SECTION NO



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SECTION NO. 16000

REVISION 2

ELECTRICAL CONSTRUCTION

PENTA PROJECT NO. 2011-0707

FREEPORT-McMoRan

RAFFINATE SYSTEM - PHASE II LEACH PAD

SAFFORD, ARIZONA

December 15, 2011

SECTION NO. 16000

TABLE OF CONTENTS

PAGE

1.00 general 2

1.01 SCOPE OF WORK 2

1.02 DESCRIPTION OF WORK 2

1.03 MATERIAL AND EQUIPMENT FURNISHED BY OWNER 3

1.04 MATERIAL AND EQUIPMENT FURNISHED AND INSTALLED BY CONTRACTOR 3

1.05 CODES AND STANDARDS 4

1.06 GENERAL INSTALLATION 4

1.07 EQUIPMENT AND MATERIAL 4

1.08 VOLTAGE/SIGNAL CLASSIFICATIONS 4

1.09 ELECTRICAL CLEARANCES 5

2.00 EQUIPMENT AND COMPONENTS 5

2.01 GENERAL POWER AND CONTROL ITEMS 5

2.02 PANELBOARDS 5

2.03 CONTROL POWER TRANSFORMERS 6

3.00 GENERAL INSTALLATION REQUIREMENTS 7

3.01 HANGERS, ANCHORS, GUIDES AND SUPPORTS 7

3.02 PULL, JUNCTION AND TERMINAL BOXES 8

3.03 CONDUIT 9

3.04 CONDUIT FITTNGS 11

3.05 CABLE TRAYS 11

3.06 WIREWAYS 12

3.07 UNDERGROUND CABLE/CONDUIT/DUCT AND MANHOLES 12

3.08 WIRE AND CABLE MATERIALS 14

4.00 SPECIAL INSTALLATION REQUIREMENTS 20

4.01 INSTRUMENTATION 20

5.00 SYSTEM INSTALLATION REQUIREMENTS 22

5.01 GROUNDING SYSTEM 22

5.03 LIGHTNING PROTECTION SYSTEM 24

6.00 TESTING 26

6.01 GENERAL TESTING REQUIREMENTS 26

6.02 CABLE TESTING 26

6.03 GROUND SYSTEM TESTING 27

6.04 ELECTRICAL EQUIPMENT TESTING 27

general

1 SCOPE OF WORK

1.01.1 The Contractor shall provide all labor, tools, materials, supervision, and transportation for construction of a complete electrical system as indicated in these specifications, drawings, and other related construction documents. It is the intent of this specification that the Contractor shall install a complete and satisfactory electrical system, whether or not every individual component is specifically set forth in these specifications.

2 DESCRIPTION OF WORK

1.02.1 In this description the term “install” when referring to process equipment shall mean to electrically install all material components related to that equipment including but not limited to conduit, raceway, conductors, instruments and electrical devices and components. In this description the term “remove” when referring to process equipment shall mean to electrically disconnect at equipment and source and remove all conduit, raceway, conductors, instruments, and electrical devices and components. Electrical equipment including panelboards, instrument junction boxes/control cabinets, fiber patch panels, and transformers will be completely installed by the Contractor.

1.02.2 The following is a detailed description of the work to be performed. However, the entire description of the work is defined by this document as well as all other contract documents. This description is not intended to be used as a check-off list for determining completion of the work.

A. RAFFINATE 3700 BOOSTER STATION

Install new instrumentation including new Panelboard, Transformer, and Instrumentation Junction Box. The new transformer feeder shall be tapped from the line side terminals of existing auxiliary power distribution panel. Contractor shall re-use existing cable tray to feed new Instrumentation Junction Box as much as possible.

B. PHASE II RAFFINATE LATERAL CELL DISTRIBUTION

Install new Instrumentation for raffinate lateral cell distribution pipes (17 Wireless Flow/PressureTransmitters, Total of 34 Instruments) including new Instrument Junction Box complete with WirelessHART Gateway, Antenna, Photo-Voltaic (PV) Power Units, and Discrete Input Transmitters (Repeaters).

1.03 MATERIAL AND EQUIPMENT FURNISHED BY OWNER

1.03.1 The Owner will supply the following material and equipment. The Contractor shall unload, inspect, inventory, store, on-site transport, install and test these pieces of equipment and materials.

A. Instrumentation and WirelessHART Gateways.

B. Photovoltaic (PV) Units including solar cells, inverter, and rectifier.

1.04 MATERIAL AND EQUIPMENT FURNISHED AND INSTALLED BY CONTRACTOR

1.04.1 All material and equipment shall be furnished by the Contractor required for a complete installation unless specifically indicated otherwise. The Contractor shall unload, inspect, inventory, store, on-site transport, install and test these pieces of equipment and materials. The scope of Contractor’s supply includes, but is not limited to, the following:

A. All wire and cable for power, control, instrumentation, networks, grounding and lightning protection. All cables supplied for exterior installations should be interlocked aluminum armored unless otherwise specified.

B. Fusible Safety Disconnects Switches including engraved nameplates.

C. Conduit, fittings, hangers, wireways, ducts.

D. Pull boxes, terminal boxes, and instrument junction boxes as defined in dwg. 110707-E-201 and 110707-E-202.

E. Fiber-optic patch panels, and static wire/fiber junction boxes.

F. Grounding and lightning protection materials.

G. Panelboards and transformers.

H. Instrumentation mounting hardware and tubing.

I. Material necessary for modifying Owner's existing equipment where required.

5 CODES AND STANDARDS

1.05.1 All applicable provisions of the latest revisions of the following codes and standards shall be considered integral to these specifications.

A. National Electric Code (NEC, NFPA 70).

B. Mine Safety and Health Administration (MSHA) Regulations (30 CFR).

C. National Electric Safety Code (ANSI C2)

D. Occupational Safety and Health Administration (OSHA) Regulations.

E. Applicable local codes.

1.05.2 The Contractor is responsible for enforcing these codes and standards during construction as well as in the completed product.

