Ele
Section |
Title | Page | ||
| Purpose | 3 | |||
| Scope | 3 | |||
| Related Documents | 3 | |||
| Materials and Equipment | 4 | |||
| General | 4 | |||
| Substitution of Materials | 4 | |||
| Conduit | 4 | |||
| Electrical Boxes and Conduit Fittings | 5 | |||
| Wire and Cable (Power and Control Over 32v) | 6 | |||
| Motor Starters and Contactors | 6 | |||
| Manual Starters | 7 | |||
| Pushbuttons, Selector Switches, and Indication Lights | 7 | |||
| Panelboards, Lighting Fixtures, and Convenience Receptacles | 7 | |||
| Receptacles and Ground Fault Interrupters | 7 | |||
| Installation of Dedicated Neutrals | 7 | |||
| Grounding Equipment | 8 | |||
| Terminal Lugs | 8 | |||
| Terminal Blocks | 9 | |||
| Hardware | 9 | |||
| Miscellaneous | 10 | |||
| Air Products Furnished Equipment/Materials (Handling and Installation) | 10 | |||
| Installation Procedures | 11 | |||
| Conduit and Cable | 11 | |||
| Conduit Entry into Equipment | 12 | |||
| Wiring | 12 | |||
| Splices in Wiring | 13 | |||
| Taping of Lugs and Busses | 13 | |||
| Torquing of Bolted Connections | 14 | |||
| Spare Wires | 14 | |||
| Protection of Wiring | 14 | |||
| Low Voltage Wiring | 14 | |||
| Cable Tray and Cable | 16 | |||
| Bus Duct | 17 | |||
| Labeling (Wire and Cable) | 17 | |||
| Labeling of Electrical Areas and Equipment | 18 | |||
| Patching, Replacement, and Modification of Existing Work | 19 | |||
| Section | Title | Page
|
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| Working on Incoming Power System (During Construction) | 20 | ||
| Location of Safety Grounds | 20 | ||
| Safety Work Permit System for Safety Grounds | 20 | ||
| Method of Attachment | 21 | ||
| Communication with Power Supplier | 21 | ||
| Removal of Safety Grounds | 21 | ||
| Inspection and Testing | 21 | ||
| Wiring and Terminations | 23 | ||
| Testing Oil-Filled Transformers | 23 | ||
| Testing Vacuum and Gas Circuit Breakers | 23 | ||
| Testing Motors | 23 | ||
| Testing and Inspection of Grounding Electrode System | 23 | ||
| Insulation Resistance Test | 24 | ||
| User Tests | 24 | ||
| Change Log | 25 | ||
| Insulation Resistance Test Results | 26 | ||
| Grounding Electrode Conductor Resistance Test Results | 27 | ||
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1. purpose
1.1 This specification defines for the contractor the minimum requirements for material, installation, and testing of an electrical system.
2. SCOPE
2.1 The contractor shall provide all labor, services, tools, materials, and equipment (other than that specifically called out on the contract drawings and specifications as being provided by Air Products) necessary to install a complete and operative electrical system according to the contract drawings, this specification, the latest issues of the National Electrical Code and all other applicable codes, manufacturers’ drawings and instructions, and the direction of the Air Products field representative.
2.2 This specification is intended for use within the United States.
2.3 Any conflict between the various standards, codes, specifications, and the contract drawings shall be brought immediately to the attention of the Air Products field representative.
2.4 The requirements of this specification shall be applied to the supply and installation of all materials and equipment as shown on the contract drawings or as listed in 600.002. The requirements of 600.002 shall supplement the contract drawings. Requirements that are in conflict with the contract drawings shall be brought to the immediate attention of an Air Products field representative.
3. RELATED DOCUMENTS
3.1 Air Products Engineering Documents
4WCE-600001 General Scope of Work for Construction Contracts
600.002 General Project Data (project specific)
4AEL-620100 Electrical Equipment Commissioning
4AEL-620102 Commissioning: High Voltage Circuit Breakers/Contactors/Switches and Control
4AEL-620103 Commissioning: Substations and Outdoor Bus Structures
4AEL-620104 Commissioning: Substations High Voltage Oil/Vacuum/Gas Circuit Breakers
4AEL-620105 Commissioning: Liquid-Filled Transformers
4AEL-620106 Commissioning: Rotating Equipment – Motors greater than 600 HP
4AEL-620107 Commissioning: Low Voltage Distribution Systems/Motor Control Centers/Load Centers/Auto-Transfer Switches
4AEL-620108 Commissioning: Low Voltage Power and Control Distribution Equipment
4AEL-620109 Commissioning: Uninterruptible Power System, Batteries and Chargers
4AEL-620110 Commissioning: Emergency Generators
4AEL-620111 Commissioning: Bus Duct Systems
4AEL-620112 Commissioning: Grounding Systems
4AEL-620301 Hazardous Area Requirements for Class I Areas
4AEL-620302 Standard Wire and Cable Types
4AEL-620303 Installation and Testing of Medium Voltage Cable
STD-G309A Electrical Standard – Grounding Cable Trays
STD-G310A Electrical Standard – Grounding Conduit to Cable Tray
STD-P306A Electrical Standard – Conduit Connection Solenoid Valve
STD-P308A Electrical Standard – Conduit Connection to Pigtailed Switch
STD-P309A Electrical Standard – Conduit Connections to Field Devices – Class I Hazardous Area
STD-P331A Electrical Standard – Cable Tray Supports
STD-P338A Electrical Standard – Low Point Drain Installation Details
STD-S304A Sheets 3 & 4 – Electrical Standard – Symbols – Welding & Power Receptacles
3.2 Institute of Electrical and Electronic Engineers (IEEE)
81 Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Grounding System – latest edition
837 Qualifying Permanent Connections Used in Substation Grounding
3.3 Instrument Society of America (ISA)
3.4 National Electrical Manufacturers Association (NEMA)
C82.9 American National Standard for Lamp Ballasts— High-Intensity Discharge and Low-Pressure Sodium Lamps— Definitions
VE 2 Cable Tray Installation Guidelines
3.5 National Fire Protection Association (NFPA)
70 National Electrical Code (NEC) – Latest Edition
3.6 NETA (International Electrical Testing Association)
ATS-2013 Acceptance Testing Specifications
4. MATERIALS AND EQUIPMENT
4.1 General
4.1.1 Equipment and materials provided and installed by the contractor shall be of first quality, free from defects and imperfections, of recent manufacture (new, unused), and of the classification and grade described in this specification or on the contract drawings. Whenever possible, electrical materials and equipment shall be labeled by Underwriters’ Laboratories, Inc. (UL).
4.1.2 Substitution of Materials—The contract drawings and specifications contain manufacturers’ catalog numbers to establish grade and quality. Design details are based on the materials or equipment described. Equivalent materials or equipment of other manufacturers may be substituted unless such items are marked “No Substitution.” When substitutions are proposed, the contractor shall be governed by 600.002.
4.1.2.1 If 600.002 is not provided as part of this document, or does not specifically identify requirements for substitution of materials, the contractor shall contact the responsible Air Products Electrical Design group for approval of material substitutions. All requests for substitutions and all approvals of substitutions shall be made in writing.
4.1.2.2 All equipment and materials provided for use in areas classified as electrically hazardous shall be approved for use in such areas and shall be installed in an approved manner. All equipment and devices must bear an appropriate approval label. Unless otherwise noted on the contract drawings, or by the inclusion of a Hazardous Area Classification drawing, the installation shall be assumed to be in a non-hazardous location. Additional requirements for hazardous locations are contained in 4AEL-620301.
4.2 Conduit
4.2.1 Unless otherwise specified on the contract drawings, all conduit shall be rigid galvanized steel (RMC). The following list is a description of the various conduit types that might be specified on the contract drawings:
Rigid Metal Conduit Type RMC (steel): Conduit and conduit elbows, couplings, and similar fittings shall have an outer zinc protective coating and an inner protective coating of zinc, enamel, or an equivalent corrosion-resistant material.
Rigid Metal Conduit Type RMC (aluminum): Conduit and conduit elbows, couplings, and similar fittings shall be a corrosion-resistant aluminum alloy containing not more than 0.4% copper.
Liquid-tight Flexible Metal Conduit Type LFMC: Flexible conduit shall have a liquid-tight, PVC outer jacket over a flexible galvanized steel core. Flexible conduit shall be 105°C rated, type ATLA with integral ground wire up to 1-1/4″ and fully interlocking strip up to 4″. (No Substitution.) This conduit is suitable for use in Class 1, Division 2 hazardous areas as required by Article 501-30(b) of the NEC.
