E - C& I Standards GSR - Rev03

IPRO Industrieprojekt GmbH Client: Star Trading Company Project: Golden Sugar Refinery Project-No.: 7048.
09
E+I Standards Current status: October 14, 2010
0. Electrical / Control & Instrumentation Standardization: Table of contents

Sheet Description
1 2 3 4 5 6 7 8 9 10 11 Electrical standard list Control & Instrumentation standard list Electrical consumer list info Control & Instrumentation Identification list Control & Instrumentation IO - list info Control & Instrumentation Instrument list Specification of electrical motors Specification of frequency converters Color code of wiring in electro distribution boards Cable standards Hazardous areas
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IPRO Industrieprojekt GmbH Client: Star Trading Company Project: Golden Sugar Refinery Project-No.: 7048.09
1. Electrical Standardization List
General High voltage main power distribution board: - Air-insulated - Gas-insulated SF6 Circuit breaker: fix-mounted or truck-mounted Power compensation: power factor cos phi at the medium voltage transfer point (value required by the power supply company) Transformators: Oil transformer or dry transformer (cast iron) Diesel emergency generator Motor protection in the motor distribution boards (MCC) Motor controls: a. Manual by local On/Off switches b. Automatic remote control by the process automation system Disconnection of the main power supply for motor drives: By local 3-pole maintenance switches installed near by the motor drives Motor protection by controlling of the motor winding temperature Motor Control Center (MCC): a. Fix-mounted switch gears or b. In-line plug-in technic or c. withdrawble technic Protection of the motor starters: a. By fuses or b. Fuseless (by motor circuit breakers) Thermal overload protection Internal Protection General degree of protection Motors Frequency converters Transformators Dry transformer Oil transformer Cable ducts (cable tray system) Cable trays Cable ladders Distribution boards/ switch gears Motor starter Arrestor (lightning protection) Power meter for current/ voltage/ cos phi etc. Power compensation Programmable logic computers SPS Main circuit breakers / Disconnectors Circuit breakers for motor protection Automatic cut-outs DC power unit/ 3 phase AC 400V/DC 24V Emergency switch/ basic hardware Terminal strips Motor distribution boards MCCs Switch gears (contactors) Electro panels Fuses Motor DOL direct on line Motor Star-Delta operation Motors 132 kW up to 250 kW with softstarter Thermistor relay for motor temperature control/ Thermal overload protection IPRO-Proposal Air-insulated
For SF6 only fix-mounted cos phi = 0,95
Cast resin (dry) transformer Max. 2.500 kW each at low voltage By an electronic relay/ (e.g.: Siemens Simocode Pro) a. Manual by local On/Off switches and b. Automatic remote control by the process automation system By local 3-pole maintenance switches installed near by the motor drives
Realized by thermistor motor protection c. Withdrawble technic
b. Fuseless (by motor circuit breakers)
If possible: electronic overload protection IP54 IP65 IP54 Brand ABB/ Siemens ABB/ Siemens/ Alstom/ Helmke Brand RICO/ Niedax/ Stago Wibe (sendzimir galvanized) RICO/ Niedax/ Stago Wibe (sendzimir galvanized) Brand Siemens/ ABB/ Moeller Dehn/ Phnix Siemens SIMEAS P/ alternativ: single instruments Siemens/ ABB / Schneider / Moeller Siemens/ ABB / Schneider / Moeller Siemens/ ABB / Schneider / Moeller Siemens/ ABB / Schneider / Moeller Siemens/ ABB / Schneider / Moeller Siemens/ ABB / Schneider / Moeller Siemens/ 3TK 28.. Siemens/ Phnix/ Weidmller/ Wago Siemens/ ABB / Schneider / Moeller Siemens/ ABB / Schneider / Moeller RITTAL Siemens/ ABB / Schneider / Moeller Siemens/ ABB / Schneider Siemens/ ABB / Schneider Siemens/ ABB / Schneider Siemens/ ABB/ Moeller
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1. Electrical Standardization List
Installation materials Switches for lighting Socket outlets 230V/400 V Sockets for explosion proof areas Local Control switch for motor operation: automatic (remote) / manual (local) Illuminats High Pressure Sodium Metal Halide Fluorescent lamp Emergency lighting DC/AC alternator/ centralized batteries Central unit with DC Batteries/ illuminats will be switched from AC to DC/AC alternated voltage Frequency converters Frequency converters Electro motors Electro motors Battery bank Battery bank Brand Siemens/ Jung/ Gira Menneckes/ Gifas Menneckes/ Gifas Siemens Brand Schuch/ Siemens/ Beghelli/ Norka Schuch/ Siemens/ Beghelli/ Norka Schuch/ Siemens/ Beghelli/ Norka Brand CEAG/ Przisa CEAG/ Przisa
Brand Siemens/ ABB/ Schneider / Moeller / Control Technik/ Rockwell Brand Siemens/ ABB/ Schorch Brand Nickel cadmium or Lead Acid types
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2. Control & Instrumentation (C&I) Standardization List
Process-Automation-System All instruments, valves and accessories shall have attached a shipping label showing the instrument tag-number and the purchase order number All instruments, cabinets and terminals, wiring, etc. shall have nameplates, labels or markers showing the Tag- or identification-number Control system based on DCS-System with Fieldbus HMI-Software (Human Machine Interface) Fieldbus Motor protection control device Management Information System and / or Advanced Monitoring System MES-Software (Manufacturing Execution System) Flow measurement Float type flowmeter (glas) Float type flowmeter (metall) Dam flap type flow meter Vane type, cup type flow meter Volumetric flow meter Local pointer type temperature measurement Thermeowell as a set-in nozzle, DIN16179 Thermowells Weld-in protection tube DIN Standard type BS , 1.4571 , for thermometer with fixed screw R1/2" , connection 11 Bimetall pointer-type , R 1/2" thermometer every angle,1.4301, Gas filled case bimetall pointer-type , R 1/2" thermometer every angle , 1.4301 Bimetall pointer-type , R 1/2" thermometer throug long distance line , 1.4301 Local pressure gauge and differential pressure gauge measurement Bourdon tube pressure gauge, G 1/2" , phenolic case, acrylic windows , stainless steel 1.4301 Bourdon tube pressure gauge, G 1/2" , liquid filled case by pulsating service, phenolic case , acrylic window , stainless steel 1.4301 Contact pressure gauge , R 1/2", phenolic case , acrylic window , stainless steel 1.4301 Differential pressure measuring instrument , R 1/2", phenolic case , acrylic windows , stainless steel 1.4301 Diaphragm pressure gauge, G 1/2" IPRO-Proposal / Brand
Siemens PCS7, Emerson DeltaV, Yokogawa Centrum or similar Profibus DP/PA or Fieldbus Foundation Siemens Simocode or similar Siemens/ Emerson AMS SAP/ R3 IPRO-Proposal / Brand Bopp & Reuter / Kobold Bopp & Reuter / Kobold Heinrichs Bopp & Reuter / Kobold Bopp & Reuter / Kobold IPRO-Proposal / Brand WIKA / Labom WIKA / Labom WIKA / Labom WIKA / Labom WIKA / Labom IPRO-Proposal / Brand WIKA / Labom WIKA / Labom WIKA / Labom
WIKA / Labom