6 GENERAL INSTALLATION

1.06.1 In general, the equipment and installation shall conform to non-hazardous, dust laden air conditions and shall be minimum NEMA Type 12 dust-proof for filtered or air-conditioned space use, and NEMA Type 4 watertight for use elsewhere, unless otherwise noted.

7 EQUIPMENT AND MATERIAL

1.07.1 All electrical equipment and devices furnished by the Contractor shall bear the Underwriter's Laboratory label.

8 VOLTAGE/SIGNAL CLASSIFICATIONS

1.08.1 Plant Primary Distribution: 13,800/4,160V, 3 phase, 3 wire, 60 HZ, resistance ground.

1.08.2 Plant Secondary Distribution: 480V, 3 phase, 3 wire, 60 Hz, solid ground.

1.08.4 Control: 120V, 1 phase, 60 Hz.

1.08.5 Instrumentation: 4-20 mA,

1.08.6 WirelessHART Instrumentation/Devices: 24VDC

1.09 ELECTRICAL CLEARANCES

1.09.1 Electrical clearances at all voltage classes shall be in accordance with the requirements of the National Electrical Code, National Electrical Safety Code and IEEE Standards.

EQUIPMENT AND COMPONENTS

1 GENERAL POWER AND CONTROL ITEMS

2.01.1 Control stations shall be NEMA 4 oil-tight, heavy-duty with base mounted contact blocks. The type of operator contact arrangement and indicating light color, if any, shall be as indicated in the construction documents.

2. All fusible or non-fusible disconnect switches shall be heavy duty, three-pole, 600 volt, lockable in the open position, quick-make, quick-break operating mechanism with control interlock contact. The disconnect switch enclosure shall be in accordance with the General Installation requirements. Fuses, if applicable, shall have at least 100,000 amperes RMS symmetrical interrupting current.

3. All disconnects, transfer switches, and other equipment enclosures shall include engraved plastic nameplates (black letters on white background):

A. First line---Equipment Number

B. Second line--Equipment Description

C. Third line---Control Function (control stations)

D. Third line---Do not open under load (disconnects)

2 PANELBOARDS

2.02.1 Panelboards shall consist of automatic short circuit and overcurrent protective devices of the circuit breaker type, assembled into a single interior unit which shall be mounted into a sheet steel enclosure, consisting of a box and front design to be placed against a wall or partition.

2.02.2 Panelboards shall be of the dead-front type and shall be in accordance with the Underwriter's Laboratories, Inc. standards for panelboards and enclosing cabinets and shall be so labeled.

2.02.3 Panelboards shall be provided with a main circuit breaker and shall be sized in accordance with the National Electrical Code.

2.02.4 Panelboards short circuit rating shall be 10,000 amps interrupting.

2.02.5 A typewritten circuit directory shall be provided on the inside of the door by the Contractor upon completion of start-up. A handwritten directory is acceptable for the construction stage.

2.02.6 Panelboards shall be separate from motor control centers.

2.02.7 Cabinets shall be of code gauge steel with ample wiring gutters for all wires and connections. Doors shall be the single type with spring latches with locks all keyed alike and two keys provided for each panel.

2.02.8 Enclosures for panelboards located outside electrical rooms shall be NEMA 4/4X.

9. Doors shall have formed edges on four sides and shall be provided with neoprene gaskets.

2.02.10 Enclosures shall have a phosphate treatment, a zinc chromate prime coat and a finish of baked blue-gray enamel.

2.02.11 Circuit breakers rated for 600 volts and less AC, 60 Hz, shall have trip free, quick make, quick break mechanism, meet NEMA and UL specifications and have ampere trip rating, number of poles and short circuit interrupting capacity as required. Breakers shall be bolted-in type with a common trip for two and three pole breakers.

3 CONTROL POWER TRANSFORMERS

2.03.1 Control power transformers shall be:

A. Dry type with embedding compound.

B. Outdoor type

C. Class 80°C rise with Class 220 insulation.

D. Copper windings.

E. Primary taps of 2, 2½% FCAN and FCBN, or 2, 2½% FCAN and 4, 2½% FCBN.

4 GENERAL INSTALLATION REQUIREMENTS

1 HANGERS, ANCHORS, GUIDES AND SUPPORTS

3.01.1 All supports and braces shall be furnished and installed by the Contractor for the proper installation of cables, conduits, panels, control centers, transformers, switchgear, raceways, etc.

3.01.2 All conduit, raceways and boxes, lighting and power panels, cabinets, etc., shall be furnished and hung, guided and anchored with structural channels such as Unistrut or approved equal so as to maintain required locations and elevations, to be secure and reasonably rigid even where vibrations will be present.

3.01.3 Conduit, cable trays, cable accessories, brackets, supports, and hangers installed by the Contractor shall be installed without causing a stumbling hazard, headroom limitation, or obstacle to clear passage.

3.01.4 All steel supports and braces shall be galvanized.

3.01.5 Masonry anchors shall be rustproof, UL listed, machine bolt type. They shall be sized to safely carry the load and not vibrate loose.

3.01.6 Hollow wall anchors shall be of the toggle bolt type with spring action wings, plated steel, and mushroom head. They shall be sized to fit the hole of the piece of equipment it is to fasten.

3.01.7 Blind fasteners of the screw type shall be used on sheet metal.

3.01.8 Beam clamps shall be plated malleable iron and of proper design to hold firmly to beam under vibration. The clamps shall be designed specifically for the application, such as holding conduits either horizontal, vertical, or parallel to the beam, holding hanger rods, channel, etc.

3.01.9 Hangers shall be hot-dipped galvanized, zinc electroplate, or electroplate steel. Hangers shall be fastened, clamped, etc., by nut and bolt, threaded rod and nuts and shall not be fastened by spring clips. Channel type hangers shall be manufactured to fit the channels and do not necessarily require threaded type fasteners to hold to the channels. All hardware used with the hangers shall have some form of plating for corrosion protection. Hangers shall be properly selected for the installation as to designed shape, proper support, safe loading, etc.

3.01.10 One-hole straps shall be malleable iron with a hot-dipped galvanized finish. These straps shall not be used to hold conduit whose diameter is 1-1/2" or larger.

3.01.11 Two-hole straps shall be heavy gauge steel with a hot-dipped galvanized finish. These straps shall be used to hold conduit whose diameter is not over 4".

