Spécification for Modular Substation

Document No : A-ELE-SPE-800-30021
Revision 0

Revision History
Revision Changes

A Issued for Review & Comments

0 Issued for Design

This revision checked and signed off by:

Name Function or Job Title

Nassim Benmessaoud Electrical Engineer

Rajaram Kahandal Senior Electrical Engineer

Madhav Deshpande Lead Electrical Engineer

Mohammad Siddiquie Project Engineering Manager

Holds
Hold No. Location Description

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Content
REVISION HISTORY 2
CONTENT 3
1 ABBREVIATIONS 4
2 INTRODUCTION 5
2.1 Project Description 5
2.2 Purpose of the Document 5
2.3 Order of Precedence 5
2.4 Definitions 6
3 CODES AND STANDARDS 7
3.1 General 7
3.2 Algerian Government Requirements 7
3.3 Project Documents 7
3.4 International Codes and Standards 8
4 SITE CONDITIONS 12
5 SCOPE OF SUPPLY 13
5.1 Supplier Proposals and Exceptions 13
5.2 Conflicts 13
5.3 General requirements 13
5.4 Modular Substation 13
5.5 Substation Layout 15
5.6 Clearances 15
5.7 Cable Entry 15
5.8 Lighting and Small Power requirement 16
5.9 Wiring and Cabling 17
5.10 Earthing Protection 18
5.11 HVAC System 18
5.12 Fire Detection, Fighting and Safety Equipment 20
5.13 Operator provided items 21
5.14 Warning labels 21
5.15 Painting 22
6 TEST, DELIVERY AND INSTALLATION 23
6.1 Testing 23
6.2 Transportation 24
6.3 Lifting 25
6.4 Installation 25
6.5 Special Tools and Test Equipment 26
7 SPARES 27
8 QUALITY ASSURANCE 28
9 DOCUMENTATION 29

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1 ABBREVIATIONS
API American Petroleum Institute

ATEX Directive for the supply and use of equipment in potentially explosive
atmospheres (Atmosphere Explosive)

HVAC Heating, Ventilation and Air Conditioning

ICSS Integrated Control and Safety System

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronics Engineers

IP Ingress Protection

ISO International Organization for Standardization

PMS Power Management System

SLL Chartered Institute of Building Services Engineers

UPS Uninterruptible Power Supply

HSSD High Sensitive Smoke Detection

GTG Gas Turbine Generator

UCP Unit Control Panel

GCP Generator Control Panel

LV Low Voltage

HV High Voltage

PGB Power Generation Building

MCC Motor Control Centre

ERSV Etablissement de Réalisation de Systèmes de Vidéosurveillance

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2 INTRODUCTION

2.1 Project Description

Groupement ISARÈNE (the “COMPANY”) will develop the Ain Tsila gas field which is
located in the Illizi basin in the eastern part of the Sahara Desert in south-east Algeria,
south of the Grand Erg Oriental. The field was discovered within the Périmètre Isarène
(Blocks 228, 229a) in 2007 and has been appraised to hold approximately 65 billion
cubic metres (2.29 trillion cubic feet) of recoverable hydrocarbon reserves. The field lies
in the Sahara Desert, approximately 1,100km south-east of Algiers, 175km west of In
Amenas, 175km north- west of Illizi and 450km to the south-east of Hassi Messaoud.
Central Processing Facility (CPF) is designed to produce 10.3 MMSCMD sales gas.
A gathering system, comprising wellsites, wellsite systems, flowlines, manifold stations
and trunk pipelines to gather the produced fluids and transport them to the reception
facilities at the CPF. Raw gas will be treated in the CPF. Processing facilities comprising
pipeline reception facilities, slugcatcher(s), feed gas compression, mercury removal,
gas dehydration, gas conditioning (natural gas liquids extraction), export compression,
condensate stripper, LPG fractionation facilities, condensate and LPG export facilities
and associated utilities, storage and buildings (all located at the CPF). Fiscal metering
for sales gas, LPG and condensate, located at the CPF battery limit.
Sales quality gas will be delivered to SONATRACH TRC’s (TRC) sales gas pipeline
system at a tie-in point on a manifold next to the TFT compressor station. Liquefied
petroleum gas (LPG) will be delivered to TRC’s LPG pipeline system at a tie-in point
located at a block valve station west of the TFT compressor station. Stabilised
condensate will be delivered to TRC’s condensate pipeline system at a tie-in point
located at Méderba, approximately 165km north of Ain Tsila.

2.2 Purpose of the Document

This specification defines the minimum basic requirements for the design, manufacture,
testing and supply of Modular Substation for the EPC for Ain Tsila Development Project
–located in Algeria.
Compliance with this specification shall not relieve the supplier of the responsibility to
furnish equipment and accessories of a proper electrical, civil/structural and mechanical
design to meet the specified service conditions.

2.3 Order of Precedence

Where Algerian regulations, codes and standards exist, their recommendations shall
always take precedence.
The order of Precedence for all the Technical documentation shall be as follows:
• Algerian Legislation and Regulatory Authorities Regulations
• Project Philosophies
• Equipment datasheets
• Primary Equipment Specification

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• Other Project Specifications

• International codes and standards
In case of conflict between any of the above then the most stringent shall apply unless
a dispensation has been approved by the COMPANY.

