Specification - Packaged Substation: Medium Term ESP Power Supply

RUMAILA PROJECT
Specification - Packaged Substation

Medium Term ESP Power Supply
00100W-C-PG-PP03-EL-SPC-00001 Rev B
20 December 2012
WorleyParsons Europe Limited

Parkview, Great West Road
Brentford, Middlesex
TW8 9AZ
United Kingdom
Tel: +44 (0)20 8326 5000
Fax: +44 (0)20 8710 0220
© Copyright 2012 WorleyParsons

RUMAILA PROJECT
SPECIFICATION - PACKAGED SUBSTATION
MEDIUM TERM ESP POWER SUPPLY
REVISION DESCRIPTION SHEET
Rev. Para. Reason for Revision
A All Issued for Inter-Discipline Check
B All Issued for Client Review
Hold
Para. Description of Hold
No.
00100W-C-PG-PP03-EL-SPC-00001 Page 3 of 46
Rev B (21 December 2012) Rumaila Template R3
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CONTENTS
1. INTRODUCTION ................................................................................................................ 8
1.1 Purpose and Scope ............................................................................................................8
1.2 Distribution and Intended Audience .................................................................................... 8
1.3 Definitions, Acronyms and Abbreviations ........................................................................... 8
1.3.1 General Definitions ................................................................................................ 8
1.3.2 Specific Terms, Definitions, Acronyms and Abbreviations .................................... 9
1.4 Reference Documents ........................................................................................................ 9
1.4.1 Project Specifications ........................................................................................... 10
1.4.2 Applicable Standards ........................................................................................... 10
1.5 Hierarchy........................................................................................................................... 12
2. GENERAL REQUIREMENTS........................................................................................... 13
2.1 Operation and Design Life ................................................................................................ 13
2.2 Service Conditions ............................................................................................................13
2.3 Scope of Supply ................................................................................................................ 13
2.4 Proven Equipment Criteria................................................................................................ 14
2.5 Language .......................................................................................................................... 14
2.6 Units of Measurement ....................................................................................................... 14
2.7 Plant Utility Voltages ......................................................................................................... 15
2.8 Harmonics ......................................................................................................................... 15
2.9 Voltage Drop ..................................................................................................................... 16
2.10 Materials ........................................................................................................................... 16
2.11 Noise Limits ...................................................................................................................... 17
2.12 EMC Requirements........................................................................................................... 17
2.13 Ingress Protection ............................................................................................................. 17
2.14 COMPANY / CONTRACTOR Interfaces .......................................................................... 17
2.15 Deviations, Concessions and Change control .................................................................. 18
3. DESIGN REQUIREMENTS FOR PACKAGED SUBSTATION ........................................ 19
3.1 General Design Requirements ......................................................................................... 19
Rev B (21 December 2012)
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3.2 Specific Design Requirements.......................................................................................... 19
3.2.1 Location................................................................................................................ 20
3.2.2 Clearances ........................................................................................................... 20
3.3 Design Loads .................................................................................................................... 20
3.3.1 Equipment Loads ................................................................................................. 21
3.3.2 Handling and Erection Loads ............................................................................... 21
3.3.3 Wind Loads .......................................................................................................... 21
3.3.4 Seismic Loading ................................................................................................... 21
3.4 Construction ...................................................................................................................... 21
3.4.1 Structure............................................................................................................... 21
3.4.2 Base ..................................................................................................................... 22
3.4.3 Cable Entries........................................................................................................ 22
3.4.4 Battery Installation ............................................................................................... 23
3.4.5 Access Platforms ................................................................................................. 23
3.5 Fittings .............................................................................................................................. 24
3.5.1 Doors.................................................................................................................... 24
3.6 Miscellaneous Requirements............................................................................................ 25
3.6.1 Roof-water Run-off ............................................................................................... 25
3.6.2 Sealants ............................................................................................................... 25
3.6.3 Control and Communication Equipment .............................................................. 25
3.7 Substation Services ..........................................................................................................25
3.7.1 Flash Protection ................................................................................................... 26
3.7.2 Lifting Devices ...................................................................................................... 26
3.8 Identification and Labels ................................................................................................... 26
3.9 Heating, Ventilation and Air Conditioning (HVAC)............................................................ 27
3.9.1 Design .................................................................................................................. 27
3.9.2 Construction ......................................................................................................... 28
3.9.3 Testing and Commissioning Requirements ......................................................... 28
3.10 Lighting and Small Power ................................................................................................. 29
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3.10.1 Internal Lighting ................................................................................................... 29
3.10.2 External Lighting .................................................................................................. 29
3.10.3 Emergency Lighting ............................................................................................. 29
3.10.4 Sockets Requirements ......................................................................................... 30
3.11 Earthing & Lightning Protection ........................................................................................ 30
3.11.1 Equipment Earth bar ............................................................................................ 30
3.11.2 Tray and Ladder Rack ......................................................................................... 30
3.11.3 Cabling ................................................................................................................. 31
3.11.4 Lightning Protection ............................................................................................. 31
3.12 Safety Equipment..............................................................................................................31
3.13 Electrical Installation ......................................................................................................... 32
3.13.1 Cabling ................................................................................................................. 32
3.13.2 Electrical Conductors ........................................................................................... 33
3.13.3 Cable Tray and Ladder Rack ............................................................................... 33
3.13.4 Terminations ........................................................................................................ 34
3.13.5 Shipping and Installation ...................................................................................... 35
3.14 Fire Detection and Alarm .................................................................................................. 35
4. QUALITY ASSURANCE, INSPECTION & TESTING ....................................................... 37
4.1 Quality Assurance .............................................................................................................37
4.2 Inspection.......................................................................................................................... 37
4.3 Testing .............................................................................................................................. 37
4.3.1 Factory Acceptance Tests (FAT) ......................................................................... 37
4.3.2 Site Testing .......................................................................................................... 38
4.4 Inspection and Test Plan (ITP) ......................................................................................... 38
4.5 Commissioning and Start-Up ............................................................................................ 38
4.6 Training and After Sales Support...................................................................................... 39
5. PROTECTIVE COATINGS ............................................................................................... 40
6. NAMEPLATE DETAILS .................................................................................................... 41
6.1 Tag Plates ......................................................................................................................... 41
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6.2 Rating Plates..................................................................................................................... 41
7. PACKING, SHIPPING AND STORAGE ........................................................................... 42
8. SPARE PARTS & SPECIAL TOOLS ................................................................................ 44
8.1 Spares ............................................................................................................................... 44
8.2 Special Tools .................................................................................................................... 44
9. DOCUMENTATION .......................................................................................................... 45
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1. INTRODUCTION
1.1 Purpose and Scope

The purpose of this document is to define the minimum requirements for the design, manufacture,
inspection, testing, painting and supply of Packaged Substations complete with all associated
auxiliaries for the Medium Term ESP Power Supply requirements of the Rumaila Project.
This document shall be read in conjunction with other applicable specifications, Project Data Sheets,
Project Drawings and documents.
Compliance with this specification does not relieve the SUPPLIER from meeting the requirements of
the ultimate user or his nominated representative when stipulated in the enquiry documentation.
1.2 Distribution and Intended Audience

Unless otherwise authorized by COMPANY, the distribution of this document is confined to
COMPANY and its authorized Contractors and Suppliers.
1.3 Definitions, Acronyms and Abbreviations
1.3.1 General Definitions

COMPANY BP Iraq NV
PROJECT Rumaila Project – FEED.
CONTRACT The formal agreement between COMPANY and

CONTRACTOR
CONTRACTOR The Contractor performing the WORK described under

the CONTRACT with the COMPANY
WORK Any and all works and/or services and/or materials to be

provided by the CONTRACTOR under the CONTRACT
with the COMPANY.
SHALL AND MUST Indicates mandatory requirements.
SHOULD Indicates that a provision is not mandatory, but

recommended as good practice.
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1.3.2 Specific Terms, Definitions, Acronyms and Abbreviations

In addition to the Project acronyms and abbreviations referred to in the Abbreviations and Acronyms
Procedure (ref. 1) the following are applicable to this document:
Term / Acronym / Abbreviation Explanation / Definition

A Ampere
AC / a.c. Alternating Current
BEDD Basic Engineering Design Data
CIBSE Chartered Institute of Building Services Engineers
DC / d.c. Direct Current
DCS Distributed Control System
HV High Voltage (>1000V)
HVAC Heating, Ventilating and Air Conditioning
IBC International Building Code
IEC International Electrotechnical Commission
IES Illuminating Engineering Society
IP Ingress Protection
ISO International Organization for Standardization
ITP Inspection and Test Plan
kV Kilovolts
LDB Lighting and Distribution Boards
LV Low Voltage (≤1000V)
MCT Multi-cable Transits
Ni-Cd Nickel Cadmium (batteries)
PVC Polyvinyl Chloride
SDRS Supplier Documentation Requirements Schedule
SI Système International d’Unités
SPIR Spare Parts Interchangeability Record
UPS Uninterruptible Power Supply
V Volt
XLPE Cross- Linked Polyethylene
1.4 Reference Documents

