5.2E ELECTRICAL EQUIPMENT AND WORK 5.2E.1 GENERAL ELECTRICAL REQUIREMENTS 5.2614 EXTENT AND VALIDITY All electrical equipment forming an integral part of the power plant, whether specifically mentioned or not shall be designed, manufactured, supplied, erected, tested and commissioned in compliance with the general and specific requirements of this contract, Basic configuration of the supplied SCCGT-2 Plant i.e. Conversion of EXISTING Open Cycle Gas ‘Turbines to Combined Cycle Plant and their auxiliaries shall fulfil the basic requirement as outlined in the indicative tender single line diagram SCCGT-2/E/3001 as a minimum. However, tenderer may develop their own single line diagram and power flow configuration fuliling the basic requirements as ‘mentioned in the indicative tender single diagram and tender specification Power export of the supplied SCCGT-2 Plant i.e, Conversion of the existing Open Cycle Gas Turbines to Combined Cycle shall be achieved by the tenderer while connecting the generator step-up transformer with 400kV high voltage XLPE cable which shall be further connected to the available spare feeder (C-16) in the existing 400kV Switchgear (SWPS-2) Mfd: M/s. Siemens located at a distance of approx. 500 m in West away from assigned location of SCCGT-2 Plant as shown in site layout drawing, ‘As described above and indicated clearly in the Tender Single Line Diagram, plant is connected with aforesaid 400KV SWGR for the dual purpose of power export to the Grid and also for power import to back energize transformer/SWGR of the plant for commissioning purpose. No other separate power source shall be made available for commissioning purpose from MEW. Indicative single line diagram of the plant as well as basic protection and monitoring diagram of generator, unit transformer, generator step-up transformer & 400kV HV cable, integrated with the spare feeder C16 of existing 400 kV Switchgear (SWPS-2) to achieve reliable power export, is attached in Tender document for Tenderer compliance. The scope of work in general is indicated in Section §.1 of Tender document, however any electrical work and equipment as needed for the requirement of Mechanical, Instrumentation & Civil works mentioned elsewhere in the tender document shall be considered within the contract 5.26.1.2 BASIC DESIGN CRITERIA 5.2E.1.2.1. GENERAL DESIGN PHILOSOPHY ‘All electrical equipment except packages of original equipment manufacturer for steam turbine generator shall be designed to include an additional margin of 10% of the full load capacity, when considering the worst case to be met in service. The duty and rating shall be indicated on the relevant documents submitted for approval ‘Specifigation No, MEW / SCCGT -2 1 Contractor's Initial and StampAl electrical equipment shall be designed to withstand the maximum stresses imposed on them for the fault levels and durations obtained under the worst possible conditions. Short circuit calculations shall be carried out as part of the contract to verify the ratings of the proposed equipment and shall be submitted for approval by the Owner/Engineer. The calculations shall assume ‘worst case’ values of all parameters, including upper and lower tolerance limits as well as lowest values of transformer tapping ranges. The fault level shall be ‘considered as 80KA, 3 seconds for the 400kV system, the Contractor shall confirm and consider the ‘actual fault levels during the design phase through coordination with NCC. MV switchgear shall have a minimum rating of SC level as 40KA, 1 Sec. whereas all LV main ‘switchgear and MCCs shall have a minimum rating of SC level as SOKA, 1 Sec. However, based on calculation during detail design stage, if it is found that a higher level of SC levels are needed for ‘above switchgears/MCC, they shall be provided accordingly within the scope of contract with no additional cost to the contract. SC level of other AC & DC boards such as but not limited to AC distribution board, DC & safe AC switchgear / distribution boards AC/DC sub-distribution boards, lighting boards.....ete shall be decided based on calculation during detail design stage. The installation shall be designed for operation, where continuity of power supply is the prime consideration. All plant and equipment shall be designed to ensure satisfactory operation under sudden variations of load and voltage as may be met under all operating conditions, including those due to starting loads, transient short circuit and other internal and external fault conditions, The design shall incorporate every reasonable safeguard and provision for the safety of all personnel concemed in the commissioning, operation and maintenance of the installation ‘The plant and equipment shall be capable of being controlled under normal operation from the Central Control Room. Description of Central Control Room is indicated elsewhere in the tender document. Local contro! facilities shall be provided for testing and maintenance purposes. ‘The installation shall have the maximum possible levels of reliability and availabilty in service. To this end tried and proven equipment shall be used in the installation; prototype equipment shall be excluded. ‘The design and installation shall be such as to minimize the risk of outbreak of fire and consequential damage. Materials used shall not support