2.4 Definitions
The terms and definitions as used within this document are listed below:

“COMPANY” means Groupement ISARÈNE (the operator of the Ain Tsila

development)

“CONTRACTOR” means the party, which carries out all or part of the design,
engineering, installation and commissioning, procurement
and construction applicable to this specification

“shall” or “must” indicates that the specified action is mandatory (i.e. must be
done by the specified action party)

“should” indicates that the specified action is recommended but not

mandatory. However, the action party will be responsible for
the consequences in the event that he/she elects not to do it

“will” indicates a commitment by others or a statement of fact

“Purchaser” means the entity defined as such in the purchase order or

contract

“Supplier” means the entity defined as such in the purchase order or

contract

“Sub-supplier” means the entity responsible for the supply of components or

services to the Seller

“Manufacturer” means the entity responsible for the manufacture of an item

ultimately supplied by the Seller to the CONTRACTOR

“Goods” means the physical items delivered under the terms of the
purchase order or contract

“Services” means any services provided pursuant to the purchase order

or contract but not incorporated in the Goods

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3 CODES AND STANDARDS

3.1 General
The design, construction and supply of the Modular Substation shall be in accordance
with the latest revisions of the following specifications, data sheets, codes and
standards.
Where national Algerian regulations, codes and standards exist, their recommendations
shall always apply. Such national regulations shall therefore supplement or amend the
provisions of this document.
Equipment supplied shall in addition to complying with national standards, also be in
compliance with the following guides and recommended standards. Codes and
Standards referred here shall be of the latest revision issued at the effective date 21st
Dec-2018

3.2 Algerian Government Requirements

The design shall meet the requirements and regulations of the Algerian Government
including all laws, decrees and ordinances.

3.3 Project Documents

Project Documents consist of the following: Refer Modular substation inquiry for
detailed list.

DOCUMENT NUMBER DESCRIPTION

Discipline: Electrical
A-ELE-BOD-800-30001 Electrical System Basis of Design
A-ELE-PHL-800-30001 Power System Design Philosophy
A-ELE-SPE-000-00012 Distribution board specification
A-ELE-SPE-000-00015 Electrical Power and Control Cables Specification
Discipline: Instrumentation
A-INS-SPE-000-30016 Specification of Instrument cables
A-INS-SPE-000-30015 Specification of Fire and Gas Devices
A-INS-BDM-000-30000 Integrated Control & Safety System Architecture Diagram
A-INS-BOD-000-30000 Control and Instrumentation Design Basis
A-INS-SPE-000-30000 Specification of General Instrumentation
Discipline: Civil & Structural
A-CIV-BOD-000-30001 Civil & Structural Design Basis
A-ARC-PHL-000-30000 Architectural Works Philosophy
A-CIV-SPE-000-30013 Specification for Building Materials
A-CIV-SPE-000-30007 Specification for Str Steel Fab & Erection
Discipline: HSE
A-TSE-PHL-000-30000 HSE Design Philosophy

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DOCUMENT NUMBER DESCRIPTION

A-TSE-SPE-000-30001 Fire Suppression system Specification
A-TSE-SPE-000-30003 Human Factors Engineering Design Specification
A-TSE-SPE-000-30000 Specification for Fixed Fire Fighting & Safety Equipment
Discipline: HVAC
A-HVA-BOD-000-30000 HVAC Design Basis & Specification
Discipline: Telecom
A-TEL-PHL-970-30001 Telecommunications Philosophy
Discipline: Metallurgy
A-MTL-SPE-000-30003 Specification for Painting
Discipline: QA/QC
A-QAC-SPE-000-00001 Specification for ARH Compliance Requirements
A-QAC-SPE-000-30007 Specification for Material Traceability requirement
A-IMT-SPE-000-30000 Equipment Labelling Specification
A-QAC-PRO-000-30006 Welding Procedure Qualification Procedure
A-QAC-PRO-000-30007 Welder Qualification Procedure
A-QAC-PRO-000-30013 Inspection & Test Control Procedure

3.4 International Codes and Standards

As a minimum, equipment shall confirm on design, materials and performance in
accordance with the relevant sections of the latest editions of the international codes
and standards. Codes and standards used for this project shall be the latest revisions
including all addenda available at the time of purchase order placement.

Document Number Description

ASTM A36/A36M Standard Specification for Carbon Structural Steel
ASTM A90/A90M Standard Test Method for Weight (Mass) of Coating on Iron
and
Steel Articles with Zinc or Zinc-Alloy Coatings
ASTM A653/A653M Standard Specification for Steel Sheet, Zinc-Coated
(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the
Hot-Dip Process
ASTM B117 Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM E84 Standard Test Method for Surface Burning Characteristics of
Building Materials
ASCE/SEI 7-05 Minimum Design Loads for Building and Other Structures
AWS D1.1 Structural Welding Code - Steel
BS 50288-7 Part :7 Sectional Specification for Instrumentation and control
cables
BS 7655 Specification for insulating and sheathing materials for cables

