost center. Process groups shall no
subdivided i d nto
M eifferent n O CCs, w xceptions
a T f eed o awner’s
process group shall form a block arrangement within the MCC.

An overload device shall protect every motor. Large motors 75 kW and specifically loaded motors
(heavy start, high torque) shall use electronic type of motor protecti on. Overload devices sha
designed to prevent single phasing. The overload device shall have automatic reset (self-reset type).
Reversible motor feeders shall be provided with internal interlocks to prevent short-circuiting.
Each motor control module shall contain all elements for the control and monitoring of one motor
and for the protection of its circuitry.
Internal wiring shall be coded by numbering. Color-coded wires shall be app
between different voltage levels.

2.4 Control Voltage Supply

LV-distribution and MCC-panel internal control voltage shall be fed from a separate Control / UPS-
system arranged per department or electrical room. Availability of control voltage shall be
monitored through the control interface.

2.5 Uninterruptable Power Supply (E30-2A)

UPS shall s fervet f or
o t he
p eed
s I f u he a trocess
i tations,
T o /O ni
stations, servers and the communication Equipment shall have a separate UPS. The UPS shall be of
the static battery-buffered type.

2.6 Control Interface with Process Control System

All controlled Equipment (e.g., motor starters, sub-control systems) shall ha
requirements a r llowing
c a m emote t f ontrol
t o nd
r onitoring,
a t
allow fully automati c control and supervision (discrete and analogue) through the process con
system
.

2.7 Low Voltage Power Factor Correction Equipment (1C)

Low voltage power distribution directly connected to a transformer, or at remote locations shall be
equipped w a a ith nc utomatically
r c c ontrolledE t eactive
a t urren
desired o p verallf T ower
c b actor. s b s he t a apacitor ap f anks
a f l hall
o p e r a ti o n . I n a n y c a s e a n o v e r a l l p l a n t p o w e r f a c t o r i n a c c o r d a n c e w i t h t h e r e q u i r e m e n
utility company shall be achieved.
The reactive power units shall be designed as follows:
 Modular design using standard capacitor units

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 Complete with protective devices and contactors

2.8 Emergency Diesel Generator System (E30-EG)

The e mergency
d g siesel
s s enerator
f t e set ohalle erve
p i cor he
of a f ailure
w t M ithin
d heo o t VM s istribution
p Am ur mf b hec V tandb
for this case.
This concept may include a separate small LV standby diesel generator for most critical Equipment
(kiln auxiliary drive, lighting), separate standby transformer or solutions with mobile Equipment.

3. GROUP E40: LIGHTING

3.1 General Requirements

The lighting and power distribution panels within the main process areas shall either be fed directly
f r o m t h e n o n - p r o c e s s s e c ti o n o f t h e d e p a r t m e n t a l L V D p a n e l o r
transformers connected to the non-process part of the departmental LVD pa
distribution.
L i g h ti n g fi x t u r e s t h r o u g h o u t t h e p l a n t s h a l l b e o f t h e l o n g - r a t e d l i f e , h
maintenance t L fiype. f iightinga w a oxtures i or s ndoorb i ss a ell s
to allow easy maintenance and access. Installation on walls and structures is preferred.
All apparatus shall be dust-proof and impact-resistant. All lighti ng fi xtures shall be suitable for t
conditions w t where
b m hey L illm be c ounted. w p ighting
h a ust
(ATEX zone) designations as applicable.
Mobile Equipment such as stacker, reclaimer, mobile crusher, ti ppler, etc. shall be equippe
their own on-board lighting system fed from the machine distribution system.
S e p a r a t e d i s t r i b u ti o n p a n e l s s h a l l b e u s e d f o r e a c h b u i l d i n g o r p a r t s o f l a r g e b u
distributi on circuits and control for roads and outdoor areas shall be separated from distributi
for process buildings and offices.
The installati on shall be executed as TN-S system in accordance with IEC 364 or NEMA equivalent
whereby the single-phase voltage is defined as phase to neutral voltage.
Single-phase consumers shall be distributed equally to the 3 phases in order to establish a suitably
balanced transformer load and to minimize stroboscopic effect of lighting.
Receptacles and lighting shall not be combined together in common circuits.
All s witches,
c b ircuit
r a areakers, s b elays
o t s dnd a ccessories
m a hall
the Equipment for the process MCCs to ensure interchange-ability and reduce spare parts stock.
For offi ces, laboratory, control rooms and similarly occupied rooms and buildings, cabling shal
routed inside walls and ceilings/floors using conduits.

