T2927-0-44 (Rev C) Electrical Design Basis NT

T2927-0-44
PREPARED FOR
BILFINGER LTD
ELECTRICAL DESIGN BASIS
DESIGN SPECIFICATION
DONCASTER,UK
13 APRIL 2023
Anergy Pte Ltd

#02-01
23 Lorong Telok
Singapore
049035
www.anergy.com
ed, Date: 2023-04-13 09:36:13+01:00, By: Devayani, Reviewed by: Nithyapriya Madhanagopal, Approved by: Leelakrishnan Mohanraj, Download on: 2023-04-27 12:29:07+0100, Download by: Bilfinger UK Document Control
Electrical Design Basis, Design Specification T2927-0-44 Rev C
This document has been prepared by Anergy Private Limited.
All information in this document and the document itself is subject to copyright © governed
by the law of the UK.
Revision History
Rev Date Description By Chk. Apr.
A 20/12/2022 Preliminary issue HR MLK MCM
B 07/02/2023 Issued for internal review MNP MLK MCM
C 13/04/2023 Issued for Client approval DD MNP MLK
Page 2 of 21 Anergy – Transforming Waste
CONTENTS
CONTENTS 3
SCOPE AND CONDITIONS 4
1 Definitions 4
2 Scope 5
3 Site Conditions and Requirements 6
ELECTRICAL SYSTEM 7
4 Overview 7
5 General Requirements 7
6 Incoming Connection 8
7 Export Connection (To be confirmed) 9
8 Power Distribution 9
9 Electrical Panel 10
10 Field Mounted Electrical Equipment 11
11 Uninterrupted and Backup Power Supplies 11
INSTRUMENTATION & CONTROL 13
12 Use of Instruments 13
13 Instrument Selection and Arrangement 14
14 Cables and Panel Wirings 16
15 Control, Networking and Interface Hardware 17
FUNCTIONAL REQUIREMENTS 18
16 Logic Controller 18
17 Human Machine Interface 18
18 Communications Interface 18
19 Safety Instrumented Systems 19
20 Explosive Atmospheres 19
21 Quality and Functional Testing 20
SCOPE AND CONDITIONS

1 Definitions
1. This document defines the criteria that will be used for the electrical design
of the electrical system for the Reverse Coal Willows To Biochar, Power and
Heat Demonstration Plant where:
‘Asset’ or ‘Assets’ are then given a unique identification number
or Tag Number and these shall conform to the Project
Specification.
‘Authority’ or ‘Authorities’ shall mean any government or
government appointed agency having specific jurisdiction over
any part of the Plant once installed or operating at the Site.
‘Certificate’ or ‘Certification’ are those documents required to be
certified by a specified party or Authority for the Installation and
Operation of the Plant.
‘Common Plant’ is Plant or Subsystems that are intended to be
used with more than one Module.
‘Contractor’ is the Bilfnger will be having the scope of supply as
per clause 2.2
‘Subcontractor’ is Anergy who has the responsibility to provide
electrical systems for the equipment and subsystems as per
scope defined in clause 2.1.
‘Purchaser’ is Lapwing who has the Authority to the Plant,will be
having the scope of supply as per clause 2.3.
‘Manufacturer’ is the Sub contractor and will have the
responsibility to provide the electrical system for the equipment
under the Subcontractor's scope.
‘Designer’ of the Electrical System is the subcontractor, who will
be have the responsibility of meeting the requirements of this basis
of design;
‘Installer’ is the party who will install the subsystems into a facility
located at the Site and will be responsible to any local authorities
for the safe installation and operation of any electrical equipment.
‘Development Software’ is the software package used to create
and maintain any software applications embedded in any Plant
and required to Operate the Plant.
‘Electrical Equipment’ are any Plant which has a specific
purpose of controlling, generating, supplying, transforming or
transmitting electricity. This may or may not include electrical
equipment embedded into mechanical plant.
‘Emergency Shutdown’ or ‘ESD’ is that state in which the Plant
is being, through the supervision of the control system only and
without the intervention of Operators, taken from an Operating
state to a state of rest.
‘Feed’ is raw material used in the Process from which Products
are made.
‘Infrastructure’ shall mean any additional structure, mechanical
plant, electrical plant, site works or other such work that will be on
the Site and will interact with the Plant.
‘Inspection’ for the purposes of this Specification only shall
mean inspections mandated by an Authority.
‘Instrument’ or ‘Instruments’ includes any Plant that is a sensing

