VOLUME 3

TECHNICAL SPECIFICATIONS

Section 4- Particular Electrical Works Requirements

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 VOLUME 3 – TECHNICAL SPECIFICATIONS

The Technical Specifications – Volume 3 has been arranged in four volumes as follows:

VOLUME 3.1 - GENERAL PROVISIONS

VOLUME 3.2 – PARTICULAR CIVIL WORKS REQUIREMENTS

VOLUME 3.3 – PARTICULAR MECHANICAL REQUIREMENTS

VOLUME 3.4 - PARTICULAR ELECTRICAL REQUIREMENTS

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3.4 Electrical Works Requirements 5
3.4.1 Introduction 5
3.4.2 Scope of Works 5
3.4.3 General Requirements 6
3.4.3.1 Suppliers’ Certificates 6
3.4.3.2 Standards, Regulations and Engineer’s Approval 7
3.4.3.3 Abbreviations and Terms 7
3.4.3.4 Design Quality and Design Life 8
3.4.3.5 Design Safety Features 9
3.4.3.6 Fabrication Generally 10
3.4.3.7 Storage and Operating Conditions 10
3.4.4 General Installation Requirements 10
3.4.4.1 Cables and Lines Generally 11
3.4.4.2 Openings, Sleeves and Seals 12
3.4.4.3 Electromagnetic Compatibility (EMC) 13
3.4.4.4 Protection against Corrosion 13
3.4.5 Testing and Commissioning 14
3.4.5.1 Preliminary Steps for Testing and Commissioning 14
3.4.5.2 Test Methods 14
3.4.5.3 Test on Completion Requirements 14
3.4.5.4 Documentation Required for Commissioning 19
3.4.5.5 Start-up Checklist 20
3.4.5.6 Automatic Reactive Power Factor Compensation 20
3.4.6 LV Distribution Control Panel and Switchgear 21
3.4.6.1 Standard and Rating 21
3.4.6.2 General Design and Construction 21
3.4.6.3 Inspection and Testing 26
3.4.7 Auxiliary Power Source - Battery System 28
3.4.7.1 Standards 28
3.4.7.2 General Requirement 28
3.4.7.3 Rechargeable Batteries 29
3.4.7.4 Motorised Circuit Breakers 29
3.4.7.5 Uninterruptible Power Supply (UPS) 29
3.4.8 Low Voltage Distribution System 30
3.4.8.1 Standards 30
3.4.8.2 Voltage Levels and Colour-Codes 30
3.4.8.3 General Requirements 31
3.4.8.4 Cable Supply and Installation 32
3.4.8.5 Local Distribution Panel, Switchgear Assemblies and Components 34
3.4.8.6 Wiring Blocks 40
3.4.8.7 Frequency Converter 40
3.4.8.8 Capacitors 41
3.4.8.9 Electronic Motor Soft Starter 42
3.4.8.10 Electronic Line Monitor 42
3.4.8.11 Electronic Motor Monitor 43
3.4.8.12 Remote Terminal Units (RTU) 44
3.4.8.13 Spare Parts for LV Stations, Automation, Instrumentation and Control Systems 44
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 3.4.9 Automatic Control Systems 45
3.4.9.1 Standards 45
3.4.9.2 General Requirements 45
3.4.9.3 Implementation Plan and Design Criteria 46
3.4.9.4 Hardware – Generally 49
3.4.9.5 Software - Generally 49
3.4.9.6 Level 1 Equipment 53
3.4.9.7 Level 2 Controller/ PLC Equipment 53
3.4.9.8 Level 3 Equipment 57
3.4.9.9 Communication System 57
3.4.10 Instrumentation and Sensors 58
3.4.10.1 Standards 58
3.4.10.2 General Requirements 58
3.4.10.3 Functional Requirements and Material Generally 59
3.4.10.4 Electromagnetic Flow Meter 61
3.4.10.5 Ultrasonic Flow Meter 62
3.4.10.6 Ultrasonic Water and Sludge Level Meter 63
3.4.10.7 Hydrostatic Level Meter 64
3.4.10.8 Limit-Detector 65
3.4.10.9 Pressure Measuring Device 66
3.4.11 Indoor Installations 66
3.4.11.1 General 66
3.4.11.2 Standards 66
3.4.11.3 Explosion Proof Electrical Installations 67
3.4.11.4 LV Distribution Panel 67
3.4.11.5 Indoor Cable Installation - Generally 68
3.4.11.6 Under-floor Cable Trunking 68
3.4.11.7 Surface Cable Duct 68
3.4.11.8 Cable Tray 68
3.4.11.9 Steel Conduit 69
3.4.11.10 Terminal Boxes 69
3.4.11.11 Metal Constructions 69
3.4.11.12 Tap-Drill Holes 69
3.4.11.13 Watertight Bushings 69
3.4.12 Outdoor Installations 70
3.4.12.1 Outdoor Equipment 70
3.4.12.2 Cabling, Wiring for Indoor and Outdoor Installations 70
3.4.13 Data and Voice Communication Systems 70
3.4.13.1 Data Communication System Generally 70
3.4.13.2 Patch Panels 71
3.4.13.3 Copper Communication Cable Supply and Installation 72
3.4.13.4 Optical Fibre Cable Supply and Installation 73
3.4.13.5 Intrusion Alarm System 74
3.4.13.6 Earthing/ Grounding 74

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3.4 Electrical Works Requirements
3.4.1 Introduction

This volume of the Technical Requirements provides the Mechanical Works requirements which are applicable for
the construction of the Works.

This section of the Technical Specifications is one of the five sections which comprise Volume 3 are listed hereafter:
 Volume 3.1 General Administrative, Design and Works Requirements
 Volume 3.2 Civil Works Requirements
 Volume 3.3 Mechanical Works Requirements
 Volume 3.4 Electrical Works Requirements (this volume)
The provisions specified in this section are to be read in conjunction with the other sections of Volume 3 as listed
above.

In addition to the provisions for electricical equipment described in this section of the technical requirements, other
general requirements concerning functionality, security, operation and maintenance are also described in the other
sections of the technical requirements.

In the performance of the Works, the Contractor must comply with all the technical requirements provided in all the
different sections and where there are ambiguities or different requirements from different sections or within the
same section; the most constraining or higher quality requirements shall prevail.

3.4.2 Scope of Works

This specification covers the design, fabrication, delivery, installation and commissioning of electrical equipment
necessary for a fully functional facility. The type of works covered under this section includes the following:
 Low voltage control panel including  Power distribution system
components  Telemetry and control system
 Local control panels and components  DCS/ SCADA Software
 Distributed control system controllers  Operational internal/ external and safety
and components lighting
 Human machine interface  Intranet, internet and telephone services
 Programmable logic controllers  Spare parts and special tools
 Sensors  Other essential equipment not listed
 Flowmeters
The Contractor shall design and build the equipment in complete manner which includes all parameters relating to
the required shape, type, quality, tolerances, functional standards, safety criteria, and limits on the whole-life cost of
the permanent works upon completion; the tests which must be successfully completed both during and after
construction; the expected and required performance of the permanent works upon completion; the design life and
durability of the permanent works upon completion; how the permanent works are expected to be operated and
maintained upon completion; the operational software and manuals to be supplied; and details of the spare parts
required to be provided and their cost.

The scope of works that is covered by this Section of the specific Requirements also includes the building and civil
works necessary for a fully functional facility including the supply and delivery of material, construction,
completion, installation of equipment and commissioning.

The Contractor shall design and install power distribution, auxiliary (emergency) supplies and control system as
required to satisfactorily operating the new plant and equipment being supplied under this Contract.

Automatic fire detection system shall be provided, designed to enable continuous supervision of the fire threats.

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In compliance with the project of explosive gas protection, for all (eventually) determined outdoor hazardous gases
dangerous zones 1 and for other indoor space determined in the referred project the proper dangerous gas detection /
control system should be designed and provided.

3.4.3 General Requirements

The1 Works shall consist of newly manufactured materials only. Materials which differ galvanically shall not be used
in close proximity.

Top finish colour coats shall be determined in agreement with the End Beneficiary. Colour samples shall be
submitted if so required.

The Contractor shall be liable for the first fill of oil and grease for all mechanical Works and equipment.

Lifting equipment shall be provided for all Works items over 50 kg (where not under the lift area of overhead cranes
specified elsewhere).

The Contractor shall be responsible for the protection of Works up until the date of handover. Suitable measures
such as temporary timber covers or plastic sheeting shall be used.

Each item of Works shall bear, in an easily readable position, an identification plate with text in Serbian and the
language of the country of origin stating the name of the manufacturer, year of manufacture and type and serial
numbers.

Where the Contractor includes bought-in manufactured items, then full details shall be submitted to the Engineer for
approval prior to incorporation in the works.

3.4.3.1 Suppliers’ Certificates

All manufacturers shall be certified in accordance to ISO 9001.

The electro-/mechanical equipment (MEICA2) must be provided with the certification “CE” in accordance to
Machinery Directive 98/37/EEC, in particular the following directives shall be considered:
 Machinery Directive 98/37/EEC
 Low Voltage Directive 73/23/EEC
 EMC Directive 2004/108/EC
 And others as required by Directive 98/37/EEC
In addition the following documentation shall be included for each individual machines and/or apparatus:
 Certificate of Conformity in acc. to EN 10204/2.1
 Manufacturers Test Certificate in acc. to EN 10204/2.2 3
 Manufacturers Work’s Test Certificate in acc. to EN 10204/2.34
 Certificate attesting the durability (sustained loading) of the given material (for materials in contact with the
medium such as pipelines, pipe shapes, sealings, fittings, etc.) in case of given medium, given temperature
and given operational pressure

All certificates are subject to approval from the Engineer. Expenditures for certification of equipment are to be
included in the Contractors prices.

1 Q19
2
MEICA = Mechanical-, Electrical-, Instrumentation-, Control & Automation
3
For main equipment, such as pumps, blowers, mixers, etc.
4
For main equipment, such as pumps, blowers, mixers, etc.as required by the technical requirements
and on request of the Engineer
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3.4.3.2 Standards, Regulations and Engineer’s Approval

National Standards or harmonised EU-Standards in their latest Edition shall be used throughout this Contract,
generally. Authoritative are all standards that are valid at the location of the Plant during the time of implementation.

The conditions specified in these general specifications are minimum requirements for all deliveries and
performances. If special requirements are given for particular items they apply only to these particular items. The
Contractor may propose Standards for the execution of the Works, which shall be approved by the Engineer. The
design, workmanship, materials, strength and dimensions of all parts shall comply with one or more of the standards,
as mentioned above and to the satisfaction of the Engineer.

Where no standards are stated in the Contract, all materials, components, equipment, workmanship and tests for
which EN or DIN or their acceptable equivalents are available, they shall be in accordance with such standards.

The electrical installations shall comply with and be tested in accordance with national or internationally recognised
regulations or codes of practice subject to any specific requirements of the local electricity supply authority.

Material and equipment supplied and work performed shall comply with these standards and regulations as a
minimum. Where manufacturers offer equipment to other standards, the standards shall be equal or superior to those
specified and full details of the difference shall be supplied to the Engineer if requested.

Equipment to be installed in areas likely to explosion incidents shall be designed to the required Ex-proof standards.

Where the design or choice of materials or Works is affected by Statutory Safety Acts, then the materials and works
supplied shall comply with all relevant sections of those acts even though no particular reference may be made in the
Specification.

The operation and arrangement of the standby generator and the incoming switchgear shall comply with the current
recommendations issued by the Public Utility Company.

After completion of all electrical works, the system must be verified by an accredited institution to obtain an
electrical safety permit.

3.4.3.3 Abbreviations and Terms

Following abbreviations and terms are used in the text with equal meaning:

Contractor = Contractor = Bidder = Tenderer

Engineer = Consultant = Site Supervision

Tender = Quotation = Offer

P.S. = Provisional Sum

L.S. = To be measured as Lump Sum

No. = To be measured by Number

M = To be measured by Running Meter

sq.mm = To be measured by Square Millimetre (mm²)

sq.m = To be measured by Square Meter (m²)

cu.m = To be measured by Cubic Meter (m³)

HV (MV) = High (medium) Voltage (more than 1 kV)

LV = Low Voltage (0.4 kV)

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V = Volt

VDE = Verband Deutcher Electotechniker (VDE Association for Electrical, Electronic and Information
Technologies e.V)

DIN = Deutsches Institut fur Normung (German Institute for Standardization)

ISO = International Organisation for Standardization

IEC = International Electrotechnical Commission

CEN =Committee European de Normalisation (European Committee for Standardization

CENELEC = Commite European de Normalisation (Electronique European Committee for Electrotechnical

Standardization)

A = Ampere

mA = Milli-Ampere

W = Watt

Var = Reactive Power

kWh = Kilowatt-hour

f = Frequency

T = Temperature

AC = Alternating Current

DC = Direct Current

IP = International Protection Class

PTC = Positive Temperature Coefficient

RMS = Root-Mean-Square value

UPS = Uninterruptible Power Supply

MCC = Motor Control Centre

PLC = Programmable Logic Controller

SCADA = Supervisory Control and Data Acquisition System

ICA = Instrumentation, Control and Automation

3.4.3.4 Design Quality and Design Life

The Contractor shall design the Works and all Equipment in accordance with the ER and to the satisfaction of the
Engineer. The design of works shall be in accordance with good modern practice and shall be such as will facilitate
operation, inspection, cleaning, lubrication and repair to ensure long life and satisfactory operation under all service
conditions. The Contractor’s design calculations shall be submitted to the Engineer as required.

Works shall be designed for a long reliable operating life and shall be suitable for 24 hours per day continuous
operation for prolonged periods in the climatic conditions applying and with a minimum of maintenance.

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The Contractor may be called upon to demonstrate this for any component, either by the service record or evidence
of similar equipment already installed elsewhere or by records of relevant type tests.

All equipment proposed shall have been in use successfully for a period of at least five (5) years in two projects prior
to any proposal for incorporation into the Works. The Engineer may request signed references on the quality and
operation of such equipment from the owner or operator of the equipment proposed. Additionally the Engineer may
request that the Contractor arrange a site visit for the Engineer and End Beneficiary to witness first hand operation of
the proposed equipment. The cost of this site visit shall be borne by the Contractor as part of the Contract costs.

Wherever possible works shall be designed and arranged so that the degree of skill required maintaining and
servicing the works shall be minimal. Except for consumable items such as carbon brushes and the like, which
normally require more frequent replacement, no part subject to wear shall have a design life from new to replacement
or repair of less than five (5) years of continuous (24 hours and 7 days) normal operation, and, where major
dismantling is required to replace a part, the life of such parts shall not be less than ten (10) years.

High voltage switchgear shall have a service life of 10,000 operations.

Electrical contactors and switches shall have a minimum life under normal full load working conditions of one (1)
million operations without replacement of any part for AC3 loads.

Electrical relays and light current switching devices (AC5) shall not require maintenance of any kind before
completing two (2) million operations under normal full working load.

The Works and Equipment shall be designed for the prevention of corrosion, entry of insects and vermin, entry of
dirt and dust, and to minimise risk and damage in the event of a fire. Works shall operate without undue vibration
and parts shall be designed to withstand the maximum stresses under the most severe conditions of normal service
after loss due to any corrosion allowance, or the specified test condition including any corrosion allowance.

Works shall be designed so that when operating at the normal condition, the intensity of emitted noise in the working
environment shall be compliant with Serbian and EU health and safety regulations and does not constitute a health
hazard to operators and other personnel or cause a nuisance outside the boundary of the works.

3.4.3.5 Design Safety Features

General health and safety requirements are provided in Section 3.1 of these technical requirements.

Works, as designed and installed, shall have no feature that could be a hazard to operators, maintenance staff,
visitors or other persons having access thereto.

All control equipment (switches, interrupters, valves, panels …) shall be located such that they are accessible and
can be operated safely without having to overreach. Access ladders, stairs and working platforms shall be provided
where this is not possible.

Guard for electrical safety devices, thermal insulation, noise suppression devices, written notices, safety covers,
lifebelt and the like shall be provided where needed.

Adequate safeguards shall be provided to prevent personnel accidentally coming into contact with dangerous
machinery mechanisms, hot surfaces, electrically live parts and any other hazardous components or contents.

Emergency stop devices shall be provided and positioned adjacent to all motor driven equipment which:
 Involves a risk of injury to personnel during norm and maintenance operations;
 Handles high pressure fluid or dangerous chemicals;
 Is located at a distance of more than five metres from its controller;
 Has no direct, unimpeded access between the controller and the item of controlled works, irrespective of
distance.

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Rubber mats shall be provided in front of all motor control centres, distribution boards, instrument and battery
supply power cabinets.

3.4.3.6 Fabrication Generally

Only new equipment of highest quality may be installed. For similar tasks, uniform appli¬ances by the same
manufacturer shall be used. The number of different brands shall be kept to a minimum. For extensions, only such
appliances shall be tendered, which are functionally and constructively identical to those that are already in use.

Works and any component parts thereof shall be made of new materials of suitable grade, quality and strength,
protected where appropriate for the operating conditions and the working and climatic environments.

Material for equipment shall be carefully selected for the function and shape which the equipment has to fulfil as
well as the operating environment. In particular the structural and corrosion resistance limitations must be considered
prior to selection. In selecting materials, which are at different levels on the electrolytic scale, the dangers of these
being in close proximity shall be addressed by the Contractor in his design and suitable preventative measures taken.

Where there is potentially slight relative motion of two materials which are in contact and one or both being metals,
suitable precautions shall be taken, to prevent seizure by fretting.

Where dissimilar materials in contact or proximity can be bridged by an electrolyte producing a corrosive condition,
the Contractor shall demonstrate to the satisfaction of the Engineer that adequate precautions have been taken to
prevent galvanic corrosion. Anodic index difference between the metals shall be 0.15V for outside installation and
0.25V for internal installation. At risk metals installed outside shall be provided with corrosion protection Class C5
and C3 in accordance with EN 12944-6.

Materials shall have a high resistance to any change in their properties due to the passage of time, environmental
exposure (light, heat, air, humidity, water, chemicals …) or any other cause, which may have a detrimental effect
upon the performance or life of the works.

Where brass and bronze are to be used in environments where “de-zincification” or “de-aluminification” may occur,
suitable inhibitors to prevent this type of attack shall be incorporated.

The components of air conditioners (e.g. cryogenic fluid, insulation) shall not contain any CFHC (Chloro -
Fluorinated Hydro - Carbons).

3.4.3.7 Storage and Operating Conditions

Equipment supplied shall be capable of withstanding any combination of the following environmental conditions in
which it can be stored or operated without mechanical or electrical damage or degradation of performance:

(i) Indoor Equipment

0o to 40o C ambient.
0% to 98% humidity with condensation due to temperature change.
(ii) Outdoor Equipment
0o to 40oC ambient under full sunlight.
0 to 100% humidity with condensation due to temperature change.

3.4.4 General Installation Requirements

All parts of the electrical equipment shall be able to be installed or dismantled without any modification of the
supporting structure.

Apparatus and devices shall be arranged in a way that they can easily be operated, regulated, repaired and replaced
from the front opening or door.

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Outdoor equipment shall be protected against direct sunlight and rain by installation inside with an IP 65 (or IP55 if
mechanically ventilated) enclosure or under a canopy.

There shall be a key system for the plant and all doors of electrical rooms or enclosures that guarantees that the
equipment is quickly accessible for operation, maintenance and fault removal. Keylock-switches and locks shall be
compatible with the plant's master lock system. If installed outdoor, keylock-switches shall be protected against dirt
and moisture by a IP54 protective casing, made of stainless steel - 1.4301.

The doors or shutters for the protection of operational devices shall close automatically.

All switchgear cabinets and the rooms of the switching stations shall be supplied with ventilation, heating and air-
conditioning devices to maintain the equipment at air temperature of between +15°C and +30°C.

The penetration of dust and insects through ventilation openings into the switchgear cabinets shall be prevented with
stainless steel mesh screen.

Electrical rooms must not be located below ground level and shall be kept dry under any operating conditions.

Air conditioning units or other piping systems shall not be installed overhead of any electrical gear.

In all rooms with electrical switchboards the Contractor shall provide a sufficient number of CO 2 - fire extinguishers
and other fire protection equipment as required in the regulations.

3.4.4.1 Cables and Lines Generally

Cable Type

In general cables of the NYY-J type according to DIN VDE 0250 with the designed cross section area shall be used
for cabling. The voltage-drop shall be limited to 3% in all circuits at full load.

For the supply of drives controlled by frequency converters, shielding cables of the NYCY or NYCWY type with
concentric conductor shall be used.

For internal installation of LV-units, cables of the NYM-J type according to DIN VDE 0250 with the suitable cross
section shall be used.

For indoor-transmission of data signals, screened paired measuring- and control-installation-cables of the PYCYM
type, 230 V, and for installation in the ground, cables of the A-2YF(L)2Y type according to DIN VDE 0250 shall be
used.

Specialised cables for data-transmission, safety devices, high-frequency signals, short-circuit-proof installation,
optical transmission shall be suitable for the specific purpose. Further requirements for these cables are provided in
later sections.

Intrinsically safe circuits shall be carried out with cables of the EBCY 2x2x0.75 type, blue, according to DIN VDE
0165; fire-signal cables shall have respective markings.

Underwater cables shall be suitable for the intended purpose and shall be compatible for installation at their intended
location without loss of performance.

Identification

All cables shall be identified at both connecting points with labels which indicate voltage, purpose and consecutive
numbering. The information on the labels shall be systematic. The labels shall be mechanically attached, resistant to
high temperature and long lasting.

Buried Cables

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Directly buried cables shall be placed in cable trenches on a 10cm layer of sand and then covered with a finishing
layer of sand 10cm thick. The cable shall be laid loose without any straight section in the trench to permit stretching
over time and prevent any possible tension on the cable. All cables shall terminate at each ends with and
equipotential bonding terminal.

High (medium) voltage (HV) cables shall be laid at a depth of 1.0 m; LV cables, control and signalling lines at 0.7 m
in depth.

The top of the sand shall be covered with plastic cover plates or concrete tiles. A warning tape, with markings to
identify the kind of service in Serbian and English language throughout the entire length, shall be laid 50 cm above
the cables. For optical fibre cables the warning tape shall include an integral stainless steel wire to allow inductive
location of the optical cable.

Before the excavation of trenches is allowed to begin, the cable route shall be marked and inspected together with
the Engineer. Surfaces that shall be restored afterwards shall be recorded by means of reports and photos. Excavation
works shall follow the requirements in Section 3.3 of the TR.

