Inst 343 Cap DS Ele 002 R3

Electrical Installation Specification (South)
Cokeside Extraction for Battery Discharge

CAP Acero Huachipato
Talcahuano Works
Coke Plant
Contract: C-343-CAP-DS
Document Ref JMH: INST-343-CAP-DS-ELE-002
Version: English
Revision: 3
Date: February 2023
Author: Steven Lee
INST-343-CAP-DS-ELE-002
Contents
1. Revision History ............................................................................................................................ 7
2. Introduction ................................................................................................................................. 8
2.1. Project Background ........................................................................................................................................... 8

2.1.1. Abbreviations ............................................................................................................................................ 9
2.1.2. JMHM Installation Reference Drawings.................................................................................................. 10
2.1.3. JMHM Engineering Reference Drawings................................................................................................. 12
2.1.4. Control System Services Reference Drawings......................................................................................... 15
2.1.5. Client Reference Drawings ...................................................................................................................... 22
2.1.5.1. General ............................................................................................................................................ 22
2.1.5.2. Main Disconnecting Switch Box ...................................................................................................... 22
2.1.5.3. Auxiliary Disconnecting Switch Box ................................................................................................ 23
2.1.5.4. Motor Control Panel ....................................................................................................................... 23
2.1.5.5. Control Feeder Panel....................................................................................................................... 23
2.1.5.6. Local Control Box ............................................................................................................................ 24
2.1.5.7. Distribution Box............................................................................................................................... 24
2.1.5.8. PLC & Relay Panel............................................................................................................................ 25
2.1.5.9. Operation Consol ............................................................................................................................ 26
2.1.5.10. Lubrication Panel............................................................................................................................. 27
2.1.5.11. Cooler Heater Panel ........................................................................................................................ 27
2.1.5.12. Interface List.................................................................................................................................... 27
2.1.5.13. PLC System ...................................................................................................................................... 28
2.1.5.14. List Motor-Sensor ............................................................................................................................ 28
2.1.5.15. Travel Control Panel ........................................................................................................................ 29
3. Standards ................................................................................................................................... 30
3.1. Client Standards .............................................................................................................................................. 30

3.2. British, European, International Standards and Regulations .......................................................................... 31
4. General Requirements ................................................................................................................ 33
5. Installation Requirements ........................................................................................................... 34
6. Safety ......................................................................................................................................... 35
6.1. Risk Assessment .............................................................................................................................................. 35

6.2. Toolbox Talk .................................................................................................................................................... 35
7. Scope of Work & Supply (Disassembly) ........................................................................................ 36
7.1. Pre-Work ......................................................................................................................................................... 36
2
7.2. Disassembly..................................................................................................................................................... 36
8. Scope of Work & Supply (Installation) ......................................................................................... 37
8.1. Control System Enclosures.............................................................................................................................. 37

8.1.2. Control System Services Reference Drawings......................................................................................... 38
8.1.3. Installation .............................................................................................................................................. 39
8.1.3.1. Enclosures ....................................................................................................................................... 39
8.2. Wet Scrub & Coke Guide Cage Installation ..................................................................................................... 40
8.2.1. JMHM Installation Reference Drawings.................................................................................................. 40
8.2.3. Installation Steps ..................................................................................................................................... 45
8.2.3.1. Junction Box Assemblies ................................................................................................................. 45
8.2.3.1.1. JB20 Assembly ................................................................................................................................. 45
8.2.3.1.2. JB21 Assembly ................................................................................................................................. 45
8.2.3.1.3. JB22 Assembly ................................................................................................................................. 45
8.2.3.1.4. JB23 Assembly ................................................................................................................................. 45
8.2.3.1.5. JB24 Assembly ................................................................................................................................. 46
8.2.3.1.6. JB25 Assembly ................................................................................................................................. 46
8.2.3.1.7. JB27 Assembly ................................................................................................................................. 46
8.2.3.1.8. JB31 Assembly ................................................................................................................................. 46
8.2.3.1.9. JB32 Assembly ................................................................................................................................. 47
8.2.3.1.10. JB33 Assembly................................................................................................................................ 47
8.2.3.1.11. JB34 Assembly................................................................................................................................ 47
8.2.3.1.12. JB35 Assembly................................................................................................................................ 47
8.2.3.1.13. JB40 Assembly................................................................................................................................ 48
8.2.3.1.14. JB50 Assembly................................................................................................................................ 48
8.2.3.1.15. JB51 Assembly................................................................................................................................ 48
8.2.3.2. Emergency Stop Assembly .............................................................................................................. 48
8.2.3.3. Light Support Assembly................................................................................................................... 49
8.2.3.4. General Machine Preparation ......................................................................................................... 50
8.2.3.4.1. 3 Phase Related Devices Installation............................................................................................... 50
8.2.3.4.2. Sensor Installation........................................................................................................................... 50
8.2.3.4.3. Cable Tray & JB Installation ............................................................................................................. 51
8.2.3.5. Cable Installation............................................................................................................................. 53
8.2.3.5.1. Cable J3501 ..................................................................................................................................... 53
8.2.3.5.2. Cable J3502 ..................................................................................................................................... 53
8.2.3.5.3. Cable J3503 ..................................................................................................................................... 53
3
8.2.3.5.4. Cable J3505 ..................................................................................................................................... 53

8.2.3.5.5. Cable J3507 ..................................................................................................................................... 54
8.2.3.5.6. Cable J5001 ..................................................................................................................................... 54
8.2.3.5.7. Cable J5101 ..................................................................................................................................... 54
8.2.3.5.8. Cable J2301 ..................................................................................................................................... 54
8.2.3.5.9. Cable J2501 ..................................................................................................................................... 54
8.2.3.5.10. Cable PFN01 ................................................................................................................................... 55
8.2.3.5.11. Cable PFN02 ................................................................................................................................... 55
8.2.3.5.12. Cable J2001 .................................................................................................................................... 55
8.2.3.5.13. Cable J2002 .................................................................................................................................... 55
8.2.3.5.14. Cable J2004 .................................................................................................................................... 55
8.2.3.5.15. Cable J2005 .................................................................................................................................... 56
8.2.3.5.16. Cable J2007 .................................................................................................................................... 56
8.2.3.5.17. Cable J2008 .................................................................................................................................... 56
8.2.3.5.18. Cable J2105 .................................................................................................................................... 56
8.2.3.5.19. Cable J2107 .................................................................................................................................... 56
8.2.3.5.20. Cable J2108 .................................................................................................................................... 57
8.2.3.5.21. Cable J2201 .................................................................................................................................... 57
8.2.3.5.22. Cable J2204 .................................................................................................................................... 57
8.2.3.5.23. Cable J2401 .................................................................................................................................... 57
8.2.3.5.24. Cable J2404 .................................................................................................................................... 57
8.2.3.5.25. Cable J2405 .................................................................................................................................... 58
8.2.3.5.26. Cable D05 ....................................................................................................................................... 58
8.2.3.5.27. Cable D06 ....................................................................................................................................... 58
8.2.3.5.28. Cable D10 ....................................................................................................................................... 58
8.2.3.5.29. Cable D11 ....................................................................................................................................... 58
8.2.3.5.30. Cable D18 ....................................................................................................................................... 59
8.2.3.5.31. Cable D19 ....................................................................................................................................... 59
8.2.3.5.32. Cable C11 ....................................................................................................................................... 59
8.2.3.5.33. Cable C20 ....................................................................................................................................... 59
8.2.3.5.34. Cable D13 ....................................................................................................................................... 59
8.2.3.5.35. Cable D14 ....................................................................................................................................... 60
8.2.3.5.36. Cable D15 ....................................................................................................................................... 60
8.2.3.5.37. Cable D16 ....................................................................................................................................... 60
8.2.3.5.38. Cable D26 ....................................................................................................................................... 60
8.2.3.5.39. Cable D27 ....................................................................................................................................... 60
8.2.3.5.40. Cable D28 ....................................................................................................................................... 61
4
8.2.3.5.41. Cable D29 ....................................................................................................................................... 61

8.2.3.5.42. Cable D40 ....................................................................................................................................... 61
8.2.3.5.43. Cable E01 ....................................................................................................................................... 61
8.2.3.5.44. Cable E02 ....................................................................................................................................... 61
8.2.3.5.45. Cable E03 ....................................................................................................................................... 62
8.2.3.5.46. Cable E15 ....................................................................................................................................... 62
8.2.3.5.47. Cable E16 ....................................................................................................................................... 62
8.2.3.5.48. Cable E17 ....................................................................................................................................... 62
8.2.3.5.49. Cable E18 ....................................................................................................................................... 62
8.2.3.5.50. Cable UPS01 ................................................................................................................................... 63
8.2.3.5.51. Cable UPS02 ................................................................................................................................... 63
8.2.3.5.52. Cable UPS03 ................................................................................................................................... 63
8.2.3.5.53. Cable UPS04 ................................................................................................................................... 63
8.2.3.5.54. Cable UPS05 ................................................................................................................................... 63
8.2.3.5.55. Cable UPS06 ................................................................................................................................... 64
8.2.3.5.56. Cable UPS07 ................................................................................................................................... 64
8.2.3.5.57. Cable F07........................................................................................................................................ 64
8.2.3.5.58. Cable F15........................................................................................................................................ 64
8.2.3.5.59. Cable F21........................................................................................................................................ 64
8.2.3.5.60. Cable F22........................................................................................................................................ 65
8.2.3.5.61. Cable F23........................................................................................................................................ 65
8.2.3.5.62. Cable F24........................................................................................................................................ 65
8.2.3.5.63. Cable F25........................................................................................................................................ 65
8.2.3.5.64. Cable F27........................................................................................................................................ 65
8.2.3.5.65. Cable F28........................................................................................................................................ 66
8.2.3.5.66. Cable J2701 .................................................................................................................................... 66
8.2.3.5.67. Cable J2702 .................................................................................................................................... 66
8.2.3.5.68. Cable J2703 .................................................................................................................................... 66
8.2.3.5.69. Cable L23 ........................................................................................................................................ 66
8.2.3.5.70. Cable L24 ........................................................................................................................................ 67
8.2.3.5.71. Cable L25 ........................................................................................................................................ 67
8.2.3.5.72. Cable L26 ........................................................................................................................................ 67
8.2.3.5.73. Cable L27 ........................................................................................................................................ 67
8.2.3.5.74. Cable L28 ........................................................................................................................................ 67
8.2.3.5.75. Cable L22 ........................................................................................................................................ 68
8.2.3.5.76. Cable C08 ....................................................................................................................................... 68
8.2.3.5.77. Cable C09 ....................................................................................................................................... 68
5
8.2.3.5.78. Cable C10 ....................................................................................................................................... 68