combustion and shall preferably be fire retardant. Emergency diesel generators shall be provided to supply essential auxiliaries in the event of loss of connection to the grid, as well as to provide an independent supply to ensure safe shutdown of the plant and ensure the operation of all essential equipment during periods of stendstil, including fire- fighting requirement ofthe plant Specification No, MEW / SCCGT-2 2 Contractor's z Initial and Stamp§.2E.1.2.2 DESIGN OF ELECTRICAL POWER SYSTEMS Where any electrical equipment is essential for the continuous operation of the plant, the associated auxiliary systems shall be arranged to be fed from an alternative supply, so 2s to allow recovery from fault conditions and also to permit inspection and maintenance of equipment without interference with the normal operation of the plant. A suitable fast transfer scheme, with automatic and manual control facilities for MV system (if applicable) shall be provided to ensure smooth changeover to alternative supplies. A momentary paralleling of the MV system shall be (if applicable) envisaged in design. A suitable transfer scheme shall be provided for LV system so that changeover between incoming and coupler is achieved without tripping of any associated load while plant is running at its full continuous rated output The essential supplies systems shall be capable of maintaining the supply to all instruments, controls and auxiliaries required for the safe and reliable operation of the plant and equipment under all normal and abnormal operating conditions and also for safe shutdown and placing of the turbine onto turning gear following the total loss of the grid connection to the station, ‘The design shall require only minimal operator intervention to reconfigure the auxiliary systems upon restoration of normal supplies. ‘The electrical plant and equipment shall be provided with suitable means for electrical disconnection, isolation and earthing of connections to facilitate maintenance and reconfiguration of the electrical power system in the normal operation of the power station. §.2E.1.2.3 REQUIREMENTS DUE TO THE ENVIRONMENT All electrical equipment shall be of tropical design and entirely suitable for use under the prevailing Kuwait site conditions specified elsewhere in this specification ‘An ambient temperature of 50°C for indoor equipment and 55°C for outdoor equipment shall be taken as design reference. 85°C shall be considered for equipment subject to direct sun radiation. Ratings of all electrical equipment, whenever specifically mentioned or not shall be based on these conditions. However, if the equipment is located in pre-designed capsules/modules with continuous redundant HVAC arrangement having reduced continuous temperature in modulesicapsules, ‘equipment may be rated accordingly for reduced temperature as per manufacturer standard, whereas all other electrical equipment whether located in room with forced ventilation or HVAC shall be rated for 50°C. All bushings of transformers (neutral bushing, surge arrestor, neutral circuit breaker, etc.) which are exposed to the outdoor environment shall have increased creepage distances of 55 mmikV as a minimum due to the environmental conditions of the site, In order to establish design and length of the exposed bushing, value of voltage shall be based on actual worst fault condition which is substantiated with calculation during design stage in accordance with relevant IEC standards and approved by MEW, Specification No. MEW / SCCGT-2 3 Contractor's Initial and Stamp5.26, 4 HAZARDOUS AREAS, AREA CLASSIFICATION AND ELECTRICAL EQUIPMENT All areas of the plant where concentrations of gas or other hazardous substances may occur due to normal leakage or process fault or ventilation system fallure shall be classified as hazardous locations. Unless otherwise specified, the design of all electrical installations in such areas shall be explosion proof in compliance with the latest issue of IEC 60079 or equivalent international standard and ‘electrical equipment shall be suitable for use in these areas, ‘All explosion proof equipment shall be of approved design and must have undergone type tests ‘according to the appropriate standards by neutral international inspection authority. Type test report shall be submitted for information as an essential pre-requisite for equipment approval. ‘The Contractor shall produce area classification drawings and documentation for the whole site area. ‘The classified area shall be as defined under IEC 60079 or equivalent standard. All gas groups, electrical equipment maximum surface temperature, (T ratings), and equipment types shall be approved by the Engineer. All equipment that Is located in hazardous areas shall be manufactured, certified and installed in accordance with IEC 60079 or equivalent standard, ‘A consistent approach to the design of the hazardous area electrical systems shall be adopted throughout the contract. §.2E.1.2.6 POWER SUPPLY AND DISTRIBUTION SYSTEM ‘The system shall have the following voltage levels, 8) HV transmission - 400 kV b) MV distribution — 11 or 6.6 KV (based on Tenderer’s discretion) ©) LV distribution (3 phase) - 415 V 4) LV distribution (single phase) - 240 V ©) DC system - 220V,110 V and 48V (as required) ) UPS system-240V Ail electrical equipment shall be designed to withstand the following voltage variations, Specification No. MEW / SCCGT -2 4 Contractor's r Initial and Stamp \\|. 