Installation in Chambers or Enclosures

Cables must be installed on cable trays when running on surface of walls, floors or ceilings, direct installation on
surfaces is not acceptable.

In the case when cables shall be installed either concealed, in insulating conduit, cable duct or cable trenches, the
cable bundles shall be held together with corrosion resistant cable-cleats. Cable bundles shall be grouped by types
with the necessary separation. Galvanised or high-grade-steel cable trays shall be used where larger amounts of
cables are installed.

Cables shall be installed without any joint as far as practically possible. Cable junctions shall be carried out in
insulating junction boxes according to the cables cross-section; the degree of protection shall be IP 54. Terminal
boxes located indoor shall be IP 54 and IP 65 (or IP55 if mechanically ventilated) for outdoor locations and where
the line changes from solid to flexible wiring. In Ex-Zones the junction boxes shall be of the approved type for
explosion areas.

If cables are crossing walls or ceilings between fire-protection sections, there shall be fire-proof bushings according
to EU Directive 94/9 that can easily be opened for future extensions. At bushings into sections that are endangered
by water or gas, sealed and elastic gas- and watertight bushing-systems shall be installed.

Only stainless steel material shall be used for fixing cleats, terminals, cables, trays, ducts, lamps, switches, outlets,
etc. The fixation to walls and ceilings shall be carried out in a suitable manner using plugs from plastic.

Telecommunications cables shall have an additional conductor (steel strip 30  3.5 mm zinc plated) laid in the same
trench to be connected to the equipotential bonding system at both ends.. The connections shall be visible and
protected against corrosion.

3.4.4.2 Openings, Sleeves and Seals

Sleeves of appropriate size shall be provided at locations where cables pass through exterior walls, to permit
watertight sealing of the cable entrances into the structure. PVC sleeves shall be provided at locations where cables
pass through floors and interior walls of the structure. The PVC sleeves shall protrude from the finished floor level
by 100mm.

Cables entering the structure shall be fitted with identification ferrules at the point of entry if the cable function is not
readily apparent.

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All holes through wall, beam and floor slab and the annular space between the cable and the PVC sleeve shall be
back filled with fire resistant material of appropriate fire resistance rating after cabling. Fire barrier for trunking
passing through the structure shall also be installed.

All barriers and seals shall protect against entry of insects, vermins, soil and water into the structure, truncking
system or trenches.

3.4.4.3 Electromagnetic Compatibility (EMC)

All electrical and electronic equipment shall create minimal electromagnetic disturbances and shall be
electromagnetically compatible as provided in the standards.

Standards
 Electromagnetic compatibility Directive - EMC 2014/30/EU
 EN 61326 Electrical equipment for measurement, control and laboratory use - EMC requirements
 IEC 61000 Electromagnetic Compatibility (EMC) General - Methodology for the achievement of
functional safety of electrical and electronic systems including equipment with regard to electromagnetic
phenomena
 IEC 61000-6-4:2006/AMD1:2010 ED2 Amendment 1 - Electromagnetic compatibility (EMC) - Part 6-4:
Generic standards - Emission standard for industrial environments

General Requirements

The following recommendations shall be adopted for fabrication and installation of electrical and electronic
equipment.

All switching cabinets shall be closed metal casings. All metal parts shall be connected to each other with low
resistance connection. Mechanical connections of varnished casing-parts shall also be electrical conductive, e.g. by
using contact or scratching disks. The cabinet-door shall be connected to the frame by earthing strips as short as
possible.

All components shall be protected against damaging influences and radiations by adequate earthing, shielding, filters
and inductors, to reduce electromagnetic interferences and increased EMC from equipment-generated distortion
(mains pollution) as well as radio interferences.

Signal and power lines shall be kept apart by physical separation of at least 20 cm in switchgear cabinets and 40 cm
in switching stations. Unscreened wires shall be twisted.

Contactors, relays, magnetic valves, operating hours counters and electrical operated breakers shall be always be
protected by installation of suppression devices at the source of interference.

Shielding of signal and power cables shall be connected to the casing by a low-resistivity screening clamp. Screens
for analogue-signal lines shall be connected to casings on one end.

Earthing system shall be designed in a star-network and connected to the earthing electrodes at the central point.
Metal cable trays, pipes, ducts, etc. shall be electrically connected to form an equipotential structure. Both ends shall
be connected to the earthing electrodes.

3.4.4.4 Protection against Corrosion

All metal goods used for electrical and electronic work shall be protected against corrosion as specified in Section
3.3. Alternatively, inherently corrosion resistant material such as stainless steel of the appropriate quality shall be
adopted.

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3.4.5 Testing and Commissioning

Testing and commissioning (T&C) is a contract requirement and must be satisfactorily completed as defined in the
Contract.

The Contractor shall depending on his plan propose that commissioning proceed by zone. Commissioning of the
electrical system shall be completed before commissioning of the whole facility.

3.4.5.1 Preliminary Steps for Testing and Commissioning

Before carrying out T&C for the facility or for each zone, the Contractor shall take the following steps:
 Prepare testing checklists and pro-forma for each equipment to be tested;
 Submit draft T&C method statement including checklists and pro-forma to the Engineer for approval. The
draft T&C method statement shall include essential procedures mentioned in this procedure plus additional
T&C procedures required for specific installations as well as manufacturer’s recommendation;
 Correct method statement and resubmit for acceptance
 Obtain design drawings and specifications and to be thoroughly acquainted with the design intent
 Obtain copies of approved shop drawings and equipment schedules
 Review approved shop drawings and equipment schedules
 Check manufacturer’s operating instructions and statutory requirements
 Physically inspect the installation and equipment to determine variations from designs and/or specifications
 Check individual components, e.g. key switches, control equipment, circuit breaker status, etc. for proper
position and settings for completeness of installation
 Check inclusion of manufacturer’s typical equipment testing data or factors before T&C of particular
equipment
 Arrange statutory testing required by legislation

3.4.5.2 Test Methods

The following tests are expected to be completed on the electrical network:

 Dielectric absorption tests shall be performed with a 2,500 volt DC megger.
 Megger tests shall be performed at a DC voltage of 1,000 volts for 600 volt rated equipment, and at a DC
voltage of 500 volts for 120-300 volt rated equipment.
 Continuity checks shall be performed with a low voltage DC meter, light or bell.
 Test instruments shall be calibrated to national standards to insure the accuracy of tests. These calibration
reports shall be made available with test reports.
The Contractor is to propose other additional tests he considers necessary.

3.4.5.3 Test on Completion Requirements

Tests on completion is a contractual requirement as defined in Sub-Clause 1.1.3.4 of the Contract and clarified in
Section 3.1 of the TR.

There is a requirement in legislation for statutory electrical safety tests. These statutory tests are not substitute for the
required tests on completion described hereafter.

Most of the tests described hereafter are for pre-commissioning purposes and must be completed prior to start of
commissioning tests.

Some of the following tests can be completed in the factory and the completed test pro-forma shall be submitted for
approval by the Engineer.

Switchboards, Control Panels, and Motor Control Centres

A 1,000 volt DC megger test shall be performed on busbars, motor starters, circuit breakers, and disconnect
switches. This test may be combined with the power cable megger test by testing the devices and terminated cables
together.

A continuity check shall be performed on motor control circuits and control panel internal wiring.

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An operational test shall be performed on the motor controls.

Motor heater sizes shall be checked for proper size.

High Voltage Primary Cables

A continuity test, a 2,500 volt DC megger test, a DC high potential test, and a second 2,500 volt DC megger test
shall be performed on 15 kV primary cables after the cables have been spliced or terminated. The high potential test
shall be performed at 45kV on new cable installations and at 30kV on existing installations or when new cable has
been spliced to existing cable.

450/750 Volt Power Cables

A continuity check and a 1,000 volt DC megger test shall be performed on 450/750 volt power cables - 25mm2 and
larger. The megger test shall be performed between each pair of conductors and from each conductor to ground.
Each test shall be performed for 15 seconds or until the insulation resistance value stabilizes.

The insulation resistance between conductors, and from each conductor to ground, shall be 100 megohms minimum
in one minute or less. In addition, the lowest insulation resistance value shall not differ from the highest value by
more than 20 percent. If all megger readings for a given circuit are above 1000-meghoms, the 20 percent balance
requirement may be waived.

Control Cables

A continuity check shall be performed on control and instrumentation wiring.

Fans

Setting and operation of the fan control panel shall be verified to ensure that the fans are operable and functional.
Temperature of the probes in each winding shall be measured.

Motors

A 1,000 volt megger test shall be performed on 400 volt motors. A 500 volt megger test shall be performed on
200/240 volt and 120 volt motors.

Motors shall be “bumped” to verify proper direction of rotation.

Motors shall be run to verify proper ampere draw and to verify vibration and heating are within required limits.

Capacitors

Capacitors shall be inspected for proper fuses before testing. A 1,000 volt DC megger test shall be performed on 400
volt capacitors, and a 500 volt megger test shall be performed on 200/240 volt capacitors. After each megger test,
proper discharge shall be checked.

Tests during Construction

Before functional testing can proceed, tests and inspection of different installations shall be carried out during
construction. These shall include as a minimum the followings:
 Visual inspection;
 Earth electrode resistance;
 Continuity of protective conductor.
The visual inspection shall include a check on the following items, where appropriate:
 Adequacy of working space, access, and maintenance facilities;
 Connections of conductors;
 Identification of conductors;

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  Adequacy of the sizes of conductor in relation to current carrying capacity and voltage drop;
 Correct connections of all equipment with special attention to socket outlets, lampholders, isolators, switches,
residual current devices, miniature circuit breakers, and protective conductors,
 Presence of fire barriers and protection against thermal effects;
 Methods of protection against direct contact with live parts (including measurement of distances where
appropriate), i.e. protection by insulation of live parts, or protection by barriers or enclosures;
 Presence of appropriate devices for isolation and switching;
 Choice and setting of protective and indicative devices;
 Labelling of circuits, fuses, protective devices, switches, isolators and terminals;
 Selection of equipment and protective measures appropriate to adverse environmental conditions;
 Presence of danger and warning notices;
 Presence of diagrams, instructions and other similar information;
 Connection of single pole devices for protection or switching in phase conductors only;
 Method of protection against indirect contact;
 Prevention of mutual detrimental influence;
 Presence of undervoltage protective devices and:
 Erection method
Additional Relevant Tests

The following items, where relevant, are to be tested preferably in the sequence indicated below:
 Continuity of protective conductors, including main and supplementary equipotential bonding,
 Continuity of ring/ final circuit conductors,
 Insulation resistance,
 Polarity,
 Earth electrode resistance,
 Earth fault loop impedance,
 Functions of all protective devices,
 Functions of all items of equipment.
In the event of any test indicating failure to comply, that test and those preceding, the results of which may have been
influenced by the fault indicated, shall be repeated after the fault has been rectified.

Continuity of Protective Conductors

Every protective conductor, including all conductors and any extraneous conductive parts used for equipotential
bonding should be tested for continuity. The test should be made by connecting together the neutral and protective
conductors at the mains position and checking between earth and neutral at every outlet by a continuity tester, which
should show a reading near zero.

Continuity of Ring/ Final Circuit

The ring circuit should be tested from the distribution board. The ends of the two cables forming the phase
conductor should be separated, and a continuity test should show a reading near zero between the two; the same tests
to be made between the two cables that form the neutral conductor, and between the two cables that form the
protective conductor.

The testing method in above paragraph is only applicable when the ring circuit has been inspected throughout, prior
to the test, to ascertain that no interconnection (multi-loops) exists on the ring circuit. Otherwise, the testing methods
stipulated in Part 3 of the Guidance Note 3 to BS7671, should be adopted instead.

Insulation Resistance

A suitable direct current (d.c.) insulation tester should be used to measure insulation resistance. Care should be taken
to ensure that the insulation of the equipment under test could withstand the test voltage without damage.

To carry out this test, it is acceptable to divide large installation into sections with groups of outlets, each group
containing not less than 50 outlets. The term �outlet� in this case includes every point and every switch. A socket
outlet or appliance or luminaire incorporating a switch is regarded as one outlet.

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Measurement shall be performed with all fuse links in place, all switches and circuit breakers (including, if
practicable, the main switch) closed and all poles or phases of the wiring electrically connected together. For best
practice, the insulation resistance shall not be lower than 1.0 mega ohm for low voltage installation under a test
voltage of d.c. 500V.

Insulation resistance measurement shall be performed between all conductors connected to any one phase or pole of
the supply and, in turn, all conductors connected to each other phase or pole. For best practice, the insulation
resistance shall not be lower than 1.0 mega ohm for low voltage installation under a test voltage of d.c. 500V.

For the sake of enhanced safety, when the value of insulation resistance measured is near the minimum values as
required in this T&C procedure, or at a relatively low valves where considered abnormal to trade’s practice, the
concerned circuit /installation shall be re-checked to improve and re-test shall be conducted afterward.

Polarity

A test of polarity should be carried out to verify that:

 Every fuse and single-pole control and protective device is connected in the phase conductor only,
 Centre-contact bayonet and Edison-type screw lampholders to IEC 60238 in circuits having an earthed
neutral conductor, have their outer or screwed contacts connected to that neutral conductor, and
 Wiring has been correctly connected to equipment, socket outlets and similar accessories.

Earth Electrode Resistance

A proper earth electrode resistance tester should be used to measure earth electrode resistance. An alternating current
at 50 Hz of a steady value is passed between the earth electrode T and an auxiliary earth electrode T1 placed at a
separation distance recommended by the manufacturer of the tester but in any case should not be less than 20 metres
away. A second auxiliary earth electrode T2, which may be a metal spike driven into the ground, is then inserted
half-way between T and T1, and the voltage drop between T and T2, divided by the current flowing between T and
T1, gives a measured earth electrode resistance of earth electrode T.

For an electrical installation having four or more earth electrodes which are installed more or less in line, following a
general direction not exceeding 15o deviation and with separation between adjacent electrodes not less than the
recommended distance by the manufacturer of the tester but in any case not less than 20 metres, these electrodes can
be used in turn as the auxiliary electrodes for the purpose of measuring the earth electrode resistances.

The following alternative method for measuring the earth electrode resistance may be used if the electricity supply is
connected. A loop impedance tester should be connected between the phase conductor at the origin of the installation
and the earth electrode with the test link open, and a test performed. This impedance reading could be treated as the
electrode resistance.

Earth Fault Loop Resistance

The earth fault loop impedance should be measured by a phase-earth loop tester with a scale calibrated in ohms.

Before the test begins, it is essential to establish, by inspection, that the earthing conductor and all relevant earth
connections are in place, and that the bonding connection to electricity supplier’s earthing facilities is disconnected.
Measures should be taken, during the impedance tests especially when the earth leakage protective devices are
effectively removed for the duration of the tests, to ensure that the installation is not being used other than by
person(s) carrying out the tests.

Functions of Protective Devices

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Function of other protective devices, such as RCD, miniature circuit breakers, moulded case circuit breakers, air
circuit breakers, fused switches, switch-fuses and protective relays etc. should be checked by hand operation as
appropriate.

Function of all items of equipment such as isolators, switches and indicative devices should be checked by hand
operation.

Functional Performance Tests of Consumers

The purpose of functional performance tests is to demonstrate that the equipment/ installation can meet the
functional and performance requirements as specified in the General/ Particular Specifications. Functional
performance test should proceed from the testing of individual components to the testing of different systems in the
installation.

The Contractor may have to make temporary modifications as the test proceeds. The specific tests required and the
order of tests will vary depending on the type and size of systems, number of systems, sequence of construction,
interface with other installations, relationship with the structural elements and other specific requirements as
indicated in the General/Particular Specifications. The testing of systems may have to be carried out in stages
depending on the progress of work or as proposed by the Contractor.

Tests on Suppliers’ Premises

Part of the tests may be required to be carried out in suppliers’ premises in accordance with the provisions in the
General/Particular Specification. Any performance deficiencies revealed during the functional performance tests
must be evaluated to determine the cause and whether they are part of the contractual obligations. After completion
of the necessary corrective measures, the Contractor shall repeat the tests.

Failure to Complete a Test

If any test cannot be completed because of circumstances that are beyond the control of the Contractor, it shall be
properly documented and reported to the Engineer who shall then liaise with the relevant parties to resolve the
situation.

The Contractor shall resume his testing work immediately upon the attainment of a suitable testing environment.

Functional Test Reports

Functional test reports covering all measured data, data sheets, and a comprehensive summary describing the
operation of the system at the time of the functional tests shall be prepared and submitted to the Engineer. Deviations
in performance from the General/Particular Specifications or the design intent should be recorded, with a description
and analysis included.

Where required in the General/Particular Specification, the Contractor shall conduct a final evaluation of the
performance of the Electrical Installation, the results of which shall be included in the commissioning report.

Installation in Hazardous Environment

The following additional check, where appropriate, shall be carried out for installations in hazardous environment
including "Ex-Zone".

(a) Where appropriate, the area involved should be checked to ensure ‘gas free’ condition before insulation and earth
fault loop impedance test are carried out.

(b) All equipment should be suitably protected according to the types of protection. The integrity of the type of
protection provided for the equipment should not be jeopardised by the method of installation. No alteration that
may invalidate the conditions of protection can be used.

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(c) Equipment should be kept clean and free from condensation, accumulation of dust, foreign particles and
deleterious substances.

(d) All lamps, fuses and replaceable parts should be checked so that correct rating and types are being used.

(e) The surface temperature of all equipment should be appropriate to the type of protection being provided.

Lightning Protection System

The whole lightning protection system shall be tested for continuity between air terminations and earthing
terminations and the resistance shall be recorded.

The earth termination resistance shall be tested and recorded. Each earth termination shall have a resistance to earth
not exceeding the product given by 10ohms times the number of earth terminations to be provided. The whole of the
lightning protection system shall have a combined resistance to earth not exceeding 10ohms.

Where the steel work of the structure is used as down conductor, the continuity of the steel work shall be tested and
recorded.

Locations of all earth electrodes and down tape routing shall be checked to be clear of any dangerous goods store,
diesel tanks and inflammable stores, etc.

All connections at terminations, tee off points and earth electrodes shall be checked for tightness.

All connections at terminations, tee off points and earth electrodes shall be checked for tightness.

3.4.5.4 Documentation Required for Commissioning

Prior to commissioning of the whole electrical system for the whole facility or for each each zone the following
information shall be submitted in detail:

 List of documents, block diagram,  start-up-report with information about

 list of components, mechanical sequence
installation diagram,  and effect of external interlocking,
 drawings and description of installed  inspection drawings,
machinery,  fittings and devices list,
 function diagram,  list of electrical consumers,
 terminal diagram,  list of electrical instruments,
 cable-list,  list of identification numbers,
 measuring reports,  protocol of earthing resistances,
 cable routes diagram,  circuit diagrams,
 installation data,  software descriptions,
 special characteristics,  operating manuals,
 indication,  inspection- and maintenance table,
 control and automatic control devices,  spare parts list,
 device's function,  required tools,
 safety devices,  fault identification and troubleshooting
 instructions for operational devices, instructions, etc.
 functional scheme drawing of the whole
plant,

Drawings, diagrams, programs and texts shall also be submitted as electronic-files for data processing systems as
required by the Engineer.

The programs and source code of PLC or other programmable units shall be submitted with a written
documentationin a machine-readable and processable way.

All test records, forms, commissioning protocols and certificates shall be submitted to the Engineer.

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3.4.5.5 Start-up Checklist

After completion of the electrical works, the Contractor shall perform the start-up procedure together with the
mechanical, civil and process-equipment and structures. Start-up shall be performed according to checklists, which
shall be submitted beforehand by the Contractor to the Engineer.

Together with the start-up checklists also list with all adjustable values and their set values and the possible ranges
shall be submitted.

Frequency converters with constant voltage intermediate circuitry shall be preferred. The noise level shall be limited
according to the location of installation.

3.4.5.6 Automatic Reactive Power Factor Compensation

Reactive power is necessary for equipment such as transformers, motors but is detrimental to the efficient
distribution of active power and also incurs additional high tariffs.

Equipment shall be provided to automatically compensate the reactive power.

Standards
 IEC 60143 Series Power Capacitors for Power Systems
 IEC 60871 Shunt capacitors for a.c. power systems having a rated voltage above 1 000 V

General Requirement

The power factor shall be limited according to the requirements of the public electricity supply company but at least
to cos  approx. 0.95 by automatic three-phase reactive current compensation units.

The necessary compensation units shall be located one for each power transformer. Each compensation unit shall be
divided into approx. 10 steps. Several capacitors each shall be provided. If harmonic distortions created by large
frequency converters and soft starters can be envisaged, each capacitor shall be connected in series with a suitable
reactive coil such forming individual resonant circuits. The resonance frequencies of these draining circuits shall be
adjusted to the 5th, 7th, 11th, and 13th harmonic (250 Hz, 350 Hz, 550 Hz, 650 Hz) in order to achieve a sinusoidal
mains voltage. The power factor compensation capacity of the plants shall be divided approximately as follows:
 50 % at the 5th harmonic
 25 % at the 7th harmonic
 25 % at the 11th and 13th harmonic
The power factor compensation plants shall be carefully designed and shall be adjusted with and approved by the
electricity supply company, the manufacturer of the frequency converters and the End Beneficiary.

Each unit shall have the following characteristics:

 Rated voltage: 400 V
 Rated frequency: 50 Hz
 Control voltage: 230 V, 50 Hz
 Degree of protection: IP 20
It shall be mounted in cabinets according to the design criteria for low voltage distributions.

Power capacitors shall have the following characteristics:

 Low losses, dielectric loss < 0.2 W/kvar
 Self-sealing capacitor elements
 Constructed in a way, that guarantees automatic disconnecting of capacitor elements in case of over
temperature or faults
 Compressible granulated filling in a steel casing
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  Dry insulation, free of PCB (Poly-Chlorinated-Biphenyls)
 Compact and stable design
 Mounting possible in any position
Each var-controller shall be mounted to the respective cabinet door including cos -indicator. Miniature circuit
breakers, switches, discharge device, undervoltage tripping and remote control input shall be included in the service.
All wiring, mounting materials and complete installation ready for operation shall be also included.

3.4.6 LV Distribution Control Panel and Switchgear

3.4.6.1 Standard and Rating

Standard :
 Low Voltage Directive (LVD) 2014/35/EU
 IEC 61439 Low-voltage switchgear and control gear assemblies
 EN 60947 Low-voltage switchgear and controlgear
 EN 50274 Low-voltage switchgear and controlgear assemblies
 IEC 61869 Instrument transformers
 IEC 60664 Insulation coordination for equipment within low-voltage supply systems
 IEC 60079 Electrical apparatus for explosive gas atmospheres

Degree of Protection: Control Panel - IP 54; LV Switchboard - IP 32; general application.- IP 54 chemical
installations. For cabinets which are to be installed outdoor and exposed to natural environment the degree of
protection shall be IP65 or IP55 if mechanically ventilated.

