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TMS16482 Electrical Instrumentation and Control System

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0% found this document useful (0 votes)

357 views96 pages

TMS16482 Electrical Instrumentation and Control System

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Tuesou Machere

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TMS1648 Electrical, Instrumentation and Control Systems Design Criteria Standard Technical Specification

Electrical, Instrumentation
and Control System
Design Criteria
TMS1648

Standard Technical Specification

TMS1648 Electrical, Instrumentation and Control Systems Design Criteria Standard Technical Specification

REVISION CONTROL

Revision Date Revision Details Responsible

Number Officer
0 March 2017 First Draft – Issued for stakeholder comments Steve Bourke
1 May 2017 Issued for Use Steve Bourke
2 Jan 2019 General Updates – Re-issued for Use Steve Bourke

DOCUMENT CONSULTATION

Revision Name Position Comments Date

Received
2 Mark Davanzo Planner – Electrical Asset Y Dec 2018
Maintenance Management
2 Gerard Anderson Senior Electrical Engineer Y Dec 2018
2 John Clayton Senior Commissioning Engineer Y Dec 2018
2 Craig Moir Senior Electrical Engineer Y Dec 2018
2 TEG Y Dec 2018

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E:\QUU\Specifications\E,I and C Design Criteria\TMS1648 Electrical, Instrumentation & Control Sytems Design Criteria- Rev2.docx
TMS1648 Electrical, Instrumentation and Control Systems Design Criteria Standard Technical Specification

Contents
REVISION CONTROL ..................................................................................................................................... 2
DOCUMENT CONSULTATION ....................................................................................................................... 2
1 SCOPE .................................................................................................................................................... 7
1.1 DEFINITIONS .............................................................................................................................. 7
1.2 ACRONYMS AND ABBREVIATIONS ........................................................................................... 7
1.3 REFERENCE DOCUMENTS ....................................................................................................... 9
1.4 REFERENCE TYPICAL DRAWINGS ......................................................................................... 12
1.4.1 Sewerage Treatment Plants ..................................................................................... 12
1.4.2 Network Sites ........................................................................................................... 13
2 STANDARDS AND REGULATIONS ..................................................................................................... 15
2.1 AUSTRALIAN STANDARDS ...................................................................................................... 15
2.2 INTERNATIONAL STANDARDS ................................................................................................ 18
2.3 ACTS AND REGULATIONS ....................................................................................................... 20
2.4 SUB-CONTRACTORS ............................................................................................................... 20
2.5 CONTRACTOR EXCEPTIONS .................................................................................................. 20
2.6 ORDER OF PRECEDENCE ....................................................................................................... 21
3 GENERAL DESIGN ............................................................................................................................... 22
3.1 OPERATING CONDITIONS AND DESIGN LIFE ........................................................................ 22
3.2 SITE CLIMATIC CONDITIONS................................................................................................... 22
3.3 OPERATING REQUIREMENTS ................................................................................................. 23
3.4 DESIGN SERVICE..................................................................................................................... 23
3.5 UTILITY DATA ........................................................................................................................... 23
3.6 MATERIALS............................................................................................................................... 24
3.7 MEASUREMENT UNITS ............................................................................................................ 25
3.8 DESIGN PERSONNEL............................................................................................................... 25
3.9 WEATHER AND INGRESS PROTECTION ................................................................................ 26
3.10 EQUIPMENT TAG NAMING....................................................................................................... 26
3.11 EQUIPMENT LABELS ............................................................................................................... 26
4 ELECTRICAL DESIGN .......................................................................................................................... 28
4.1 MINIMUM REQUIREMENTS ...................................................................................................... 28
4.2 ENERGY EFFICIENCY .............................................................................................................. 28
4.3 ELECTRICAL SAFETY .............................................................................................................. 28
4.3.1 Protection from Live Parts......................................................................................... 28
4.3.2 Equipment Design and Location ............................................................................... 29
4.3.3 Induced Voltage ....................................................................................................... 29
4.3.4 Evacuation ............................................................................................................... 30
4.4 ENVIRONMENT......................................................................................................................... 30
4.4.1 Audible Noise ........................................................................................................... 30
4.4.2 Spills and Emissions ................................................................................................. 30
4.4.3 Pests ........................................................................................................................ 31
4.5 CLASSIFYING LOADS............................................................................................................... 31
4.5.1 Essential Service Supply .......................................................................................... 32
4.6 SYSTEM VOLTAGES ................................................................................................................ 32
4.6.1 Voltage Level Definitions: ......................................................................................... 32
4.6.2 HV Network .............................................................................................................. 33
4.6.3 LV Network............................................................................................................... 33
4.6.4 ELV Equipment ........................................................................................................ 33
4.6.5 Distribution Transformer Ratings .............................................................................. 34

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4.7 POWER SYSTEMS ANALYSIS.................................................................................................. 34

4.8 DESIGN MARGINS .................................................................................................................... 34
4.8.1 Normal Plant Loading ............................................................................................... 35
4.8.2 Motor Starting........................................................................................................... 35
4.8.3 Maximum Demand ................................................................................................... 35
4.8.4 Load Allocation......................................................................................................... 35
4.8.5 Load List .................................................................................................................. 36
4.8.6 Supply Capacity ....................................................................................................... 36
4.8.7 Equipment Loadings ................................................................................................. 36
4.8.8 Power Network Configuration ................................................................................... 37
4.9 FAULT AND INSULATION LEVELS ........................................................................................... 37
4.9.1 Equipment Fault Current Ratings and Insulation Levels ............................................ 38
4.10 ELECTRICAL PROTECTION ..................................................................................................... 38
4.10.1 Primary Protection .................................................................................................... 38
4.10.2 Secondary Protection ............................................................................................... 39
4.10.3 Instrument Transformers .......................................................................................... 39
4.11 POWER NETWORK TOPOLOGY .............................................................................................. 39
4.11.1 Point of Supply ......................................................................................................... 40
4.11.2 Power Factor Correction ........................................................................................... 40
4.11.3 Harmonics Distortion ................................................................................................ 40
4.11.4 Electromagnetic Compatibility ................................................................................... 41
4.12 POWER CABLES ...................................................................................................................... 41
4.12.1 Power Cable Type and Design Constraints ............................................................... 42
4.12.2 Power Cable Sizing .................................................................................................. 42
4.13 EARTHING SYSTEMS ............................................................................................................... 43
4.13.1 General .................................................................................................................... 43
4.13.2 LV Switchrooms ....................................................................................................... 43
4.13.3 HV Substations and Switchrooms ............................................................................. 44
4.13.4 Existing Earth Systems ............................................................................................. 44
4.13.5 Equipment Earthing .................................................................................................. 44
4.13.6 Transfer Potentials ................................................................................................... 44
4.13.7 Equipotential Bonding............................................................................................... 45
4.13.8 Low Frequency Induction.......................................................................................... 46
4.13.9 Instrumentation Earthing........................................................................................... 46
4.13.10 Static Electricity ........................................................................................................ 46
4.14 EARTH SYSTEM DESIGN DOCUMENTATION ......................................................................... 47
4.15 LIGHTING .................................................................................................................................. 47
4.15.1 General .................................................................................................................... 47
4.15.2 Lighting Intensities .................................................................................................... 48
4.15.3 Gate Approach Lighting ............................................................................................ 49
4.15.4 Plant Area Lighting ................................................................................................... 49
4.15.5 Maintenance Lighting ............................................................................................... 50
4.15.6 Emergency Lighting .................................................................................................. 50
4.15.7 Prefabricated Switchroom Lighting............................................................................ 51
4.16 LIGHTNING PROTECTION........................................................................................................ 51
4.17 ELECTRICAL EQUIPMENT ....................................................................................................... 52
4.17.1 HV Switchboards and Ring Main Units...................................................................... 52
4.17.2 LV Switchboards ...................................................................................................... 52
4.17.3 Variable Speed Drives and Soft Starters ................................................................... 53
4.17.4 Transformers ............................................................................................................ 53
4.17.5 Motors ...................................................................................................................... 54
4.17.6 Diesel Generators .................................................................................................... 55
4.17.7 Junction Boxes ......................................................................................................... 55
4.17.8 Uninterruptible Power Supplies ................................................................................. 55

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4.17.9 DC Power Supply ..................................................................................................... 56