400kV system continuous operation with 46% rated voltage variation L.e. between 380KV ~ 420kV. |. AC systems ~ Continuous operation between 90-1 10% rated voltage, operation at 80% voltage for short durations (<30s) lll, Secure AC systems ~ continuous operation between 90-110% voltage, maximum frequency variation of + 0.5%. IV. DC systems — continuous operation between 90 -110% voltage ‘While establishing the capacity of the continuous current rating of electrical equipment such as but not limited to generator, transformers, motors, IPB, MV/LV bus duct, power cables, inverter rectifier..etc, negative voltage variationsitolerance as described here and specification clause 5.2.2 shall be considered besides other factors specified in Tender document, 5.2E.1.3 GENERAL REQUIREMENTS FOR ELECTRICAL EQUIPMENT This part of the Specification details the requirements for ancillary electrical equipment such as wiring, terminals, switches, panels and cubicles common to all items of plant. The equipment shall comply with the requirements of IEC 60947 and other relevant IEC standard, 5.26. 4 SWITCHBOARDS, CUBICLES AND ENCLOSURES All switchboards, cubicles and enclosures shall be manufactured from sheet steel. The cubicles shall be protected against corrosion by immersion in phosphate solution or by spray galvanising, Fixing screws and bolts for metal enclosures shall be of non-corrosive material (e.g, stainless steel or brass). All other bolts and screws shall be chrome or cadmium plated. ‘The overall height of switchboards, cubicles and enclosures for electrical apparatus shall not exceed 2.5 m above floor level. Maintenance access, as applicable, shall be provided at the front and rear of all switchboards and relay cubicles. ‘The design of the equipment shall be such as to prevent accidental contact with live parts and to avoid the spread of fire or damage from short circuits or other causes. Equipment to be installed indoors shall have degree of protection IP 42 Equipment and panels which are located outdoors shall be completely weatherproof with degree of protection IP 65. ‘Specification No, MEW / SCCGT -2 5 Contractor's Initial and StampHowever, if pre-designed capsulesimodules are used for housing of switchgear/panel, suitable IP class for equipment, as per the manufacturer standard, shall be used provided the capsule/module housing themselves are having higher IP class not less than IP65. 5.2E.1.3.2 WIRING All secondary wiring in panels, cubicles and equipment racks shall be carried out using 600/1,000 V grade multi-stranded copper wire to BS 6231. The primary insulation of all wiring shall be PVC for installations with internal temperatures below 60°C and silicon rubber or similar material for installations with internal temperatures above 60°C. All wiring shall consist of stranded copper wires of not less than 0.5mm’ cross-section except for wiring associated directly with switchgear control and protection shall not be less than 2.5 mm* whereas CT and VT secondary circuits shall be not less than 4mm’, Wires shall not be jointed or teed between termination points. Only one wire shall be connected to one terminal, The ‘terminal’ is the fixing device on the apparatus and the ‘termination’ is the device fitted to the wire, All wires shall have an identification marking at each end numbered in accordance with manufacturer's standard. 5.2E.1.3.3 TERMINALS AND TERMINATIONS Terminal blocks shall have separate terminals for incoming and outgoing connections. ‘Terminal blocks shall be either of the stud or insertion type as per manufacturer's standard A provision for spare terminals shall be made to cater for possible future modifications, such @ provision shall not be less than four in number or 20 percent of the total whichever is greater. Terminals shall be numbered and terminal blocks shall be grouped according to function. 5.2E.1.3.4 | ACCESSORIES All enclosures containing electrical equipment shall be provided with thermostatically controlled anti- condensation heaters arranged to operate at 240 V ac if the panel is not located in permanently available HVAC rooms/prefabricated modules ....etc.,.. Local indication of ON/OFF status of heaters shall be provided Panels, boards, cubicles etc., shall be provided with suitable LED lamps having 6500K LED bar and 13.A power socket outlets if not located inside pre-fabricated modules/capsules. SpeciigaligniRioc MEW /SCCGT-2 6 Contractor's \ Initial and Stamp. J5.26. 