DEPARTMENT: ARCHITECTURAL

STANDARD NO: 60-R400-A0/A.02d/0009

STANDARD TITLE: UMM WU'AL PHOSPHATE PROJECT

MINE MAINTENANCE AREA
SWITCHROOMS

A02 8 Mar 2013

PROJECT REFERENCE
PROJECT NO:
PROJECT LOCATION:
PROJECT TITLE:
CLIENT:
CLIENT PROJECT NO
CLIENT DOCUMENT NO
60-R400-A0
SAUDI ARABIA
UMM WU'AL PHOSPHATE PROJECT
MA'ADEN (SAUDI ARABIAN MINING COMPANY)
2-115-12-12-2-2
MD-511-0000-EG-AR-SPF-0009_B

PM Authorisation: D. EVANS

APPROVALS
Rev Issue Date Pages Revision Description Prepared Checked Approved
A01 22 Feb 2013 ALL ISSUED FOR CLIENT REVIEW AD DAE DAE
A02 8 Mar 2013 ALL ISSUED FOR FEED PK DAE DAE
A03 12 Nov 2014 ALL New document A.ANTON

DOCUMENT ISSUED FOR:

Preliminary For Information
For Review For Use
For Approval For Enquiry
For FEED

PROPRIETARY & CONFIDENTIAL

This document and the information contained herein is Ma’aden proprietary know-how. This document
or any part thereof should not be reproduced, stored in a retrieval system or transmitted by any
means,electronic or otherwise, or divulged without prior written permission of Ma’aden.
 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC

Hold Record
Specify any Holds within the document.
Hold
Section Description of Hold
No.
<1>

Revision Tracking
Specify significant change from previous revisions of the document. (From Rev. A onwards)
Rev. Section Description of Change
A01 ALL Initial issue
A02 ALL Issued for FEED
A03 ALL Separated into two documents, add page from 6 to 13

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC

TABLE OF CONTENTS
1.0 PURPOSE...............................................................................................................................5
2.0 SCOPE...................................................................................................................................5
3.0 DEFINITIONS......................................................................................................................5
4.0 REFERENCES.....................................................................................................................5
4.1 Ma’aden Saudi Arabian Mining Company Standards...........................................................5
4.2 Project Specifications........................................................................................................... 5
4.3 Drawings............................................................................................................................... 5
5.0 FUNCTIONS OF SUBSTATION SWITCHROOMS BUILDINGS...............................6
6.0 SUBSTATION SWITCHROOMS BUILDINGS FACILITIES......................................6
7.0 BUILDING CODE OF SAUDI ARABIA...........................................................................6
8.0 CLIMATIC DESIGN CONDITIONS................................................................................6
8.1 External Design Temperatures............................................................................................. 6
8.2 Internal Design Temperatures.............................................................................................. 7
9.0 BUILDING MATERIAL.....................................................................................................7
10.0 BUILDINGS EQUIPMENT................................................................................................7
10.1 Electrical equipment............................................................................................................. 7
10.1.1 Distribution panel.................................................................................................................. 7
10.1.2 Interior lighting...................................................................................................................... 8
10.1.3 Exterior lighting..................................................................................................................... 8
10.1.4 Exit emergency lighting......................................................................................................... 8
10.1.5 Outlets.................................................................................................................................. 8
10.1.6 Cabling.................................................................................................................................. 8
10.2 Grounding............................................................................................................................. 9
10.3 Safety accessories................................................................................................................ 9
10.4 Sanitary equipment............................................................................................................... 9
10.4.1 Air conditioning..................................................................................................................... 9
10.4.2 Fire alarm............................................................................................................................ 10
10.5 Telephone and data network.............................................................................................. 11
10.6 Lightning protection............................................................................................................ 11
10.7 Junction boxes.................................................................................................................... 11
10.8 Marshalling cabinet............................................................................................................. 11
11.0 EQUIPMENT INSTALLED IN THE BUILDINGS.......................................................12
11.1 MV-PCM building................................................................................................................ 12
11.1.1 Equipment fixing................................................................................................................. 12
11.1.2 Cable entries....................................................................................................................... 12
12.0 SCOPE OF SUPPLY..........................................................................................................13
12.1 Design................................................................................................................................. 13
12.2 Procurement....................................................................................................................... 13

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC
12.3 Installation........................................................................................................................... 13
12.4 Cables interconnection....................................................................................................... 13
12.5 FAT Tests........................................................................................................................... 13

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC

1.0 PURPOSE
The company has engaged Jacobs to prepare a Bankable Feasibility Study (BFS) for the
proposed Mine Maintenance Area (MMA).