3.01.12 Conduit larger than 4" shall be supported by a channel and hanger system. Each support shall be secured with a minimum of two bolts or screws of sufficient size to support conduit and wire safely.

3.01.13 Cable straps shall be malleable iron with hot-dipped galvanized finish. They shall be one-hole and shaped to hold the cable snug.

2 PULL, JUNCTION AND TERMINAL BOXES

3.02.1 All pull, junction, and terminal boxes shall be furnished and installed by the Contractor as required. Boxes shall be sized in accordance with the NEC and local codes. Where these boxes drain conduits, drain plugs shall be installed in the bottom of the boxes and breathers installed on top. Minimum size of pull and junction boxes shall by 6" x 6" x 6" and minimum size of terminal boxes shall be 10" x 8" x 6".

3.02.2 Conduit fittings, pulling sleeves, expansion fittings, etc., shall be provided by the Contractor wherever necessary to facilitate the installation of wire and cable.

3.02.3 Pull boxes shall be provided by Contractor on all vertical runs over 50 feet in length. Whenever possible, pull boxes in vertical conduit runs shall be located within reach from walkways or floors.

3.02.4 Pull and junction boxes shall be fabricated from code gauge sheet steel with continuous welds at all corners and seams and hot-dipped galvanized after fabrication. Gasketed screw covers shall be provided on all boxes. No knockouts shall be provided.

3.02.5 Terminal boxes shall have continuous welds at all corners and seams, and hinged gasketed doors. Terminal boxes shall be hot dipped galvanized and without knockouts. Terminal boxes shall contain terminal blocks properly labeled with wire number designations and shall accommodate all terminations within the box. Wire terminating at terminal blocks shall carry the same designation as the terminal blocks.

3.02.6 Terminal blocks shall be Weidmuller copper-nickel alloy terminals. Terminal blocks shall be 0.24 inches (6mm), single level, din rail mounted design.

3.02.7 All boxes installed inside filtered or air-conditioned rooms shall be NEMA 12, while other boxes shall be NEMA 4. There shall be no knockouts in the boxes.

3.02.8 All connections of conduit to boxes in wet or dusty areas shall be watertight threaded-hub type.

3.02.9 Boxes shall be mounted and supported separate from the conduit runs entering them and all boxes shall be spaced out from walls and ceilings and not attached directly to the wall.

3 CONDUIT

3.03.1 Conduits shall be rigid steel hot dipped galvanized delivered to the job site in not less than 10 foot lengths and be listed by the Underwriter's Laboratory, unless otherwise specified.

3.03.2 Exposed conduits shall be installed parallel with or at right angles to adjacent walls or building columns. When conduits are run on walls or ceiling, they shall be spaced out and installed with galvanized structural channels such as Unistrut and not mounted directly on the wall or ceiling surfaces.

3.03.3 Exposed conduit runs shall be located such that straight runs will be achieved in either vertical or horizontal direction avoiding, wherever possible, the use of offsets.

3.03.4 Conduits shall not be installed near heat sources such as the clinker cooler or process ductwork except where required to make final connections. In no case shall a conduit run within 3" of process ductwork, steam or hot water pipes.

3.03.5 Conduits shall not be installed in a material flow area or in an area likely damaged by moving equipment (i.e., directly under a belt conveyor).

3.03.6 Conduit shall not be supported from equipment.

3.03.7 The ends of all conduits shall be cut square and reamed, and all joints shall be brought butt to butt in standard threaded couplings. Exposed threads shall be treated with anti-corrosion spray.

3.03.8 Supports of conduit shall be per NEC requirements. Where bends are present in the conduit run, each side of the bend shall be supported. Where conduit is run into a pull box, junction box, etc., there shall be a support on the conduit not more than 3'-0" from the box.

3.03.9 Conduit expansion fittings with bonding jumpers shall be provided on straight runs of exposed conduit every 100 feet and also wherever conduits cross building expansion joints or between silos or tanks.

3.03.10 No conduit smaller than ¾" trade size shall be used unless specifically indicated.

3.03.11 All conduits shall be thoroughly dry and free of foreign material when wire is installed. Conduit ends shall be capped to prevent the entrance of debris, until wires are ready to be pulled.

3.03.12 Liquid-tight conduits shall be used on equipment subject to vibration or where necessary to accommodate adjustable drives, or for convenience in maintaining motors, limit switches, pressure switches, etc. For all installations, liquid-tight flexible conduit with ground and with proper connectors shall be used. The liquid tight flexible conduit shall have a synthetic jacket, gray in color, extruded over the galvanized steel core to make a moisture and oil proof conduit.

3.03.13 Low voltage signal circuits (less than 120VAC) shall be installed in separate conduit (i.e., the conduit shall contain only low voltage signal circuits).

3.03.14 Control circuits shall be installed in conduits separate from low voltage power and motor feeds.

3.03.15 The Contractor shall install power circuits to each motor in separate conduit to avoid de-rating the ampacity of circuits as a result of grouping circuits in the same conduit and for better isolation, fire damage limitation, etc., unless specifically noted otherwise.

3.03.16 The Contractor may mix different voltage level lighting circuits (120, 208, 277 and 480 VAC) in the same conduit, according to NEC.

3.03.17 Medium voltage circuits shall be installed in separate conduits from low voltage circuits.

3.03.18 All conduit bushings shall be metal and of the type that have a plastic sleeve insert.

3.03.19 All conduit bends shall be per NEC required radius. The quantity of bends in any conduit run shall be limited to NEC and local code requirements.

3.03.20 Expansion joints installed within a run shall be one size larger than required by NEC regulations.

3.03.21 Conduits shall be installed in a manner that avoids moisture accumulation. Where conduits cannot be sloped down to either pull, junction, or terminal boxes, drain fittings shall be installed at the low points.

3.03.22 Conduits in areas designated as hazardous by NEC or local codes shall be sealed and installed in accordance with these codes.

3.03.23 Conduit terminating in trays and channels shall be electrically and mechanically tied to the trays and channels by appropriate fittings.