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3.2 Indoor Lighting (1F)
In P lanta o nd
a d ffice t flreas laylights b u ypet uorescent
e i h b amps
areas (height > 5m). High bay areas shall be illuminated with high effi ciency lamps; however, suc
circuits shall contain a certain number of instantly restarting lamps.
When fluorescent fixtures are used the lighting tubes shall be secured to prevent them from falling
and injuring personnel.
Lighting s switches
b a ahall
am e b rranged e r e s d ainimum
fl a a esides
well as on all fl oor levels of staircases. Further additi onal arrangements depend on the room siz
L i g h ti n g s w i t c h c i r c u i t s s h a l l g e n e r a l l y b e o p e r a t e d t h r o u g h p u l s e r e l a y c o n t r o
simple arrangement where one only switch is needed and no further switch may be re
future. Fixtures with separate covers to attain dust tightness shall not be used.
A n e m e r g e n c y l i g h ti n g s y s t e m c o m p r i s i n g a n a d e q u a t e n u m b e r o f fi x e d i n s t a l l e d , f u l l y a
lamps with their own battery and charger as well as exit markings shall be used for safe evacuation
of all buildings, electrical rooms and parts of the Plant in the event of the complete loss of electric
power supply.
A ti g h t e r d i s t r i b u ti o n o f s u i t a b l e e m e r g e n c y l i g h ti n g s h a l l b e u s e d i n t h e
generation a w a s s ell
a m s p tandby- d t and f sain w ower
c wistribution
restoring the permanent power feed.
Furthermore, a n o m umber
b f e obile l attery-operated
w a c s merg
b e i n s t a l l e d a t m a i n a c c e s s r o u t e s a n d o n e a c h m a i n fl o o r w i t h a h i g h c o n c e n t r a ti o
Equipment.
The design of the lighting distribution shall be in such a way that the lighting distribution panels of
each main electrical room is fed from the standby power generating unit so as to guarantee supply
also in the event of a main power failure.
T y p e s o f s u b s u r f a c e m o u n t e d l u m i n a r i e s f o r o ffi c e s , c o n t r o l r o o m s , s o c i a l b u i l d i n g s , e
selected in accordance with the architectural design and the individual room requirement. Control
rooms a o ndr ther
s p ooms P erving s r redominantly
i l w a C-work
dimming. L c ighting w t o ircuitsm s sith b wwo o rt pore r pwitches o ha
with “intelligent” lighting control systems.

3.3 Outdoor Lighting (1F)

On roads and other outdoor areas, high effi ciency lamps shall be used. Wherever possible lighti n
fixtures serving street lighting and lighting of places shall be fixed to nearby building structures but
shall be fed from the respective road lighting distribution system.
W h e r e a p p r o p r i a t e , fl o o d l i g h ti n g s h a l l b e i n s t a l l e d f o r l a r g e a r e a l i g h ti n g i n p l a c e o
individual masts.
For the outdoor lighting, photocells (twilight) control for automatic switching in dark shall be used.
Simultaneous switching of all outdoor illumination within the whole Plant shall be assured.

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Warning lights for aircraft on high structures shall be used in accordance with applicable la
applicable codes and standards.

3.4 Traffic Lighting (1F)

Traffi c signals to control the traffi c in the gate and dispatch areas shall be used as required by the
o r g a n i z a ti o n . T h e s y s t e m s h a l l f u r t h e r i n f o r m a n d g u i d e t h e t r u c k d r i
loading/unloading activities.
Such signaling shall either utilize large clear text displays or a normal traffic lighting system. Special
care shall be given in the design to account for sustainable visibility in dusty environments.

3.5 Power Sockets, Plug Sockets (1U)

One or several single-phase receptacles shall be provided beside each room door and floor access.
Further distribution will depend on the room size.
Plug s ocket
c s enters
b o i thall ( e o fe ndustriali a eype fl metallic
o e
production building. A maximum of 3 plug sockets centers may be connected in parallel (looped).

4. GROUP E50: PROCESS CONTROL SYSTEM (PCS)

4.1 General Requirements

T h e p r o c e s s c o n t r o l s y s t e m ( P C S ) s h a l l b e b a s e d o n t h e a p p l i c a ti o n o f a w e l l - p r o v e n
p a i r e d w i t h e ff e c ti v e s t a n d a r d i z a ti o n o f a l l E q u i p m e n t a n d m a t e r i a l s t h r o u g h
following general guidelines shall be considered:
a) Separation of the cement process into highly independent sub-processes (departments) shall
be reflected in the design and layout of the process control system. The HAC system shall be
used as a guideline for defining the sub-processes.
b) The design of the process control system shall provide to the exte
a r c h i t e c t u r e a n d a l l o w f o r e a s y i m p l e m e n t a ti o n o f n e w r e q u
replacement of obsolete parts.
Following terms and definitions will be used:
Distributed I/O:I/O devices connected via Plant-Field-Bus, mounted in fi eld I/O boxes or panels to
connect field sensors and actuators (as specified in paragraph 5.) and motor control (as specified in
p a r a g r a p ha sn d 2) o r d i r e c t P l a n t - F i e l d - B u s c o n n e c ti o n t o m e a s u r i n g s y s t e m s a
systems (as specified in paragraph 5 and 7).
BUS systems: The Plant-fi eld-bus for the communicati on of the I/O with the process stati ons
P l a n t - C o n t r o l - B u s f o r t h e c o m m u n i c a ti o n b e t w e e n p r o c e s s s t a ti o n s a n d s e
Automation-Bus for the communication between servers, operator stations and other IT devices.

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Process stations (PS):using industrial controllers (processors) with their software, assuring the safe
o p e r a ti o n o f m a c h i n e s , o f t h e p r o d u c ti o n p r o c e s s a n d p r o v i d
interfaces.
Operator s ( tations
u sings tandard
OS):
I E a T c quipment i s nd aorresponding
a simple and efficient human machine interface (HMI) for the remote operation of the Plant.
S e r v e r us :s i n g s t a n d a r d I T E q u i p m e n t a n d c o r r e s p o n d i n g i n d u s t r i a l s o ft w a r e ,
efficient data storage.
Screen: Is the displayed content (text and picture/graphic) on a HMI monitor.
Screen area: is a p art of th e t ot al disp la yed con ten t, show in g e .g. proce ss (dep artme nt or gr
information or standardized navigating information.