Electrical Metallic Tubing (EMT): Tubing and fittings shall be steel or aluminum and shall have the same protective coatings or alloys as specified for rigid steel or aluminum conduit. Fittings shall be of the compression type. Note: The use of EMT conduit is limited to indoor, non-process area applications only (for example, offices, maintenance areas, electrical rooms, or control rooms).
Rigid Metal Conduit, Steel, Plastic Coated (RMC/PVC): Conduit, elbows, couplings, and similar fittings shall have an outer and inner protective coating of zinc, as well as a 40 mil, polyvinyl chloride coating bonded to the outer surfaces.
Rigid Nonmetallic Conduit (RNC): Schedule 40, 90°C, wire-rated, heavy wall, rigid plastic conduit. Carlon PV-DUIT, or equivalent.
4.3 Electrical Boxes and Conduit Fittings
4.3.1 Pull boxes shall be standard gauge galvanized steel, aluminum, fiberglass, or stainless steel as indicated on the contract drawings, with captive stainless steel cover screws and a neoprene gasket attached to the cover. All pull boxes in wet or outdoor locations shall be weatherproof, NEMA type 4X as indicated on, or referenced through, the contract drawings.
4.3.2 Terminal boxes and equipment enclosures shall be NEMA-rated galvanized steel, aluminum, fiberglass, or stainless steel as indicated on the contract drawings with a hinged door and a removable mounting panel or terminal straps as specified. A 12 mm ½” stainless steel drain fitting Hubbell #DPE-30-29-S3 or equal shall be installed in the bottom of all outdoor enclosures. Enclosure rating shall be selected as follows:
NEMA 1 General indoor use
NEMA 4 Indoor use where frequent water hose-down of equipment occurs
NEMA 4X General outdoor use and corrosive areas
NEMA 7 Hazardous locations as required
NEMA 12 General indoor use
4.3.3 Receptacle, switch, and junction boxes for dry, indoor locations shall be standard gauge galvanized steel with captive screw-fastened covers. Cast boxes with threaded hubs and gasketed rain-tight covers (Crouse-Hinds or Appleton FD or FS) shall be used for wet or outdoor locations.
4.3.4 Conduit fittings for rigid galvanized steel conduit shall be Crouse-Hinds Form 8 with gasketed covers, retained cover screws, and threaded hubs or Appleton FM 8 Grayloy-iron with FG series cast cover and neoprene gasket. Conduit fittings for conduit systems containing 4/0 AWG (American Wire Gauge) conductors, or larger, and high voltage cables shall be Crouse-Hinds or Appleton “Mogul” series.
4.3.5 Conduit fittings for rigid aluminum conduit shall be Crouse-Hinds Mark 9 with gasketed covers, retained cover screws, and threaded hubs, or Appleton FM85 with cast cover and neoprene gasket. When aluminum fittings terminate on rigid galvanized steel conduit, threads shall be coated with zinc chromate to minimize galvanic reaction between the dissimilar metals.
4.4 Wire and Cable (Power and Control over 32V)
4.4.1 The wire and cable provided and installed by the contractor shall be according to the contract drawings and this paragraph. All wire and cable (except thermocouple wire) shall be manufactured of stranded conductors. Solid conductor wire is not permitted. The minimum size for all power and lighting wire shall be #12 AWG, and for all control wire shall be #14 AWG, unless specified otherwise on the design drawings. In some instances, #14 AWG wire is too large for terminals on instrumentation and other electronic devices. In these instances, a smaller wire gauge will be permitted with approval from Air Products Design. Insulation color shall be provided as follows:
| Application | Surface Color | |
| AC Power | Black | |
| AC Neutral | White | |
| Equipment Ground | Green | |
| AC Control or switched AC | Red | |
| DC Control/Power (over 32V) | Yellow | |
| Current Transformer | Blue | |
| Isolated ground (Iso-ground) | Green
(with visible ends taped with orange tape as identified in the following) |
Note: In the preceding chart, wire colors white and green are mandatory by the NEC. No deviations may be made in these wire colors. All other wire colors are required by Air Products. If the appropriate wire colors are not available, Air Products will accept taping visible ends of nonconforming wire with a minimum of 75 mm (3 in) of tape of the appropriate wire color except for colors white or green where the entire visible wire must be taped. When multi-conductor power and control cables are specified, standard manufacturer’s wire surface coloring is acceptable except for white and green as identified above. Once a wire color scheme is adopted in a control system, it must be consistent throughout.
4.4.2 For thermocouple and instrument wire color codes, see paragraph 5.3.3.
4.4.3 See 4AEL-620302 for standard wire and cable types.
4.4.3.1 Substitutions for the specified type of cable require approval by the responsible Air Products Electrical Design group unless identified “No Substitution.” All requests for substitutions and all approvals of substitutions shall be made in writing.
4.5 Motor Starters and Contactors
4.5.1 Magnetic starters provided by the contractor shall be minimum NEMA Size 1, complete with thermal overload relay heater element for each ungrounded conductor, specifically rated for the motor nameplate full-load current and starter enclosure ambient temperature. Unless otherwise identified, the nominal operating coil voltage shall be rated 120 volt, 60 Hertz. When starters are used where available line voltage is greater than 120 volts, they shall be provided with control transformer to provide 120 volt operating voltage from line conductors unless otherwise identified.
4.5.2 Ambient compensated, bimetallic-type thermal overload relay heater elements, fuse reducer clips if necessary, and fuses shall be provided by the contractor for all magnetic starters including those in Air Products supplied motor control centers. The contractor shall size the heaters specifically for the motor nameplate full-load current and service factor. Fuses shall be rated according to contract drawings and have 200,000 ampere interrupting capacity.
4.6 Manual Starters
4.6.1 Manual starters provided by the contractor for unit heaters, ventilation fans, or other single-phase motors shall be double pole, single throw complete with one thermal overload relay heater element specifically rated for the motor nameplate full-load current and starter enclosure ambient temperature.
4.7 Pushbuttons, Selector Switches, and Indicating Lights
4.7.1 The contractor shall provide all push buttons, selector switches, and indicating lights according to the contract drawings. Each device shall be provided with a laminated plastic legend plate indicating the function and the name or number of the equipment or device controlled. If not identified on the contract drawings, the Air Products field representative will supply the wording for the nameplates.
4.8 Panelboards, Lighting Fixtures, and Convenience Receptacles
4.8.1 Lighting fixtures shall be as indicated on the contract drawings. Fixtures shall be provided complete, including such accessories as lamps, ballasts, and mounting brackets.
4.8.2 For process power, lighting, and miscellaneous power dry-type transformer voltage and kilovolt‑ampere (kVA) ratings, refer to the contract drawings. Other characteristics shall be as follows:
Single-phase transformer taps up to and including 25 kVA, 2% to 5% taps below normal; above 25 kVA, 4% to 2-1/2% taps below normal.
Three-phase transformer taps up to and including 30 kVA, 2% to 5% taps below normal; above 30 kVA, 4% to 2-1/2% taps below normal.
All 3 phase Transformers to be Delta primary, Wye secondary.
185°C insulation (115°C rise) for 5 kVA to 25 kVA single-phase and 3 kVA to 15 kVA 3‑phase.
220°C insulation (150°C rise) for 37-1/2 kVA to 167 kVA single-phase and 30 kVA to 150 kVA 3-phase.
Enclosures shall be suitable for location in which equipment is installed.
Transformers shall meet all NEMA C82.9 requirements.
4.8.3 Lighting panel boards shall be of the factory-assembled, dead front safety type provided with bolt-in type single, 2-pole or 3-pole branch circuit breakers. Mains shall be arranged for a grounded, solid neutral system with main circuit breaker unless otherwise indicated. When required, the neutral bus shall be insulated from contact with any grounded surfaces within the enclosure. The grounding bus shall be solidly bonded to the panel enclosure. Refer to the contract drawings for the number of single, 2-pole or 3-pole branches, system voltages, and enclosures required.
4.8.4 Receptacles and Ground Fault Interrupters—Receptacles and wall switches shall be as described on the contract drawings. All convenience receptacles located in lavatories, kitchens, maintenance areas, outdoors, and all temporary construction power shall be protected by a 5 mA personnel protection type ground-fault interrupting (GFCI) circuit breaker or integral ground fault receptacle. A ground wire shall be installed with each lighting and convenience receptacle circuit. Air Products does not use metallic conduit as the sole ground path.