8.2.3.5.79. Cable C12 ....................................................................................................................................... 68
8.2.3.5.80. Cable C17 ....................................................................................................................................... 69
8.2.3.5.81. Cable D01 ....................................................................................................................................... 69
8.2.3.5.82. Cable D02 ....................................................................................................................................... 69
8.2.3.5.83. Cable D20 ....................................................................................................................................... 69
8.2.3.5.84. Cable D21 ....................................................................................................................................... 69
8.2.3.5.85. Cable D22 ....................................................................................................................................... 70
8.2.3.5.86. Cable D23 ....................................................................................................................................... 70
8.2.3.5.87. Cable D24 ....................................................................................................................................... 70
8.2.3.5.88. Cable D25 ....................................................................................................................................... 70
8.2.3.5.89. Cable CM1 ...................................................................................................................................... 70
8.2.3.5.90. Cable CM2 ...................................................................................................................................... 71
8.2.3.5.91. Cable F01........................................................................................................................................ 71
8.2.3.5.92. Cable F02........................................................................................................................................ 71
8.2.3.5.93. Cable F16........................................................................................................................................ 71
8.2.3.5.94. Cable F17........................................................................................................................................ 71
8.2.3.5.95. Cable F18........................................................................................................................................ 72
8.2.3.5.96. Cable F19........................................................................................................................................ 72
8.2.3.5.97. Cable F29........................................................................................................................................ 72
8.2.3.5.98. Cable F30........................................................................................................................................ 72
8.2.3.5.99. Cable F31........................................................................................................................................ 72
8.2.3.5.100. Cable F32...................................................................................................................................... 73
8.2.3.5.101. Cable F33...................................................................................................................................... 73
8.2.3.5.102. Cable F34...................................................................................................................................... 73
8.2.3.5.103. Cable F45...................................................................................................................................... 73
8.2.3.5.104. Cable CTV03 ................................................................................................................................. 73
8.2.3.5.105. Cable CTV04 ................................................................................................................................. 74
8.2.3.5.106. Cable C21 ..................................................................................................................................... 74
8.2.3.5.107. Cable F46...................................................................................................................................... 74
8.2.3.5.108. Cable F47...................................................................................................................................... 74
8.2.3.5.109. Cable J3508 .................................................................................................................................. 74
8.2.3.5.110. Cable TX01 ................................................................................................................................... 75
8.2.3.6. Earthing Installation ........................................................................................................................ 75
6
1. Revision History
Created Approved
Revision Description By Created Date Approved Date
First Issue –
0  For Client Information to support S.L. 27.02.2023 A.D. 06.04.2023
installation works
Second Issue –
 Sections 2.1.2., 2.1.4. updated.
1  Section 8.2.3.5.109 added. S.L. 16.05.2023 A.D. 16.05.2023
 Notes added to sections under
sub-section 8.2.3.1 regarding JB
assembly
Third Issue –
2  Additional table added to section S.L. 17.05.2023 A.D. 17.05.2023
2.1.4. following customer request
for additional information
Fourth Issue –
 Section 2.1.2 updated to
reference cable TX01.
 Additional drawing (343-ELE-
A613-S1) added to section 2.1.3.
 Additional installation note for
JB30 added to section 8.1.3.1.
3
 Section 8.2.1 updated to S.L. 25.05.2023 A.D. 30.05.2023
reference cable TX01.
 Section 8.2.3.5.97 updated to
reference cable F29 not F20.
 Additional section added to
section 8.2.3.5 (8.2.3.5.110)
 Additional installation notes for
PE40 to PE49 were added to
section 8.2.3.6.
7
2. Introduction
This specification covers the installation, testing and commissioning of the Electrical equipment in the following
areas at CAP Acero/Talcahuano Works, Chile.
 Existing Door Machine (South)

 New Coke Guide Cage & Hood System for South Door Machine
Work is to be performed in conjunction with manufacturer’s instructions/drawings, standard industrial practices,

and relevant codes and standards.
The Mechanical, Hydraulic and Water installation work is identified in separate documents.
The Electrical work shall be coordinated with the Mechanical, Hydraulic and Water work to provide a complete
and operational system.
Wherever conflict exists between manufacturer’s instructions/drawings, this specification, other specification, or
codes, the JMHM Site Supervisor shall be notified and shall provide a final resolution.
2.1. Project Background
John M Henderson Machines were awarded a contract by CAP Acero/Huachipato, Talcahuano Works to provide a
new emission system that incorporated a new Coke Guide Cage and replace with new the existing control system
on the Door Machines using the Best Available Technology (BAT).
The project will develop a new Coke Guide Cage c/w Hood System using BAT and a new 3rd rail structure to support
the new Hood System.
The Control System equipment will be manufactured by sub-contractors, which has been selected by JMHM. These
items will be delivered to CAP Acero/Huachipato, Talcahuano Works, where it will then be installed by a CAP
Acero/Huachipato selected sub-contractor.
8
2.1.1. Abbreviations
The following is presented to help understand the information presented within this document.
Abbreviation Definition
A Ampere
AC Alternating Current
BAT Best Available Technology
BS British Standard
CE Conformité Européene
CPU Central Processing Unit
CSS Control Systems Services
DC Direct Current
DM Door Machine
EC European Community
EN Euronorm
E-Stop Emergency Stop
GA General Arrangement Drawings
HMI Human Machine Interface
HS Hood System
Hz Hertz
I/O Input / Output
IEC International Electrotechnical Commission
ISO International Standards Organization
JMHM John M Henderson Machines
kW Kilo Watt
LT Long Travel
LAN Local Area Network
PLC Programmable Logic Controller
PSU Power Supply Unit
RA Risk Assessment
SCADA Supervisory Control and Data Acquisition
TBT Toolbox Talk
Vac Voltage Alternating Current
Vdc Voltage Direct Current
VSD Variable Speed Drive
W Watt
°C Degrees Celsius
°F Degrees Fahrenheit
Ω Ohms
9
2.1.2. JMHM Installation Reference Drawings
NOTE – Please ensure that the latest revision of drawings are used at all times.
Drawing No. Drawing Description

343-ELE-A703-S1 Cable Connection Details - J3501
343-ELE-A703-S10 Cable Connection Details - PFN01
343-ELE-A703-S26 Cable Connection Details - D05
343-ELE-A703-S32 Cable Connection Details - C11
343-ELE-A703-S43 Cable Connection Details - E01
10

343-ELE-A703-S50 Cable Connection Details - UPS01
343-ELE-A703-S57 Cable Connection Details - F07
343-ELE-A703-S69 Cable Connection Details - L23
343-ELE-A703-S89 Cable Connection Details - CM1
11

343-ELE-A703-S104 Cable Connection Details - CTV03
343-ELE-A703-S106 Cable Connection Details – C21
343-ELE-A703-S107 Cable Connection Details – F46
343-ELE-A703-S109 Cable Connection Details – J3508
343-ELE-A703-S110 Cable Connection Details – TX01
2.1.3. JMHM Engineering Reference Drawings

343-ELE-A113 Sensor List
343-ELE-A123 Motor List
343-ELE-A133 Junction Box List
343-ELE-A143 Equipment List
343-ELE-A303-S1 Interconnection Diagram
343-ELE-A353-S1 Equipment Layout
343-ELE-A363-S1 Lighting & Small Power Layout
343-ELE-A363-S2 Lighting Support Bracket
343-ELE-A373-S1 Lighting & Small Power Distribution
343-ELE-A393-S1 CCTV Configuration
343-ELE-A393-S2 CCTV Layout
343-ELE-A403-S1 Electrical Cabin Layout
343-ELE-A423-S1 Upper Hydraulic Cabin Layout
343-ELE-A423-S2 Lower Hydraulic Cabin Layout
343-ELE-A443-S1 Operator Cabin Layout
343-ELE-A453-S1 Operator Console Layout
343-ELE-A503 Cable Schedule
343-ELE-A603-S1 Machine Cable Routing
12

343-ELE-A603-S3 Machine Cable Routing – Mounting Bracket
343-ELE-A603-S7 Machine Cable Routing (BoM)
343-ELE-A613-S1 3rd Rail Earthing Routing
343-ELE-A623-S1 Electrical Cabin Cable Routing
343-ELE-A633-S1 Upper Hydraulic Cabin Cable Routing
343-ELE-A633-S2 Lower Hydraulic Cabin Cable Routing
343-ELE-A643-S1 Operator Cabin Cable Routing
343-ELE-A653-S1 Junction Box Layout (JB20)
13

343-ELE-A683-S1 SSTB Junction Box Cover
343-ELE-A683-S2 Emergency Stop Cover
343-ELE-A683-S3 Junction Box Cover for JB40
343-ELE-A693-S1 Junction Box Labels
14
2.1.4. Control System Services Reference Drawings
The control system will have been configured/assembled in accordance with the following CSS drawings:

343-ELE-A903-S1 to S2 Main Disconnecting Switch Box wiring schematic
343-ELE-A903-S3 to S7 Line In & Power Distribution Control Panel wiring schematics
343-ELE-A903-S8 to S10 Lighting & Small Power Distribution Board, 220V AC Power Distribution
343-ELE-A903-S11 to S20 Auxiliaries Control Panel wiring schematics
343-ELE-A903-S21 to S36 Long Travel Motor Control Panel wiring schematics
343-ELE-A903-S37 to S42 Control Distribution Panel Control Panel, Power Distribution
343-ELE-A903-S43 to S113 PLC Control Panel
343-ELE-A903-S114 to S140 Operators Desk
343-ELE-A903-S141 to S142 Main Disconnecting Switch Box, External General Arrangement
343-ELE-A903-S143 to S144 Line In & Power Distribution Control Panel, External General Arrangement
343-ELE-A903-S145 to S146 Auxiliaries Control Panel, External General Arrangement
343-ELE-A903-S147 to S148 Long Travel Motor Control Panel, External General Arrangement
343-ELE-A903-S149 to S150 Control Distribution Control Panel, External General Arrangement
343-ELE-A903-S151 to S152 PLC Control Panel, External General Arrangement
343-ELE-A903-S153 to S155 Operators Desk, External General Arrangement
343-ELE-A903-S156 to S157 Remote Operating Panel, External General Arrangement
343-ELE-A903-S158 to S165 Lighting/Small Power Distribution Panel, External General Arrangement
The following table is to provide a cross-reference between the JMH drawing numbers noted in the table
above and the CSS drawing numbers.
CSS Drawing CSS Sheet JMH JMH