3.03.24 There shall be no openings in the conduit runs. Any unused openings shall be plugged.

3.03.25 All fittings with covers shall have gaskets and be screwed down securely.

3.03.26 All conduit fittings, supports, and connections shall be completed in a conduit run before wire is installed in the conduit.

3.03.27 All field work on conduit installation will be touched up with zinc paint.

3.03.28 Galvanized joints will be made up with a metal-oxide paint on threads of the joint.

4 CONDUIT FITTNGS

3.04.1 Changes in direction of exposed conduit runs may be made with ferrous-alloy threaded hub fittings of a type approved by the NEC. Conduit fittings shall be installed complete with cover gaskets.

3.04.2 No conduit fittings less than 3/4" trade size shall be used except for instruments where 1/2” is allowable.

3.04.3 Conduit connections to outdoor enclosures and to NEMA 4 boxes, terminal boxes and equipment shall be with Scru-Tite zinc hubs as manufactured by the Myers Electric Products Company, or Owner approved equal.

3.04.4 Conduit connections to NEMA 1 and 12 enclosures indoors shall be made with two lock nuts and bushings. Insulated bushings shall be used on all conduit terminations.

5. Conduit fittings shall not be used to change direction for cables rated over 600 volt and/or for cables larger than #4/0 AWG. In no case shall cable be pulled around these fittings.

6. Any unused openings in conduit bodies shall be sealed with threaded metal plugs.

3.05 CABLE TRAYS

3.05.1 No new cable tray installation is foreseen. Contractor shall re-use Existing.

3.06 WIREWAYS

3.06.1 Wireways shall be furnished and installed complete with necessary complement of fittings, connectors and accessory parts. Wireways shall be used by the Contractor as required for ease of installation and maintenance of control and instrument devices. They shall also be installed to minimize a congestion of conduit fittings.

3.06.2 Wireways shall be of the "lay-in" type without standard knockouts and with screw covers for full channel access. All sheet metal parts shall be coated with rust inhibitor and finished in baked enamel. All screws shall be captive. Hold-down clamps shall be captive and sufficient in quantity to provide a tight seal. All exterior hardware (such as clamps, clamp screws, hinge pins, etc.) shall be stainless steel or plated to prevent corrosion. The wireways shall conform to the NEC. All seams shall be continuously welded and there shall be no holes or knockouts. All sections and fittings shall have smooth, rounded edges to prevent damage to insulation. Hinged covers shall not be removable. The wireway shall be UL listed.

3.06.3 Wireways and fittings shall be general purpose type, as manufactured by Square D or Owner approved equal and NEMA 12 for filtered or air-conditioned rooms and NEMA 4 for other areas.

3.06.4 Wireways shall be securely supported by approved methods at 5 feet intervals. Number of conductors per wireway shall conform to the NEC requirements.

3.06.5 All wireways shall be marked with its identification number with a permanent legible marker.

3.06.6 Wiring duct shall be made of a fire retardant plastic and UL listed. The openings for the wires shall be so constructed that the wires will not come out of the slots; that is, the top of the slot will be restricted but capable of inserting the wires by pushing side wall next to slot. The cover shall be the snap-on type; no screws or bolts shall hold it on. The wiring duct shall not be secured by adhesive, but by nylon rivets, screws, or bolts. There shall not be any sharp metal within the duct.

7. Wiring duct shall be used only inside boxes and cabinets.

8 UNDERGROUND CABLE/CONDUIT/DUCT AND MANHOLES

1. Conduit runs under floors shall be at least 8” below floor level.

2. Conduit coming through floors shall have appropriate type pipe sleeves that extend 2" above the finished floor.

3. In unpaved areas, underground conduit risers shall have at least 4" of concrete encasement extending it 6" above finish grade.

4. Underground runs shall be run true to line and grade and supported by spacers not more than 5'-0" apart. All duct lengths shall be staggered so joints do not fall in line with other joints in the same duct bank.

5. Conduit shall be sloped not less than 1" per hundred feet length to provide proper drainage. The bracing shall allow no low points or pockets in the run that would accumulate moisture.

6. At least 2" clearance shall be around each conduit in the bank to permit concrete to be worked in. At least 3" of concrete shall envelop the outside boundary of the duct bank.

7. All bends and couplings shall be of the same manufacturer as the conduit or duct.

8. A minimum of 3'-0" of earth shall cover the duct bank.

9. All joints in duct runs shall be watertight and made per manufacturer's instruction.

10. Routing between manholes shall be straight with no horizontal bends if possible. Standard factory bends shall be used unless design drawings indicate otherwise.

11. All duct runs, joints, and supports shall be inspected and approved by the Owner before concrete encasement.

12. Ducts approaching a manhole shall be fanned out to enter the manhole for ease in protecting and routing cables in manhole.

13. Ducts shall be cleaned before any cable is pulled into a duct. All ducts shall be capped until cables are ready to be pulled. Spare conduits shall be capped. If spares are stubbed up and outdoors, exposed to the weather, a pipe type conduit cap shall be used.

14. Duct risers on short runs shall be galvanized steel of the same size as the duct, with the largest practical radius. Connection shall be made with an adapter coupling. Stub-ups shall be provided with insulated grounded bushings and grounding bond.

15. Excavation for all cable, conduit, duct banks, bare grounding copper cable, and connections buried directly in the earth shall be large enough to permit ease of work and to accommodate concrete encasement where applicable. Back-filling material shall be clay and sand, wetted and tamped in layers.

16. Underground wire and cable, unless otherwise specified or shown on the drawings, shall be run in UL listed Class II, Schedule 40, PVC adhesive joined, filament wound fiberglass reinforced epoxy conduit encased in a reinforced concrete envelope (duct bank). The bottom of the concrete envelope shall be below the frost line. The duct bank concrete shall be 3000 psi mix. Encased conduit shall be arranged in tiers as noted on the duct bank cross sectional details.

17. Where concrete duct bank crosses beneath roadways, rock storage areas, soft fill utility mains, or as noted on the drawings, it shall be reinforced with #5 or larger steel reinforcing rods in each corner of the duct bank. Reinforcing shall extend 3 feet beyond area requiring additional protection.