4.2 Basic Design Criteria

The p rocess
c s ontrol
( s c ystem a n PCS) h hall a s omprisef m a ll ecessa
process control and for interface and Technical Information System (TIS).
It shall include all Equipment required for safe, local, remote, manual and automati c operati o
the process, pre-process departments and of the relevant auxiliary departments.

4.3 I/O Devices (E50-2J)

Input and output modules (I/O) shall be installed decentralized in the different areas of sensors and
control centers. Plant-field-bus communication shall be applied from the I/O to the Process Station
( P S ) . F i e l d I / O ’ s s h a l l b e 2 4 V D C . T h e d i ff e r e n t t y p e s o f I / O m o d u l e s s h a l l b e
maximum of 4 different types of DI, 3 different types of DO, 2 type of AI and AO (0 or 4-20mA).

I/O-Panels and field I/O-Boxes:

Input/Output (I/O) components shall be mounted in field I/O boxes (FIOB) of standardized modular
d e s i g n a n d s i z e . T h e s e b o x e s s h a l l b e c o n n e c t e d w i t h t h e s t a n d a r d P l a n t - fi e l d - b u s s y s t
Process Station (PS). Power supply to these FIOB shall be from department UPS. Power supply and
communication shall be individually supervised per Plant-field-bus node and indicated/alarmed.
FIOB shall be totally enclosed.
Field signals shall be directly wired (2 wire concept) through a wire guide with one labeled position
(e.g. h pole)s a er c ignal b c ndc onnected
t o t m y I age c lampsu ermin
one terminal per wire.
Signals from power distributi on and motor control shall be connected to I/O's directly installe
the respective panels.

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4.4 Communication Networks (E50-2S)
F i b e r o p ti c c o m m u n i c a ti o n n e t w o r k s ( g l a s s t y p e ) s h a l l b e i n s t a l l e d b e t w e e n b u i l d i n g
boxes and process control systems installed outside of buildings for transport systems.
The communication networks for the PCS (plant-control-bus and plant-field-bus) have to be strictly
s e p a r a t e d f r o m t h e o ffi c e n e t w o r k . I n t e r n e t a n d e m a i l a c c e s s f r o m t h e P C S a u t o m
p r o h i b i t e d . T h e P C S c o m m u n i c a ti o n n e t w o r k s s h o u l d c o n s i s t o f s e p
i n f r a s t r u c t u r e ( s w i t c h e s , fi b e r o p ti c s e t c . ) a n d b e m a n a g e d
appropriate security measures with a firewall connection to the office network.

4.5 Process Stations (E50-2P)

4.5.1 General
P r o c e s s S t a ti o n s ( P S ) s h a l l b e a r r a n g e d p e r d e p a r t m e n t , a l l
supervision of each distinct department. Small departments may be controlled by a common PS as
shown on the PCS layout.

4.5.2 Hardware
T h e p r oc e ss s t a ti o n c o n t ro l le r sh a l l b e lo c a t e d i n t h e c om p u t e r r o om n e a r t h e r e sp e c ti v e
control building.

4.5.3 Software
The software shall be structured as follows:
 System software
 Standard software
 Application software (based on functional description)
The system and standard software is understood to be equal on all process station (PS).

4.6 Operator Stations (E50-2H)

4.6.1 General
The PC based Operator Stati ons provide high-performance human-machine communicati on to th
process.
All main operator commands shall be possible with mouse only.
The mouse (keyboard) Equipment and the displays shall be arranged to allow the operator an easy
control from a sitting or a standing position.
The PCs and servers shall be installed in the computer room in a panel.

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 Venezuela INVECEM
The servers shall be applied for data storage of the confi gurati on and for intermediate storag
process data. All data of process values and of all events shall be stored and be on-line available on
the o perator
s f a l tation1 w eeks.Hor t ardware
a east
s s gnd oftware
b o s t a hall e
m a k e a s t h e O S b u t w i t h a d d i ti o n a l h a r d a n d s o ft w a r e t o c o p e w i t h t h e s p e c i
regarding data security and redundancy.
Communication to OS and PS shall be with standard Ethernet TCP/IP.

4.6.2 Operator Station Input Device

Standard PC input devices (optical mouse or trackball, PC-keyboard) shall be used.
All o perator c s ommands
b p a d hall a p e erformed
g n u ms t irectly
t
hierarchical levels (e.g. first: display selection, second: operator command).

4.6.2.1 User rights/ security levels

Parameter a djustments
( l s a sengineer
o a l evel)
P l s uch e ss etting
b
clearly separated from the normal operator commands.

4.6.2.2 Department Overview (Main, pre-process and auxiliary departments)

All main process Equipment within a department shall be shown on department overviews in dynam
symbol f a ormw p long a vith a rocess c T nalog d s aluesb u f ndm ontrollers.
process v malues, a akingt a c djustments
s a s o o dnalog a ontrol,
s tartin
process routings. A fixed trend screen area showing the main measuring values of the department shall
be included on this overview.
A u x i l i a r y d e p a r t m e n t ( s ) s h a l l i n c l u d e i n f o r m a ti o n f r o m e l e c t r i c a l p o w e r d i s t r i
system, b auilding p utomation,
c a p w lante ompressed
p s e I ir, lant
from small departments can be combined on one screen area.
S o m e d e p a r t m e n t o v e r v i e w s c r e e n s w i l l n e e d i n f o r m a ti o n f r o m 2 o r m o r e p h y s i c a l d e p
example, the main process gas flow circuit).
The status of the department shall be presented in a standardized form showing the status of all control
groups belonging to the department.