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Velocity- and mass flow measurement IPRO-Proposal / Brand Inductive flow meter E&H / Krohne / Rosemount not used Nuclear density meter in screw conveyor and pipes Intra Automation Orifices plates measurement venturis measurement E&H / Rembe Weight rate of flow meter for bulk material E&H / Krohne / Rosemount Vortex shedding flowmeters Bopp & Reuter / Kobold Turbine measurement Bitzer / Rembe / Boekels / Kukla Belt weigh beam system Mass flowmeter with flanges (coriolis type) E&H / Rosemount Micro Motion Level measurement IPRO-Proposal / Brand Flange-type-transmitter (DN 80) with integral indicator Siemens / E&H / Rosemount Siemens / E&H / Rosemount Flange-transmitter (DN 80) with tube and integral indicator DP-transmitter (R 1/2") with integral indicator , through long distance line, flanges DN 80 (flexible Siemens / E&H / Rosemount capillary) Ultrasonic level gauges Siemens / E&H / Rosemount RF capacitance measurement with high frequency probes and integral electronic, covering 316 Siemens / E&H / Rosemount SS or PTFE Electro/mechanical level indicator for bulk materia Siemens / E&H Float type level indicator Krohne Siemens / E&H / Rosemount Level meter with pulsed radar Pressure and differential pressure measurement IPRO-Proposal / Brand DP-transmitter (R 1/2") with integral indicator , throug long distance line, flanges DN 80 (flexible Siemens / E&H / Rosemount capillary) DP-transmitter (flange type DN 80) with integral indicator Siemens / E&H / Rosemount DP-transmitter (miniature diaphragm G 1") with integral indicator Siemens / E&H / Rosemount Absolut pressure transmitter Siemens / E&H / Rosemount Temperature measurement IPRO-Proposal / Brand RTD resistance temperature detector (PT 100) Siemens / E&H / Rosemount RTD resistance temperature detector (PT 100) with integral transmitter (4-20 mA) Siemens / E&H / Rosemount Thermocouple element, Type K Siemens / E&H / Rosemount Thermocouple element, Type R Siemens / E&H / Rosemount
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Density measurement Micro wave density meter Quality mesurement pH-measurement Redox-measurement Conductivity-measurement Flame photometer for boiler feed water Purity measurement Process-refractometer Oxygen-analyzer Carbon-monoxide-analyzer Carbon-dioxide-analyzer Dew point / humidity / moisture measurement Speed measurements Speed counter Speed switch Globe control valves Control valve , single seat , with spring return diaphragm actuator positioner (4-20mA)
IPRO-Proposal / Brand Harrer and Kassen / Berthold IPRO-Proposal / Brand Yokogava / E&H / Knick / Rosemount Yokogava / E&H / Knick / Rosemount Yokogava / E&H / Knick / Rosemount Venema DR. Kernchen / Schmidt & Haensch / Mettler-Toledo DR. Kernchen / Schmidt & Haensch Siemens / E&H / ABB Siemens / E&H / ABB Siemens / E&H / ABB Mtec / Mettler-Toledo IPRO-Proposal / Brand IFM / Pepperl+Fuchs IFM / Pepperl+Fuchs IPRO-Proposal / Brand ARI / Arca / Chemat with Sipart PS 2 PA Positioner Control valve , single seat , with 230V~ electrical multi turn actuator (4-20mA) ARI / Arca / Chemat / Auma Control valve , double seat , with spring return diaphragm actuator positioner (4-20mA) ARI / Arca / Chemat / Crane with Sipart PS 2 PA or PMV D3 Positioner Control valve, double seat, with 230V~ electrical multi turn actuator (4-20mA) ARI / Arca / Chemat / Auma Three-way-valve , with spring return diaphragm actuator positioner (4-20mA) ARI / Arca / Chemat / Crane with Sipart PS 2 PA PMV D3 Positioner Three-way-valve , with 230V~ electrical multi turn actuator (4-20mA) ARI / Arca / Chemat Butterfly control valves and open / close valves IPRO-Proposal / Brand Open/close butterfly valve actuator single-acting , integral 3/2-way solenoid valve, fully open and Crane / Gefa / ARI / Keystone close limit switches from IFM Typ IND Open/close butterfly valve actuator double-acting , integral 5/2-way solenoid valve, fully open and Crane / Gefa / ARI / Keystone close limit switches from IFM Typ IND Open/close butterfly valve, 230V~ electrical actuator, with integral fully open/close limit switches Crane / Gefa / ARI / Keystone from IFM Typ IND Control butterfly valve actuator single-acting, positioner (4-20mA) Crane / Gefa / ARI / Keystone with Sipart PS 2 PA or PMV D3 Positioner Control butterfly valve actuator double-acting, positioner Crane / Gefa / ARI / Keystone with Sipart PS 2 PA or PMV D3 Positioner (4-20mA) Control butterfly valve , 230V~ electrical multi turn actuator (4-20mA) Crane / Gefa / ARI
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Ball control valves and open / close ball valves IPRO-Proposal / Brand Open/close throttling ball valve actuator single-acting, integral 3/2-way solenoid valve, fully open Gefa / Chemat / Megafrance and close limit switches from IFM Typ IND Open/close throttling ball valve actuator double-acting, integral 5/2-way solenoid valve, fully open Gefa / Chemat / Megafrance and close limit switches from IFM Typ IND Open/close Throttling ball valve, 230 VAC electrical actuator, with integralfully open/close limit Gefa / Chemat / Megafrance switches from IFM Typ IND Control Throttling ball valve, actuator single-acting, positioner (4-20mA) Gefa / Chemat / Megafrance with Sipart PS 2 PA or PMV D3 Positioner Control Throttling ball valve, actuator double-acting, positioner (4-20mA) Gefa / Chemat / Megafrance with Sipart PS 2 Paor PMV D3 Positioner Control Throttling ball valve, 230VAC electrical multi turn actuator (4-20mA) Gefa / Chemat / Megafrance Actuators IPRO-Proposal / Brand Pneumatic Actuator with proximity switch from IFM Typ IND Norbro / Valbia / Ebro / Elomatic / PMV 400 VAC electro multi turn actuator with proximity switch Auma SA Knife-gates IPRO-Proposal / Brand Open/close knife-gate with pneumatic air-cylinder fully open/close limit switch from IFM Typ IND Erhard / Ebro Iris diaphragm control valve Iris diaphragm control valve with positioner (4-20mA) Limit - switches Flow switch (in-line) spring opposed paddle type Flow switch (in-line) thermal effect type for low and no-flow service Solid level switch or similar paddle wheel type switch Level alarm switch (float) Level alarm switch (float) for chemicals level switch (vibration) Temperature switch Pressure switch Proximity switch Pull rope switch for belt conveyor Misaligment switch / Belt drift switch IPRO-Proposal / Brand Egger IPRO-Proposal / Brand E&H E&H E&H Bestobell Mobrey Bestobell Mobrey Siemens / E&H / Vega Fanal Fanal IFM / Pepperl+Fuchs Kiepe Kiepe
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Fittings / Mountings Oiler Reducers Filter Filter - Reducer Pipes for measurements points Stainless steel diameter 12 mm and 16 mm Pipes for pneumatic controls Stainless steel diameter 12 mm and 16 mm Coupling out Brass Stainless steel Valve blocks Control plug valves Solenoid valve Transducer Electro pneumatic measurement transducer Pneumatic electro measurement transducer Galvanic Isolator (4-20mA) without power-supply Galvanic Isolator (4-20mA) with power-supply temperature transmitter (4-20mA) with power-supply
Festo / Parker Hannifin / Norgren Festo / Parker Hannifin / Norgren Festo / Parker Hannifin / Norgren Festo / Parker Hannifin / Norgren Standard Material Standard Material Standard Material with UV protection Standard Material Festo / Serto Festo / Serto Festo / Serto Klinger / Festo / Burkert Klinger / Festo / Burkert Herion / Rexroth / Burkert Siemens / E&H Siemens / E&H Siemens / E&H / Labom Siemens / E&H / Labom Siemens / E&H / Labom / Rosemount
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3. Electrical consumer list
OM=Operation Mode: DOL=Direct On Line SD=Star-Delta RL=Right/Left SO=Soft-Starter VFC=Variable Frequency Converter TS=Two Speeds SC=Static Converter REC=Rectifier loop control for DC Drive MES=Motor Electrical System MCU=Motor Control Unit OP=Operation SB=Stand by
Revision Legend: N=New MOTOR Running No. Revision C=Cancelled xx=Change P TAG-No. Machine MachineNo.
(Installed rated motor load for MCCs)
3. Electrical consumer list
LVDB 1 S Back-up Power [kVA] SF