Type of : Form 4 separation to IEC 60439-1.

Method of Mounting: Fixed installation except for motor starters below 100A which may be of drawout type.

Environmental Conditions: Equipment shall be suitable for an ambient temperature of 35 oC; 98% relative
o
humidity over any 24-hour and a maximum of 40 C; 98% relative humidity over any 4-hour period. Direct sunlight
an UV protection shall be provided for outdoor cabinets or enclosures.

Anti-condensation heaters shall be provided for panels. The surface temperature of any part which is exposed shall
not exceed 65oC. Heaters shall be so situated that no deterioration can cause to equipment or wiring adjacent to the
heaters. The heating circuit shall be provided with an individual ON/OFF switch and one set of HBC fuse and
neutral link in fuse holders. Humidity sensors shall be mounted remote from the heaters and other sources of heat.

3.4.6.2 General Design and Construction

Switchgear shall consist of metal-clad freestanding vertical structures. Modules and provisions shall include: circuit
breaker compartments and circuit breakers, primary bus system, ground bus system, auxiliary compartments and
current transformers, relays, protection and control devices, control bus (as required) and connection provisions for
primary, ground and control circuits.
Constructional Requirements
LV panel rooms shall be kept dry under any operating conditions. Panels must not be located in basements or below
ground.
Cables shall be either installed in trenches or under raised floor.

Underground cable entries shall be via ducts built into external walls which are properly sealed against water or
vermin intrusion. In areas with potential explosion, the duct seal shall be gas proof. At least 25% additional ducts
shall be provided for installation of future cables.

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Free Standing Panel Design

Free standing control panel shall be formed of cubicles fitted together to form a flush front board of uniform height
and shape when viewed from the front. The Incoming Supply Panels may be of different depth from other panels.

The cabinets shall be installed side-to-side against the walls and shall provide the following modular dimensions, to
guarantee an arrangement for easy mounting and operation, regarding the local conditions:
 Height: 1,600, 2,000, 2,200, 2,400 mm (without pedestal)
 Width: 600, 800 or 1,200 mm
 Depth: 600 or 800 mm
Cabinets shall be installed upon a pedestal. The pedestals' height shall be 100 mm at installation upon a raised floor
and upon concrete bases, otherwise it shall be 200 mm. For external installation, the cabinet shall be on top of a
concrete plinth 300mm high.

The panels shall be divided into compartments by metal partition walls.

Corrosion protection for metal enclosures shall be in accordance with ISO 12994 and Volume 3, Section 4
Mechanical Equipment.

Doors, covers and sides shall be made from galvanised sheet metal of at least 2mm, double primed with two different
colours and with top-colour according to the Engineer's instructions or approvals for prefabricated items. To avoid
earthing problems, internal parts may not be varnished.

Equipment mounting plates shall also be galvanized with a minimum thickness of 2.5 mm. Plates shall be suitably
braced to form a rigid structure for swing panels and access doors.

Windows shall be provided as necessary for viewing internal devices. Windows shall be of toughened glass or UV
stabilised polycarbonate held in place by neoprene rubber gaskets with a thickness of not less than 1.6 mm.

Panel-doors shall close in the direction of escape routes and shall be fitted with locks for double-bit-keys or an
approved equivalent and central locking system.

A pocket shall be provided on the door or inside the panel where the P&I diagram and single line diagrams for the
equipment and system shall be provided and stored.

All positions shall be tendered as complete and functional units, including delivery, mounting, wiring connecting,
etc.

All devices shall be labelled with lasting signs, white with black engravement, fixed with screws. Each cubicle, cell
or panel section shall carry a designation plate (title) on its outside surface, identifying the description of the section
and the number. All inscriptions shall be in Serbian and English language. Switch-position indicators for all
switches, indicating instruments, switches, pushbuttons, indicating lights, operating hour meters, potentiometers, etc.
shall be fixed in a height, where they can be operated and read by a standing person without any difficulties.

All distributions panels equipped with double feeder cables shall be marked with signs "Caution! Reverse voltage" at
the respective places.

The arrangement of the panels shall be designed to suit the room shape and the process requirements with an
additional reserve of 30%. Wherever possible, the control panel shall be extensible at both ends. Equipment shall be
symmetrically arranged with projections kept to a minimum. Before fabrication, the arrangement shall be submitted
to the Engineer for approval.

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For transport purposes, a long switchboard shall be split up into convenient transport sections with weight not
exceeding 1300 kg each. Detachable lifting angles shall be provided on panels for lifting and handling. The lifting
angles shall run the full length of each shipping section with provisions for the attachment of slings or shackles.

Doors and Covers

Single leaf swing panels shall be hinged at the left with swing limited to 120o. For swing panel mounted with
protective relays, alarm annunciators or similar heavy equipment, the panel shall be suitably reinforced with steel
channels to form a rigid structure. Hinges shall be of sufficient number and strength to ensure that no wobbling
would occur when swinging the panel. Swing panels and access doors shall be fitted each with a handle with integral
lock. The lock shall not be used as the sole means of fastening where the height of door exceeds 400 mm. Gaskets to
prevent dust entry shall be fitted in a suitably designed recess on the interior surface i.e. not on the fixed parts of the
cubicle and shall be continuous without joints around corners. For cabinets installed externally in the open, the
cabinet, doors or covers shall not distort under direct sunlight or under frost condition.

Access doors shall be double-leaf if the opening width exceeds 900 mm.

Busbars and external power cable terminations chambers shall have access covers. Chromium plate captive knurled
nuts with heads suitable for screwdriver fixing or captive stainless steel bolts shall be used for fastening hinged
panels and detachable access covers. Fixing bolts and knurled nuts shall be spaced as type tested arrangement but in
any event shall be not more than 1000 mm apart.

An interlock shall be provided to prevent the opening of the panel door while the isolator is at “ON” position.

Electrical Functionalities
The distributions shall be designed as partially type-tested low voltage switchgear assemblies. Test reports about the
short-circuit strength and heating up shall be submitted to the Engineer.
All cabinets shall be supplied with internal light, socket outlet with earthing contact, anti-condensation heater and
miniature-circuit-breakers.

Cables shall be fitted from below; cable clamps and auxiliary fittings shall be included. Cables shall be connected to
terminal strips or partially directly to the devices. Cables for light and outlet socket circuits shall be partially fitted
from above to internal connected terminal strips. Terminal strips shall be marked with snap-on marking tags
beginning with „1“. Parallel cables shall be connected to auxiliary busbars. All insulation shall be of class C,
tropicalised insulation.

Cabinets with frequency converters or high heat production equipment shall be provided with suitable ventilation or
cooling devices.

The degree of protection shall be IP 42 for installation in electrical operating rooms and at least IP 54 at installation
within the plant or in humid rooms. Outdoors it shall be IP 65 or IP55 if mechanically ventilated.

Bus bar systems (material copper) provide 3 phases + neutral + earth. All bus bar systems shall be of the tin-coated
type. Type testing reports about the installed bus bar system shall be submitted to the site supervision.

All parts of the bus bar system and the feeders that are under voltage shall be covered and shall be safe against
accidental touching. In each switchgear cabinet a potential equalisation conductor shall be installed.

The distribution panel shall be equipped with a suitable number of momentary-contact twist switches and devices for
lamp testing, failure indication and failure acknowledgement.

Internal light shall be LED with light emission of 800 lumens.

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Status indicator lights shall be LED-indicators for 24 VDC of high light intensity and long life-span. They shall be
controlled independently from the PLC, to provide full manual operation from the panel even in case of a PLC
failure.

Test reports on the short-circuit strength and temperature rise of the switching stations shall be submitted to the
Engineer, the proof of the short-circuit strength by calculation shall meet DIN VDE0103, IEC 60865-1, SRPS IEC
865-1 and SRPS IEC 60865-2. Switchgear cabinets shall be protected against accidental touching, in accordance
with DIN VDE 0106 and IEC 60990.

Panel Instrumentation

Instruments shall be delivered with moving-iron measuring element for alternating current and voltage and with
moving-coil for direct current and voltage or digital. All instruments have a black frame according to DIN 43718
with a replaceable scale and a non-reflecting front glass. The degree of protection shall be IP 54, the accuracy class
shall be at least 1.5. Dimensions of all instruments must be 96  96 mm. Instrumentation shall be installed at
locations where they are at maximum visibility.

Arrangement of Components

Front panel start push-button shall be at right hand side of stop push button. For equipment occupying a complete
panel with vertical front plate, push buttons shall be placed about 1500 mm from the floor level. Layout of indication
lamps shall correspond with the function of the respective push-buttons.

Each panel and circuit section shall have identification labels both at the panel front and rear. Labels at panel interior
may be fixed by screws or adhesive. Labels on the panel exterior shall be fixed with chromium plated screws.
Integral labels for components such as push-buttons and indicating lamps, selectors, etc. may be used and fixed by
manufacturers standard method.

Separate mounting plates shall be used for individual groups of components for easy removal of and access to
components. Mounting plates shall be arranged such that it shall not be necessary to remove one group of equipment
before another group can be removed or fitted.

Modular components such as relays and fuse holders which are mounted in a row shall be spaced for ready
installation and removal. For equipment generating impact force such as air circuit-breakers, fuse-switches or
contactors, rigid supports shall be provided to avoid excessive vibration.

A silver-plated or tinned copper earth bar shall be fixed near the rear base of the switchboard or control board. It
shall extend to the full length of the board. Provision shall also be made for bonding cable gland plates and metallic
casing of switchgear to the earth bar. The minimum dimensions of earth conductor shall be 50 x 6 mm for circuit-
breaker switchboard, 30 x 6 mm for fuse-switchgear and control board.

For swing panels and doors, a flexible copper cable of 6 mm2 shall be used to provide an earth link with the panel.

Busbars

Busbars shall comprise insulated or approved travelling-arc-proof solid copper bars rectangular in cross-section.
Copper-clad or aluminium busbars will not be accepted.

Main busbars shall be accommodated in IP 54 busbar chambers at the top of the switchboard and shall be extensible
at both ends.

Busbars shall be not less than the cross-sectional area based on Copper Development Council’s recommendation, for
a temperature rise not exceeding 50oC above the ambient, but derated by 30% for the insulation and IP 54 enclosure.

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The phase and neutral busbars shall be accommodated in the same compartments. The busbar orientation when
viewed from the front of the board shall be neutral-L1-L2-L3 from left to right or from top to bottom. The busbar
orientation of Incoming Supply and Bus-section Panels may be revised as deemed necessary to suit the requirements
of power company.

Busbars at either end of a panel shall be joined to the adjacent panel with copper bars of similar cross-section as the
busbars.

The busbar insulation material shall be flame retardant. If heat shrinkable tubings are used for busbar insulation, it
shall be suitable for insulation of copper conductors at maximum temperature of 90 oC and shall be of black vinyl,
matt-surfaced, of minimum thickness 0.86 mm when shrunk. Busbar phase designation shall be clearly indicated by
colour labels at regular and prominent positions. Joints throughout the complete system, inclusive of connections to
switchgear, shall be insulated with moulded removable insulated covers. Designs involving taping of joints or
components shall not be accepted.

Jointing of sections of busbars shall be by bolts & nuts complete with spring washers. Soldered, brazed, welded or
riveted joints shall not be used in busbars. Copper bar for joining two busbars at panel ends shall have elongated
holes.

Circuit Breakers

Circuit breaker insulation shall be either solid dielectric or vacuum/clean air systems. Gas insulated system can be
proposed but SF6 gas insulation shall not be acceptable.

Each phase shall have its own interrupter all of which shall be mounted on a single frame for synchronised operation.

All circuit breakers shall include a mechanically operated indicator recording either open or closed position.

In vacuum circuit breakers, viewing access shall be provided for monitoring the contact erosion and gap. Mechanism
for adjustment of the contact gap shall be provided. The contact poles shall be completely sealed in a vacuum
chamber which shall be replaceable.

Current/ Instrument Transformer

Current transformer for measuring current including ground fault shall be provided on each phase of the system.

The primary rated current shall be selected to be approximately 10% - 40% higher than the estimated operating
current, which gives the highest resolution on the metering equipment and instruments. Multi-ratio current
transformers shall be provided if necessary. The secondary rated current can be 1A.

The continuous thermal current rating (extended current rating) shall be selected for potential increase in continuous
primary current.

The current transformer class shall be 5P for protection function and 3 for other instrumentation. Current
transformers class used for metering purpose shall be acceptable to the public utility company or 0.5.

Local Control, Motor Control Centre and PLC

All pumpsets shall be controllable from a local panel located adjacent to the pump motor. The design of the panel
shall be compatible with the pumpset and available for emergency operation of the motor when the Programmable
Logic Controller (PLC) is out of order.

The panel shall form part of the Distributed Control System (DCS) of the station and shall be wired to the pumpset
instruments and the switchgear panel via control cables such that local manual operation of the pumpset is fully
functional when the panel is not connected to the data network of the DCS. The panel shall include an emergency
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stop push-button and the “Start” and “Stop” push-buttons (for low voltage (LV) motors) or “Neutral/Start” selector
switch (for high voltage (HV) motors).

The main control panel shall contain PLC, a touch screen, flow, temperature and vibration monitoring units and
other auxiliary equipment to facilitate monitoring and control of the pumpset.

The PLC shall be from a reputable manufacturer and shall be suitable for connection to the DCS via dual optical
fibre or Ethernet cables.

The PLC shall be programmed to provide the control, indication and alarm functions for the pumpset. The
programme settings shall be adjustable by the operator via a human machine interface (HMI). The programming
language shall either be open-source or the Contractor shall provide a lifetime licence for the software.

Main HMI shall be a touch screen which shall be mounted on the panel front and provide the following functions:-
 To display all the status signals, alarm signals and push-buttons for the local control of the pumpset
 To show the readings of all the temperature monitoring units and vibration monitoring units of the pumpset
The PLC shall conform to the following minimum requirements:-
 Screen Ingress protection - IP 65
 Display: 12.1” color active matrix TFT or equivalent
 Resolution: 800 x 600 18-bit color graphics, 300 cd/m2
 Backlight: 50,000 hours – field replaceable
 Real-time clock with battery-backed time clock and timestamps of critical data
 Application memory: 128MB
 Touch screen type: Analog resistive or equivalent
 Communication ports: Ethernet; RS-232; 2 x USB-A and 2 x USB-C
 Data transfer: Ethernet - 100 Gbit/s; USB - 10 Gbit/s
 Spare I/O ports: 30%
Flow monitoring units shall be provided to initiate alarm and tripping of the pumpset when the water flow in the
mechanical seal or water-cooled bearings (if applicable) is below its threshold value.

The monitoring unit for the pump delivery no-flow switch shall also be supplied and installed in the panel.

Temperature monitoring units for the motor winding embedded temperature detectors (ETD), pump and motor
bearing temperature detectors and motor exhaust air temperature detector shall be installed in the panel to provide
temperature signals and initiate temperature high alarm and trip operation. The alarm and trip settings of the
monitoring units shall be adjustable for individual detecting elements.

Vibration monitoring units for the pump and motor shall be installed in the panel and shall have a continuously
adjustable alarm/trip setting from 50-300% of the normal vibration amplitude. The unit shall be fitted with an alarm
reset push button and alarm indicating lights. The vibration monitoring unit and detector shall be designed to prevent
false alarm due to transient shocks by incorporating a time-delay device.

3.4.6.3 Inspection and Testing

Pre-commissioning tests shall be carried out on electrical equipment fabricated off site.

Tests in the manufacturer’s works shall be inspected and witness-tested by an accredited institution at the
Contractor’s expense. The Engineer or his representative at the manufacturer’s works may personally witness the
tests prior to shipment.

A detailed test report shall be submitted within one week after the witnessed tests to the Engineer. Goods shall not be
delivered until the Engineer has approved the test report.

Switchboard and Control Panels

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The following tests shall be carried out on switchboard and control panels:-

(1) Power frequency voltage withstand test between phases and phase to earth on the main circuits and
busbars.

The following test voltages shall be applied for a new control panel:-

System Voltage 30kV 11kV 6.6kV 3.3kV 380V

Test Voltage 60kV 24kV 15.2kV 8.6kV 2.5kV

The test duration shall be 60s.

Megger tests (1000V for LV and 5000V for HV switchboards) shall be carried out before and after the power
frequency voltage withstand test. For LV switchboards, the tests shall also be carried out on the neutral busbars.

(2) Insulation test on all secondary small wiring circuits.

(3) Milli-volt drop tests on all main busbars connections, circuit breakers, isolators, earthing switches, fuse-
switches, contactors and switchboard main earthing bars.

(4) Primary injection tests up to rated C.T. primary current for all CTs. The test shall measure the C.T.
secondary current and spill current and initiate operation of protection relays and tripping of circuit
breakers and contactors.

(5) Secondary injection tests for all protection relays.

(6) Intertrip and commissioning tests for incoming supply circuits in conjunction with the power company
including phase sequence and rotation tests.

(7) Functional tests to demonstrate the correct operations and connections of all control, alarm and indication
circuits and equipment including the PLC circuits and equipment in the metering cubicle.

(8) All mechanical tests specified for testing at the manufacturer's works shall be re-checked to ensure
satisfaction operation of the plant in the final erected state.

(9) All electrical and mechanical interlocks for circuit breakers, isolators, earthing switches, contactors and
interlocks with other panels shall be demonstrated.

Circuit-breakers

The following routine tests in accordance with IEC 60947-2 shall be carried out:-

(1) Power frequency voltage withstand tests on the main circuit.

(2) Voltage withstand tests on control and auxiliary circuits.

(3) Insulation resistance tests on the main circuit and auxiliary circuits.

(4) Mechanical operating tests.

(5) Milli-volt drop test.

Metal-enclosed Switchgear

The following routine tests in accordance with IEC 60947 shall be carried out:-

(1) Power frequency voltage tests on the main circuit.

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(2) Dielectric tests on auxiliary and control circuits.

(3) Primary injection test up to rated current to measure the spill currents of current transformers and to
initiate operation of protective relays and tripping of ACB/contactors.

(4) Milli-volt drop test for busbars.

(5) Mechanical operation tests for switchgear.

(6) Tests of auxiliary electrical devices.

(7) Verification of correct wirings.

(8) Verification of interlocking facilities and correct operation of control and protection circuitries.

Current Transformers

The following routine tests in accordance with IEC 61869-2 shall be carried out:-

(1) Verification of terminal markings.

(2) Power frequency tests on primary winding (where applicable).

(3) Power frequency tests on secondary winding.

(4) Over-voltage interturn tests.

(5) Determination of errors at rated burden.

(6) Determination of rated knee-point e.m.f., magnetizing current and secondary winding resistance.

Protection Relays and Instruments

The relays, energy meters and instruments shall be tested at manufacturer’s works for verification of correct
operation and calibration.

3.4.7 Auxiliary Power Source - Battery System

Some electrical and process equipment requires auxiliary power when there is an outage such as presented in the
typical list provided hereafter:
 Uninterruptible power supply

3.4.7.1 Standards
 EN IEC 62485 Safety requirements for secondary batteries and battery installations

3.4.7.2 General Requirement

The life span shall be at least 10 years. It shall be suitable for permanent charging / parallel operation with the
charging set and supply power to the consumers at the same time.

The poles and the cell-connections shall be electrolyte-tight. The intercell-connectors shall be located below the
block cover and shall be short circuit-proof.

The vessel and the cover shall be welded to each other to be electrolyte-tight. After being mounted the batteries'
surface shall be completely insulated.

Each Battery-System shall be mounted in an acid-proof steel cabinet; all installation and mounting material shall be
included.

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For permanent charging of the Battery-Systems, a rectifier assembly with a controlled constant voltage/constant
current curve shall be installed each. It shall also be suitable for power supply to the connected consumers and the
rated capacity shall be calculated based on typical guaranteed duration of the outage on the public electricity supply,
potential sustained interruption and response time of other auxiliary power source (standby or co-generation).

The general technical specifications shall be:

 Power supply: 230 V, 50 Hz
 Constant current: According to the requirements
 Load change tolerance: 0 - 100%
 Radio suppression rating: "G" acc. to VDE 0875
 Smoothing: 5% effective without battery
 Degree of protection: IP 21
 Ambient temperature: According to the local requirements
 Control: With thyristors as actuating elements
 Rated capacity: As necessary but a minimum of 30 minutes for motorised circuit breakers at full
power

3.4.7.3 Rechargeable Batteries

Throughout the whole works there shall be only rechargeable batteries of the same operation principle utilised. The
offered price shall include the charging-units including regeneration and trickle charging. The voltage of the
charging-units shall be controlled so that the permissible voltage may not exceed the maximum voltage for the
connected equipment even when there is no battery connected.

All rechargeable batteries shall be serviceable for 10 years.

3.4.7.4 Motorised Circuit Breakers

For large battery system, motor driven circuit breakers, the distribution panel shall be equipped with miniature
circuit-breakers with signalling contact for each motor driven circuit-breaker, 1 suitable circuit breaker for
disconnecting the distribution and 6 miniature circuit-breakers with signalling contact, single pole, 16 A.

On the front panel following instruments shall be installed:

 1 voltmeter AC
 1 voltmeter DC
 1 ammeter DC for the load
 1 ammeter DC for the charging current
Each battery rectifier assembly as well as the distributions shall be installed in cabinets fitting to the switchgear
cabinets of the respective station. They shall be delivered to the site, installed and started up. The service includes all
cabling and wiring inside the cabinets, to the battery, to the main distribution and to the consumers, furthermore all
mounting materials and complete installation ready for operation.

3.4.7.5 Uninterruptible Power Supply (UPS)

An uninterruptible power supply is necessary for the following facilities:

 All PLC-units and PLC bus-system
 Telecommunication (voice/ data) and Fire Alarm system
General Requirements

Each UPS consists of a rectifier with a constant voltage / constant current curve according to DIN 41 773, a Battery-
System (life-span at least 10 years) and an inverter with electronic power switch (EPS). The batteries shall be in-
stalled in separate battery cabinets.