4.6.2.3 Group View

Within a group, all process Equipment requiring monitoring and/or cont
dynamic symbol form and in more detail than on the department overview. Dynamic alarm and not
r e a d y sy m b o l s s h a l l b e s h o w n n e a r t h e a p p r o p r i a t e p r oc e ss E q u i p m e n t . A l l p r oc e ss a n d m
protection analog values (e.g. gas pressures, temperatures) shall be shown in dynamic form. Status
of subsystems shall also be shown but not in great detail. HAC shall be permanently displayed (
operator selected, or tool tip type) at this level.
The group screen area shall be used for selecting alternate Equipment, group permissive and group
starting/stopping o m I f s otors.a s ndividual
o m s b tarting
p p nd toppi
available to the operator using pop-ups.

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The status of a group shall be presented in a standardized form, showing th
machine and measurement status (or function).

4.6.2.4 Subsystem / Main Drive Detail View

Information a s bout s a ubsystems
l a h uch
s ss bubrication
s o s nd
screen areas. Depending on the complexity of the subsystem a full group screen area or a pop-u
overlay m b c ay eS onfigured.
s s b dubsystemsa s i hall t howm b oth
useful for maintenance and diagnosis of problems (e.g. piping diagram with va
Detail views shall be configured for other Equipment that is complex by nature .

The same features that are available on the group view shall be available on these displays.

4.6.2.5 Services View

Services s a creen
s b c rea t hall
s c e s onfigured o p o show a ti ontrol
s e tti n g s , m a t e r i a l / s i l o a l l o c a ti o n s , g r o u p e d a l a r m l i m i t s e t c . I t s h
information such as scan times, processor faults, etc. including information for all network nodes.

4.6.2.6 Trend View

It s hall
b p e t possible a p o o resent
c v ny
a a rocess
i o b r v alculated
i f
of a trend curve, to present several trend curves on one screen area (window)
several trend screen areas per screen. Trend data shall be available on the operator stati on for
least 6 days.

4.7 Control Desks (E50-2Z)

Operator Stati ons (Human Machine Interface) shall be arranged on control desks located in the control
center(s).

Central Control Desks:

The control desks shall be located in air-conditi oned control rooms and shall contain all necessar
control and information elements for a safe remote operation of the process.

Local Control Panels:

Local c ontrol
r a c oomsE nds i ontrol
p c quipment
w t r halls n rincip
for the central control room/desks but additionally comply with the ambient local conditions.

List of Engineering Units to be applied

A l ist
o e f ngineering
u a t nits b bbreviations
u o g d p hat c hall ae sed
alarm text is given in the following table.

Speed (rpm) shall indicate the speed of the driven machine.

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Variable: Description of Use: Unit Description: Abbreviation:

CO gas composition Milligram per cubic meter CO mg/m3 CO

M i l l i g r a m p e r N o r m a l c3 u b i c
CO gas composition mg/Nm CO
meter CO

CO gas composition percentage CO % CO

Displacement kiln, press, VRM millimeter mm

m o t o r s & e l e c t r i c a l
Energy kilowatt-hours kWh
consumers

Specific energy rate efficiency of operation kilowatt-hours per ton kWh/t

Flow process gases cubic meter per hour m3/h

Flow materials ton per hour t/h

Flow oil, water, etc. cubic meter, Iiter per hour m3/h; l/h

Level silos, bins, etc. percentage full %

Mass materials ton (1000 kg) t

Noise ball mill loading noise %

Nitrous Oxide gas composition Milligram per cubic meter NO mg/m3 NO

M i l l i g r a m p e r N o r m a l c3 u b i c
Nitrous Oxide gas composition mg/Nm NO
meter NO

Oxygen gas composition percentage O2 % O2

Position dampers, gates, valves percentage open %

Power motors & consumers kilowatts kW

v o l t , a m p , c o s p h i ,
V, A, cosφ, THDI,
Electric power power distribution harmonic distortion current, -
THDU
voltage

millibar, bar, Pascal, m b a r , b a r , P

Pressure hydraulic, air, water, etc.
kilopascal, Mega Pascal kPa, MPa

Speed fan & feeder drives Revolution per minute rpm

Speed cooler drives strokes per minute spm

Temperature general degree Celsius °C

Time time of operation hours (seconds, minutes) h (s, min)

Vibration fans, mills, etc. millimeter per second mm/s

Weight silos, bins, etc. ton (1000 kg) t

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5. GROUP E60: INSTRUMENTATION, SENSORS AND SUBCONTROLS

5.1 General Requirements

The Standard Design Criteria shall apply to all operating elements, field devices and instruments as
well a s s ubcontrol
s r t ystems
p o equired
m a m o roperly
t P M a perate,
t y p e o f a l l fi e l d c o n t r o l d e v i c e s s h a l l b e s t a n d a r d i z e d t h r o u g h o u t t h
specified.

5.2 Basic Design Criteria

Either 2-wire transmitt ers with 4-20 mA standard signals shall be used for the signal transm
from the analog instruments to the I/O system.

5.3 Field Control Devices for Safety and Maintenance

S a f e t y d e v i c e s s h a l l b e i n s t a l l e d a s s p e c i fi e d b e l o w a n d i n c o n f o r m a n c e w i t h A p p l i c a b l e
Applicable Codes and Standards.