device that measures an aspect of the Process including but not
limited to pressure, temperature, level, flow, velocity, density,
composition and weight.
‘Mechanical Plant’ includes any machines, equipment, vessels,
tanks or bins used as part of the Process.
‘Operating’ is that state in which the Plant is making one or more
products and the Plant has achieved an effective steady state.
‘Pipe’, ‘Pipes’ or ‘Piping’ is any Plant which interconnects Plant
for the purpose of conveying fluids from one location to another.
‘Product’ is a substance created as a result of Operating the
Process.
‘Process’ is the conversion of willows to Boichar & Power which
shall be broken into a set of Subsystems.
‘SACTO’ is an acronym for staged air cyclonic thermal oxidiser
which is a type of thermal oxidiser used in the Process.
‘Software Application’ or ‘Software Applications’ are the
applications developed using Development Software and then
installed and embedded in electrical equipment for the purpose of
causing the Plant to be able to Operate.
‘Standard’ or ‘Standards’ are the published standards from
nationally or internationally recognized standards bodies. If not
provided with a version or year of publication, any quoted
Standard shall be the latest version as at six (6) months prior to
the signing of the Agreement.
‘Startup’ is that state in which the Plant, which has recently been
in an Operating state, is being, through the supervision of
Operators, taken from a state of rest to an Operating state.
‘Shutdown’ is that state in which the Plant is being, through the
supervision of Operators, taken from an Operating state to a
state of rest.
‘Structure’ includes any Plant structural design, Steel structure,
concrete structure & other structures.
‘Subsystems’ are groups of Plant that together achieve part of
the Process.
2 Scope
2. An Electrical System for each subsystems will be designed, manufactured
and integrated into their equipments by the Subcontractor that will then be
installed by the Installer at the Site such that:
2.1 Each Subsystem shall include part of the Plant such that there is
an asset shall belong to one Subsystem only. The following list of
each electrical package includes the subsystems which are in Sub
contractor’s scope:
a) Feed reception & Kiln feed;
b) HTP Kiln & Solid product handling;
c) Gas cleaning unit;
d) SACTO;
Other than the above mentioned electrical packages, will not be in
Sub Contractor’s scope of work.
2.2 Electrical System for the Balance of Plant shall be any Plant that
causes the interconnection and interoperability of the Subsystems.
This specifically includes the following as Contractor scope of

Works:
a) Interconnecting piping between the subsystems;
b) Interconnecting power, control and communications cables
between the subsystems;
c) Uninterrupted and backup power supplies;
d) Master control equipment;
2.3 The following Balance of Plant are responsibility of the Purchaser:
a) Concrete structures;
b) Steel structures that are not part of subsystems;
c) All underground services (which are interconnectors);
d) All roads, paving and drainage;
e) Control and operations building;
f) Main distribution board;
g) Small power and lighting equipment;
h) Safety showers and eyewash stations;
2.4 The electrical system will able to be safely installed in the given
Site conditions and requirements of clause 3;
2.5 The Purchaser will provide to the system an incoming connection
as given in clause 6;
2.6 The electrical system will thereafter comply with the requirements
set out in the Electrical system clause 4.
3 Site Conditions and Requirements