Unless specifically designated by date, the latest edition of each publication shall be used, together
with any amendments / supplements / revisions thereto.
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1.4.1 Project Specifications

The following are a selection taken from the range of design documents currently prepared for the
activities of the Rumaila Project:
Document Number Title / Description
00100W-C-G0-G000-GE-BOD-0001 Basic Engineering Design Data (BEDD)
00102W-C-G0-G000-EL-SPC-0013 Specification – Electrical Installation Work
00100W-C-G0-G000-EL-CRT-0001 Electrical Design Criteria - FEED
Specification - Power and Distribution

00100W-C-G0-G000-EL-SPC-0001
Transformers
00100W-C-G0-G000-EL-SPC-0002 Specification for HV Switchgear
00100W-C-G0-G000-EL-SPC-0005 Specification – AC UPS
00100W-C-G0-G000-EL-SPC-0008 Specification – HV Cables
00100W-C-G0-G000-EL-SPC-0009 Specification – LV Cables
00100W-C-G0-G000-EL-SPC-0013 Specification – Distribution Boards
00100W-C-G0-G000-EL-SPC-0015 Termination and Jointing Kits for HV Cables
00100W-C-G0-G000-EL-SPC-0016 Specification – Electrical Bulk Materials
Specification – Electrical Requirements for
00100W-C-G0-G000-EL-SPC-0017
Package Units
00100W-C-WM-CN00-HV-SPC-0001 CPS HVAC Functional Specification

00100W-C-G0-G000-ML-SPC-0009 Specification for External Painting (Shop and
Field)
Emergency Escape and Evacuation Analysis

00100W-C-DG-DN00-SR-REP-0010
Report
00100W-C-G0-G000-SR-PHL-0003 Noise Control Philosophy
00100W-C-G0-G000-IC-SPC-0010 Specification for Fire and Gas System - FEED
00100W-N-PG-PP03-EL-PHL-0001 Protection Philosophy FEED
1.4.2 Applicable Standards

The Codes, Standards and BP Group Defined Practices are stated in Project Codes and Standards
Index (ref 2).Minimum relevant standards are listed below. However, the equipment shall conform to
the latest editions of all the applicable standards. It shall be the SUPPLIER’s responsibility to be or to
become knowledgeable of the requirements of applicable portions of these standards and codes. Any
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changes or alterations to the equipment to make it meet standards and codes requirements shall be
at the expense of the SUPPLIER.
INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60034 Rotating Electrical Machines
IEC 60038 IEC Standard Voltages
IEC 60071 Insulation Co-Ordination
IEC 60073 Basic Safety Principles for Man-Machine Interface, Marking and
Identification – Coding Principles for Indicators and Actuators
IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres
IEC 60085 Electrical Insulation - Thermal Evaluation and Designation
IEC 60331 Tests for Electric Cables Under Fire Conditions – Circuit Integrity
IEC 60332 Tests on Electric and Optical Fibre Cables Under Fire Conditions
IEC 60364 Low Voltage Electrical Installations
IEC 60417 Graphic Symbols for Use on Equipment
IEC 60445 Basic and Safety Principles for Man-Machine Interface, Marking
and Identification - Identification of Equipment Terminals,
Conductor Terminations and Conductors
IEC 60598 Luminaires
IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
IEC 60617 Graphical Symbols for Diagrams
IEC 60947 Low Voltage Switchgear and Controlgear
IEC 61000 Electromagnetic Compatibility (EMC)
IEC 61439 Low Voltage Switchgear and Controlgear Assemblies
IEC 61537 Cable Management – Cable Tray Systems and Cable Ladder
Systems
IEC 61936-1 Power Installations Exceeding 1kV – Part 1: Common Rules
IEC 62271 High Voltage Switchgear and Controlgear
IEC 62305 Protection Against Lightning
IEC 62485 Safety Requirements for Secondary Batteries and Battery
Installations
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INTERNATIONAL STANDARDS ORGANISATION (ISO)

ISO 9000 Quality Management Systems - Requirements
ISO/TS 29001 Petroleum, Petrochemical and Natural Gas Industries – Sector
Specific Quality Management Systems – Requirements for
Product and Service Supply Organizations
OTHER CODES AND STANDARDS

CIBSE CIBSE Society of Light and Lighting Handbook
IBC International Building Code 2009 (replaced UBC)
IES IES Lighting Handbook
1.5 Hierarchy
The hierarchy of the codes, standards and specifications is given in Project Codes and Standards Index
(ref 2).
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2. GENERAL REQUIREMENTS
2.1 Operation and Design Life

Packaged Substations shall be designed for minimum life duration of 25 years in the environment and
for the duty specified herein and on the Project Data Sheets.
2.2 Service Conditions

The outdoor and indoor environmental conditions that may be experienced by site equipment shall be
as specified in the Basic Engineering Design Data (BEDD) (ref. 3) document.
All site equipment to be installed indoors and outdoors shall be capable of operating continuously
under the environmental conditions stated in the BEDD (ref. 3).
2.3 Scope of Supply

Packaged Substations shall be housed in either appropriately sized ISO containers or in complete
factory assembled enclosures, with dimensions equivalent to those of a standard ISO container.
The scope of supply shall include substation layout designs, as well as the design and manufacture of
the enclosure or selection and supply of the ISO container.
The scope of supply also includes the supply and installation of all specified substation equipment
including HV Switchgear, protection relays and auxiliary equipment, dry-type transformers (indoor),
small power distribution boards, AC UPS and batteries, as applicable, as well as delivery and
installation at site.
The scope of supply shall also include the specification or design, supply, installation and testing of all
electrical and services equipment housed therein, including but not necessarily limited to:
 Normal lighting complete with all cabling, switches etc.
 Emergency lighting and exit signs complete with all cabling, switches etc.
 Small power socket outlets complete with all cabling, switches etc.
 Air intake overpressure ventilation system complete with sand, fog and droplet protection as
well as demister with droplet separation
 Air conditioning system, split type, complete with all cabling, switches etc.
 Small power and lighting distribution board
 Control and instrumentation systems
 Fire alarm and detection equipment
 Earthing and lightning protection
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 Access stairs and platform
 Steel pillar supports
 Inspection and Testing
 Packaging, shipping and storage
 Spare Parts
 Special Tools
 Documentation, drawings and certification
The enclosures will be mounted on prepared foundations, as detailed in this specification or other
reference documents.
Unless otherwise specified, the enclosure is not required to be blast resistant.
Outdoor oil filled transformers and their compounds, fences, etc., are excluded from the scope of this
document.
Steam and water piping or equipment using steam or pressurized water shall not be located within
substation enclosures.
The following will be provided by others, unless otherwise specified in the Material Requisition.
 Feeder power cables, glands and termination
 Concrete foundation slab
2.4 Proven Equipment Criteria

Only equipment of proven reliability in similar service conditions shall be included in the SUPPLIER’s
Bid proposal. Prototypes shall not be offered by the SUPPLIER. The SUPPLIER shall provide the
related necessary evidence with the bid (reference lists with installation dates and run hours
accumulated by date, etc.). The referenced units shall have equivalent design features to the units
proposed.
2.5 Language
All documentation and communications shall be in the English language.
2.6 Units of Measurement

The units of measurement on all documentation and equipment shall be in accordance with the SI
system, unless otherwise specified.
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2.7 Plant Utility Voltages

The plant utility voltages are shown in the table below:
Service Rated Voltage (V) Phase/Wire Earthing

High voltage 11000 3/3 Low Resistance
distribution
Low voltage distribution
-power 400 3/4 Solid
-miscellaneous 230 1 / 2 + PE Solid
-lighting 230 1 / 2 + PE Solid
63A Welding (Power) 400 3 / 4 + PE Solid
sockets
Luminaires 230 1 / 2 + PE Solid
Convenience sockets 230 1 / 2 + PE Solid
Supply for 230 AC Solid
closing/tripping/control 1/2
for HV Circuit breakers
HV Fused Contactors Contactor operating
without mechanical coil: 230 AC 1/2
Solid
latch element
HV Fused Contactors 230 AC Solid
with mechanical latch 1/2
element
AC Uninterruptible 230 AC 1 / 2 + PE Solid
power supply
All equipment included in the SUPPLIER’S scope, shall be suitable for operation on power supplies
subject to the following variations:
 supply voltage : +/- 10%
 supply frequency : +/- 3%
 combined voltage and frequency variation : 10% (absolute)
In addition to the above variations, the supply voltage may be subject to transients comprising of
voltage depressions up to 20% of the nominal voltage during motor starting and to voltage
interruptions during system short circuits. Transient, high frequency voltages of up to 2kV may also be
superimposed on the supply voltage as a consequence of system switching operations etc.
2.8 Harmonics
Total harmonic voltage distortion shall not exceed 5 % at substation feeders, under steady state and
normal operating conditions. Individual odd harmonics will be allowed up to 2% and individual even
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harmonics will be restricted to less than 1.5%. Users that generate harmonic currents will be specified
to be provided with harmonic filtration equipment if it is determined that the total harmonic voltage
distortion would otherwise be unacceptable.
2.9 Voltage Drop