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Document Number Description

BS 1993 Structural use of Steelwork
BS 7430 Code of Practice for Earthing
BS 7671 Requirements for Electrical Installations – IEE Wiring
Regulations
BS EN 12464-1 Light and Lighting. Lighting of Workplaces. Indoor Workplaces
BS EN 12464-2 Lighting of workplaces. Outdoor workplaces
BS EN 12665 Light and Lighting – Basic Terms and Criteria for Specifying
Lighting Requirements
IEC 60079 Series Explosive Atmospheres – Equipment – General Requirements
IEC 60227 Series Polyvinyl Chloride Insulated Cables of Rated Voltages up to and
Including 450 / 750V
IEC 60228 Conductors of Insulated Cables
IEC 60309 Series Plugs, Socket Outlets and Couplers for Industrial Purposes
IEC 60331 Series Tests for Electric Cables Under Fire Conditions-Circuit Integrity
IEC 60332 Series Tests on Electric and Optical Fibre Cables Under Fire Conditions
IEC 60364 Series Low Voltage Electrical Installations
IEC 60417 DB Graphical Symbols for use on Equipment – Database Snapshots
Snapshot
IEC 60502 Series Power Cables with Extruded Insulation and their Accessories for
Rated Voltages from 1kV to 30kV
IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
IEC 60598 Series Luminaires
IEC 60664 Series Insulation Coordination for Equipment within Low Voltage
Systems
IEC 60724 Short-circuit temperature limits of electric cables with rated
voltages of 1 kV
IEC 61000 Series Electromagnetic Compatibility
IEC 61034 Series Measurement of Smoke Density of Cables Burning Under
Defined Conditions
IEC 61070 Compliance Test Procedures for Test Plans for Steady State
Availability
IEC 61084 Series Cable Trunking and Ducting Systems for Electrical Installations
IEC 61140 Protection against Electric Shock
Industrial Systems, Installations and Equipment and Industrial
IEC 61346 Series
Products - Structuring Principles and Reference Designations
Cable Management – Cable Tray Systems and Cable Ladder
IEC 61537
Systems
IEC 61869 Series Instrument transformers
IEC 62305 Series Protection against lightning
IEC/TS 61200 Series Electrical Installation Guide

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Document Number Description

Recommended Practice for Grounding of Industrial and
IEEE Std. 142
Commercial Power Systems
IEEE Std. 80 Guide for Safety in A.C. Substation Grounding
Paints and Varnishes - Corrosion Protection of Steel Structures
ISO 12944 Series
by Protective Paint Systems
Hot Dipped Galvanised Coatings on Fabricated Iron & Steel
ISO 1461
Articles - Specifications & Test Methods
Zinc coatings — Guidelines and recommendations for the
ISO 14713 Series
protection against corrosion of iron and steel in structures
ISO 9001 Quality Management Systems Requirements
Corrosion of Metals and Alloys - Corrosivity of Atmospheres -
ISO 9223
Classification
ISO 965 Series ISO General Purpose Metric Screw Threads

3.4.1 CE Marking and Certificates

All equipment, materials and components included in the delivery for installation and
application in the Ain Tsila Development shall be CE certified, shall have CE marking
and shall be compliant to the EC directives, such as, but not limited to:
• Electro Magnetic Compatibility (EMC)
o Directive 2014/30/EU Electro Magnetic Compatibility;
o Guidelines for Electro Magnetic Compatibility;
• Low Voltage
o Directive 2014/35/EU Low Voltage directive;
o Guidelines for Safety of Low Voltage Equipment.
• ATEX
o Directive 2014/34/EU concerning equipment and protective systems
intended for use in potentially explosive atmospheres;
o Guidelines on the application of Directive 2014/34/EU;
o Corrigendum on Directive 2014/34/EU.
• Machinery
o Directive 2006/42/EC Machinery Directive;
o Guidelines on the application of Directive 2006/42;
o Corrigendum on Directive 2006/42/EC.
Supplier shall provide the required explosion protection certificates in accordance with
the 2014/34/EU Directive.

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Supplier shall provide an EC declaration of conformity, which shall state full compliance
to the EC directives and standards. The declaration shall further state the method of
compliance followed, e.g.:
• Self-certification to appropriate harmonized European standards;
• Technical file, which is approved by an accepted, notified body;
• Type examination.

For equipment, components and systems manufactured outside European Union

region; relevant IEC standards mentioned in the project specifications shall be
followed and reflected in the vendor documentation. Conformance to EC directives
and CE marking will not be applicable.

3.4.2 Industry Codes of Practice, Recommendations and Guides

Document Number Description
IES HB-9-10-11 The IES Lighting Handbook – Tenth Edition
SLL Lighting Handbook of the Society of Light and Lighting
Handbook
SLL Code for Lighting Companion to the SLL Lighting Handbook
SLL Lighting Guide 6 The Outdoor Environment
SLL Lighting Guide 12 Emergency Lighting

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4 SITE CONDITIONS
Electrical equipment shall be suitable for Site conditions detailed into Specification A-
ENG-BOD-000-30001 -Basis of Design – Surface facilities. Operation will be in a desert
environment, with frequent sandstorms with both elevated and freezing temperatures
within a twenty-four (24) hour period.
Power distribution equipment shall be located in positive pressure ventilated
substations. Design criteria for equipment located inside Substation Electrical Room
(Switchboards, Distribution Boards, UPS Panels), Instrument room and Battery Room
(Cells, Automatic Isolation Breaker & System Monitoring) will be as follows:

Minimum Maximum
Area – Equipment
C C

Normal operation 15 27

Abnormal operation -5 45

Function short term limited performance N/A 55

Note: Outdoor electrical equipment shall be designed for ambient air temperature of 45 C

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5 SCOPE OF SUPPLY

5.1 Supplier Proposals and Exceptions

The Supplier shall state in his Tender that the equipment offered complies with the
requirements of this Specification without exception or shall detail the exceptions
against the section numbers of this Specification.
The Supplier may offer alternative proposals for price or technical advantage if he
wishes, but such proposals shall form a supplement to the main Tender.