18. Top of duct banks shall be colored red. A 12" wide mylar metal coated detectable tape printed with "Caution: Buried Electrical" shall be buried minimum of 4 inches below the grade and centered above underground duct banks.

19. Conduit terminations at manholes and building walls shall be with end-bells suitable for the type of duct installed.

20. All ducts shall be swabbed clean before cable installation. Spare ducts shall be plugged at both ends. Conduits shall be provided with a watertight seal after cable installation.

21. Spare conduits shall be installed with a plastic pull line secured at both ends.

22. Manholes shall be of the size and type required per good practice. Cables shall be trained in manholes and supported on racks and porcelain blocks. The Contractor shall furnish and install all inserts, racks, and supports necessary. Maximum cable support spacing shall be three (3) feet.

23. Contractor shall install piping as required to direct manhole sump pump discharge away from manholes and plant site.

24. Manholes shall have a recessed pocket in the bottom for portable sump pumps.

25. Prefabricated manholes and hand holes shall be installed per the manufacturer’s instruction.

9 WIRE AND CABLE MATERIALS

26. The terms “wire” and “cable” are used interchangeably.

27. Each coil of wire shall bear Underwriter’s Laboratories approval stamp, the name of the manufacturer, trade name and size of the wire.

28. All wire and cable shall be stranded.

29. Maximum DC resistance of all wires shall not exceed ICEA and NEC maximums.

30. Minimum control wire size is #14 AWG.

Minimum instrument wire size is #16, #18 AWG.

3.08.6 600 Volt Cables

3.08.6.1 Multi-conductor Power Cable (Transformer Feed)

a. Type MC Armored, XLP insulated XHHW-2 Conductors and bare copper grounding conductor.

b. Maximum conductor temperature 90°C.

c. An assembly of 3 600 volt power conductors and 1 bare ground conductor covered with PVC outer jacket.

d. Fillers - flame-retardant or noncombustible.

e. Overall jacket - flame-retardant sunlight resistant neoprene, Hypalon, polyvinyl chloride.

3.08.6.2 Single Conductor Control Cables.

a. Type THHN/THWN (thermoplastic polyvinyl chloride) Conductor - stranded copper.

b. Maximum conductor temperature 90°C.

c. Minimum sizes - #12 AWG for power - #14 AWG for control.

3.08.6.3 Multi-conductor Control Cable (Sizes #12 AWG and Smaller) non-jacketed.

a. Type MC Armored, XLP insulated XHHW-2 Conductors and bare copper grounding conductor.

b. Maximum conductor temperature 90°C.

c. PVC outer jacket.

d. Fillers - flame-retardant or noncombustible.

e. Overall jacket - flame-retardant sunlight resistant neoprene, Hypalon, polyvinyl chloride.

3.08.6.4 Instrumentation Single Pair.

a. Two insulated, twisted conductors.

b. 16 gauge, stranded, tinned copper with 2 inch twist of lay.

c. Insulation-thermosetting cross-linked polyethylene. Maximum conductor temperature - 90°C. 600 volts, color-coded white and black for single pair and black, white and red for triads.

d. Shielding - aluminum bonded to Mylar tape and formed for 100% coverage.

e. Drain wire - 18 gauge, stranded, tinned copper.

f. Overall jacket - black flame-retardant polyvinyl chloride.

g. Type – MC Armored.

3.08.7 Network Cables

3.08.7.1 Fiber Optic Cable

a. Steel Armored suitable for Lashed Aerial installation

b. 6 Fiber Bundles

c. BELDEN B9C172 or similar

3.08.7.2 RG-6/U Coaxial Cable

a. Aluminum Armored

d. Suitable for Mining and Industrial Operations

3.06.8 15 kV Cables

3.08.8.1 Multi-conductor Power Cable

a. Type MV-105 3/C 500 KCMIL

b. SOUTHWIRE TYPE C3T-13ET-500 or similar.

3.08.8.2 ACSR

a. 477 KCMIL (HEN)

b. Aluminum Alloy

c. Concentrically Stranded

b. SOUTHWIRE or similar.

3.08.8.3 OPGW

a. Aluminum Alloy

b. Concentrically Stranded

c. Central Aluminum Pipe (Fiber Tube)

c. 12 Fibers Minimum

b. AFL AlumaCore OPGW Size AC-57/465 or similar.

3.09 WIRE AND CABLE INSTALLATION

3.09.1 Raceways shall be installed complete before wires are installed.

3.09.2 When installing insulated wire and cable, the Contractor shall exercise maximum care to prevent the wire from coming in contact with substances injurious to the insulation and to prevent the wire being kinked, twisted or abraded in any manner.

3.09.3 The Contractor shall furnish and use appropriate pull-in compound for ease of pulling of insulated wire or cable in conduit.

3.09.4 Wire and cable in raceways and equipment shall be neatly trained and harnessed to avoid all unnecessary crossing.

3.09.5 Control cable and wire entering equipment or terminal boxes shall be securely fanned out in a neat arrangement and served into position for connection.

3.09.6 The Contractor shall not scale or use dimensions on drawings, or not take approximate lengths on cable charts as his cutting data. Actual lengths of cable run shall be determined by field measurements.

3.09.7 Where single conductors are installed in cable tray, they shall be securely bound in circuit groups to prevent excessive movement due to fault current magnetic forces.

3.09.8 The Contractor shall inspect samples of each type of wire he supplies before pulling the wire to minimize defective wire installation.

3.09.9 The Contractor shall remove and replace and reinstall all damaged wire as a result of installation or manufacturer defect at no cost to the Owner.

3.09.10 Cables on trays shall be tied to the cable trays every 3'-0" to enable cables to lie flat and stay spaced evenly.

3.09.11 Power cables in cable trays shall not be more than one layer deep. Power and control cables shall run in separate trays or with a suitable metal barrier.

3.09.12 All cable runs in trays shall follow NEC or local codes in respect to physical loading (cable fill) and ampacity values.

13. Cables in vertical runs shall be supported by basket-weave style cable grips at the top of the run and at intermediary points as required by maximum cable tension, not to exceed 50’-0” for cables 500 kcmil and smaller and 40’-0” for all other cables.