Each UPS system shall be installed in two cabinets according to the switchgear cabinets of the respective station.
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The UPS shall provide a mimic diagram with following devices mounted to the front door:
 LED testing button
 Current and voltage meters
 Circuit breaker and disconnector for manual by-pass
 LED signal "Inverter On"
 LED signal "Inverter Operation"
 LED signal "Inverter Failure"
 LED signal "Mains Operation"
 LED signal "EPS Blocked"
 LED signal "Battery Discharge"

3.4.8 Low Voltage Distribution System

The low voltage distribution panels receive electrical power from the transformers and distribute this power to the
other LV distribution panels or directly to process control panels.

3.4.8.1 Standards
 Low Voltage Directive (LVD) 2014/35/EU
 IEC 61439 Low-voltage switchgear and control gear assemblies
 EN 60947 Low-voltage switchgear and controlgear
 EN 50274 Low-voltage switchgear and controlgear assemblies
 IEC 60664 Insulation coordination for equipment within low-voltage supply systems
 IEC 60079 Electrical apparatus for explosive gas atmospheres
 IEC/EN 62061 Safety of machinery: Functional safety of electrical, electronic and programmable
electronic control systems
 EN 60204 Safety of machinery – Electrical equipment of machines
 IEC/EN 62061 Safety of machinery: Functional safety of electrical, electronic and programmable
electronic control systems
 IEC 61643 Low-voltage surge protective devices
 IEC 61009 Residual current operated circuit-breakers with integral overcurrent protection for
household and similar uses (rcbos)
 IEC 61869 Instrument transformers
 EN 60044 Instrument transformers
 IEC 62305 Protection against lightning

3.4.8.2 Voltage Levels and Colour-Codes

Standards
 IEC/EN 62061 Safety of machinery: Functional safety of electrical, electronic and programmable
electronic control systems
 EN 60204 Safety of machinery – Electrical equipment of machines

The Low Voltage (LV) system shall be designed as TN-S or TN-C-S system for 400/230 V three - phase alternating
current, as required by Electricity Distribution company. The energy shall be to be distributed from the LV-
distributions preferably through a 5-wire-system to the Sub-Distributions and consumers.

Control-power-supplies shall primary and secondary be protected by circuit breakers with signalling contacts.
Tripping of any circuit breaker shall cause a central indication. At a single point the control voltage shall be
connected single-pole to the protective-conductor-system by an isolating terminal. The control-voltage shall be
230 V / 50 Hz in power circuits and 24 VDC at in- and output-units of the PLC and the supervisory control system.
60 VDC is optional and shall be used if control signals shall be transmitted over long distances to field units and in
all cases where 24 VDC would not be suitable for reliable signalling or when that voltage is envisaged for motor
driven / tripping devices of the circuit breaker. In power transformer station, direct current supply can be supplied
from the central rectifying unit, while, for each major consumer there shall be an individual control voltage power-

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supply (e.g. for each pump of an important pumping station there shall be one individual set of power-supply-units,
including 230 VAC, 24 VDC and 60 VDC (optional)).

The wires used in switchboards shall be marked by a suitable identification system and a colour-code, for example:
 Phases L1, L2, L3: black, marked with phase-colours
 Neutral conductor N: light blue
 Potential Equalisation PE: green / yellow
 DC main circuits : black
 AC control circuits: red
 Measuring-transformer lines: white
 DC control circuits – 24V: violet
 DC control circuits – 60V: orange, if applicable
 Signal lines 20 mA: grey (screened)

3.4.8.3 General Requirements

The Contractor shall deliver a complete and functional Low Voltage (LV) System for the facility, including all
Supervising and all accessories that are necessary to get a very reliable energy supply system which meets the
present state of the art.

The capacity of the system shall be sufficient for extension of the facility during the 2nd phase.

In the Transformer Station there shall be a LV Main Distribution panel to receive electrical power from the
transformers and to distribute this power to the LV Local distribution and Process distribution panels. LV Main
distribution shall be segmented into sections according to the number of connected transformers and a minimum of
two (2).

Each incoming feeder shall be equipped with a suitable motor or electromagnetic latch driven circuit-breaker as
specified and with an Electronic Line Monitor. All sections shall be connected via motor or electromagnetic latch
driven circuit-breakers. During normal operation all sections of a LV Main Distribution shall be switched on
together. During faults or maintenance each section can be isolated independently.

The sections shall be designed to ensure smart distribution satisfying the process demand for high quality, efficient,
secure, reliable, resilient energy supply whilst considering the flexibility provided by the various auxiliary power
sources available or to be provided. Each section shall group LV process distribution panels which are either
geographically or process related. Additional panels for future extension shall also be allowed for in the design of
each section.

The LV Local distribution panels shall either be arranged into a ring topology LV network or for a star topology.
The LV local distribution panels shall be supplied by double incoming feeders. In case of a failure of one incoming
line, the remaining line shall be sufficient to supply all connected consumers.

Energy critical processes shall be grouped to allow resilient supply and to modulate demand such that emergency
electricity supply can be matched to production from on-site generation equipment such as standby generator or co-
generation.

The outgoing feeders at the LV Main Distributions shall be equipped with suitable motor driven or electromagnetic
latched circuit-breakers. Furthermore they shall be assigned to the busbar sections in a way that all consumers of
each process distribution can be supplied from just one section of the corresponding LV Main Distribution.

When circuit-breakers are motor driven, an auxiliary battery system shall be provided.

The LV Main Distribution shall be equipped with one automatic reactive current compensation unit for each busbar
section.

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The front of the LV Main Distribution and LV Local distribution panels shall be equipped with all control switches,
touch screens, PLC, indicators, meters, instruments, etc. required to support all the functions of the distributed
control system.

The LV Process Distribution panels receive power from the respective LV Main Distribution or LV Local
distribution panel and distribute this power via distribution panels or motor control centres (switchgear assemblies,
soft starters, frequency converters, etc...) to all electrical consumers.

The front of each LV Process Distribution Panel or Motor control centre (MCC) shall be equipped with all control
switches, indicators, meters, instruments, operator panels, etc. required to control the process consumer assigned to
the control panel..

All process consumers shall be supplied with electrical power on a very reliable level. Protection shall be provided
as necessary against the following potential faults:
 Transients  Waveform distortion
 Interruptions  Voltage fluctuations
 Sag / Undervoltage  Frequency variations
 Swell / Overvoltage
The protection measures provided can be provided with the process equipment or on process distribution or local
distribution panels.

For each electrical consumer an appropriate switchgear assembly with current transformer, ammeter, measuring
transmitter, operation hour meter, etc. shall be provided as specified hereinafter.

3.4.8.4 Cable Supply and Installation

Standards
 IEC 60502 Power cables with extruded insulation and their accessories for rated voltages from 1 kV
up to 30kV
General Requirements

Cable installation under streets, pavements and otherwise surfaced areas shall generally be installed in ducts between
cable drawpits. At least 50% spare duct capacity shall be provided for future extensions and maintenance.

Where cables are directly lad in the ground, other protective measures such as armoured cables and protective slabs
shall be provided. The cables shall be laid out in a “snaked” manner, so that movements of the ground may not
create extra tensile forces in the cable.

All cables and wires shall be delivered in sufficient length to enable cutting, convenient maintenance and free of
mechanical tension during installation. The cables shall be installed in partial lengths according to the requirements.
There shall be no cuts or extensions within the lengths between start and end of each connection. At both ends the
cables shall be identified permanently with clearly legible and long lasting special cable labels. Splicing shall be
provided only in drawpits or special chambers.

The installation shall include all connection splicing work and accessories, labels, glands, lugs; direct ground
installation, in pipes, in cable conduits, on cable trays and on walls; cable ducts and cable conduits, floor and wall
cuts and holes, all making good and builders work, cable supports, terminal boxes and junction boxes, mounting
materials, accessories, documentation, etc.

Power and Control cables for 0.4 kV systems shall be 1000 V grade with copper conductors according to DIN VDE
0271 and shall be one of the following:

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  Multi-core, PVC insulated, armour of galvanized flat steel wires and counter helix of galvanized steel tape,
with overall black PVC sheath, NYFGY type or equivalent
 Multi-core, PVC insulated, concentric conductor of copper wires (applied in waveconal formation) and
copper tape (applied helically), with overall black PVC sheath, NYC WY type or equivalent
 Multi-core, PVC insulated, concentric conductor of copper wires and copper tape (applied helically), with
overall black PVC sheath, NYCY type or equivalent
 Single- and multi-core, PVC insulated, with overall black PVC sheath, NYY type or equivalent
 Single- and multi-core PVC insulated, with overall PVC sheath, NYM type or equivalent
 Single- and multi-core PVC insulated, NYA type or equivalent
 Single-core, rubber insulated, according to DIN VDE 0250, NSGAFOU type or equivalent
Signal cables according to DIN VDE 0816 shall conform to the latest International Standards and be suitable for the
proposed purpose (e.g. A-2YF(L)2Y type or equivalent, PYCYM type or equivalent, EBCY type or equivalent,
IY(ST)Y type or equivalent, etc.).

LV Process Distribution Panel/ Motor Control Centre

Each motor control system shall be supplied with protective devices against overcurrent and short-circuit (fuses,
bimetal relays with phase-failure protection, respectively motor circuit-breakers). Electronic switching devices
(frequency-converters, soft starters, etc.) shall be protected by additional semiconductor fuses. In general, fuseless
technology shall be applied, if necessary with current-limiters shall be used.

Fuses in control-circuits shall be spatially separated miniature circuit breakers with signalling contacts.

Clock timers shall be supplied with automatic change from winter-time to summer-time, reserve power, program
memory and with manual and automatic control selector. The actual state shall be indicated on the timer.

All low-voltage switching devices shall always agree with IEC specifications. Power contactors shall be designed for
utilisation category AC3, at a power reserve of at least 10%.

The Contractor shall produce the final design of his equipment after his own technical clarification and obtain
written approval of the design from the Engineer.

Small Wall Mounted Control Panels

Galvanised sheet steel plates of minimum 1.0 mm thick shall be used for the fabrication of panels. Equipment
mounting plates shall also be galvanized with a minimum thickness of 1.5 mm. Plates shall be suitably braced to
form a rigid structure for swing panels and access doors.

Corrosion protection shall be as specified in Section 3.4 of the TR.

The enclosures shall have IP54 protection, gland cable entrances with grip and with a lockable door. All material
used for enclosures shall be fire-resistant, non-flame propagating and waterproof.

Windows shall be provided as necessary for viewing internal devices. Windows shall be of toughened glass or UV
stabilised polycarbonate held in place by weather and UV proof neoprene rubber gaskets with a thickness of not less
than 1.6 mm.

Corrosion protection for metal enclosures shall be in accordance with Volume 3, Section 4 Mechanical Equipment.

A pocket shall be provided on the door or inside the panel where the P&I diagram and single line diagrams for the
equipment and system shall be provided and stored.

Alarms

Each tripping of a protective device shall be indicated at the LV Local distribution panel and reported through the
SCADA by flashing signalling lights and acoustic centralised alarm. After an accept switch has been operated, the
flashing light turns to steady light. The optical signalling devices shall have lamp-testing buttons..
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3.4.8.5 Local Distribution Panel, Switchgear Assemblies and Components

The LV Process Distribution panels receive power from the respective LV Main Distribution or LV Local
distribution panel and distribute this power via distribution panels or motor control centres (switchgear assemblies,
soft starters, frequency converters, etc...) to all electrical consumers.

The front of each LV Process Distribution Panel or Motor control centre (MCC) shall be equipped with all control
switches, indicators, meters, instruments, operator panels, etc. required to control the process consumer assigned to
the control panel..

For each electrical consumer an appropriate switchgear assembly with current transformer, ammeter, measuring
transmitter, operation hour meter, etc. shall be provided as specified hereinafter.

Switchgear assemblies shall be complete combinations of electrical components to supply and control electrical
motors and electrical consumers (i.e. Motor Control Centres / MCC).

LV switching devices shall comply with EN 60947. Power contactors shall be suitable for utilisation category AC 3.
All switchgear assemblies shall be at least type tested according to IEC 60664-1 shall be observed concerning
insulation and creeping paths.

Each tripping of protective units shall cause an optical and acoustic alarm given at the panel and at the Central
Control Room. The alarm shall be accepted by operating an alarm switch that shall be mounted at the switchgear
panel. Unaccepted alarms shall be indicated by flashing indicator lights alternatively with an alarm horn, accepted
alarms shall be indicated by steady lights without alarm horn.

Circuits for lighting and socket outlets shall be equipped with miniature circuit breakers. Socket outlets shall be
connected to surge-proof, peak-current-sensitive and universal-current-sensitive current operated earth-leakage
circuit breakers, providing a tripping current of 30 mA.

Circuits for heating units with an poor accessibility shall be equipped with current operated earth-leakage circuit-
breakers with a tripping current of 300 mA.

All switchgear assemblies shall be installed into switchgear cabinets and shall also include the following devices:
 Connection to the busbar
 Protective devices against overcurrent and short circuit (fuses, bimetal relay with phase failure protection,
motor circuit breaker)
 Protective relays for build in motor temperature thermistors (if applicable)
 Frequency converters and electronic soft starters (if applicable)
 Star-delta starting or soft starters for all drives of more than 15 kW (mech.)
 If a drive is started with a time delay, the activation of the delay period shall be indicated at the cabinet front
door
 Contactors for main- and auxiliary circuits
 Clock timers (if required) with automatic change from winter- to summer-time, reserve power, program
memory, selector for automatic and manual operation
 Time delay relay for all screw pump feeders, adjustable from 0 - 5 min; screw pumps shall be locked for the
adjusted time before they are started
 Contactors for the heating of the switching mechanism box of valve drives
 Coupling relays for all voltage levels (24 VDC/60 VDC, 24 VDC/230 VAC, 60 VDC/24 VDC, 60 VDC/230
VAC, 230 VAC/24 VDC, 230 VAC/60 VDC) – 60VDC5 only if required by Contractor’s design
 Automatic fuses with signalling contact for 24 VDC, 60 VDC (as required by Contractor’s design) and
230 VAC in adequate number
 Steady-contact twist switch as operation mode selector "manual" - "locked" - "automatic" - "central control"

5 60VDC Control voltage level can be omitted, if Contractor finds and specify solution that all functions
can realized with other control voltage level
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  Momentary-contact switches "start", "stop", "open", "stop", "close" or as required by the drives purpose
 LED indicators "on", "fault", "open", "closed", "local control", etc. as required by the drives purpose,
identification colours according to EN 60204-1.
 Mechanical operation hour meter
 Wiring, cable ducts, terminals, etc. and all required mounting material
Protection devices of the drives shall be in control during any operating mode. The control systems shall assure that
large drives are started in a sequence.

At the switchgear cabinets the unit control level shall be located. By means of operating and indicating devices
mounted to the front door of the cabinets, it shall be possible to operate separately each drive in automatic and
manual mode. The main purpose of the unit control level shall be an emergency operation in case of failures of the
PLC or the communication bus-system. It shall work with circuitry without PLC on the 230 VAC-level, using
conventional hardware.

If consumers are equipped with additional protection devices (e.g. leakage or excess temperature monitoring), the
respective relays and units supplied by the manufacturer shall be integrated. Submerged drives shall be always
equipped with leakage and excess temperature monitoring. Signals shall be connected potential free via coupling
relays to the terminals.

Each drive shall be equipped with a field control unit. Each switchgear assembly includes all required devices for the
connection of a field control unit and of an emergency-stop momentary-contact switch.

If the local control is selected at the field control unit, all other control levels shall be disabled.

Thermistor motor protection relays shall be included in the service and connected to the temperature sensor of the
respectively motor. If the relay is energised, the motor control voltage shall be interrupted immediately. This state
shall be indicated by a signal light on the relay. The relay shall provide a push-button for manual resetting of the
device. It shall be equipped with a reversing type auxiliary contact.

Especially regarding the devices equipped with semiconductors and the function of data acquisition and processing,
the regulations of IEC 61643 as well as the local power supply company shall be followed thoroughly.

The internal lightning and overvoltage protection shall be realised by a consequent lightning protective potential
bonding, according to separation into protection zones 0-2. This is important especially at devices of the measuring
and data-system. The cable routes to these devices shall provide a minimum of loops causing voltage induction. All
data and measuring signals shall be supplied with overvoltage respectively lightning-protective devices according to
DIN VDE 0675 part 6, if they enter a higher lightning-protection zone, to include them in the lightning-protective
potential bonding. The LV-auxiliary-power-supply of electronically units shall be protected against remote strikes,
induced overvoltage and switching overvoltage by surge arresters. Lighting protection shall be provided In
accordance with IEC 62305.

Circuit-breakers

Each circuit-breaker shall provide the following characteristics:

 Triple pole
 Withdrawable
 Able for synchronise switching
 Solid-state overcurrent release
 Magnetic short-circuit trip and thermal overcurrent trip adjustable and equipped with tripping delay
 Motor type stored energy operating mechanism or electromagnetic latch
 Integrated control panel for and with ON and OFF pushbuttons
 Release and blocking devices for 60 VDC, if applicable
 Adequate number of signalling contacts
 Rated short-circuit capacity according to the necessary requirements but at least 60 kA
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Miniature circuit-breakers

For AC circuits, in single and three-pole configuration, for mounting on supporting rails with spring catch fastening:
 Current rating 0.5 - 50 Ampere
 Nominal breaking capacity 10,000 Ampere or greater if necessary for short current power
withstanding
Each miniature circuit-breaker shall be equipped with 1 reversing auxiliary contact.
In the case of overload tripping, the automatic fuse shall break automatically all poles, also if tripping occurs on one
pole only or if the actuator is retained in the closed position.
Fault current guard switches (earth-leakage circuit breaker)
A fault current guard compliant with IEC61009 shall be provided for various circuits, protecting them from indirect
contact. The fault current guard switches to be provided shall break the circuit within 0.2 seconds upon occurrence
of dangerous contact voltages that may be due to insulation faults. Earth leakage currents achieving the nominal
amperage of the fault current shall be provided to check the guard switches for their efficiency.
The fault current guard switches shall be provided for spring catch mounting on a supporting rail. The following
construction sizes shall be taken into account:
 Size 1 a) power rating 25 Ampere
 b) nominal fault current 30 mA
 Size 2 a) power rating 40 Ampere
 b) nominal fault current 30 mA
 Size 3 a) power rating 40 Ampere
 b) nominal fault current 300 mA
 Size 4 a) power rating 63 Ampere
 b) nominal fault current 300 mA
 Size 5 a) power rating 125 Ampere
 b) nominal fault current 300 mA
Each fault current guard switch shall be equipped with 1 normally open and 1 normally closed auxiliary contact.

Motor Circuit Breakers

The motor circuit breakers used shall be inherently safe, i.e. they shall be able to be installable at any random
location without any fuse provided before.
Making and breaking shall be performed by two push-buttons provided for this purpose, which simultaneously
indicate the switch position.
The motor circuit breakers shall be provided with adjustable overload tripping and high-speed short-circuit tripping.
Auxiliary contacts shall be provided for control and signalling purposes, at least 1 normally open and 1 normally
closed contact.
Three-phase AC air-type power contactors

Three-phase AC air-type power contactors for switching of three-phase AC consumer stations shall be designed with
a 25 percent spare performance.

The air-type contactors shall have a high service life without exchanging the actuator element and without any
maintenance needed.

Depending on their use and installation, the air-type contactors shall be designed for at least 3 million actuations.

Each air-type contactor shall be provided with auxiliary contacts, 2 normally open and 2 normally closed.

Auxiliary contactors

The auxiliary contactors needed for control shall be of a quickly mountable type provided with spring catch fasteners
on a supporting rail. The possibility of screw fastening shall also be provided.

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The mechanical service life of the auxiliary contactors shall be designed for at least 30 million actuation cycles.

The actuation voltage of the auxiliary contactors shall be either 230 VAC, 60 VDC or 24 VDC, depending on the
place of installation.

In general, auxiliary contactors shall be provided with 4 normally open and 4 normally closed contacts.

The load bearing capacity of the auxiliary contacts at 230 VAC shall be at least 10 Amps.

Motor protection by thermistor

These devices shall be connected to the temperature sensor integrated in motor by the manufacturer, if applicable.

If the motor is heated by a clogged cooling system or by sun radiation, this relay shall be energised, immediately
interrupting the control of the motor drive.

A signal lamp on the relay shall indicate this condition.

Acknowledgement or resetting of the relay shall be effected by a push-button installed on the relay.

The auxiliary contact shall be of the reversing type.

Coupling relays

The power section of the system shall be controlled via miniature relays of the spring catch type to be snapped on the
terminal bars.

These relays shall be of the same mechanical configuration as the terminals, to permit incoming leads being
connected directly (terminal-type relays).

The contact shall be normally open.

A light-emitting diode (LED) indicating the status of the relay shall be integrated within the housing.

Electronic digital timers:

The actuation times or delay shall be adjusted digitally, indicating the time set. The operational readiness shall be
indicated by light-emitting diodes (LED’s). The timers shall be designed for 6,000 actuation cycles per hour
minimum. Depending on their function, timers shall be of a make or break time-delayed type. The timers shall be
provided with at least one delayed and one undelayed contact of the reversing type.

Depending on the purpose of installation, the following adjustment ranges and actuation voltages shall be
considered.

Operation voltage 230 VAC or 24 VDC

Adjustment range 1 - 9,999 seconds

0.1 - 99.9 hours

Clock Timers:

Clock timers shall be of the electronic type for an actuation voltage of 230 VAC, including a working range of 7
days minimum.

Each clock timer shall provide the following characteristics:

 Two independent contact systems
 Setting of the starting and stopping times by means of buttons and LCD-display
 Daylight saving time automatic

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  Two switching contacts of the reversing type shall be allocated to each daytime dial.
 Design features according to VDE 0660
Current transformers

Current transformers in accordance with IEC 61869 and EN 60044 for secondary connection of 5 A shall be
provided for current measurements of various consumer stations.

In general, current transformers shall be designed as plug-on transformers through which both busbars and wires can
be routed.

Fastening shall be effected either directly on the busbar or by means of fastening legs on the mounting plate.

The individual transformers shall be selected in their transformation ratio so as to minimise the number of different
construction sizes and transformation ratios.

The power rating shall be established in accordance with the instruments and devices to be connected, the minimum
power rating being 10 VA.

The precision class shall be determined to be 1.

Summation current transformers shall be provided wherever various nominal currents shall be summarised.

The summation current transformers shall be of the leg mounting type.

Each of the inputs and the totalling output shall be for 5 Amps.

The precision of the summation current transformers shall be classified by 1.

The power rating shall be established in accordance with the consumer stations and the measuring circuit connected.