5.3.1 Rope Switches (Emergency Pull Cord)

Rope switches shall be installed along every conveyor walkway and shall extend over
length o t c f he W onveyor.
t c i a here f bhe s onveyor
( o g o sw ccessible
t
walkways), rope switches shall be used along both sides of the conveyor.

5.3.2 Panic Stop Push Buttons

Panic s p topb ush
s b i uttons a t k hall p Pe nstalled
m t t p heb ey oint
s h a l l b e u s e d . D e p e n d i n g o n l o c a l r e g u l a ti o n s a d d i ti o n a l b u tt o n s m a y b e r e q u i r e d
isolate the entire electrical room for fire fighting.

5.3.3 Local Start and Stop Push Buttons

Local start and stop push buttons shall be installed for all process machines. They must be installed
in such a way, that when starting, the machine can be observed. For valves or a set of valves start
p u s h b u tt o n s s h a l l b e i n s t a l l e d f o r t e s ti n g p u r p o s e s . A d d i ti o n a l s t a r t / s t o p p u
installed where required for maintenance (e.g. bucket elevator openings).

5.3.4 Start-up Notice (Start-up Warning)

Au d i b l e a n d v i s u a l s t a r t - u p n o ti c e d e v i c e s s h a l l b e i n s t a l l e d i n o r d e r t o a tt r a c t
personnel to indicate remote starti ng of machines. Such start-up noti ce devices shall be arra
per group (sequence) of machines or otherwise in accordance with all applicable regulations.

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5.4 Field Control Devices for Machine Protection
All sensors shall be individually wired to the field I/O box for individual signaling. Protection sensors
m o u n t e d a t l o c a ti o n s w i t h d i ffi c u l t a c c e s s o r p r o n e t o w e a r s h a l l b e d o u b l e d ( e . g .
winding temperature or filter inlet temperature).

5.4.1 Proximity Switches

Proximity switches shall be standardized 2 wire proximity switches
elements. T t o his
s s ype b a f twitch c g hall
b t e t ppliedp o v hute
position, clutch position, brake position and similar applications.

5.4.2 Limit Switches

Me ch a ni ca l t yp e lim it sw it ch e s sh al l be re p la ce d wi t h p rox im it y swi t ch e s. W h e re re qu i re d
application, they shall be equipped with 1 NO, 1NC contact and an appropriate heavy duty lever for
the application.

5.4.3 Belt Drift Switches (Misalignment Switches)

B e l t d r i ft s w i t c h e s s h a l l h a v e o n e N C c o n t a c t , a n d t h e s w i t c h l e v e r s h a l l b e o f t h e s p r
heavy duty mechanism without reset.

5.4.4 Temperature Sensors PT100

W h e r e s p e c i fi e d o r n e c e s s a r y f o r p r o t e c ti o n a n d m o n i t o r i n g o f l a r g e b e a r i n g
r e s i s t a n c e t e m p e r a t u r e d e t e c t o r s t y p e P T 1 0 0 s h a l l
1 6 0k W w i l l g e n e r a l l y b e s u p e r v i s e d o n 1 w i n d i n g ( o u t o f 3 i n s t a l l e d ) , m o t o
450kW will generally be supervised on 3 windings out of 6 installed.

5.4.5 Vibration Sensors

F a n s w i t h c a p a c i t y e q u a l o r h i g h e12
r 5t h
0 ka W
n a n d o t h e r c r i ti c a l i t e m s s h a l l b e e q u i p p e d w
vibration sensor for fan’s bearing. The Scope of Supply includes the sensor and the locally mounted
transmitter.

5.5 Process Instrumentation

The primary elements and transmitters shall suit the individual applications. Locally mounted..

5.5.1 Level Sensors

T y p e s o f l e v e l s e n s o r s v a r y f o r i n d i v i d u a l a p p l i c a ti o n s . S e n s o r s m o u n t e
additional installations are generally to be used (microwave type).

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 Venezuela INVECEM
Inspection openings shall be provided close to the location of the sensor (for visual checking of the
level).

5.5.2 Load Cells

Load cells shall be applied to bin of kiln feeder.

5.5.3 Control Valves and Actuators

Solutions with variable speed drives (for pumps, fans, etc.) are preferred to solutions with constant
speed drive and control actuators. Where this is not possible, control valves and
corresponding mechanical linkages shall be used. Actuators and valves shall be standardize
feedback element shall be 4-20 mA, galvanically isolated or by the Plant-field-bus. Where required,
the f eedback
e s blement
d c hall t t se A
irectly w onnected
c o w o he
internal limit and torque switches, are preferred. Setpoint control shall be with a standard 4-20mA
signal or by the Plant-field-bus system.
Actuator travel time and flow characteristic shall be adjusted to the specific application.

5.5.4 Solenoid Valves

Solenoid v s alves
b e hall
w i e quipped
s i V ith s ntegrated
b c w a tatus
plug according DIN 43650 or equivalent. All valves for cooling sy
pneumatic transports, etc. shall be standardized.