3.09.14 Armored, mining and other cables not installed in raceway or tray shall be supported every 6’-0” by the cable manufacturer’s recommended cable clamp, or laid on the ground next to raffinate distribution piping.

3.09.15 Fiber Optic Installation

A. Lead installer for fiber optic cable shall be experienced in fiber optic installation. Owner reserves the right to approve lead installer.

B. All manufacturer’s installation instructions shall be strictly observed, including but not limited to maximum bending radius, maximum pulling tension, and installed tension.

C. Avoid putting twist in cable.

D. Pull on fiber strength members only. Do not pull on fibers.

3.10 TAPS, SPLICES AND TERMINATIONS

3.10.1 Materials supplied by the Contractor include splice kits, lugs, terminals, terminal blocks, insulating media, tools, etc., required for the complete working installation.

3.10.2 Cables shall not be spliced except where directed in writing by the Owner. No splice shall be pulled into a conduit or placed in an inaccessible place. Splicing in the manholes is prohibited.

3.10.3 Ring tongue compression and wrench type lugs, Burndy or approved equal, shall be used on power cable terminations. Connectors and lugs shall be sufficiently large to enclose all strands of the conductor, shall be securely fastened and shall not loosen under vibration or normal strain. Cable ends and lugs shall be cleaned and covered with oxide protection before lugs are applied. Termination shall be clean and shall make good electrical contact.

3.10.4 Control and instrument cable shall be supported at the entrance points and shall be terminated on Owner approved solderless compression type terminal boards, rated 600V. Control cables, where separated and distributed to and along terminal blocks, shall be corded or cabled together, or routed in plastic wiring ducts. Conductors shall be arranged to avoid unnecessary crosses. Control cables shall be adequately supported where necessary.

3.10.5 All 600V and less power cable ends and lugs or connectors such as motor leads, etc., shall be filled, wrapped and taped in accordance with manufacturer's instruction.

3.10.6 The Contractor shall terminate all wire installed for this project.

3.10.11 Fiber Option Installation

A. All fiber optic terminations shall utilize ST type connectors with ceramic connector tips.

B. Only fusion splicing shall be used. All splice shall be approved by Owner prior to installation. Contractor shall not plan on splicing cable.

C. Clean all terminations after cable installation with lint free cleaner.

D. All fiber optic terminations shall be adhesive ST connections or shall consist of factory preterminated fiberoptic pigtails fusion welded onto the main fiber trunk.

3.11 WIRE DESIGNATION

3.11.1 All power, control and instrumentation wires and cables shall be tagged at each end, in all terminal boxes, and all intermediate points including pull boxes with wire number identification shown on the wiring diagrams and control schematics.

3.11.2 Where existing conduits containing existing circuits are being extended, the wire shall be tagged in accordance with the wiring diagrams and control schematics. All old tags shall be removed.

3.11.3 All tags shall be Brady, Bradysleeve B-320 PVC vinyl printed on Bradymarker XC Plus Printer; or approved equal.

3.11.4 All spare wires shall be tagged at each end and tapped with wire numbers as shown on the wiring diagrams.

3.11.5 All wire identification shall be verified at both ends by a "sound powered phone" or other industry acceptable testing method that positively identifies both end of each conductor.

3.11.6 Cable shall be identified by color as follows:

A. 3 phase power

1. Phase A – brown.

2. Phase B – yellow.

3. Phase C – orange.

B. Single phase power and control

1. Line (120V) – black.

2. Line (other) – red.

3. Neutral – white.

4. Other – red.

C. DC power – blue.

D. Ground – green, with yellow strip.

3.11.7 Phase color designations for wire larger than #12 AWG shall be made by tape at both conductor ends. All others shall be made by the insulation color of the wire.

5 SPECIAL INSTALLATION REQUIREMENTS

1 INSTRUMENTATION

4.01.1 Contractor shall install instruments according to the Instrumentation List, Instrument Mounting Details, Engineer's and Vendor's drawings.

2. Contractor shall provide and install mounting bases and brackets for all instruments as shown on the Drawings, unless otherwise noted.

4.01.4 Instrument Tubing

A. All materials shall be as noted on the Instrument Mounting Details. Materials shall meet the following requirements noted as follows:

1. Copper/Brass Pipe and Tubing: E4.25 STD YB1.

2. Copper/Brass/Galv. Pipe and Tubing: E4.25 STD YB2.

3. Type 316 SS Pipe and Tubing System: E4.25 STD YT1.

B. Tubing shall be accessible and protected from mechanical damage. Tubing entering or leaving the supporting channel or tray shall not run over the edge. Avoid routing tubing over or supporting on sharp edges.

C. Copper tubing shall be straightened before installation by stretching. The maximum stretch shall not exceed ¼” per foot. Tubing runs shall be as long as practicable without splicing. Bending tools shall be used to make accurate bends without kinks or visible flattening of the tubing. Tubing shall be cut with a cutting tool to provide a clean square cut. Saw cutting will not be acceptable. Burs shall be removed with a burning tool. Fittings shall be made up in strict accordance with the manufacturer’s recommended procedures.

D. Tubing support members (channels, angles, etc.) shall not be installed so that they become a fluid trough or trap. Tubing supports and tubing shall not be attached to vibrating equipment, or within six inches of hot process lines.

1. Tubing runs over three feet long shall be supported by clips, clamps, straps, etc., at a maximum spacing of three feet. Horizontal runs of tubing installed in channels or trays need not be fastened, but shall be installed with a minimum of criss-crossing or overlapping.

E. Tubing shall be cleaned by blowing out using clean dry air. Instruments shall be disconnected to prevent damage from foreign matter or over pressure.

4.01.5 Instrument Piping

A. All instrument piping shall be 312 stainless steel threaded pipe with 150 psi 304 stainless steel fittings.

B. All instrument piping shall be black, galvanized, Schedule 40 threaded pipe with 150 psi malleable iron fittings.

C. All joints shall be sealed airtight with 400°F, 1000 psi (gas), plumber’s pipe dope.

D. Pipe support members shall match that specified for conduit. Instrument piping shall be supported every 6’-0”.

E. Piping shall be cleaned out using dry, clean air. Instruments shall be disconnected to prevent damage from foreign matter or over pressure.