3.8 LABELS, TAGS AND NAMEPLATES, Every electrical device or component shall be provided with suitable nameplates, tags and identification labels to identify their ratings, purpose and any specific information required to allow efficient maintenance and operation. All nameplates and tags installed outdoors shall be manufactured from stainless steel or installed indoors shall be of laminated plastic and shall be engraved in both English and Arabic (with the exception of standard equipment nameplates which shall be in English only) All plates and tags shall be permanently fixed to the equipment by screws (stainless steel screw for name plates located outdoor and brass screws for name plates located indoor) 5.2E.1.3.6 LOCKS, KEYS AND CABINETS Al hinged doors in switchboards, panels, cubicles etc as well as withdrawable switchgear chassis shall be secured by means of a suitable lock. Key cabinets shall be provided in the Central Control Room for storing all keys in use. Each key shall be provided with an attached identification label and a further identification label fixed above the hanging hook inside the cabinet. ‘The contractor shall prepare a comprehensive key system proposing the individual groups and master keys. A minimum of three keys shall be provided for each lock as well as a master key for each zone. ‘The complete key system shall be subject to approval of the Owner/Engineer, Specification No. MEW / SCCGT -2 7 Contractor's Initial and Stamp5.2E.10 EARTHING & LIGHTNING PROTEGTION SYSTEM 5.2E.10.1 GENERAL ‘The earthing system shall conform to the relevant sections of BS 7430, IEC 60364, IEEE 80 and IEEE 665, The Contractor shall present calculations for approval to show that the proposed system complies with IEEE 80 and Is safe in terms of touch, step and transferred potential Earthing point distribution bars shall be strategically located within an area in which items of plant are to be located. A minimum of two earthing point distribution bars shall be provided in all main plant areas, The bars shall have pre-drilled holes complete with screw or nut and bolt type fastenings for the attachment of lug type cable connections. The bars shall also have disconnecting links to enable testing of the connections to the main earthing system. All electrical equipment shall be earthed at a ‘minimum of two points. ‘The earthing and bonding system shall fulfil te following requirements: a. Maintain a low overall resistance to the ground mass so as to limit the plant potential rise and ensure protective relay operation in the event of an external fault. b. Provide ground connections to all electrical equipment enclosures and structural steelwork, which are adequate to carry prospective ground fault currents without overheating. Limit potential differences within the power station in the event of ground current originating from within or outside the station and so ensure the safety of personnel and eliminate interference or damage to electronic circuits, DESIGN AND ARRANGEMENT OF EARTHING AND BONDING POWER TRANSFORMERS Power transformer shall be earthed at two points diagonally opposité each other. These connections shall be madé Tray two different points of the earth grid, Where the neutral conductor is carried directly from the neutral Bushing to earth, an additional cerinection between bushing and tank shall be provided to ensure a straight ‘between tank and the neutral leg. The neutral conductor shall be brought directly at f st distance to an earth electrode. ‘Specification No, MEW / SCCGT -2 6 Contractor's Initial and Stamp5.2E.10.2.3 BUILDINGS AND STRUCTURES ‘The design of the earthing system within buildings shall comply with the requirements of IEC 60364. Structural steel shall be connected to the earthing grid at @ minimum of two points of Re-enforcement bars of each foundation of building/structure and shall have adequate earthing in line with international standard and also shall be connected with sub-grade earthing, 5.2E.10.2.4 MOTORS ‘The body of the MV Motor shall be earthed at two points diagonally opposite each other whereas body of LV motors can be earthed at one point only. Each motor shall be connected to the earthing grid or with the earth bus by the shortest route, Each motor shall have earthing for the motor body and the terminal boxes. 5.2E.10.2.5 SWITCHGEAR AND SWITCHBOARDS All switchboards, metal enclosures and conductive structures of circuit breakers, isolating switches, measuring transformers..etc., shall be connected to the earthing grid. The housings of the operating mechanisms shall be earthed at a point as near to the operating handle as possible, All panels, desks and switchgear located in a room shalll be connected to a common earth bus. SURGE ARRESTERS arrester is mounted. 5.2E.10.2.7 PIPELINES A shall be connected to the main ‘lating flanges. The two outer flanges of Motor operated valves in pipelines fit earthing grid and insulated from the pipeline the pipelines shall be bonded together. the occurrence of dangerous potential id both within and outside the site. 5.2E.10.2,8 FENC! Specification No. MEW / SCCGT -2 70 Contractor's . Initial and Stamp2.9 ELECTRONIC EARTHING Earthing of electronic &% section of this document. juirements specified in the 1&C 5.2E.10.2.10 FOUNDATION (6F the re-enforcement bar of foundation of each building/structa Televant standard, which will be connected with sub-grad earthing system. 