JMH Format Document Title
Ref. No. Drawing No. Sheet No.
Main Disconnecting Switch Box, 380V AC
P3860-001 1 343-ELE-A903 1 343-ELE-A903-S1
Power Distribution
Main Disconnecting Switch Box, 380V AC
P3860-001 2 343-ELE-A903 2 343-ELE-A903-S2
Power Distribution
Line In & Power Distribution Control
P3860-001 3 343-ELE-A903 3 343-ELE-A903-S3
Panel, 380V AC Power Distribution
P3860-001 4 343-ELE-A903 4 343-ELE-A903-S4
P3860-001 5 343-ELE-A903 5 343-ELE-A903-S5
P3860-001 6 343-ELE-A903 6 343-ELE-A903-S6
P3860-001 7 343-ELE-A903 7 343-ELE-A903-S7
Lighting & Small Power Distribution
P3860-001 8 343-ELE-A903 8 343-ELE-A903-S8
Board, 220V AC Power Distribution
P3860-001 9 343-ELE-A903 9 343-ELE-A903-S9
P3860-001 10 343-ELE-A903 10 343-ELE-A903-S10
15

Auxiliaries Control Panel, 380V AC Power
P3860-001 11 343-ELE-A903 11 343-ELE-A903-S11
Distribution
P3860-001 12 343-ELE-A903 12 343-ELE-A903-S12
Distribution
P3860-001 13 343-ELE-A903 13 343-ELE-A903-S13
Distribution
P3860-001 14 343-ELE-A903 14 343-ELE-A903-S14
Distribution
P3860-001 15 343-ELE-A903 15 343-ELE-A903-S15
Distribution
P3860-001 16 343-ELE-A903 16 343-ELE-A903-S16
Distribution
Hydraulic Pumps No.1 & No.2, Panel
P3860-001 17 343-ELE-A903 17 343-ELE-A903-S17
Mount Energy Meters
Water Spray System Motors No.1 & No.2,
P3860-001 18 343-ELE-A903 18 343-ELE-A903-S18
Panel Mount Energy Meters
Door Extractor & Guide Cage Canopy,
P3860-001 19 343-ELE-A903 19 343-ELE-A903-S19
Panel Mount Energy Meters
P3860-001 20 343-ELE-A903 20 343-ELE-A903-S20
Distribution
Long Travel Motor Control Panel, 380V AC
P3860-001 21 343-ELE-A903 21 343-ELE-A903-S21
Power Distribution
P3860-001 22 343-ELE-A903 22 343-ELE-A903-S22
Power Distribution
Long Travel Motor Control Panel, Long
P3860-001 23 343-ELE-A903 23 343-ELE-A903-S23
Travel Motor No.1 VSD
P3860-001 24 343-ELE-A903 24 343-ELE-A903-S24
P3860-001 25 343-ELE-A903 25 343-ELE-A903-S25
P3860-001 26 343-ELE-A903 26 343-ELE-A903-S26
P3860-001 27 343-ELE-A903 27 343-ELE-A903-S27
Power Distribution
P3860-001 28 343-ELE-A903 28 343-ELE-A903-S28
Power Distribution
Long Travel Motor Control Panel, 24V DC
P3860-001 29 343-ELE-A903 29 343-ELE-A903-S29
Redundant Power
Long Travel Motor Control Panel, 24V DC
P3860-001 30 343-ELE-A903 30 343-ELE-A903-S30
Power Distribution
P3860-001 31 343-ELE-A903 31 343-ELE-A903-S31
Travel Motor 1 VSD Control Unit
P3860-001 32 343-ELE-A903 32 343-ELE-A903-S32
P3860-001 33 343-ELE-A903 33 343-ELE-A903-S33
P3860-001 34 343-ELE-A903 34 343-ELE-A903-S34
Long Travel Motor Control Panel, 8-Port
P3860-001 35 343-ELE-A903 35 343-ELE-A903-S35
Smart Ethernet Switch
16

P3860-001 36 343-ELE-A903 36 343-ELE-A903-S36 Blank Sheet
Control Distribution Panel Control Panel,
P3860-001 37 343-ELE-A903 37 343-ELE-A903-S37
380V AC Power Distribution
P3860-001 38 343-ELE-A903 38 343-ELE-A903-S38
P3860-001 39 343-ELE-A903 39 343-ELE-A903-S39
P3860-001 40 343-ELE-A903 40 343-ELE-A903-S40
P3860-001 41 343-ELE-A903 41 343-ELE-A903-S41
24V DC Power Distribution
PLC Control Panel, 220V AC Power
P3860-001 43 343-ELE-A903 43 343-ELE-A903-S43
Distribution
PLC Control Panel, 110V AC Power
P3860-001 44 343-ELE-A903 44 343-ELE-A903-S44
Distribution
PLC Control Panel, 24V DC Redundant
P3860-001 45 343-ELE-A903 45 343-ELE-A903-S45
Power
PLC Control Panel, 24V DC Power
P3860-001 46 343-ELE-A903 46 343-ELE-A903-S46
Distribution
PLC Control Panel, Simatic DP CPU 1512SP
P3860-001 47 343-ELE-A903 47 343-ELE-A903-S47
F-1 PN
Simatic ET 200SP Rack 0, 24V DC Digital
P3860-001 48 343-ELE-A903 48 343-ELE-A903-S48
Inputs - Slot 2
P3860-001 49 343-ELE-A903 49 343-ELE-A903-S49
Inputs - Slot 2
P3860-001 50 343-ELE-A903 50 343-ELE-A903-S50
Inputs - Slot 3
P3860-001 51 343-ELE-A903 51 343-ELE-A903-S51
Inputs - Slot 3
P3860-001 52 343-ELE-A903 52 343-ELE-A903-S52
Inputs - Slot 4
P3860-001 53 343-ELE-A903 53 343-ELE-A903-S53
Inputs - Slot 4
P3860-001 54 343-ELE-A903 54 343-ELE-A903-S54
Inputs - Slot 5
P3860-001 55 343-ELE-A903 55 343-ELE-A903-S55
Inputs - Slot 5
P3860-001 56 343-ELE-A903 56 343-ELE-A903-S56
Inputs - Slot 6
P3860-001 57 343-ELE-A903 57 343-ELE-A903-S57
Inputs - Slot 6
P3860-001 58 343-ELE-A903 58 343-ELE-A903-S58
Inputs - Slot 7
P3860-001 59 343-ELE-A903 59 343-ELE-A903-S59
Inputs - Slot 7
P3860-001 60 343-ELE-A903 60 343-ELE-A903-S60
Inputs - Slot 8
P3860-001 61 343-ELE-A903 61 343-ELE-A903-S61
Inputs - Slot 8
17

P3860-001 62 343-ELE-A903 62 343-ELE-A903-S62
Inputs - Slot 9
P3860-001 63 343-ELE-A903 63 343-ELE-A903-S63
Inputs - Slot 9
P3860-001 64 343-ELE-A903 64 343-ELE-A903-S64
Inputs - Slot 10
P3860-001 65 343-ELE-A903 65 343-ELE-A903-S65
Inputs - Slot 10
P3860-001 66 343-ELE-A903 66 343-ELE-A903-S66
Inputs - Slot 11
P3860-001 67 343-ELE-A903 67 343-ELE-A903-S67
Inputs - Slot 11
P3860-001 68 343-ELE-A903 68 343-ELE-A903-S68
Inputs - Slot 12
P3860-001 69 343-ELE-A903 69 343-ELE-A903-S69
Inputs - Slot 12
P3860-001 70 343-ELE-A903 70 343-ELE-A903-S70
Inputs - Slot 13
P3860-001 71 343-ELE-A903 71 343-ELE-A903-S71
Inputs - Slot 13
Simatic ET 200SP Rack 0, 24V DC Safety
P3860-001 72 343-ELE-A903 72 343-ELE-A903-S72
Digital Inputs - Slot 14
P3860-001 73 343-ELE-A903 73 343-ELE-A903-S73
P3860-001 74 343-ELE-A903 74 343-ELE-A903-S74
P3860-001 75 343-ELE-A903 75 343-ELE-A903-S75
P3860-001 76 343-ELE-A903 76 343-ELE-A903-S76
P3860-001 77 343-ELE-A903 77 343-ELE-A903-S77
P3860-001 78 343-ELE-A903 78 343-ELE-A903-S78
P3860-001 79 343-ELE-A903 79 343-ELE-A903-S79
P3860-001 80 343-ELE-A903 80 343-ELE-A903-S80
P3860-001 81 343-ELE-A903 81 343-ELE-A903-S81
P3860-001 82 343-ELE-A903 82 343-ELE-A903-S82
P3860-001 83 343-ELE-A903 83 343-ELE-A903-S83
P3860-001 84 343-ELE-A903 84 343-ELE-A903-S84
Outputs - Slot 20
P3860-001 85 343-ELE-A903 85 343-ELE-A903-S85
Outputs - Slot 20
P3860-001 86 343-ELE-A903 86 343-ELE-A903-S86
Outputs - Slot 21
18