The maximum voltage drops in various sections of the electrical system shall be within the limits
stated in the following table, as applicable:
Item System Element Maximum Permissible

No.
Voltage Drop
1 Cables between upstream HV switchgear and 0.5%

downstream HV switchgear
2 Cables between switchgear and primary of transformer 2%
3 Cable between transformer secondary and switchgear 1%
4 Cables between LV switchgear and downstream LV
switchboard
Location of switchboard :
- Near LV switchgear (within 50m) 0.5 %
- Remote (>50m) 2.5 %
5 Maximum voltage drop in HV motor feeder cable in % of
rated motor terminal voltage
- during running condition 5%
- during starting or re-acceleration condition at the motor 15%
terminals
6 Maximum voltage drop at switchboard bus during motor 10%
starting
7 Circuit between LDB and luminaires 5%
8 AC UPS circuits ±1% for AC UPS Circuits
2.10 Materials
The materials of construction for the equipment shall be as specified in the equipment data sheets
and this specification. When materials are not specified, the materials proposed in the offer shall be
suitable for the process fluid, operating and design conditions.
All materials, equipment or supplies furnished under this specification shall be the product of a
manufacturer who is experienced in the design and construction of such materials, equipment, or
supplies, and who has furnished similar materials, equipment, or supplies that have been in
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satisfactory operation for a minimum of three years, preferably in similar environmental conditions, to
establish its reliability.
Alternate materials may be offered to those specified, however any such alternatives shall be clearly
indicated in the Bid, along with any cost adjustments and technical data supporting the alternative.
Alternative materials shall be subject to COMPANY’s written approval.
All materials shall be new, free of defects and be identifiable against their certification.
Dissimilar metals shall not be coupled directly. Suitable insulation (for example: insulation washers /
gaskets, fluorocarbon coated bolts and nuts) shall be used if dissimilar metal coupling cannot be
avoided.
Asbestos products shall not be used.
2.11 Noise Limits

The noise levels for each item of operating equipment (including drivers where applicable) shall meet
limits specified in the Material Requisition or other referenced documents.
2.12 EMC Requirements

For EMC immunity, all equipment covered by this specification shall, as a minimum, be suitable for
operation on electrical power distribution systems having overall disturbance characteristics defined in
IEC 61000-6-2 for industrial environments.
Unless otherwise specified, all equipment covered by this specification shall meet the emission
requirements for industrial systems as defined in IEC 61000-6-4.
All low voltage equipment covered by this specification shall comply with EMC emissions and
immunity requirements in accordance with IEC 61439-1, Annex J, as specified for Environment A and
for communication ports shall also meet the emissions requirements of IEC CISPR 22.
All power system protection relays and Intelligent Electronic Devices (IED) shall comply with EMC
requirements in accordance with IEC 60255.
2.13 Ingress Protection

The levels of ingress protection for all electrical equipment shall comply with the relevant IEC
Standards and shall be in accordance with the following:
 Equipment to be installed in indoor areas : IP 42 (minimum)
 Equipment to be installed in outdoor areas : IP 55 (minimum)
2.14 COMPANY / CONTRACTOR Interfaces

The equipment package shall be required to fall within the parameters defined in Project Drawings.
These parameters may include any or all of the following:
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1. Maximum overall package dimensions
2. Structural hard points / fixing locations
3. Electrical and Instrument junction box / tie-in locations
4. Maximum allowable weight.
2.15 Deviations, Concessions and Change control

The SUPPLIER shall refer to the Material Requisition for the procedure for raising deviations or
concession requests to the technical content of this specification.
The COMPANY will consider all deviations and concession requests and approval may be granted at
the discretion of the COMPANY. No deviation or concession shall be implemented prior to approval
being granted. Any deviations or concession implemented prior to approval shall be subject to
rejection.
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3. DESIGN REQUIREMENTS FOR PACKAGED SUBSTATION
The design shall be based on the specific requirements stated in this specification, Project Data
Sheet(s) and other applicable documents inclusive of the applicable editions of codes and standards
listed under clause 1.4.2.
Any deviations shall be submitted by the SUPPLIER together with the Bid in the format specified in
the Material Requisition. In the absence of this, it shall be construed that the SUPPLIER fully
complies with this specification.
3.1 General Design Requirements

The basic equipment design shall be the responsibility of the SUPPLIER.
SUPPLIER shall submit, with the BID, full technical details of proposed standard structural equipment
that most nearly meets the requirements detailed herein. Aspects of the requirements that cannot be
met, or for which the SUPPLIER proposes new or alternative technology, shall be identified and the
variances explained.
Unless otherwise specified, all equipment shall be designed for continuous working under the service
conditions stated in the relevant documents and the Project Data Sheet.
The enclosure SUPPLIER shall produce the detailed equipment layout for a pre-assembled concept
showing all clearances and aisles with dimensions, subject to the COMPANY’s approval.
Common operating aisles are preferred for the switchgear. Where this layout is used, the operating
sides of the different equipment on each side of the operating aisle shall preferably be aligned. Front
and back clearances may be increased where necessary to permit this arrangement.
3.2 Specific Design Requirements

Minimum clear unobstructed headroom in equipment rooms shall be 2.5m.
All doors shall be designed as escape doors with a push bar and shall open outwards.
Unless otherwise specified, all substations shall have a minimum of two doors and no dead leg
greater than 23m.
Main escape routes shall be at least 1200mm wide and 2200mm high.
Battery Rooms shall have acid resisting surfaces on the floor and walls (2.0m high).
Handrails in front of equipment doors shall be demountable.
The enclosure shall include1000mm high steel pillar supports suitable for installation onto concrete
foundations (by others) and shall include all necessary external access stairs, platforms and roof
above entrance doors.
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The building shall be suitable for installation and continuous operation in the environmental conditions
defined in the BEDD (ref. 3).
The building design shall include all necessary services and ancillary equipment and shall meet the
following minimum environmental requirements:
 Overall ingress protection: IP 54 in accordance with IEC 60529 (EN 60 529)
 Fire resistance: 90 minutes in accordance with SS-EN ISO 13501-2, CL. El

90 with fire direction from both inside to outside and
outside to inside
 External environmental withstand ISO12944-2/5 cl. C4 (M)
 Internal environmental withstand ISO12944-2/5 cl. C4 (M)
 Entrance roof above door ISO12944-2/5 cl. C4 (M)
3.2.1 Location
The Packaged Substations will be located in non-hazardous areas.
3.2.2 Clearances
Clearances between equipment and those between equipment and the walls shall be as specified in
the Electrical Design Criteria – FEED (ref. 4).
Where specified, additional floor space shall be provided to allow for future expansion of the
equipment. Specified clearances shall be maintained from the future equipment.
Equipment spacing clearances for packaged substations shall be such that clear, safe exit from the
building is possible, even when drawout type equipment, is in either the connected, test or fully
disconnected position (breaker in front of switchgear) with doors open.
Adequate space shall be allowed for equipment removal for maintenance, isolation and inspection.
Where specified, or if applicable, space for circuit-breaker trucks and a Test Station shall be provided,
at locations that do not obstruct clear passage to the access doorways.
Space between the top of switchgear and the bottom of any high level cable support systems shall
not be less than the bending radius of the largest installed cable.
Indoor rear access shall be provided for all equipment requiring rear access for maintenance.
3.3 Design Loads

The structural design shall consider loads imposed on the package during transportation, lifting,
installation and operation. The structural design of the enclosure shall be in accordance with
International Building Code (IBC). If the substation is housed in an ISO container, the SUPPLIER
shall verify that the structural design of the selected container is suitable for loads imposed on the
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package during transportation, lifting, installation and operation. Deflections shall be limited to avoid
any adverse effect on the pre-installed equipment.
3.3.1 Equipment Loads

Switchgear line loadings and all other equipment loadings on the substation floor or support frames
shall be used in determining the suitability of the container structure. Equipment load shall include for
fitting out of spare compartments and installation of future ring main units if required.
3.3.2 Handling and Erection Loads

All loading conditions during handling and installation shall be considered for each member of the
enclosure structures. The most severe condition shall be taken into account.
3.3.3 Wind Loads

Wind loads shall be determined to accommodate the specified wind velocity in the BEDD (ref. 3).
Wind loads can act on structures from any direction and the most unfavourable cases shall be
considered.
Any directionality reduction factor shall only be used for the determination of resultant forces and
overturning moments on complete enclosures and major framing elements. It shall not be used for the
design in individual structural elements.
3.3.4 Seismic Loading