4.8.5 Installation of Dedicated Neutrals—Each lighting and convenience receptacle circuit shall have a separate, dedicated neutral. Multiwire branch circuits are not permitted. Lighting and convenience receptacle circuit wiring shall be tagged with the panelboard circuit breaker number. Hot and neutral wires of these circuits shall have the suffix “H” and “N” added respectively to the circuit number. Tagging shall be as described in paragraph 5.6.
4.8.6 All circuit breakers serving heat tracing circuits shall be 30 mA equipment protection ground fault interrupting (GFP) type.
4.9 Grounding Equipment
4.9.1 Ground rods shall have a copper surface over a steel center 19 mm (3/4 in) in diameter (Copperweld type). When rods longer than 3 m (10 ft) are required, threaded 3 m (10 ft) long rod sections shall be joined using threaded couplings. The contractor shall provide all driving studs for all ground rods.
4.9.2 Ground wire shall be made of bare, soft-drawn stranded copper with a conductivity of 100% International Annealed Copper Standard (IACS) (20°C). Refer to the contract drawings for conductor sizes.
4.9.3 All splices and connections, unless indicated otherwise, shall be made using a connection method from one of the following manufactures. No Substitutions.
- Cadweld process as manufactured by ERICO Products, Inc.
- Burndy “HYGROUNDTM” compression system. Calibration tests shall be done on the compression tool before using each day; records of test shall be forwarded to Air Products site personnel. Use only Burndy tools for crimps.
- Panduit “STRUCTUREDGROUNDTM” Direct Burial Compression Grounding System. Calibration tests shall be done on the compression tool before using each day; records of test shall be forwarded to Air Products site personnel. Crimps shall use the 3-step enhanced process to meet IEEE Std 837. Use only Panduit dies and approved tools.
4.9.3.1 Where above ground connections cannot be made using the exothermic welding process (for example, aluminum structures, building columns under 6 mm (1/4″) thick, motors, and equipment with bolted ground pads), connections shall be made with copper compression terminal lugs. Refer to paragraphs 4.10.3.1 and 4.10.3.2 for lug requirements.
4.10 Terminal Lugs
4.10.1 All terminations shall be self-tested after installation by pulling on wire with a moderate force to ensure the integrity of crimped lug or proper insertion in box connector.
4.10.1.1 When installing stranded wire in lugs or box connectors, contractor shall ensure all strands are properly inserted before crimping or tightening screw.
4.10.1.2 For all wire sizes #10 AWG and smaller, locking type, insulated fork, compression type lugs shall be used for all wiring terminating on terminal strips with terminal screws. Locking fork lugs shall be sized to match wire size and terminal block screws. All terminal lugs shall be crimped with lug manufacturer’s approved ratcheting type crimping tool.
4.10.2 Low voltage DC wiring—For 24 VDC power, control and instrument signal wiring, terminal lugs shall be used for all stranded wire terminations wherever possible per paragraph 4.10.1.2.
4.10.2.1 When equipment is furnished with terminal blocks or terminal connectors that will not accept lugs, conductors shall terminate directly to the connector without the use of a cable lug.
4.10.2.2 Resistors, diodes, or MOVs installed external to the terminal blocks must be supplied with its own terminal lugs installed under the same screw as the field wire. Terminal screws may have a maximum of two lugs. If the terminal will not accept a terminal lug, then a terminal block with an integral resistor must be used. Air Products will be responsible for specifying this terminal block.
4.10.3 Low voltage AC wiring—For AC power and control wiring up to and including 600 volts, terminal lugs shall be used for all stranded wire terminations, wherever possible per paragraph 4.10.1.2.
4.10.3.1 When wires #8 AWG and smaller are not terminated on terminal strips or under terminal screws (for example, low horsepower motor terminal boxes or electric heater terminations) copper, compression type one-hole lugs, Burndy YA-L series or equal, shall be used. Lugs shall be bolted together then taped as described in paragraph 5.2.7.
4.10.3.2 Contractor may use one-hole lugs for wire sizes #6 AWG through #4/0 AWG on copper wire up to and including 600 volts. For wire sizes 250 kcmil and above, use two-hole lugs. All lugs shall be electro-tin plated copper long barrel seamless compression lugs, Ilsco type CLN series, or equal. The lugs shall be crimped with a compatible hydraulic compression tool of the same manufacturer as the lug. Crimping shall be performed from the hole end of the lug toward the cable end. Mechanical screwed cable connectors shall not be used. Whenever equipment has provisions for two-hole drilling, provide the appropriate two-hole lug. Lugs shall be bolted together then taped as described in paragraph 5.2.7.
4.10.3.3 Lugs are not required when equipment is provided without provisions for bolting of lugs (for example, mechanical box connectors of motor control centers or molded case circuit breakers). Connectors shall be torqued according to the equipment manufacturers’ recommendations.
4.10.3.4 For all #6 AWG and above, flexible, stranded motor leads (supplied with motor) for motors below 600 volts, the contractor shall provide compression connector as described in paragraph 4.10.3.2.
4.10.3.5 When motor leads are provided with lugs that do not employ fully circular compression barrels (for example, open barrel type with folding flaps), the contractor shall remove the lugs and replace them with compression connectors as described in paragraph 4.10.3.2. If unsure regarding a lug’s acceptability, consult the Air Products field representative to determine if furnished lugs are appropriate.
4.10.3.6 Ring-tongue, insulated, compression-type lugs shall be used for all terminations in current transformer driven circuits.
4.10.3.7 Quick-disconnect, nylon-insulated terminations shall be used for all pigtailed device terminals when standards STD-P306A, STD-P308A and STD-P309A apply.
4.10.4 Medium voltage AC wiring—See 4AEL-620303 for lug requirements on medium voltage power wiring.
4.11 Terminal Blocks
4.11.1 Terminal blocks, for instrumentation, 120VAC power and control shall be as specified on the contract drawings or have screw-type terminals for use with locking fork lugs. Terminals shall be sized to accommodate the lugs and current involved and shall have a voltage rating suitable for the system.
4.11.2 Terminal blocks for thermocouple wiring (solid conductors) shall be equipped with pressure plates or wire clamps.
4.11.3 Short circuiting-type terminal blocks shall be provided for all terminations of current transformer wiring.
4.12 Hardware
4.12.1 Screws, nuts, bolts, flat washers, and lockwashers provided by contractor for electrical current-carrying connections or grounding connections shall be of a silicone-bronze alloy (or stainless steel) approved for electrical work. Hardware associated with an individual connection shall be either stainless steel or silicone bronze. Suitable flat washers and lockwashers shall be installed on all connections.
4.12.2 Screws, nuts, bolts, flat washers, and lockwashers furnished with manufacturer-furnished equipment (for example, switchgear, motor control centers, substation equipment and structures, or bus duct) for electrical current-carrying connections or grounding connections shall be installed as furnished, without substitution, regardless of the material supplied. Substitution of materials may result in performance issues or void manufacturer’s warranty.
4.12.3 Screws, nuts, bolts, flat washers, and lockwashers used for mounting electrical equipment shall be galvanized. Electroplated galvanizing is acceptable for bolt sizes 6 mm (1/4 in) in diameter and smaller. Suitable flat washers and lockwashers shall be installed on all connections.
4.12.4 Items such as anchor bolts, inserts, and support steel used for mounting electrical equipment on building steel, masonry, or concrete shall be provided by the contractor. The location of these items shall be verified by the contractor. All necessary items such as, brackets, rods, and hangers for supporting electrical equipment and conduit shall be furnished by the contractor. All support steel shall be hot-dipped galvanized or stainless steel. In cooling tower areas, water treatment buildings, and any other area subject to continuous moisture, all required conduit supports shall be aluminum or stainless steel.
4.13 Miscellaneous
4.13.1 All materials and equipment not mentioned in the preceding paragraphs shall be provided according to descriptions on the contract drawings.
4.14 Air Products-Furnished Equipment/Materials (Handling and Installation)
4.14.1 The provisions of Sections 17 (Equipment and Tools) and 18 (Layout of Work and Site Conditions) of 4WCE-600001 and the requirements of 600.002 apply to all Air Products-furnished electrical equipment and materials, including major items that are to be set by others. The contractor’s responsibility shall include, but is not limited to, the following:
4.14.1.1 The contractor shall provide Air Products with written acceptance of all furnished cable reels. This acceptance shall state that before installation the cable reel and visible portions of the cable(s) were visually checked and the cable reel and cable insulation or jacket appeared sound and undamaged. Any visible damage identified shall immediately be brought to the attention of an Air Products field representative. All cable reels shall be handled and stored according to manufacturer’s instructions.