3. The design of the Electrical System will need to be able to meet the Site
Conditions or Requirements described in this Clause. Note that whilst the
Installer has the responsibility to any Authority, the Subcontractor is
expected to support and assist the Installer in meeting this as given by their
scope of supply or through variation to that scope.
3.1 Electrical system and components shall be selected and installed
to accordance with the climatic conditions of the site being:
i) Location Doncaster, UK.
j) Elevation mASL 22.5
k) General environment Outdoor or Covered(Client
to nominate)
l) Min.Ambient Temperature 50 C
m) Max.Ambient Temperature 250 C
n) Design Relative Humidity 70%
3.2 Complete installation must meet the requirements of IEC
60364-5-51 standards.
3.3 Other than the requirements specified in the remainder of this
document, no other specific conditions have been specified for the
electrical system.
ELECTRICAL SYSTEM
4 Overview
4. The Electrical System for the each package as mentioned in the clause 2.1
will include and meet the requirements of this clause:
4.1 General requirements of clause 5 will be applied to any component
or functionality of the electrical system.
4.2 The Electrical System for subsystems will include:
a) Each Electrical Panel to the requirements of clause 9;
b) Field mounted electrical equipment including motors and
control devices to the requirements of clause 10;
c) An uninterruptible power supply (UPS) to the requirements of
clause 11;
d) Instruments to the requirements of clause 12&13;
e) All interconnecting wiring and cabling to the requirements of
clause 14; and
f) Control, networking and interfaces to the requirements of
clause 15.
4.3 The Electrical system for each package as described in the clause
2.1 shall have the functional requirements for safe and smooth
operation including:
a) Logic controller in accordance with clause 16;
b) A Human Machine Interface (HMI) in accordance with clause
17;
c) A Communications interface with the installers equipment in
accordance with clause 18.
d) Safety Instrumented Systems in accordance with clause 19;
e) Provision for electrical equipment in hazardous areas in
accordance with clause 20;
4.4 All components of the electrical system will be subjected to quality
management and testing by the Subcontractor prior to delivery to
the Site in accordance with clause 21.
5 General Requirements
5. Unless specifically stated otherwise, any part of the electrical equipment
shall meet the requirements of this clause.
5.1 With reference to IEC 60364-5-54 and BS 7671, the subsystems
shall be of the TN-C-S type connecting to the Installers system. All
conductive parts of the subsystem equipment shall be
equipotential bonded back to the earthing connection provided by
the Installer.
5.2 Electrical equipment for subsystems shall operate on voltages as
follows:
a) for motors and three phase equipment, 415V AC at 50Hz;
b) for electrical equipment in burner applications, 230V AC at
50Hz;
c) for control circuits including PLC inputs and outputs in
electrical panels, 24V DC;
d) for instruments, control valves & SOVs requiring power,
24VDC; or
e) for instruments using loop power, 0-10V/4-20mA DC.
5.3 The electrical wiring system and components for the subsystems
shall be selected and manufactured in accordance or be able to be
installed in compliance with the following standards:
Low-voltage electrical installations (IEC 60364 series)
IEC 60364-1 Fundamental principles, assessment of general
characteristics
IEC 60364-4 Protection for safety
Part 41: Protection against electric shock
Part 42: Protection against thermal effects
Part 43: Protection against overcurrent
Part 44: Protection against voltage disturbances and
electromagnetic disturbances.
IEC 60364-5 Selection and erection of electrical equipment
Part 51: Common rules
Part 52: Wiring systems
Part 53: Isolation, switching and control
Part 54: Earthing arrangements
IEC 60364-6 Verification
IEC 60364-7 Requirements for special installations or locations
Part 714: External lighting
Part 715: Extra-low-voltage lighting installations
Explosive Atmospheres (IEC 60079 series)
IEC 60079-14 Electrical installations design, selection and erection
IEC 60079-17 Electrical installations inspection and maintenance
5.4 The electrical system shall include the protections against lightning
strike required to prevent any harm to personnel or Plant in
accordance with the following standards:
Protection against lightning (IEC 62305 series)
IEC 62305-1 General Principles
IEC 62305-2 Risk Management
IEC 62305-3 Physical damage to structures and life hazard
IEC 62305-4 Electrical and electronic systems within structures
5.5 Tagging for all Electrical Components, Panel, Cables, and
Instruments in the subsystems should be in accordance as
described in Asset Tagging & Naming Specification(T2927-0-40).
6 Incoming Connection
6. The incoming electrical supply connection or ‘Incomer’ from plant to the
every individual Electrical systems as listed in clause 2.1 has the
characteristics of this section.
a) a separate dedicated main incoming supply 415VAC will
have the characteristics described in sub clause 6.4
b) 230VAC Uninterrupted power supply as given by the sub
clause 6.5
c) Export connections to Infrastructure as given by clause 7.
6.1 The Incomer is a low voltage, alternating current, three phase
power supply. The Incomer has a capacity higher than the total
Plant electrical load.
6.2 The Incomer is connected through Infrastructure to the national
grid as owned and operated by the Authority named by the
Purchaser.
6.3 The Infrastructure will include any three phase earthing
transformers and necessary upstream and downstream protection
of the transformer such that the design fault level for the main
distribution board connected to the incomer is less than 10kA for 1
second.
6.4 The Plant will operate to design capacity and availability of main
incomer when supplied through the incomer with the following
characteristics:
a) Nominal phase to phase voltage is 415V AC;
b) Voltage is consistently within ± 3% of the rated voltage;
c) Nominal frequency is 50Hz;
d) Frequency is consistently within ±1% of the rated frequency;
e) Harmonic distortion does not exceed the requirements of
IEC 61000-3-2; and
f) Flicker within the requirements of IEC 61000-3-3.
6.5 Electrical system requires a 230VAC uninterrupted power supply
with the characteristics listed below.
a) Nominal phase to phase voltage is 230V AC;
b) The Performance requirements of Uninterrupted power
supply should be in accordance with IEC 62040
c) Voltage is consistently within ± 3% of the rated voltage;
d) Nominal frequency is 50Hz;
e) Frequency is consistently within ±1% of the rated frequency;
7 Export Connection (To be confirmed)

7. The outgoing connections from the Plant to Infrastructure will have the
characteristics of this Clause.
7.1 The Purchaser shall name the Authority relevant to the generation
and distribution of power from the export along with the technical
rules that must be complied with by the Contractor.
7.2 Each connection to Infrastructure has the capacity of the entire
Gas Generator output including reactance power.
7.3 Each Gas Generator shall be fitted with the appropriate equipment
to safely synchronise and automatically connect or disconnect
from the export line. Protection requirements on the closing
breaker will be in accordance with the technical rules as provided
by the Authority. Power quality requirements will also be in the
technical rules as provided by the Authority.
7.4 Exported power shall be provided to at least the quality if not better
than as described for the incomer.
7.5 Any metering, conditioning, transforming or monitoring of the
exported power shall be carried out by Infrastructure.
7.6 All Gas Generator signals required by the Authority or
Infrastructure shall be marshalled and collected as part of the
control system. A specific hard-wired interlock facility will also be
provided for provision of a remote permissive by either the
Authority or Infrastructure. It is expected however in normal
practice that the Operator shall be given a thirty (30) minute
warning in which to shutdown one or more generators
8 Power Distribution
8. The incomer will terminate at a main distribution board which will distribute
power to the Plant and subsystems as described in this clause.
8.1 The main distribution board shall be the single point of power
connection where power is to be consumed in the Plant other than
at the Gas Generators(refer Clause 7). This distribution board shall
be located either in or in the vicinity of the control and operations
building.
8.2 Each subsystem shall have not more than one switchboard, an
electrical panel containing circuit breakers, motor starters, variable
speed drives, relays and other components, required to distribute