5.2 Conflicts
If any of the reference documents conflict and definition is not established in this
Specification, then the Suppliers shall bring this to the attention of Ain Tsila Project and
shall state the basis of design used.

5.3 General requirements

Conceptual design, detailed design and fabrication of the Substation enclosure,
including the support structure and lifting equipment.
The modular buildings shall include installed lighting, socket outlets, switches, panel
boards, HVAC system, fire and gas system, earthing system, cable, cable tray, doors,
hardware, steps and platforms, wiring, lifting eyes and other components required for a
complete unit. All material shall be new and free from defects in material and
workmanship.
The modular building shall be capable of accommodating the specified free issued
electrical and control system equipment, which include the following: GTG UCP/GCP,
Gas Insulated Switchgear, High voltage and low voltage air insulated switchgear, Motor
control centers, Variable frequency drives, LV busducts, Interposing relay panels,
annunciator panel, UPS systems, Batteries, Process control system equipment, and
other electrical distribution and control equipment like Desks, PMS/ICSS Cabinet,
Server panel, Ethernet switches, Printer etc.
The modular building Manufacturer shall furnish all material, labour, equipment, testing,
supervision, plant facilities, consumable supplies, and tools required for and incidental
to the design, construction and testing of the building as defined in the scope of work.
The building shall be designed and fabricated so that field work at the job site shall be
minimized.

5.4 Modular Substation

The design and fabrication of the Modular Substation as a single piece or multiple piece
of equipment to meet this shipping and transportation limitation. The Supplier shall be
responsible for ensuring that the package meets the shipping and transport restrictions
for the entire route.
If the substation is a split design, the split must be made clear. A detailed list of works
to be completed on site shall be provided with relevant drawings.

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The substation unit shall be supported on concrete columns (by CONTRACTOR) and
shall be of 2.1m in height. Base of the substation unit shall have 2.3m clearance above
the FGL.
Floor penetrations for switchgear shall be made as large as practical especially those
beneath the Switchgear, LV MCC’s. The cable entry systems shall be in situ for
shipment to site. Where cable entries are provided for single core cables, the design
and materials used shall prevent circulation of eddy currents.
The Supplier shall provide a detailed description, including drawings and technical data
of the cables/busduct penetration system.
Walls shall be made sufficiently rigid to allow for the support of typical wall mounted
equipment. The roof shall be pitched along the width of the structure for adequate
drainage, away from doors and any equipment mounted through the substation walls.
The substation shall have a personnel access door at each end. The door nearest the
switchgear shall be designed to permit the passage of the largest equipment item
installed in the substation.
All doors shall have a minimum swing of 105o and shall open outward.
Each door shall be of uniform thickness free from warps, bows and shall have sufficient
rigidity to maintain a positive seal when closed.
Exterior door furniture shall consist of a stainless-steel handle and cylinder lock. All
external doors shall be locked and keyed to master key system, unless noted otherwise.
Four keys shall be provided.
Interior door furniture shall consist of a panic bar assembly designed to override all
locks for emergency exit from the substation. Doorknobs shall not be provided to
escape doors.
Each door shall be equipped with a pneumatic or hydraulic door closer, heavy duty type,
surface mounted, fixed and adjusted to ensure the smooth, slow full closing of the door
leaf and doorstop to lock the door in the open position.
A designated entrance door shall be complete with observation window (to ascertain
any fire hazard etc. in response to a fire alarm signal) and shall be blast proof where
applicable.
In addition to the personnel door, an equipment door of suitable size shall be provided
to move the installed and future equipment.
The modular building shall include all features and equipment necessary to house and
protect the equipment in the site environmental conditions and provide for adequate
access to support maintenance and system expansion.
Air locks: The package shall be complete with an additional set of doors to form an
airlock, out with each of the inner doors to preserve the positive pressure within the
building.
Ingress Protection (IP) Rating: The equipment provided inside the building will be
minimum IP42 as defined in IEC 60529.

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Equipment within the Substation shall be labelled in accordance with Specification for
Equipment numbering system.
The Substation shall be fitted with 2 x 100% HVAC units with suitable dust
filtration/extraction (constant temperature control) as per HVAC Design basis and
Specification Doc.no A-HVA-BOD-000-30000. It shall be possible to monitor the
temperature in each room remotely.

5.5 Substation Layout

Refer attached layout drawings of below mentioned individual substation buildings.
a) SS-800: PGB & HV/LV Distribution
b) SS-300: Fluid Reception and Separation
c) SS-400: Essential Services and Utilities
d) SS-700: Storage and Export
e) SS-500: Process Train-1
f) SS-600: Process Train-2
g) SS-1700: Base Industriielle

5.6 Clearances
The layout of substation electrical equipment shall be arranged to provide adequate
access for installation, inspection, maintenance, operation and possible repairs. The
clearances for main HV & LV equipment shall be as per Electrical System Basis of
Design (Doc.no. A-ELE-BOD-800-30001, clause no.6.6.2)
If the equipment manufacture recommends a larger clearance, this shall be followed.
Vertical clearance shall be measured from the highest part of the equipment to the
underside of the lowest roof beam or HVAC ducting.