Seismic loading for the Packaged Substation shall be as specified in the BEDD (ref. 3).
3.4 Construction
3.4.1 Structure
The enclosure supplied shall be of metal construction and shall be self-supporting and free standing.
All metal work shall be free from burrs and sharp edges. Elements may be connected by bolts, thread
forming screws, or welds.
The enclosure height shall be determined by the specified in-house equipment and bending radii of
cables.
The enclosure shall not have windows.
Allowance shall be made in the design, in collaboration with the main electrical equipment suppliers to
accommodate, without ill effects, the venting of explosion products from electrical switchboards. Arc
Flash Vents shall slope away from switchgear to wall to prevent any condensation or leaks from
entering switchgear. Rain shield, sun shield, etc., shall be provided where necessary to meet the
environmental conditions.
Structure walls shall be insulated between the inner and outer walls with mineral fibre insulation.
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The ceiling and roof structure shall consist of two layers of formed interlocked 304/304L stainless
steel panels and galvanized steel inner ceiling panel of 1.4mm minimum thickness and shall be
insulated to match the walls.
All internal enclosure finishes shall be to the approval of the COMPANY / CONTRACTOR. All internal
metal sheeting shall be neatly finished. All visible sealant joints shall be neatly finished and made
flush with adjacent surfaces.
The enclosure shall preferably be designed and constructed to allow direct lifting from the top, without
the use of spreader beams or lifting frame. Where special lifting equipment is necessary, it shall be
included in the scope of supply and shall include all straps, chains, shackles and hooks, as required.
All lifting equipment shall be fully load tested and shall be supplied with the relevant load test
certificates and, where appropriate, third party test certificates.
3.4.2 Base
Where the supply of complete factory assembled enclosures is proposed, the base shall be
constructed of structural members sized by design structural calculations and reinforced to meet or
exceed specific static and dynamic loads. Structural members shall be located to coordinate with the
enclosed equipment so as to support it properly and allow maximum access to equipment openings
for cable penetrations.
Where the enclosure cannot be lifted from the top, the base shall be designed with base lifting lugs
capable of lifting the fully equipped structure at the specific lifting points with no distortion of
equipment in the enclosure.
The floor plate shall be 6.3mm steel minimum stitch welded to the structure base assembly. The
installed structure shall be capable of supporting a floor loading of 10kN/m2 and be able to absorb the
shock of circuit breaker operation without transferring it to other equipment and the seismic loading as
specified in the BEDD (ref. 3). Every removable floor panel shall be provided with tapped holes for
attachment of a lifting aid.
The floor installed for equipment shall be levelled and flush with the finished floor. A smooth finished
floor is required. Equipment having removable elements which roll out on the enclosure floor shall be
mounted level with respect to the finished floor so that elements can be rolled in and out of their
compartments.
3.4.3 Cable Entries

All cables entering the enclosure shall do so through Multiple Cable Transit (MCT) frames or other
sealable, fire resistant solutions (e.g. adapter chamber) which shall be installed by the Substation
SUPPLIER. Where MCTs are used, all MCT components (solid blocks, stay plates, compression
plates, etc.) shall be supplied and installed by the Substation SUPPLIER to ensure the enclosure IP
rating is maintained.
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Cable entrances through substation walls from continuous rigid cable support systems shall be kept
to a minimum but shall be sealed to prevent entrance of dust, insects, rain and moisture, and, where
applicable, maintain the enclosure fire rating.
3.4.4 Battery Installation

Batteries shall be installed in accordance with the manufacturer’s instructions and shall comply with
the safety requirements of IEC 62485-2.
Provisions shall be made for sufficient diffusion and ventilation of gases from the battery to prevent
the accumulation of an explosive mixture within the substation enclosure or battery enclosure.
Where necessary, a ventilation system shall provide an air exchange rate adequate to prevent the
accumulation of an explosive mixture. Battery enclosures, if used, shall have ventilating louvers.
Determination of air exchange requirements shall be based on the charge method and the battery
SUPPLIER's stated volume of H2 gas evolved.
Where mechanical ventilation systems are used to provide adequate air exchange to prevent
accumulation of an explosive mixture, provision shall be made for a “ventilation failed” alarm signal to
be hardwired to the control and communications system. Ventilation failure shall prevent high rate
battery charging and, if recommended by the battery manufacturer, shall also prevent float charging.
Where required, the substation shall be fitted with a portable wall-mounted eyewash station, which
shall be drained through the floor.
3.4.5 Access Platforms

Access stairs and platforms shall be designed to be fully self-supporting onto grade level concrete
foundations (by others).
Stairways and landings shall be provided with 30mm thick open grill rectangular pattern flooring with
bearing bars at 30mm centres and transverse bars at 100mm centres with 5mm thick (double
serrated) main bearing bars or similar approved equivalent, together with handrails and they shall all
be galvanised.
At equipment entrances, rails shall be removable to facilitate handling of equipment, and the platform
shall be designed for the maximum weight of equipment to be moved in or out as one piece.
Stair treads shall be fitted with non-slip nosings. Hand-railing posts, top and knee rails shall be made
from angle steel. Floor, platforms and walkways shall be provided with 100 x 6mm kick plates. The
minimum width of platforms to external equipment doors shall be 1500mm. The slope of stairs shall
be a maximum of 5 (vertical) in 6 (horizontal), and the rise of the treads shall be 200mm maximum.
Platforms and ladders shall be trial fitted at works prior to delivery and should be delivered loose for
fitting on site.
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3.5 Fittings
3.5.1 Doors
At least one single and one double door shall be provided at opposite ends of the Substation, opening
outward. All doors shall be steel with solid upper and lower panels. Door frames shall consist of
insulated steel hollow box sections of suitable sizes to resist high wind pressures.
The single and double doors shall be used for access to the equipment and egress of personnel, and
shall be equipped with a lock, which accommodates the plant master key for Substations. If the size
of the double door is too cumbersome to be used as an emergency exit door, a second single door
shall also be provided. Each door shall be fitted with an automatic door closing mechanism sized to
close against enclosure pressurization and to be robust for high winds. They shall be complete with
heavy duty hinges, lockable lever latch handles with overriding internal, horizontal, full width panic
bars and high performance seals. A nylon check rope to retain the door at 90 degrees to opening
shall be provided for all doors. Locks, handles and hinged pins shall be stainless steel. The inside
face of each door shall be fitted with a Panic Bar, which shall override the door lock. All ironmongery
and hardware shall meet local fire safety Regulation and shall be subject to COMPANY approval.
The double door entrance shall be sized to permit passage of the largest unit of equipment installed
within. This shall be accomplished by utilizing standard height doors with a removable metal panel
located above. The panel shall have retaining straps/chains to guard from accidentally dropping when
unbolted. The dimensions for external and internal doors are as follows. They are minimum
dimensions and shall be increased if required.
a) External personnel access doors shall be 930mm (wide) x 2200mm (high) structural opening.
b) Internal personnel access doors shall be 930mm (wide) x 2200mm (high) structural opening.
c) External equipment access doors shall be 2150mm (wide) x 2780mm (high) structural opening.
d) In the case where an external equipment access door is used as the emergency exit door, the
following items shall be provided:
i. 2150mm wide x 642mm high transom that shall be removable for equipment access:
ii. 2150mm wide x 2842mm high structural opening for door; and
iii. 930mm wide x 2200mm high structural opening for door with panic exit bar.
The SUPPLIER shall ensure that should the major electrical equipment be larger than the noted
opening dimensions, the doors shall be sized accordingly.
A metal awning shall be installed over the entrance of all doors into a substation to limit rain water
ingress.
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3.6 Miscellaneous Requirements
3.6.1 Roof-water Run-off

Roof gutters are deemed to be a common breeding ground for mosquitoes and are banned for use on
new buildings. Roof slopes and profiles shall be suitable for local storm-water conditions and direct
water away from places such as cable trenches where run-off could accumulate. The minimum roof
slope shall be 1 in 30 (2 degrees). The SUPPLIER shall ensure, by design, that the absence of
guttering and down-pipes will have no adverse effects on the enclosure structure or on any of its
contents or associated equipment.
3.6.2 Sealants
Where required, mastic sealants shall be used to caulk openings and joints between walls and door
frames, walls and louver frames, walls and ceiling frames, air duct frames and walls and to permit
flexible movement between materials.
For gas tight joints and fire resistant joints, fire proof mastic shall be applied, fire rated as adjacent
construction. All sealants shall be installed in accordance with the manufacturer’s recommendations
and shall be suitable for the site conditions.
3.6.3 Harmonic Filters

Harmonic filters shall be installed within each substation, if required. These will be free-issued to the
SUPPLIER, who shall allow space for their location when designing the substation layout. Equipment
dimensions shall be as stated in the Material Requisition or reciprocal documents.
3.6.4 Control and Communication Equipment

The SUPPLIER shall allow space for the location of future control and communications equipment
when designing the substation layout.
3.7 Substation Services

All equipment shall be designed and installed to facilitate inspection, testing, cleaning, replacing and
repair in order to form a system where continuity of operation is of prime importance.
All equipment, when working under the environmental conditions prevailing, shall be capable of
operating for extended periods without interruption caused by overhaul or adjustments and without
risk of overheating of any part.
Any free issue equipment to be installed in the substation will be identified by the COMPANY at the
order stage. The free issue equipment will be delivered to the SUPPLIER's works for installation by
the SUPPLIER unless agreed otherwise. It is the SUPPLIER's responsibility to liaise with the free
issue equipment SUPPLIER in order to ensure correct interface regarding space requirements,
interconnection diagrams, heat losses, delivery dates and any other issues.
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The number and size of supports, brackets and associated fixings shall be adequate to support
equipment, tray, ladder rack or cables in position, without imposing strain and the finished installation
shall present a neat appearance.
The enclosure shall be designed to contain electrical switchgear and associated equipment, and to
provide an environment suitable for that equipment. All items of equipment shall be fully installed and
wired so that it shall only be necessary to terminate incoming and outgoing cables, auxiliary power
supplies and final earthing connections in order to make the unit fully operational.
Electrical apparatus located inside the substation shall be standard industrial equipment.
Switchboards, distribution boards and ancillary apparatus, etc., included in the substation
SUPPLIER’s scope, shall have IP42 degree of protection as a minimum. Small power socket outlets
shall be 230V, 13A, 3 pin switched type in accordance with BS 1363.
3.7.1 Flash Protection