4.17.10 Batteries ................................................................................................................... 57
4.17.11 Packaged Plant Equipment....................................................................................... 57
4.17.12 Socket Outlets .......................................................................................................... 57
4.17.13 Transportable Switchrooms ...................................................................................... 58
4.18 SWITCHROOM HVAC SYSTEMS.............................................................................................. 58
4.19 FIRE DETECTION SYSTEMS .................................................................................................... 60
4.19.1 Manual Call Points.................................................................................................... 61
4.19.2 PAGA Speakers ....................................................................................................... 62
4.19.3 Very Early Smoke Detection Apparatus .................................................................... 62
4.19.4 Smoke Detectors ...................................................................................................... 63
4.20 SOLAR PHOTOVOLTAIC SYSTEMS ......................................................................................... 63
4.20.1 General .................................................................................................................... 63
4.20.2 Inverters ................................................................................................................... 63
4.20.3 Photovoltaic Panels .................................................................................................. 64
4.21 PROTECTION PHILOSOPHY .................................................................................................... 65
4.21.1 HV Protection Schemes............................................................................................ 65
4.21.2 LV Protection Schemes ............................................................................................ 68
4.21.3 Metering ................................................................................................................... 68
4.22 COROSION PROTECTION........................................................................................................ 69
4.23 CATHODIC PROTECTION ........................................................................................................ 69
5 INSTRUMENTATION DESIGN .............................................................................................................. 70
5.1 GENERAL.................................................................................................................................. 70
5.2 INSTRUMENT OPERATING RANGE ......................................................................................... 70
5.3 INSTALLATION AND INTERCONNECTIONS ............................................................................ 71
5.3.1 Tubing and Fittings ................................................................................................... 71
5.3.2 General Requirements.............................................................................................. 71
5.3.3 Flow ......................................................................................................................... 72
5.3.4 Level ........................................................................................................................ 74
5.3.5 Pressure................................................................................................................... 77
5.3.6 Temperature............................................................................................................. 78
5.3.7 Temperature Elements and Transmitters .................................................................. 79
5.4 ANALYSERS ............................................................................................................................. 79
5.5 INSTRUMENTATION AND CONTROL CABLES ........................................................................ 80
5.5.1 General .................................................................................................................... 80
5.5.2 Process Control Network Cabling ............................................................................. 80
5.5.3 Junction Boxes ......................................................................................................... 80
6 CONTROL SYSTEM DESIGN ............................................................................................................... 81
6.1 CONTROL PANELS................................................................................................................... 81
6.2 SWITCHBOARDS ...................................................................................................................... 81
6.2.1 LV Switchboards for STP’s ....................................................................................... 81
6.2.2 LV Switchboards for Network Assets ........................................................................ 82
6.2.3 HV Switchboards ...................................................................................................... 82
6.3 DOL MOTOR STARTERS .......................................................................................................... 82
6.4 VSD AND SOFT STARTERS ..................................................................................................... 83
6.5 EMERGENCY MOTOR CONTROL ............................................................................................ 84
6.6 SINGLE PHASE MOTORS......................................................................................................... 84
6.7 LV SWITCHING ......................................................................................................................... 84
6.8 HV MOTOR CONTROL.............................................................................................................. 85
6.9 AUXILIARY DEVICES ................................................................................................................ 85
6.10 LOCAL CONTROL STATIONS................................................................................................... 85
6.11 EQUIPMENT INTERLOCKING................................................................................................... 85

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6.12 FUNCTIONAL SPECIFICATIONS .............................................................................................. 86

6.13 IEC 61850 IMPLEMENTATION .................................................................................................. 86
6.14 CLOSED CIRCUIT TELEVISION ............................................................................................... 88
7 COMMUNICATION SYSTEMS .............................................................................................................. 90
7.1 GENERAL.................................................................................................................................. 90
7.2 COMMUNICATION CABLES ..................................................................................................... 90
7.3 COMMUNICATION PANELS ..................................................................................................... 90
7.4 PRIVATE RADIO AND 3G/4G COMMUNICATIONS................................................................... 91
7.4.1 Radio Network Desktop Design ................................................................................ 92
7.4.2 Radio Signal Site Survey .......................................................................................... 93
7.4.3 Communications Network Design Report .................................................................. 94
8 HAZARDOUS AREAS ........................................................................................................................... 95
8.1 GENERAL REQUIREMENTS ..................................................................................................... 95
8.2 CLASSIFICATION ...................................................................................................................... 95
8.3 EQUIPMENT EX CERTIFICATION ............................................................................................ 95
8.4 PROTECTION TECHNIQUES .................................................................................................... 95
8.5 HAZARDOUS AREA DOSSIER ................................................................................................. 95

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1 SCOPE

This specification outlines the minimum requirements for the design of Electrical,
Instrumentation and Control Systems equipment installed at QUU assets. This
specification is intended to complement the information contained in other QUU
technical specifications and provide further clarity to Contractors when delivering
design services. Contractors shall comply with the requirements of this specification and
other technical specifications referenced by this document.

1.1 DEFINITIONS

In this document, the following definitions apply:

Project Governing technical documents for the specific item(s) for the
Documentation specific works included or referenced in the Contract
Contractor The entity bound (including sub-contractors appointed by the
contractor) to execute the work having responsibility for design,
manufacture and supply, delivery, documentation and other functions
as further defined in the documents related to the work.
Contract The agreement between QUU and the Contractor to which this
specification pertains.

1.2 ACRONYMS AND ABBREVIATIONS

AC Alternating Current
ACB Air Circuit Breaker
mAHD Meters elevation with respect to Australian Height Datum
ALARP As Low as Reasonably Practical
ATS Automatic Transfer Switch
CB Circuit Breaker
CBF Circuit Breaker Fail
CDEGS Current Distribution, Electromagnetic Fields, Grounding and Soil Structure
CT Current Transformer
CSA Cross Sectional Area
DB Distribution Board
DC Direct Current
DOL Direct On Line

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DP Differential Pressure
EF Earth Fault
EI&C Electrical, Instrumentation and Control Systems
ELV Extra Low Voltage
EMC Electromagnetic Compatibility
ESW Earth Switch
FAT Factory Acceptance Test
IEC International Electro-technical Commission
HA Hazardous Area
HVAC Heating Ventilation and Cooling
I/O Input / Output
IP Ingress Protection
IRIG Inter-Range Instrumentation Group
ITP Inspection and Test Plan
LBS Load Break Switch
LCP Local Control Panel
LED Light Emitting Diode
LFI Low Frequency Induction
LV Low Voltage
MCC Motor Control Centre
MCCB Moulded Case Circuit Breaker
MPR Motor Protection Relay
MPPT Maximum Power Point Tracker
MTS Manual Transfer Switch
NC Normally Closed
NO Normally Open
OC Over current
ONAF Oil Natural Air Forced
PAGA Public Address and General Alarm
PF Power Factor
PFC Power Factor Correction
PLC Programmable Logic Controller
PPE Personal Protective Equipment

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PQA Power Quality Analysis

PRV Pressure Reducing Valve
PSA Power System Analysis
PV Photovoltaic
RCD Residual Current Device
REF Restricted Earth Fault
RFI Radio Frequency Interference
RMU Ring Main Unit
RTU Remote Telemetry Unit
QUU Queensland Urban Utilities
SEF Sensitive Earth Fault
SAT Site Acceptance Test
SCADA Supervisory Control and Data Acquisition
SDV Shutdown Valve
SLD Single Line Diagram
SPD Surge Protection Device
SS Stainless Steel
STP Sewerage Treatment Plant
TCS Trip Circuit Supervision
UCP Unit Control Panel
UPS Uninterruptable Power Supply
VRLA Valve Regulated Lead Acid
VT Voltage Transformer

1.3 REFERENCE DOCUMENTS

Document Number Title

BMS04075 Energex Customer Performance Standards and Technical Requirements
for Major Customers
FOR893 Instrument Schedule – Template
MP71 Electrical Safety Management Plan
MP183 Hazardous Areas Management Plan
PRO450 Electrical Safety Standard Operating Procedure
PRO521 Safety in Design Standard Operating Procedure

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Document Number Title

PRO363 WHS Hazard and Risk Management Procedure
PRO662 Safety in Design Guidelines
TEM336 Power System Analysis Guidelines
TEM514 Functional Specification Template for Complex Sites
TEM515 Sewerage Pump Station - Site Specific Functional Specification
TEM518 Hazardous Area Verification Dossier Template
TEM523 Cable Schedule Template
TEM587 Water Booster (MPC) – Site Specific Functional Specification Template
TEM588 PRV – Site Specific Functional Specification Template
TEM590 Water Booster (Lowara) - Site Specific Functional Specification
Template
TEM591 Water Booster (VSD) - Site Specific Functional Specification Template
TEM592 Water Pump Station - Site Specific Functional Specification Template
TEM593 Reservoir - Site Specific Functional Specification Template
TEM596 Radio Network Desktop Design Report Template
TEM597 Radio Signal Site Survey Report Template
TEM598 Communications Network Design Report Template
TMS60 Low Voltage Switchboards and Enclosures Technical Specification
TMS62 Preferred Equipment List – Electrical and Instrumentation
TMS76 Corrosion Protection for Electrical and Mechanical Equipment and
Structures
TMS117 Security, Access, Control and CCTV – Technical Specification
TMS200 PRV – Standard Functional Specification
TMS828 Standard Functional Specification Reservoir Sites
TMS1151 Preferred Equipment List – Control Systems
TMS1185 Distribution Power Transformer (Less than 5MVA) – Technical
Specification
TMS1186 HV Switchboards – Technical Specification
TMS1187 AC Uninterruptible Power Supply (UPS) – Technical Specification
TMS1188 Transportable Switchroom – Technical Specification
TMS1200 Electrical Installation – Technical Specification
TMS1201 Instrumentation Installation – Technical Specification
TMS1202 Control System Implementation – Technical Specification

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Document Number Title

TMS1203 General Requirements for Hazardous Area Installation – Technical
Specification
TMS1221 DC Power Supply Systems– Technical Specification
TMS1222 Control Panels – Technical Specification
TMS1404 HV Motors – Technical Specification
TMS1406 LV Variable Speed Drives – Technical Specification
TMS1589 LV Diesel Generator – Technical Specification
TMS1595 Pipeline and Structures Cathodic Protection – Technical Specification
TMS1621 Typical Pump Station Maximum Demand Template
TMS1625 Dry Type Distribution Transformers – Technical Specification
TMS1631 Vacuum Pump Station – Standard Functional Specification
TMS1637 LV Motors – Technical Specification
TMS1639 General Mechanical Works – Technical Specification
TMS1643 Water Booster Site (VSD) – Standard Functional Specification
TMS1645 Packaged Plant EI&C Requirements - Technical Specification
TMS1647 Equipment Tag Naming – Technical Specification
TMS1649 Standard MPC Water Booster – Functional Specification
TMS1650 Fixed Speed Sewage Pumping Station – Standard Functional
Specification
TMS1651 Machine Safety Implementation– Technical Specification
TMS1654 Engineering Documentation Naming Requirements
TMS1706 Typical Water Pump Station - Functional specification
WI58 Arc Flash Assessment and PPE Selection
WI140 Access to LV Electrical Equipment for Visual Inspection

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1.4 REFERENCE TYPICAL DRAWINGS

The typical drawings and other documentation is provided for information only to
demonstrate minimum content and layout of information and may not represent all the
requirements specified in the Project Documentation. The Contractor is responsible for
the detail design.