power appropriately to individual loads for that subsystems.
However, each subsystem shall be directed through only one
switchboard from the main distribution board.
8.3 Isolators for any motor or three phase load shall be provided
preferably alongside that device. These can be locked in both the
on and off position and are for maintenance isolation. The control
system shall be able to detect any such isolation.
8.4 Demand power load for the Plant will be estimated using an
appropriate methodology using a power factor of 0.9 and load
factors based on expected operational parameters of equipment,
instruments, plant lighting and small power, offices, workshops and
HVAC loads. An appropriate growth factor will also be applied to
allow for additional load.
8.5 The incomer and main distribution board will be installed to be
able to meet the demand requirement.
8.6 Distribution boards and switchboards will have a growth factor of
approximately 20%. This includes additional gland spacing,
additional terminal spaces, capacity on any distribution
transformers.
9 Electrical Panel
9. The Electrical panel will be designed, manufactured & installed in
accordance with the following characteristics.
9.1 Electrical panels and their associated components shall be
manufactured in accordance with the following standards:
Low voltage switchgear and controlgear assemblies (IEC 61439 series)
IEC 61439-1 General Rules
IEC 61439-2 Power switchgear and controlgear assemblies
IEC 61439-3 Distribution boards intended to be operated by
ordinary persons
IEC 61439-6 Busbar trunking systems (busways)
Panels shall have a minimum segregation of Form 2A. Preferred
equipment nominated will be utilised where possible.
9.2 The electrical panel and the corresponding components mounted
on the panel's surface shall have an IP rating that complies with
clause 10.1.
9.3 Electrical panel specified in the clause 2.1 will have multiple power
connections from the Infrastructure:
d) a separate dedicated main incoming supply connection from
the Infrastructure as given by clause 6.
e) An Uninterrupted power supply from the Infrastructure as
given by the clause 11
f) Export connections to Infrastructure as given by clause 7.
9.4 A single isolation switch (or “main isolator”) shall be provided for
each Electrical panel to isolate the system from the incoming
power supply. The selection of isolators shall be as specified in
clause 8.3.
9.5 The Main isolator in each subsystem will completely disconnect
the circuit from the electrical supply in order to achieve absolute
isolation from the Main distribution board. The Main Isolator shall
be selected and installed shall comply with IEC-60947-3
standards.
9.6 This may include circuit breakers, motor starters, variable speed
drives, relays, Controllers and other components required to
distribute power appropriately to individual loads for that system.
9.7 Isolation for any other electrical equipment outside of the main
panel shall be through the main isolator only or as specifically
otherwise described in this document.
9.8 The electrical panels will have capacity for growth of approximately
20%, which includes isolator switches, additional gland spacing
and additional terminal spaces.
9.9 Thermostat and Hygrostat units shall be installed for use of
temperature control for electric surface heating systems inside the
electrical Panels in Non-Hazardous Areas.
10 Field Mounted Electrical Equipment

10. Electrical equipment which is located outside of any dedicated electrical
room shall have the characteristics of this clause.
10.1 The IP rating (in accordance with IEC 60529) of any device which is
located outdoors shall be as a minimum:
a) for motors, IP54;
b) for panels and instruments in dry areas, IP54; and
c) for panels and instruments in wet areas, IP55.
For devices located indoors, IP ratings for water protection only
can be reduced.
10.2 All three phase motors or electrical panels shall be supplied with a
local isolation station for the purpose of maintenance only. The
control system shall monitor any isolation. No local control is
otherwise provided.
10.3 Instrumentation shall be as given in clause 12&13.
10.4 Any motor shall be high efficiency with a minimum rating of IE3 (as
per IEC 60034-30.1). Motors in hazardous areas with variable
speed drives providing the power will be fitted with thermistors.
10.5 Cables between electrical equipment installed in the subsystems
will preferably be in accordance with the following Standards:
IEC 60502-1 Cables for rated voltages of 1kV and 3kV
IEC 60584 Thermocouples - extension and compensating cables
IEC 61158 Industrial communication cables
EN 50288 Multi-element metallic cables used in analogue and
digital communication and control (various parts)
EN 50289 Communication cables
11 Uninterrupted and Backup Power Supplies

11. Uninterrupted 230V AC power supply(UPS) from the Plant to each electrical
panel as categorised in clause 2.1, as well as backup power supplies (BPS)
for various uses as outlined in this clause.
11.1 The control system shall have the UPS for the purposes of:
a) maintaining power on the control & monitoring devices;
b) maintaining power for the communication network;
c) maintaining power to any instruments which are inputs to
the PLC; and
d) maintaining power to any outputs and devices thereafter
where they are nominated as requiring a UPS other than as
given by this clause.
11.2 The HTP Kiln needs an emergency 24 Volt DC drive, which will be
converted from the source of 230 Volt Uninterrupted Power Supply,
to protect the heat tube.
11.3 Each Gas Generator shall be equipped with a battery system and
starter motor as required by the manufacturer inside of the
respective cubicle.
11.4 During ESD, the SACTO subsystem will continue to operate
effectively with backup power or alternatively if this is unavailable
then in such a manner to safely remove dirty syngas.
11.5 Lighting UPS shall be provided by rechargeable batteries located
within lights nominated as an emergency.
INSTRUMENTATION & CONTROL