Current Loop Measurements

Current loop measurement with signal output between 0/4mA and 20 mA shall be provided for for the transmission
of electrical values to the PLC.
Alternatively, in the case of intelligent meters, the transmission can be provided through process control bus.
The following measurements shall be taken into account:
 Amperages
 Voltages
 Frequencies
 Effective power
 Power factor
The transmitters shall be installed in housings to be incorporated in the cubicles of each distribution system. The
input amperages shall be designed for 5 A.
The effective power transmitters shall be provided for a four-conductor measurement of random load.
Transistorised switching relays for intrinsically safe circuits

Wherever signals and control commands shall be received from rooms subject to explosion hazard, including
instruments and devices that do not provide an explosion-proof protection system, these signals and control
commands shall be received by transistorised switching relays with intrinsically safe inputs.

These switching relays shall meet the relevant specifications and standards, the test and safety adequacy of which
shall be proved.

Auxiliary voltages 230 VAC

The contact shall be of the reversing type.

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AC voltage control relay:

The mains voltage shall be supervised by a microprocessor-based protection relay with a two-step independent three-
phase over- and undervoltage characteristic with completely separate time and voltage settings. The phase voltages
shall be continuously compared with the preset thresholds. For the overvoltage supervision the highest voltage of
each phase shall be decisive for energising and for undervoltage supervision the lowest.

The characteristics shall be:

 Rated voltage: 400 VAC
 Rated frequency: 50 Hz
 Power consumption in voltage circuit: < 1 VA
 Setting ranges for U</U<< and U>/U>>: 2...460 V, tolerance  1% or <0.3V
 Setting ranges for delay time: 0.04...50 s, tolerance  1% or  15 ms
 Dropout time: 30 ms
 Auxiliary voltage: 230 VAC, respectively 60 VDC
Deviations of the auxiliary voltage in the range of 80 to 120% shall not have any influence on the voltage measuring.
The function of the device may not be affected if the auxiliary power is interrupted for less than 50 ms.

For the output the relay provides 4 trip relays and 1 alarm relay with change-over contacts.

Frequency relay

The mains frequency shall be supervised by a microprocessor-based protection relay with a two-step independent
over- and underfrequency characteristic with separate time and frequency settings. Additionally the rate of change of
frequency shall be supervised. The measuring principle shall be based on the time measuring of complete cycles
which minimises the influence of harmonics. To avoid tripping due to voltage or phase transients, the measuring
system uses the average frequency value of an adjustable number of periods. The rate of change of frequency df/dt
shall be also averaged over the period of time.

The characteristics shall be:

 Rated voltage: 400 VAC
 Rated frequency: 50 Hz
 Setting ranges for f</f<< and f>/f>>: 40...70 Hz, tolerance 0.005 Hz
 Setting ranges for delay time: 0.1...50 s, tolerance  1% or  15 ms
 Blocking of measuring in case of undervoltage: Adjustable from 6 to 100% UN
 Dropout time: 30 ms
 Auxiliary voltage: 230 VAC, respectively 24 VDC
Deviations of the auxiliary voltage in the range of 80 to 120% shall not have any influence on the frequency
measuring. The function of the device may not be affected if the auxiliary power is interrupted for less than 50 ms.

For the output the relay provides 4 trip relays and 1 alarm relay with change-over contacts.

Electronic Limit Controller:

In order to automatically control pumps or other electrical consumers according to the signal of a monitoring
instrument or to trigger an alarm signal, for instance according to a water level, adjustable electronic limit controllers
shall be installed, if required. These control units shall be installed in the front doors of the respective switchgear
cabinets in instrument housing of 144 x 144 mm front panel size. At the front panels there shall be following easy
and clearly readable LCD displays:
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  Digital display, -1,000...+1,999, 10 mm high
 Analogue semi circular indicator with 40 LCD segments
 4 indicators for the limit and control relays
Normally the actual measured value shall be indicated at the digital display in its correct physical unit. At the same
time, the actual measured value and the values of the set limits shall be indicated qualitatively (0...100%) at the
analogue display.

There shall be two independently selectable limit relays and two selectable control relays. If the measured value
supersedes a set limit, the corresponding limit relay shall actuate its reversing contact and keep this position with a
hysteresis of 1% until the measured value drops below the limit. The control relays work similar to the limit relays,
but instead of a fixed hysteresis they have adjustable hysteresis in the form, that there are two separate selectable
limits for each control relay. While a limit relay or a control relay is actuated, the respective status indicator shall be
on. For each limit or control relay it can be individually programmed if the relay is on or off during the activated
condition.

To smoothen the signal, there shall be a dampening circuitry built in, that allows selecting 4 grades of dampening.

In order to set a limit, the protective front door of the electronic limit controller can be opened. The display can then
be switched over to indicate the various set limits and each limit can be easily and simply set by use of an ordinary
screw driver.
 Input: 0/4...20 mA (measured value), 50 Ohms
 Power: 230 VAC +10...-15%, 48...62 Hz, 8 VA
 Outputs: 4 reversing contacts, 250 VAC, 500 VA
The service includes the complete technical clarification, delivery, installation, calibration, adjustment, etc. including
all wiring auxiliary relays and auxiliary contactors etc. necessary to control 2 consumers and two limit values/alarms
according to the requirements of the specific application.

3.4.8.6 Wiring Blocks

The main and control-circuits 230 VAC shall be connected to the switching stations on terminal strips. Signalling
lines and measuring signals shall be put on terminal blocks to guarantee a clearly arranged connection to the PLC.
According to the amount of signals the terminals shall be designed as terminal strips or e.g. as wire-wrap-technology.
Overvoltage-protection devices, coupling relays and optical couplers shall be included in the terminal level.

3.4.8.7 Frequency Converter

If required, for pumps, motors, etc. suitable switchgear assemblies including frequency converters shall be installed.

These switchgear assemblies shall be arranged in a way that provides following operating capabilities:
 Start of the drive with initial higher start-up (break loose) torque
 Manual operation of each drive including setting of variable speed
 Software for automatic operation via the separately specified PLC
 Soft stop of the drives to prevent pressure peaks in the pipes
 Automatic restart of the drives after power failure in the same mode as before power loss
 Sequential start in all modes
 Save emergency stop with complete isolation of the mains

The variable frequency drive system shall include a central emergency Stop-Button, switches and controls for
manual operation and fault reset, LED status indicators (Manual - Auto - Fault - Excess temperature - Leak -
Control Voltage Fault), main contactor, semiconductor fuses, complete set of spare fuses, mains filter, motor filter,
individual voltage power supply for control voltage, isolation amplifiers 0/4...20 mA, thermostat, cooling fan, etc.

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Integrated relays and circuitry shall be provided to protect the pumps against dry running and leakage, protection
relays and circuitry for motor-excess temperature and overload/excess temperature of the frequency converter,
including warning and alarm signals.

Software for automatic operation shall provided for the distributed control system to control the motorpump for
different targets e.g. to keep a constant level in the tank, fully automatic operation of the necessary number of drives,
automatic changeover between the drives to keep equal running hours for all pumps, etc. Software may be integrated
into the frequency converter.

The frequency converter shall be fully digital with low-loss, constant link voltage, sinusoidal pulse width
modulation, for standard 3-Phase motors, modular and easily serviceable.

Functionalities of the variable frequency drive include the following:

 Comprehensive self-diagnosis
 Non-volatile memory for settings, status and fault signals incl. timestamp
 LED-display and status indicators
 Automatic and manual programming at built in, removable control panel
 Interface to connect to a computer complete with all required access for serial communication
 Computer software for programming and diagnosis of the frequency converter
 Outputs 0/4...20 mA for mains current and motor speed
 Digital outputs for status signals
 Control inputs
The frequency converter shall be provided with all the protection such as: mains overvoltage; mains undervoltage;
phase failure; short circuit; earth fault; idling; overload.

Technical data of the frequency converter:

 For motor: According to the requirements
 Mains voltage: 0.4 kV, 50 Hz, 3 phase, +/- 10 %
 Cooling: Forced air cooling
 Overload capacity: 1.5 x Nominal Current for 60 Seconds
 Protection class: IP 20
Motor filters and line filters shall be provided as protective measures. Measuring devices and displays for current
and rotational speed shall be installed for controlling frequency converters. To prevent overheating, motors driven by
frequency converters shall be equipped with forced ventilation and 3 PTC thermistors, 2-steps, for high-temperature
warning and release, and with the relevant protective relays.

The frequency converters shall be completely delivered, installed, carefully programmed according to the connected
machines, tested etc. The contactors, fuses, circuit breakers required to complete the circuitry of the switchgear
assembly shall be included in the service.

The Contractor shall follow the VFD manufacturers requirements for types of power cables connecting the variable
frequency drive to the AC motor; the VFD isolation transformer to the converter; cable and panel grounding. Special
cables shall be provided to control harmonics, phase imbalance (such as independent phase grounding and sheath),
and crosstalk by proper separation of power and control cables.

3.4.8.8 Capacitors

Capacitors shall not contain PCB (Poly-Chlorinated Biphenyls). They shall be equipped with filters, respectively
inductors to follow the actual electricity supply company-regulations concerning harmonic-wave contents, especially
regarding the damping of ripple-control signals. The power factor according to the regulations of the electricity
supply company shall be maintained.

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3.4.8.9 Electronic Motor Soft Starter

These units perform the soft starting, reduction of starting current, soft stopping, breaking, energy saving and motor
protection functions. By use of thyristors the built-in microprocessor unit of a soft starter controls the voltage of the
connected motor in a way that during the starting phase the voltage is continuously increased while the motor current
and the motor torque is monitored and limited to a preset value. To make sure that motors start in a reliable manner,
the units can be programmed to send an initial pulse of a higher voltage to the motors. For soft stopping, the soft
starters reduce the voltage so that the torque of the motor reduces gradually without sudden steps. Included shall be
among others the power supplies for the electronic units, mains filter, motor filter, high power fuses suitable for
semiconductor-equipped sets, circuit breakers with signalling contact for the control voltages, a set of spare control
fuses, etc..

Included in the soft starter shall be also a temperature limit switch to protect the unit in case of excess temperature, a
number of control inputs and outputs to control the associated motor starter circuitry, five LED indicators to display
the operating condition and a covered control panel with following elements: adjusters for ramp time (0..180 sec),
start voltage (20..100%), current limit (0.5...6x nominal motor current) and stop time. DIP switches to programme
the operating modes.

If not specified differently, the soft starters shall be connected in series with a main contactor to enable emergency
shut off. In parallel to the soft starter there shall be another contactor to bypass the soft starter after starting is
complete to reduce power losses. The latter shall also allow running the connected motor directly in case the soft
starter is malfunctioning. The soft starters shall be completely delivered, installed, carefully programmed according
to the connected machines, tested etc... The contactors, fuses, circuit breakers required to complete the circuitry of
the motor starter shall be included in the service.

3.4.8.10 Electronic Line Monitor

All Low Voltage Distribution Switchboards need to have Electronic Line Monitors. These devices shall constantly
monitor the three phase voltages and currents at the feeding point. The ratios of the connected current and potential
transformers shall be field adjustable at the monitor unit. The units shall be mounted in the doors of the switchgear
cabinets. All programmed and recorded data shall be kept in non-volatile memory. No batteries required. Data and
limit values can be easily selected and keyed in by the user at buttons at the front panel.

The measured values shall be processed by a built in microprocessor and at least the following data shall be
indicated at a digital display at the front panel and shall be updated every 1.5 seconds:
 AC Amperes (three phases, 1% accuracy)
 AC Voltage (three phases-phase, three phases-neutral, 1% accuracy)
 Watts, Vars, Watt demand, Watt-Hours (2% accuracy)
 Power Factor (4% accuracy), Frequency (0.5% accuracy)
 Alarm Condition, Trip Condition, Unit Factor (Kilo, Mega)
At least following protection functions shall be implemented:
 Phase loss (depending on voltage or current)
 Phase unbalance
 Phase reversal
 Overvoltage
 Undervoltage
Additional Features:
 Pulse generation for watt-hour measurement
 Suitable for 3-wire or 4-wire systems
 Self protected from fault, Self diagnosis
 Energy management
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  Outputs:
 Output contacts for Trip and Alarm conditions and Watt-Hour pulses
 Analogue outputs for Current, Voltage, Power, etc.
 If intelligent device is going to be used, it can be connected to the process communication bus and / or
interface to the process slave (or master) PLC
The line monitors shall be completely delivered, installed and programmed, tested, etc., including a set of spare fuses
and the circuit breaker with signalling contact for the supply of the control voltage.

3.4.8.11 Electronic Motor Monitor

For electrical motors, upon Designer’s justification electronic protection relays may be installed together with the
electric starter circuits of the motors to protect the motors against overcurrent and excess temperature. The motor
monitors shall continuously measure the motor currents of the three phases and the temperatures of the windings and
determine on the basis of true RMS calculations and on the basis of the user-programmable motor characteristics and
limit values if there is normal operation, or if there is a trip or an alarm condition. The programmable motor
characteristics shall include: Full Load Amps, Locked Rotor Current, Locked Rotor Time, Ultimate Trip current. All
programmed and recorded data shall be kept in non-volatile memory. Batteries would not be required. Protection
relays should be for door mounting. Data and limit values can be easily selected and keyed in by the user by buttons
at the front panel.

At least all following protection conditions shall be monitored:

 Locked rotor current, Ultimate trip current, Instantaneous overcurrent trip
 Maximum allowable stall time, I2T alarm level
 Ground fault trip, Motor excess temperature trip and alarm
 Jam trip and alarm, Underload trip and alarm, Phase loss and phase unbalance trip and alarm
On the front plates of each motor monitor shall be a digital display to indicate at least:
 Motor currents - 3 phases and ground
 Temperature reading of up to 11 sensors (°C or °F selectable)
 Operation count
 Run time
 Remaining starts
 Highest phase current
 Highest winding temperature
 Number of trips (sorted by reason)
 Conditions stored prior to a trip
 Timer
 Status LED’s
Following inputs shall be available:
 Supply voltage
 Remote trip signal (programmable)
 11 temperature sensors
 3 current transformer connections (programmable ratios 10:5...4000:5)
 Ground fault transformer connection
 Following programmable outputs shall be provided:
 Alarm contacts
 Trip contacts
 Auxiliary Trip contacts
 Transition contacts
 0/4...20 mA output for relative motor current or temperature
The motor monitors shall be completely delivered, installed and programmed, tested, etc., including a set of spare
fuses and the circuit breaker with signalling contact for the supply of the control voltage to the motor starter circuit.

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3.4.8.12 Remote Terminal Units (RTU)

For the purpose of maintenance and testing, it shall be possible to manually operate some equipment (valves, pumps,
aerators and other consumers) from a location very close to the equipment.

A remote terminal unit (RTU) shall consist of a field-mounted panel consisting of a simple switch control or small
PLC and some form of communication telemetry which can operate the equipment under remote/ manual control.

For each piece of equipment to be controlled in such manner, the RTU shall be mounted at a location where the
functioning of the equipment can be observed.

The casings for surface mounting shall be installed vertically, with cables fitted from below to a screwed watertight
gland according to the cables. Labels, white with black inscription, shall be fixed with screws.

Switchgear and control assemblies shall be provided with the degree of protection suitable for the location.

The switchgear assembly consists of:

 Suitable number of pushbuttons with flat button and a cover plate resistant to abrasion, with inscription (e.g.
"Open", "Close", "Stop", "On", "Off", "Slow", "Fast", etc.)
 1 keylock switch according to plant's locking system, for electrical blocking of the pushbuttons, with
abrasion-proof label "Local control - Off - Central control", key removable in all switch positions
 1 mushroom-head emergency pushbutton (red), latching, including keylock according to plant's locking
system and surrounding circular yellow label with black inscription "Emergency Stop".
The emergency-stop-button shall be equipped with three NC contacts. One emergency pushbutton may be sufficient
for a group of drives that shall be stopped together in case of an emergency.

External switchgear assembly shall be surface-mounted into a weather-proof casing made of high-grade steel
(1.4404) installed on a suitable pole with protective sun and weather roof, made of high-grade steel (1.4404).

Field-mounted keylocks may be subject to heavy abrasions and may be blocked by dirt if no special precautions are
taken. Therefore the Contractor shall propose various adequate locking systems like safety-lock, square-key,
triangular-key, etc... to the Engineer for consideration.

The installation ready for operation and all mounting and installation material shall be included.

3.4.8.13 Spare Parts for LV Stations, Automation, Instrumentation and Control Systems

During the early years of a new facility, the new operator will not have time to identify the supply chain for such
parts. For this purpose spare parts are to be provided to cover parts and consumables for at least two years after Issue
of Taking Over Certificate. Other electrical spare parts are to be provided as specified hereafter.

General Requirements

The Contractor shall supply all spare parts, recommended by the manufacturer of the various equipment for the
period of two years. The Contractor shall submit a list of the offered spare parts together with the offer.

The provision of spare parts shall include but shall be not limited to the following items for the WWTP:
 30% of the respective number of built-in LV fuses of each size that is required for the facilities (at least 6
pieces per size),
 10% of the respective number of built-in indicator lights of each colour that is required for the plants (at least
20 pieces per colour),
 10% of the respective number of built-in coupling relays, auxiliary relays and isolating amplifiers of each
type that is required for the plants (at least 5 pieces per type),
 20% of the respective number of built-in overvoltage protection units of each type and size that is required
for the plants (at least 6 pieces per type),
 10% of the respective number of built-in miniature circuit breakers of each type that is required for the plants
(at least 5 pieces per type),
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  1 complete set of spare parts for each cogeneration unit/ diesel generating set, including all belts, sealings,
hoses, flexible connections, bearings, fuel and lubricant filters, rotary diodes for alternator, etc.,
 For all offered works: 1 piece of each installed PLC module, such as CPU, I/O-modules of each installed
type, communication-modules, interface modules, power supply modules, etc.,
 20% of the respective number of built-in lamps of each size and type that is required for the plants (at least 5
pieces per size),
 100% of the respective number of built-in non-rechargeable batteries of each type and size that is required for
the plants,
 Filter material sufficient for the replacement of all installed filters within switchgear cabinets, air-
conditioning units, etc.
All spare parts shall be new parts from the original producers, delivered in undamaged original packing. The
package shall guarantee that the parts are not damaged by mechanical, electromagnetic, temperature stress, self-
discharging, etc. during storage. They shall be sorted in one set of labelled stable plastic boxes for each WWTP that
can be used for storage of the spare parts.

3.4.9 Automatic Control Systems

The delivery of quality services including treatment of wastewater relies on a battery of sensors, different controllers
each with different level and scope of control. Some of the controllers are integrated into the provided equipment as
they become smarter. The coordinated and safe operation of the system requires a solid automatic control system for
which the technical requirements are provided in this section.

3.4.9.1 Standards
 IEC 61131 Programmable Logic Controllers
 IEC 60870 Telecontrol equipment and systems
 IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related
Systems
 IEC/EN 62061 Safety of machinery
 IEC/EN61511 Functional safety - Safety instrumented systems for the process industry sector

3.4.9.2 General Requirements

The control system shall be hierarchy based multi-layered client server model. A four layer configuration is planned
for the public utility company. For each facility covered by this contract, a three layer configuration shall be
implemented. All the different layers must be compatible with the adjacent layers and communication must be via
common industry standard protocols.

Following control levels shall be realised:

 Level 1 - Local control Control at the location of the equipment/ drive
 Level 2 - Group/unit control Control at the switchgear cabinet, respectively MCC
 Level 3 - Central control Control at the supervisory control system
 Level 4 – Corporate control Integration into enterprise resource planning software
At the lowest level 1, the equipment is controlled directly with control ranging from simple manual on/off switch to
fully automatic co-generation unit and its built in electronic controller/ PLC and innumerable intermediate degree of
monitoring and control of all kinds. Monitoring of the simplest process can be just the value measured by a sensor
without requirement for a response.

At the next level 2, the operation and function of the equipment shall be supervised by a second layer of control
which must be compatible with Level 1 control. The Level 2 controller shall collect other information either from
other sensors or higher level controllers to compute new settings for Level 1 equipment. The Level 2 controllers shall
supervise a number of equipment and sensors and automatically compute the operational settings.

Level 3 supervises the operation of the whole facility, collects information from all the level 2 controllers for
analysis prior to adjustment of settings; monitors alarms and initiate the programmed reaction; processes information
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and prepares management reports; and archives collected data. Level 2 and Level 3 systems can be combined for
small systems.

Level 4 will be the wide area network which will be implemented by the public utility company and is not the subject
of this contract. Level 3 system must be designed for communication with level 4 system and respond to request for
information. The communication protocol shall be industry standard TCP/IP, Ethernet, Modbus and Profibus.

All control levels shall implement a Safety Instrumented System (SIS) in accordance with IEC61511 which is used
to monitor the status of values and parameters of a piece of equipment against the operational limits and, when risk
conditions occur, trigger alarms and place the plant in a safe condition or shutdown.

3.4.9.3 Implementation Plan and Design Criteria

The Contractor shall carry out the realisation of the automation systems according to the following work programme,
regarding the whole electrical and process control systems:
 Creation of description of functions, lists of consumers and measurements, Process Flow and P&I Diagrams,
circuit diagrams, workshop- and installation drawings for the whole electrical equipment
 Creation of the plant identification system
 Design of control computers
 Creation of the logical diagrams and control algorithms
 Creation of program descriptions for PLC units and the bus system
 Submission of facility control philosophy with hardware and software proposals
 Creation, installation and implementation of the software, start-up
 Submittal of draft of the final commissioning documentation
 Training of operational staff
 Test-run during defect notification period
 Multiple optimisation of the system according to the experience, gained by the operating personnel
 Creation and submittal of the final documentation, firmware and software
Each step includes the respective technical clarification, production of the required documents, and multiple revision
of documentation until approval by the Engineer.

The Contractor shall submit a fully developed plant control philosophy for the facility and include full details of the
hardware and software. It shall be based on the process requirements of Volume 3 Section 1, the mechanical and
electrical requirements of Volume3 Sections 3 and 4.

The SCADA system shall be designed with consideration of the following:

 Standard design principle shall be prepared for use in present design and future extension of the system;
 Naming convention, symbols and colour scheme (status and groups) for graphic screens shall be consistent
across the system;
 Controls should be arranged and grouped in an intuitive and logical manner;
 Decentralised control system (DCS) shall be adopted;
 Long term data storage and retrieval shall be provided;
 Flexible communications topology linking master terminal unit, programmable logic controllers, remote
terminal units and intelligent electronic devices shall be provided;
 All levels (master or slave) shall be provided with sufficient redundancy for future expansion of the system;
 SCADA protocols (Modbus, Profibus, Ethernet/IP) shall be open and non-proprietary
 Standby facility shall be provided;
 SCADA equipment should be protected from the effects of dust, dirt, water and other contamination by
appropriate location within the facility or within appropriate enclosures;
 Transient voltage suppression shall be provided to protect the SCADA system.