The flash protection boundary shall be calculated and documented by the SUPPLIER for each piece
of switchgear. The calculation method shall be approved by the COMPANY. A clearly visible red line,
75mm wide, shall be placed on the Substation floor around each piece or grouping of ring main units
to indicate the flash protection boundary perimeter. This line shall be durable. The location of this
boundary line and the method / material used for marking shall be approved by the COMPANY.
3.7.2 Lifting Devices

If breakers or controllers over 10kg are not designed to rollout at floor level in a level plane,
permanent handling facilities are required. Accessory spreaders, shackles, and similar equipment
shall be supplied as needed for proper support of devices being lifted and suitable storage facilities
provided.
3.8 Identification and Labels

All equipment furnished shall have name tags labelled in English. A summary of proposed
identification and labelling including tags and nameplate text shall be prepared and submitted for
review. Equipment identification labels shall be engraved white-black-white laminated plastic
('Traffolyte' or equivalent), and are required on the front of each functional unit and shall be duplicated
where practical. Rear access covers, if required, shall be labelled with the compartment reference.
Labels shall not be secured to equipment covers that can be interchanged. Labels fixing methods
shall not infringe on IP rating or safety of any enclosure.
Specific labelling requirements for electrical equipment are given in the particular equipment
specifications. The Packaged Substation building name shall be provided with a large door mounted
nameplate. The label for an item of equipment shall include the Tag Number for the item. The Tag
Number shall be specified in the Material Requisition.
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Cables shall be fully identified using proprietary plastic cable markers referenced to the SUPPLIER’s
cable schedule. Identification of each cable shall be unique and permanently attached to the cable
exterior jacket.
Cables shall be identified at each cable termination location and at transitions through wall
penetrations and where cables rise from one level to another through an enclosure or structure (entry
and exit sides – 2 labels) and in particular in the cable space below elevated substations.
All individual conductors shall be labelled at each termination point with unique wire numbers as
shown on the applicable SUPPLIER’s wiring diagrams. Spare conductors shall be identified as spare.
Nameplates mounted on the equipment, or on a support immediately adjacent to the equipment, shall
be provided for panel boards, cabinets, junction boxes, safety switches, contactors, motor controllers,
circuit breakers, control devices, and any other equipment used to disconnect, switch, marshal or
control electrical or instrumentation circuits .
Nameplate lettering sizes shall be proportional to the size of the equipment to be identified and need
to be seen for operational and safety considerations.
All internally mounted components in panels, e.g. relays, terminal blocks, switches, etc., shall be
identified with a label fixed adjacent to the component. The identification on the label shall coincide
with that shown on the SUPPLIER's schematic and wiring diagrams.
Internal component and equipment identification labels shall be of laminated (white-black-white)

plastic. Self-adhesive paper labels are not acceptable.
Individual terminal blocks shall be complete with integral marking tags that are identified with a unique
tag as referenced on the SUPPLIER’s wiring diagrams. The marking tag identification shall be
duplicated on the conductors terminating on the terminal block.
Safety warning labels shall have black characters or symbols on a yellow background, and shall
comply with IEC 60417.
3.9 Heating, Ventilation and Air Conditioning (HVAC)
3.9.1 Design
The relevant sections of CPS HVAC Functional Specification apply to the HVAC functional requirements
within the Packaged Substation. Where conflicts exist between the CPS HVAC Functional
Specification and this document, this document shall take precedence.
The enclosure SUPPLIER shall submit calculations of air-conditioning sizing, which shall include all
heat sources, for COMPANY review prior to placing a Package Substation order. Heating (in addition
to the normal heat dissipation from the electrical equipment) to control condensation will be provided
by electric space heaters (anti-condensation) located inside equipment.
The air conditioned cooling design of the enclosure shall include moisture-proofing and thermal
insulation to prevent corrosion and limit indoor temperature extremes.
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Mechanical refrigeration shall be provided to limit the indoor temperature. Commercial, wall-mounted
air conditioner units are preferred for incorporation into the HVAC design. The design shall include a
redundant HVAC unit sized such that 100% cooling capacity is available with one unit failed (n + 1).
Provision shall be made for the connection of HVAC equipment alarms to the control and
communication system, if required.
Evaporation units shall be located outside the substation wall to prevent leaks into the enclosure.
Refrigerated air exhausted into the substation shall be directed down aisles and not directly onto any
electrical equipment.
Standard disposable filters shall be provided in the return air system to the cooling unit. These shall
be capable of removing contaminants such as dust and dirt. Contaminant levels shall be specified by
the COMPANY and detailed in the Material Requisition.
Battery ventilation shall be installed as per Sec 3.4.4.
3.9.2 Construction
All equipment and manually operated components shall be readily accessible for operation and
maintenance, and spare parts shall be easily interchangeable.
The installation shall be undertaken so as to facilitate inspection, cleaning and repairs where
continuity of operation is of prime importance. The SUPPLIER shall be responsible for checking that
the specified equipment will be suitable for the application, will meet the specified design conditions
and is suitable for operation in the conditions prevailing at site.
All materials shall be resistant to corrosion from the dust laden, desert atmosphere, and be of a grade
to suit their usage. Particular attention shall be paid to the prevention of corrosion due to the close
proximity of dissimilar metals. Where it is necessary to use dissimilar metals in an assembly,
intermediate non-conducting isolating components shall be used.
All systems shall be interlocked with the fire detection system to shut down on alarm. Operating
control panels shall provide local alarm indication and provide remote indication of fault, alarm, and
room temperature.
 The temperature setting controller shall be located in a locked enclosure in order to prevent
unauthorised changes to the set temperature.
 A copper condensate waste pipe shall run from each air handling unit to a suitable outlet.
 The refrigeration pipe work shall be insulated and clad to provide protection from mechanical
damage.
3.9.3 Testing and Commissioning Requirements

The entire HVAC system shall be tested at the enclosure SUPPLIER’s works prior to shipment, to
demonstrate correct operation in accordance with the requirements of the Specification and with the
previously submitted and approved test procedures.
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The whole system, including standby equipment, shall be tested and commissioned over a
continuous operating period, under summer conditions. The smoke alarm interlock shall be proved
rigorously.
The air distribution systems shall be adjusted to obtain the design air flows, and the outlets adjusted
to obtain the required diffusion.
3.10 Lighting and Small Power

Each individual circuit breaker on low voltage lighting and power panels shall be equipped with
devices enabling locking of the circuit breaker in the off position.
Globes and guards on luminaires shall remain attached by hinge to the luminaire when opened for re-
lamping.
3.10.1 Internal Lighting

Internal lighting shall be provided to afford a minimum illumination level of 300 lux at floor level
in-service. The lighting design should also be in accordance with recognised guides for lighting, as
produced by organisations such as the IES and CIBSE.
Luminaires shall be fully enclosed batten fixing type with the enclosure constructed of white polyester
painted, zinc coated steel body and frame along with silicon rubber gasket and polycarbonate diffuser
with IP 55 minimum degree of protection.
Control gear shall be high frequency, electronic type and the power factor shall be not less than 0.9.
All luminaires shall be switched by a metal clad switch located inside the enclosure adjacent to every
access door.
3.10.2 External Lighting

External lighting shall be provided to illuminate the entrances to the enclosure. These shall be fed
from the substation normal lighting distribution board and switched by an externally mounted photo
cell.
3.10.3 Emergency Lighting

Emergency lighting and luminaires shall be in accordance with local regulations and with guidelines
laid down by the IES, CIBSE or other internationally recognised organisations. Emergency luminaires
shall be located within the Substation so as to provide illumination of egress routes for a minimum of
30 minutes. As a minimum this will require the location of emergency luminaires above each
enclosure exit and may be of the “running man” type emergency luminaire.
Emergency luminaires are also required to be located so as to illuminate the location of all incoming
breakers on the switchboards, UPS, battery chargers, etc.
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These luminaires shall be supplied from the Lighting Distribution Board, as well as be equipped with
integral battery, to be used as a back-up power source in the case where mains power is not
available. Upon loss of supply, a minimum of 30 minutes emergency lighting illumination is required.
Emergency luminaires shall be of the “maintained” type and shall be on at all times.
3.10.4 Sockets Requirements

Sockets shall be installed at a minimum of six convenient locations within the enclosure. Each
location shall be provided with double, ring connected, 230V three pin metal clad switched socket
outlets. All sockets shall be wall mounted. Final quantity shall be agreed with the COMPANY.
3.11 Earthing & Lightning Protection