12 Use of Instruments
12. The Plant uses Instruments to support the Operation as described by this
clause.
12.1 The subsystems will be provided with instrumentation that sensors
a process variable for the purpose of:
a) Controlling the quality or quantity of part of the Process;
b) determining if the Process is within operational limits;
c) providing a safety function to prevent damage to people or
the Plant.
Any Instrument that does not perform a function above but is
required for analytical purposes does not form part of this
Specification. Such instruments if otherwise required to be
installed by the Agreement must be compatible with this
Specification.
12.2 Instruments, embedded within mechanical plant, shall be also
considered to be a part of that mechanical plant for the purpose of
this Specification. Instruments that form part of the burner system
for thermoprocessing equipment are considered to be part of that
mechanical plant.
12.3 Instruments that are also electrical equipment shall be
considered as both an instrument and electrical equipment for the
purposes of this Specification.
If additional accessories including support brackets, manifolds,
tubes, isolation valves or other fittings are required to attach the
sensing device to mechanical plant, structure or piping, this
forms part of the instrument and is also subject to this clause.
12.4 Instruments that provide function of clause 12.1(b) only can be
local indication only (for example gauges) if it is unlikely to
fluctuate, is ambiguous, or is more likely to provide a
troubleshooting role. Local indication on instruments that are
electrical equipment will generally be not provided.
12.5 Instruments that are electrical equipment shall have a minimum
rating in accordance with IEC 60529 (Degrees of protection
provided by enclosures) of:
a) IP54 if not in a wet area or likely to require washdown; or
b) IP65 otherwise.
This excludes any instrumentation required for burner systems
which apply EN 746-2 (Combustion and fuel handling systems).
12.6 Instruments, selected and arranged as given by clause 12 and 13,
shall be able to be removed from service and replaced and where
Instrument inputs can be suspended for short periods in order to
perform maintenance whilst the Process is in operation.
12.7 Connections by instruments to the Process and particularly piping
shall where practicable adhere to the requirements of the concern
piping.
12.8 Instruments where they are to be supported by structure and in
fact connection by instrument tubing to piping will be clustered
together as is possible.
13 Instrument Selection and Arrangement

13. Any instrument that is not a part of mechanical plant shall be preferably
selected and arranged as given by this clause.
13.1 For instrument tubing, Where connections to the process are to
gases or liquids which are to be considered hazardous, stainless
steel tubing systems such as Swagelok or Hoke brands. Single
point connection systems will run through a 3 port manifold and
two point connection systems will run through a 5 port manifold.
13.2 For thermocouples, thermometers thermostats and temperature
transmitters, Temperature instruments attached to pipes will be
placed in thermowells when the pipe service is either a liquid that
cannot be easily drained or is a gas that is either toxic or is likely to
create an explosive atmosphere in the process of removing and
installing the instrument.
13.3 Type ‘K’ thermocouples for measuring any temperature above
200°C to IEC 60584-1 or otherwise Pt100 RTD sensors to IEC
60751 are preferred. Signals from temperature sensors can be
either converted to 4-20mA in a local transmitter mounted in the
head of the sensor or taken directly to the input with care taken to
use appropriate cables and terminals in accordance with IEC
60584-3.
13.4 Cast aluminium heads on mineral sheathed probes are preferred. If
the temperature sensor is in a hazardous area, the head shall have
IECEx protection Ex ‘d’.
13.5 Analytical instruments used to measure pH or ORP will be placed
in barometric legs ensuring flooding of the instrument and the
associated pipe shall have an isolation and bypass to allow the
instrument to be removed safely.
13.6 The pressure transmitters (including for pressure, velocity, flow or
level) will be loop powered and have a 4-20mA output. If a pressure
transmitter is to be placed in a hazardous area, the instrument will
have protection in order of preference either IECEx Ex’d’ or IEXEx
Ex’i’. The instrument will be positioned preferably on nearby
structure with tubing going to measuring points on the HTP Kiln
system.Any tubing shall be connected as given by sub clause 13.1.
13.7 For inserted devices including orifice plates, venturi nozzles and
nozzles used to create differential pressure will conform to the
Standards listed below. Straight pipe both before and after the
instrument will conform to manufacturers instructions. Head loss
from the instrument will be appropriate to the line and duty.
Measurement of fluid flow by pressure differential devices (IEC 5167
series)
IEC 5167-1 General principles and requirements
IEC 5167-2 Orifice plates
IEC 5167-3 Nozzles and venturi nozzles
IEC 5167-4 Venturi tubes
13.8 For gas services, flow transmitters and switches which conform to
the following clauses are preferred.
a) For pressure transmitters (including for pressure, velocity,
flow or level):
i)
Transmitters will be loop powered and have a
4-20mA output. If a pressure transmitter is to be
placed in a hazardous area, the instrument will have
protection in order of preference either IECEx Ex'd'
or IEXEx Ex'i'. The instrument will be positioned
preferably on a nearby structure with tubing going
to measuring points on the HTP Kiln system.
b) For inserted devices including orifice plates, venturi nozzles
and nozzles used to create differential pressure:
i) These instruments will conform to the Standards
listed below. Straight pipe both before and after the
instrument will conform to the manufacturer's
instructions. Head loss from the instrument will be
appropriate to the line and duty.
ii) Measurement of fluid flow by pressure differential
devices (IEC 5167 series)
iii) IEC 5167-1 General principles and requirements
iv) IEC 5167-2 Orifice plates
v) IEC 5167-3 Nozzles and venturi nozzles
vi) IEC 5167-4 Venturi tubes
13.9 However in other cases particularly liquid duties, paddle type,
magnetic flow and other such measurement devices will be used if
appropriate. Straight pipe both before and after the instrument will
conform to manufacturers instructions. Head loss from the
instrument will be appropriate to the line and duty.
13.10 Transmitters will be loop powered and have a 4-20mA output. If a
pressure transmitter is to be placed in a hazardous area, the
instrument will have in order of preference either IECEx Ex’d’ or
IEXEx Ex’i’.
13.11 Control Valves and actuators will be selected appropriate to the
duty in the Process required including consideration for the
accuracy and precision. Valves will otherwise be in accordance
with their fluid code requirements as per following clauses:
a) Metallic Industrial Piping (EN 13480 series)
b) Pressure piping (ASME B31 Series)
c) Plastics piping systems for gaseous fuels-Polyethylene (EN
1555 series)
13.12 In order of preference and with consideration for requirements,
actuators can be solenoids, pneumatic quarter turn, pneumatic
linear, rotating motorised actuators or linear motorised actuators.
13.13 On/off type actuators will use control voltages as given by clause
5.2. Auxiliary power will be avoided if possible. Modulating
actuators will use a 4-20mA signal and whilst it is preferred the
actuator is loop powered, if the power consumption is excessive it
will be self-powered.
13.14 The use of pneumatic actuators particularly will be preferred to
avoid having any electrical components placed inside hazardous
areas. If this is unavoidable, the preference will be to have
protection in order of preference either IECEx Ex‘d’ or IEXEx Ex‘i’.
13.15 Level transmitters including ultrasonic, radar, optical, conductivity
or magnetic proximity can be used in various duties within the
subsystems other than level or position transmitters and switches
given in sub clause 13.6. Nucleonic devices will be avoided. In
each case, the installation will satisfy the manufacturer's
instructions.
13.16 Transmitters will be loop powered and have a 4-20mA output. If
the transmitter or switch is to be placed in a hazardous area, the
instrument will have protection in order of preference either IECEx