Before coding the software and supply of hardware for the computer system the Contractor shall compile a detailed
design report of all functions of the proposed system and submit it to the Engineer for his approval. The functions
shall be demonstrated with the aid of a functional demonstration unit. Corrections according to the Engineer'

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direction shall be included into the description. After the final acceptance of the description by the Engineer the
Contractor may begin the programming of the software according to the said description. Following aspects shall be
covered:
 Operating System  Data Backup
 Application Software  Network (Ethernet)
 Communication with the PLC's  Hardware
 Communication between the computers  Plant identification system, complete
 Graphical software functions list
 Processing of status signals  List of all consumers and data
 Reports  List of all measurements and date
 Manual data input  Graphical display images, draft printout
 Menus for the operation of the system of all images
 Archives
 Implementation of third party software
The description of the desired functions shall be completed and shall be submitted to the Engineer for his approval.
The computer system shall be implemented exactly according to the approved description.

Specific network topology, network realisation and control system devices / components selection remain the
responsibility of the Contractor. The proposed control system hierarchy, concepts explanation and definition of the
scope of delivery is presented on the following Diagram 1.

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Diagram 1: Control System Hierarchy

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3.4.9.4 Hardware – Generally

All control equipment located in control panels of all levels shall operate with a control voltage of 230 VAC.

All equipment shall be provided with interlocking protection devices against overcurrent-relay, limit switches, dry
running and overpressure protection, etc.

The connection between the central or process control system and the PLC shall be carried out by a connecting
system with diagnosis features. The required plug-in cards, power supply and communication units shall be included.
The data shall be transferred from the PLC-system to the computer in real time mode. For monitoring the system,
diagnosis of faults and fault signals with acknowledgement each digital outputs and inputs shall be installed. At a
failure of data connection or any other fault an alarm shall be given.

Controllers/ Programmable Logic Controllers

All controllers shall be from the same manufacturer for maximum compatibility and shall have the ability to execute
custom-written code to control field I/O, RTU, slave PLC and other devices. The code and programmes shall be
stored on a EPROM memory.

The controller’s CPU and in particular their cycle time shall be selected as a function of the future number of I/O and
requirements of the applications.

The amount of memory provided on the CPU and as RAM/ EEPROM shall be as high as possible for the control
requirements.

Controllers shall be able to control devices over communication protocols such as TCP/IP, Ethernet, Modbus or
Profibus.

Controllers shall be able to handle a multitude of different signal types—such as 120VAC discrete, 24VDC discrete,
4-20mA analog, 0-10V analog, RTD and Thermocouple inputs and high speed inputs.

Each controller unit shall be provided with its marshalling cabinets suitable for the environment where it shall be
installed. The human machine interface with all necessary software shall be included and shall be suitable for the
duties of the controller.

The cabinets shall be protected from corrosion as specified in Section 3.4.

3.4.9.5 Software - Generally

The system software shall be based on general purpose software modules adjusted to specific requirements of water/
wastewater treatment plant. Organization of system software depends on selection of computer equipment, but
generally, it should contain the following elements:
 Operating system and system programs
 Programs for creation of application software
 Diagnostic programs
Operating system and system programs should enable operation of computers and programmable controllers in
the network and real time operation.

Programs for creation of application software enable creation of SCADA computers and sequent algorithms of
programmable controllers. Programs for creation of application software include a communication package, data
processing package (trends, statistical calculations, tables, databases, etc.), data filing package, sequence algorithms
creation package, etc. Diagnostic programs test all the components of computer and programmable controllers,
peripheral devices and communication lines. Test results are to be presented as reports on displays, monitors and
printers.

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Application software consists of interconnected software modules which enable dialogue between the operator and
computers, and provide optimum and reliable operation of plant in normal conditions, as well as undertaking
necessary actions in case of emergency. Emergency occurs upon detection of alarm conditions in the process. Alarms
are internal variables generated in SCADA system, resulting from: unfavorable digital signals (errors, minimums,
maximums, feeding failures, etc.), of high or low analogue values and unfavorable trends.

Human machine interface shall allow the following functions:

 Indication of operating conditions and measurements on monitors and printers;
 Indication of alarm conditions on monitors and printers and sound signaling at their occurrence;
 Issuing commands by keyboard and mouse.
Computers and servers shall be provided with an industry operating system complete with office software including
word-processors, spreadsheets, presentation software; all suitable for analysis preparation of reports, presentation.
The necessary licences for installation of all the computers shall be provided.

Information are presented to the operator by printer and monitor, and commands from operators are issued by touch
screen color monitor, keyboard and mouse. Information are presented by graphical and alphanumerical symbols. The
number of required presentations is determined so as to embrace all the plant elements with necessary information.
New presentations could be created, if required, at on-line regime of computer operation.

All data are saved on hard disk, and the data which need to be permanently preserved are saved on an optical disk
and also on backup hard disks. Summary reports are printed at scheduled intervals or upon operator's request.

The following presentations should be created on the monitors:

 mimic schemes,
 trends,
 bar diagrams,
 sheets,
 text reports,
 tables,
 other presentations.
Presentations are created as mask-shaped with fixed contents and with parts to be refreshed by instantaneous data
gathered from the lower level process controllers. Basic fields which must be shown on each presentation are the
following:
 Consumer information on the name of presentation and actual date and time,
 Presentation field (graphical presentation, sheets, tables, text reports),
 Consumer information field sent to the operator by the controller,
 Warnings and alarm.

Mimic Presentations. Mimic presentations include parts of the plant together with structures, pipelines and
equipment in them. They consist of static background and dynamic presentation of measured and computed values,
equipment conditions, alarm, etc. Digital and analogue values monitoring is achieved by setup sample times
(changeable). On these presentations, at convenient spots, there are switches for control of corresponding parts of
equipment. Commands which are not available to the operator at the moment must remain visible on the
presentation, but coded by a colour different from the available commands. In order to decrease the possibility of
entering a false command, parts of equipment can be controlled only from presentations containing those parts of
equipment. Operating conditions of parts of equipment are coded by colour, and alarm conditions are coded by
colour and blinking which terminates upon operator's confirmation of alarm. Besides the symbolic marks of
technological consumers, these presentations also contain alphanumerical symbols for indication of local, remote,
manual and automatic operation, minimum and maximum technological and hydraulic values, etc.

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Trends. Trends are presentations of analogue values in graphical form as maximum, minimum or mean value in a
determined time range.

Bar Diagrams. Bar diagrams are graphical presentations of measurements and statistics data from the process.

Sheets. Sheets are intended for providing detail information on alarms, measurements, signalizations, and
commands. All the sheets share the same form. The sequence number of the signal is followed by the location and
the moment of the signal occurrence.

Text Reports. Application software enables the operator (dispatcher and analyst) to create text reports upon request.

Schedules. Schedules are intended for remote definition and changing of parameters of plant elements such as:
 measured ranges of analogue values;
 referent values of regulation loops;
 duration of particular technological processes.
Other Presentations. Other presentations include block schemes of the system and its parts such as hydraulic
system, computer system, etc.

Data Presentation on Printers. For reports printing, A4 format printers are anticipated. The reports may be:
 spontaneous,
 upon request.
Spontaneous reports include automatic printing of events such as alarms, particular conditions of equipment,
operator manipulations, etc. The report contains the structure and the part of equipment to which the event refers,
time of its occurrence and its description.

Reports upon consumers' request include printing of graphical and text reports, sheets and shift reports.

A modern controller includes an embedded computer which requires software codes to turn it into a fully functional
and programmable logic controller. Software for controllers shall be designed to combine PLCs’ discretes, PID and
digital/analog I/O control with high performing computer networking, data handling, and computational capabilities.

Human Machine Interface (HMI) system shall allow the custom design of graphics and the animation of those
graphics, based on the value of instrumentation signals coming from the field.

Software shall be written to optimise the response time of all triggered event.

Normal Functionality

The HMI software shall be used to control the function of the facility and to carry out this function sensors will
measure parameters which will be used in the following manner:
 To initiate a particular action depending on the measured value
 To control the efficient operation of the facility
 To record for reporting on the operation of the facility
 To store for future use
The software shall thus gather data collected by the sensors and based on their values initiate one or more actions to
start or adjust particular process. The data collected and the resulting action shall update the mimic diagram and all
events be recorded by the monitoring system. Coordination and synchronisation of time based events across the
SCADA system shall be possible.

Automatic analysis of the collected data shall allow the presentation of the efficacity of treatment, energy
consumption and trends for different zones within the facility. Alarms shall be raised when critical values are noted.

The HMI systems will allow creation of custom alarming and data logging/ trending. HMI systems shall have remote
notification capabilities such as text or email alerts,

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Extensive data collection and storage capabilities in a database shall be available for automatic report generation as
described for Level 3 control system.

Security

Security features shall be designed, implemented and configured to restrict user access at all control levels. Using
assigned security level and login credentials, any operator with access rights can go to any controller and view or
control the area under the responsibility of the controller. Access rights shall be arranged such that top level access
with full software change rights shall be limited to original programmer and password shall be provided on physical
media which can be safely stored. Operators’ access rights shall be limited to adjusting process parameters either
across the whole plant or in zones.

Power source for the system shall be ensured such that all critical processes shall be maintained for the minimum
duration indicated in the process design or for as long as possible.

Power source for data acquisition and storage shall be uninterruptible for a duration, after the power interruption
event, sufficient for safeguarding the data.

Control of other critical processes shall be possible through the distributed control system or RTU even if
communication to the server has failed.

Redundancy shall be provided to prevent shut-down of every process on failure of the HMI server or other critical
hardware.

The design of software shall ensure that programme execution errors do not hang/ freeze the controller but initiate a
reboot. The controllers must be provided with automatic backup of the necessary process parameters, thus enabling
regular operation upon restarting.

Software shall include fault recovery procedures to be executed in case of failure of level 1 RTU or slave PLC and to
prevent unsafe operation of the equipment.

Safe backup of data shall be automatic.

Communication

Communication protocols shall include TCP/IP, Ethernet, Modbus and Profibus as a minimum. All connected
equipment (PLC, process controllers, data servers) shall provide the necessary drivers to connect to the HMI system.

Architecture

The HMI system shall be a server/client application with all the HMI tags, graphic screens, alarms, data points, etc.,
for the whole facility loaded on a single or redundant server. Client software shall then be loaded on controllers in
the various process areas of the plant, and these clients communicate with the server to read and write the data
required to monitor and control the facility. Graphic screens for each distributed control zone shall be the same as
those presented on the main SCADA screen.

The DCS (PLC, RTU) controller may also have additional control capabilities which are not available at the central
control screen but changes in status must be reported.

Redundancy shall also be designed in the architecture to recover from hardware failure.

Programming Language

The software used for developing the HMI system shall be standard and readily available. The software shall be able
to support a real-time SCADA system with response time suitable for the different installed equipment and DCS
without resulting in unsafe operation or situation.

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The language selected for programming shall depend on the complexity of the control. For simple RTU, simple
ladder diagram/ instruction lists or function block are acceptable. For more complex control, the programming
language shall be structured text such as object oriented “C++”. It shall also be possible to load functions developed
in other languages such as Fortran, Java, C, or C++ languages.

Local Support

The Contractor shall ensure that local support is available for the SCADA software provided. The contact details of
the support shall be provided to the Engineer.

3.4.9.6 Level 1 Equipment

Level 1 control includes remote terminal unit (RTU) or slave controllers (Slave PLCs) which control the equipment
in response to status of built in sensors or also on external sensors. Closed loop controls are usually provided for
such equipment and since they do not depend on other inputs, they can operate independently. Normally
modification can only be carried out by the manufacturer either through hardware or software changes.

The local field control has the highest priority and it shall be designed for emergency control, i.e. it shall be
operational even if the automatic control is out of function. With local control any equipment/drive can be operated
under direct visual observation while being maintained and in case of a control-failure. Local control shall be
implementable only after a positive be used, after a key-switch is turned on, which at the same time blocks the
control of other levels.

Any equipment under Level 1 control can normally be switched on/ off permanently but if permanent operation is
not allowable because of the process requirement, local control shall be designed to only allow just inching-mode for
testing operation.

Outdoor cabinets and control panels shall be of stainless steel 1.4404 with IP65 (or IP55 if mechanically ventilated)
ingress protection with status indication lights. Rotary switches shall be provided for selection of the different
operation modes. The control panel (incl. signal lights) shall remain completely functional in manual mode or
SCADA failure.

Point to point cables shall provide communication means. The communication protocol shall be industry standard
TCP/IP, Ethernet, Modbus and Profibus.

3.4.9.7 Level 2 Controller/ PLC Equipment

All PLC provided shall be from the same manufacturer and shall have the ability to execute custom-written code to
control field I/O, RTU, slave PLC and other devices.

Level 2 controllers shall be geographically located such that the equipment under control are in close proximity. The
Contractor will decide on optimal number / locations / configurations of level 2 PLCs, having in mind the physical
units of the technological process, physical locations, functions and system complexity. The number of level 1
equipment under the control of level 2 controllers shall be limited such that the computing capacity is not excessive
and response time is reasonable.

Marshalling and Instrumentation Cabinets

At Group/Unit Level 2 control, four operating modes can be selected at the switchgear cabinet respectively at the
MCC:

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  The "manual"-mode allows the manual control of equipment by means of RTU/ slave PLC in the field or in
the respective equipment room. In this mode the Level 2 controller and Central Control are disabled.
 To turn a piece of equipment off for a longer time (e.g. for maintenance or repair) the "locked"-mode shall be
used. In this case, the equipment shall be disconnected and alarm signals shall be suppressed. While working
on the drive, additional safety measures shall be taken (safety switch, remove fuse, etc.).
 In the "auto" mode the equipment shall be controlled by the Level 2 controller. The operation from the RTU
and central control room shall be locked.
 In the “remote” mode the control function is passed to the central control system (CCS) and the central
control room.
Each PLC unit shall be housed in a marshalling and instrumentation cabinet of identical design as the PLC cabinet
and of sufficient size, installed as a switchgear cabinet according to the specifications for LV equipment.

The PLC cabinet shall be delivered uniform with front connections respectively front plug connectors, including
connection wiring, interface element and built-in hardware-clock.

The PLC cabinet shall be delivered and mounted completely functional with mounting racks, power supply units,
under/ overvoltage protection devices, circuit breakers, monitoring devices, interfaces, bus connections, connecting
cables with plugs, coupling relays, isolating amplifiers, terminals, fitting material, etc. including the wiring of the
switchgear cabinets.

The marshalling and instrumentation cabinets shall provide a sufficient number of terminal blocks for the
marshalling of all incoming signal cables to the I/O units of the PLC. Inputs/ Outputs racks shall be expandable and a
minimum of 35% of spare basic types of I/O shall be available.

Equipment

The inputs and outputs of the PLC provide the following specifications:
 Digital inputs (DI) isolated, 24 VDC
 Digital outputs (DO) potential-free via coupling relays, 24 VDC, 2 A
 Analogue inputs (AI) isolated, 0/4…20 mA, converter resolution 11 bit
 Analogue outputs (AO) isolated, 0/4…20 mA, converter resolution 11 bit
 System interfaces, transmission speed min. 187.5 kbit/s
All level 2 controllers shall be supplied via an uninterruptible power supply unit. A switch "UPS / Main"
to select the power source shall be installed at the front of each PLC unit cabinet.
The program memory and all status registers shall be buffered with a long lasting (minimum 3 years) readily
available standard battery.

All signals and analogue values shall be connected potential-free by means of suitable coupling relays and isolating
amplifiers.

Communication

For important signals and signals for safety purposes the bus system may not be used. These signals, optionally, may
be transmitted directly by means of control cable with a transmission voltage of 60 VDC - if necessary for the reason
of long distances transmissions / high electro- magnetic disturbing environment.

Contractor is required to analyse and justify (eventual) necessity for 60VDC control system.

As a minimum the following signals shall be processed and transmitted to the Central Control Room either via
communication bus system:

For motors, drives and valves:

 commands (on, off, faster, slower, high speed, low speed, open, closed, right, left, etc.)
 status signals (fault, on, off, faster, slower, high speed, low speed, open, closed, right, left, active starting
delay, etc.)
 analogue values (motor current, rotation speed, measurements, etc.)

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  further signals as required
For measuring devices:
 status signals (fault, maintenance, limit alarms, etc.)
 analogue measuring values
For electric switchgear:
 commands (open, close, etc.)
 status signals (open, close, fault, tripped, etc.)
 analogue values (current, etc.)
 further signals as required
Other signals from or to the plant:
 electricity supply (voltages, frequencies, all signals from the generating sets, etc.)
 from the process (calculated values, etc.)
 all signals provided from machinery units with separate control devices
All further signals that can be gathered from any device installed at the plant

Automation devices shall be installed within separate switchgear cabinets in the respective LV-Room. Switchgear
cabinets shall be designed according to the specifications concerning the low voltage distributions. The electrical
specifications shall be:
 Operational voltage: 400 / 230 V, 50 Hz
 Control voltage: 230 V, 50 Hz
 Scanning voltage (optional): 60 V, DC
 PLC and light indicators: 24 V, DC
 Following materials shall be included:
 Cable ducts
 Mounting material
 Connecting material
 Fitting material
 Connecting terminals
 Automatic fuses with signalling contact for 24 VDC, 60 VDC (if applicable) and 230 VAC in adequate
number for each panel
 Operator panel with LCD-display in order to show the operational status of the PLC, the controlled plant and
to input control variables
Level 1 RTU/ slave PLCs and sensors shall communicate directly (point to point) with Level 2 controllers to
minimize response time using one of the following industry standard communication protocol such as TCP/IP,
Ethernet, Modbus and Profibus.

Communication with Level 3 central control system shall be industry standard TCP/IP, Ethernet.

Controller Software

The Level 2 PLC software includes all the programmes for the automatic control of the devices connected to the
controller/ PLC and for the connection to the Level 3 process control system, including input and output via
communication modules with the necessary communication software. The suite of programmes may include a
mixture of industry standard operating systems, purposely written codes and code libraries.

The system shall allow the processing of all inputs and outputs (I/O) and transfer them respectively to and from the
Level 3 process control system.

The programs shall be designed in a way that the normal operation will carry on automatically right after a power
supply failure. If necessary, an audible warning shall be given, before any equipment is restarted automatically.

Equipment blocked because of undervoltage shall not be restarted automatically.

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Power demand shall be continuously monitored to manage the operation of all electricity consumers and some
consumers automatically stopped when power demand exceeds a pre-determined value. For such event, equipment
on a priority list shall either be stopped or it shall be not started.

The operating personnel shall always be able to change important setting values without going through an extensive
programming with the computer, to adjust the control to changing processing conditions. This shall be realised by
menu-assisted operator panels with usage instructions on screen.

Digital outputs from the PLC shall be supplied with relay contact-assemblies. Wherever possible the PLC programs
shall be finally implemented in non-volatile memory (e.g. EPROM), if possible, after all functional tests and
adjustments have been successfully completed.

Programmable logic controllers (PLC) programming standards should be in compliance with IEC 61131.

The correct function of the programs shall be tested and optimised in all parts of the process while the machinery is
working.

PLC and automating devices shall be protected against electromagnetic influence and power-supply failures and
shall be supplied with extensive diagnosis facilities.

The software shall include extensive self-diagnostic routines to continuously check safe operation of all systems.

Testing shall be intensive and simulation of some events shall be tested during commissioning.

All operating systems provided with controllers shall be upgraded at no cost whenever there is a software upgrade.

When the Level 2 controller has been set to “remote” control, the Operator in the central control room shall be able
to set / change process parameters and initiate automatic control sequences normally available at the Level 2
controllers. For safety reasons, manual control through the Central Control System shall not be possible.

Graphical Plant Display Images (GPI)

All Process Data shall be presented symbolically in the form of high-resolution graphical images at the monitors. All
components of the WWTP shall be shown in a way that they can be easily recognised even by not experienced plant
personnel. All displayed data shall be dynamically updated at least once every second, so that the data on a visible
GPI are virtually up-to-date at any moment. The time from the selection of a specific GPI until shall be fully
displayed and updated shall be maximum 1 second. By usage of keyboard or mouse the personnel can choose a
particular GPI and zoom and roll to the specific point of interest. After a specific object is selected by a mouse click,
more data about this object shall be shown and a menu with further commands shall be displayed. By using this
method the motors can be operated, set-points shall be adjusted, information about the handling of the process data
can be programmed and inspected, memos can be inserted by the operating personnel (e.g. to inform other staff
members, to remind about faults, experiences etc.). These memos shall appear whenever the specific subject is
selected.

Digital Process Data shall be presented in following ways:

 As symbols or texts with changing colours
 As alphanumeric texts to appear or change
 As changes of the display of analogue data (e.g. alarms)
Analogue Process Data shall be presented in following ways:
 As numbers with designation of the physical units or %
 As thermometer-like bars (vertical or horizontal)
 As instruments with moving pointers
 As freely defined areas (such as filling tanks)
 As changing colours of areas or bars (e.g. exceeding limits)

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  As trend curves over the time as x-axis
 As curves of an analogue value over another value (xy-trend)
For each analogue signal at least two limit values and one hysteresis-value shall be adjusted.

Alarm, fault and warning signals with precise and comprehensive messages and suggestions for required actions
shall be indicated within the actual GPI. For each possible alarm, fault or warning the priority and the need of
acknowledgement can be selected.

The GPI shall be programmed and implemented as follows:

The Contractor shall make himself familiar with the exact functions of the facility. The GPI shall be designed by the
Contractor after a discussion with the Engineer about the general concept of the GPI. Afterwards the Contractor
presents a first proposal of the GPI as a coloured paper-print. This proposal shall be discussed with the Engineer,
corrected and a first revision shall be submitted. This process may be repeated until the third revision of the GPI on
paper. Then the GPI shall be installed into the process computer as a first proposal of the final GPI. Afterwards 2
revisions may be necessary until the GPI is preliminary accepted by the Engineer. After 3 months of continuous
operation of the computer by the personnel the GPI may be submitted for final acceptance. If not accepted, the GPI
may undergo another 2 revisions for correction if the Engineer desires further changes.

The GPI shall be finally handed over as coloured paper prints, as implemented GPI within the computer and on CD
or DVD for storage.