(Simulta neous Factor)
LVDB 2
LVEB
Building Location
Extern Machine
Extern LVDB
VFC SC
[kW] 0,00
P P Stan Estimate d-by d [kW] Power
Status
U [V]
I [A]
Speed [1/rpm]
LF (Load Factor)
(Appeare nt Power)
Power Factor [cos phi] [kVA] 0,00
Eta
(Efficien (Emergency cy) Power Supply) [%]
Kind Enviro Emerg of nment ency operat conditi Switch ion ons
Thermistor
OM
MES
P OP [kW]
P SB [kW]
P OP [kW]
P SB [kW]
P [kW]
Location
Level
Axis
delivered by
Remarks
PID DrawingNo.
0,00
0,00
0,00
0,00 0,00
0,00
0,00
1 2 3 4 5
03 03 03 03 03
ES ES ES ES ES
020 020 030 030 040
M01 M02 M01 M02 M01
Drum prewasher Drum prewasher Drum type rock catcher Drum type rock catcher Belt type weed catcher
03S020 03S020 03S030 03S030 03S040
0,00 0,00 0,00 0,00 0,00
400 400 400 400 400
0.0 0.0 0.0 0.0 0.0
VFC VFC VFC VFC DOL MCU
0003-0211 0003-0211 0003-0211 0003-0211 0003-0211
For example only!
For example only!
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4. Control & Instrumentation Identification
Code-letter A B C D E F G H I J K L M N O P Q R S T U V W X Y Z 1st.letter Addition of a letter Following letters Fault report
C&I assortment of electric equipment (DIN 40719) Signal converter
Control Density Electrical dimension Flow Position, amplitude Hand Difference Sensor function Rate Frequency converter High(upper limit) Indicator Scanning Time/Sequence Level Humidity Disposable Low(lower limit) Disposable Power supply
Motor Local measurement/indicating
Pressure Quality, analysis Radiation rate Rotational speed, frequency Temperature Compound dimension Viscosity Scale Various
Integral, total Registration Switching, sequence control Transducer, transmitter Analog/digital transducer Positioner, actuator
Function Protection, emergency switch
Valve, (and) addition M (YM)
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6. Instrumentation List (C&I)