5.6 Sub-Control Systems (E60-2C)

5.6.1 General
Electrical control systems supplied as a complete standard pre-tested system for certain Equipment
shall be considered as "Sub-Control Systems" (SCS).
For example, such systems may contain control Equipment for:
 Electrostatic precipitators (excluding rapping and transport system)
 Bag filters
 Stackers, reclaimers
 Packing machine

5.6.2 Specification of Sub-Control System (SCS)

Electrical panels of Sub-control shall to the extent possible be equipped with the same make
t y p e o f c o n t a c t o r s , c i r c u i t b r e a k e r s , i n d i c a ti n g e l e m e n t s , e t c .
E q u i p m e n t . T h e c o l o r o f c a b l e s , p u s h b u tt o n s , i n d i c a ti n g e l e m e n t s , c o n t r o l s w i t c h
shall be standardized throughout the Plant according to the function of the element.

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The " failsafe"
p s brinciple
a t a c hall c e T pplied
m t c o b ll ontrol
a w ircu
as loss of voltage shall be detected and treated as a fault.
U n l e s s o t h e r w i s e s p e c i fi e d t h e S C S s h a l l b e d e l
d o c u m e n t a ti o n ) w i t h a l l r e q u i r e d e l e m e n t s a n d d e v i c e s s u c h a s c o n t r o l E q u i p m e n
etc.), motors, sensors, control panel, cable connectors, cables and installation material.
Protection of the drives as well as the provision of the internal control voltage is part of the SCS.
S C S o p e r a ti n g t o l e r a n c e s s h a l l b e a s s p e c i fi e d i n 0p a(Gr ar og ur appEh0 0 : G e n e) raanl d s h a l l n o t
need any “reset” feature after a power failure.
Control v f oltage
t S o s or w
he a CSs r b ystems,
s p A o hich
s b f ref upplied
the UPS-supply.

5.6.3 Definition of Input and Output Circuits

 Signal: D
The "ON/OFF command" affects the SCS as a whole. Contact closure (relay energized) causes
t h e S C S t o s t a r t - u p a u t o m a ti c a l l y w i t h t h e c o r r e c t s e q u e n c e a n d c a r r i e s o u t
internal circuits are correct). Contact opening (relay not energized) causes the SC
automatically in the correct sequence and terminate its service.
 Signal: K
The " availability"
c a t ontact
S a aw ffects
T i he " CS s s s thole.
the p rocess
c t r ontrol o t She b eadiness
o I i n f d he CS
o w efore
the "run" signal is present or not.
The following conditions must be continuously fulfilled in order that this contact may remain
closed:
 Control voltage available
 No fau lt in the sy ste m (ne it her "overload ", n or "em ergen cy", nor "off "- switch es
must be activated)
 All switches "service" or "remote" must be in the "remote"-position.
If any of the conditions given above is no longer fulfilled, the contact "availability" will open
immediately.
 Signal: R
The "run" is the feedback signal after a normal start. It means that the SCS is carrying out its
service. If the "run" signal does not appear within a fixed, predefined time after starting, the
relay’s "ON/OFF command" (D) is de-energized by the process control.
All the above-mentioned signals shall be included from each SCS.

The following signals shall be included, as required by the specific control application:
 Signal: W

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The "warning" signal is a pre-alarm which does not (or not yet) stop the normal "run" of the
SCS. The warning contact shall open as long as the warning condition prevails.
 Signal: F
The "fault" signal is an alarm which causes the SCS to stop automati cally. The fault con
shall open until the fault has been locally rectified.
 Signal: xx.SP
The " setpoint(s)"
w b r i fill o ae 2 eceived
4 m s no b orm
ac f t t -wire
Plant-field-bus s T s ystem. s b c he g ignal i hall ( e g ompletely
a
possible power supply) in the SCS unit.
 Signals: xx.PV
The "actual values" shall be a 2-wire 4-20 mA signal or by a connection of the Plant-field-bus
system. The signal shall be galvanically isolated (against ground and possible power supply).
All signals shall preferably be transmitted over the Plant-field-bus or with OPC through Ethernet, if
more complex data transfer is required.

5.6.3.1 List of Alarms

The following alarms shall be individually monitored (per machine or drive), interlocked as required
to avoid nuisance alarms, displayed in clear text on the local panel and transmitted over the Plant-
field-bus:
 Non - availability of individual motor feeder circuits (including supervisio
power- and control power circuit breakers, and/or by supervision of control voltage)
 Contactor fail to open or fail to close (contactor failure)
 Thermal protection (Overload)
 Safety switch (e.g. disconnect switch, pull-cord etc.)
 Control system failures and warnings

5.6.4 Installation
T h e C o n t r a c t o r s h a l l i n c l u d e a l l r e q u i r e d c a b l e s a n d i n s t a l l a ti o n m a t e r i a l f o
sensors a m nd v otors,
e c falves t S tc. a w aontrolled
s f c rom( h he CS,
duty trailing cables for stackers and reclaimers).

5.7 Special Instruments

Special instruments shall be evaluated together with Owner to cope with latest Holcim Standards.

5.7.1 Pyrometers and Special Temperature Measurement

T w o c o l o r r a ti o t y p e p y r o m e t e r s s h a l l b e i n s t a l l e d t o s u i t t h e i n d i v i d u a l a p p l i c a ti
Locally mounted, continuous temperature monitoring devices are to be used.
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 Venezuela INVECEM
5.7.2 Pyrometer and Camera Systems (E60-2V)
Color p yrometer
c s sameras
b u a t ystems
k fi h fhalll ei t sedk a ta he
the cooler to look towards the kiln outlet. They shall be equipped
automatic retraction systems on failure (preferably of the pneumatic type or connected to standby
power), alarm signals, cooling system (as required), and monitor displays locate
c o n t r o l r o o m . I n t e g r a t e d v i d e o a n d t e m p e r a t u
measurement of multiple user definable areas of interest.
Criti cal process areas shall be equipped with cameras using separate monitor displays or sy
i n t e g r a ti n g w i t h t h e g e n e r a l b u i l d i n g a u t o m a ti o n m o n i t o r 6s .( RG er foeurp t Eo 7 p0 a: r a g r
Building Automation / Communication system).