3.4.9.8 Level 3 Equipment

Level 3 equipment includes the following:

 Processing unit
 Control software
 Human machine interface
 Output peripherals
 Public service telecommunication equipment or private system
 Uninterruptible power supply system
Depending on the size of the facility, Level 3 equipment can be merged with Level 2 equipment.

3.4.9.9 Communication System

Communication between Level 1 RTU/ slave PLCs and Level 2 controllers shall normally be a point-to-point or star
connection system consisting of cable laid underground or on cable racks.

Level 2 controllers/ PLCs units shall be connected to a data bus system at a central location (star coupler) or through
ringed bus structure. The network shall include an interface for connection of all controllers/ PLC, the programming
unit and the process control system, with sufficient capacity (ports) for this and final phase of construction. It
consists of connecting modules for the PLC units, a module for the programming unit and a module for the process
control system. The bus system provides a continuous fault diagnosis that gives alarm signals via potential free
contacts in case of faults. Suitable coordinated communication processors at the bus, the PLC, the process control
system and the programming unit shall be included.

For remote facilities such as underground pumping stations, communication between the level 2 controllers and the
central control system shall be through Universal Mobile Telecommunication System (UMTS) or 4G hardware or
the best available telecommunication system and a dedicated SIM (subscriber identity module) card.

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All cables shall be placed in ducts without any connection or splicing. Where connections are inevitable, they shall
be located at drawpits. The construction of drawpits and cable ducts are specified in Section 3.2.
Physical connection shall be completed as follows:
 Level 1 control cable - standard copper wire
 Level 2 communication - optical fibres or UMTS

When other designing requirements, such as EMI interferences, significant trace lengths distances, transmission
speed…) do not require other choice, standard copper made bus cabling is preferred for the reason of the easier
maintenance / repairs. Optionally, if analysis shows it is inevitable, important signals and commands shall be
transmitted directly on the 60 VDC level.

3.4.10 Instrumentation and Sensors

The6 automatic control of the facility will require installation of instrumentation and sensors which provides
measurement of different parameters for the control system.

3.4.10.1 Standards
 IEC 60873 Electrical and pneumatic analogue chart recorders for use in industrial process control
systems
 EN 60027 Letter symbols to be used in electrical technology
 EN 60050 International electrotechnical vocabulary

3.4.10.2 General Requirements

For automatic control, measuring and monitoring of the facility, all instruments and SCADA components in
compliance with the specifications in this section shall be supplied, installed, calibrated, tested, commissioned and
documented, wherever required. If specifications of instrumentation are given elsewhere in the technical
requirements, these shall be regarded in addition to the specification made in this section.

Instrumentation System and Sensor Selection

Instrumentation measurements will be used in the following manner:

 To initiate a particular action depending on the measured value
 To control the efficient operation of the facility
 To record for reporting on the operation of the facility
 To store for future use
The instrumentation system provided shall be suitable for the purpose of the measurements and designed with due
regards for the following potential issues:
 Accuracy/ tolerance/repeatability
 Zero/ sensitivity drift to environmental conditions
 Range of measurement/ thresholds (minimum and maximum)
 Noise
 Response time
 Failure
 Maintenance

Selected sensors shall have the accuracy/ tolerance and repeatability necessary for the purpose of the measurement.

6 10a

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Calibration of the sensors shall be kept to a minimum as a result of zero and environmental drift. Calibration shall be
automated wherever possible.

The range of each sensor shall be selected to maximise the accuracy of the measurement. Different type of sensors
shall be provided where the measurement range of a particular type of sensor is insufficient.

Degradation of measurement signals because of noise and interference shall be minimised by providing the required
cable separation, good cable connection, use of twisted pair signal cables, efficient grounding/ earthing and shielding
of the cables. Where excessive noise and interference is still prevalent other techniques such as filters, phase-locked
loop or lock-in amplifiers shall be used to control the amount of noise produced by some equipment. All equipment
shall comply with the EU Electromagnetic Compatibility (EMC) Directive and various euronorms.

Response time is an important factor of real time control and is mainly the physical response time taken by the
hardware to perform any action initiated by the software. This time is generally dependent on the provided
equipment and is always constant once the equipment is installed. However, the controller and software response
time i.e. the time required for processing an input and producing an output can be variable.

Controller’s response time must be less than the latency of the controlled physical process i.e. the mean time the
process reacts from a change in one or several of the inputs and is dependent on the physical, chemical and electrical
laws governing such process. For water related processes latency is between 2 and 5 minutes and rule of thumb
normally requires that controller’s must be a maximum of 20% of the latency of the facility or about 30 seconds to 1
minute.

Digital controllers are implemented using logical gates, flip-flops, and buffers which have very fast response time
measured in nanoseconds even when the response time of all components are considered should be less a
microsecond. On the other hand the response time of the application can be measured in minutes depending on the
efficiency of the coding.

The impact of failure of a measurement system and sensor has to be evaluated and where measurements are process
critical; redundant systems or equipment with high “Safety Integrity Level” such as SIL 3 with probability of failure
on demand of between 10-3 and 10-4 in accordance with IEC 61508-1 shall be provided.

The impact of failure or maintenance on the continuity and response of the control system shall be addressed.

In case of maintenance or repair of a measuring device, the control system might get false or meaningless values and
result in initiation of unexpected action. To avoid this, an alternative value shall be stored on the Level 2 controller
and provided to the Level 2 control system on disconnection through keylock maintenance switch or failure of the
sensor.

The key lock switch shall have a removable key and include ON/ OFF to indicate the status of the instrumentation.
The cabinet shall be installed vertically, with bottom entry cables with watertight gland

Due to heat, dust and rain all field-mounted keylocks shall be subject to heavy abrasions and may be blocked by dirt
if no special precautions are taken. Therefore the Contractor shall propose various adequate locking systems like
safety-lock, square key, triangular-key, etc. to the Engineer for consideration.

3.4.10.3 Functional Requirements and Material Generally

The Contractor shall deliver a complete good quality and fully functioning instrumentation for the facility, including
all Supervising and all accessories that are necessary to get a very reliable measuring system that meets the present
state of the art.

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Indicating instruments shall be analogue or digital display. Measuring units shall be easily accessible for
maintenance and calibration.

The Contractor’s design shall provide detailed description of the instrumentation and justification of the adopted
control system together with full Instrumentation list, Process Flow and P&I Diagrams.

Material for sensors and the housing shall be suitable for and not deteriorate in contact with the monitored medium
and the operational environment outside of the medium.

All instrumentation shall be solidly installed with and to corrosion-free fittings. It shall be mounted in an appropriate
way using a mounting structure made of high-grade stainless steel 1.4404, so that the devices can easily be removed
for maintenance and repair. In areas where the stainless steel is not suitable (e.g. chemical tanks), other materials that
are long lasting and corrosion-free shall be used. All instruments and sensors shall be installed in a way, that they can
be calibrated and inspected / repaired without interruption of the process.

The material and construction of all sensors for use in wastewater shall be suitable for this purpose. Instruments for
installation in chlorine or other chemicals shall be made of other non-corrosive material according to the medium.
Devices that are installed in potentially explosive atmospheres shall be approved for this purpose.

All instruments shall be suitable to operate under high humidity as present within the works. They shall operate
without problems under the condition of power supply as given at the place of installation.

All measuring transmitters and signal processors shall be equipped with appropriate protection for all power- and
signalling lines at both ends, cable inlets shall be water-tight and shall fit to the cable size.

All measuring transmitters shall be installed together with all the required electrical system protection within a
stainless steel cabinet including bottom entry water proof cable glands. A protective canopy and panels to protect the
device against sunlight and weather shall be provided. The lifespan and reading of displays shall not be affected by
daylight and UV radiation.

The distance between the measuring sensor and the measuring transmitter respectively signal processor shall be as
short as possible but with enough cable length for easy maintenance of the sensor. Extra lengths of cables shall be
orderly arranged on cable holders next to the measuring transmitters.

The equipment shall include all accessories and materials that are necessary for the correct operation of the
measurements, as well as adjustment and on site calibration.

The equipment shall be maintenance free as far as possible.

All spare and wear parts, as well as calibration devices; tools, calibration liquids and gases for two years shall be
delivered with each instrument.

Where a certain principle of measurement is used for the level measurement and where at the same location a second
level indicator is utilized for backup and safety switching purposes (for instance ultrasonic level meter to control
pumps in a pump sump and separate level switch for dry running protection), the backup system shall utilize a
different method of measurement.

The method of measurement for the backup system (secondary instrumentation), if not shown on the instrumentation
table or on the drawing shall be indicated by the Contractor and based on his design philosophy for control /
protection and as described in this section.

All measuring signal shall be transmitted standardised and potential-free digital signal (such as pulse signals) or an
analogue signal (current 0/4 -20mA). The receiving unit shall indicate a transmission fault, if the signal level is less
than 2.5 mA. The overall accuracy of each instrument shall be 0.5% of the measuring range.

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Each measured value shall be indicated
 At the measuring transmitter itself
 At an instrument in the relevant panel at the LV process distribution or marshalling / instrumentation
cabinets. Furthermore each measured value shall be indicated
 At the central control room of the facility on the central control system.
Measuring and automatic-control devices shall be constructed in a way that guarantees a stable behaviour of the
control system over the measuring range.

Volumetric flow measurements shall provide both analogue and pulse outputs to allow measurement of volumes.

Electrical kWh- respectively KVArh measuring units and flow meters shall always be equipped with a counting pulse
output to enable the calculation of totals to the PLC. The PLC units shall be equipped with special counting input
modules that are suitable for the actual counting pulse rates.

All measuring and controlling devices shall be tested for and be suitable at usage in water and wastewater treatment
and water distribution. They shall mainly be built up of a modular structure with easily replaceable groups (plug-in
units). They shall allow the operating personnel to carry out tests, calibrations and maintenance by itself with a
minimum expense.

If measuring devices is faulty or has to be stopped for maintenance it shall be possible to enter an estimated value in
the control system either automatically or manually. The procedure shall be described in the operation manual for the
SCADA.

Process-measuring units shall be put to operation by the personnel from the original manufacturer. The Contractor
shall be present, report the start-up and together with the manufacturer certify the smooth and correct functioning of
the unit.

Cabinets, mounting brackets and fittings for measuring units which are installed near aggressive water, waste water
or sludge shall be made of high-grade steel or other suitable stainless steel - 1.4404. Near chlorine treatment sections
or chemical treatment areas other non-corrodible materials shall be used.

3.4.10.4 Electromagnetic Flow Meter

Purpose: To measure the flow rate and quantity of wastewater, sludge or other liquids

Location:

The locations for instrumentation shall be as presented in Section 3.2 but shall be as a minimum at the following
locations:
 Before the primary settling tank distribution chamber
 Return sludge lines at WWTP
 Excess sludge lines at WWTP
 Digester, raw sludge
 Mechanical Dewatering, inlet sludge
 Facility effluent pipe
 At locations necessary for control of equipment
General Requirements

The electromagnetic flow meter uses the principle, that an electrical conductor (in this case the flowing medium)
induces a voltage if moved in a magnetic field that is proportional to the average flow velocity. This voltage is
measured with two electrodes inside the pipe, while two coils mounted on the pipe generate the alternating magnetic
field. From this the measuring transmitter determines the flow value of the medium.

The measuring sensor shall have the following characteristics:

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  Flow rate: suitable for the required purpose
 Diameter of the sensor: adequate to the media pipe
 Magnetic field: alternating by pulsed direct current
 Protected against flooding: min. 24 h, 3m, according to location
 Permissible pressure: min. PN10, according to location
 Materials: pipe: Steel, coated with PTFE
 Electrodes: High grade steel 1.4571
 Casing: Aluminium, powder coated
 Medium temperature: 0°C....90°C
 Min. conductivity of medium: 5 µS/cm
 Degree of protection: IP 67
 Calibration Automatic zero
The outputs shall include the following:
 Digital display for momentary flow rate and total quantity, separately mounted (8 digits) at a location, where
it can be easily calibrated, operated and read
 Monitoring of pulsed magnetic field
 Output signals, 0/4...20 mA, counting pulse, status output
All surfaces being in contact with the medium shall be coated with suitable material, so that cleaning is not necessary
and accuracy is not impaired during operation. The selected material shall be suitable for use in raw water,
wastewater, sewage sludge, and chemicals or as required by the respective purpose.

The flow meter shall be mounted to the pipes, regarding the right location where no turbulent disturbances may cause
false results. Flow straightener shall be provided where the required straight pipe lengths upstream and downstream
is not available.

Mounting material, construction pipes, replacement pipes to install while the sensor is removed, telescopic pipes to
ease the removal of the sensor, earthing system, reference electrode system and all electrical connections shall be
provided. The measuring transmitter shall be mounted separately so that it can easily be checked and calibrated.

Electromagnetic flow meters shall be preferably used. Other kinds of flow measurement shall only be installed, if
electromagnetic flow meters are not applicable (e.g. in open channels, concrete pipes, etc.).

3.4.10.5 Ultrasonic Flow Meter

Purpose Measurement of flow rate and total quantity of waste water, sludge or other liquids in channels

Location

The locations for instrumentation shall be as presented in Section 3.2 but shall be as a minimum at the following
locations:
 Inlet channel
 Effluent channel
 Optional (where electromagnetic flow meter as specified above is not suitable)
 At locations necessary for control of equipment

General Requirements

At these flow meters the water flow shall be measured with a Venturi constriction, where the flow changes from
laminar to turbulent. In this case the flow can be determined by a single ultrasonic depth measurement upstream of
the throat.

Variations of the ambient temperature shall not influence the measurements' accuracy and therefore shall be compen-
sated automatically by use of a temperature sensor. The complete measuring system consists of the Venturi channel,
the ultrasonic level meter, the measuring transmitter and the signal processor to calculate the flow rate and to
generate count pulses according to the quantity of water passing the sensor.

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The venture throat shall have the following characteristics:
 Type: Khafagi venturi, rectangular cross section
 Size: Fitting to the channel
 Materials: Sealed polypropylene, zinc plated steel reinforcements
 Flow rate: suitable for the required purpose
The ultrasonic sensor shall have the following characteristics:
 Integrated temperature sensor for compensation
 Temperature: -20°C...+80°C
 Measuring range: suitable for the required purpose
 Degree of protection: IP 68
 Connection to processor: Via cable
The signal processor shall have the following characteristics:
 Digital display for momentary flow rate and total quantity (4 digits)
 Continuous flow measurement
 Field-mounted housing, IP 65
 Output signals, 0/4...20 mA, 1 status contact, counting pulse, all potential-free
The components of the Venturi channel shall be delivered and integrated into the concrete structure of the channel
during the time of construction. The inlet stretch and outlet stretch shall be according to the manufacturers'
specifications as to achieve the accuracy and repeatability certified for cost-accounting purposes. The installed meter
shall be resistant against gases, humidity and weathering. The function of the meter shall not be affected by these
phenomena.

The sensor shall be mounted above the channels' middle to a stainless steel bracket that shall be fixed to poles on
both sides of the channel. The distance to the water surface shall be more than the sensors block distance. The
measuring ultrasonic signal shall not be disturbed by any fittings inside the channel to get reliable results. The
original manufacturer shall calibrate the flow meter on site. A certificate stating the accuracy at least at 10 different
flow rates within the total range after installation at the wastewater plant shall be submitted.

All fittings shall be easy to access and to remove for maintenance or repair. All mounting material also shall be
provided.

3.4.10.6 Ultrasonic Water and Sludge Level Meter

Purpose: To determine the level of various media in tanks, channels, chambers, etc.

Location

The locations for instrumentation shall be as presented in Section 3.2 but shall be as a minimum at the following
locations:
 All sludge tanks
 All chemical storage tanks (such as FeCl3,
 At locations necessary for control of equipment
General Requirements

At this measuring instrument an echo system transmits ultrasonic pulses towards the medium surface from above and
receives the returning echo. It determines the level from the speed of sound, the propagation time, and the sensors'
height. The complete measuring system consists of the ultrasonic level meter and the fitting-measuring transmitter.

The ultrasonic sensor shall have the following characteristics:

 Integrated temperature sensor for compensation
 Temperature: -20°C...+80°C
 Measuring range: suitable for the required purpose
 Degree of protection: IP 68

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  Connection to transmitter: Via cable
The measuring transmitter shall have the following characteristics:
 Digital display for momentary level respectively level difference (m, %) and volume (cu.m, %), 4 digits
 Permanent measurement of the medium level
 Field-mounted housing, IP 65
 Output signals, 0/4...20 mA, 1 status contact, 2 limit contacts, potential-free
 Power supply, 230 VAC, 50 Hz
The installed meter shall be resistant against gases, humidity and weathering. The function and accuracy of the meter
shall not be affected by these phenomena.

The sensor shall be mounted according to the purpose. At open channels or tanks it shall be fitted to a stainless steel
bracket that shall be fixed to a pole on the edge of the channel or tank. Closed pipes or tanks shall be supplied with a
suitable flange fitting with gaskets. The material of the mounting devices shall be suitable for the material of the
respective tank or pipe and shall be thermo-insulating. The distance to the medium surface shall be more than the
sensors block distance. The measuring ultrasonic signal shall not be disturbed by any fittings inside the channel, tank
or pipe to get reliable results. All fittings shall be easy to access and to remove for maintenance or repair. All
mounting material shall be included. In order to avoid excessive condensation at the sensors membrane, the sensor
shall be mounted in a thermal-insulated manner so that the temperature of the sensor follows the air temperature. The
membrane of the sensor shall be water-repellent and shall be shaped in a way that there is no built-up of water films.

3.4.10.7 Hydrostatic Level Meter

Purpose: To determine the level of various media in tanks, channels, chambers, etc. where water surface is
below foam

Location

The locations for instrumentation shall be as presented in Section 3.2 but shall be as a minimum at the following
locations:
 Before and behind the screens
 Inlet pumping station, pump sump
 Grit chamber, pump sump grease hopper
 Gravity pre thickener
 Return sludge pumping station, pump sump
 Excess sludge pumping station, pump sump
 Digester feed tank, pump sump
 Digester, foam
 Digested sludge gravity thickener
 Supernatant collecting basin
 Buffer tank supernatant
 At locations necessary for control of equipment
General Requirements

The hydrostatic level meter shall be mounted at the bottom of the respective tank to measure the pressure caused by
the medium. From this the level can be determined, if the medium density is known. Thus effects like foam on the
medium surface do not influence the measuring unit.

The sensor shall have the following characteristics:

 Suitable for installation in potentially explosive atmosphere (if required)
 Measuring range: suitable for the required purpose
 Output signal: 0/4...20 mA
 Degree of protection: IP 65
 Medium temperature: -30 ... +100 °C
 Housing and mounting material made of high grade steel (material 1.4301)

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The measuring transmitter shall have the following characteristics:
 Self monitoring
 Noise-free, two wire signal transmission
 integrated linearization
 two limit contacts with adjustable hysteresis
 power supply for measuring sensor
 Suitable for installation in potentially explosive atmosphere (if required)
 Field-mounted housing, IP 65
 Input signal: 0/4...20 mA
 Output signals: 0/4...20 mA, 4 limit contacts, potential-free
 Power supply for transmitter unit, 230 VAC, 50 Hz
 LCD display, 4 digits
The sensor shall be mounted to a suitable flange fitting with shutoff valve and vent valve. The material of the
mounting device shall be suitable to the material of the respective tank or pipe. All fittings shall be easy to access
and to remove for maintenance or repair. All mounting material shall be also included.

3.4.10.8 Limit-Detector

Purpose To detect critical liquid levels in tanks, channels, chambers, etc.

Location

The locations for instrumentation shall be as presented in Section 3.2 but shall be as a minimum at the following
locations:
 In sump for each underground part within the facility
 In sump for each underground valve chamber
 Each channel, tank or pump sump where a low/ high level alarm is required
 At locations necessary for control of equipment
General Requirements

For the verification of the existence or the permissible level of liquids in a tank or sump, for instance to prevent a
basement against flooding by giving an acoustic alarm signal, limit detectors shall be installed. The limit detector
works by using the vibration principle. The sensor in the form of tuning fork shall be made to vibrate at its resonant
frequency. When the sensor is immersed in the liquid, the resonant frequency changes. The frequency change is
detected and then converted into a potential free switching signal.

The Limit-Detector shall have the following characteristics:

 Rugged design
 Standard or length extension version according to the location
 Temperature: -20 °C ... +70 °C
 Switching hysteresis: approx. 5 mm
 Potential free contact: 230 VAC, 3 A
 Power supply: 230 V, 50 Hz
 Degree of protection: IP 66
 Sensor material: Stainless steel (material 1.4571)
 Housing: Aluminium with epoxy coating

The service includes the delivery and the complete installation at the correct position of the respective location
including all necessary accessories, mounting materials, adjustment, etc.

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3.4.10.9 Pressure Measuring Device

Purpose For measuring the pressure of liquids or gas

Location

The locations for instrumentation shall be as presented in Section 3.2 but shall be as a minimum at the following
locations:
 Air pipes before and after blowers
 Biogas piping at digester
 Biogas storage tank
 Biogas piping before co-generation
 At locations necessary for control of equipment

General Requirements

Pressure-measurements shall be realised in several parts of the plant, e.g. the air-pipes of the aeration. Where the
value of pressure-differences is needed this value shall be calculated electronically from the pressures measured by
two identical pressure-measurements as described below and a suitable calculating transmitter.

Each pressure-measurement consists of the sensor and the related signal transmitter.

The sensor shall have the following characteristics:

 Measuring range: suitable for the required purpose
 Temperature range of medium: -30°C...+100°C
 Permissible overpressure: 400%
 Output signal: 0/4...20 mA
 Degree of protection: IP 65
The measuring transmitter shall have the following characteristics:
 Self-supervision of function
 Display: LCD, 4 digits
 Degree of protection: IP 65
 Output: 0/4...20 mA,
The sensor shall be mounted to a suitable flange fitting with shutoff valve and vent valve. The material of the
mounting device shall be suitable to the material of the respective tank or pipe. All fittings shall be easy to access
and to remove for maintenance or repair. All mounting material shall be also included.

3.4.11 Indoor Installations

3.4.11.1 General

The installation shall include the complete service, including technical supervisoring, clarification, delivery,
transportation, insurances, installation, testing, documentation, commissioning, etc.

The Contractor shall be liable for the correct design of all parts of the building installation according to the relevant
DIN, international and Serbian standards.

In areas where explosive atmosphere may occur, the entire electrical installation shall be carried out accordingly.

All parts of the equipment shall also meet the specifications given for the LV systems in earlier sections.