P3860-001 87 343-ELE-A903 87 343-ELE-A903-S87
Outputs - Slot 21
P3860-001 88 343-ELE-A903 88 343-ELE-A903-S88
Outputs - Slot 22
P3860-001 89 343-ELE-A903 89 343-ELE-A903-S89
Outputs - Slot 22
P3860-001 90 343-ELE-A903 90 343-ELE-A903-S90
Outputs - Slot 23
P3860-001 91 343-ELE-A903 91 343-ELE-A903-S91
Outputs - Slot 23
P3860-001 92 343-ELE-A903 92 343-ELE-A903-S92
Outputs - Slot 24
P3860-001 93 343-ELE-A903 93 343-ELE-A903-S93
Outputs - Slot 24
P3860-001 94 343-ELE-A903 94 343-ELE-A903-S94
Digital Outputs - Slot 25
P3860-001 95 343-ELE-A903 95 343-ELE-A903-S95
P3860-001 96 343-ELE-A903 96 343-ELE-A903-S96
P3860-001 97 343-ELE-A903 97 343-ELE-A903-S97
P3860-001 98 343-ELE-A903 98 343-ELE-A903-S98
P3860-001 99 343-ELE-A903 99 343-ELE-A903-S99
Simatic ET 200SP Rack 0, 4-ch Analog
P3860-001 100 343-ELE-A903 100 343-ELE-A903-S100
Inputs (Current) - Slot 28
Simatic ET 200SP Rack 0, 4-ch Analog
P3860-001 101 343-ELE-A903 101 343-ELE-A903-S101
Inputs (Current) - Slot 29
PLC Control Panel, Interface Control
P3860-001 102 343-ELE-A903 102 343-ELE-A903-S102
Relays
P3860-001 103 343-ELE-A903 103 343-ELE-A903-S103
Relays
P3860-001 104 343-ELE-A903 104 343-ELE-A903-S104
Relays
P3860-001 105 343-ELE-A903 105 343-ELE-A903-S105
Relays
P3860-001 106 343-ELE-A903 106 343-ELE-A903-S106
Relays
P3860-001 107 343-ELE-A903 107 343-ELE-A903-S107
Relays
P3860-001 108 343-ELE-A903 108 343-ELE-A903-S108
Relays
P3860-001 109 343-ELE-A903 109 343-ELE-A903-S109
Relays
P3860-001 110 343-ELE-A903 110 343-ELE-A903-S110 PLC Control Panel, Safety Control Relays
P3860-001 111 343-ELE-A903 111 343-ELE-A903-S111 PLC Control Panel, Safety Control Relays
PLC Control Panel, 8-Port Smart Ethernet
P3860-001 112 343-ELE-A903 112 343-ELE-A903-S112
Switch
19

Operators Desk, 220V AC Power
P3860-001 114 343-ELE-A903 114 343-ELE-A903-S114
Distribution
Operators Desk, 110V AC Power
P3860-001 115 343-ELE-A903 115 343-ELE-A903-S115
Distribution
Operators Desk, 24V DC Power
P3860-001 116 343-ELE-A903 116 343-ELE-A903-S116
Distribution
Operators Desk, Simatic ET 200SP IM155-
P3860-001 117 343-ELE-A903 117 343-ELE-A903-S117
6PN
P3860-001 118 343-ELE-A903 118 343-ELE-A903-S118
Inputs - Slot 1
P3860-001 119 343-ELE-A903 119 343-ELE-A903-S119
Inputs - Slot 1
P3860-001 120 343-ELE-A903 120 343-ELE-A903-S120
Inputs - Slot 2
P3860-001 121 343-ELE-A903 121 343-ELE-A903-S121
Inputs - Slot 2
P3860-001 122 343-ELE-A903 122 343-ELE-A903-S122
P3860-001 123 343-ELE-A903 123 343-ELE-A903-S123
P3860-001 124 343-ELE-A903 124 343-ELE-A903-S124
P3860-001 125 343-ELE-A903 125 343-ELE-A903-S125
P3860-001 126 343-ELE-A903 126 343-ELE-A903-S126
Outputs - Slot 5
P3860-001 127 343-ELE-A903 127 343-ELE-A903-S127
Outputs - Slot 5
P3860-001 128 343-ELE-A903 128 343-ELE-A903-S128
P3860-001 129 343-ELE-A903 129 343-ELE-A903-S129
P3860-001 130 343-ELE-A903 130 343-ELE-A903-S130
P3860-001 131 343-ELE-A903 131 343-ELE-A903-S131
Operators Desk, Industrial Operator
P3860-001 132 343-ELE-A903 132 343-ELE-A903-S132
Interface HMI1
Operators Desk, 8-Port Smart Ethernet
P3860-001 133 343-ELE-A903 133 343-ELE-A903-S133
Switch
Main Disconnecting Switch Box, External
P3860-101 1 343-ELE-A903 141 343-ELE-A903-S141
General Arrangement
20

Main Disconnecting Switch Box, Internal
P3860-101 2 343-ELE-A903 142 343-ELE-A903-S142
General Arrangement
P3860-101 3 343-ELE-A903 143 343-ELE-A903-S143
Panel, External General Arrangement
P3860-101 4 343-ELE-A903 144 343-ELE-A903-S144
Panel, Internal General Arrangement
Auxiliaries Control Panel, External General
P3860-101 5 343-ELE-A903 145 343-ELE-A903-S145
Arrangement
Auxiliaries Control Panel, Internal General
P3860-101 6 343-ELE-A903 146 343-ELE-A903-S146
Arrangement
Long Travel Motor Control Panel, External
P3860-101 7 343-ELE-A903 147 343-ELE-A903-S147
General Arrangement
Long Travel Motor Control Panel, Internal
P3860-101 8 343-ELE-A903 148 343-ELE-A903-S148
General Arrangement
Control Distribution Control Panel,
P3860-101 9 343-ELE-A903 149 343-ELE-A903-S149
External General Arrangement
Control Distribution Control Panel,
P3860-101 10 343-ELE-A903 150 343-ELE-A903-S150
Internal General Arrangement
PLC Control Panel, External General
P3860-101 11 343-ELE-A903 151 343-ELE-A903-S151
Arrangement
Control Panel PLC Section, Internal
P3860-101 12 343-ELE-A903 152 343-ELE-A903-S152
General Arrangement
Operators Desk, External General
P3860-101 13 343-ELE-A903 153 343-ELE-A903-S153
Arrangement
Operators Desk, Desk Workspace
P3860-101 14 343-ELE-A903 154 343-ELE-A903-S154
Arrangement
Operators Desk, Internal General
P3860-101 15 343-ELE-A903 155 343-ELE-A903-S155
Arrangement
Remote Operating Panel, External General
P3860-101 16 343-ELE-A903 156 343-ELE-A903-S156
Arrangement
Remote Operating Panel, Internal General
P3860-101 17 343-ELE-A903 157 343-ELE-A903-S157
Arrangement
Lighting/Small Power Distribution Panel,
P3860-101 18 343-ELE-A903 158 343-ELE-A903-S158
External General Arrangement
Lighting/Small Power Distribution Panel,
P3860-101 19 343-ELE-A903 159 343-ELE-A903-S159
Internal General Arrangement
21
2.1.5. Client Reference Drawings
NOTE – The following drawings relate to the existing installation configuration and in a number of instances
have been superseded by the drawings (referred to in Section 2.1.3 and 2.1.4 above) as part of scope of work
in this project.
2.1.5.1. General

33-7431 Door Extractor Motion
33-7492 Outline Dwg. Of Tank Unit
33-7550a Conduit Piping Arrangement
33-9334 Instalcion Canalizacion de transmisores de temperature vista det.
33-9430 Single Line Diagram
33-9431 Interlocking Table
33-9432 Flow Chart
33-9433 Time Chart
33-9434 Travel Control Panel No.1 & No.2
33-9435 PLC and Relay Panel
33-9436 Arrangement of Operator’s Console
33-9437 Arrangement of Operator’s Console
33-9438 Outline Drawing of Operator’s Console
33-9439 Wiring Block Diagram
33-9440 Grounding Network
33-9441 Main Disconnecting Switch Box General Arrangement
33-9442 Auxiliary Disconnecting Switch Box General Arrangement
33-9443 Motor Control Panel General Arrangement
33-9444 Control Feeder Panel General Arrangement
33-9445 Distribution Box General Arrangement
33-9446 Local Control Box (Coke Guide Cage) General Arrangement
33-9447a Conduit Piping Plain Plan
33-9448a Conduit Piping Side Plan
33-9449 Travelling Device Conduit Argt.
33-9450 Extractor Conduit Piping Plan
33-9451 Door Cleaner Conduit Piping Plan
33-9452 D/M & G/C Connection Box
33-9454 (alumbrado) Instalaciones Electricas de Alumbrado Planta Y Secciones
2.1.5.2. Main Disconnecting Switch Box

33-2X9707 Front Sheet
33-2X9708 Cover
33-2X9709 Explanation of Schematic Diagram
33-2X9710 General Arrangement
33-2X9711 Power Circuit
33-2X9712 Terminal Schedule
33-2X9713 Back Sheet
22
2.1.5.3. Auxiliary Disconnecting Switch Box

33-2X9715 Cover
2.1.5.4. Motor Control Panel

33-2X9722 Cover
33-2X9725 Power Circuit (Sheet 1)
33-2X9728 Power Circuit Materials
33-2X9729 Control Circuit (Sheet 1)
33-2X9734 Output Circuit (Sheet 1)
33-2X9735 Output Circuit (Sheet 2)
33-2X9736 Terminal Schedule (Sheet 1)
2.1.5.5. Control Feeder Panel

33-2X9740 Cover
33-2X9745a Power Circuit (Sheet 3)
33-2X9746a Terminal Schedule
23
2.1.5.6. Local Control Box

33-2X9749 Cover
33-2X9751 Local Control Box (Coke Guide Cage) General
Arrangement
33-2X9752 Local Control Box Control Circuit
33-2X9757 Cover
33-2X9759 Local Control Box Outline
33-2X9760 Local Control Box Control Circuit
2.1.5.7. Distribution Box

33-2X9786 Cover
33-2X9788 Distribution Box General Arrangement
24
2.1.5.8. PLC & Relay Panel

33-2X9793 Cover
33-2X9794 Cover
33-2X9796 PLC and Relay Panel General Arrangement
33-2X9797 Main Circuit (Sheet 1)
33-2X9799 Tosline Allocation
33-2X9818 Solenoid Circuit (Sheet 1)
33-2X9824 Interface (Sheet 1)
25
2.1.5.9. Operation Consol

33-2X9831 Cover
33-2X9832 Cover
33-2X9834 Arrangement of Operators Console
33-2X9835 Arrangement of Operators Console
33-2X9836 Outline Drawing of Operators Console
33-2X9840 Computer Link Module Switch Setting Method
26
2.1.5.10. Lubrication Panel

33-2X9867 Electric Control Panel
33-2X9868 Equipment
33-2X9869 Sequence Diagram
33-2X9870 External Wiring
33-2X9871 Instruction Manual (Sheet 1)
33-2X9872 Instruction Manual (Sheet 2)
2.1.5.11. Cooler Heater Panel