C&I - List Rev.xx issued: dd-mm-yyyy
"Control mode"and"MotorElectricalSystem": OM=Operation Mode DOL=Direct On Line SD=Star-Delta RL=Right/Left SO=Soft-Starter VFC=Variable Frequency Converter VS=Variable Speed SC=Static Converter SR=Slip Ring "Legend": N=New ; C=Cancelled ; 4=Change
MSR-Nr. Process Medium Working Range
Legend
Unit Function
Tag
MSR
Loop Tag
Comment
Field Electrical Equipment
Supplier
Action of valve
Spec-N.
Type
Connection Type
Control mode
Motor electrical system
Equipment location Number 01A010 01T040
Type
Medium
Operating Voltage
Range
Unit
01 N9 9 9 9 01 01 01 01 01 N1 01 01 N1 N9 9 9 N9 01 01 01 01 01 01 N1 01 01 N1 01 01
W I HS LS LS XA ES SS ES SS HS LS LS XA ES SS ES SS ES
010 040 040 040 040 050 050 055 055 060 060 060 060 070 070 075 075 080
U01 B01 B01 B02 B01 M01 B01 M02 B01 B01 B01 B02 B01 M01 B01 M02 B01 M01
W-01.010.01
L-01.040.01 L-01.040.02
E-01.050.01 S-01.050.01 E-01.050.02 S-01.055.01
L-01.060.01 L-01.060.02
E-01.070.01 S-01.070.01 E-01.070.02 S-01.075.01 E-01.080.01
Weighing scale for goods waggon Signal unit for unloading or not Level Hopper for unloading train Line 1 Level Hopper for unloading train Line 1 interval time for start warning Discharge screw conveyor Speed switch scraper chain conveyor Discharge screw conveyor Speed switch scraper chain conveyor Signal unit for unloading or not Level Hopper for unloading train Line 2 Level Hopper for unloading train Line 2 interval time for start warning Discharge screw conveyor Speed switch scraper chain conveyor Discharge screw conveyor Speed switch scraper chain conveyor Inclined screw conveyor for raw sugar Misalignment switch conveyor left Misalignment switch conveyor right Misalignment switch conveyor left Misalignment switch conveyor right Rope Switch Belt Conveyor left Rope Switch Belt Conveyor right
Electronic platform scale for train Pilot light (green or red light) Level switch / vibration principle Level switch / vibration principle Signal-horn Motor Inductive proximity switch (speed control) Motor Inductive proximity switch (speed control) Pilot light (green or red light) Level switch / vibration principle Level switch / vibration principle Signal-horn Motor Inductive proximity switch (speed control) Motor Inductive proximity switch (speed control) Motor AMF AMF
QI
230 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V
0...xxx on/off on/off on/off on/off
LS LS XS DOL IFM IG500A DOL AMF IFM IG500A MCU MCU
01T040 01T040 01T040 01C050 01C050 01C055 01C055 01T060
on/off
rpm
on/off on/off on/off on/off on/off
rpm
LS LS XS DOL IFM IG500A DOL AMF IFM IG500A DOL MCU MCU MCU
01T060 01T060
For example only!

01T040 01C070 01C070 01C075 01C075 01C080 -
24 V
on/off
rpm
24 V
on/off
rpm
N1 N1 N1 N1 N1 N1
01 01 01 01 01 01
GZ GZ GZ GZ HZ HZ
080 080 080 080 080 080
B01 B02 B03 B04 B01 B02
G-01.080.01 G-01.080.02 G-01.080.03 G-01.080.04 H-01.080.01 H-01.080.02
belt Limit switch belt Limit switch belt Limit switch belt Limit switch Emergency Limit Switch Emergency Limit Switch
AMF AMF AMF AMF AMF AMF
LS LS LS LS LS LS
Kiepe HES 011 Kiepe HES 011 Kiepe HES 011 Kiepe HES 011 Kiepe HEN 001 Kiepe HEN 001
01C080 01C080 01C080 01C080 01C080 01C080
24 V 24 V 24 V 24 V 24 V 24 V
on/off on/off on/off on/off on/off on/off
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6. Instrumentation List (C&I)

Client:xxx Project: xxx Project-No.: xxx
Automatic System / Process control system
Process
Process data
Signal
Process Station
Electrical System
Adressing (1)
Adressing (2)
Adressing (3)
Field EQP/ Pipe Number
Pipe DN
Connection DN
PN
Fitting length
Pressure ( bar )
Temperatur ( C )
Density ( Kg/m )
Flow ( m/h )
Flow ( t/h )
Remarks
Status
PID Nummer
4-20mA 0/1 0/1 0/1 0/1
RIO RIO RIO RIO RIO MCU
AI DI / DO DI DI DO
CH... CH... CH... CH... CH... CH...
01A010 Manual operation 01T040 01T040 1" 1"
Hold
0001-0211 0001-0211 0001-0211 0001-0211 0001-0211
01ES050M01 DI CH... 01C050 01ES055M01 DI DI / DO DI DI DO CH... CH... CH... CH... CH... CH... 01ES070M01 DI CH... 01C070 01ES075M01 DI CH... 01C075 01ES080M01 01T060 01T060 01C055
See motor list 10-55 VDC; max. 250 mA See motor list 10-55 VDC; max. 250 mA Manual operation
0001-0211 0001-0211 0001-0211 0001-0211 0001-0211 0001-0211 0001-0211 0001-0211
0/1
RIO MCU
0/1 0/1 0/1 0/1 0/1
RIO RIO RIO RIO RIO MCU
1" 1"
See motor list 10-55 VDC; max. 250 mA See motor list 10-55 VDC; max. 250 mA See motor list
0001-0211 0001-0211 0001-0211 0001-0211 0001-0211
0/1
RIO MCU
0/1
RIO MCU
0/1 0/1 0/1 0/1 0/1 0/1
RIO RIO RIO RIO RIO RIO
DI DI DI DI DI DI
CH... CH... CH... CH... CH... CH...
01C080 01C080 01C080 01C080 01C080 01C080
0001-0211 0001-0211 0001-0211 0001-0211 0001-0211 0001-0211
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7. Specification for electrical motors