1.4.1 Sewerage Treatment Plants

Drawing Number Title

QUU-STD-STP-00 Title Block
QUU-STD-STP-01 Legend
QUU-STD-STP-02 Power Flow Cable Block Diagram
QUU-STD-STP-03 Communication Network Architecture Diagram

Single Line Diagrams

QUU-STD-STP-04 Protection Line diagram - HV/LV

QUU-STD-STP-05 Main Switchboard Single Line Diagram 400VAC & 230VAC
QUU-STD-STP-06 Area 1 Switchboard Single Line Diagram 400VAC & 230VAC
Area 1 Switchboard Single Line Diagram 400VAC & 230VAC Light and Power
QUU-STD-STP-07
DB
QUU-STD-STP-08 Area 1 Switchboard Single Line Diagram 400VAC & 230VAC UPS DB
QUU-STD-STP-09 Area 1 Switchboard Single Line Diagram 24VDC Distribution Panel 1 of 2
QUU-STD-STP-10 Area 1 Switchboard Single Line Diagram 24VDC Distribution Panel 2 of 2

General Arrangement Drawings

QUU-STD-STP-20 General Arrangement - Main Switchboard

QUU-STD-STP-21 General Arrangement - Main Switchboard
QUU-STD-STP-22 General Arrangement - Motor Control Centre
QUU-STD-STP-23 General Arrangement - Motor Control Centre
QUU-STD-STP-24 General Arrangement - PLC & Communication Panel
QUU-STD-STP-25 General Arrangement - Outdoor Switchboard
QUU-STD-STP-26 General Arrangement - Local Control Panel
QUU-STD-STP-27 General Arrangement - Construction Details 1 of 2
QUU-STD-STP-28 General Arrangement - Construction Details 2 of 2
Schedules
QUU-STD-STP-30 Equipment Schedule
QUU-STD-STP-31 Cable Schedule
QUU-STD-STP-32 Label Schedule
Schematic Diagrams

QUU-STD-STP-40 Schematic Diagram – Incomer ACB

QUU-STD-STP-41 Schematic Diagram - Auto Transfer Switch
QUU-STD-STP-42 Schematic Diagram - UPS
QUU-STD-STP-43 Schematic Diagram - DOL Starter
QUU-STD-STP-44 Schematic Diagram - DOL Reversing Starter
QUU-STD-STP-45 Schematic Diagram - VSD Starter 75kW & Above
QUU-STD-STP-46 Schematic Diagram - VSD Starter Under 75kW

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Drawing Number Title

QUU-STD-STP-47 Schematic Diagram - Motorised Control Valve
QUU-STD-STP-48 Schematic Diagram - Modulating Control Valve
Field Device Connection Diagrams
QUU-STD-STP-49 Field Device Connection Diagram - Solenoid Valves
QUU-STD-STP-50 Field Device Connection Diagram - Level Switches
QUU-STD-STP-51 Field Device Connection Diagram - Flow Switches
Instrument Loop Diagrams
QUU-STD-STP-52 Instrument Loop Diagram - Level Transmitter
QUU-STD-STP-53 Instrument Loop Diagram - Flow Transmitter
QUU-STD-STP-54 Instrument Loop Diagram - Level Relay
Termination Diagrams
QUU-STD-STP-60 Termination Diagram - PLC Layout Diagram (GE Fanuc)
QUU-STD-STP-61 Termination Diagram - Digital Input Card - 16PT (GE Fanuc)
QUU-STD-STP-62 Termination Diagram - Digital Input Card - 32PT (GE Fanuc)
QUU-STD-STP-63 Termination Diagram - Digital Input Card - 32PT (GE Fanuc)
QUU-STD-STP-64 Termination Diagram - Digital Output Card - 16PT (GE Fanuc)
QUU-STD-STP-65 Termination Diagram - Analog Input Card - 12PT (GE Fanuc)
QUU-STD-STP-66 Termination Diagram - Analog Output Card - 8PT (GE Fanuc)
QUU-STD-STP-70 Termination Diagram - Digital Input Card - 32PT (Siemens)
QUU-STD-STP-71 Termination Diagram - Digital Output Card - 16PT (Siemens)
QUU-STD-STP-72 Termination Diagram - Analog Input Card - 8PT (Siemens)
QUU-STD-STP-73 Termination Diagram - Analog Output Card - 8PT (Siemens)
QUU-STD-STP-74 Termination Diagram - DOL Starter
QUU-STD-STP-75 Termination Diagram - DOL Reversing Starter
QUU-STD-STP-76 Termination Diagram - VSD Starter 75 kW & Above
QUU-STD-STP-80 Termination Diagram - VSD Starter Under 75kW
QUU-STD-STP-81 Termination Diagram - Motorised Control Valve
QUU-STD-STP-82 Termination Diagram - Modulating Control Valve
QUU-STD-STP-83 Termination Diagram - PLC Layout Diagram (GE Fanuc)
QUU-STD-STP-84 Termination Diagram - Digital Input Card - 16PT (GE Fanuc)
QUU-STD-STP-85 Termination Diagram - Digital Input Card - 32PT (GE Fanuc)

1.4.2 Network Sites

Drawing Number Title

General
486/5/5-0171-561 Field Instrumentation Installation Details Level Probes
486/5/25-0003-342 Valve Pit Pressure Sensor Installation and Details
486/5/7-0470-024 Field Instrumentation Installation Details
486/4/7-0032-016 Water Meters General Arrangement

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Site Description Electrical Functional RTU

Drawings Specification Code
Trio Radio Repeater √ NA NA
Reservoir – Up to 2 off Reservoirs and Inlet Valves √ √ √
Sewage Pump Station (Full option switchboard) √ √ √
Sewage Pump Station (Reduced option switch board) √ √ √
Sewage Pump Station ( Low Risk switchboard) √ √ √
Sewage Pump Station ( Form 1 switchboard) √ √ √
Vacuum Sewage Pump Station √ √ √
Water Booster - Lowara √ √ √
Water Booster - MPC √ √ √
Water Booster - VSD √ √ √
Water Monitoring Stations- PRV, FM, PG, Valves √ √ √
Water Pump Station √ √ √

√ - Available on request from QUU

NA – Not Available

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2 STANDARDS AND REGULATIONS

All design, equipment and workmanship shall conform to the most recent requirements
of the relevant statutory Local, State and Commonwealth Authorities and current
applicable Australian Standards. Alternatively, where no Australian Standard exists,
work shall conform to the most current and applicable International standard.

Where conflict exists between different Codes, Standards or Regulations, the most
onerous conditions of specification shall apply unless accepted otherwise in writing by
QUU.

The Contractor shall not deviate from the provisions of the relevant standard without
first obtaining agreement in writing from QUU.

Particular standards and regulations relevant to the work include but are not necessarily
limited to the following:

2.1 AUSTRALIAN STANDARDS

All equipment shall be designed in accordance with the latest edition of all relevant
Australian and International Standards, Codes and Regulations except where modified
by this specification.

AS 1000 International System of Units (S.I.) and its Applications

AS1319 Safety Signs for the occupational environment
AS 1020 Control of Undesirable Static Electricity
AS 1081 Acoustics - Measurement of airborne noise emitted by rotating electrical machinery
– All Parts
AS 1101 Graphical symbols for general engineering
AS 1192 Electroplated coatings, Nickel and chromium.
AS/NZS 1158.3.1 Lighting for roads and public spaces Pedestrian area (Category P) lighting -
Performance and design requirements
AS 1214 Hot-dip galvanised coatings on threaded fasteners (ISO metric coarse thread series)
AS 1275 Metric Screw Threads for Fasteners
AS 1284 Electricity Meters– All Parts
AS 1307.2 Surge Arresters – Metal-Oxide Surge arresters without gaps for A.C. systems
AS 1319 Safety Signs for the occupational environment
AS 1324 Air Filters for use in Air Conditioning and general ventilation – All Parts
AS 1345 Identification of the contents of piping, conduits and ducts.
AS 1359 Rotating electrical machines – General Requirements – Al Parts
AS 1428 Design for access and mobility – All Parts
AS/NZS 1429.1 Electric Cables- Polymeric Insulated – For working voltages 3.6kV up to and
including 36kV
AS 1530 Methods for fire tests on building materials, Components and structures – All Parts
AS 1603 Automatic Fire Detection and Alarm Systems – All Parts
AS 1627 Metal Finishing – Preparation and pre-treatment of surfaces – All Parts.