5.7 Cable Entry

Floor penetrations shall also be provided for electrical equipment, which are wall
mounted, or which stands against the wall of the substation enclosure.
In addition, spare floor penetrations of approximate size 280 mm x 120 mm shall be
provided around the perimeter walls of the substation room. They shall be covered and
shall be available for use when required.
A high-level penetration shall be provided in Substation internal wall of approximate
size L = 400 mm, H = 240 mm.
Gland plates at floor level shall be used for Electrical field power and control cables
entering to the Substation.
Cable Transit frames for battery and instrument room shall be provided with a minimum
of 30% spare entries complete with seal blocks to provide a total gas/watertight entry
system in accordance with applicable IP requirements. As a minimum, transit frames
shall be the same rating as the enclosure wall.

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5.8 Lighting and Small Power requirement

Design criteria specified are:
• Lighting and small power shall be supplied from 400 V lighting/small power
panels respectively.
• Lighting and small power circuits shall be provided with 30mA earth fault
protection.
• 30% of lighting system shall be considered as essential lighting and shall be fed
from essential services EDG power.
• Out of above 30% essential lighting, 10% lighting shall be designed as escape
light fixtures and shall be equipped with self-contained back up batteries with
autonomy time of 90 min. Escape light shall be fed from essential services EDG
power.
• Escape lighting shall identify building exits, access ladders, muster areas, safe
refuges and escape routes with fittings located at every change of direction.
• A portable lighting fixture complete with battery and battery charger shall be
provided for each substation building.
Average Illumination levels guideline is given on API RP 540 and EN 12464 for
workplaces. Performance criteria shall be as per Electrical System Basis of Design
(Doc.no. A-ELE-BOD-800-30001, clause no.6.15)
All substation services small power, lighting etc. shall be supplied from the substation
small power & lighting boards.
HVAC System shall be powered from a dedicated Distribution board.
The lighting installed by the Supplier in the substation should be a mixture of normal
fluorescent lighting and battery backed fluorescent lighting fixture.
The Distribution boards shall comply with requirement mentioned in Distribution Board
Specification (Doc.no. A-ELE-SPE-000-00012).
The board shall come complete with all MCB’s or fuses installed including those for
spare ways.
The Supplier shall install dedicated 400V, 3P+N normal, essential lighting and small
power distribution boards for each substation. These will take the form of two main
types, photocell controlled for the supply of exterior lighting circuits and non-photocell
controlled for the supply of interior lighting and small power. The Supplier shall also
supply all ancillary components required for the operation of the boards, such as
photocells, circuit breakers, contactors etc.
Lighting controlled by photocell shall have an un-switched battery maintain supply
which is not disconnected during daylight hours.

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5.9 Wiring and Cabling

5.9.1 Cables
All Electrical cables shall be provided by the Contractor comply with Electrical Power &
Control Cables Specification (Doc. no. A-ELE-SPE-800-30015).
All cabling and wiring shall be continuous; splices are not permitted. Cables shall be
installed in one length.
Single phase lighting and small power cables shall include an integral earth conductor.
All Instrumentation cables shall comply with Specification for Instrument Cables
(Doc.no. A-INS-SPE-000-30016).

5.9.2 Cable Trays

In general cables shall be routed on supporting steel work, i.e. heavy duty, hot dip
galvanised cable ladder racks and/or cable tray and held in place with stainless steel
cable straps or Nylon 12 (Heavy) Cable ties.
Signal and power cables shall be adequately separated to ensure integrity and prevent
any form of interference.
Separate cable trays shall be provided for MV power, LV power and instrument/telecom
cabling.
As per API RP 552, following minimum distances shall be maintained, between the
cable trays:
Cable Routing Minimum Distances
Horizontal & Vertical distance between 300mm
cable tray carrying MV cables & cable tray
carrying LV cables
Horizontal & Vertical distance between 1000mm (Horizontal)/300 mm (Vertical)
cable carrying MV cables & cable tray
carrying Instrument/Telecom cables
Horizontal & Vertical distance between 300mm
cable carrying 690V cables & cable tray
carrying Instrument/Telecom cables
Horizontal & Vertical distance between 300mm
cable carrying 400V cables & cable tray
carrying Instrument/Telecom cables

5.9.3 Cable Glands

Glands shall be Ex‘e’/ Ex‘d’ type, double compression, dual certified nickel-plated brass,
ISO metric threads, complete with all accessories including shrouds. However, entry
into Exd equipment shall be via barrier glands.