Earthing and lightning protection shall be in accordance with the relevant IEC standards and local
Iraqi regulations.
3.11.1 Equipment Earth bar

All electrical equipment within the enclosure shall have the non-current carrying metal structures
effectively bonded to the main substation earth bar, at two points. Four M20 through wall brass earth
bosses connected to the main substation earth bar shall be provided, one at each corner of the
enclosure. External connections to the main earth of the plant will be by others. The substation
earthing bar shall be suitable for the maximum specified fault rating and shall consist of a 6 x 50mm
(or flat bar with equivalent cross-sectional area) tinned copper bar installed round the inside perimeter
of the substation. Care shall be exercised when bonding equipment and cable protective conductors
in order to minimise the effect of noise and harmonic currents. All parts of the enclosure structure
shall be bonded to the earth bar.
3.11.2 Tray and Ladder Rack

Tray and ladder rack cable support systems shall be electrically continuous across all joints using
proprietary fixing plates. Where this cannot be achieved, 25mm2 wire connections shall be used.
Each cable support system shall be earthed at each end and a minimum of every 3m. Braided tinned
copper or green-yellow insulated 35mm2 copper bonding jumpers shall be used wherever gaps in the
cable support system are required. Breaks or gaps in cable support systems shall be COMPANY
approved. Earthing and bonding shall be equipotential generally in accordance with IEC codes. Each
cable support system run shall be completed and earthed prior to the installation of any cable in the
tray.
Bonding jumpers shall be provided between adjacent sections of cable trays to insure earth
continuity.
Other metal enclosures for wire and cable, such as conduits and raceways, shall be earthed at both
ends by connection to the switchgear or control centre earth bus, or by connection to an earthed
metallic equipment enclosure. The electrical continuity of metal enclosures, or wire and cable, shall
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be ensured between terminals. Non-metallic conduit sections or fittings shall not be used in metal
conduit systems unless bonding is provided across such sections and fittings.
3.11.3 Cabling
All electrical power and control cables shall have their metallic armour and sheaths, and metallic
insulation shielding earthed at both ends.
Telecommunication and instrument type cables shall have their screens earthed at one end only.
Earthing of cable armours shall be via the cable gland. Where cables are terminated in non-metallic
enclosures, a separate earth bonding conductor shall be connected between the gland and the
equipment earth bar or substation earth bar.
Metal enclosures of portable equipment shall be connected to an earthing conductor located within
the same cable assembly as the line conductors supplying the equipment as follows:
 Earthing conductor shall be the same size as the line conductor.
 Earthing conductor shall be connected to the receptacle enclosure through separate contacts in
the supply plug and receptacle, and shall be bonded to the plug enclosure.
 Plug and receptacle shall be polarized and arranged so that the earth connection makes first
and breaks last.
3.11.4 Lightning Protection

Lightning protection shall be in accordance with IEC 62305 and local Iraqi regulations. Substation
enclosures which are not within a zone of protection and which comprise metallic frame or continuous
metallic sides will be protected by connection to earth at the corners, using separate down conductors
to the earthing grid. All metallic parts forming the roof and main framework shall be bonded to each
other.
3.12 Safety Equipment

Each enclosure shall be equipped with the following items of safety equipment:
a) One 9kg CO2 fire extinguisher at each entrance door.
b) First aid instructions
c) Electrical safety gloves
d) Face shield or visor. When specified or required by national standards, this face shield/visor
shall be properly rated for the maximum amount of heat/arc flash that the equipment would be
expected to protect the user from.
e) Portable eye-wash facility for battery rooms (if required)
f) Wall mounted Single Line Diagram
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g) Unless otherwise specified, electrically insulated matting in front of all switchgear. Mats shall
not interfere with opening of switchgear doors, and need to be removable to enable rolling
heavy switchgear. It is preferred that these mats do not cover any flash protection boundary
floor markings.
h) Electric shock notice to be mounted in a prominent position on the wall.
i) Emergency Exit signs (“Running Man” type)
j) All safety and fire warning / fire fighting equipment shall be to local Regulatory requirements.
k) Complete fire and smoke detection and alarm system in accordance with the Project Data
Sheets.
3.13 Electrical Installation

The electrical installation within the Packaged Substation shall be in accordance with the relevant
parts of Specification - Electrical Installation Work, and local regulations. Where the Specification -
Electrical Installation Work (ref. 5) conflicts with provisions of this document, this document shall take
precedence.
3.13.1 Cabling
All internal wiring shall be run in galvanised steel conduit or trunking, and shall conform to standard
installation practice. In general low voltage power and control cables shall be stranded copper
conductor, XLPE insulated, galvanised steel wire (or aluminium for single core cables) armoured with
a PVC sheath. The SUPPLIER is responsible for sizing, supplying and installing all the cables linking
electrical items within the Substation. Cable numbers shall be requested from the COMPANY.
All conduit, trunking and trays shall be sized for 25% spare cable.
All cabling and wiring shall be continuous; splices are not permitted. Cables shall be installed in one
length. Where shipping splits are required, cables are to be coiled back for re-connection on site.
All external cabling shall be run under floor and fixed to cable tray installed on Unistrut or a similar
support arrangement provided on the underside of the Substation for cables coming into the
Substation supplied and installed by others. The SUPPLIER shall provide facilities for fixing tray /
support, which will be installed by others after installation of the Substation. Those locations will be
advised by the COMPANY when the layout of the Substation is approved.
All cable entries will be vertical from below unless otherwise specified, refer to section 3.4.3 for Detail
of cable entries.
The SUPPLIER shall ensure that sufficient vertical distance exists below the gland plates to permit
installation and termination of the specified cables without contravening the minimum radii bending
limits. Floor mounted equipment shall be provided with gland plates a minimum of 300mm above
floor level. Gland plates shall be appropriately sealed to prevent entry of dust, moisture, etc.
Optionally, a box may be provided at the bottom of the substation floor for this purpose.
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3.13.2 Electrical Conductors

Electrical conductors shall comply with the following:
 Conductors for power and lighting circuits shall have a minimum size of 2.5 mm2
 230V a.c. control wiring shall have a minimum size of 1.5 mm2
 All single core panel wiring shall be low smoke, halogen-free insulation
 All conductors shall be identified at each end by a number corresponding to those of wiring
diagrams and/or elementary diagrams
 All instrument pairs shall be identified with the instrument tag number
 The identification tags shall be sleeve type and heat shrinkable
 C-type clamp-on identification tags or wrap-around tags are not acceptable
 Conductors of different power systems shall be separated in accordance with the Material
Requisition and Project Data Sheets
 Conductors of lighting and power systems of 600V or less, whether d.c. or a.c., shall be
permitted to occupy the same enclosure or conduit when all conductors are insulated for
0.6/1kV
 Instrumentation and communications wiring shall not occupy the same enclosures and conduits
as conductors of lighting, power and control circuits. Instrumentation and communications
wiring shall be installed in separate conduit systems
 Power system control, metering, alarm, and relaying circuits shall be segregated (i.e.
power/control/alarms/instruments)
3.13.3 Cable Tray and Ladder Rack

Cable tray and ladder rack systems shall be provided to support all packaged equipment cables
including cables installed directly to equipment termination locations as provided by the SUPPLIER
(such as Substation feeders, motor supplies and control cables). Cable tray and ladder rack systems
shall have a designed spare capacity of 25% after allowance has been made for the SUPPLIER's
cables. Cable trays and ladder racks selected by the SUPPLIER shall be designed and installed in
accordance with IEC 61537 and be of adequate strength as determined by the manufacturer's data to
carry the weight. The cable tray and ladder rack shall be supported at no more than the
manufacturer's specified spacing. Fabricated or factory assembled bends shall be used in the running
of tray above 400mm width, and shall be supported in the centre of the bend. If the galvanised trays
are cut or welded they should be immediately protected and made good.
Cable ladder rack and accessories shall be an approved purpose made support system manufactured
from hot dip galvanised mild steel. Galvanising shall be applied after manufacture. Cable racks shall
be assembled and supported in accordance with the manufacturer's instructions and installed in a
workmanlike manner.
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Cable tray shall be heavy duty, section flange galvanised steel. All cable tray shall be installed to
provide continuous support to cables along their full length although short breaks at changes in
elevation are permitted.
Where cables pass over an edge, or through trays, the edge shall be turned down or slots cut and
protected to prevent abrasion of the cables.
The rating of cables on trays shall be based on the following details:
 Cables shall preferably be installed in no more than one layer on the same tray. Where two
layers are unavoidable they shall be separated by horizontal spacers at least every 500mm to
create a continuous 35mm deep ventilated space between the two layers. Cables shall not be
installed in more than two layers. Cables shall be arranged to minimise the number of
crossovers.
 Where COMPANY’s cables are to be installed with defined spacing, SUPPLIER shall ensure
that sufficient cable tray and ladder rack is installed to accommodate all of the cables specified
in the Material Requisition or Project Data Sheets.
 Power, instrument and communication cables shall be run on separate tray or ladder rack, with
adequate separation distances. Where impracticable, power cables shall be separated by
earthed metallic barriers.
The fixing centres for cables on all surfaces and supports shall be as follows:
 Horizontal, inclined or vertical cable tray for all cable diameters – 300mm centres
Cables shall be secured with saddles, straps and clamps in accordance with the cable installation
detail drawings enclosed with the Material Requisition. The minimum bending radii of the cables shall
be within manufacturer's recommendation.
3.13.4 Terminations
All terminal boxes shall have gland plates with sufficient area to permit termination of all specified
cables. Control / indication terminals shall be screw-clamp type terminals suitably sized for
conductors. 25% spare terminal capacity shall be provided.
Cables shall be terminated at all equipment using compression glands of the correct type and size as
recommended by the cable SUPPLIERs. Cable glands shall be industrial brass with nickel plated
surface finish, mechanical compression type with seals and positive clamping of all strands of wire
armour. The thread shall be ISO metric. Glands terminating in unthreaded holes in metallic
enclosures shall incorporate a star washer under the back nut to ensure continuity between gland and
gland plate and an external sealing washer shall be included to maintain the relevant ingress
protection rating of the enclosure.
Cable ends which are not terminated immediately after cutting shall be sealed effectively to prevent
ingress of moisture and shall be protected from damage with the use of heat-shrink sealing caps and /
or water resistant sealing tape.
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Conductors to terminal blocks shall not exceed one connection per terminal point. In the case of
more than one connection required to a single point, multiple terminals with jumpers shall be used.
In no case shall any bare power wire be terminated. Power wiring shall be terminated with crimp pins
or compression lugs.
Where conductors are left to be terminated by another party, or left to be connected later, they shall
be suitably identified.
For lighting and small power terminations, crimped lugs are not required.
3.13.5 Shipping and Installation