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AS 1657 Fixed Platforms, Walkways, Stairways and Ladders

AS 1660 Test methods for Electric Cables – All Parts
AS 1668 The use of Ventilation and Air-Conditioning in Buildings – All Parts
AS 1670 Fire Detection, warning, control and intercom systems – All Parts
AS 1680 Interior Lighting - All Parts
AS 1682 Fire Dampers – All Parts
AS 1767 Insulating liquids – All Parts
AS/NZS 1768 Lightning Protection
AS 1789 Electroplated zinc (electrogalvanized) coatings on ferrous articles (batch process)
AS 1824 Insulation Coordination – All Parts
AS 1841 Portable Fire Extinguishers – All Parts
AS 1897 Fasteners – Electroplated coatings
AS 1905 Components for the protection of openings in fire resistance walls – All Parts
AS/NZS 2053 Conduits and fittings for electrical installations – All Parts
AS 2067 Substations and High Voltage installations exceeding 1kV
AS 2239 Galvanic (sacrificial) anodes for cathodic protection
AS 2293 Emergency escape lighting and exit signs for buildings – All Parts
AS 2360 Measurement of fluid flow in closed conduits – All Parts
AS 2374.1.2 Power Transformers – Minimum Energy Performance Standard (MEPS)
requirements for distribution transformers
AS 2374.8 Power Transformers – Application Guide
AS 2467 Maintenance of Electrical Switchgear
AS 2700 Colour Standards for General purposes
AS 2832 Cathodic Protection of Metals – All Parts
AS/NZS 2857 Timber Drums for Insulated and Bare Cables
AS 2865 Safe Working in a Confined Space
AS/NZS 3000 Electrical installations (known as the Wiring Rules)
AS/NZS 3008.1.1 Electrical Installations – Selection of Cables – Cables for Alternating
Voltages up to and Including 0.6/1kV – Typical Australian Installation
Conditions
AS/NZS 3010 Electrical Installation – Generator Sets
AS 3011 Electrical Installations – Secondary batteries installed in buildings – All Parts
AS 3017 Electrical Installations – Verification guidelines
AS/NZS 3100 Approval and test specification - General requirements for electrical
equipment
AS/NZS 3111 Approval and test specification - Miniature overcurrent circuit-breakers
AS/NZS 3133 Approval and test specification – Air-break switches
AS/NZS 3190 Approval and test specification – Residual current devices (current-operated earth-
leakage devices)s
AS/NZS 3808 Insulation and sheathing materials for electric cables
AS/NZS 3863 Galvanised mild steel wire for armouring electric circuits
AS 3894 Site testing of protective coatings – All Parts .
AS 3983 Metal drums for insulated and bare electric cables
AS 4044 Battery chargers for stationary batteries
AS 4009 Software reviews and audits

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AS 4070 Recommended practices for protection of low voltage electrical

installation and equipment in MEN systems from transient overvoltages
AS 4024 Safety of Machinery – All Parts
AS/NZS 4325.1 Compression and mechanical connectors for power cables with copper or
aluminium conductors – Test methods and requirements
AS 4398 Insulators- Ceramic or glass- Station post for indoor and outdoor use – Voltages
greater than 1000V AC – All Parts
AS 4428 Fire Detection, Warning, Control & Intercom Systems – All Parts
AS 4436 Guide for the selection of insulators in respect of polluted conditions
AS 4509 Stand-alone power systems – All Parts
AS/NZS 4534 Zinc and zinc/aluminium-allow coatings on steel wire
AS/NZS 4680 Hot-dip galvanised (zinc) coatings on fabricated ferrous articles
AS 4761.1 Competencies for working with electrical equipment for hazardous areas (EEHA) –
Competency Standards
AS 4777 Grid-connections of energy systems via inverters
AS/NZS 4792 Hot-dip galvanised (zinc) coatings on ferrous hollow sections, applied by a
continuous or specialised process
AS/NZS 4805 Accessories for Electric Cables-Test Requirements – Power Cables from 3.6kV up
to 36kV – All Parts
AS 4827.1 Coating defect surveys for buried pipelines – Direct current voltage gradient
(DCVG)
AS 4853 Electrical hazards on metallic pipelines
AS/NZS 5000.1 Electric Cables – Polymeric insulated for working voltages up to and including
0.6/1(1.2)kV

AS/NZS 5000.2 Electric cables - Polymeric insulated - For working voltages up to and
including 450/750 V
AS/NZS 5000.3 Electric cables - Polymeric insulated - Multicore control cables
AS 5033 Installation of photovoltaic (PV) arrays
AS 6183 Fire protection equipment – Carbon dioxide extinguishing systems for use on
premises – Design and installation
AS ISO 14520 Gaseous fire-extinguishing systems – All Parts
AS 60034 Rotating Electrical Machines
AS 60038 Standard Voltages
AS 60044.7 Instrument transformers - Part 7: Electronic voltage transformers
AS 60044.8 Instrument transformers - Part 8: Electronic current transformers
AS 60060.3 High-voltage test techniques Part 3: Definitions and requirements for on-site
testing
AS 60076 Power Transformers – All Parts

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AS/NZS 60079 Explosive Atmospheres – All Parts

AS 60265.1 High Voltage Switches Part 1: Switches for rated voltages above 1kV and less than
52kV
AS/NZS 60137 Insulated bushings for alternating voltages above 1000 V
AS 60146 Semiconductor Converters – General Requirements and Line Commutated
Converters
AS 60214.1 Tap-Changers – Performance Requirements and test methods
AS 60422 Mineral insulating oils in electrical equipment – Supervision and maintenance
guidance
AS 60470 High-voltage alternating current contactors and contactor-based motor-starters
AS 60529 Degrees of Protection Provided by Enclosures (IP Code)
AS 60849 Sound systems for emergency purposes
AS/NZS 60947 Low-voltage Switchgear and Control gear – All Parts
AS/NZS 61000 Electromagnetic Compatibility (EMC) – All Parts
AS IEC 61131 Programmable Controllers – All Parts
AS/NZS 61439 Low-voltage switchgear and control gear assemblies All Parts
AS 61508 Functional safety of electrical/electronic/programmable electronic safety-related
systems
AS/NZS 61558 Safety of power transformers, power supplies, reactors and similar products - All
Parts
AS 62040 Uninterruptible Power Supply (UPS) – All Parts
AS 62061 Safety of machinery - Functional safety of safety-related electrical, electronic and
programmable electronic control systems
AS 62271 High-Voltage Switchgear and Control Gear – All Parts
AS/NZS CISPR Industrial, Scientific and medical equipment – Radio-frequency disturbance
11 characteristics – Limits and methods of measurements

2.2 INTERNATIONAL STANDARDS

IEC 60034 Rotating electrical machines – All Parts

IEC 60038 Standard Voltages

IEC 60044.7 Instrument transformers - Part 7: Electronic voltage transformers

IEC 60044.8 Instrument transformers - Part 8: Electronic current transformers
IEC 60050 International Electro-technical Vocabulary – All Parts
IEC 60051 Direct Acting Indicating Analogue Electrical
Measuring Instrument and their Accessories – All Parts
IEC 60060-1 High-voltage test techniques Part 1: General definitions and test requirements

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IEC 60060-2 High-voltage test techniques Part 2: Measuring systems

IEC 60071 Insulation co-ordination All Parts
IEC 60228 Conductors of Insulated Cables
IEC 60269 Low Voltage Fuses – All Parts
IEC 60296 Fluids for Electro-Technical applications – Unused Mineral insulating oils for
transformers and switchgear
IEC 60332 Tests on electric and optical fibre cables under fire conditions – All Parts
IEC 60417 Graphical Symbols for Diagrams – IEC database edition
IEC 60445 Basic and safety principles for man-machine interface, marking and identification -
Identification of equipment terminals, conductor terminations and conductors
IEC 60660 Tests on Indoor post insulators of organic material for systems with nominal
voltages greater than 1000V up to but not including 300kV
IEC 60694 Common Specifications for high-voltage switchgear and control gear standards
IEC 60751 Industrial platinum resistance thermometers and platinum temperature sensors
IEC 61158 Industrial communication networks - Fieldbus specifications – All Parts-