4.14.1.2 Perform dc insulation resistance test on all medium-voltage motors upon receipt to measure polarization index. All motor space heaters shall be continuously energized with temporary power according to the nameplate until the permanent power may be tied in and energized. Subsequent motor dry-out because of noncompliance is the contractor’s responsibility.
4.14.1.3 Dielectric test of an oil sample from each filled transformer on receipt. A positive nitrogen pressure shall be established and maintained on each filled transformer until job completion. Subsequent oil servicing because of noncompliance is the contractor’s responsibility.
4.14.1.4 Provision for heated and dry storage facilities for equipment and materials that might be damaged or degraded by outside storage. The electrical distribution portion of buildings shall not be used for storage of materials and equipment after any of the electrical equipment is energized.
4.14.1.5 Final assembly of equipment as required. This includes, but is not limited to, transformer fins, fans and other accessories, oil for filled transformers and circuit breakers, switchgear, E2 starters, motor control centers, bus duct, battery racks, high-voltage motor connection cubicles, Kirk-interlock hardware, attachment of motor terminal boxes to motor throats, and installation of neutral grounding resistors on transformers when applicable. It also includes the provision of oil-handling equipment (including a pump and a filter press/drier) for oil-filled transformers and circuit breakers as required for assembly.
4.14.1.6 Removal of all drain plugs in the outdoor bus duct to prevent water accumulation and insertion of suitable bug screen.
4.14.1.7 The contractor shall install all RTD/thermocouple elements in the thermowells installed by the mechanical contractor.
5. INSTALLATION PROCEDURES
5.1 Conduit and Cable
5.1.1 All conduit shall be installed according to the contract drawings, the NEC, local codes, and this specification. If there is a difference in requirements, the most stringent shall apply. The conduit layout on the contract drawings, when shown, is diagrammatic and shall be verified by the contractor in the field. The contractor shall route conduit to avoid tripping hazards, blocking walkways, and access to valves and equipment. Conduit routing shall be coordinated with other trades and not interfere with dimensioned routings (for example, field piping including insulation, heating, ventilating and air conditioning (HVAC) ducting, or building cross bracing). Rigid or flexible conduit shall not use instrumentation or valves as a supporting method. This applies especially to solenoid valves, because the weight of the conduit destroys the casing and causes valve failure.
5.1.2 All metal conduit shall be cut with a power hacksaw, band saw, or rotary pipe cutter. A (flute) reamer shall be used on the interior of the conduit until all burr is removed.
5.1.3 All galvanized steel and aluminum conduit joints shall be coated with a metallic lubricant sealant (Lead Plate 250 as manufactured by Armite Laboratories or Crouse-Hinds STL).
5.1.4 When conduit is run on pipe bridges or its own structure, the spans between structural members shall not exceed the requirements of the NEC.
5.1.5 All metal conduit terminations shall have a nylon-insulating throat bushing, unless the termination is in a device having a threaded hub. Bushings and hubs shall be inspected for rough edges that can damage wire. All metal conduit terminating in nonmetallic enclosures shall have a nylon-insulating grounding bushing. All grounding bushings shall be jumpered together with a copper wire equivalent to the largest grounding conductor within the enclosure.
5.1.5.1 All metal conduit stub-ups not directly connected to metallic enclosures by means of a locknut or equivalent connector (for example, conduit stub-ups into the bottom of motor control centers, switchgear, sub-station transformer terminal chambers) shall have a nylon-insulating grounding bushing. All grounding bushings shall be jumpered per 5.1.5.
5.1.6 RMC conduit connections to items such as, indoor sheet metal enclosures, panelboards, or pull boxes shall be made with two locknuts, one on the outside and on the inside along with an insulated throat grounding bushing. RMC conduit connections outdoors and in wet locations shall be made with Myers ‘Scru-tite’ hubs with grounding hubs or equal.
5.1.7 All conduit runs to low-voltage motors (600 volts and below) in non-hazardous and Class 1, Division 2, hazardous areas shall have a section of liquid tight flexible conduit type LFMC at the motor terminal box to permit belt take-up and isolate vibration. Flexible conduit shall be routed and installed to avoid hot apparatus (for example, intercoolers or heaters).
5.1.8 After all cables have been installed, all conduit runs terminating at cable trays shall be adequately sealed with an approved sealing compound, Polywater® FST or equal.
5.1.9 Conduit and Cable Entry into Equipment—Conduit and cable shall enter field instruments, cabinets, terminal boxes, and switches at a bottom or side connection only. Drainage of water from the conduit system into instruments, cabinets, terminal boxes, or switches shall be prevented by the layout of the conduit and by installation of low point tees and conduit drains as required. Refer to STD‑P338A for recommended low point drain installation details.
5.1.9.1 Raceways passing through exterior walls of buildings or where subject to different temperatures shall be sealed per NEC using approved sealing compound, Polywater® FST or equal.
5.1.9.2 Where raceway enters a building, structure or electrical equipment from an underground distribution system, it shall be sealed per NEC using approved sealing compound, Polywater® FST or equal.
5.1.10 Spare conduits shall be installed as shown on the drawings. These conduits shall be cleaned and caps shall be installed at both ends.
5.1.11 Above-ground Rigid Nonmetallic Conduit (RNC) installation requirements include:
5.1.11.1 All bends shall be made only with bending equipment intended for the purpose.
5.1.11.2 All joints shall be made using the PVC solvent cement according to the manufacturer’s recommendations. Solvent cement must be approved by the conduit manufacturer.
5.1.11.3 Expansion couplings shall be installed in all conduit runs greater than 1.5 m (5 ft) per NEC and manufacturer’s recommendations. Expansion couplings shall be installed per manufacturer’s instructions based on maximum temperature change at location of installation.
5.1.11.4 Conduit shall be supported with Carlon “Snap Strap” or equal wall hangers to allow for conduit expansion and contraction.
5.1.12 Cable Installation
5.1.12.1 A cable-pulling compound shall be used with all wire and cable pulls in conduit. The cable pulling compound shall be Polywater “J” (American Polywater Corporation). This compound meets the requirements of all currently approved MV cable suppliers. If substitutions are required, the compound shall be certified by the manufacturer of the cable as being harmless to the type cable used. No substitutions are permitted without written approval.
5.1.12.2 Pulling of medium voltage cable in conduit shall be performed by using conductor for pulling, not only the insulation or cable jacket.
5.1.12.3 The installation of low voltage cable shall be performed using industry accepted methods and tools manufactured for the pulling of wire and cable.
5.1.12.4 A tension meter/recording device shall be used with all cable and wire pulls. Recorded data shall be made available for Air Products representative review.
5.2 Wiring
5.2.1 All wiring shall be installed in raceway systems, cable tray as indicated on the contract drawings. Wiring installed in below-grade concrete pits, manholes, pull boxes, or wireways shall be supported from, and secured to, cable trays or similar supports. Cable racks shall be provided on manhole walls to route and support cables along the perimeter of the walls.
5.2.1.1 Whenever possible, all wire and cable shall be fed directly from spools or reels into conduits or manholes to prevent cable damage caused by dragging the cable over the ground during cable pulling. If pulling the cable over the ground is necessary, the ground surface must be smooth, clear of sharp gravel, and covered with protective material.
5.2.2 Splices in Wiring—Wire and cable runs for 480 volt or higher system voltages must be continuous and without splice.
5.2.2.1 Splices in 120 volt control, alarm, instrumentation, and thermocouple wires are only permitted to be made on terminals as identified on the contract drawings for that purpose.
5.2.3 Splices in lighting and convenience receptacle circuits shall be made with indent-type splicing sleeves insulated with ScotchÒ 33+ tape 3M “ScotchlokÔ” electrical spring connectors, or equivalent, and secured to the wires with ScotchÒ 33+ tape. All splices must be accessible and in approved enclosures.
5.2.3.1 Termination’s to solenoid valves and pig-tailed devices shall be according to STD-P306A, STD‑P308A, and STD-P309A. All other switches and devices shall be wired directly without intermediate terminations.
5.2.4 All field wiring installed within panels or equipment enclosures shall be neatly bundled and adequately secured unless wiring ducts are provided for field wiring. Bundles shall be secured by the attachment of the cable ties to the internal structure of the enclosure or to screw‑attached or epoxide cable tie mounts. Self-adhesive cable tie mounts shall not be used.