Ex’d’ or IEXEx Ex’i’.
13.17 Pressure gauges shall preferably have a 100mm dial face and be
installed facing upwards with the dial readily readable by an
Operator. An isolation valve shall be provided between the
connection point and the gauge. If the service is particularly hot
then a pigtail type syphon will be installed.
14 Cables and Panel Wirings
14. The following details the type of cables & handling of cables.
14.1 Cable Specifications
a) All cables shall comply with UK, BS standards along with the
following unless otherwise noted:
i) IEC 60502-1 (1kv power cables);cable specifications
ii) IEC 60228 (conductor size and rating);
iii) IEC 61158
iv) EN 50575 (fire rating);
v) EN 50288 (instrumentation and communications
cables);
vi) EN 60445 (colours for conductors).
b) All multicore cables shall be provided with an integral
insulated earth conductor. minimum core size shall be 2.5
mm².
Table-1 Specification of Power cables
Service Type Spec. Insulation/ Protection Screen. Min.Size

Sheath
LV Power XVB OR 0.6/1.0kV, XLPE/ N/A-Flexible - 2.5mm2

(excl. VSD cables) Equivalent V75 PVC
XVB OR
LV Power 0.6/1.0kV, XLPE/ STA/SWA - 2.5mm2
Equivalent
(excl. VSD cables) V75 PVC
Hazardous areas
VSD motor power 2XSLCH-J 0.6/1.0kV, XLPE/ N/A-Flexible Aluminiu 2.5mm2

CCA EMC V90 PVC m
Table-2 Specification of Control & Instrumentation cables
Service Type Spec. Insulation/ Protection Screen. Min.Size

Sheath
LV Control XVB OR 0.6/1.0kV, PVC STA - 1.5mm2

Equivalent V75
SiHT
Burner ignition 10kV Si - - -
cables
Instrumentation RE-2X(St)y- Plain V-90 RP Steel wire Aluminium 0.5mm2

(twisted pairs) PiMF annealed PVC tape
copper
IS circuits RE-2X(St)y- Plain V-90 RP Steel wire Aluminium 0.5mm2