General The complete contract work for the three phase standard motors is based on an accepted quality assurance system which meets the requirements according to the respective norms and regulations, especially the following: IEC = International Electrical Commission EN = European Norm Technical specifications for standard motors Motors are to be delivered according to the specification as follows (particular deviations will be separately emphasized): IEC/EN 60034-xx IEC/EN 60038 IEC/EN 60072 IEC/EN 60085 DIN/ISO 10816 IPRO - Proposal
Motor type: Induction Motors, 3 pase squirrel cage IC 411 Cooling: a. IC 411, totally-enclosed fan-cooled: Cooling air is blown over the totally enclosed motor surface by a fan mounted on the shaft. For this self-cooling the minimal speed (>40% of nominal motor speed) of the converter should be defined to guarantee the cooling. b. IC 416, external surface cooling: Cooling air is blown over the totally enclosed motor surface by a separately excited fan motor. If the desirable speed of the motor will be less than 40%, external cooling will be needed. Mounting type: a. B3, foot mounting b. B5, flange mounting Terminal box: Completely delivered with cable entry threads, rotable 180 Nominal voltage: appropriated for star delta start according to: Nominal frequency, according to IEC 60034-1: Mode of operation, Duty-type to EN60034/VDE 0530: - S1 Steady state - Other duty-types if required. Cast-iron construction, standard metric frame, Enclosure: Insulation class / utilization: Painting for wet areas; color: Operation with Frequency converters The motors have to be suitable for operation with a frequency converter at a nominal voltage of: Heating The stator terminals can be used with 4-10% of the motor rated voltage as an anti-condensation heater. Classification coefficient of efficiency a. EFF1: (High efficiency motor), motor with high coefficient of efficiency b. EFF2: (Improved efficiency), motor with improved coefficient of efficiency c. EFF3: (Convential motors) B3
400/690 VAC 5% IEC 60034-1 IEC 60085 50 Hz 2% S1
IP 65 F/B RAL.... IPRO - Proposal 3ph 400 V IPRO - Proposal
IPRO - Proposal EFF2
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Starting procedure IPRO - Proposal Motors are standard operating as direct starter (DOL - direct 30 kW on line), up to: Motors are starting in Star-Delta (depending on the kind of 30 kW mechanical drive) with a rated power output above: The definitive starting mode has to be determined in coordination with the supplier of the mechanical drives. Preferred methods are soft starter or frequency converter. Thermistor motor protection IPRO - Proposal PTC binary (3 thermistors) for warning Thermistors for winding temperature have to be installed PTC binary (3 thermistors) for shut-off ready for connection in the motor terminal box: a. For controlling the winding temperature, the three phasemotors are to be supplied with PTC thermistors (PT100). b. Alternatively the motors vare to be equipped with: - PTC binary (3 thermistors) for warning - PTC binary (3 thermistors) for shut-off The difference in temperature between warning and shut off has to be 15 K. Bearing current protection IPRO - Proposal Measures against bearing current, caused by AC induction on Needed for type/size 315 and above and converter feeded the motor shaft could be the following: - sinusoidal filter - du/dt filter - moderate puls frequency - isolated bearing or isolated bearing seat Counter measures should be conducted at motor sizes above:
Bearing temperature control To observe the bearing temperature, three phase-motors are to be supplied with PT100 to capture and to monitor the bearing temperature: Vibration control To prevent for hazards coused by vibrations motor are to be supplied with a vibration control.
IPRO - Proposal Should to be used for motors of 200kW and above
IPRO - Proposal Required for centrifugals, vacuum pumps
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Overview to explosion proof motors Ex- Zone operation has to be defined during detail engineering under consideration to the following standards: IEC 60079-0, IEC 60079-1, IEC 60079-7, IEC 60079-15, IEC 61241 Gas: Category: 1G: Zone 0: Not common Category: 2G: Zone 1: Type of protection:EX de IIC; Temperature class T1-T4; Grade of protection: minimum IP55 Category: 2G: Zone 1: Type of protection:EX e II; Temperature class T1-T3; Grade of protection: minimum IP55 Category: 3G: Zone 2: Type of protection:EX nA II; Temperature class T1-T3; Grade of protection: minimum IP55 Dust: Category: 1D: Zone 20: Not common Category: 2D: Zone 21: Conductive and nonconductive dust; Max. frame temperature 125C; Grade of protection: minimum IP65 Category: 3D: Zone 22: Non conductive dust; Max. frame temperature 125C; Grade of protection: minimum IP55 Brands Stipulated motor brand name (depending on local possibilities): Requirements for the supplier: - Service has to be customized, world wide, according to international standards. - Specific solutions according to the clients requirements - Experience for extrem environmental conditions (explosion zones, flammable atmosphere, high humidity) IPRO - Proposal
Not used Operation: mains-operated, converter-operated
Operation: mains-operated
Operation: mains-operated, converter-operated
Not used Operation: mains-operated, converter-operated
Operation: mains-operated, converter-operated
IPRO - Proposal Siemens, ABB
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8. Specification for Frequency converters
General requirements Line voltage: a. 3ph. 380480V AC b. 3ph. 660690V AC c. Medium voltage Line frequency: Output voltage: Output frequency: Rated putput power according to motor list: Overload capacity: Grid configuration / earthing system: a. TN-C b. TN-S Degree of protection: a. IP20 at conditioned indoor installation b. IP54 c. IP 65 Motor type: Induction Motors, 3 pase squirrel cage Ambient temperature: -10C 40C General: PC tool for engineering, tool for start-up and tool for communication with the PLC-controlled drives, local support for distribution and service Technological functions Contro technique: a. V/f open control loop b. Vector control Dynamic functions: a. Flying restart b. Automatic restart c. Kinetic buffering d. Compound braking e. DC braking f. Dynamic (regenerative) braking Safety functions: a. Safe torque off b. Safe operating stop c. Safe brake control d. Safe stop 1 (category 1, EN 954-1) e. Safe stop 2 (category 2, EN 954-1) f. Safe speed limitation Protection: Undervoltage, supply and DC Link overvoltage, phase loss, drive overload, Instantaneous overcurrent, over temperature, short circuit, ground fault, thermal motor protection, watchdog Bypass circuit: As an option Interface: Digital, analog, serial (RS232/RS485), Profibus DP Minimal input/output configuration: Digital input: On, interlock Digital output: Failure 2x, ready Analog input: Setpoint Analog output: free configurable for actual values (current, speed, ) Front end converter: a. 6 pulse diode or thyristor bridge b. 12 pulse diode or thyristor bridge c. Active front end IGBT converter Filtering: a. Mains reactor b. Output reactor c. dv/dt-filter d. Sine wave filter e. Radio interference suppression filter class A
3ph. 380480V AC, others depending on motor list and power consumption
4763Hz, possible frequency slew rate > 2% f LN /sec according to EN61800-3 0 Line voltage 0100Hz See motor list 10% minimum TN-S
IP 54
V/f open loop control, others depending on permormance and start up torque Flying restart especially for long slow-down time, dynamic (regenerative) braking is essential for centrifugal drives
Safe operating stop, safe stop 1 and 2 (category 1 and 2), safe torque off, safe speed limtation
The system has to meet the following criteria: - The EMC requirements: THD, Harmonics, (see electromagnetic compatibility) - The dynamic functions: Dynamic (regenerative) braking (see dynamic functions) if required according to process Preferred mains reactor and dv/dt-filter, suppression filter class A
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8. Specification for Frequency converters
Electromagnetic compatibility (EMC) Compliance with: EN 61000-2-2 Environment - Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems: Environmental Class 2 -> THD-u = 8%, ... EN 61000-2-4:Environment - Compatibility levels in industrial plants for low-frequency conducted disturbances: Environmental Class 2 -> THD-u = 8%, ... EN 61000-6-2: Generic standards - Imunity for industrial environments EN 61000-6-2: Generic standards - Emission standard for industrial environment EN 61800-3: Adjustable speed electrical power drive systems - EMC requirements and specific test methods
Brand Stipulated brand names depending on local possibilities
Siemens, ABB, Reliance, Klckner or equal
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9. Color code of wiring in electro distribution boards