5.2.4.1 Wherever type TC multiconductor power and control cable, or equivalent, enters an enclosure or motor control center wireway, the outer jacket shall be completely removed within 50 mm (2 in) of entry.
5.2.5 A cable-pulling compound shall be used with all cables or wires as required for underground or long above-ground conduit pulls. The compound shall be certified by the manufacturer of the cable as being harmless to the type cable used. No alkaline soap compounds shall be used.
5.2.6 Whenever aluminum conductors are terminated, they shall be treated with a corrosion inhibitor and oxide penetrating compound (such as “Penetrox A” manufactured by the Burndy Company).
5.2.7 Taping of lugs and busses (no substitutions)—The contractor shall not perform taping or boot installation until requested by the Air Products field representative. See specification
4AEL-620303 for medium voltage lug taping requirements.
5.2.7.1 All terminal lugs for low voltage AC power wiring that are not terminated on terminal strips or under terminal screws (for example, motor leads to field conductors in motor terminal boxes) shall be insulated using 3MÒ “Motor Lead Splicing Kits” 5300 Series, sized as required. If necessary, taping may also be used as an alternate method using the following procedure and materials.
| 1st Release Layer: | Two, half-lapped layers of ScotchÒ 33+ tape, sticky side out |
| 2nd Insulation: | Three, half-lapped layers of ScotchÒ 130C tape |
| 3rd Jacket: | Two, half-lapped layers of ScotchÒ 33+ tape |
5.2.7.2 Non-insulated busses of bus duct in motor control centers, switch gear, and all non-insulated motor control center (MCC)/switch gear bus splice connectors shall be taped using the following procedure and materials. Removable molded insulating boots (Raychem type BCIC or equivalent) may be used instead of taping, if the boots are of the suitable voltage rating and applied to match the exact bus/cable or bus/bus configuration. Heat-shrink-type insulation systems are not acceptable.
| Low Voltage | |
| 1st Release Layer: | Two, half-lapped layers of ScotchÒ 33+ tape, sticky side out |
| 2nd Insulation: | Two, half-lapped layers of ScotchÒ 33+ tape |
| Medium Voltage, 5 to 15kv | |
| 1st Release Layer: | Two, half-lapped layers of ScotchÒ 70 tape |
| 2nd Insulation: | Three, half-lapped layers of ScotchÒ 130C tape |
| 3rd Jacket: | Two, half-lapped layers of ScotchÒ 70 tape |
5.2.8 Torquing of Bolted Connections—All low and medium voltage power cable connections to lugged connectors and the joints of bus sections regardless of voltage shall be torqued per the manufacturer’s requirements. Connections shall be made using a calibrated hand torque wrench. These terminations must be witnessed by and signed off by the Air Products field representative. When the manufacturer’s data is not available, consult the Air Products field representative for proper torque values to be used.
5.2.9 Spare Wires—All spare wires and instrument pairs/triads shall be neatly bundled, coiled, and individually labeled “SPARE” and the appropriate conduit or cable tag, that is, “SPARE-MV21” wire length shall be long enough to reach any termination point within the enclosure or programmable electronic system (PES) and motor control centers lineups. Spare wires entering motor control centers via pits shall be coiled in the top horizontal wireway. All 600V spare wires and conductors in multiconductor cables shall be grounded at both ends using split bolt connectors or equivalent. Ensure the grounding conductor in multiconductor cable is identified with a green surface according to the note in paragraph 4.4.1. The contractor shall not ground spare conductors until requested by the Air Products field representative.
5.2.10 Continuously wrapped pre-bundling of individual ac control and power wiring is prohibited. This is prohibited to prevent overheating of the innermost wires of the pull bundles.
5.2.11 Protection of Wiring
5.2.11.1 Where wiring passes through access holes between adjacent metal or fiberglass enclosures, (for example, rear of motor terminal boxes for motor lead access, wire routing cut-outs between motor control center, and switchgear sections) either field cut by the contractor or provided by the equipment manufacturer, contractor shall protect wiring from damage caused by sharp edges around the entire opening using a poly-cushioned, nylon-coated stainless steel push-on grommet strip.
5.3 Low-Voltage Wiring
5.3.1 Air Products generally uses shielded instrument and thermocouple wire. Individual shield drain wires and overall shield drain wires shall be tied to ground either at a central ground point or at the instrument (refer to paragraph 5.3.1.6 and 5.3.1.7 for exceptions when wiring thermocouples). Such wiring shall be installed without spurious grounding of the shield system to metal surfaces or exposed portions of conductors. Procedures to be followed include:
5.3.1.1 Overall and individual shields shall be stripped back only as far as necessary for installation, and the ends of the shields shall be secured with tape or heat-shrink tubing, as required. Overall shield drain wires shall be grounded only at one point, the programmable electronic system (PES) equipment (safety) ground bus or control panel safety ground bus. If the multi-cable does not extend to the PES or control panel, overall shield drain wires shall be grounded at the terminal box electrically closest to the PES or control panel.
5.3.1.2 Outer jacket of single pair cable and single triad cable in terminal boxes, control panels, and PES cabinets shall be stripped back only as far as necessary for installation—generally the portion between the cable tag and the termination point. When wireways are provided for routing wiring, only the portion of the cable extending beyond the wireway between the cable tag and the termination point of the conductors shall be stripped back only as far as necessary for installation.
5.3.1.3 All terminated shield drain wires shall be insulated with clear heat-shrink sleeving for their entire exposed length, to prevent accidental contact with grounded surfaces or exposed portions of conductors. Cables shall not be stripped, exposing shields, until actual termination of cable conductors is being performed, particularly when electronic system testing is being performed before complete termination of all system wiring.
5.3.1.4 The ground wire from plant grounding electrode system, individual shield connections to grounded instruments, and overall shield/drain wire connections must be terminated before PES or control panel power is energized.
5.3.1.5 The contractor shall report to the Air Products field representative any shield drain wire that is not grounded or is grounded at more than one point.
5.3.1.6 Air Products generally uses grounded thermocouples; all thermocouple conductors shall be installed, terminated, and checked for spurious grounding before final connection to the grounded field element.
5.3.1.7 In the thermocouple head, the contractor shall strip back shield and drain wire only and allow for a small service loop. The shield shall be secured with heat shrink or tape, and the drain wire shall be connected to the grounding screw. Since the drain wire has been connected at this field device, make sure that the other end of this drain wire has not been tied to ground, cut back, and insulate shield and drain wire.
5.3.1.8 Wiring to control panel terminal strips shall be installed such that all wire markers are visible without removing wiring duct covers.
5.3.2 All thermocouple and instrument wiring shall be checked for continuity and point-to-point terminations.
5.3.3 Thermocouple and instrument wire shall be terminated as follows:
| Device | Device Marking | Wire Color |
| ISA Type T | + | Blue |
| Thermocouple | – | Red |
| ISA Type J | + | White |
| Thermocouple | – | Red |
| ISA Type K | + | Yellow |
| Thermocouple | – | Red |
| Resistance | Red (Black) | Red |
| Temperature | White (Yellow) | White |
| Detectors (RTDs) | Red (Black) | Black |
| Instruments | + | Black |
| (mV and mA) | – | White |
| Bentley Nevada | -18 Vdc | Red |
| Proximitors | Common Output | Black |
| White |
5.3.4 Low voltage wiring to instrumentation should be done such that there is a service loop in cable or wiring runs inside junction boxes and control panels and inside instrumentation termination heads so that there is additional wire available for service/replacement/retrofit activities.
5.4 Cable Tray and Cable
5.4.1 Cable trays shall be installed according to the latest revision of the NEC, NEMA VE 2, and manufacturer’s installation instructions.
5.4.2 Cable tray elbows shall be supported per STD-P331A and NEMA VE 2 requirements.
5.4.3 Cable tray supports shall be located so that connectors between horizontal straight sections of tray fall between the support point and the quarter-point of the span. Cable tray installations shall be installed so connectors are not located in center points of span between supports or directly on supports. Cable trays shall be fastened to the support system using guides that allow for longitudinal movement.
5.4.4 Expansion connectors shall be provided at building expansion joints and in long runs of outdoor tray at intervals of 30 m (100 ft) or per NEMA VE 2. A bonding jumper shall be installed at each expansion joint according to STD-G309A. All cable tray systems shall be bonded together with bonding jumpers.
5.4.5 Cable trays shall be grounded at least every 15 m (50 ft) and at both ends.
5.4.6 All cable tray conduit drop-outs shall be bonded to the cable tray according to STD-G310A or with grounding bushing on conduit end and bonding wire bolted to the cable tray with a compression lug.