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5.10 Earthing Protection

The substation shall be provided with two main earth bars located at each end of the
substation. These earth bars shall be connected in a ring using earthing cable of the
equivalent total cross section to the bars.
All equipment shall have 2 no. earthing connection in the substation, and these shall be
connected either directly to the earth bars or via a local earthing ring.
The earth bus bar shall be connected to the substation main earth bars at each end
using earthing cable or bar.
The earthing system shall be designed to incorporate the following requirements:
• Protection against indirect contact
• Protection against the accumulation of electrostatic charge
• Protection against lightning discharge
For the earthing system the following requirements are foreseen:
• All main metallic structures shall be utilised and configured as main earth loop
facilities
• Electrical continuity shall be ensured for the various bolted joints.
• Small Power and Lighting circuits shall have double pole isolation
• Earthing of suspended ceilings, raised computer floors and HVAC ducting
• Earthing of building services pipes
• Earthing of radio antennae
• Earthing of HVAC ducts and equipment
• All other equipment supplied by Supplier
The Supplier shall earth the metallic structure of the substation at two diagonal corners
to the substation main earth bar. The Supplier shall use at least 70mm2 earthing cable.
The earthing conductor sizes to be used for various application as per Electrical System
Basis of Design (Doc.no. A-ELE-BOD-800-30001, clause no.6.18)
Note:
1) Single earthing connection will be provided to the motors/ equipment having single earthing
stud as per manufacturer’s standard.
2) Instrument equipment, enclosures and cables shall be earthed in accordance with
Instrument Earthing Philosophy.

5.11 HVAC System

The substation Supplier shall be responsible for the design and supply of all HVAC
system equipment in accordance with HVAC Design Basis and Specification Doc.No.
A-HVA-BOD-30000.

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The Substation building shall be provided with 2x100% package HVAC System utilising
R134 a to maintain the building positive pressure in order to prevent ingress of
potentially flammable gases and to maintain the internal design condition as per
referred HVAC Design Basis and Specification.
Package air conditioning shall have pre-filter and final filter. The ventilation system for
the battery room shall have 2x100% exhaust fans suitable for Zone-1, IIC, T3. The
ventilation system shall be designed to provide adequate air changes and cooling to
limit internal air temperature as specified in the HVAC Design basis and Specification
referred above.
Humidifiers and heaters shall be provided as required to maintain the inside design
condition.
The fresh air intake (drawn from safe area) shall be provided with sand trap louver with
filter, gas detection and fire and gas damper. The Supplier shall ensure all ventilation
incorporates enough filtering to prevent the ingress of sand and dust into the substation.
The ventilation of the battery room shall extract air from the higher part of the room and
shall always provide enough air changes to keep the hydrogen concentration below
25% of the Lower Flammable Limit (LFL). Continuous ventilation at an appropriate rate
of changes per hour should be provided for the battery room/cabinet associated with
the 110V DC tripping and closing system. The ventilation should be enough to ensure
no hazardous build-up of battery gases within the room/cabinet or substation package.
Air into the battery room shall be once through and will not pass into other rooms.
Battery chargers shall be interlocked with supply fan, battery room shut-off dampers
and battery room extract fan such that boost charging of batteries shall not take place
without a functioning extract system. The extract system shall continue to operate upon
hydrogen detection in either battery room, whilst boost charging shall be inhibited.
The HVAC system filters shall be located so that they can be readily inspected, cleaned
or replaced with the minimum use of special tools or equipment.
The substation building complete HVAC System power supply shall fed from normal
and essential power distribution board to ensure that during a power outage, the
substation building complete HVAC system will be kept running by the essential
services diesel generator. Heating and ventilation design calculations and all design
documents shall be prepared as per the HVAC Design basis and specification referred
above and submitted for Operator engineers review and approval before fabrication
begins.
Based on the QRA report, in case of any blast rated building design, all external wall
duct penetrations, shall be provided with blast resistant dampers meeting the blast
overpressure requirements specified.
Earthing of HVAC ducts to be followed as per Electrical Earthing installation drawing.
The complete HVAC system shall be monitored and controlled from a dedicated DDC
HVAC Control panel. All fire dampers, fire and smoke dampers shall be controlled by
HVAC control panel.

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Three gas detectors at the inlet to the HVAC shall be provided to detect any hazardous
gas drawn into the substation from outside. The gas detectors shall be wired to a
Junction box supplied by building supplier. These gas detectors from the Junction box
to Plant F&G system cabinet shall be wired by CONTRACTOR. Upon confirmed
detection of flammable gas and confirmed fire detection, the Plant F&G system/FACP
shall provide command to HVAC Control Panel to close the certified gas tight inlet
damper and set the HVAC to shutdown mode.
Following signals of each HVAC unit shall be communicated from the HVAC control
panel to ICSS through hardwired signal.
• HVAC System Running
• HVAC Common Fault
• HVAC Shutdown
• HVAC Common alarm

5.12 Fire Detection, Fighting and Safety Equipment

Seller shall refer to the HSE Design Philosophy document (Doc.no: A-TSE-PHL-000-
30000) for the Firefighting equipment, fire detection, alarm requirements, safety signs
and eye wash bottle requirements etc., in substations.
Cabling for the smoke detection system shall be of appropriate construction for the
service and coloured to distinguish them from other cables.
All fire detection system cabling shall be segregated from all other cabling according to
the appropriate regulations.
Eyewash bottles (minimum two nos. at each battery room) shall be mounted on the
substation wall located near batteries or equipment containing batterie. As a minimum
a battery backed emergency exit light shall be provided above each exit from the
substation.
CO2 and FM200 Fire extinguishing system shall be provided in Substations in
accordance with Specification for Fire Suppression System (Doc. No: A-TSE-SPE-000-
30001). Modular Substation with fire detection and alarm systems shall be provided
with an addressable type fire alarm panel (FAP). The addressable FAP shall raise local
alarms and execute CO2/ FM200 total flooding system release as per ‘Specification for
Fire Suppression System’.
For substations all Fire, Smoke & Heat detectors shall be connected to the Building Fire
Alarm Control Panel provided by Package substation supplier and executive actions
such as building & plant alarms, HVAC shutdown, etc. shall be initiated by outputs from
the respective building F & G control panel.
Each transformer bay shall be provided with Linear Heat Detection cable these heat
detectors shall be wired to the building Fire alarm panel.