2.0 SCOPE
The scope of this document is to describe the basis of design for the Substation Switchrooms.

3.0 DEFINITIONS
BFS Bankable Feasibility Study
HVAC Heating, Ventilation and Air Conditioning
MMA Mine Maintenance Area

4.0 REFERENCES
4.1 MA’ADEN SAUDI ARABIAN MINING COMPANY STANDARDS
The following standards have been referenced for the design:
Document Number Title
MD-101-SMEM-EG-ST-CRT-0002 Structural Design Criteria – Non-Process
Buildings & Structures
MD-101-1000-EG-GE-CRT-0001 Geographic, Climatic and Seismic Data
Criteria

4.2 PROJECT SPECIFICATIONS

Document Number Title
60-R400-00/P.02a/0006 Site and Utility Conditions
60-R400-00/C.02a/0001 Basis of Design
60-R400-00/H.02a/0012 Building Services Basis of Design for EPC
Packages
OP4.4501 Standard Loadings

4.3 DRAWINGS
Drawing Number Drawing Title
MD-511-0000-EG-CV-DLA-0002 Umm Wu’al Phosphate Project
Mine Maintenance Area
Layout Plan
MD-511-0000-EG-AR-DLA-0002 Umm Wu'al Phosphate Project
Mine Maintenance Area
Switchrooms No. 1 & No. 2
Layout Plan

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC

5.0 FUNCTIONS OF SUBSTATION SWITCHROOMS BUILDINGS

The Substation Buildings incorporate facilities to provide the following servicing activities:
 Support of Transformers and Diesel Generator
 Storage of switchboards and motor control centre
 Cable enclosure under substation floor
 Precast concrete firewalls around each transformer and diesel generator
 Bunded concrete around each transformer filled with crushed rock for hazardous fluid
leaks
 Extensions to site wide wireless radio system and telephone system
 Alarm and siren speakers

6.0 SUBSTATION SWITCHROOMS BUILDINGS FACILITIES

A summary of the facilities contained within the Substation Building is as follows:
 Heating and cooling (HVAC) for the entire substation building
 Lighting
 Electrical services
 Communication services

7.0 BUILDING CODE OF SAUDI ARABIA

General building classification and design characteristics:
 Hours of operation: 24 hours per day, 7 days a week, 365 days a year.
 Occupancy: No permanent staff, maintenance only
 Floor areas: Switchrooms No. 1 and 2 110m2

 Volume: Switchrooms No. 1 and 2 465m3

Switchyard N/A
 Effective Height: Substations Switchrooms 11.25m

8.0 CLIMATIC DESIGN CONDITIONS

8.1 EXTERNAL DESIGN TEMPERATURES
Summer Design Conditions
 Dry Bulb Temperature 38°C
 Wet Bulb Temperature 23°C
 Relative Humidity 24%

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC

Winter Design Conditions

 Dry Bulb Temperature -1°C
 Relative Humidity 99%

8.2 INTERNAL DESIGN TEMPERATURES

Non-HVAC Supplied Area
 Summer Design Temperature 40°C ± 5°C

HVAC Supplied Area

 Summer Design Temperature 24°C ± 2°C
 Summer Design Humidity 50% ± 5%
 Winter Design Temperature 22°C

9.0 BUILDING MATERIAL

Substation and Switchrooms
 External Walls:
 Roof:
 Floor:
 Foundations:
 External stairs:
Switchyard
 External Walls:
 Transformers Plinths:
 Foundations:
 Roof over Diesel Generator:
25m render external face, 200m CMU block work, 50m air
gap, 100m insulation, 200m blockwork
Reinforced concrete slab with overhang and parapet.
Reinforced suspended concrete slab over ‘cable gallery’
Reinforced concrete raft slab with edge and internal
ground beams
Reinforced concrete slab
200m thick precast concrete reinforced panels,
cantilevered from foundations.
Reinforced concrete
Reinforced concrete raft slabs with edge beams and
thickenings under transformer plinths.
Uninsulated metal cladding on steel
purlins.

10.0 BUILDINGS EQUIPMENT

10.1 ELECTRICAL EQUIPMENT
10.1.1 DISTRIBUTION PANEL
This distribution panel is 415V 4W+E wall type and feeds:
 Lighting
 Outlets

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC
 Building appliances such as air conditioning, ventilation fans, fire alarm panel.
It is fed by the LV main switchboard.