IEC 61243-5 Live working - Voltage detectors - Part 5: Voltage detecting systems (VDS)
IEC TR 61641 Enclosed low-voltage switchgear and control gear assemblies - Guide for testing
under conditions of arcing due to internal fault
IEC 61643 Low-voltage surge protective devices – All Parts
IEC 61850 Communications networks and systems for power utility automation – All Parts
IEC 62444 Cable glands for electrical installations
IEC 62443 Security for industrial automation and control systems.– All Parts
IEC 62541 OPC unified architecture – all parts
IEC TS 62941 Terrestrial photovoltaic (PV) modules - Guideline for increased confidence in PV
module design qualification and type approval
IEEE 519 Recommended Practices And Requirements For Harmonic Control In Electrical
Power Systems
IEEE Std 1815 Electric Power Systems Communications – Distributed
Network Protocol (DNP3)
IEEE 802.3 Ethernet
ISO 13849 Safety Of Machinery - Safety-Related Parts Of Control Systems – All Parts
ISO 9001 Quality Management Systems
NFPA 70E:2015 Standard for Electrical Safety in the Workplace

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2.3 ACTS AND REGULATIONS

The current regulations and statutory requirements of the State of Queensland,

Australia, shall be complied with, including:

• Queensland Electricity Act 1994

• Queensland Electricity Regulations 2006
• Queensland Work Health and Safety Act 2011
• Queensland: Environmental Protection Act – 1994
• Environmental Protection Regulation 2008
• Environmental Protection (Air) Policy 2008
• Environmental Protection (Noise) Policy 2008
• Environmental Protection (Water) Policy 2009
• National Construction Code 2016, volumes 1, 2, 3 and The Guide
• Queensland Electricity Connection and Metering Manual (QECMM) Version 11
• Work Health and Safety Regulations 2011
• Work Health and Safety Codes of Practice 2015
• Queensland Electrical Safety Act 2002
• Queensland Electrical Safety Code of Practice 2013
• Queensland Electrical Safety Regulation 2013
• Queensland Professional Engineers Act 2002
• Queensland Professional Engineers Regulation 2003
• Queensland Workers’ Compensation and Rehabilitation Act 2003 and Amendment
Act 2015

2.4 SUB-CONTRACTORS

The Contractor shall disclose, at the tender stage, all sub-Contractors they intend to use
for the contract works. The Contractor shall not sub-contract any work to any party
without the prior written consent of QUU. It shall remain the Contractor’s responsibility
to audit and co-ordinate the performance of their sub-Contractors with results being
disclosed to QUU.

All requirements applicable to the Contractor are applicable to sub-Contractors or sub-

suppliers.

2.5 CONTRACTOR EXCEPTIONS

The Contractor shall be responsible to submit, together with the Tender, a list of
deviations or exceptions to this Specification. In the absence of any exceptions, it shall
be construed that the Contractor fully complies with this Specification.

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2.6 ORDER OF PRECEDENCE

In the event of any conflict arising between this Specification and other documents
listed herein, refer comments to QUU for clarification before design or fabrication
commences.

The order of precedence that applies is as follows:-

• The Contract or Purchase Order Scope of Work

• Project Data Sheets
• This Specification
• Project Drawings
• Australian Codes and Standards
• International Codes and Standards

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3 GENERAL DESIGN

3.1 OPERATING CONDITIONS AND DESIGN LIFE

EI&C equipment shall generally be designed for minimum service-life duration of 20

years in the environment and for the duty specified herein and on the Project Data
Sheets. The equipment shall also be suitable for a minimum of 1 year normal
continuous operation without maintenance at the duty specified herein and on the
Project Data Sheets.

All EI&C equipment shall be designed to operate continuously at full load for 24 hours
per day, 365 days per year under the climatic conditions detailed in this specification.
All equipment shall be designed to perform this duty safely and without being attended.

Refer to the technical specifications in section 1.3 for minimum design service life of
specific EI&C equipment.

3.2 SITE CLIMATIC CONDITIONS

Where equipment is installed in a temperature controlled weatherproof building, the

design environmental conditions shall be as specified on the Project Data Sheets. For
all other cases equipment shall be designed for the site conditions as defined below:-

Location South East Queensland

Altitude above mean sea level. 0-300m

Ambient Temperature Minimum -5°C
Maximum (dry bulb) 45°C
Relative Humidity Minimum 26%
Maximum 100% condensing
Solar Radiation Black bulb design temperature - 85°C
minimum mechanical design
temperature for equipment
exposed to solar radiation

Note: Corrosive environments are locations where H2S gas or other corrosive chemicals
and gasses can exist under normal operating conditions and can be both indoor and
outdoor areas. This is applicable to all wet wells installations. All areas including inside
air conditioned switch rooms at STP sites are considered corrosive environments. All
materials installed shall be suitable for the environment.

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3.3 OPERATING REQUIREMENTS

The equipment ratings shown on the design drawings shall be the required ratings after
all derating factors have been applied.

All equipment shall be selected and installed so that all circuits can operate
simultaneously at the full load rating shown on the drawings at the worst climatic
extreme detailed in Clause 3.2 of this specification.

The full load rating for motor circuits shall be taken as the motor full load current while
the rating for other circuits shall be the power or current rating nominated on the
manufacturer’s equipment nameplate or label. The maximum demand of DB’s and
associated circuits shall be as per AS3000 maximum demand calculations.

3.4 DESIGN SERVICE

Equipment shall be suitable for operation in water and sewerage facilities. Assets
typically operated by QUU include the following:-

• Sewerage Treatment Plants

• Water Treatment Plants
• Sewerage Pump Stations
• Water Pump Stations
• Water Booster Sites
• Reservoirs
• Odour Control Facilities
• Valve Stations
• Water Sampling and Chemical Dosing sites

3.5 UTILITY DATA

The electrical system may have the following voltage levels:

High Voltage Power Supply 33 kV AC, three phase 3 wire, 50 Hz,

11 kV AC three phase 3 wire 50 Hz,
6.6 kV AC, three phase 3 wire, 50 Hz
Low Voltage Supplies 3 ph, 4 Wire, 400 Volt +10,-6% 50 Hz ± 2%,
MEN System Voltage Unbalance <5%
Single Phase Power Supplies 230 V AC, +10,-6%, 2 wire, 50Hz ± 2%,
Control Power Supplies: UPS 230 V AC, single phase 2 wire, 50 Hz
Regulated 24 V DC
Special Purpose Power Supplies Regulated 48VDC and 110VDC

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The EI&C equipment shall be designed to operate continuously under the following
conditions:-

• HV Distribution: Steady State Voltage ± 5% nominal voltage

• LV Distribution: Steady State Voltage +10,-6% nominal voltage
• Steady State Frequency ± 2.5% nominal frequency
• Transient Voltage ± 20% nominal voltage
• Transient Frequency ± 5% nominal frequency

The harmonic voltage and current distortion shall be provided as per TEM336 PSA
Guidelines.

3.6 MATERIALS

All materials shall be as detailed on the Project Data Sheets and referenced
specifications. When materials are not specified the Contractor may offer standard
materials suitable for the environmental and operating design conditions. All materials
shall be new and unused, free of defects and shall be supplied with relevant certification
and documentation.

All supplied electrical equipment and instrumentation shall be selected from TMS62
Preferred Equipment List– Electrical and Instrumentation. The Contractor shall not
deviate from these requirements without prior written approval from QUU. Where the
required components are not specified the Contractor may offer standard components
suitable for the application, environment and operating conditions.

Unspecified equipment shall be of the same type, grade and quality as similar items
specified in the Project Documentation. Corresponding parts of similar equipment shall
where possible be interchangeable.

All components shall be of standard manufacture and readily available from suppliers
unless specified otherwise in the Project Documentation. All equipment to be supplied
shall be sourced from local OEM (Original Equipment Manufacturer) Authorised
Distributors within Australia.

The selected components shall be suitably rated for the application with particular
attention given to the following:
• Process conditions
• Power rating
• Voltage rating
• Frequency rating
• Duty rating

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• IP rating
• Temperature rating
• Corrosion protection

All equipment and materials shall be new and comply with the relevant specifications,
regulations, codes and standards. All components and materials supplied by the
Contractor shall be free from:
• Asbestos (all types)
• Ceramic fibre
• Chlorofluorocarbons
• Polychlorobiphenyls (PCB) and their isomers
• Radioactive materials (unless specified otherwise in Project
Documentation)
• Mercury

3.7 MEASUREMENT UNITS

AS/ISO 1000 (metric SI system) shall be used. All documentation and correspondence
shall be in the English language. Additional clarifications of units as follows:

Variable Units
Flow
• Mass kg/h
• Liquids (volumetric) l/s, kl/day, Ml/day
Level %, m, mAHD
Density kg/m3
Pressure
• Gauge kPag
• Absolute kPaa
• Differential kPa

Temperature °C
Conductivity S/cm
Viscosity cP
Analysers % or ppm

3.8 DESIGN PERSONNEL

Personnel engaged for EI&C design services shall be accredited, suitably experienced,
competent and skilled in the particular field of work in which they are engaged. All

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design works shall be completed by or under the direct supervision of RPEQ Electrical
Engineers.

3.9 WEATHER AND INGRESS PROTECTION

For ingress protection requirements of specific EI&C equipment refer to the technical
specifications listed in section 1.3.

3.10 EQUIPMENT TAG NAMING

All EI&C equipment and associated cables shall be assigned unique tagnames by the
Contractor and must be accepted by QUU. Tagnames shall be assigned to existing
equipment and cables if not already assigned, where the project scope of work requires
interfacing new equipment with existing operational equipment.