33-2X9874 Wiring Diagram
33-2X9875 Switch Panel for SC15EYE Dimensions
33-2X9876 Wiring Diagram
33-2X9877 Switch Panel for SC8JYE Dimensions
33-2X9878 Digital Printer Arrangement
2.1.5.12. Interface List

33-2X9879 Interface List Front Sheet
33-2X9880 Cover
27
2.1.5.13. PLC System

33-2X9957 PLC System Front Sheet
33-2X9958 PLC System
33-2X9960 PLC #1 I/O Modules
33-2X9963 Tosline Address Front Sheet
33-2X9964 PLC #2 Tosline Address (5 sheets)
33-2X9965 PLC #3 Tosline Address (5 sheets)
33-2X9966 Timer List Front Sheet
33-2X9967 PLC #2 Timer List (5 sheets)
33-2X9968 PLC #3 Timer List (5 sheets)
33-2X9969 Digital Printer Message List Front Sheet
33-2X9970 Message List (10 sheets)
33-2X9971 Detail Flow Chart (PLC #1) Front Sheet
33-2X9972 Contents (2 sheets)
33-2X9973 Door Extractor Flow (15 sheets)
33-2X9974 Coke Guide Way flow (5 sheets)
33-2X9975 Door Cleaner Flow (16 sheets)
33-2X9976 Jamb Cleaner Flow (6 sheets)
33-2X9977 Spilled Coke & Coal Flow (2 sheets)
33-2X9978 Block Auto. Mode Flow (20 sheets)
33-2X9979 Mode Auto/Manual Flow (15 sheets)
33-2X9980 Operation Module Flow (2 sheets)
33-2X9981 Detail Flow Chart (PLC #2,3) Front Sheet
33-2X9982 Contents
33-2X9983 Door Extractor Flow (25 sheets)
33-2X9984 Coke Guide Way Flow (10 sheets)
33-2X9985 Door Cleaner Flow (37 sheets)
33-2X9986 Jamb Cleaner Flow (10 sheets)
33-2X9987 Spilled Coke & Coal Flow (4 sheets)
2.1.5.14. List Motor-Sensor

33-2X9953 Motor List (3 sheets)
33-2X9954 Sensor List (8 sheets)
33-2X9955 Solenoid Valve List (4 sheets)
33-2X9956 Cable List (10 sheets)
28
2.1.5.15. Travel Control Panel

33-2X9762 Cover
33-2X9763 Cover
33-2X9779 Timer Unit Program (Sheet 1)
29
3. Standards
The design and supply of all equipment within this Agreement shall be compliant with CAP Acero Standards,
British, European and ISO Engineering Standards as listed. JMHM design Coke Oven Machines based on
considerable experience. The system and associated equipment will be compliant to the following standards.
3.1. Client Standards
Standard Description
NO-90-019_13222-1-Anexo 7.1 ESP 1-5, Index Index
NO-90-019_13222-2-Anexo 7.2 ESP 1-5
General Electrical Specification
Resumen
NO-90-019_13222-3-Anexo 7.3 ESP 1-5
General Electrical Specification
Summary
NO-90-019_13222-4-Anexo 7.4 ESP 1-5-A General Electrical Specification
NO-90-019_13222-5-Anexo 7.5 ESP 1-5-B Equipment and Installation
NO-90-019_13222-6-Anexo 7.6 ESP 1-5-C Tests and Checks
NO-90-019_13222-7-Anexo 7.7 ESP 1-5-D Automation and Process Control
NO-90-019_13222-8-Anexo 7.8 ESP 1-5-E Electrical Construction Engineering I Design Guidelines
NO-90-019_13222-9-Anexo 7.9 ESP 1-5-F Electrical Construction Engineering II Specific Requirements
NO-90-019_N1@13222 Especificaciones
Electrical Technical Specifications
Tecnicas Electricas
NO-90-019_N1@13222 Electrical Technical Specifications
30
3.2. British, European, International Standards and Regulations
All equipment designed, manufactured, tested, installed, and commissioned shall comply with UK
Legislation and shall be in accordance with all relevant British, European and International Standards that
are applicable and including those that are specifically listed below. The standards shall be the latest issue,
including all parts, revisions, and addenda current at the date of contract.
Directive 2006/42/EC Machinery Directive
Directive 2014/30/EU EMC Directive
Directive 2014/35/EU Low Voltage Directive (LVD)
EN 614 Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles
Mechanical vibration and shock. Vibration isolation of Machines. Information for the
EN 1299
application of source isolation
Hydraulic fluid power — General rules and safety requirements for systems and their
ISO 4413
components
Pneumatic fluid power — General rules and safety requirements for systems and their
ISO 4414
components
BS 5424-3 Specification for Control Gear – contactors
BS 7671 IEE 18th Edition Requirements for Electrical Installations.
Ergonomic requirements for the design of displays and control actuators — Part 1: Human
ISO 9355-1
interactions with displays and control actuators
Ergonomic requirements for the design of displays and control actuators — Part 3: Control
ISO 9355-3
actuators
Ergonomic principles related to mental workload – Part 1: General issues and concepts, terms,
ISO 10075-1
and definitions
ISO 10075-2 Ergonomic principles related to mental workload – Part 2: Design Principles
ISO 12100 Safety of machinery. General principles for design. Risk assessment and risk reduction.
Ergonomics of the thermal environment. Methods for the assessment of human responses to
ISO 13732-1
contact with surfaces – Hot surfaces.
ISO 13849 Safety of machinery. Safety related parts of control systems. General principles for design
ISO 13850 Safety of Machinery. Emergency stop. Principles for design
ISO 14118 Safety of machinery – Prevention of unexpected start-up
Safety of machinery. Interlocking devices associated with guards. Principles for design and
ISO 14119
selection
Safety of machinery. Guards. General requirements for the design and construction of fixed
ISO 14120
and movable guards
ISO 14163 Acoustics — Guidelines for noise control by silencers
ISO 15667 Acoustics — Guidelines for noise control by enclosures and cabins
IEC 60038 IEC Standard Voltages
IEC 60059 IEC standard current ratings
IEC 60076 Power Transformers
IEC 60085 Electrical Insulation – Thermal evaluation and designation
IEC 60196 IEC standard frequencies
IEC 60204 Safety of machinery. Electrical equipment of machines – ALL PARTS
IEC 60228 Conductors of insulated cables.
Safety of machinery - Indication, marking and actuation - Part 1: Requirements for visual,
IEC 61310-1
acoustic, and tactile signals
Safety of machinery - Indication, marking and actuation - Part 3: Requirements for the
IEC 61310-3
location and operation of actuators
IEC 60331 Tests for electric cables under fire conditions – Circuit integrity
IEC 60332 Tests on electric and optical fibre cables under fire conditions - ALL PARTS
IEC 60364 Low-voltage electrical installations
31
Basic and safety principles for man-machine interface, marking and identification -
IEC 60445
Identification of equipment terminals and conductor terminations.
Basic and safety principles for man-machine interface, marking and identification – Actuating
IEC 60447
principles
IEC 60529 Degrees of protection provided by enclosures (IP Code).
IEC 60947-1 Low-voltage switchgear and control gear
BS EN 60947-2 Low-voltage switchgear and control gear – Circuit-breakers
Low-voltage switchgear and control gear – Switches, disconnectors, switch-disconnectors, and
BS EN 60947-3
fuse-combination units
Low-voltage switchgear and control gear – Contactors and motor-starters. Electromechanical
BS EN IEC 60947-4-1
contactors and motor-starters
Low-voltage switchgear and control gear – Contactors and motor-starters. AC semiconductor
BS EN 60947-4-2
motor controllers and starters.
Low-voltage switchgear and control gear – Control circuit devices and switching elements.
BS EN 60947-5-1
Electromechanical control circuit devices
Low-voltage switchgear and control gear – Multiple function equipment. Transfer switching
BS EN 60947-6-1
equipment
Low-voltage switchgear and control gear - Multiple function equipment. Control and
BS EN 60947-6-2
protective switching devices (or equipment) (CPS)
BS EN 60950-22 Information technology equipment. Safety – Equipment to be installed outdoors
IEC 61000 Electromagnetic Compatibility
IEC 61131 Industrial-process measurement and control – Programmable controllers
IEC 61158 Industrial communication networks – Fieldbus specifications
IEC 61310 Safety of machinery – Indication, marking and actuation
IEC 61347 Lamp control gear
IEC 61439 Low-voltage switchgear and control gear assemblies
IEC 61508 Functional safety of electrical/electronic/programmable electronic safety-related systems
IEC 61511 Functional safety – safety instrumented systems for the process industry sector
IEC 61537 Cable management. Cable tray systems and cable ladder systems.
IEC 61558 Safety of power transformers, power supplies, reactors, and similar products
IEC 61643 Low-voltage surge protective devices
IEC 61926 Design automation
IEC 62040 Uninterruptible power systems (UPS)
IEC 62041 Transformers, power supplies, reactors, and similar products – EMC requirements
Safety of machinery: Functional safety of electrical, electronic, and programmable electronic
IEC 62061
control systems
ISO 7010 Graphical symbols. Safety colours and safety signs. Registered safety signs
PD 5304 Guidance on safe use of machinery
32
4. General Requirements
 The Contractor shall provide labour, equipment, materials, tools, and supplies unless specifically noted as being
provided by others, to perform the work described herein in accordance with this document and the referenced
specification, drawings, and related documents. Work not specifically shown on the drawings or enumerated herein,
but that is reasonably necessary for the proper completion of the contract shall be provided by the Contractor the
same as if shown on the drawings or enumerated herein.
 The electrical equipment shall be installed in accordance with all the applicable codes, standards, rules, regulations,
and laws including, but not limited to, the codes and standards referenced in Section 3 of this specification.
 The Contractor shall provide means of unloading equipment and materials when they arrive On-site.
 The Contractor will be responsible for the storage of all equipment and materials ‘free issued’ by JMHM / CAP.
 The Contractor will be responsible for loading and transporting equipment and materials from the storage area to
the installation location.
 Install all the equipment shown on the drawings or as noted in other contract documents.
 All materials and equipment furnished by the Contractor shall be in accordance with the specifications. Substitution
of any materials deviating from the specifications and drawings shall be approved in writing by JMHM. A description
of Contractor supplied substituted material shall be submitted to JMHM for approval.
 All materials and equipment ‘free issued’ by JMHM / CAP shall be handled with care.
 The Contractor will be responsible for any material or equipment that is ‘free issued’ by JMHM that is subsequently
lost or damaged.
 The Contractor will be responsible for completing site Risk Assessments in compliance with CAP working practices
prior to commencing any work.
33
5. Installation Requirements
 The Contractor shall read and understand the manufacturers installation requirements prior to beginning the
installation of the equipment.
 Before installation, area should be blown down with compressed air to rid of excess coke dust.
 Bolts and screws shall be tightened uniformly without overstressing the threads.
 On-site alterations to equipment to facilitate installation shall not be made without written approval from JMHM.
Sub-assemblies shall be dismantled only to the extent necessary to verify clearances and equipment condition. Total
dismantle of the sub-assemblies, if necessary, shall be carried out only with written approval from JMHM.
 Welding shall not be performed in the proximity of bearings. Grounding for welding shall not be through the shaft
or bearing.
 It will be the Contractors responsibility to do touch up painting on all finished surfaces damaged or abraded during
installation or left unpainted for on-site welding. Contractor shall prepare the surface by removing all oil, dirt, scale,
rust, and damaged paint and shall feather edge breaks in existing paint. Contractor shall furnish and apply the
materials including primer and paint needed to properly restore the damaged surface coating.
34
6. Safety
6.1. Risk Assessment
Prior to the Installation work commencing, a Risk Assessment should have been conducted in accordance with
BS EN ISO 12100 and where hazards have been identified appropriate measures have been implemented to
allow the testing to be carried out in a safe environment.
6.2. Toolbox Talk
It is important that the workforce involved has the required skills and training to competently perform their
tasks in a healthy, safe, and environmentally sound manner.
Toolbox talks are an effective means of increasing the knowledge of workers on the HSE risks they face, and
the precautions required, when carrying out the installation work. They also encourage and reinforce safe,
healthy, and environmentally sound behaviours.
The TBT should include, but not be limited to the following:
1. Description of the work task:

1.1. The hazards associated with that work.
1.2. Precautions needed to do the job safely and correctly.
2. Keep a record of the people who attended.
35
7. Scope of Work & Supply (Disassembly)
7.1. Pre-Work
As part of the scope of the project, the existing Toshiba control systems that are currently installed on the
South Door Machine is being replaced with a completely new Siemens control system.
Before removal of the existing enclosures, and to assist with a smoother installation it is highly recommended
that the existing cable installation on both machines is traced and marked up accordingly (especially at the
control panel end). It is recommended that this work is carried out in advance of the Disassembly/Assembly
work commencing to avoid any potential delays during this period.
The following reference file should be used during this process as it relates to the original installation:

33-2X9956 Cable List (10 sheets)
However, to align with the new configuration that will be installed the following reference file should be used
to identify the cables ready for the installation of the new control system enclosures:

NOTE: Please ensure the latest revision of the new Cable Schedule (343-ELE-A503) is used during this process
to avoid any potential issues at a later stage.
7.2. Disassembly
All field cables shall be disconnected and suitably protected to avoid damage during the removal of the
control system enclosures.
Once all field cables are disconnected, any interconnections between the control panel sections should be
removed to assist with the removal process. Once confirmed that any interconnections have been removed
the process of removing each enclosure section can begin.
Due to the weight of the panels, it would be recommended to remove the back plates of all the enclosures to
reduce the weight of the enclosures.
Once the back plates have been removed all the enclosures can now be removed but ensure that any
equipment not being removed in the surrounding area within the cabins is not damaged during the removal
process.
NOTE: Please ensure suitable lifting equipment is used during to removal process and ensure that everyone
knows where the old equipment is being removed to.
36
8. Scope of Work & Supply (Installation)
8.1. Control System Enclosures
To install the new control system enclosures, the following drawings are to be used: -

343-ELE-A453-S1 Operator Console Layout
37
8.1.2. Control System Services Reference Drawings
The control system will have been configured/assembled in accordance with the following CSS drawings:

343-ELE-A903-S1 to S2 Main Disconnecting Switch Box wiring schematic
343-ELE-A903-S3 to S7 Line In & Power Distribution Control Panel wiring schematics
343-ELE-A903-S8 to S10 Lighting & Small Power Distribution Board, 220V AC Power Distribution
343-ELE-A903-S11 to S20 Auxiliaries Control Panel wiring schematics
343-ELE-A903-S21 to S36 Long Travel Motor Control Panel wiring schematics
343-ELE-A903-S37 to S42 Control Distribution Panel Control Panel, Power Distribution
343-ELE-A903-S43 to S113 PLC Control Panel
343-ELE-A903-S114 to S140 Operators Desk
343-ELE-A903-S141 to S142 Main Disconnecting Switch Box, External General Arrangement
343-ELE-A903-S143 to S144 Line In & Power Distribution Control Panel, External General Arrangement
343-ELE-A903-S145 to S146 Auxiliaries Control Panel, External General Arrangement
343-ELE-A903-S147 to S148 Long Travel Motor Control Panel, External General Arrangement
343-ELE-A903-S149 to S150 Control Distribution Control Panel, External General Arrangement
343-ELE-A903-S151 to S152 PLC Control Panel, External General Arrangement
343-ELE-A903-S153 to S155 Operators Desk, External General Arrangement
343-ELE-A903-S156 to S157 Remote Operating Panel, External General Arrangement
343-ELE-A903-S158 to S165 Lighting/Small Power Distribution Panel, External General Arrangement
38
8.1.3. Installation
8.1.3.1. Enclosures
1. Install each enclosure section for the electrical cabin in accordance with drawing 343-ELE-A403-S1
2. Install each enclosure section & operators’ desk for the operator cabin in accordance with drawing 343-ELE-
A443-S1.
3. Install JB30 enclosure labelled ‘Estación de control Local’ into the area behind the door located outside the
lower hydraulic cabin (see photo for reference).
4. Once each of the enclosure sections are installed into the respective cabins, all the cabling that was removed
during the process noted in Section 7.2 should be installed into the panels. The drawings referenced in Sections
8.1.1. & 8.1.2. should be utilised for this stage of the installation.
5. Work Complete.
39
8.2. Wet Scrub & Coke Guide Cage Installation
To install the equipment on the new machine, the following drawings are to be used: -
8.2.1. JMHM Installation Reference Drawings

40

41

343-ELE-A703-S106 Cable Connection Details – C21
343-ELE-A703-S109 Cable Connection Details – J3508
343-ELE-A703-S110 Cable Connection Details – TX01

343-ELE-A133 Junction Box List
343-ELE-A143 Equipment List
343-ELE-A353-S1 Equipment Layout
343-ELE-A363-S1 Lighting & Small Power Layout
343-ELE-A373-S1 Lighting & Small Power Distribution
343-ELE-A393-S1 CCTV Configuration
343-ELE-A393-S2 CCTV Layout
42

343-ELE-A603-S7 Machine Cable Routing (BoM)
43

343-ELE-A683-S1 SSTB Junction Box Cover
343-ELE-A683-S2 Emergency Stop Cover
343-ELE-A683-S3 Junction Box Cover for JB40
44
8.2.3. Installation Steps
8.2.3.1. Junction Box Assemblies
8.2.3.1.1. JB20 Assembly
NOTE: Points 1 to 3 have been completed in the UK.
1. Assemble (free issued) components for JB20 (North End Machine Devices JB) in accordance with drawings 343-
ELE-A653-S1 to 343-ELE-A653-S5.
2. Attach enclosure label to enclosure lid (Refer to drawing 343-ELE-A693-S1 for specific label).
3. Prepare gland entries for JB in accordance with drawing 343-ELE-A653-S3.
4. Work Complete.
1. Assemble (free issued) components for JB21 (South End Machine Devices JB) in accordance with drawings 343-
ELE-A653-S6 to 343-ELE-A653-S10.
4. Work Complete.
1. Assemble (free issued) components for JB22 (Long Travel No.3 JB) in accordance with drawings 343-ELE-A653-
S11 to 343-ELE-A653-S15.
4. Work Complete.
NOTE: Points 1 to 3 have been completed in the UK but point 4 is required to be completed on site.
1. Assemble (free issued) components for JB23 (Long Travel No.3 Encoder JB) in accordance with drawings 343-
ELE-A653-S16 to 343-ELE-A653-S20.
4. Mount enclosure into SSTB Junction Box Cover (Refer to drawing 343-ELE-A683-S1) in preparation for mounting
onto the machine.
5. Work Complete.
45
1. Assemble (free issued) components for JB24 (Long Travel No.4 JB) in accordance with drawings 343-ELE-A653-
S21 to 343-ELE-A653-S25.
4. Work Complete.
ELE-A653-S26 to 343-ELE-A653-S30.
onto the machine.
5. Work Complete.
1. Assemble (free issued) components for JB27 (Water Sprayer System Water Tank JB) in accordance with drawings
343-ELE-A653-S31 to 343-ELE-A653-S35.
4. Work Complete.
1. Assemble (free issued) components for JB31 (Machine Lighting – LF16 JB) in accordance with drawings 343-ELE-
A653-S36 to 343-ELE-A653-S40.
onto the machine.
5. Work Complete.
46
1. Assemble (free issued) components for JB32 (Machine Lighting – LF17 & LF18 JB) in accordance with drawings
343-ELE-A653-S41 to 343-ELE-A653-S45.
onto the machine.
5. Work Complete.
1. Assemble (free issued) components for JB33 (Machine Lighting – LF19 & LF20 JB) in accordance with drawings
343-ELE-A653-S46 to 343-ELE-A653-S50.
onto the machine.
5. Work Complete.
1. Assemble (free issued) components for JB34 (Machine Lighting – LF21 JB) in accordance with drawings 343-ELE-
A653-S51 to 343-ELE-A653-S55.
onto the machine.
5. Work Complete.
1. Assemble (free issued) components for JB35 (Coke Guide Cage JB) in accordance with drawings 343-ELE-A653-
S56 to 343-ELE-A653-S60.
4. Work Complete.
47
1. Assemble (free issued) components for JB40 (Hood Interface JB) in accordance with drawings 343-ELE-A653-
S61 to 343-ELE-A653-S65.
4. Mount enclosure into Junction Box Cover for JB40 (Refer to drawing 343-ELE-A683-S3) in preparation for
mounting onto the machine.
5. Work Complete.
ELE-A653-S66 to 343-ELE-A653-S70.
onto the machine.
5. Work Complete.
ELE-A653-S71 to 343-ELE-A653-S75.
onto the machine.
5. Work Complete.
8.2.3.2. Emergency Stop Assembly
1. Mount Emergency stop stations (free issued) into Emergency Stop covers (Refer to drawing 343-ELE-A683-S2)
in preparation for mounting onto the machine.
2. Work Complete.
48
8.2.3.3. Light Support Assembly
1. Assemble (free issued) components for Light Support Brackets (4 off) in accordance with drawings 343-ELE-
A363-S2. NOTE: The brackets shall be supplied from CAP as part of the manufacture supply.
2. Assemble (free issued) components for Light Support Brackets (1 off) in accordance with drawings 343-ELE-
A363-S3. NOTE: The brackets shall be supplied from CAP as part of the manufacture supply.
3. Attach Floodlight (5 off) assembly (reference on drawing 343-ELE-A363-S1) to the support assemblies that were
assembled in points 1 & 2.
4. Attach JB31 Assembly (referenced in section 8.2.3.1.8) to one of the Light Support Assembly referenced in point
1, in preparation for mounting onto the machine.
5. Attach JB32 Assembly (referenced in section 8.2.3.1.9) to one of the Light Support Assembly referenced in point
1, in preparation for mounting onto the machine.
6. Attach JB33 Assembly (referenced in section 8.2.3.1.10) to one of the Light Support Assembly referenced in
point 1, in preparation for mounting onto the machine.
7. Attach JB34 Assembly (referenced in section 8.2.3.1.11) to one of the Light Support Assembly referenced in
point 1, in preparation for mounting onto the machine.
8. Work Complete.
49
8.2.3.4. General Machine Preparation
Note: The following details are in accordance with drawings 343-ELE-A353-S1, 343-ELE-A363-S1, 343-ELE-A393-S2,
343-ELE-A603-S1 to S7, 343-ELE-A623-S1 & 343-ELE-A643-S1 along with 343-ELE-A503.
8.2.3.4.1. 3 Phase Related Devices Installation
NOTE: The following steps should only be carried out if the devices haven’t already been installed by others and
should only be carried out when safe to do so.
1. Please utilise 343-ELE-A123 to assist with the following points.