3.4.11.2 Standards
 EN 13032 Light and lighting
 EN 12464 Lighting of workplaces
 EN 1838 Lighting applications – Emergency lighting

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  EN 60598 Luminaires
 EN 60670 Boxes and enclosures for electrical accessories for household and similar fixed electrical
installations

3.4.11.3 Explosion Proof Electrical Installations

Devices installed in chambers & open space that are potentially endangered by explosive materials and therefore
assigned to an "Ex-Zone" shall be approved for use in such locations. Devices for Ex-zone 1, like the channels for
wastewater, shall be provided according to EN 50014 and IEC/EN 60079-10-1 or 2 and EU Directive 1999/92/EC
(Ex d IIB T3 respectively part Ex ia IIB T3).

3.4.11.4 LV Distribution Panel

Each facility shall be equipped with a separate “LV distribution panel”.

Electricity Distribution Panel

Electricity panel for LV distribution shall be totally enclosed. The degree of protection shall be at least IP 43 for
indoor mounting. They shall be factory assembled. Each panel board shall be equipped with a sufficient busbar and
earthing bar. All panel boards shall be made of galvanised steel and be suitable for the ambient conditions. The
surfaces shall be painted with top colour RAL 7032 or as required by the Engineer. Panel boards shall be mounted to
the wall.

Each panel boards shall be provided a main incoming circuit breaker of the fuseless type. A branch circuit breaker
shall be provided for each outgoing circuit. A sufficient number of spare circuit breakers and a space reserve of 30%
after completion of the works shall be provided.

Doors shall be equipped with cylinder locks, fitting to the lock-system of the plant. Doors that are higher than 1000
mm shall provide a central locking system.

A list of all installed devices and circuits shall be fixed to the inner side of the door to provide an overview for all
connected circuits. For this purpose, each device shall be labelled clearly with the respective circuit number.

Moulded Case Circuit Breakers

Moulded case circuit breakers shall provide the following characteristics:

 totally enclosed, moulded case construction
 high temperature resistant, tropicalised7 insulation materials
 front operated handle mechanism for simultaneous operations of all contacts
 bimetal inverse time delay overcurrent tripping
 instantaneous magnetic short-circuit tripping
 clear indication of the state by the operating handle

Miniature Circuit Breakers

Miniature circuit breakers shall provide the following characteristics:

 thermal-magnetic tripping, not adjustable
 short circuit breaking capacity minimum 10 kA at 230/400 VAC
 1-, 3- or 4- pole construction as required
 rated currents from 6 to 100 A as required
Earth-Leakage Circuit Breakers

7 The term “tropicalised” is used here and in throughput this Volume with meaning not for use in tropical
regions, but to provide protection against the destructive effects of moisture and fungi.

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Earth leakage circuit breakers shall be supplied at least for all circuits that contain socket outlets. They shall meet the
specifications given for LV systems.

3.4.11.5 Indoor Cable Installation - Generally

The Contractor shall provide the complete cabling and wiring for indoor installations including all required auxiliary
material as cable trenches, cable ducts, trays, conduits, terminal boxes, watertight bushings, etc. as specified
hereinafter.

The installation shall include the complete service, including technical Supervising, clarification, delivery,
transportation, insurance’s, installation, testing, documentation, commissioning, etc.

The mode of installation shall be as presented in the following table:

Table 3.4.11-1 Mode of Cable Installation

Location Installation
Offices, conference room, dining room, kitchen Flush mounted
Laboratory Dado trunking above workbench
Electrical room Cable trench, computer floor, floor trunking
Workshops Surface mounted in ducts
Operational areas Ducts and cable trays

3.4.11.6 Under-floor Cable Trunking

Under-floor cable trunking shall be approx. 33 x 350 mm, suitable for installation in screed floor. The bottom shall
be made of 1 mm galvanized sheet steel and welded to the top. The trunking shall be divided into two compartments
to separate the power- from the signal-lines. Floor outlet boxes also made of galvanized sheet steel shall be
adjustable to the floor surface and suitable for the installed trunking. They shall be also divided into compartments.
The removable covers shall be made of 4 mm galvanized sheet steel and shall be suitable for the floor covering of
the respective room. Flush covered outlets for connection of power-, control- or communication devices shall be
adjustable and supplied with self-closing cover and inserts for horizontal installation. Inserts for installation of any
connecting devices shall be supplied with strain relief clamps for cables of 4-13 mm diameter.

The whole under-floor trunking system shall be in accordance with DIN 49073. The Engineer determines the colour
of any visible part. The service includes all adjustments, connections between the trunking elements and accessories
as sealing material, carpet protection frames, etc. Mounting and all mounting material shall be also included.

3.4.11.7 Surface Cable Duct

Cable ducts according to the requirements, made of grey plastic (PVC) RAE 7035, the dimensions shall be approx.
30 x 60 mm - 60 x 110 mm as required, the bottom shall be punched for mounting, and clamps shall hold the cover.
Mounting and non-corrosive mounting material shall be included.

3.4.11.8 Cable Tray

Standard
 IEC/EN 61537 Cable Tray and Cable Ladder Systems
General Requirements

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If required, cables shall be laid upon cable trays suitable for indoor and outdoor installation according to EN61537
and made of 1 mm galvanized sheet steel for indoor mounting, outer colour as required W by the Engineer. Outdoor
cable trays shall be made of stainless steel (1.4404). The characteristics shall be:
 Height 40 mm up to 80 mm, as required
 Width 100 mm up to 400 mm, as required
 Following material shall be included in an adequate quantity:
 Adjustable telescope connections 0- 200 mm
 Adjustable angle connections 45-90
 T-shaped connections
 Cross-connections
 Vertical branches
 Vertical branches 90 twisted
 Connecting pieces for width reduction
 Partitions
 Covers for the entire length of the gutters
 Mounting cantilevers
If signalling and power cables are laid upon the same cable tray they shall be separated by suitable partitions. Plastic
inserts to protect the cable insulation shall cover sharp edges. All mounting, adjustment and mounting materials shall
be also included.

3.4.11.9 Steel Conduit

If required, cables shall be laid in galvanized steel conduits for heavy mechanical load. The size shall be Pg 16 - Pg
42, as required. The service includes all required couplings and 90 arches. Plastic inserts to protect the cable
insulation shall cover sharp edges. Complete installation and all mounting materials shall be also included.

3.4.11.10 Terminal Boxes

Terminal boxes shall be designed for surface mounting according to EN 60670. They shall be of suitable size. The
degree of protection shall be IP 65. The service includes clamps, terminals, sealing, complete installation and
mounting material.

Terminal boxes shall be readily accessible.

3.4.11.11 Metal Constructions

Metal constructions as poles, fittings, gratings, railings, platforms, etc. shall be made of galvanized steel for indoor
mounting. The pieces shall be welded or bolted construction. The installation includes all mounting, corrosion
protection and stainless mounting material.

3.4.11.12 Tap-Drill Holes

Tap-Drill holes shall be included according to the requirements. The drilling of tap-drill holes with diameters from
100 up to 300 mm through brickwork and concrete with a width of approx. 30 cm includes all necessary material.
The penetration shall be sealed with gas and noise proof cable bushings.

3.4.11.13 Watertight Bushings

Watertight bushings in concrete walls shall be realized with mounting galvanized frames. These shall be integrated
into the concrete construction. According to the number and size of the cables to be routed through the watertight
bushings, their size shall be determined. The installation includes installation of the cables and provision of gas and
watertight glands, including all mounting and sealing material. Replacement bushings shall be readily accessible.

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3.4.12 Outdoor Installations

The Contractor shall provide the complete outdoor installations, consisting of equipment control panels, outdoor
lighting and combined outdoor socket outlets for portable drives, pumps, tools and general purposes. The offered
equipment shall be complete and functioning and shall meet all relevant EN- and Serbian standards and regulations.

3.4.12.1 Outdoor Equipment

All equipment located out of doors shall have enclosures including control panel, switches and push buttons which
shall be weather, dust, rainwater, snow and insect proof.

The enclosures shall have minimum IP65 protection or IP55 if mechanically ventilated, gland cable entrances with
grip and with a lockable door. All material used for enclosures shall be UV resistant, distortion free, fire-resistant
and waterproof.

Corrosion protection for metal enclosures shall be in accordance with EN12994 and Volume 3, Section 4
Mechanical Equipment.

Windows shall be provided as necessary for viewing internal devices. Windows shall be of toughened glass or UV
stabilised polycarbonate held in place by weather and UV proof neoprene rubber gaskets with a thickness of not less
than 1.6 mm.

Non-metallic enclosures shall be made from UV stabilised material, and be distortion-proof.

The design shall take due attention of direct insolation, ambient temperature, differential temperature which may
distort the enclosures and render ineffective the dust and water protection. Rainwater shall not be allowed to remain
on any horizontal surface.

3.4.12.2 Cabling, Wiring for Indoor and Outdoor Installations

The Contractor shall provide the complete cabling and wiring for indoor and outdoor installations of the whole
facility with all required indoor and outdoor installations. Furthermore he shall deliver and install all required
auxiliary material as cable trenches, cable ducts, trays, conduits, terminal boxes, watertight bushings, etc. as
specified hereinafter.

The offered price shall include the complete service, including technical Supervisoting, clarification, delivery,
transportation, insurance’s, installation, testing, documentation, commissioning, etc. Any objection or comments
shall be stated by the Contractor in writing together with his offer. Thereafter the Contractor bears the complete
responsibility for the services.

3.4.13 Data and Voice Communication Systems

The8 automatic control system and telephone system require installation of data communication systems.
Independent systems shall be provided for data transmission and for voice/ telephone communication.

3.4.13.1 Data Communication System Generally

Data transmission over a physical medium (cable) is by definition analog; modern communication systems, however,
place all of the processing in the digital domain so that the only interface with the medium is the final digital:
analogue (D/A) converter at the end of the processing chain. The process is reversed at the receiving end and digital
data is recreated by a modem analogue: digital converter.

8 52n

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Data communication systems shall serve the following:
 Level 1 and Level 2 control system
 Level 2 and Level 3 control system
 Fire alarm
 Intrusion alarm with video surveillance
 Data outlets in operation, office areas and control room
The installation shall include the UPS systems, batteries, wire, cable, racks, patch panels, connecting devices, data
outlets, cable support D-rings, all installation and testing for wiring systems and components to be used as signal
pathways for high-speed data transmission and telephone communication.

The data communication system shall be designed such that communication is facilitated between the different
devices. The design shall optimise the mix of communication protocols (TCP/IP, Modbus, Profibus), cable types
(copper, fibre optic) to suit the data transmission requirements. The hardware and transmission protocols shall also
include mechanisms to detect and correct hardware and transmission errors to restore the integrity of the data.

The Contractor shall select the suitable mode of data communication bearing in mind the limitation of 100m for use
of UTP cables. Transmission distances of fibre optic cables are also limited depending on the type of cable, data rate
and mode (single/ multi). Use of UTP cables is much simpler to implement and is the preferred solution.

Cable Database

A database of all cable runs shall be maintained and for each cable run the following information shall be
maintained:
 Circuit ID (This would be the Port Designation, i.e.: 121-a1)
 Facility Location
 Length of cable run
 Communications Room number
 Date of Test
 Cable Type: (e.g., Cat5e UTP)
 Type of Scanner Used
 Overall Test Result of Cable: (e.g., PASS)

3.4.13.2 Patch Panels

Patch panel, also known as patch bay, is a device featuring a number of jacks used to facilitate the connection of
different Level 1 and Level 2 devices with the Level 3 control system. Patch panels are also locations where adapters
for change between different types of cables are also installed.

Copper patch panels shall be of the 24 port type and shall be supplied from the same manufacturer to facilitate
swapping of spare parts.

24 port Copper Patch Panel

Copper patch panel shall have feed-through and blank keystone patch panel.

The number of racks of 24 ports shall depend on the number of data pathways with at least 50% extra spare capacity
shall be provided.

Fibre Patch Panel

If fibre optic cable is used anywhere on the data communication system, fibre patch panel has to be provided to
manage the transfer of data between different types of cables.

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The fibre patch panel may include inline coupler for connecting cables of the same type, fibre to copper converter,
and multiplexer for transmission of multiple signals on one cable.

Fibre to Ethernet Converters which use a copper transceiver to transform the signal from a UTP / RJ45 Ethernet link
to one that can be used by a fibre optic transceiver and vice versa..

These Media Converters are used to enable connections of UTP copper-based Ethernet equipment to various optical
fibre cable systems such as multimode, single mode, or single strand fibre.

3.4.13.3 Copper Communication Cable Supply and Installation

Cables for transmission of data will connect the various devices and the material to be used shall depend on the
Contractor’s design to comply with the functionalities specified in this technical requirements.

Copper signal cables shall be unshielded twisted pair (UTP). Cat.5 cables comprising of 4 pairs of twisted copper
wires with higher number of twists per unit length with a common sheath shall be provided for high volume and
speed transmission. Telephone cable shall be Cat 1 cable with minimum one twisted pair cable.

Installation of copper signal cables shall completed observing the following:

 Cable connections shall comply with the ANSI/TIA-568 standard
 No single Cat5e or Cat6 run shall exceed 100 meters
 Splices are not acceptable.
 Cables shall be installed in duct, conduit and cable trays
 Twisted pairs must remain twisted to within 5mm of the connector to minimise noise interference
 Cable shall be bundled with cable ties and ends of each cable labelled on the termination at the back of the
patch panel
Wiring terminations shall be connected in a straight pattern i.e. not turned over, no open, crossed, reversed or split
pairs from start to end point.

Wiring will not be installed near fluorescent lighting, high-voltage sources, electrical motors, or other sources of
interference. Recommended distances for UTP cabling shall be at least thirty (30) cm. for unshielded florescent
lighting, and one (1) m for transformers or unshielded motors.

All cables being run for horizontal distribution within the same areas must be bundled together neatly and untangled,
with cable ties every three (3) m. Cabling shall lie flat without kinks within and be supported by cable trays, and/or
structures attached directly to the structure/ ceiling area.

Where cabling trays and conduit are not provided, wiring shall be attached and supported to upper decking by way of
J- Hooks or bent steel rods installed between decking grooves, or comparable support devices, attached directly to
the structure or like framework. Wiring shall not be supported by ceilings, ceiling hangers, or from other electrical,
plumbing, or air ventilation structures or conduit.

Routing of the wiring shall not interfere with access to panels, switches, valves or other systems which require
maintenance access.

Manufacturers’ requirements for bending radius and pulling tensions for all cable runs shall be complied with.

All conduits must have bushings at the end of the conduit to prevent damage to cable jacket.

Copper Cable Testing

Copper wiring shall be tested, measured and reported as complying using specialist automatic testing equipment for
the following individual tests:

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  Wire Map show that the wiring is straight through, with no open, crossed, reversed or split pairs.
 Resistance shall be measured in ohms and compared with limit, with pass/fail conclusion.
 The length of each copper cable pair reported by measuring electrical delay shall be reported and compared
with physical measured length with pass fail for the testing equipment.
 Propagation delay of each pair shall be measured in nanoseconds and shall be less than 5.7 nS/m.
 For cables longer than 5 meters, the Impedance shall be measured for each pair and be within the range of 80-
120 ohms.
 Return Loss being the measurement of the difference between the power of a transmitted signal and the power
of the signal reflections caused by variations in link and channel impedance shall be as specified in the IEEE
802.3 Ethernet standard. Limits at the worst frequency shall be 7.5 dB (for main data) or 10.4 dB (for remote
data).
 Attenuation: Measure the loss of signal over the length of the cable. Attenuation for each pair in (dB),
frequency for 100 MHz, and limit tested for each pair (dB).
 ACR: Measures the difference between the signal attenuation and the near-end crosstalk, representing the
strength of the attenuated signal in the presence of crosstalk.
 Next: Measure the near-end crosstalk of a cable, and verify the cable has adequate immunity from the next
pairs signal being transmitted back onto the receive pairs. Specify Next Loss, for each of the pairs, send and
receive combinations.
 FEXT: Measures the far-end crosstalk of a cable. Specify FEXT Loss, for each pair, send and receive
combinations.
 PSNEXT: Measures the NEXT induced on a pair from all adjacent pairs.
 PSELFEXT: Measures the ELFEXT induced on a pair from all adjacent pairs.
All signal cables runs shall be tested and the test results with report shall be submitted to the Engineer.

3.4.13.4 Optical Fibre Cable Supply and Installation

Standards
 IEC 60793 Optical fibres

General Requirements

If used, optical fibre cables shall conform to the latest International Standards an be suitable for the proposed
purpose. They shall provide the following characteristics:
 Transmission rate: > 1 Mbit/sec.
 Cable Type: According to the requirements
 Number of fibres: 6
 Fibre size: 62.5/125 µm
 Attenuation: According to the requirements
 Wave length: 1,300 nm
 Type per DIN VDE 0888: A-VF(ZN)2Y 6G62.5/125LG type or equivalent
 Metal-free cable for direct underground installation, installation in PE-ducts or on cable trays

The fibre optic cable shall be provided with the necessary modulator, converter to connect to the copper cable
system.

Fibre optic cable shall be installed in cable ducts.

Optical Cable Testing

An Optical Time Domain Reflectometer (OTDR) trace of the fibre optic cable shall be completed and actual loss
values for all events (connectors, splices, and fiber loss - dB) in the link shall be reported. The results of the tests on
each cable segment and the report shall be submitted to the Engineer for approval.

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3.4.13.5 Intrusion Alarm System

An intrusion alarm system based on motion detectors (PID) shall be installed to monitor different zones at each
facility. Signals shall be transmitted through the SCADA system for processing at the corporate level monitoring
system.

3.4.13.6 Earthing/ Grounding

All the MV and LV electrical installation equipment, the electrical consumers and their connections elements, metal
pipes, steel structures, metal basements and their connection screen, metal doors and other metal parts that are not
used as electrical conductors shall be earthed effectively.

Earth electrodes for protective and operational grounding shall be carried out as surface- respectively buried earth
electrodes. Metal building installations shall be connected by spark gaps according to the current regulations.
Depending on the ground conditions, either galvanised steel strip 30x3.5 with a zinc coating of 500 g/m² or high-
grade stainless steel (1.4404) with rounded edges shall be used as earth electrodes.

The total grounding resistance of all grounding electrodes shall be less than 2 Ohm.

The materials used and the connecting methods shall be in a way, that the deterioration of materials due to electrical
respectively electro-chemical potential differences is avoided. Connecting lugs or earthable points shall be provided
in all rooms containing important electrical distributions, transformers and large machinery.

Grounding points shall be marked by numbered plates. Galvanised grounding rods, connecting the grounding
electrodes to the lightning protection system, shall also be protected thoroughly against corrosion.

The components of the grounding system shall be individually connected to a potential bonding bus, so that they can
be disconnected and tested separately at any time.

Grounding shall be of TN-S-C type in accordance with IEC.364-3. Installations of lighting and socket outlets must
fulfill the grounding requirements

Grounding Electrode

In the required sections, the grounding networks shall be installed for the grounding of the electrical installation and
the metal section of the structures.

Foundation grounding electrodes will be embedded into concrete foundation of buildings such as control and
mechanical building, clarifiers, reservoirs, pump stations etc.

Connection of foundation earth electrode with steel reinforcement shall be done at maximum 6 m intervals. For every
room up-conductors rising to (1-2) m above floor level shall be provided in sufficient numbers.

For connections between foundation earth electrodes and reinforcement, as well as for connections of up-conductor
with grounding system, cross-joints conductor-conductor SRPS N.B4.936 or similar, shall be used.

The concrete inspection holders shall be installed for the tests and periodical inspection in the grounding network.

The total grounding resistance of grounding network shall be less than 2 ohm. The grounding networks, if required,
shall be connected to each other in order to reduce the earth resistance below 2 ohm.

In the grounding networks, the connection of the earth conductors to the groundng electrodes shall be made of
corrosion resistant materials.

In the buildings and other structures, a main grounding terminal shall be installed to which all the main grounding
conductors and grounding cables, the grounding busbar on the switchgear plant and main distribution switchboards,

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the equipment basement and grounding electrodes will be connected. The grounding connections to the electrical
consumers and metal structures shall be installed with copper conductors or copper cables with suitable cross-
sections.

The components of the grounding system shall be individually connected to a potential bonding bus, so that they can
be disconnected and tested separately at any time.

Control Grounding Electrodes

For all parts of the installation which are outside grounding grid and which are connected to the same, control
grounding electrodes shall be foreseen. They shall be placed at a distance of approximately 1,0 m from the plant and
buried at about 20 cm. Potential checking via control electrodes is not necessary, if the surface of the grounding
network is covered by an insulating material. Covered area should be at least 1,5 m around conductive parts. Broken
stones or gravel of 10 cm thickness may serve as the above cover. Asphalt of minimum 1 cm thickness may also be
accepted as an insulting material.

Copper braid of minimum cross section 50 m2 may be used as a control electrode.

Grounding shall be of TN-S-C type in accordance with IEC 364-3.

Installations of lighting and socket outlets must fulfill the grounding requirements

Outoor Grounding Installation

For grounding of the equipment such as steel structures, ends of protection wires of transmission lines, fences: two
copper braids each of 50 mm2 cross-section shall be used.

For the connection of equipment and steel structures appropriate double compression cable lugs should be used.

Control of voltage should be provided at the outer fence. This should be done by horizontal grounding electrodes.
The same should be made of galvanized steel rope 25 x 4 mm laid at 1,0 m away from the fence on the outside side
at a depth of 0,5 m. Fence and grounding conductor shall be connected at every 6 (six) meters.

Indoor grounding installation

For indoor installation grounding system is composed of main grounding conductors, grounding conductors to
equipment and steel parts and grounding bus-bars. Main grounding conductor shall be galvanized conductor 25 x 4
mm. Main conductor shall be fixed on appropriate supports placed around rooms. Connection with up conductor as
well as with grounding busbar shall be carried out by welding or by other method which is approved by the Engineer.
For all above mentioned indoor installations which is fastened onto walls adequate space shall be left between
conductors and walls and possibility for easy access shall be secured.

All metal parts, which are during normal operating conditions voltage free, whall be connected to grounding busbar
by a copper braid of 50 mm2 cross section.

Door and window frames should be connected to nearby reinforcement or to the grounding system, while their
moveable parts are to be connected to the frame by a flexible conductor of adequate cross-section.

0,4 kV Installation Grounding System

Grounding system in 0,4 kV installation is of TN-C-S system, in accordance with the latest revision of IEC 364-3.
This means that neutral and protection bus-bar are mutually connected in distribution boards while neutral and
protection conductor are led separately throughout installations.

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