Equipment and cable tag names shall be presented in the following formats for QUU
acceptance at the early stage of the design process:-

• Cable Schedule
• Instrument List
• Valve List
• Motor List
• Equipment Lists

Refer to TMS1647 Equipment Tag Naming Technical Specification

3.11 EQUIPMENT LABELS

Refer to QUU technical specifications in section 1.3 for labelling requirements to be

provided to EI&C equipment.

All electrical enclosures including DB’s, switchboards, MCC’s, control panels and
communications panels shall have a label clearly identifying the highest voltage level
present inside the enclosure.

All sources of voltage supply shall be clearly identified on the label which shall be fixed
to the front of the enclosure or adjacent to the enclosure. The label(s) shall indicate
where all voltage sources are fed from.

Typical red label with white text enclosure label shall state:-

Danger ZZZ Volts

Fed from Panel XXX and CB YYY

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Where XXX and YYY are equipment tag numbers assigned by the Contractor and used
throughout the design documentation and ZZZ is the voltage level. Enclosures with
ELV as the highest voltage source do not require “Danger” stated on the label and can
be a white label with black text.

The design intention is that personal should not require to refer to electrical
documentation to be able to quickly locate and isolate all voltage supplies to an
enclosure.

CB’s feeding fire services equipment; emergency lighting and other circuits related to
personnel safety shall have warning labels that comply with relevant industry standards
and in particular AS2293.1.

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4 ELECTRICAL DESIGN

The electrical system shall be designed to be cost effective, with no technical

compromise of the performance, operation and safety of the equipment or other assets.

Power system protection devices shall be selected to provide safe fast and coordinated
operation, providing tripping of the upstream device nearest the point of fault or
overload.

4.1 MINIMUM REQUIREMENTS

Equipment shall be designed to satisfy the minimum requirements listed in order of

priority below unless specified otherwise in the Project Documentation:

• Safety of personnel,
• Protection of plant and environment
• Ease of operation to meet process requirements
• Reliability and continuity of supply
• Maintainability
• Minimisation of overall capital and operating costs, including replacement costs
• Ease of future expansion and upgrade

4.2 ENERGY EFFICIENCY

Energy efficient designs shall take budget constraints, industry norms, and good
practice into consideration.

Wherever possible, designs shall incorporate all practical energy sources and design
features in order to conserve natural resources and be environmentally conscious.

4.3 ELECTRICAL SAFETY

4.3.1 Protection from Live Parts

Equipment shall be designed and constructed to avoid direct contact with live parts.
Protection shall be provided against injury that may arise from contact with parts of the
electrical installation that are live in normal service or may become live under fault
conditions. Accepted protection methods shall be one or combination of the following:

• Insulation
• Barriers/obstructions
• Enclosures
• Parts to be installed out of reach
• Earthing and bonding

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Residual Current Devices (RCD’s) are not accepted as a standalone basic protection;
however RCD’s may be used in conjunction with the aforementioned protection
methods.

Consideration towards access, during fault finding and maintenance, must be taken into
account during the design phases. This may include specifying a degree of protection
IP2X when covers are removed.

Switchrooms, transformer enclosures and other electrical equipment shall not be

accessible to unauthorised persons. Oil transformers are preferred to be installed
outdoors within a fenced area or locked metal enclosure. Small isolation or dry type
transformers may be located indoors. Switchrooms shall be lockable and provided with
statutory signs in compliance with AS 1319.

4.3.2 Equipment Design and Location

Equipment shall be designed and installed to meet the following constraints:-

• Eliminate hazards that impact the safety and protection of the operators and
other plant occupants.
• Ensure that dangerous forces and gases produced by electrical short circuit faults
are contained or directed away from the operating areas of personnel. Gases
which arise as a result of interruption of a short circuit shall be collected and
controlled to safe temperatures and pressures before being allowed to escape
from the equipment.
• Insulating and di-electric materials used in all electrical equipment shall be non-
toxic and shall not contain chemical compounds which contain hazardous
environmental contaminants
• Exposure to arc flash hazard risks, toxic or flammable substances when
operating and maintaining equipment must be eliminated or minimised to as low
as reasonably possible (ALARP).

4.3.3 Induced Voltage

In the design phase, consideration shall be given towards the following aspects of
energising equipment and induced voltages:

• Malfunction of control systems equipment

• Back feed from instrument transformers
• Open circuiting of current transformers
• Capacitive coupling
• Induction via parallel circuits

It shall be possible through equipment selection, isolation and standard operating

procedures to protect against these and associated hazards.

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4.3.4 Evacuation

All services required for safe evacuation of the facilities shall be designed for 90 minute
autonomy after loss of both main and emergency generation. Electrical power shall be
provided for sufficient light fittings and communications systems to be available to
allow personnel to be mustered and to be safely evacuated and to maintain contact with
external emergency services.

Refer to section 4.15.6 of this document for emergency lighting design requirements.

Sufficient clearance for access and evacuation must be maintained, even with equipment
doors open. Refer to AS 3000 and AS 2067 for minimum requirements.

Exits shall be arranged so that the maximum length of the escape route complies with
the requirements of Section D of the National Construction Code.

Switchrooms shall have a minimum of two exits.

4.4 ENVIRONMENT

4.4.1 Audible Noise

Electrical equipment, especially rotating machines, rectifiers, transformers, inverters

and VSD’s shall be selected in consideration of the maximum permissible sound
pressure level. Noise levels for electrical equipment shall be no greater than the levels
stated in the relevant Australian Standards mentioned for that particular equipment.

Areas which require specific consideration include:

• Blower Rooms
• Air Compressors
• Diesel Generators
• Switchrooms
• Pump Rooms

The accumulated peak noise level (all equipment operating at rated load) shall not
exceed 80db unless specified otherwise in the Project Documentation.

Refer to TMS1639 General Mechanical Works – Technical Specification for other

design constraints regarding noise emission levels.

4.4.2 Spills and Emissions

The following measures shall be undertaken to manage the risk of spills and emissions:-

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• Oil insulated transformers shall be situated within a bunded area to contain any
spills and bund containment volume shall comply with AS2067.
• Wet cell batteries shall to be housed in a suitable enclosure such that spills are
contained without posing a hazard to the environment
• Corrosive, toxic or flammable gases emitted by equipment in normal or
abnormal operation shall be vented to areas not occupied by personnel and other
equipment.

4.4.3 Pests

Pests normally encountered are rats, mice, birds, termites, insects, spiders, geckos,
snakes, bats and burrowing animals. All installations shall be designed to prevent
vermin from accessing equipment and cabling. If access cannot be completely
prevented the equipment and cables must be resistant to attack or degradation from
vermin.

Bird resistance barriers or made-for-purpose netting shall be installed on eaves, under

roofs and around exposed beams where birds might roost.

4.5 CLASSIFYING LOADS

Electrical loads shall be classified as performing a service which is:

• Essential service – where required to meet a legislative requirement or when

failing in operations or failing if called upon to operate and can affect the
continuity, quality and quantity of the assets production.
• Non-Essential service

Essential loads shall be connected to a dedicated essential bus section of the main LV
switchboard for the site or process area. The essential bus supply shall be backed up by
a standby generator unless specified otherwise in the Project Documentation. For new
assets the generator can be portable or permanently installed. For modifications to
existing assets the generation spare capacity shall be assessed for any proposed new
loads.

Network assets typically have a single bus arrangement and all connected loads are
considered as essential services.

During the design phase the Contractor shall undertake a risk assessment with
collaboration from QUU stakeholders to determine if a permanently installed generator
or mobile generator connection facility is required. The Contractor shall select the
generator rating required to meet the essential service loads. The generator design shall
comply with TMS1589 LV Diesel Generator Technical Specification.

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Unless specified otherwise in the Project Documentation the Contractor shall allow a
fixed price provisional sum for a permanently installed generator with ATS connection
to the essential services switchboard and an option price for a mobile generator
connection plug at the essential services switchboard with a manual transfer switch. The
generator connections shall be in accordance with QUU typical design drawings and
shall be provided in an arc fault contained enclosure that complies with TMS60 LV
Switchboard Technical Specification unless specified otherwise in the Project
Documentation.

For mobile generators a permanent external socket outlet or termination box connection
shall be provided for connection of the generator. Hard stand space shall be reserved for
the generator in the plant layout, outside of hazardous zones and within the boundary of
the buried earth grid for HV installations. Two accessible earth bonding points in the
vicinity of the generator shall be installed - one for connection to the mobile generator
and one for connection to diesel refuelling tankers.

4.5.1 Essential Service Supply

An uninterruptable Power Supply (UPS) shall provide the means to sustain loads
requiring continuity of service under supply interrupt conditions. The back-up power
supply system shall be designed with eight (8) hour backup battery banks, unless
specified otherwise in Project Documentation. Battery Charger DC systems are only
accepted for HV Switchboard installations.