2. Utilising drawing 343-BOG-S300-S1, install the Long Travel No.3 (Guide Cage) motor (GC01).
3. Utilising drawing 343-BOG-S400-S1, install the Long Travel No.4 (Hood System – 3rd Rail) motor (HS01).
4. Utilising drawing 343-LPW-A002-S1, install the Water Spray System Pump Motor No.1 (HS02-1).
5. Utilising drawing 343-LPW-A002-S1, install the Water Spray System Pump Motor No.2 (HS02-2).
6. Utilising drawing 343-SHS-S500-S1, install the Door Extractor Canopy Suction Fan Motor (HS03-1).
7. Utilising drawing 343-SHS-S400-S1, install the Guide Cage Canopy Suction Fan Motor (HS03-2).
8. Utilising drawing 343-LPW-A002-S1, install the Hose Reel Drive Motor No.1 (HS04-1).
9. Utilising drawing 343-LPW-A002-S1, install the Hose Reel Drive Motor No.2 (HS04-2).
10. Utilising drawing 343-LPW-A002-S1, install the Water Tank Heater (HS05-H).
11. Utilising drawing 376-BOG-A001-S1, install the Long Travel No.1 (Door Machine South) motor (DM01).
12. Utilising drawing 376-BOG-A001-S1, install the Long Travel No.2 (Door Machine North) motor (DM02).
13. Work Complete.
8.2.3.4.2. Sensor Installation
NOTE: The following steps should only be carried out if the devices haven’t already been installed by others and
should only be carried out when safe to do so.

2. Utilising drawing 343-CGC-A001-S2, install the Guide Cage Travel (Retract) limit sensor (LS301A).
3. Utilising drawing 343-CGC-A001-S2, install the Guide Cage Travel (Extend) limit sensor (LS301B).
4. Utilising drawing 343-CLD-S100L-S1, install the Guide Cage Lock (North) Retract limit sensor (LS302A).
5. Utilising drawing 343-CLD-S100R-S1, install the Guide Cage Lock (South) Retract limit sensor (LS302C).
6. Utilising drawing 343-LPW-0011-S1, install the Water Pumps Low Pressure Shutdown Pressure Switch (PS011).
7. Utilising drawings 343-LPW-A002-S1 & 343-LPW-A004-S1, install the Water Tank Low Level Shutdown Pressure
Switch (PS010).
8. Utilising drawings 343-LPW-A002-S1 & 343-LPW-A004-S1, install the Water System Level Sensor (LV010).
NOTE: Care should be taken when installing this device to avoid damage to the probe.
9. Utilising drawing 343-STR-9050-S1, install the Travel End Switch (LS110).
10. Work Complete.
50
8.2.3.4.3. Cable Tray & JB Installation
NOTE: The following steps should only be carried out when safe to do so.
1. Please utilise 343-ELE-A603-S1 to 343-ELE-A603-S7 to assist with the following points.

2. Utilising drawings 343-ELE-A603-S1 & 343-ELE-A603-S7, install the support brackets shown on drawing 343-
ELE-A603-S3 – To be ‘free issued’ by CAP.
6. Utilising drawings 343-ELE-A603-S1, 343-ELE-A603-S2 & 343-ELE-A603-S7, prepare and install the Unistrut
supports that will be required for the junction boxes and Emergency Stop.
7. Utilising drawings 343-ELE-A353-S1, 343-ELE-A363-S1 & 343-ELE-A603-S1, install the Light Support Assemblies
that were prepared in Section 8.2.3.3.
8. Utilising drawings 343-ELE-A353-S1 & 343-ELE-A603-S1, install the Emergency Stop Assembly for ES2 that was
prepared in Section 8.2.3.2, using 4 off M6 x 30mm bolts, flat washers, and spring washers.
prepared in Section 8.2.3.2, using 4 off M6 channel nut with 4 off M6 x 30mm bolts, flat washers, and spring
washers.
washers.
washers.
washers.
washers.
washers.
51
21. Utilising drawings 343-ELE-A353-S1 & 343-ELE-A603-S1, install the Junction Box Assembly for JB20 that was
prepared in Section 8.2.3.1.1., using 4 off M8 channel nut with 4 off M8 x 30mm bolts, flat washers, and spring
washers.
washers.
washers.
washers.
washers.
washers.
washers.
washers.
prepared in Section 8.2.3.1.13., using 4 off M10 channel nut with 4 off M10 x 30mm bolts, flat washers, and
spring washers.
washers.
washers.
32. Utilising drawing 343-ELE-A623-S1, prepare and install the cable tray lengths in accordance with the drawings,
using M6 x 16mm roofing bolt & nut.
33. Utilising drawing 343-ELE-A643-S1, prepare and install the cable tray lengths in accordance with the drawings,
using M6 x 16mm roofing bolt & nut.
34. Utilising drawings 343-ELE-A603-S1, 343-ELE-A603-S2 & 343-ELE-A603-S7, prepare the cable tray lengths in
accordance with the drawings.
35. Mount cable tray to suit cable routing as shown on drawings 343-ELE-A603-S1 & 343-ELE-A603-S2 using M6 x
16mm roofing bolt & nut (referenced on drawing 343-ELE-A603-S7).
36. Couplers should be used to join each section of cable tray to create one full structure.
37. For cable separation within the cable tray, dividers should be installed throughout the installation.
38. Earth braids shall be installed at each join of cable tray.
39. Any Bracketry and support clamps that are not stated within the reference drawings or any other relevant
documentation are in the supplier’s scope of supply.
40. Work Complete.
52
8.2.3.5. Cable Installation
Note: The following details are in accordance with drawings 343-ELE-A703-S1 to 343-ELE-A703-A703-S110.
8.2.3.5.1. Cable J3501
1. Prepare and install Cable J3501 utilising drawing 343-ELE-A703-S1.

documentation are in the installer’s scope of supply.
3. Ensure all cable glands are protected with a cable shroud.
4. Carry out Cable Insulation tests on new cables.
5. Provide initial commissioning support.
6. Work Complete.
8.2.3.5.2. Cable J3502