First Phase Second Phase Third Phase Neutral Protection Earth PE Main circuit Phase L01 / 230V AC Main circuit Phase L02 / 0V AC Neutral Switch circuit L01 230V AC Switch circuit L02 230V AC Control Voltage 24V DC for Instruments and DIO Control Voltage 0V DC for Instruments and DIO External voltage Digital In-/Output-signals to the PLC Analog In-/Output-signals to the PLC Black [BK] Black [BK] Black [BK] Light-blue [BL] Green-Yellow [GN/YE] Black [BK] Light-blue [BL] Red Red Line Orange [OR] Purple [VIO] Orange Brown Purple
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10. Standard Cabels (IEC-Standards)

Type NYM-J Cores - 1x1,5 - 3x1,5 - 4x1,5 - 5x1,5 Features - Solid, - Coloured single core, - Without shield, - Three cores and more with PE - Colour coded cores according DIN VDE 0293-308. - Different type of conductors as follows: Multi wired cables: 1,5mm to 16mm solid round conductor, 25mm round conductors, multiple wired, 35mm to 240mm stranded, sectional core conductor - Single core - 1x4 to 1x16 round conductor single wire - 1x25 to 1x630 round conductor, multiple wire - Solid for cores until 10mm, - Single round wire, colored, up to 25mm - Sector formed wire from 35 up to 240mm - WScreened, resistant for inand outdoor applications. - Solid for cores until 10mm - Single cores, coloured, if more than colour black and numbered - Cables are shielded - Resistant against normal acid chemicals applicable for in- and outdoor Application Lighting, General power installation indoors (outdoors only with protection against sun light) Motorcabel, power cable, general purpose
to 1x16 to 3x10 to 4x35 to 5x25
NYY-J
NYY-0
- Multi core cable - 3x1,5 to 3x240 - 3x35/16 to 3x300/150 - 4x1,5 to 4x240 - 5x1,5 to 5x35 - 7x1,5 to 61x2,5 Single core cables and multi core cables without PE core - Single core - 2x10/10 to 2x16/16 - 3x6/6 to 3x240/120 - 4x10/10 to 4x240/120 - single core - 1x10 RE/10 to 1x25 RM/25 - 2x1,5 RE/1,5 to 2x6 RE/6 - 3x1,5 RE/1,5 to 3x6 RE/6 - 4x1,5 RE/1,5 to 4x6 RE/6 - 5x1,5 RE/1,5 to5x6 RE/6 - 7x1,5 RE/2,5 to 7x6 RE/6 - 8x1,5 RE/2,5 to 8x2,5 RE/4 - 10x1,5 RE/2,5 to 10x2,5 RE/4 - 12x1,5 RE/2,5 to 12x6 RE/6 - 14x1,5 RE/2,5 to 14x2,5 RE/6 - 16x1,5 RE/4 to 16x2,5 RE/6 - 19x1,5 RE/4 to 19x2,5 RE/6 - 21x1,5 RE/6 to 21x2,5 RE/10 - 24x1,5 RE/6 to 24x2,5 RE/10 - 30x1,5 RE/6 to 30x2,5 RE/10 - 40x1,5 RE/10 to 40x2,5 RE/10 - 52x1,5 RE/10 to 52x2,5 RE/10 - 61x1,5 RE/10 - Single core cable - 2x1,5 to 2x4 - 3x1 to 3x16 - 5x1,5 to 5x35 - 7x1,5 to 24x2,5 - Twisted cores - 2x1,5 to 100x1,5 - 2x2,5 to 100x2,5 - 2x4 to 12x4 - 3x6 to 7x6 - 3x10 to 7x10 - 3x16 to 7x16 - 3x25 to 7x25 - 3x35 to 5x35 - 3x50 to 4x50 - 3x70 to 4x70 - 3x95 to 4x95 - 4x120 - Twisted - 3x1,5RE to 12x2,5 RE - Twisted - 2x2x0,8 to 52x2x0,8
Earthing potential, equalization, inand outdoor applications
NYCWY
Motorcabel when shielded (cable required e.g. for VFC), power cable, general purpose Motorcabel, power cable, general purpose
NYCY
H07RN-F
- Flexible wired cores without shield, - Resistant against normal acid chemicals - Applicable for in- and outdoor
Motor cabel from the safety switch to the motor
lflex -110
- Flexible cores, - Twisted and numbered without shield - Mostly resistant against oil andchemicals - Three wires and more: with PE
Oil resistant, applicable for indoors
(N)HXH E 90
JEH(ST)H...BD E 90 orange YSLY-JZ/-OZ
- Halogen-free and flame retardend, - Power cable, safety operation E90 - Safety isolation, FE 180 according to DIN VDE 0472 - Halogen-free and flame retardend - Twisted pairs, numbered, shielded, without PE
Installation for Fire protection equipment Installation for Fire protection equipment, control cable, indoors (outdoors only with protection against sun light) Control cable, indoors (outdoors only with protection against sun light)
- Twisted - 2x0,5 to 100x0,5 - Other core cables identical to lflex-110
- Flexible, - Twisted and numbered, without shield - with PE (OZ without PE)