Electrical conduit, wire, tray, ladder rack and cable shall be installed in a manner that makes it
unnecessary to dismantle any part of the system for shipping or erection at the site and that does not
interfere with subsequent equipment removal or service. During construction, open conduits and
fittings that are outdoors shall be plugged or covered to prevent the entrance of water or other foreign
matter.
Conduit seals, where required, shall be packed at the SUPPLIER's plant but left to be poured in the
field after the equipment has been installed, tested, and made ready for operation. The SUPPLIER
shall ship sealing compound loose with the skid.
3.14 Fire Detection and Alarm

Optical type smoke detection shall be provided within the Substation. The detection system in the
Substation shall be a fully self-contained system, independent of the main plant system, complying
with the relevant parts of Specification for Fire and Gas System - FEED.
All indicators and facilities to initiate shutdown of the air conditioning units shall be provided in the fire
detection panel. Smoke detectors shall individually alarm at the panel. Each alarm shall be identified
with the location of the smoke detector. Alarms shall be both visible and audible. Substations shall be
fitted with an external beacon and sounder (near the main personnel entrance) which will operate in
the event of fire or smoke being detected inside the enclosure by the fire detection system.
The fire detection panel enclosure shall be painted, using a paint process suitable for the
environmental conditions encountered at site, in the SUPPLIER’s standard colour. The SUPPLIER
shall submit a detailed paint procedure for review by the COMPANY.
The fire detection panel shall be provided with a 230V a.c. power supply for normal operation. On loss
of the normal power supply, the fire detection system shall continue to function for at least 60 minutes
from an internal, rechargeable, sealed Ni-Cd battery. Loss of normal power supply shall initiate
operation of the visual and audible alarms.
The fire detection panel shall be provided with facilities for transmission of status diagnostic data and
alarms via independent redundant data communication links as well as with potential free contacts
that provide a remote common alarm. Details of the communication media type and protocols shall be
as stated in the Material Requisition and will be agreed during the Bid stage.
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The fire detection panel enclosure shall be fitted with an external earthing stud which shall be
connected to the substation earthing system. The cable gland plate and any doors or covers having
current carrying equipment on them shall be earthed to the main enclosure by a flexible cable.
RUMAILA PROJECT
4. QUALITY ASSURANCE, INSPECTION & TESTING
For the activities listed below, the SUPPLIER shall comply with the requirements specified in relevant
Sections of the Material Requisition in addition to the following.
4.1 Quality Assurance

The SUPPLIER shall demonstrate that they operate a quality system in accordance with an
internationally recognized standard. The effectiveness of the quality system and the SUPPLIER’s
compliance with it shall be subject to monitoring by the COMPANY and in addition, may be audited
following an agreed period of notice.
The SUPPLIER shall submit a quality control programme for COMPANY review at the time of Bid.
The SUPPLIER shall provide facilities for, and cooperate with COMPANY Inspectors during
manufacturing, assembly and testing.
4.2 Inspection
The COMPANY or its authorised representatives shall be permitted at all times free access to all parts
of the SUPPLIER’s workshops that concern the construction and testing of the Packaged Substation.
4.3 Testing
All testing shall be carried out at the SUPPLIER’s test facility (except for type tests to be done in other
premises). Test equipment shall be supplied by the SUPPLIER and shall be calibrated within six
months of the test date. The minimum scope of testing is summarised below. The SUPPLIER shall
supply an Inspection and Test Plan with the bid.
The SUPPLIER shall provide the COMPANY with advance notice as per the provisions of the Material
Requisition, to witness tests performed in either the SUPPLIER’s workshop or his sub-SUPPLIER’s
workshops.
The SUPPLIER shall be responsible for the testing and commissioning of the equipment, including
the provision of all necessary test apparatus.
4.3.1 Factory Acceptance Tests (FAT)

Tests shall be performed on all equipment after installation in the Substation enclosure, in accordance
with the agreed Test Procedures. Equipment shall have been tested at individual manufacturing site
and accompanied by full FAT documentation. Testing shall be performed by the SUPPLIER in
accordance with the Specification - Electrical Installation Works, project specifications for equipment,
individual equipment manufacturer’s recommendations, and Iraqi regulations.
As a minimum, testing shall include an inspection of the assembly of the ring main units, bus-bar
connections, contactor resistance tests, insulation tests and functional tests.
RUMAILA PROJECT
Additional tests shall include, but not limited to:
a) Proving all fire alarm panel inputs
b) Proving of all lighting and small power circuits
c) HVAC System functional tests and alarms
d) Verification of data communication networks within the substation
4.3.2 Site Testing

Site testing shall be performed by the CONTRACTOR in accordance with Specification - Electrical
Installation Works, and manufacturer’s recommendations. The SUPPLIER shall support the
COMPANY during these tests as detailed in the Material Requisition.
4.4 Inspection and Test Plan (ITP)

The SUPPLIER shall submit an Inspection and Test Plan along with bid documents, in accordance
with the Material Requisition. The ITP shall list all inspections and tests proposed for the equipment
by the SUPPLIER, between the date of ordering and the date of delivery.
The SUPPLIER shall be responsible for the planning and execution of all inspections and tests, but
the COMPANY’s representative shall have the right to witness any or all of the manufacturing,
inspection and tests.
The COMPANY and the SUPPLIER shall sign off the final version of the ITP, which, thereafter, shall
form part of the contract documents.
The SUPPLIER shall provide the COMPANY with advance notice as per the provisions of the Material
Requisition of the date on which any of the inspections or tests nominated as Hold or Witness Points
on the ITP are due to be carried out.
Certificates of Test shall be provided for each item of equipment to prove it has been satisfactorily
tested to meet all requirements of its appropriate manufacturing standards, whether or not witnessed
by the COMPANY.
Where appropriate, test certificates shall state values for all test results. Tests for which the results
are indicated as pass or fail shall be qualified by the relevant acceptance criteria.
4.5 Commissioning and Start-Up

The SUPPLIER, in the Bid, shall identify any special requirements or recommendations for
SUPPLIER support during commissioning and start-up of the equipment supplied. The COMPANY's
final acceptance of the equipment will be subject to a performance test once the equipment has been
installed and commissioned.
RUMAILA PROJECT
4.6 Training and After Sales Support

The SUPPLIER shall comply with the relevant provisions of the Material Requisition for training and
other activities.
The SUPPLIER, in the Bid, shall provide details of after sales support capability. The SUPPLIER
shall advise the nearest service representative and nearest service facility to the project location.
RUMAILA PROJECT
5. PROTECTIVE COATINGS
All surface preparation, painting and protective coatings shall be in accordance with the document the
Specification for External Painting (Shop and Field).
Where the manufacturer’s standard painting is offered, the SUPPLIER shall submit the standard paint
specification with the Bid for COMPANY approval. Where the COMPANY deem the standard painting
specification as insufficient, alternative requirements will be negotiated during the Bid evaluation.
Exterior surfaces shall be finish coated to the colours specified in the Material Requisition.
All electrical equipment in contact with the atmosphere shall be suitably protected to prevent
deterioration in the adverse environmental conditions utilising suitable plating, encapsulation and
materials with anti-fungal and anti-tracking properties.
The SUPPLIER shall supply paint for the field touch-up after installation of equipment.
RUMAILA PROJECT
6. NAMEPLATE DETAILS
All nameplates shall be in English.
6.1 Tag Plates