5.4.7 Cable Installation
5.4.7.1 Cables shall be installed in the proper cable trays as identified on the contract drawings. Cables shall be installed in a neat and workman like manner. Where drawing details dictate, laying of cables and spacing shall be maintained in trays as shown.
5.4.7.2 Pulling of medium voltage cable in cable tray shall be performed by using conductor for pulling, not insulation or cable jacket. To properly facilitate pulling a sufficient amount of cable jacket, insulation and any other material shall be removed to expose the bare conductor.
5.4.7.3 The installation of low voltage cable shall be performed using industry accepted methods and tools manufactured for the pulling of wire and cable.
5.4.7.4 A tension meter/recording device shall be used with all cable and wire pulls. Recorded data shall be made available for Air Products representative review.
5.4.7.5 Cable installation shall be performed per recommended methods and requirements of NEMA VE 2. Cable manufacturer data shall be used in the design of the cable pulls. Maximum tension and sidewall pressure shall be considered in the rigging of the cable pull. Proper radius pulling wheels shall be used and adequately supported. Care must be taken when rigging supports from existing structures. If necessary temporary supports shall be installed for rigging of the pulling equipment. It is the pulling contractor’s responsibility to ensure no damage occurs to the structure, other equipment, and/or personnel involved in pulling the cables. It is recommended that the rigging design be approved by a responsible engineer through calculation to avoid any such damages. Cable trays shall not be used to support any rigging for cable installation.
5.4.7.6 Cable clamps or straps suitable for outdoor duty and ultraviolet light shall be provided to limit the movement of conductors within the tray. Strapping shall be installed at maximum intervals of 1800 mm (6 ft) for horizontal runs and 900 mm (3 ft) for vertical runs.
5.4.7.7 Cables shall enter electrical equipment using only approved connectors suitable for the environment.
5.4.7.8 Cables runs outside of cable tray shall be installed in conduit or as otherwise shown on the contract drawings. Type MC cable shall be supported as permitted by the NEC. Cable runs must be protected from physical damage.
5.5 Bus Duct
5.5.1 Bus duct shall be installed according to manufacturer’s installation instructions.
5.5.2 Bus-duct bolted connections shall be torqued to manufacturer’s specifications. Torquing shall be witnessed by an Air Products field representative. When bus duct connections incorporate a visual method of proper bolt tightening, such as Square-D company’s “Visi-Tite” double-headed bolts, contractor shall ensure that Air Products field representative witnesses bolt head and warning tag break-off per manufacturer’s designs.
5.5.3 Refer to paragraph 7.2.14 for bus duct testing procedures during installation.
5.5.4 After bus duct installation has been completed, the contractor shall remove all drain plugs and replace with bus duct manufacturer’s approved bug screens to allow for moisture drainage.
5.6 Labeling (Wire and Cable)
5.6.1 All control, power wires, and low voltage instrument pairs and triads shall be labeled at each termination point. The numbers and letters shall be typewritten and shall correspond with those shown on the termination schedules and contract drawings. Labels shall be white and printed with a thermal transfer printer. Labels shall be Panduit polyolefin thermal transfer labels, Brady Co. Permasleeve™ marker or equivalent heat shrink, sleeve-type wire markers. Wire sizes 2/0 AWG and above may use Panduit marker plate labels #M300X050Y or equal. The labels to be positioned directly adjacent to the lug or terminal and the description shall be visible without manipulating the wire.
5.6.2 All multiconductor cables and cable bundles shall be labeled at each end. The numbers and letters shall correspond to the cable numbers shown on the cable schedules and contract drawings. Cable markers shall be Panduit marker plate labels per paragraph 5.6.1.
5.6.3 Do not shrink wire markers until requested by the Air Products field representative. Heat shrinking of markers on wires terminating in Programmable Electronic System (PES) cabinets and other sensitive electronic equipment shall be performed before termination of wire on terminal strip to prevent possible damage to electronic equipment caused by overheating.
5.7 Labeling of Electrical Areas and Equipment
5.7.1 All signs and labels shall be furnished and installed by the contractor.
5.7.2 All substation yards and transformer areas must be labeled with permanently attached “High Voltage” warning signs on the fences. The signs shall also indicate the highest level of voltage that exists inside the fenced area. Signs shall be UV- and chemical-resistant rigid polyethylene or painted aluminum. Signs shall be attached to fence with stainless steel self-locking cable ties. Other warning signs shall be installed as required by NEC article ‘Outside Branch Circuits and Feeders’, ‘Substations’.
5.7.3 Electrical rooms and buildings or any other structures that contain electrical equipment must be labeled with permanently attached warning signs on the outside of all doors to communicate the electrical hazards that exist inside. If equipment operating above 600 volts AC is present in the structure, “High-Voltage” warning signs must also be posted. The signs shall indicate the highest level of voltage that exists inside.
5.7.4 All switchgear, starter, and motor control center compartments must be labeled with permanently attached warning signs on the doors, including side and rear access panels, to indicate the highest level of voltage that exists inside. If high-voltage equipment is present, “High-Voltage” warning signs must also be posted.
5.7.5 For outdoor starters and motor control centers provided with weatherproof enclosures surrounding the equipment, in addition to labeling the equipment as identified in the preceding paragraphs, all access doors of the enclosure shall also be labeled with permanently attached warning signs on the doors to indicate the highest level of voltage that exists inside. If high-voltage equipment is present, “High-Voltage” warning signs must also be posted.
5.7.6 Covers, doors, and access panels of junction boxes, terminal boxes, pull boxes, transformer terminal chambers, motor terminal boxes, panelboards, and all other electrical enclosures and equipment shall be labeled with the highest voltage level contained inside.
5.7.7 Medium voltage conduit system access locations pull boxes and condulet fitting covers shall be labeled with the voltage level contained inside.
5.7.8 Signs identified in paragraphs 5.7.3 through 5.7.7 shall be UV- and chemical-resistant self-adhesive polyester film or equivalent.
5.7.9 All microwave antennas (dish and other types, including poles and masts) must have signs placed adjacent to them warning personnel of the dangers associated with radiation hazards. This includes systems for telemetering, control, computer, and video communications that use microwave communication systems. The sign shall read:
- “CAUTION – Radiation in this area may exceed hazard limitations and special precautions may be required. De-energize or obtain specific instructions before working near or looking into the center of the antenna.” or equivalent.
5.7.10 In addition to installing warning labels, the following electrical equipment identification labels must also be provided on electrical equipment. Unless noted otherwise, labels shall be laminated plastic and suitable for the environment in which they are installed.
- All disconnect switches, high and low voltage, shall be labeled to identify the equipment being served either by attachment of a label directly to or adjacent to the disconnect switch.
- Inside of each motor control center cubicle door, list the following: equipment number and name, load size/motor horsepower (HP), service factor, full-load/service factor amps, fuse size, and overload heater number and rating. This information may be typed on adhesive-backed cards.
- Weatherproof enclosures on outdoor switchgear, starters, and motor control centers with main disconnect means. The access doors to the disconnect shall have a sign labeled “Main Disconnect.”
- Each line-up of switchgear, starters, and motor control centers and all control panels, panelboards, terminal boxes, and control stations shall be provided with nameplates. If wording is not identified as part of contract drawings contact an Air Products representative for proper wording.
- Each lighting switch, convenience outlet, manual starter, heater, and other similar items, shall be provided with a nameplate indicating the supply panelboard and circuit protective device number. Labels may be self-adhesive polyester film or equivalent.
- Each piece of equipment or enclosures containing multiple power supplies shall be provided with a nameplate indicating the supply panelboard and circuit protective device number for each power supply.
- All transformers shall be labeled showing the location of the primary disconnect per the NEC. The label shall include panel or MCC number, breaker or bucket number or switchgear cubical.
- Per the NEC article 392, all cable trays with conductors over 600 volts shall be labeled with the wording “DANGER – HIGH VOLTAGE – KEEP AWAY” placed on both side rails where visible for all cable tray segments throughout the plant. The spacing of the warning signs shall not exceed 3 m (10 ft).
- All other cable trays shall be labeled as described in the following paragraphs. Labels shall be placed on both side rails where visible on all cable tray segments throughout the plant. Where cable trays contain a barrier with different cable systems on each side the side rail should reflect the cable type directly behind it. The spacing of the warning signs shall not exceed 15 m (50 ft).
– All cable trays with conductors rated >50 to 600 volts shall be labeled with the wording “LOW VOLTAGE POWER AND CONTROL – _____ VOLTS” Fill in the highest voltage in the tray system, usually from the LV motor control center.