10.1.2 INTERIOR LIGHTING

 2 x 36 W fluorescent lighting fixtures to maintain an average illumination level of:

Switchroom: 300 lux at 1m

Battery room: 150 lux at 1m
Offices: 400 lux at 1m
Sanitaries: 150 lux at 1m

 Control by switch at each door.

10.1.3 EXTERIOR LIGHTING

Exterior lighting is high pressure sodium luminaries outdoors adjacent to each door and on
platforms/stairs. It will be controlled by photo-electric cell and HOA.

10.1.4 EXIT EMERGENCY LIGHTING

 Fluorescent lighting fixtures with battery back-up minimum 2-hours will be provided
above each access doors.
 Automatic control by lost of the normal voltage

10.1.5 OUTLETS
 10/16A two poles + earth outlets (15 for PCM building)
 Protection of outlets circuits by a 30mA ground fault relay and circuit breaker in the
building distribution panel.

10.1.6 CABLING
Cables connecting building electric distribution panels are copper multicores cables, 1000V
XLPE insulated, PVC sheathed, unarmoured.
Cables feeding building appliances are single core or multicores cables, 750V PVC insulated
and sheathed, unarmoured.
These cables are laid in:
 Perforated galvanized steel cable trays or ladders or,
 Stainless steel cable trays or ladders or,
 PVC conduits
The electrical equipments are bolted directly on the base. The base is designed to withstand
the total loading of the equipment. The cable trays will be placed in the base or on top
according to Provider Electric studies during the design phase. All outside cables will come
from the bottom.

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC

In addition, some bus ducts are used for the power LV and MV connections as shown on the
attached drawing. Special structural frame will be used to support the bus ducts crossing the
walls.

10.2 GROUNDING
The PFB main grounding will use a 120mm² copper bar installed inside the enclosure, on the
whole perimeter of the building. As a standard, it is connected to 2 stainless steel ground pads
welded to the base located at each end of the enclosure at opposite corners. Section of the
copper cable grounding loop is designed according to the equipments electrical
characteristics.

10.3 SAFETY ACCESSORIES

Personal Protective Equipment (PPE) are included inside the MV-PCM as follows:
 Gloves and gloves box
 Pole and voltage detector
 Insulated floor matt for MV
 Emergency and safety lighting system
 Portable safety light
 Labelling / Lawful posters
 Portable fire extinguishers, one unit adjacent to the external doorways
 Fire blanket

10.4 SANITARY EQUIPMENT

Eye wash facilities is provided in the battery room. Water supply piping and draining piping are
provided for external connection.

10.4.1 AIR CONDITIONING

Air conditioning is provided to maintain indoor temperature below 25°C under outdoor
maximum temperature specified at section 4 above.
Air conditioning units are of industrial split system type. Their redundancy level is N+1. One
centralized controller will be installed in each building.
Thermal balance (estimate) (excluding the air intake impact from ventilation system): 42 000W
Operation Limits of the devices:

Temperature
Cooling operation Heating
Mode
Room temperature ≥17°C ≤30°C
0°C~50°C
-15°C~50°C: For
Outdoor temperature the models with low -15°C~24°C
temperature
cooling system)

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC

These devices is chosen because of their capability to stop all devices when fire alarm
triggered, to send an alarm signal and to control and rotate the devices running through a
centralized control system.

The units will be installed as twin systems: one outdoor unit can connect with two indoor units
as shown on the figure below:

Battery room is ventilated with fresh air intake in the building and wall exhaust fan with filter.
The impact of it is considered for the sizing of the HVAC. For that, the air intake comes from a
constant pressure ventilation system equipped with filters.

 Features of the devices:

 Compact design, super slim body size, less space requiring in installation
 Each louver can be separately controlled; more comfort air blowing is possible.
 Auto-lifting panel design, more convenient to clean and maintain the filter.
 Network control function is standard for the indoor units.
 Standard auto restart function and follow me function.
 Super slim cassette with standard remote controller, wire controller and CCM for
optional.
 Standard anti-cold air function.
 Standard auto defrosting function.
 Standard self-diagnose function.
 Standard timer functions and sleeps mode function controlled by controller.