1 All instrument mounting locations shall be approved by Owner.

2 All instrument cable shields and drain wires shall float and be insulated within field instruments. The shield shall be left around the wires as close to the terminal as possible. The Contractor shall ground all instrument cable shields at the motor control center or control panel.

6. All field instruments shall be identified with a permanent tag which indicates the instrument name and number. The tag must be transferable for instrument changeover.

7. All instrumentation shall be mounted to provide easy access for calibration and maintenance. Instruments shall be mounted in a manner so as to be protected from physical and environmental damage. Instruments shall be protected from vibration.

6 SYSTEM INSTALLATION REQUIREMENTS

1 GROUNDING SYSTEM

1 The grounding system shall obtain a low resistance to earth not to exceed 5 ohms or as required to meet OSHA, MSHA and/or local and state codes.

5.02.2 All metallic non-current carrying parts of equipment that is likely to become energized under abnormal operating conditions shall be grounded with an equipment grounding conductor wire. A general list of equipment requiring grounding is as follows:

A. PV Units

B. Panelboards

C. Transformers

D. Control panels

E. Light fixtures and receptacles

F. Controllers and cabinets

G. Disconnects

H. Field controls

3. Equipment grounding conductor shall be stranded copper sized per NEC. Circuits feeding the previously listed equipment shall have the grounding conductor pulled with the phase wires in the raceway. The Contractor shall provide a ground hub in the motor conduit box.

4. A supplemental equipment grounding conductors shall consist of raceways, cable tray, and cable armor (sheath). Connections, joints, fittings and bonding jumpers shall be tight and insure minimum electrical resistance. This type of equipment grounding conductor shall supplement the grounding conductor described previously.

5. Metallic conduits 3" and larger which terminate at sheet metal enclosures of electrical equipment shall be bonded to the rigid frame or ground bus by a branch grounding conductor connected to insulated conduit grounding bussing (similar to O.Z./Gedney type "BL").

6. Where metallic conduits terminate in electrical equipment such as switchgear, motor control centers, etc. that are not in contact with the metallic equipment enclosures (as in underground conduits), they shall be bonded together, using insulated grounding bushings and to the equipment ground bus or main grounding conductor.

7. Where flexible conduit is required at electrical equipment, an approved flexible conduit and fittings shall be used, or a bonding jumper with approved connectors shall be installed to insure an effective electrical bond between equipment and raceway. If a bonding jumper is used, it shall be stranded wire, sized in accordance with the NEC.

8. A main grounding grid shall encircle the buildings for various plant areas with radial connections between ground rings to tie all the ground grids together. Radial connections shall be accomplished with the use of ground wire in duct banks, cable tray, and directly buried.

A. Direct buried ground wires shall be #4/0 AWG wire buried 2’-0” below the surface.

B. Cable tray ground and conductor shall be installed in the cable tray with connections to each section and fitting of the tray. It shall be connected to the ground bus of the service equipment (switchgear or MCC) and shall provide convenient connection points throughout the tray system.

C. Underground duct banks shall have the grounding system adequately extended throughout this system. A #4/0 AWG main ground cable shall be installed in the center of the concrete duct bank envelope and connected to various grounding grid systems throughout the plant.

D. Manholes which are part of an electrical underground distribution system, shall have a #4/0 AWG bare copper ground loop installed within the manhole and connected to the main ground conductor of the duct bank which serves the underground distribution system and to a ground electrode located at the manhole. Bonded to this manhole ground loop shall be all metallic conduits, supporting frames or racks, cable sheaths, and other objects which if energized accidentally may be a hazard to personnel.

E. Where operating voltage exceeds 600V, the non-current carrying metallic parts of electrical equipment and surge protection equipment, when provided, shall be connected with a #2/0 AWG bare copper wire to the main ground conductor of the grounding grid system.

F. Where down conductors are required for lightning protection, they shall be connected to the grounding grid system with #2/0 AWG bare, stranded, soft drawn copper wire.

G. When cable tray is utilized as a main raceway, with branches in metallic conduit, a main common ground conductor shall be installed with a bonding connection to each section of the cable tray and parallel gutter branch taps run to, and within the branch conduits to the utilization equipment. This main common ground conductor shall be connected to the ground bus of the source equipment (switchgear, MCC, etc.)

H. All electrical equipment including motor control centers, drives, switchgear, switchboards, distribution panels and transformers larger than 75kVA shall be connected to the grounding electrode system in 2 places via #2/0 AWG copper conduits.

9. Material for grounding shall be the following:

A. Main ground grid conductors: #4/0 AWG 7-strand bare soft drawn copper wires.

B. Other ground grid conductors: #2/0 stranded, bare soft drawn copper wires.

C. Equipment grounding conductors: bare or insulated copper wires sized per NEC.

D. Ground bus: ¼" x 2" copper bar.

E. Ground rods: ¾” diameter x 10’ long copper rod.

F. Connection by exothermal welding process. Solderless bolted connection shall be used for ground busses and equipment grounding conductors.

G. Flexible conduit bonding jumpers - copper strap.

H. Ground clamps for use on copper tubing, copper, brass, or lead pipe shall be made of high copper bronze. They shall be so designed as not to collapse the copper tubing. The screw or bolt shall be captive.

I. Ground clamps for use on galvanized or iron pipe shall be hot dipped malleable iron with captive screw or bolt

2 LIGHTNING PROTECTION SYSTEM

1. Lightning protection facilities shall use air terminals (lightning rods) and positive and permanent connections to the ground grid system or electrodes, to divert the lightning current path to ground through circuits of adequately low electrical resistance. The National Fire Protection Association Code No. 780 (latest edition) on lightning protection shall be used for the installation.

2. Protection shall consist of 24” long air terminals on the high points of buildings connected by suitable down conductors to the network ground grid system. Air terminals shall consist of pointed copper or copper-clad steel rods spaced not more than 25'-0" apart and mounted on the highest ridges, edges of flat roofs, or any part of the structure projecting above the roof line. On large flat roofs, air terminals that are equivalent to intersection points of lines dividing the area into rectangles should not exceed 50'-0" in spacing.