PiMF Light annealed PVC tape
blue copper copper sheath
Thermocouple Thermo Plain PVC STA/ Aluminium 0.5mm2

extn. annealed SWA tape
copper
Data/ CAT6 - - - - -
Comm. (RJ45
terminated)
14.2 Cables & wiring for the electrical panel shall be provided in
accordance with the standard wiring sizes & specifications as
described below.
a) All control wiring shall be a minimum of seven strands of
copper with a cross section not less than 1.5 mm2.
b) Power Wiring for the loads like Motors, Packages, Utilities
shall be minimum of 2.5mm2. Selection of wiring size shall
be in calculation with load, voltage drop and accordance
with selection criteria of IEC and BS (British Standards)
c) All current transformer wiring shall be a minimum of seven
strands of copper with a cross section not less than 2.5
mm2.
d) Wiring used for the connection of signals to Programmable
Logic Controller (PLC) Input/Output (I/O) modules shall be
1.0 mm2
e) All wiring shall be terminated to components or terminal
strips, no joints shall be permitted in the wiring.
14.3 Any wiring shall be installed in accordance with the requirements of
the referred standards in clause 14. The Insulation shall be PVC
type, minimum V90, 0.6/1kV grade. Cable insulation colours shall
be as follows: (client to confirm)
415VAC 3 phase Brown,Black,Grey, Blue(neutral)
Earth Green/Yellow
230VAC Power Red-Line, Blue -neutral
230VAC Control Red-Line, Blue -neutral
24VDC Control Orange positive, Purple negative
Analog circuits Pink
Volt-free White
14.4 Standards and selection of cables shall be as described in this
Section Cables and Panel Wirings in this document.
15 Control, Networking and Interface Hardware
15. Hardware for the control (logic controller), networking and interface shall
meet the following requirements:
15.1 Programmable Logic Controller(PLC) which will contain logic for the
purpose of accepting any supervisory commands and to safely
operate only electrical equipment within the scope of the
subsystem switchboard that the PLC is housed in.
15.2 PLCs having the characteristics as described in clause 16;
15.3 Human Machine Interface shall be installed on the front door of
electrical panel whereif necessary, which allows the operator to
control and monitor the corresponding subsystems as described
in the clause 17;
15.4 PLCs shall be capable of communicating to the plant network as
specified in the communication interface clause 18.
15.5 On each electrical panel, an alarm with a simulated sound and light
shall be provided to draw the Operator's attention. Basic controls
for the local operation of the corresponding subsystem will be

provided on the panel.
FUNCTIONAL REQUIREMENTS
16 Logic Controller
16. Each electrical Panel contains a Programmable Logic Controller(PLC) to

Control and monitor their Subsystems as described in this clause.
16.1 PLCs will be installed with the necessary coding and logic to
operate safely and to meet the process and control requirements
within the scope of their subsystem.Compiled code including
function blocks can be used where complete instructions are
provided.
16.2 Each subsystem shall only be allowed to run the Process in
normal mode, that is without any interlocks being overridden. A
maintenance mode shall be provided which allows switching
individual devices on and off or manipulating their position without
necessarily heeding interlocks.
16.3 The subcontractor shall select PLC makes and models such that
each PLC shall have the capacity to:
a) Communicate on the required networks;
b) Be modified online; and
c) Be expandable by 25% in IO capacity.
16.4 Instrument inputs will be allowed to be overridden for short periods
in order to perform maintenance whilst the Process is in operation.
16.5 Any electrical or software design shall ensure that failures will result
in a state of emergency shutdown condition. It is allowable to
continue to rely on power to the PLC through the UPS however any
other potential requirements must meet the requirements of Safety
Instrumented Systems as given by clause 19.
16.6 Sequences to startup and shutdown any part of the subsystem
will be designed that if interrupted would go to fail in place and
would not in that situation cause an unsafe state.
17 Human Machine Interface
17. Electrical panels shall be equipped with a Human Machine Interface(HMI),

which will allow for process supervision and troubleshooting by Operator
and Maintenance Personnel as given in this clause.
17.1 HMI applications, unless specifically part of mechanical plant, will
present Operators with a consistent user experience.
17.2 HMI includes mimics of the process or layout making it relatively
intuitive to navigate along with the ability to see details. Additional
interfaces will be provided to access settings, trends, alarm
histories and other details.
17.3 The HMI hardware installed on the electrical panel will only be able
to fully control the electrical system's equipment of their
subsystems.
18 Communications Interface
18. Programmable Logic Controller shall be able to communicate with Plant

Network, in addition to having the features outlined in this Clause.
18.1 Provides status information for each of the equipment to the plant
control system. PLC is capable of providing the Critical and
non-critical fault information to the Plant control system.
18.2 Process data of instruments such as temperature, Pressure, Level