5.2E.10.3 - METHODS OF INSTALLATION 5.2E.10.3.1 GENERAL In the main areas of the plant the earthing system shall comprise a buried bare copper conductor grid. To minimize the effects of corrosion, all above grade conductor pigtails shall be PVC covered or tinned stranded copper conductor, but this length shall not be considered as forming part of the earth grid resistance, ‘The system shall be designed to withstand an earth fault current of 80 kA for 1 second. The mesh size shall depend on the ground resistivity and may vary in different parts of the site. To this main atid, ground rods shall be bonded at intervals and in particular at the base of lightning conductors. ‘The approximate average soil resistivity is 15 Om at a depth of 0.5 m and 3 Om at a depth of 2.5 m, however these figures are indicative only. The Contractor shall be responsible for determining the actual soil resistivity Where the ground conditions are such that a borehole is necessary then this shall be backfilled with bentonite after installation of the ground rod The system shall cover the entire plant area up to the site boundaries. A sufficient number of earth electrodes of sufficient length shall be distributed around the site to achieve an overall earth dissipation resistance of 0.1 Ohm or less. The subgrade earthing system shall be connected to the earthing system of the neighbouring Sabiya power plant at @ minimum of three locations as part of this Contract, however this interconnection shall not be taken into consideration during the design of the earthing system, 5.2E.10.3.2. JOINTS AND CONNECTIONS Joints and connections shail normally be made by brazing overlapped ends. Copper to copper joints shall be tinned using hard silver solder. When surfaces have cooled they shall be protected immediately using a suitable jointing compound. For copper to aluminium joints, the copper faces shall frst be tinned. The aluminium faces shall be leaned using a stainless steel wire brush or non-metallic abrasive pad until surface is bright. After Specification No, MEW / SCCGT -2 nm Contractor's _ Initial and Stampbrazing, both surfaces shall be protected immediately with a suitable jointing compound. Copper to steel joints shall be the same as copper to aluminium joints, Welding techniques such as Cadweld may be used as an allemative to bracing or bolting. Where bolted connections and links are necessary these shall be made above ground or in an inspection pit, Bolted connections shall be complete with one round brass and one phosphor bronze double coil spring washer. The surfaces shall be cleaned and greased with a suitable jointing compound prior to assembly to eliminate corrosion. If stranded conductors are used then approved crimp type lugs and bolts shall be used. Faulty joints should be cut and a new length of conductor inserted. ‘Where used to prevent ingress of moisture it is important that sufficient jointing compound is used to fill all voids. Extreme care shall be taken to prevent electrolytic action when running the copper strip in the vicinity of aluminium or any other metal. All items of plant and structures shall be connected to the main earthing grid. This shail include steel reinforcing. Connections between earth tags and bosses and the station eathing grid shall be by copper strip, cable or flexible braid. Normally a minimum of two separate connections shall be made. The rating of these conductors shall be sufficient to withstand the fault currents and duration after allowing for the parallel paths through the system with any one conductor disconnected. ‘Screwed conduit connections and cable tray shall be electrically continuous and grounded to the main station earth system. An earth conductor of suitable size shall run on the entire length of the cable tray and on the top tray in a group of trays with intermittent loop connections, A separate insulated conductor of the same size of the phase conductor shall run inside the conduit to all electrical equipment. 5.2E.10.3.3 MATERIALS Conductors shall be of high conductivity copper in the form of circular conductors stranded to IEC 60228 or solid rods or bars to BS 1433, The minimum conductor size for the main sub-grade earth system shall not be less than 150 mm? Equipment connections shall be designed to withstand the maximum prospective fault current, but shall not be less than 70 mm? for equipment with ratings in excess of 30 kW. Conductor sheaths shall be PVC coloured green/yellow to meet the requirements of IEC 60502, Ground rods shall be of hard drawn high conductivity copper with a diameter of not less than 15 mm and fitted with hardened steel driving caps and tips. Specification No. MEW / SCCGT -2 id Contractor's Initial and Stamp5.2E.10.3.4 FITTINGS Clips for supporting strip conductors, not buried in the ground, shall be direct contact type. Clips for circular conductors shall be of cable saddle type. Disconnecting links shall comprise a high conductivity copper link supported from two insulators on a galvanized steel base. Connections to electrical equipment shall be detachable and made at earthing studs or bolts. For single core cable circuits where the cable armours are bonded at the switchgear end only, the earth bond shall be a 25 mm x 3mm tinned copper earth bar arranged to provide the shorting strap ‘across all the glands of the circuit and the connections to the switchgear earth bar. 10.4 LIGHTNING AND SURGE PROTECTION by the Contractor during the desig approval % submitted to the Engineer for Lightning protection may be interconnected wi recommended by relevant international star ie plant sub-graded earthing system if it is (On completion of the installa termination or section thes ofall bonds verified of any modification to it, the Fesigtance to earth of each earth Chall be measured and the continuity of all Conductors and the efficiency infirm conformity with design data, “which shall be adequately drained and labelled Specification No. MEW / SCCGT -2 73 Contractor's Initial and Stamp