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Type CON-V1-02 Cores - Control Cable - 2x1 to 50x1mm - Available until 2,5mm - Control Cable - 2x1 to 50x1mm - Available until 2,5mm - Twisted - 2x0,5 to 61x0,5 - 2x0,75 to 27x0,75 - Twisted - 1x0,14 to 100x0,14 - 1x0,25 to 100x0,25 - 1x0,34 to 100x0,34 - 1x0,5 to 100x0,5 - 1x0,75 to 100x0,75 - 1x1,0 to 100x1,0 - 1x1,5 to 100x1,5 - 1x2,5 to 12x2,5 - 2x4,0 to 7x4,0 - 2x6,0 to 7x6,0 - 2x10 to 7x10 Twisted pairs Features - PVC insulated - Overall shielded - Tinned copper drain core for PE - PVC insulated - Steel wire amouring - Tinned copper drain core for PE - Flexible - twisted and numbered - without shield - Flexible - Twisted wires up to 0,75mm coloured, - More than 1,0mm numbered - With PE (non-fused earth conductor) Application Control cable, white cores, nummerical identification, especially South Africa applicable Control cable, white cores, numerical identification, especially South Africa applicable Control cable
CON-V2-02
H05VV5-F
LiYCY(JZ)
Control cable, indoor applications
LiYCY-0
- Flexible, - Twisted pairs, - Shielded and headlabeled wires regarding DIN 47100. - Without PE core - Flexible - Twisted cores, colored, shielded - Without PE core - Flexible, - Twisted wires, numbered, shielded - With PE core - Flexible - Twisted pairs, colored - Without PE core
Control cable, indoors (outdoors only with protection against sun light)
LSYCY
- Twisted - 2x0,75 to 30x0,75 - Twisted - 2x0,75 to 30x0,75
NLSCY-JZ
LSPYCY
- Twisted - 2x2x0,14 to 20x2x0,14 - 2x2x0,25 to 16x2x0,25 - 2x2x0,5 to 16x2x0,5 - 2x2x0,75 to 16x2x0,75 - 2x2x1 to 12x2x1 H05VVG4V5-k twisted and 2x0,5 to 50x0,5 NYLLCY-J 2x0,75 to 61x0,75 lflex-440 P - Twisted - 2x0,5 to 41x0,5 - 2x0,75 to 41x0,75 - 2x1,0 to 41x1,0 - 2x1,5 to 41x1,5 - 3x2,5 to 12x2,5 - 7x4,0 - 7x6,0 - twisted - 2x2x0,22 to 10x2x022 - 2x2x0,34 to 10x2x0,34 - 2x2x0,5 to 10x2x0,5 - Twisted pairs - 2x2x0,22 to 10x2x022 - 2x2x0,34 to 10x2x0,34 - 2x2x0,5 to 10x2x0,5 - 2x2x0,5 to 40x2x0,5
Control cable, indoors (outdoors only with protection against sun light) Control cable, indoors (outdoors only with protection against sun light) Indoors (outdoors only with protection against sun light)
- Flexible - Twisted wires, numbered - With PE core - Flexible - Twisted wires, numbered - Without shield - Oil-und chemical resistant - With PE
Indoors (outdoors only with protection against sun light)
Control cable for in- and outdoor application
Li2YCY (TP)
- Flexible - Twisted pairs, colored, shielded - Without PE - Flexible - Twisted pairs, coloured, shielded - Without PE - Flexible - Twisted pairs, coloured, shielded - Without PE - Solid - Twisted, colored, shielded - Without PE - Flexible - Twisted wires, numbered, shielded - Without PE
Control cable
Li2YCYv (TP)
Control cable for in- and outdoor application
JE-LiYCY ...Bd Si Profibus-DP 02Y(ST)CY 2x0,64 lflex-EB CY
Control cable for in- and outdoor application Control cable for bus installation, indoor applications For intrinsically safe circuits, indoor applications, cable colour blue only for intrinsically use
- twisted - two wire line 1x2x0,64 - twisted - 2x0,75 to 25x0,75 - 2x1,0 to 25x1,0 - 2x1,5 to 25x1,5
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Type Cores lmass-EB CY - Single - 3x1,5 to 7x1,5 Features - solid - single cores - up to 5 wires: coloured, from 7 to wires numbered - shielded - without PE - Flexible - Outer jacket oil resistant - Flexible - Shielded and twisted pair - Total shielded - Shielded and twisted pair cable Application For intrinsically safe circuits, indoor applications, cable colour blue only for intrinsically use
UNITRONICBUS AS-i Profibus-PA Typ: 02Y CY ProfibusDP 02YY (ST) CY LWL A-DQ(ZN)2Y Optical waveguide Ethernet J-02YSCY Pneumatic tube Typ: PA 12 W
- Flat wired cable, yellow - 2x1,5mm - Twisted - 1x2x1,0/ 2,55-100 - Twisted - (1x2x0,64); Unitronic Bus DP Four Fiber glass cores
Data communication and energy feeding Bus cable for field bus installation in the process area according to IEC 61158-2 Bus cable for indoor application For industrial areas, in- and outdoor applicable
2x2x0,64/1,5 PIMFF
Diameter 6, 8, 10, 12 mm;
- ITP-Standard cabel (Industrial Twisted Pair) - Four wires twisted; each wire separate shielded - Cable over all shielded - Black coloured - Ultra-violet resistant
Field bus installation in the process area Pneumatics
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11. Hazardous areas and equipment categories