4.6 SYSTEM VOLTAGES

The voltage and frequency variations given are the specified design values at the point
of supply under steady state conditions. Momentary supply system disturbances shall
not result in voltage and frequency variation in excess of steady state values

4.6.1 Voltage Level Definitions:

Voltage levels are as defined by AS3000:-

• ELV ≤ 50VAC or ≤ 120VDC ripple free

• LV Exceeding ELV, ≤ 1kV AC or ≤ 1.5kV DC ripple-free
• HV >1kV AC or >1.5V DC ripple-free

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4.6.2 HV Network

Voltage Frequency
Service Phases Neutral-Earth Connection
(kV) (Hz)

33 ± 5%,
HV 11 ± 5%, Impedance or Solid and subject
3 50
Distribution 6.6 ± 5%, to PSA
3.3 ± 5%

Large HV 6.6 ± 5%, Impedance or Solid and subject

3 50
Motors 3.3 ± 5% to PSA

4.6.3 LV Network

Service Voltage (V) Phases Frequency Neutral-

(Hz) Earth
Connection
Low Voltage Distribution 400 + 10% -6% 3+ N 50 Solid

Emergency Generator 230 + 10% -6% 1+N 50 Solid

400 +10% - 6% 3+N
Induction Motors 400 + 10% -6% 3+ N 50 Solid
Lighting and Small Power 230 + 10% -6% 1+N 50 Solid
400 +10% - 6% 3+ N
UPS Distribution 230 + 10% -6% 1 +N 50 Solid
Motor Heaters 230 + 10% -6% 1+ N 50 Solid
Instrument Power (not 230 + 10% -6% 3+ N 50 Solid
preferred)

4.6.4 ELV Equipment

Service Voltage (V) Earth Connection

LV Switchboard and MCC Internal Controls 24 ± 5% Negative

Motor Contactors 24 ± 5% Negative
Motor Control Circuits 24 ± 10% Negative
Instrument Power Supplies 24 ± 10% Negative
HV Protection and Control 24 ± 10% Negative
LV and HV Circuit Breaker spring charging 24 ± 10% Negative
Instrument Power(preferred) 24 ± 10% Negative
Digital I/O 24 ± 10% Negative
Control Systems 24 ± 10% Negative
Communication Equipment 24 ± 10% Negative

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4.6.5 Distribution Transformer Ratings

Secondary Voltage (V) Maximum Rating (MVA)

400 2.5
3300 2.5
6 600 10

4.7 POWER SYSTEMS ANALYSIS

PSA shall be conducted as per TEM336 PSA Guidelines for all new sites and projects
that require modifications to the existing power system installed at the site. Calculations
and network modelling shall be provided in support of the electrical design and the
Project Documentation will nominate the PSA deliverables required and may comprise
of the following components:-

• Fault Level Calculations

• Load Flow
• Protection Co-ordination
• Arc Flash Analysis
• Harmonics Study
• Large motor starting and dynamic/static modelling
• Earthing system modelling including step, touch and transfer potentials
• Power cable sizing calculations (AC and DC)
• Maximum Demand (LV and ELV DB’s)
• Power Factor
• Power Quality Analysis
• Generator and Transformer sizing calculations

PSA design scope of works related to development and updating the SKM Power Tools
model and device libraries shall be undertaken by Contractors pre-approved by QUU to
perform the works. Refer to QUU and Project Documentation for the list of pre-
approved PSA consultants.

4.8 DESIGN MARGINS

The complete electrical system shall be economically designed for continuous and
reliable service to ensure safety of personnel and equipment, ease of maintenance and
operation, minimum power losses, mechanical protection of equipment, interchange
ability of equipment and the addition of future loads.

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The rating of electrical equipment shall be generally based of the maximum demand and
also taking into account:-
• Diversity
• Utilisation
• Operating Time (duty/standby)
• Load Factor
• Efficiency
• Future Capacity
• Power Factor
• Insulation coordination

4.8.1 Normal Plant Loading

When evaluating loads the utilisation factors shall be applied as described in the
following table:-

Operating Mode Load Rating

Continuously operating equipment 100% with conservative load factors applied and not less
ie wet weather flows through assets than 0.8
Intermittent equipment Capacity to take into consideration configuration
redundancy and process loads. Assume 50% of nominal
loads in the absence of final design inputs
Standby plant operating Nil additional allowance where mechanical, hardwired
electrical or control system software interlocks prevent
simultaneous operation with duty plant in all modes.
Minimum load condition All transformers at the site loaded to 10% of rated
secondary current

4.8.2 Motor Starting

Refer to TEM336 PSA Guidelines for design constraints and analysis when starting new
and existing motors.

4.8.3 Maximum Demand

For LV distribution boards, the maximum demand shall be calculated to the

requirements of AS 3000. Refer to TEM336 PSA Guidelines for details on maximum
demand calculations.

4.8.4 Load Allocation

Where practical the power supplies to duplicated process plant items shall be designed
such that for a single electrical plant fault or outage, at least 50% of the plant equipment
installed shall remain in service.

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4.8.5 Load List

All new and modifications to existing assets shall have a load list documenting existing
and new loads. Refer to TEM336 PSA Guidelines for details required to be included in
the load list.

4.8.6 Supply Capacity

The power supply capacity at the electrical point of supply from the utility and
associated on site switchgear and transformers shall be capable of supplying
continuously 120% of the sites maximum demand load, assessed according to the
applicable load data, without exceeding specified voltage limits and equipment ratings.

Spare capacity shall be provided to cater for the possibility of future expansion of plant
loads. Where future expansion plans are nominated by QUU as unlikely, unfeasible or
specifically not catered for, the spare capacity at the finalisation of design may be
reduced accordingly, but not less than 10% of the maximum demand load.

4.8.7 Equipment Loadings

4.8.7.1 Feeders

Feeders and related equipment serving individual loads shall not be sized for future
growth. Where feeder circuits supply multiple loads consideration shall be given to
accommodate potential load growth, to the extent of capacity of upstream supplies.

In cases where additional (as opposed to larger) equipment is required to provide

reserve for future growth, the excess capacity shall not be installed, but the design shall
facilitate expansion should greater capacity actually be required in the future.

4.8.7.2 Transformers

The rating of all new transformers shall be the nameplate rating at the ambient
conditions specified in section 3.2. If the transformer forced cooled rating is only
required for future load growth, provision only shall be made for future cooling fans.

For supply arrangements having more than one transformer serving interconnected
buses with one transformer out of service, the remaining transformer(s) shall have
sufficient installed capacity to serve the total operating load on the buses, including
reserve for future load growth, within economic reason.

HV feeders serving unit substations shall be sized to carry the simultaneous full load
current of the transformer(s) forced cooling (ONAF) rated currents.

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4.8.8 Power Network Configuration

Power distribution features of the electrical network shall be consistent with the
Protection Philosophy Design Report provided by the Contractor during detail design.
Refer section 4.21 of this document for details on the content of the Protection
Philosophy Design Report.

Power distribution systems (transformers, switchboards, cabling etc) shall be designed

such that the largest load connected at each switchboard can be successfully energised
with all other loads operating without causing disturbances to other connected
loads(upstream and downstream).

In addition, the distribution system will be designed such that electrical faults are safely
isolated with minimum disturbances to the healthy system, such that the power system
has overall transient and steady state stability.

For large sites the main LV switchboard supply redundancy shall be provided where
practicable by means of multiple feeders and associated bus ties. The configurations of
the bus bars shall allow one switchboard bus section to be taken out of service while
still maintaining some degree of plant operations.

The provision of stand-by generation capacity to supply non-essential service loads

shall be subject to an evaluation of the load requirements in conjunction with the
relevant factors that may affect process reliability and availability. In general a 100%
redundant power supply is not required for non-essential loads.

4.9 FAULT AND INSULATION LEVELS

The maximum system fault level shall be calculated on the most onerous operating
connections that can be configured in the power network and shall include emergency
standby generator (permanently installed) and mobile generators (connection provision
only provided) operating scenarios.

LV bus system fault levels shall be calculated using the maximum HV fault level with
single transformer feeder connected to each LV bus segment (i.e. normal operating
conditions) and all duty motors contributing to the fault. LV switchboards with
operating modes that include closed bus ties, multiple feeders and/or interconnected
back feeds shall be rated for the maximum feasible fault level.

The summary of applicable maximum fault and insulation levels for switchgear and bus
bar system shall generally be as follows:

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4.9.1 Equipment Fault Current Ratings and Insulation Levels

Service Voltage Max. Fault Fault Basic Insulation

(kV) Withstand Duration (s) Level (kV- Peak)
Current (kA)
HV Secondary 33 31.5 3 170
Distribution
HV Secondary 11 25 1 95
Distribution
HV Secondary 6.6 25 1 95
Distribution
HV Secondary 3.3 25 1 95
Distribution
LV Switchboard 0.4 80 1 3
and MCC
Lighting and .400/.230 20 0.2 NA
Small Power DB

The design must allow for a 20% future increase in the maximum prospective fault level
over the intended design life of the facility.

Derivation of short circuit currents shall be generated as a system modelling output in

accordance with TEM336 Power Systems Analysis Guidelines.

4.10 ELECTRICAL PROTECTION

Protection features of the power system shall be consistent with the Protection
Philosophy Design Report produced during detail design.

A Protection Philosophy Design Report is not required for Network sites with LV
supply unless specified otherwise in the Project Documentation. For LV Network sites
the Protection Co-ordination Report in compliance with TEM336 PSA Guidelines is
adequate design documentation.

4.10.1 Primary Protection

The protective devices selected shall provide adequate safeguards against the effects of
any fault occurring on the system or component parts.