3. Air terminals shall be connected with #2/0 AWG stranded copper cable using compression connectors. These cables shall be run as short and straight as possible with cross building connections (forming a grid) to down conductors.

4. Down conductors shall be #4/0 AWG stranded copper cable and shall connect the air terminals to the grounding electrode or grid system. There shall be one down conductor for each 100'-0" of periphery but not less than a total of two. When only two down conductors are used, they shall be at opposite ends or diagonals of the building.

5. All conductors shall be securely fastened to the building. The fastenings shall be copper-clad. Each down lightning conductor shall connect to the grounding grid system.

6. Metal stacks, water towers, tanks, and dust collectors either separate or on a building need not be provided with air terminals, but shall be permanently bonded at the base with not less than two diametrically opposite ground connections to ground electrodes and/or grounding grid system.

7. Brick, concrete, or hollow tile stacks and silos shall have lightning protection consisting of air terminals and connecting down conductors. For stacks, the air terminals shall be spaced not more than 8'-0" apart around the periphery of the top of the stack and extended not less than 30" above the rim. These shall be bonded to the down conductor by a cable loop at the top. Not less than two diametrically opposite down conductors of #4/0 AWG minimum stranded copper wire shall be used. For silos, the air terminals and down conductors shall be installed as described previously for wooden frame or brick structures. In addition, any metallic projections, such as steel frame sheds, dust collectors, lighting fixture stanchions, etc., which extend above the cone of protection of the silo air terminals, shall be effectively bonded to the down conductor.

8. Fence Grounding - All metal or wire fences shall be grounded. These fences shall be grounded on both sides of each gate and at each electric line crossing and in substation areas. Non-climbable (chain link, etc.) wire fences enclosing operating areas, unless mounted on steel posts having an acceptable measured low ground resistance, or shielded throughout their length by a high structure, shall have additional grounds at intervals not exceeding 1,500'-0". A fence shall be considered shielded if it is wholly within a cone having a height equal to the base radius and having as its apex any paralleling electric line which is protected against lightning. Wire fences used only for boundary line marking, unless mounted on steel posts having an acceptable measured low ground resistance, or shielded throughout their length by high structures, shall have additional grounds at intervals not exceeding 2,500'-0". The grounds shall be so spaced as to be near occupied buildings.

6.00 TESTING

1 GENERAL TESTING REQUIREMENTS

1. Prior to equipment energization the Contractor shall be responsible for testing and startup of cable, the ground system, electrical equipment, instrumentation and electrical and control portions of process equipment.

2. The Contractor shall furnish all labor and test equipment necessary for testing and startup.

3. Any errors, defective material or unsatisfactory work supplied or performed by the Contractor as indicated in the testing or inspection of equipment shall be corrected by the Contractor at no charge to the Owner.

4. Contractor shall promptly notify the Owner of any Owner supplied defective material or equipment.

5. Contractor shall report all test and startup results on forms supplied by Owner.

6. Test results shall show values no smaller than those recommended by the NEC, IPCEA, ASA, IEEE, MSHA, and NEMA. All testing for a cable or piece of equipment shall be accepted in writing by the Owner prior to energization.

7. In all cases, equipment and material testing requirements shall be strictly followed. The Contractor shall promptly notify the Owner of any testing discrepancy between these specifications and the manufacturer’s recommendations and await a written response from the Owner prior to proceeding.

2 CABLE TESTING

8. The following cable tests are to be made and recorded and submitted to the Owner:

A. Phase to phase to ground of all power cables and wires.

B. Circuit conductor-to-circuit conductor and from circuit conductor-to-ground of all control, metering and instrumentation wires.

6.02.2 Cable rated greater than 600V shall be tested first with a 500V Megger and secondly with high potential (HI-POT) testing. Testing shall be conducted in accordance with IEEE Standard 400 and NEMA Standards WC-5, WC-7 and WC-8. The step method shall be used to conduct the tests. Megger testing shall be used as follows:

A. 1000 volt Megger for all circuits insulated for more than 300 volts but less than or equal to 600V.

B. 500 volt Megger for all circuits insulated for 300 volts or less.

C. In no case shall instrumentation, solid-state or electronic equipment be tested with a Megger or other high voltage initiating device.

3. All fiber optic cables and terminations shall be tested with an optical power, meter. Attenuation below manufacturer’s specifications shall be deemed defective.

3 GROUND SYSTEM TESTING

1. The Contractor shall perform ground grid tests in accordance with IEEE recommended practices and shall meet MSHA and other applicable code requirements. Rods shall be driven to realize the cluster resistance of 5 ohms or less. These values shall be recorded.

4 ELECTRICAL EQUIPMENT TESTING

6.04.1 The following major electrical equipment shall be subjected to, but not limited to, the following tests, inspection, and measurements;

A. Transformers.

1. Winding insulation resistance, tests, and measurements between primary and secondary and ground, and between primary and secondary windings.

2. Tap changer operation with voltage measurements.

3. Test of resistance from enclosure to ground.

2. Megger testing shall be used as follows:

A. 1000 volt Megger for all equipment insulated for more than 300 volts but less than or equal to 600V.

B. 500 volt Megger for all equipment insulated for 300 volts or less.

C. In no case shall instrumentation, solid-state or electronic equipment be tested with a Megger or other high voltage initiating device.

3. Equipment rated greater than 600V shall be tested first with a 500V Megger and secondly with high potential (HI-POT) testing. Testing shall be conducted in accordance with IEEE Standard 400 and NEMA Standards WC-6, WC-7 and WC-8. The step method shall be used to conduct the test.

4. It shall be the responsibility of the Contractor to verify that all overload heaters for individual starters are the proper size or setting for its respective motor, and to check adjustable trip setting of overload relay block and magnetic only breaker setting in motor starters. If found to be incorrect, the Contractor shall replace said heaters or adjust said settings before equipment energization.

5. All bolted connects to equipment shall be tested with a torque wrench to manufacturer’s recommended values or to UL 486 A or 486B if the manufacturer has no recommendations.

END OF SECTION

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