10.4.2 FIRE ALARM

The fire alarm system complies with EN 54 standard. As a minimum, it is made of :
 Detection panel
o POLARIS 4 8 12 GB - CIE 4 conv. DZ. 1 pcs
o EX4P10 Anglais -Ext.4 ZD Polaris 10 1 pcs
o R12P2 - 12 relays card. 1 pcs

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC
o Batterie 12 volts 7Ah 2 pcs

 Detectors and accessories

o Smoke detectors which uses an optical principle for measuring the presence
of smoke. Detection is based on the reflexion of an infra-red light source on
the smoke particles. When smoke enters the test chamber of the sensor, the
sensor sends a signal to the fire detection system that generates an alarm
signal. It will be in every room except corridor and toilets
o Optical repeater is used for alarm repetition of hidden detectors (false ceiling,
floating floor or non garrisoned rooms). It doesn’t need the power supply and
it’s connected directly to the detector base

Studies realization
 Drawings
 Overview diagrams
 As Built Drawings
Work on site (at factory)
Installation
Technical operations:
 Panels configuration - except factory acceptance test (FAT)
 Downloading
 Commissioning of manufacturer systems
 Test of detectors: 1 point on each zone
 Test of fire security systems: 1 module on each zone

10.5 TELEPHONE AND DATA NETWORK

1 RJ45 combined telephone and data outlet with conduit access on interior wall of low voltage
room.

10.6 LIGHTNING PROTECTION

To be forecasted.

10.7 JUNCTION BOXES

Cable junction boxes between modules shall be provided for assembling facilities on site if
needed. Their will be installed for fast and easy connections. The details will be provided
during the design stage of the project.
However, depending on the number of cables, all connections will not go through a junction
box.

10.8 MARSHALLING CABINET

To be forecasted.

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC

11.0 EQUIPMENT INSTALLED IN THE BUILDINGS

11.1 MV-PCM BUILDING
The following equipment is installed in the MV-PCM building:

Description Units Qty

Building including, walkways and stairs unit 2
13.8kV switchboard unit 4
MV Cast resin busduct *** unit 12
Interlocking panel unit 2
UPS DC charger (redundant) unit 4
UPS station batteries and battery rack and one battery box set 2
UPS inverter unit 2
UPS bypass transformer unit 2
420V or 480V according to SS1 or SS2 main switchboard unit 2
LV Cast resin Busduct ** unit 4
48VDC panelboard unit 2
230VAC safe “UPS” panelboard unit 2
160kVA dry-type transformer for PCM L&P panelboard unit 2
420V or 480V, PCM lighting & power, incorporating lighting contactors, heaters unit 2
Fire indication panel unit 2
HVAC panelboard unit 2
Diesel Generator panel unit 2
Cabling inside MV-PCM modules for equipment supplied by Provider. set 2

Note *: supply by other. Shop drawings complete with panels foot prints shall be furnished to
Provider to enable Provider cut-out/construct suitable cable entry holes using the dimensions
provided on the Vendor’s panel foot prints.
Note **: LV Busduct to be erected on site
Note ***: MV Busduct supply by other and erected on site.

Installation details
The building design includes suitable provision for correct installation of the above equipment.

11.1.1 EQUIPMENT FIXING

 Heavy equipment is fixed to the floor by bolting. Suitable fixing provisions include :
 Small distribution panels are fixed on the walls.

11.1.2 CABLE ENTRIES

Electric cables enter the buildings by passing through the floor. Crossing the floor is done
using gland plates made of non magnetic material. All field cables and cable glands for
external use of the MV-PCM are not in Provider scope.

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 Technical Note
Project Component Number
1778 Mine Contract 0031
Al Khabra Mining PMC
 High power low voltage busducts enter MV-PCM building through its wall on
transformer side. Special sealing adapters are delivered by supplier with the busducts
for this purpose.

12.0 SCOPE OF SUPPLY

12.1 DESIGN
The scope of this specification includes the preparation and the supply of the following
documents:
 Building detailed layout drawings
 Building structural and fabrication drawings
 Structural calculation note
 HVAC calculation note
 Civil guide drawing including civil design datas showing anchoring, fixing, static loads
to carry out the concrete block. Civil works such as concrete studies are not in
Provider Electric scope.
 Equipment list
 Cable trays and earthing circuit layout
 Cable list
 Building equipment data sheet
 Lifting and handling instructions
 Erection, commissioning, operation and maintenance manual

The drawings will be prepared in accordance with our standards and will be sent for approval
according to the project schedule. Documentation will be English. The documents must be
dated and stamped by the customer.

12.2 PROCUREMENT
Test will be done by the manufacturer.
The supply of all other equipment, material and accessories necessary for the correct and
complete fabrication and assembly of the buildings is in the scope of this specification.

12.3 INSTALLATION
Installation will be done by the manufacturer.

12.4 CABLES INTERCONNECTION

In the scope of supply, shall be included, all the internal mechanical and electrical connections
for the above listed electrical equipment.
12.5 FAT TESTS
The following tests are included:
 Mechanical and visual inspection
 Functional test of equipment
 Air conditioning test & fire system test

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