– All cable trays with 24VDC instruments, Thermocouples and RTDs shall be labeled with the wording “INSTRUMENTATION”.
– All cable trays with computer network, telephone, fiber optics shall be labeled with the wording “COMMUNICATIONS”.
– Intrinsic safe wiring systems shall be labeled with the wording “INTRINSIC SAFETY WIRING”. Labels shall be placed on all trays, conduit and other similar items.
5.8 Patching, Replacement, and Modification of Existing Work
5.8.1 After installation of the electrical work is completed, the contractor shall neatly patch and/or repair existing construction that might have been damaged, removed, or altered during the installation. Work shall be similar and equal in quality to the work removed and/or damaged, unless otherwise shown or specified. Such work shall include, but is not limited to, patching and/or replacement of existing masonry, siding, roofing, partitions, and painting to the condition it was in before the installation of the electrical equipment.
5.8.2 All items such as structural steel supports and inserts shall be painted with one coat of metal primer immediately after installation. Building steel painted surfaces that are damaged during the welding of the supports shall be immediately treated with metal primer.
5.8.3 When PVC-coated conduit is used, any coating removed or damaged during construction shall be restored using the appropriate materials.
5.8.4 All penetrations of conduit or cable tray through building walls shall be sealed with a fireproof intumescent foam, RTV or equal as required, to provide a weatherproof seal, or as instructed and shown on contract drawings.
-
Working on Incoming Power System (during construction)
6.1 No work shall be performed on incoming power supplies (for example, electrical service entrance lines from utilities, or customer feeds) without prior notification and approval from the Air Products field representative or an Air Products Global Support Services (GSS) Electrical Engineering department representative.
6.2 Location of Safety Grounds—Safety grounds shall be installed where the incoming power supply is connected to the facility distribution equipment (for example, substation circuit breaker, substation transformer, switchgear, or main service disconnecting means) as soon as the distribution equipment is set in place. Safety grounds can be removed for connection of the incoming power lines to the equipment; however, they shall be reconnected as soon as the installation of the incoming power lines has been completed. Safety grounds must remain connected until the power system is ready to be energized. (Refer to paragraph 6.9.) All safety ground connection locations must be identified on the facility Safety Work Permit form and shall be tagged per requirements of the lock-out tag-out process.
6.3 For substations at new site locations or new substation additions to existing facilities, the responsible Air Products representative will maintain communication with the incoming power supplier throughout the construction of the substation to ensure that there is always control over the energization process. The Air Products representative will schedule the time for the connection and energization of the incoming power. Every effort will be made to schedule the connection of the supplier’s incoming power lines just before energization of the substation to avoid possible energization before substation work has been completed.
6.3.1 The requirements of paragraph 6.3 shall also apply to third-party facilities when Air Products receives its incoming power from the customer. The Air Products representative will establish and maintain communications with the respective customer’s representative to ensure that there is always control over the energization process.
6.4 Safety Work Permit System for Safety Grounds—Air Products’ preference is to have a visible line break, rather than an open switch, until it is time to energize the substation. After the incoming power cables have been terminated, all activities within the substation, including isolation of the incoming power lines, shall be controlled by the Air Products Safety Work Permit system. This precaution is required to protect workers in the substation from exposure to hazardous energy caused by inadvertent energization of the substation. Whenever work in the substation is necessary within 5 m (15 ft) radius to energized power conductors under 200KV and 6 m (20 ft) >201KV to 350KV and 8 m (25 ft) for 351KV to 500KV, or if work is to be performed on any energized line, the power to the substation shall be disconnected by having the power supplier disconnect the incoming power to the facility outside of the substation and lock and tag all the switches within the substation in the open position.
6.4.1 In addition to the requirements identified in paragraph 5.8.4, safety grounds shall be installed on all incoming power lines. These safety grounds shall be installed as soon as the incoming power lines are installed. Whenever possible, safety grounds shall be installed on the incoming power lines in such a manner that they do not require removal for performing work during construction. Safety grounds must remain connected until the power system is ready to be energized. (Refer to paragraph 6.9.)
6.5 The electrical contract for substation erection shall be reviewed by the Air Products Construction Department to ensure that the contract specifies installation of grounding straps at the proper locations in the substation, and that the straps will be installed before any incoming power line to the substation is connected. The erecting contractor shall install safety grounding straps of the appropriate capacity: (1) at the Air Products substation structure or (2) before the first set of switches or (3) at the specific piece of equipment being worked on. The erecting contractor shall install grounding straps even if there are safety grounds or safety ground switches in the incoming lines to the substation.
6.6 Method of Attachment—The exact method for attachment of the safety grounds shall be reviewed with the Air Products field representative or an Air Products Global Support Services (GSS) Electrical Engineering department representative. Safety ground can be installed either across all phase legs then to ground or individually from each phase leg to ground. Safety grounds shall preferably be attached to the nearest available grounding electrode system conductor. The entire safety ground connection from incoming power line to ground connection shall be visible from a single location.
6.6.1 The contractor shall be responsible for providing all required safety grounding cables. The size of safety grounding conductors shall be based on the available fault current rating of the incoming power supply; however, conductors shall not be smaller than #2/0 AWG stranded copper. Connection clamps shall be provided to match the equipment to which the safety grounds are being connected. It shall be the responsibility of the contractor to ensure that safety grounding cables are properly tested and maintained in first class working order. Safety grounding cables displaying any signs of damage shall not be installed.
6.7 Communication with Power Supplier—Whenever the incoming power supplier must temporarily de-energize the system, the Air Products representative shall maintain communication with the power supplier’s representatives and shall notify the power supplier when it is safe to restore power to the facility.
6.8 All personnel involved in the construction of the incoming power system shall be made aware that there is always a potential for back feeds from the low voltage system to the high voltage system if transformers are connected and power is inadvertently applied to the low side of a transformer.
6.9 Removal of Safety Grounds—After completion of facility construction and before the initial energization of the incoming power supply, all safety grounds shall be removed and the location of each safety ground shall be inspected by the Air Products field representative, an Air Products Global Support Services (GSS) Electrical Engineering Department representative, or both depending on availability at the site, to ensure safety grounds have been removed.
6.9.1 After ensuring that all safety grounds have been removed, the Air Products field representative or Air Products Global Support Services (GSS) Electrical Engineering Department shall notify the incoming power supplier that it is safe to energize the system for the first time. The responsibility for performing this notification shall be mutually determined by the Air Products field representative and Air Products Global Support Services (GSS) Electrical Engineering Department representative before final inspection of the safety ground removal described in paragraph 6.9.
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7. INSPECTION AND TESTING
7.1 Inspection
7.1.1 All materials and workmanship are subject to inspection by the Air Products field representative at any place where fabrication and erection are being done. Any defective material and/or workmanship shall be corrected to the satisfaction of the Air Products field representative.
7.1.2 A minimum of 24 hours notice shall be given to the Air Products field representative before performing any required testing.
7.2 Testing
7.2.1 The contractor shall provide all labor, materials, and equipment to perform all tests included in this paragraph. The requirements of each test are coded as follows:
Test Required |
||
| A | Test reports shall be documented in duplicate. Copies shall be submitted to Air Products daily. Originals shall be assembled into an overall indexed test report to be submitted to Air Products after job completion. All documentation shall show the full nameplate data of the equipment and, if applicable, the load test current for each phase (in addition to other required test data). | |
| B | The tests must be witnessed by a qualified Air Products field representative possessing a technical understanding of the tests being performed and the test equipment being used. | |
| C | The tests shall be performed by a reputable and qualified specialized testing service approved by the Air Products field representative and, where applicable, the inspection agency having jurisdiction. | |
| D | The test equipment used shall be calibrated and certified and shall be according to the calibration requirements specified in 4WCE‑600001. Documented evidence of calibration shall be provided to the Air Products representative. Documented evidence of calibration shall include:
|
|
| Identification of the equipment being calibrated
A reference to the procedure used for calibration Equipment used to perform calibration Check method Calibration date Individual performing calibration Calibration due date |
||
Insulation Resistance Test Values for Electrical Apparatus and Systems
From NETA ATS-2013 (Table 100.1)
| Nominal Rating of Equipment in Volts | Minimum Test Voltage, DC | Recommended Minimum Insulation Resistance in Megohms |
| 250 | 500 | 25 |
| 600 | 1,000 | 100 |
| 1,000 | 1,000 | 100 |
| 2,500 | 1,000 | 500 |
| 5,000 | 2,500 | 1,000 |
| 8,000 | 2,500 | 2,000 |
| 15,000 | 2,500 | 5,000 |
| 25,000 | 5,000 | 20,000 |
| 34,500 and above | 15,000 | 100,000 |
Test results are dependent on the temperature of the insulating material and the humidity of the surrounding environment at the time of the test.