Hazardous area classification is used to identify places where, because of the potential for an explosive atmosphere, special precautions over sources of ignition are needed to prevent fires and explosions. Hazardous places are classified in terms of zones on the basis of the frequency and duration of the occurrence of an explosive atmosphere. In details the places will be defined after HAZOP study for the whole technology, folowing the description below.
For gases, vapours and mists the zone classifications are: Zone 0 A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances in the form of gas, vapour or mist is likely to occur in normal for more than 1000hrs per year. Zone 1 A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances in the form of gas, vapour or mist is likely to occur in normal operation between 10-1000hrs per year. Zone 2 A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances in the form of gas, vapour or mist is not likely to occur in normal operation but, if it does occur, will persist for less than 10hrs per year. For dusts the zone classifications are: Zone 20 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is present continuously, or for for more than 1000hrs per year. Zone 21 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur in normal operation between 10-1000hrs per year. Zone 22 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but, if it does occur, will persist for less than 10hrs per year. Electrical Equipment for Hazardous Areas Hazardous Area Zone 0 Ex ia - Intrinsically Safe Ex s - Special protection, must be certified for use in Zone 0 Hazardous Area Zone 1 Any equipment suitable for Zone 0 EX d - Fame Proof Ex p - Pressurised or Purging Ex q - Powder filled Ex o - Oil Filled/immersion Ex e - Increased Safety Ex ib - Intrinsically Safe Ex m - Encapsulation Hazardous Area Zone 2 Any equipment suitable for Zone 0 or Zone 1 Ex n - Certified that the equipment is not capable under normal operation of igniting a surrounding explosive atmosphere. Temperature Classification T1 - Surface temperature must not exceed 450C T2 - Surface temperature must not exceed 300C T3 - Surface temperature must not exceed 200C T4 - Surface temperature must not exceed 135C T5 - Surface temperature must not exceed 100C T6 - Surface temperature must not exceed 85C
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E - C& I Standards GSR - Rev03

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IPRO Industrieprojekt GmbH Client: Star Trading Company Project: Golden Sugar Refinery Project-No.: 7048.

E+I Standards Current status: October 14, 2010

0. Electrical / Control & Instrumentation Standardization: Table of contents

E+I Standards Current status: October 14, 2010

For SF6 only fix-mounted cos phi = 0,95

Realized by thermistor motor protection c. Withdrawble technic

b. Fuseless (by motor circuit breakers)

E+I Standards Current status: October 14, 2010

E+I Standards Current status: October 14, 2010

E+I Standards Current status: October 14, 2010

E+I Standards Current status: October 14, 2010

E+I Standards Current status: October 14, 2010

E+I Standards Current status: October 14, 2010

E+I Standards Current status: October 14, 2010

3. Electrical consumer list

LVDB 1 S Back-up Power [kVA] SF

P P Stan Estimate d-by d [kW] Power

Power Factor [cos phi] [kVA] 0,00

(Efficien (Emergency cy) Power Supply) [%]

020 020 030 030 040

M01 M02 M01 M02 M01

03S020 03S020 03S030 03S030 03S040

0,00 0,00 0,00 0,00 0,00

400 400 400 400 400

0.0 0.0 0.0 0.0 0.0

VFC VFC VFC VFC DOL MCU

0003-0211 0003-0211 0003-0211 0003-0211 0003-0211

For example only!

For example only!

E+I Standards Current status: October 14, 2010

C&I assortment of electric equipment (DIN 40719) Signal converter

Motor Local measurement/indicating

Function Protection, emergency switch

Valve, (and) addition M (YM)

E+I Standards Current status: October 14, 2010

E+I Standards Current status: October 14, 2010

6. Instrumentation List (C&I)

Field Electrical Equipment

Motor electrical system

Equipment location Number 01A010 01T040

E-01.050.01 S-01.050.01 E-01.050.02 S-01.055.01

E-01.070.01 S-01.070.01 E-01.070.02 S-01.075.01 E-01.080.01

0...xxx on/off on/off on/off on/off

LS LS XS DOL IFM IG500A DOL AMF IFM IG500A MCU MCU

01T040 01T040 01T040 01C050 01C050 01C055 01C055 01T060

on/off on/off on/off on/off on/off

For example only!

080 080 080 080 080 080

B01 B02 B03 B04 B01 B02

G-01.080.01 G-01.080.02 G-01.080.03 G-01.080.04 H-01.080.01 H-01.080.02

AMF AMF AMF AMF AMF AMF

01C080 01C080 01C080 01C080 01C080 01C080

on/off on/off on/off on/off on/off on/off

E+I Standards Current status: October 14, 2010

6. Instrumentation List (C&I)

Automatic System / Process control system

Field EQP/ Pipe Number

4-20mA 0/1 0/1 0/1 0/1

RIO RIO RIO RIO RIO MCU

CH... CH... CH... CH... CH... CH...

01A010 Manual operation 01T040 01T040 1" 1"

0001-0211 0001-0211 0001-0211 0001-0211 0001-0211