5.7.3 Kiln Shell and Refractory Monitoring (E60-2I.T)

A kiln shell scanner shall be used for kiln shell temperature.

5.7.4 Gas Analyzer (E60-2K)

The Equipment shall suit the individual application for CO, O2 and NO monitoring as required by the
process for the precalciner.

5.7.5 Emission and Dust Monitoring Equipment (E60-2N)

Emission and dust monitoring Equipment shall supervise the emission
local standards.

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 Venezuela INVECEM
6. GROUP E70: BUILDING AUTOMATION / COMMUNICATION SYSTEM

6.1 Fire Detection

6.1.1 General
The fi d re etection
s s b d ystemi c hall o te fi esigned
z d n b tonsideration
fi
barrier system.
T h e s y s t e m s h a l l c o n s i s t o f fi r e d e t e c t o r s a n d m a n u a l fi r e a l a r m p u s h - b u tt o n s a r e a s , a
alarm annunciation panel.

6.1.2 Fire Detection and Alarming (2F) Design

M a n u a l fi r e a l a r m s s t a ti o n s s h a l l b e i n s t a l l e d a t e x i t s , e m e r g e n c y e x i t s a n d o u t s
locked doors (e.g. electrical rooms, etc).
T h e fi r e a l a r m o f t h e a u t o m a ti c d e t e c t o r s a s w e l l a s t h e m a n u a l s t a ti o n s s h a l l b e v i s u a l
schematic Plant layout.

6.2 Telephone System

6.2.1 General
The proposed telephone system shall be in accordance with Applic
Standards and Contractor shall arrange for all necessary approvals with Authorities.

6.2.2 Telephone System (2T)

T h e t e l e p h o n e s y s t e m s h a l l p r o v i d e c o m m u n i c a ti o n w i t h i n t h e P l a n t , a s w e l l
extensions to outside parties on the public telephone network and shall be of the P.A.B.X. (Private
Automatic Branch Exchange) type.
The system shall either be a locally approved one, or such approval shall be obtained by Contractor
prior to its installation.

6.3 General Plant View Cameras

General plant view cameras shall be installed for the remote supervision of criti cal plant ar
e.g. entrance gates and loading/unloading areas. Make and type of cameras and monitors shall be
coordinated with process cameras.

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 Venezuela INVECEM
7. GROUP E80: MOTORS AND DRIVE SYSTEMS
The following motors and drive systems shall be applied:
 Medium voltage motors (Note that such motors operate at voltages between
3 kV and 10 kV, i.e. in the medium voltage range)
 Low voltage motors (Voltage <= 1000V)
 Variable speed drive systems (Voltages between 440 V and up to 6.3 kV)
 Hydraulic drives (for special applications only)

7.1 General Design Requirements for Motors

C o n s t a n t s p e e d m o t o r s o f t h e I E C r a ti n g e q u a l o r l a r g e r t h a n 2 5 0 k W s h a l l g e n e r a l l y b e
voltage motors. Refer to Contract Part V (Contractor’s Information), E00).
Constant speed motors below IEC rating 250 kW (at 400V) shall generally be low voltage motors.
All motors shall be of protection type IP 54 (TEFC).

7.2 Specific Requirements for Medium Voltage Motors (1X)

7.2.1 General Motor Requirements

All MV motors shall be duty premium efficiency.
F o r c o n t r o l o f t h e s t a r ti n g c o n d i ti o n s , l i q u i d r h e o s t a t s s h a l l b e u s e d i n c o n j u n c ti o n w
motors.

7.2.2 Liquid Rheostat for Slip Ring Motors

Automatic remote-controlled liquid rheostats shall be used in conjunction with the slip ring motors.

7.3 General Requirements for Power Cables (1H, 1L)

All power cable shall be XLPE insulated and PVC sheathed.
The c olor
o t c f s he s able b s heathst hall
t P et d tandardized
b t hrou
voltage level/function of the cables.
Neutral and grounding wires shall never serve any other than their specific purpose.

7.3.1 Loading and Spare Capacity

The current carrying capacity of the cables shall be in full compliance with App
A p p l i c a b l e C o d e s a n d S t a n d a r d s a n d t a k e i n t o c o n s i d e r a ti o n t h e d e - r a ti n g
temperature, number of cables installed, methods of installation (at most critical point), etc.

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 Venezuela INVECEM
All cables shall be dimensioned according to the uncompensated load (installe
n o m i n a l l o a d o f S C S ) o f t h e E q u i p m e n t c o n n e c t e d a n d t h e s h o r t c i r c u i t c o n d i ti o n s o f t
network. Connections to and from transformers shall be able to carry its full rated capacity.
Cable cross sections shall be sized for loading according PVC insulation.
The v oltage
d e u rop, h sven c nders n eavy
e 1 %tart
o t n onditions
v a hall
the terminals of the motors.
The voltage drop under normal operating conditions shall not exceed 2% of the nominal voltage at
the terminals of the motors.