| Test Required
|
||
| 7.2.2 | See specifications 4AEL-620100 thru 4AEL-620112 for testing requirements of substations and electrical equipment not listed here. | |
| 7.2.3 | Wiring and Terminations | A |
| · All wiring shall be tested and inspected to ensure wire is connected to the right terminals, free of short circuits, and of proper continuity. All terminations shall be checked and inspected for loose connections in lugs or terminals. | ||
| 7.2.4 | Test each oil-filled transformer or circuit breaker as follows: | A, B, C, D |
| · See specifications 4AEL-620104 and 4AEL-620105 for additional tasks to be completed by the electrical contractor. | ||
| · If oil is to be added to any unit, fill by means of a closed loop filter press process. Dielectric test an oil sample from each drum of new oil before using, and dielectric test unit oil before and after the filling process. | ||
| 7.2.5 | Test each vacuum and gas circuit breaker | A, B, C, D |
| · See specification 4AEL-620104 for tasks to be completed by the electrical contractor. | ||
Test Required
| 7.2.6 | Motors | |||
| · See specification 4AEL-620106 for additional tasks to be completed by the electrical contractor. | ||||
| · Verify motor lead markings by checking continuity with volt ohmmeter before connection. | ||||
| · Connect motor stator and any other space heaters and load check: ___________ amps. | A, B | |||
| 7.2.7 | Grounding Electrode System | |||
| · Measure the resistance of all accessible grounding electrode system pigtails and document the results on the Grounding Electrode Conductor Resistance Results form (Form 2). Tests shall be performed using a clamp-on ground resistance tester AEMC Instruments 3711 or equal. Measurements shall be made with grounding electrode pigtail connected to equipment. Any reading above the maximum resistance values identified in the following list shall be brought to the immediate attention of the Air Products field representative. | A, B, D | |||
| · See specification 4AEL-620112 for additional tasks to be completed by the electrical contractor. | ||||
| Item | Maximum Resistance (ohms) | |||
| Iso-ground Reference Plate (where applicable) | .05 | |||
| Switchgear/E2 Starter Ground Bus | .05 | |||
| Motor Control Center Ground Bus | .05 | |||
| Ground Resistor Ground Connection | .05 | |||
| Substation Equipment Frames | .05 | |||
| High-Voltage Transformer Frames | .25 | |||
| Electric Yard Support Structures | .25 | |||
| Electric Yard Fence | .25 | |||
| Moore Products DCS cabinet | .50 | |||
| Switchgear/E2 Starter Frame | .50 | |||
| Motor Control Center Frame | .50 | |||
| Distribution Transformer Frames | .50 | |||
| Distribution Panel Frames | .50 | |||
| High-Voltage Motor Ground Buses | 1.00 | |||
| · | ||||
| Test Required
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| 7.2.7.1 | · After completion of the electrical installation, the contractor and the Air Products field representative shall visually inspect and ensure that all of the grounding electrode system pigtails have been connected as identified on the contract drawings. All exothermic connections shall be strength tested by tapping the weld with a one-pound hammer. | B | ||
| · | ||||
| 7.2.8 | · Perform dc insulation resistance test on all 480-volt feeders before connection to the equipment and document the results on the Insulation Resistance Test form (Form 1). | A, D | ||
| · | ||||
| 7.2.9 | · Perform dc insulation resistance test on all 480-volt motors complete with leads to the starter before the initial energization for a rotation check. One megohm after one minute is acceptable. Remove leads at the starter, VFD or soft start before the test. Never Hi-pot motor windings. | A, B, D | ||
| · | ||||
| Test Required
|
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| 7.2.10 | · All 3-phase, 480-volt heaters shall be checked to ground with a volt ohmmeter before energization. If resistance is less than 20,000 ohms, a reduced voltage shall be applied to the unit as required to dry the insulation. Full voltage shall be applied for 30 seconds per hour maximum (unless otherwise directed by the Air Products field representative) and the load on each phase shall be measured. | A | ||
| · | ||||
| 7.2.11 | · All motor, heater, and process control circuits shall be energized and functionally checked without energizing the unit (use breaker test position, remove motor overloads, and disconnect leads, as required). The correct operation of each start, stop, bypass, interlock, and alarm device in the circuit shall be demonstrated. | A, B | ||
| · | ||||
| 7.2.12 | · All welding outlets shall be demonstrated for consistent phase rotation, proper voltage, and grounding. Outlet shall also be visually inspected to verify outlet meets Air Products manufacturer’s catalog number according to contract drawings or STD-S304A, Sheets 3 and 4. | B | ||
| · | ||||
| 7.2.13 | · All 120V receptacles shall be checked for the correct wiring with a standard three-lamp tester. GFCI-protected receptacles shall be tested with a GFCI tester. GFCI receptacles and breakers shall be tested with integral test and reset buttons. | B | ||
| · | ||||
| 7.2.14 | · Perform dc insulation resistance test on each bus duct section before assembly. Re-test as each section is added during assembly. Perform final test on the completed bus duct and perform a contact resistance test. Contact resistance test values shall be 30 micro-ohms per joint, or less. All transformer testing shall be completed before making final bus duct connections to transformer. | A, B, D | ||
| 7.3 | User Tests | |||
| 7.3.1 | Air Products Global Support Services (GSS) Engineering Department will normally perform additional testing before start-up. Unless otherwise indicated in 600.002, the contractor shall provide manpower for equipment disassembly and reassembly (as required) to permit testing. The coded requirements for each test apply only if the contractor is assigned total responsibility for “user tests” as indicated in 600.002. | |||
Form 1
| INSULATION RESISTANCE
TEST RESULTS |
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Project Name: |
Project Number: |
Contractor P.O. #: |
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Contractor Name: |
Test Voltage, Vdc: |
Circuit/Cable #: |
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Cable Mfr.: |
Cable Length, Feet: |
Aerial, Duct, or U/G: |
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# of Conductors per Cable: |
Wire Size, AWG or MCM: |
Shielded or Non-shielded: |
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Voltage Rating of Cable: |
Insulation Type: |
Insulation Thickness: |
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Pothead or Terminal Type: |
Location, Indoor or Outdoor: |
Date: |
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Time: |
Temperature, °C/°F-% R.H.: |
Weather: |
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Operator Name: |
Operator Company: |
Test Set Mfr.: |
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Model #: |
Serial #: |
Calibration Date: |
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Corona Suppression (Ionization Protection) Used, Yes/No: |
Type Used: |
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Test Set Guard Lead Used During Test, Yes/No: |
Where Connected: |
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Contacts/Cable Cleaned Before Test, Yes/No |
Cleaner Type: |
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| List Associated Equip. Used:
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| Remarks:
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TEST DATA – MEGOHMS
| Æ A- Gnd | Æ B- Gnd | Æ C- Gnd | Æ A- Æ B | Æ B- Æ C | Æ C- Æ A | |
| 1/4 Min. | ||||||
| 1/2 Min. | ||||||
| 3/4 Min. | ||||||
| 1 Min. | ||||||
| 2 Min. | ||||||
| 3 Min. | ||||||
| 4 Min. | ||||||
| 5 Min. | ||||||
| 6 Min. | ||||||
| 7 Min. | ||||||
| 8 Min. | ||||||
| 9 Min. | ||||||
| 10 Min. | ||||||
| 10/1 Min.
Ratio (PI) |
| ______________________________ | _______________________________ | |
| Contractor Superintendent/Date | Air Products Representative/Date |
Insulation Resistance Test Result
Click on link (above) for Excel Worksheet
Form 2
| GROUNDING ELECTRODE CONDUCTOR
RESISTANCE TEST RESULTS |
| Project Name: | Project Number: Date: |
| Facility Location: | Air Products Facility Identification: |
| Contractor Name: | Contractor P.O. #: |
| Test Set Operator Name: | Test Set Operator Company: |
| Test Set Manufacturer: | Test Set Model #: |
| Test Set Serial #: | Test Set Calibration Date: |
| Remarks: | |
| ITEM | RESISTANCE (OHMS) |
CURRENT READING |
| ______________________________ | ____________________________ | |
| Contractor Superintendent/Date | Air Products Representative/Date |