Unit minor sub-components such as heaters shall be fitted with a tag plate identifying their individual
tag number only.
Tag plates shall be manufactured from 316 type stainless steel. Text and numbering shall be clearly
engraved, with durable filler and a minimum of 6mm high.
Tag plates shall be secured by stainless steel screws or rivets.
6.2 Rating Plates

Individual apparatus items shall be provided with stainless steel rating plates as required by the
relevant equipment codes and standards defined in clause 1.4.2.
The rating plate shall be fitted in a visible position. Entries on the rating plate shall be indelibly
marked, by etching, stamping or engraving. The following information shall be given in all cases:
 Manufacturers name plate and trade mark
 Type, Model and Serial Number
 Standard to which apparatus is manufactured.
 All technical details required by the relevant standards
RUMAILA PROJECT
7. PACKING, SHIPPING AND STORAGE
The SUPPLIER shall ensure that detailed and specific instructions for the preservation and
maintenance of equipment while stored at the construction site, from receipt at site to operational
start-up, shall be delivered to construction site with the equipment. Such instructions shall include as
a minimum the preservation and maintenance schedule, preservative materials, lubricants to be used,
etc.
Preparation for shipment and storage, as well as handling of equipment shall be in accordance with
the SUPPLIER‘s standard procedures, which shall be subject to approval. However, the following are
the minimum requirements.
a) Each shipping container shall be clearly identified with the contents, purchase order number
and item number.
b) Any exposed equipment that may be damaged by slings and lifting equipment during
transportation and installation shall be removed and protected. All temporary supports and
bracings required for transporting or lifting condition shall be provided by the SUPPLIER and
shall be painted red. Where it is necessary to employ spreader beams to lift and handle large
equipment packages, the SUPPLIER shall quote this equipment as an option to the basic
package scope of supply.
c) Equipment and materials shall be preserved and protected to withstand road and sea transit
and an extended period of storage on the job site of 12 months. Equipment shall be protected
to safeguard against all adverse environment conditions that may be encountered during
shipment, storage and installation.
d) All parts shall be properly marked and conditioned for shipment and thoroughly cleaned of
loose scale, dirt and other foreign material before shipment.
e) All liquids used for cleaning or testing shall be completely drained and all units dried inside prior
to shipping.
f) Exposed bolted connections shall be protected by wooden cover plates and threaded
connection shall be protected by steel plugs or caps.
g) All items subject to internal preservation shall be tagged and marked, so to be identified.
Tagging shall indicate the type of preservation used.
h) All exposed unpainted surfaces shall be coated with approved preservatives or wrapped with
Denso tape or equivalent.
i) Location of lifting points, the weight and the centre of gravity shall be clearly marked on all
shipping containers.
j) Where items are required to be dismantled for shipping, instructions shall be provided for
reassembly of sections in the field.
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k) The SUPPLIER shall separately pack any miscellaneous equipment that must be removed for
shipment.
l) All cable entries shall be sealed to IP55 for shipping.
m) Load test certificates shall be shipped with all lifting equipment, spreader bars, slings and
shackles.
The Packaged Substation may not be split into shipping sections for shipment, handling and
installation.
All equipment shall have been fully tested and inspected prior to packaging. No packaging activities
shall commence without the prior consent of the COMPANY. The COMPANY shall be notified of the
dates of packaging with sufficient notice to allow attendance for completion of inspection and release
certificates without affecting the required delivery schedule.
No equipment shall be allowed to leave the SUPPLIER’s premises without such certificate being
signed, or a written waiver issued.
RUMAILA PROJECT
8. SPARE PARTS & SPECIAL TOOLS
8.1 Spares
The SUPPLIER shall comply with the requirements stipulated in the Material Requisition.
The SUPPLIER shall identify the following spares:
 Pre-commissioning, commissioning and start-up spares
 Recommended spares list for two years trouble free operation
Spares shall be itemised and priced with the Bid.
The COMPANY shall agree to Spares to be included in Purchase Order.
The SUPPLIER shall complete the Spare Parts Interchangeability Record (SPIR) Form to be supplied
by the COMPANY.
The SUPPLIER shall clearly state the location of the factory that manufactures quoted spares.
8.2 Special Tools

The SUPPLIER shall identify all necessary special tools required to perform routine maintenance and
any other recommended tools for specialised procedures.
Special tools shall be itemised and priced with the Bid.
The COMPANY shall agree to the Special Tools to be included in Purchase Order.
The equipment Operation and Maintenance Manuals shall include a list of special tools and
instructions on how to use them.
RUMAILA PROJECT
9. DOCUMENTATION
The SUPPLIER shall be responsible for providing all documentation in accordance with the Material
Requisition and the applicable documents like Supplier Data Requirements Schedule (SDRS)
provided by the COMPANY.
All documentation shall be forwarded to COMPANY’s nominated address.
Fabrication of any equipment shall not commence until the COMPANY has reviewed and approved
calculations, drawings and any other design documentation.
As part of the Bid, the SUPPLIER shall include the information requested with Bid and as instructed in
the SDRS.
RUMAILA PROJECT
10. REFERENCES
1. Abbreviations and Acronyms Procedure, 00100W-C-G0-G000-PM-PRO-0001
2. Project Codes and Standards, 00100W-C-G0-G000-GE-LST-0001
3. Basic Engineering Design Data, 00100W-C-G0-G000-GE-BOD-0001
4. Electrical Design Criteria – FEED, 00100W-C-G0-G000-EL-CRT-0001
5. Specification – Electrical Installation Work, 00102W-C-G0-G000-EL-SPC-0013

Specification - Packaged Substation: Medium Term ESP Power Supply

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Specification - Packaged Substation: Medium Term ESP Power Supply

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RUMAILA PROJECT

Specification - Packaged Substation

WorleyParsons Europe Limited

© Copyright 2012 WorleyParsons

REVISION DESCRIPTION SHEET

Rev. Para. Reason for Revision

A All Issued for Inter-Discipline Check

B All Issued for Client Review

1.1 Purpose and Scope ............................................................................................................8

1.2 Distribution and Intended Audience .................................................................................... 8

1.3 Definitions, Acronyms and Abbreviations ........................................................................... 8

1.3.1 General Definitions ................................................................................................ 8

1.3.2 Specific Terms, Definitions, Acronyms and Abbreviations .................................... 9

1.4 Reference Documents ........................................................................................................ 9

1.4.1 Project Specifications ........................................................................................... 10

1.4.2 Applicable Standards ........................................................................................... 10

1.5 Hierarchy........................................................................................................................... 12

2. GENERAL REQUIREMENTS........................................................................................... 13

2.1 Operation and Design Life ................................................................................................ 13

2.2 Service Conditions ............................................................................................................13

2.3 Scope of Supply ................................................................................................................ 13

2.4 Proven Equipment Criteria................................................................................................ 14

2.5 Language .......................................................................................................................... 14

2.6 Units of Measurement ....................................................................................................... 14

2.7 Plant Utility Voltages ......................................................................................................... 15

2.8 Harmonics ......................................................................................................................... 15

2.9 Voltage Drop ..................................................................................................................... 16

2.10 Materials ........................................................................................................................... 16

2.11 Noise Limits ...................................................................................................................... 17

2.12 EMC Requirements........................................................................................................... 17

2.13 Ingress Protection ............................................................................................................. 17

2.14 COMPANY / CONTRACTOR Interfaces .......................................................................... 17

2.15 Deviations, Concessions and Change control .................................................................. 18

3. DESIGN REQUIREMENTS FOR PACKAGED SUBSTATION ........................................ 19

3.1 General Design Requirements ......................................................................................... 19

3.2 Specific Design Requirements.......................................................................................... 19

3.2.1 Location................................................................................................................ 20

3.2.2 Clearances ........................................................................................................... 20

3.3 Design Loads .................................................................................................................... 20

3.3.1 Equipment Loads ................................................................................................. 21

3.3.2 Handling and Erection Loads ............................................................................... 21

3.3.3 Wind Loads .......................................................................................................... 21

3.3.4 Seismic Loading ................................................................................................... 21

3.4 Construction ...................................................................................................................... 21

3.4.1 Structure............................................................................................................... 21

3.4.2 Base ..................................................................................................................... 22

3.4.3 Cable Entries........................................................................................................ 22

3.4.4 Battery Installation ............................................................................................... 23

3.4.5 Access Platforms ................................................................................................. 23

3.5 Fittings .............................................................................................................................. 24

3.5.1 Doors.................................................................................................................... 24

3.6 Miscellaneous Requirements............................................................................................ 25

3.6.1 Roof-water Run-off ............................................................................................... 25

3.6.2 Sealants ............................................................................................................... 25

3.6.3 Control and Communication Equipment .............................................................. 25

3.7 Substation Services ..........................................................................................................25

3.7.1 Flash Protection ................................................................................................... 26

3.7.2 Lifting Devices ...................................................................................................... 26

3.8 Identification and Labels ................................................................................................... 26

3.9 Heating, Ventilation and Air Conditioning (HVAC)............................................................ 27

3.9.1 Design .................................................................................................................. 27

3.9.2 Construction ......................................................................................................... 28

3.9.3 Testing and Commissioning Requirements ......................................................... 28