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Supplier shall comply with firefighting and safety equipment specification for Fire
extinguisher, eye wash stations/bottles, fire blankets, first aid kits, safety signage,
Electrical safety kit, stretcher.
Supplier shall comply the requirement of Specification for Fire Suppression System
(Doc no: A-TSE-SPE-000-30001) for FM200 and CO2 system.

5.13 Operator provided items

ERSV provided items shall be made available at site for the installation.
The Supplier shall provide the support provision for the installation and all necessary
interface cabling within the substation for ERSV provided items.
A CCTV camera, PAGA speakers, telephones and associated junction box shall be
provided by CONTRACTOR (and same shall be install at site) for communication
between the substation and the plant wide telephone system. Supplier shall provide the
support provision at a prominent position to install these CCTV camera, PAGA
speakers, telephones and associated junction boxes.

5.14 Warning labels

The following labels warning notices, along with internationally recognised symbols,
should be provided on all doors according to the type of equipment housed,
a) “Doors to be kept closed”
b) “Entry for authorised personnel only”
c) “Danger 230 Volts”
d) “Danger 400 Volts”.
e) “Danger 5,500 Volts”.
f) “Danger 11,000 Volts”.
g) “Danger 30,000 Volts”.
All equipment labelling shall be as per Equipment Labelling Specification (Doc.no. A-
IMT-SPE-000-30000. The labels shall indicate function and, where necessary, give
operating instructions.
Labels shall be fixed with stainless steel screws. Fixing by adhesive is not acceptable.
Safety signs shall be provided throughout the substation to provide warning or
information, or to identify locations of safety, firefighting and survival equipment, etc.
The sign colours, dimensions, shape and symbols shall be according to international
standards. All signs with descriptive text shall be in French and English languages.
Refer Specification for Fixed Fire Fighting & Safety Equipment (Doc no: A-TSE-SPE-
000-30000).
In accordance with international standards, safety signs are divided into four main
categories as follows:

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Table - Safety Signs

Meaning Shape Colour

Prohibitive signs Circular Red band with red cross

band

Obligation sign Circular Blue background White

(Mandatory sign) contrast

Warning sign Triangular Yellow background Black

contrast

Emergency Information Rectangular Green background White

contrast
All safety signs shall be illuminated by one of the following means:
• Directly or indirectly by the essential lighting;
• Photoluminescence.
Safety signs shall be located in accordance with statutory requirements and good
engineering practice.

5.15 Painting
Surface finish and painting shall be compliant with the Specification for Painting
(Doc.no. A-MTL-SPE-000-30003) and suitable for the expected environment at site.
The Supplier / Vendor can suggest using his standard painting finish (if suitable for the
environment specified) with the agreement of the COMPANY.

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6 TEST, DELIVERY AND INSTALLATION

6.1 Testing
Supplier shall be responsible for the testing and commissioning of the equipment in his
scope of supply. Testing shall be in accordance with equipment Specifications.

6.1.1 Factory Acceptance Tests (FAT)

Tests shall be performed on all equipment (supplied by Supplier) after installation in the
Substation, in accordance with the agreed Test Procedures. Equipment shall have been
tested at individual manufacturing site and accompanied by full FAT documentation.
Supplier shall provide sufficient power to supply all building utilities (HVAC, lighting, etc)
so that these systems can be fully operated for the duration of the FAT. The power
supply shall be compatible for the utilization equipment serviced (i.e. 400 volts AC, three
phase, 4 wire, 50Hz)
The FAT shall include, but not be limited to the following:
• Compliance to standards, specifications, and Manufacturers drawings approved
by CONTRACTOR.
• Physical and dimensional check.
• Proving all alarm panel inputs from the room.
• HVAC System functional tests, performance test and alarms.
• Lighting system functional test and lux level confirmation.
• Check equipment type and rating of components (fuses, relays, etc).
• Verification of equipment installation and busbar connections.
• Insulation resistance tests for HVAC motors, control panels and wiring, lighting
and small power system panels.
• Earth continuity test.
• Functional test of ICSS to ensure correct installation and system operation.
• FAT of FACP with detectors, HSSD shall be carried out at OEM factory with
PIUL witness, before installation/integration at yard. Vendor shall include this in
the ITP for CONTRACTOR approval. Followed by FAT at yard and SAT at site.
• Interface test between ICSS F&G cabinet and FACP shall be carried out at
Modular substation yard. Interconnecting cable shall be free issued to the yard
by CONTRACTOR. Cable laying, termination shall be by modular substation
vendor.
• Interface functional test between FACP and HVAC / HSSD / Fire Suppression
System (FM200/C02) / ACS at yard.
• Interface functional test between free issued ICSS PCS & F&G panels and
HVAC at yard. Interconnecting cable shall be free issued to the yard by

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CONTRACTOR. Cable laying, termination shall be by modular substation

vendor.
After testing and acceptance by CONTRACTOR/COMPANY, the unit shall be partially
disassembled (as required), for transportation to the site.
Prior to shipment, a final inspection shall be made by CONTRACTOR/COMPANY to
ensure that all equipment, tags, etc are as specified.