7.3.2 High-voltage (HV) - & Medium-voltage (MV) Cables (1H)

A l l h i g h a n d m e d i u m v o l t a g e d i s t r i b u ti o n s s h a l l b e o f t h e 3 - w i r e s y s t e m . T h e s a m e
colors shall be allocated to the 3 phases throughout the Plant.
HV- and MV - cables shall be either 3-conductor or single-conductor type and shall be unarmor
unless required to be armored by local standards.
No cables shall be buried directly in ground.

7.3.3 Low-voltage (LV) - Cables (1L)

Low voltage motor cables shall have four conductors, with the fourth wire to be used for grounding
purposes; provided, however, for large drives, single-conductor cables may be used with a separate
conductor for grounding purposes.
All power cab le s sha ll h ave a ground wire a nd in th e case of fe eding a single phase consum
panel, a neutral wire in the appropriate color shall be included in addition.
3 p hasef c eedert n ables E o c on-process t L w a quipment
c s onnected
consumers, shall have 5 conductors (phases, neutral, grounding), or 4 conductors if Equipm
provided w i itht solatingP f ransformer.
c t M mrocess h peedersa on
ground conductor only (with isolation transformers for single phase consumers).
C a b l e s i n a r e a s w i t h h i g h a m b i e n t t e m p e r a t u r e s ( r a d i a ti o n ) s h a l l b e o f t h e s p e c i a l h e a
type.

7.4 Control and Communication Cables

Extra low-voltage control cables shall be capable of carrying analogue and discrete signals and shall
be arranged in twisted pairs.
Only 2 or 3 types of control cables shall be used throughout the whole Plant (e.g. 4/12 conductors).
C o m m u n i c a ti o n c a b l e s a r e c o n s i d e r e d a s s p e c i a l c a b l e s . C o m m u n i c a ti o n c a b l e s s
optic, c o-axial,
t t wisted-pair
o a r b t n ype a ra r s equired b t o y he
product designer of the Plant-field-bus system.
The type of optical fiber shall be standardized to preferably one, max 2 types.

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 Venezuela INVECEM
The n umber
o fi p cf sbers b s er able
t 2 o 3 t hall w aem tandardized
o 6 fi p o
cable for secondary connections (e.g. to field I/O box).
All fibers of a cable (including spare) shall be terminated at a fiber optic panel.
Ethernet and Plant-field-bus cabling may be copper within an individual building only.

7.5 Cable Installation

Depending on the Plant layout, underground walk-through cabl
ov e r h e a d st e e l s t r u c t u r e c a b l e b ri d g e s ( g a l l e r ie s) w it h w a lk w a y s s h a l l b e u s e d b e t w e e n
electrical power distribution center, the different electrical and control rooms and major buildings.

7.5.1 Loading and Spare Capacity

C a b l e w a y i n s t a l l a ti o n s s h a l l b e d e s i g n e d t o g u10
a r%a nf rt e e sa p m
a ci ne i m
a tu m
t h eo
completion of the whole installation.

7.6 Grounding
As a guideline the grounding system shall correspond to the followin
Standards:
 IEC 60364
 Equivalent latest IEEE and NEC standards are also admissible.
 Authority requirements.
Grounding of all Equipment shall be provided using an integrated
E n g i n e e r i n g a n d e x e c u ti o n o f t h e g r o u n d i n g n e t w o r k s h a l l b e c l o s e l y c o o r d i n a t e
Works. Refer to Contract Part IV-1-4 (Civil and Structural Works).
" F o u n d a ti o n G r o u n d i n g " w i t h e m p h a s i s o n p o t e n ti a l e q u a l i z a ti o n s h a l l b e a p p
g r o u n d i n g n e t w o r k . R e f e r t o " P o t e n ti a l E q u a l i z a ti o n a n d F o u n d a ti o n G r o
18014" or IEEE Std. 80.
A l l g r o u n d i n g c o n d u c t o r s s h a l l b e b a r e , s t r a n d e d , s o ft - d r a w n c o p p e r a n d a l l e
connections shall be made by thermo-welding or by type tested connection material.
A i m i n g a t a n i n t e g r a l s y s t e m f o r c o m m o n p o t e n ti a l e q u
e q u a l i z a ti o n r e s p e c ti v e l y t h e f o l l o w i n g E q u i p m e n t s h a l l b e c o n n e c t e d t o t
building:
 All motor, generator and other electrical Equipment frames and/or bases
 A l l m e t a l l i c e l e c t r i c a l p a n e l s , E q u i p m e n t e
installations.

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7.7 Lightning Protection
As a guideline the lightning protecti on system shall correspond to the following Applicable
and Standards:
 IEC 62305-3
A comprehensive lightning protection system shall be installed to cover all buildings and structures
i n a c c o r d a n c e w i t h A p p l i c a b l e C o d e s a n d S t a n d a r d s . L i g h t n i n g p r o t e c ti o n f a
terminals ( rlightning
a d dods) c nd t s edicatedl g own e onductor
to divert the lightning current path to ground through circuits
r e s i s t a n c e . T h e l i g h t n i n g p r o t e c ti o n s y s t e m s h a l l b e b o n d e d t o t h e P l a n t g
separate tapping points. Such connections shall be at the outside of the building walls, and shall be
individually, directly connected to the common below grade Plant ground electrode system.
Overhead power lines shall be furnished at both ends by overvoltage arrestors.

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