6. Work Complete.
8.2.3.5.3. Cable J3503

6. Work Complete.
8.2.3.5.4. Cable J3505

6. Work Complete.
53
8.2.3.5.5. Cable J3507

6. Work Complete.
8.2.3.5.6. Cable J5001

6. Work Complete.
8.2.3.5.7. Cable J5101

6. Work Complete.
8.2.3.5.8. Cable J2301

6. Work Complete.
8.2.3.5.9. Cable J2501

6. Work Complete.
54
8.2.3.5.10. Cable PFN01
1. Prepare and install Cable PFN01 utilising drawing 343-ELE-A703-S10.

6. Work Complete.
8.2.3.5.11. Cable PFN02
1. Prepare and install Cable PFN02 utilising drawing 343-ELE-A703-S11.

6. Work Complete.
8.2.3.5.12. Cable J2001

6. Work Complete.
8.2.3.5.13. Cable J2002

6. Work Complete.
8.2.3.5.14. Cable J2004

6. Work Complete.
55
8.2.3.5.15. Cable J2005

6. Work Complete.
8.2.3.5.16. Cable J2007

6. Work Complete.
8.2.3.5.17. Cable J2008

6. Work Complete.
8.2.3.5.18. Cable J2105

6. Work Complete.
8.2.3.5.19. Cable J2107

6. Work Complete.
56
8.2.3.5.20. Cable J2108

6. Work Complete.
8.2.3.5.21. Cable J2201

6. Work Complete.
8.2.3.5.22. Cable J2204

6. Work Complete.
8.2.3.5.23. Cable J2401

6. Work Complete.
8.2.3.5.24. Cable J2404

6. Work Complete.
57
8.2.3.5.25. Cable J2405

6. Work Complete.
8.2.3.5.26. Cable D05
1. Prepare and install Cable D05 utilising drawing 343-ELE-A703-S26.

6. Work Complete.
8.2.3.5.27. Cable D06

6. Work Complete.
8.2.3.5.28. Cable D10

6. Work Complete.
8.2.3.5.29. Cable D11

6. Work Complete.
58
8.2.3.5.30. Cable D18

6. Work Complete.
8.2.3.5.31. Cable D19

6. Work Complete.
8.2.3.5.32. Cable C11
1. Prepare and install Cable C11 utilising drawing 343-ELE-A703-S32.

6. Work Complete.
8.2.3.5.33. Cable C20

6. Work Complete.
8.2.3.5.34. Cable D13

6. Work Complete.
59
8.2.3.5.35. Cable D14

6. Work Complete.
8.2.3.5.36. Cable D15

6. Work Complete.
8.2.3.5.37. Cable D16

6. Work Complete.
8.2.3.5.38. Cable D26

6. Work Complete.
8.2.3.5.39. Cable D27

6. Work Complete.
60
8.2.3.5.40. Cable D28

6. Work Complete.
8.2.3.5.41. Cable D29

6. Work Complete.
8.2.3.5.42. Cable D40

6. Work Complete.
8.2.3.5.43. Cable E01
1. Prepare and install Cable E01 utilising drawing 343-ELE-A703-S43.

6. Work Complete.
8.2.3.5.44. Cable E02

6. Work Complete.
61
8.2.3.5.45. Cable E03

6. Work Complete.
8.2.3.5.46. Cable E15

6. Work Complete.
8.2.3.5.47. Cable E16

6. Work Complete.
8.2.3.5.48. Cable E17

6. Work Complete.
8.2.3.5.49. Cable E18

6. Work Complete.
62
8.2.3.5.50. Cable UPS01
1. Prepare and install Cable UPS01 utilising drawing 343-ELE-A703-S50.

6. Work Complete.
8.2.3.5.51. Cable UPS02

6. Work Complete.
8.2.3.5.52. Cable UPS03

6. Work Complete.
8.2.3.5.53. Cable UPS04

6. Work Complete.
8.2.3.5.54. Cable UPS05

6. Work Complete.
63
8.2.3.5.55. Cable UPS06

6. Work Complete.
8.2.3.5.56. Cable UPS07

6. Work Complete.
8.2.3.5.57. Cable F07
1. Prepare and install Cable F07 utilising drawing 343-ELE-A703-S57.

6. Work Complete.
8.2.3.5.58. Cable F15

6. Work Complete.
8.2.3.5.59. Cable F21

6. Work Complete.
64
8.2.3.5.60. Cable F22

6. Work Complete.
8.2.3.5.61. Cable F23

6. Work Complete.
8.2.3.5.62. Cable F24

6. Work Complete.
8.2.3.5.63. Cable F25

6. Work Complete.
8.2.3.5.64. Cable F27

6. Work Complete.
65
8.2.3.5.65. Cable F28

6. Work Complete.
8.2.3.5.66. Cable J2701

6. Work Complete.
8.2.3.5.67. Cable J2702

6. Work Complete.
8.2.3.5.68. Cable J2703

6. Work Complete.
8.2.3.5.69. Cable L23
1. Prepare and install Cable L23 utilising drawing 343-ELE-A703-S69.

6. Work Complete.
66
8.2.3.5.70. Cable L24

6. Work Complete.
8.2.3.5.71. Cable L25

6. Work Complete.
8.2.3.5.72. Cable L26

6. Work Complete.
8.2.3.5.73. Cable L27

6. Work Complete.
8.2.3.5.74. Cable L28

6. Work Complete.
67
8.2.3.5.75. Cable L22

6. Work Complete.
8.2.3.5.76. Cable C08

6. Work Complete.
8.2.3.5.77. Cable C09

6. Work Complete.
8.2.3.5.78. Cable C10

6. Work Complete.
8.2.3.5.79. Cable C12

6. Work Complete.
68
8.2.3.5.80. Cable C17

6. Work Complete.
8.2.3.5.81. Cable D01

6. Work Complete.
8.2.3.5.82. Cable D02

6. Work Complete.
8.2.3.5.83. Cable D20

6. Work Complete.
8.2.3.5.84. Cable D21

6. Work Complete.
69
8.2.3.5.85. Cable D22

6. Work Complete.
8.2.3.5.86. Cable D23

6. Work Complete.
8.2.3.5.87. Cable D24

6. Work Complete.
8.2.3.5.88. Cable D25

6. Work Complete.
8.2.3.5.89. Cable CM1
1. Prepare and install Cable CM1 utilising drawing 343-ELE-A703-S89.

6. Work Complete.
70
8.2.3.5.90. Cable CM2
1. Prepare and install Cable CM2 utilising drawing 343-ELE-A703-S90.

6. Work Complete.
8.2.3.5.91. Cable F01

6. Work Complete.
8.2.3.5.92. Cable F02

6. Work Complete.
8.2.3.5.93. Cable F16

6. Work Complete.
8.2.3.5.94. Cable F17

6. Work Complete.
71
8.2.3.5.95. Cable F18

6. Work Complete.
8.2.3.5.96. Cable F19

6. Work Complete.
8.2.3.5.97. Cable F29

6. Work Complete.
8.2.3.5.98. Cable F30

6. Work Complete.
8.2.3.5.99. Cable F31

6. Work Complete.
72
8.2.3.5.100. Cable F32

6. Work Complete.
8.2.3.5.101. Cable F33

6. Work Complete.
8.2.3.5.102. Cable F34

6. Work Complete.
8.2.3.5.103. Cable F45

6. Work Complete.
8.2.3.5.104. Cable CTV03
1. Prepare and install Cable CTV03 utilising drawing 343-ELE-A703-S104.

6. Work Complete.
73
8.2.3.5.105. Cable CTV04
1. Prepare and install Cable CTV04 utilising drawing 343-ELE-A703-S105.

6. Work Complete.
8.2.3.5.106. Cable C21

6. Work Complete.
8.2.3.5.107. Cable F46

6. Work Complete.
8.2.3.5.108. Cable F47

6. Work Complete.
8.2.3.5.109. Cable J3508

6. Work Complete.
74
8.2.3.5.110. Cable TX01
1. Prepare and install Cable TX01 utilising drawing 343-ELE-A703-S110.

6. Work Complete.
8.2.3.6. Earthing Installation

2. Run new cable PE6 (1 core 6mm²) from external earth stud on North End Machine Devices Junction Box (JB20)
to local Machine Earth Boss and attach using a Crimp ring terminal.
3. Run new cable PE7 (1 core 6mm²) from external earth stud on South End Machine Devices Junction Box (JB21)
4. Run new cable PE8 (1 core 6mm²) from external earth stud on Long Travel No.3 Junction Box (JB22) to local
Machine Earth Boss and attach using a Crimp ring terminal.
5. Run new cable PE9 (1 core 6mm²) from external earth stud on Long Travel No.3 Encoder Junction Box (JB23) to
local Machine Earth Boss and attach using a Crimp ring terminal.
6. Run new cable PE10 (1 core 6mm²) from external earth stud on Long Travel No.4 Junction Box (JB24) to local
7. Run new cable PE11 (1 core 6mm²) from external earth stud on Long Travel No.4 Encoder Junction Box (JB25)
8. Run new cable PE12 (1 core 6mm²) from external earth stud on Water Sprayer System Water Tank Junction Box
(JB27) to local Machine Earth Boss and attach using a Crimp ring terminal.
9. Run new cable PE14 (1 core 6mm²) from external earth stud on Coke Guide Cage Junction Box (JB35) to local
12. Run new cable PE30 (1 core 70mm²) around the external edge of the cable tray installation. Ensure it is securely
clipped onto the cable tray. NOTE: This requirement is outlined in CAP standard NO-90-019_13222-9-Anexo 7.9
ESP 1-5-F, Section 1.11 Grounding – p.
ESP 1-5-F, Section 1.11 Grounding.
75
23. Work Complete.
76
77

Inst 343 Cap DS Ele 002 R3

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Electrical Installation Specification (South)

Cokeside Extraction for Battery Discharge

1. Revision History ............................................................................................................................ 7

2.1. Project Background ........................................................................................................................................... 8

3.1. Client Standards .............................................................................................................................................. 30

5. Installation Requirements ........................................................................................................... 34

6.1. Risk Assessment .............................................................................................................................................. 35

7.1. Pre-Work ......................................................................................................................................................... 36

8.1. Control System Enclosures.............................................................................................................................. 37

8.2.3.5.4. Cable J3505 ..................................................................................................................................... 53

8.2.3.5.41. Cable D29 ....................................................................................................................................... 61

8.2.3.5.78. Cable C10 ....................................................................................................................................... 68

 Existing Door Machine (South)

Work is to be performed in conjunction with manufacturer’s instructions/drawings, standard industrial practices,

2.1. Project Background

2.1.2. JMHM Installation Reference Drawings

Drawing No. Drawing Description

Drawing No. Drawing Description

Drawing No. Drawing Description

2.1.3. JMHM Engineering Reference Drawings

Drawing No. Drawing Description

Drawing No. Drawing Description

Drawing No. Drawing Description

2.1.4. Control System Services Reference Drawings

Drawing No. Drawing Description

CSS Drawing CSS Sheet JMH JMH

CSS Drawing CSS Sheet JMH JMH

CSS Drawing CSS Sheet JMH JMH

CSS Drawing CSS Sheet JMH JMH

CSS Drawing CSS Sheet JMH JMH

CSS Drawing CSS Sheet JMH JMH

CSS Drawing CSS Sheet JMH JMH

2.1.5. Client Reference Drawings

Drawing No. Drawing Description

2.1.5.2. Main Disconnecting Switch Box

Drawing No. Drawing Description

2.1.5.3. Auxiliary Disconnecting Switch Box

Drawing No. Drawing Description

2.1.5.4. Motor Control Panel

Drawing No. Drawing Description

2.1.5.5. Control Feeder Panel

Drawing No. Drawing Description

2.1.5.6. Local Control Box

Drawing No. Drawing Description

2.1.5.7. Distribution Box

Drawing No. Drawing Description

2.1.5.8. PLC & Relay Panel

Drawing No. Drawing Description

2.1.5.9. Operation Consol

Drawing No. Drawing Description

2.1.5.10. Lubrication Panel

Drawing No. Drawing Description

2.1.5.11. Cooler Heater Panel

Drawing No. Drawing Description

2.1.5.12. Interface List

Drawing No. Drawing Description

2.1.5.13. PLC System

Drawing No. Drawing Description

2.1.5.14. List Motor-Sensor

Drawing No. Drawing Description

2.1.5.15. Travel Control Panel

Drawing No. Drawing Description

3.1. Client Standards