6.1.2 Test certificates and Test Reports

The Supplier shall conduct test and inspections necessary to determine that equipment
and wiring is installed in accordance with the individual specifications and is in
satisfactory condition to be energized.
A functional test shall be performed to ensure proper operation of all devices and
components.
Type test certificates shall be submitted for all Supplier supplied equipment for the
Building sub-systems (HVAC equipment, fire suppression system, lighting and small
power system etc.) in accordance with the associated equipment specifications.
Certified test reports shall be provided giving details of test performed and results
achieved.
Test certificates are to include values of results of test and results for any witnessed
tests shall be available for signature on the day of testing.
Free issued equipment shall be installed and tested before shipping to site.

6.2 Transportation
The enclosure should be fabricated and fitted out as a complete enclosure and if
necessary, the Supplier shall give consideration to the need to ship the enclosure in
sections in order to facilitate transportation.
Where shipping splits are required, the number of sections should be kept to the
minimum possible and the Supplier shall take into consideration the need to minimise
electrical cross connections between sections.
Enclosures shall preferably be split into transportable sections across the width of the
enclosure. Care should be taken to ensure that in-housed equipment is not disturbed
or damaged in any way. Supplier shall include for temporary walls and other
arrangements as appropriate to provide complete weather protection and to protect the
materials, equipment and component parts against corrosion, dampness, breakage or
vibration damage during transportation and handling and for prolonged storage in a
humid, high temperature environment.
If the enclosure is shipped in two or more sections, junction boxes shall be provided at
the interface between the sections for enclosure lighting only. The dc power, CT and
instrumentation/relaying control cable shall be connected by coiled cable connected at
site, not through an interface junction box.

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Supplier shall be responsible for shipping the package from their factory to the site
installation location and for building into their design whatever shipping limitations,
enclosure breakdown and protection that may be necessary. Electrical equipment to be
installed in substations by others shall be transported separately.
Any applicable weight limitations will be advised later. Shipped loose items shall be
clearly marked and identified in documentation, installation procedures and shipping
manifests.
The Supplier shall provide shipping details for approval prior to shipping to site.
The sections of all modules shall have enough support to withstand lifting and lashing
during transit. Suitable lifting unions and lashing points shall be provided on modules.
Modules shall be restrained to max 21 x 6.0 x 4.5 meters / 25 x 4.5 x 4.5 meters (Lx W
x H) and supported with transportation drawings. All internal fittings shall be suitably
fixed to avoid any damage during road transportation over 2000 KMS of unpaved road
in Algeria.

6.3 Lifting
Supplier shall advise on the locations, details and loadings of the base plates to the
support structure, platforms and stairs in order to design and construct concrete
foundations by others. Supplier shall provide all drawings about support structure,
stairs, handrails, walls, platforms etc. for approval. The schedule of this interface
information shall be agreed in advance. Supplier shall provide drawings of each housing
showing centre of gravity co-ordinates and lifting point reactions and the calculated
weight of finished unit(s).
All purpose-made spreader beams or lifting frames, shipping steel and tools shall be
the responsibility of the Supplier. Site cranage and standard slings, shackles, etc., will
be available at the job site. Care shall be taken in both design and handling to ensure
that electrical panels are not distorted or damaged during transport.
Location of lifting points and the weight shall be clearly marked on all shipping
containers.

6.4 Installation
Each pre-assembly shall be completely fitted out with all equipment and internal
services prior to despatch. The Supplier shall provide all documentation and procedures
necessary for the installation of the substation by others.
Where items are required to be dismantled for shipping, instructions shall be provided
for reassembly of sections in the field. Delivery shall include all bolts, splices, etc., for
joining the units together. These joining parts shall be securely packaged and clearly
labelled to enable immediate installation.

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6.5 Special Tools and Test Equipment

The Supplier shall advise of the need for any special tools or test equipment required
for the installation of electrical equipment. Such items must be shipped with the
package.

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7 SPARES
The provision of commissioning spares is included in the scope of the CONTRACTOR.
Operational spares are required in addition to commissioning spares, which shall be
replaced as necessary. Spares shall be included in accordance with Specification for
Spare Parts, document.

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8 QUALITY ASSURANCE
To ensure that design objectives are met, the CONTRACTOR and its major SUB -
CONTRACTORS shall operate an accredited quality management system in line with
ISO 9001:2015 “Quality Management Systems – Requirements” or equivalent if agreed
with the COMPANY and demonstrate that effective quality control procedures are in
place to ensure that the requirements of this Specification, recognised codes, national
and industry standards are met. The Purchaser reserves the right to conduct a quality
audit at the Supplier’s/sub-supplier’s facilities at any stage during the design,
manufacture, assembly, inspection and/or factory acceptance testing processes.

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9 DOCUMENTATION
All installation, commissioning and operating instructions for the offered electrical
equipment shall be included and indexed in the Installation, Commissioning, and
Operating Manuals for the modular Substation as per the Contract, as described in the
Requisition.
Shipping, handling and storage documentation shall be in the English and French
languages.
Manuals, training documents and documents produced by equipment suppliers shall
be in the English and French languages.

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