and Flow instruments will be shared to the Plant control system.
18.3 PLC shall be programmed to give access to control and modify the
process setpoints from remote via communication protocol for the
operation of the corresponding subsystem.
19 Safety Instrumented Systems
19. The subsystem control system will include safety instrumented systems,
that is systems that perform critical functions for safe operation, as given by
this clause.
19.1 Any safety instrumented system that is identified either in this
Specification or through the implementation of the Plant
subsystems unless otherwise noted will be in accordance with the
following Standards:
Safety instrumented systems for the process industry sector
(IEC 61511)
IEC 61511-1 Framework
IEC 61511-2 Guidelines for application of IEC 61511-1
IEC 61511-3 Determination of the required safety integrity
levels
19.2 Burner systems in the subsystems will comply with the following
standards.
Industrial Thermoprocessing Equipment (EN 746 series)
EN 746-1 Common safety requirements
EN 746-2 Combustion and fuel handling systems
EN 746-3 Generation and use of atmosphere gases
19.3 Emergency Stop on the subsystems Control panel will be
connected in the fail-safe loop and will be classified as a safety
instrumented system.
19.4 The emergency bypass valve between the Kiln Subsystem and the
SACTO subsystem will be classified as a safety instrumented
system.
19.5 Burner Flame Management has been designed, built in and in
compliance with IEC 61511 standards and applying the known
technical rules of safety and envisaging all the potential danger
situations.
20 Explosive Atmospheres
20. The syngas generated by the Process is flammable and feed and product
char are each both combustible. As such, risks arise from fire and explosion
which are mitigated by the Plant in accordance with this clause.
20.1 The Plant will be analysed for any hazardous areas (or areas with a
NT Comment; potentially explosive atmosphere) in accordance with the following
This needs to be Standards.
done as Area Explosive Atmospheres (IEC 60079 series)
Classifiction IEC 60079-10.1 Classification of areas - Explosive gas atmospheres
Drawings not IEC 60079-10.2 Classification of areas - Explosive dust atmospheres
received and 20.2 In areas designated hazardous, mechanical plant and electrical
datasheets do not equipment shall be selected with appropriate protection to mitigate
reference risks as put forwards by the following Standards:
requirements
Explosive Atmospheres (IEC 60079 series)

IEC 60079-14 Electrical installations design, selection and erection
IEC 60079-17 Electrical installations inspection and maintenance
IEC 60079-25 Intrinsically safe electrical systems
20.3 Equipment with or requiring protection will have ATEX
certifications.
21 Quality and Functional Testing
21. The Subcontractor shall maintain a quality management procedure to

ensure the quality, the design and performance requirements described in
this specification.
21.1 Ensure process of Designing, manufacturing & integration of the
subsystem electrical panel as classified in clause 9 shall be
followed throughout the project as per electrical design basis
stated in this document.
21.2 Every step of the designing, manufacturing, and integration
processes should involve inspections, with reports resulting from
those inspections.
21.3 Functional tests shall be performed to ensure the function of every
individual Equipment, Wiring system & associated components and
also checked for their operations.
21.4 Ensure Components associated with the panel,wiring system &
FIeld mounted equipment shall be complied with the standards
required by electrical design basis.
21.5 The Subcontractor must perform all functional tests at the factory
prior to shipment to ensure that the equipment and its operations
are in accordance with the Factory Acceptance Test regulation.
21.6 Ensure the safety of the personnel when accessing the panel and
electrical safety procedures must be followed when accessing low
voltage electrical equipment and components.
21.7 The testing of the software applications' functionality and
interlocks, in all its aspects, must be done by the Subcontractor
in line with plant operations. All the subsystems in the scope of
Subcontractor shall be examined in accordance with Equipment
interlocks at the factory prior to shipment.

T2927-0-44 (Rev C) Electrical Design Basis NT

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T2927-0-44 (Rev C) Electrical Design Basis NT

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T2927-0-44

ELECTRICAL DESIGN BASIS

Anergy Pte Ltd

This document has been prepared by Anergy Private Limited.

Rev Date Description By Chk. Apr.

A 20/12/2022 Preliminary issue HR MLK MCM

B 07/02/2023 Issued for internal review MNP MLK MCM

C 13/04/2023 Issued for Client approval DD MNP MLK

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SCOPE AND CONDITIONS

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‘Instrument’ or ‘Instruments’ includes any Plant that is a sensing

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This specifically includes the following as Contractor scope of

3 Site Conditions and Requirements

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7 Export Connection (To be confirmed)

speed drives, relays and other components, required to distribute

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10 Field Mounted Electrical Equipment

11 Uninterrupted and Backup Power Supplies

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INSTRUMENTATION & CONTROL

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13 Instrument Selection and Arrangement

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instrument will have protection in order of preference either IECEx

14 Cables and Panel Wirings

Table-1 Specification of Power cables

Service Type Spec. Insulation/ Protection Screen. Min.Size

LV Power XVB OR 0.6/1.0kV, XLPE/ N/A-Flexible - 2.5mm2

VSD motor power 2XSLCH-J 0.6/1.0kV, XLPE/ N/A-Flexible Aluminiu 2.5mm2

Table-2 Specification of Control & Instrumentation cables

Service Type Spec. Insulation/ Protection Screen. Min.Size

LV Control XVB OR 0.6/1.0kV, PVC STA - 1.5mm2

Instrumentation RE-2X(St)y- Plain V-90 RP Steel wire Aluminium 0.5mm2

IS circuits RE-2X(St)y- Plain V-90 RP Steel wire Aluminium 0.5mm2

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Thermocouple Thermo Plain PVC STA/ Aluminium 0.5mm2

15 Control, Networking and Interface Hardware

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for the local operation of the corresponding subsystem will be

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16. Each electrical Panel contains a Programmable Logic Controller(PLC) to

17. Electrical panels shall be equipped with a Human Machine Interface(HMI),

18. Programmable Logic Controller shall be able to communicate with Plant

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18.2 Process data of instruments such as temperature, Pressure, Level

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Explosive Atmospheres (IEC 60079 series)

21. The Subcontractor shall maintain a quality management procedure to

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