Where appropriate unit protection schemes shall be utilised. All protective devices,
including relays and current transformers, shall be adequately rated to withstand the
prospective short circuit current which can flow or be induced in the power network.

Multifunction protective relays shall be implemented for HV protection schemes unless

specified otherwise in the Project Documentation. The relay protection devices shall be
such that a clear indication is given of the fault which caused a trip. HV circuit breakers
shall not be capable of re-closure without first manually resetting the fault at the
appropriate protection relay.

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4.10.2 Secondary Protection

CB fail protection schemes shall be implemented to achieve the primary protection

where practical. Secondary or back up protection shall be provided by time / current
grading of upstream protective devices. The design criteria shall be to clear a fault as
fast as possible and the total clearance time shall not exceed 0.5 seconds if the primary
protection fails. Any deviation to this criteria must be accepted in writing by QUU.

4.10.3 Instrument Transformers

CTs and VTs shall be specified with characteristics, e.g. rated output and accuracy
class, which are adequate for the associated protection, control and / or monitoring
equipment. Separate CTs windings shall be used for metering and protection functions.

The rated output of CTs shall, as a minimum, be equal to the connected burden of the
protection, control and/or monitoring devices, including the load burden, rounded up to
the next standard rating. All CTs and VTs shall have complete saturation test sheets.
CTs shall be suitable for use taking into consideration the future capacity of the system,
within economic reason.

Refer TMS1186 HV Switchboard Technical Specification for other requirements when

designing CT’s and VT’s to be installed in HV Switchboards.

4.11 POWER NETWORK TOPOLOGY

The structure of the electrical distribution system is generally based on the following
criteria:
• The rating of the system is based on the specified power consumption of the
electrical equipment and the allocation of this equipment to the production areas
at the site.
• The power distribution system to switchboards with multiple incomers shall be
selective. In normal operation, the bus tie breakers shall be open to minimise
fault currents on the bus bar.
• The equipment shall be rated for the maximum short-circuit current that may
occur in the respective section of the supply system, i.e. adequate thermal and
dynamic short-circuit strengths are required. Parallel operation of incomers shall
be prevented by means of mechanical and electrical hardwired interlocking. If
parallel operation can occur then the fault current rating of downstream
equipment must be assessed and confirmed adequately rated. This is applicable
for short duration switching operations where switchboards are fed from
multiple transformers simultaneously.
• Automatic load transfer schemes shall be implemented at 11kV and above
voltage levels, where multiple utility incomers are provided to the site and the
incomers are each rated to alone supply the site maximum demand load. The
scheme shall be fully commissioned and disabled for future use if all incomers

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or their required capacities are not available at the time of commissioning

completion to supply the site.
• System protective devices including CB’s and fuses shall be selected and
coordinated to ensure that the interrupter nearest the point of fault (or high
overload) shall open first and minimize system disturbance.

4.11.1 Point of Supply

All sites shall be supplied from utility (grid) connection unless advised otherwise in the
Project Documentation.

4.11.2 Power Factor Correction

The formal Connection and Access Agreement with Energex requires power factor (PF)
limitations at the point of common coupling. For modifications to existing operational
sites the Contractor shall assess the actual PF range and any modifications to the
existing site must ensure the entire site at the point of common coupling and within the
plant power network is within PF limits specified in TEM336 PSA Guidelines.

If required the PFC shall be installed indoors in an air conditioned switchrooms. The
capacitor banks shall each be provided with an integral control panel. The control panel
shall be equipped with the main controller (auto control), auto/manual selector switch,
PLC interface relays, induction lights, ammeter and selector switch and all necessary
control equipment. The PFC unit controller shall be integrated into the site protection
philosophy and site control system.

4.11.3 Harmonics Distortion

The specification of harmonic distortion producing equipment such as rectifiers,

inverters, variable speed drives, power factor correction equipment, etc. shall give due
consideration to the level of harmonic voltage and current distortion caused by the
equipment.

The total harmonic voltage and current distortion at the point of common coupling on
the network caused by the equipment shall be within values specified in TEM336 PSA
Guidelines.

Harmonic mitigation techniques provided by the Contractor shall be in the following

order of preference:-

• Specification of equipment which generates low levels of harmonic voltage and

current distortion, or has integral harmonic filtering equipment.
• Provision of standalone harmonic filtering equipment including passive and
active harmonic filters.

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For addition of non-linear loads to existing operational assets the Contractor shall
measure the actual harmonic distortion levels at the design phase and provide a Power
Quality Analysis (PQA) Report. After the new equipment is commissioned the
Contractor must ensure the entire site at the point of common coupling and other points
in the site power network are within harmonic limits stated in TEM336 PSA Guidelines.
A separate PQA report shall be provided by the Contractor when commissioning of the
new equipment is completed to demonstrate harmonic distortion limits are not exceeded
under all operational modes.

4.11.4 Electromagnetic Compatibility

For electromagnetic interference requirements of specific equipment refer to the

technical specifications listed in section 1.3.

Measures shall be taken to reduce the probability of low frequency induction and radio
frequency interference with regard to:

• Equipment specification
• Equipment location
• Cable installation segregation
• Earthing and bonding

The extent of any RFI shall be such that it does not interrupt normal operation of the
process or process related equipment, including controllers, instrumentation and
telecommunications. RFI shall be generally as specified in AS 61000 series on
electromagnetic compatibility (EMC).

4.12 POWER CABLES

The LV and HV cables shall be standard types in regular production by reputable

manufacturers with supply chains based in Australia. Manufacture of all cables shall be
copper, circular cross section unless otherwise specified with a consistent diameter and
profile for the full length of the supplied cable.

The following general criteria shall be adhered to for selecting power cables:

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4.12.1 Power Cable Type and Design Constraints

Performance Criteria Suitable for installation in water and waste water facilities with
elevated levels of H2S gas in waste water facilities and other
environmental conditions present.
Suitable for installation in HA’s where present.
UV Rated Other Sheath Where routed outdoors above ground with exposure to direct
sunlight
Termite Protection – Nylon All underground cables including those run in conduits
sheathed

Flame Retardant Yes – In accordance with AS 1660.5.1 Category C

Fire Resistant Fire and Gas Detection systems and other special applications
Low Smoke Zero Halogen -All cables routed in control rooms and office buildings
(<0.05%) -Cables installed in switchrooms and where both ends of the
cable terminate inside the switchroom.
Water IP Outer Sheath All cables installed underground.
HV cables shall have double water blocking where installed at
sites with a high water table.
Insulation XLPE/PVC for cables 16mm2 and above
PVC/PVC for cables less than 16mm2
Steel Wire Armoured Special situations only where accepted by QUU

Note that the following cable construction types shall not be accepted:

• Mineral insulated cable

• Lead and lead alloy sheath cable
• Oil impregnated paper insulated cable.

Nominal power cable ratings shall be based on:

• ambient air temperature of 45°C.

• maximum soil temperature 30°C for buried cables.

Derating factors shall be applied as necessary to take account of installation

configuration and variation in ambient temperature, in accordance with AS 3008.1.

The minimum cross-sectional area for LV power cables shall be 1.5mm².

Direct buried cables are not accepted under any circumstances.

The design of power cables shall ensure compliance with TMS1200 Electrical
Installation Technical Specification.

4.12.2 Power Cable Sizing

Refer TEM336 PSA Guidelines for details on HV and LV power cable sizing
calculations. Cable sizing calculations are also required for ELV power cables.

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4.13 EARTHING SYSTEMS

4.13.1 General

Earth grids for sites containing HV supply shall be designed strictly in accordance with
AS2067. The HV and LV earth grids for new and modifications to existing sites shall
be combined and the design shall ensure the earth system installation complies with
TMS1200 Electrical Installation technical specification. Where an existing site has
segregated LV and HV earth grids, any new design works to the site earth grids shall
include for permanent continuous bonding of all the grids together at the site.

Bonding of new earth systems to building foundations and other structures shall be
provided; however the connections shall not be relied upon in the design process to
achieve safe step and touch voltage levels.

The earth grid design shall allow for 20% increase in prospective fault level at the site
over its intended design life. The fault clearing time to be assumed for the basis of the
earth grid design is the protection maximum back-up clearance time and in no cases
shall the value be less than 0.5 secs, unless accepted otherwise in writing by QUU.

The soil testing methods, earth system testing methods and ultimate earth grid design
shall comply with the requirements specified in TMS1200 Electrical Installation –
Technical Specification.

Refer TEM336 PSA Guidelines for other design specifications and deliverables required
for earth system design.

Refer to section 4.16 for bonding of the site lightning protection systems to the site earth
grid.

4.13.2 LV Switchrooms

The earth grid for LV switchrooms shall consist of a minimum 120mm2 bare annealed
copper conductor routed underground around the switchroom perimeter and minimum
600mm2 depth of soil cover. As a minimum the electrodes shall be located near each
corner of the building and bonded to the underground earth conductor in an electrode
pit. A minimum of two 120mm2 PVC earth cable connections shall be run from the
internal wall mounted LV switchroom earth bar to the underground earth grid.

The earth system for Network Assets typically containing a single LV switchboard
(indoor or outdoor) shall have two earth electrodes in a separate earth pits bonded to the
main earth bar in the switchboard.

For all sites the MEN connection shall be located in the main LV switchboard.

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4.13.3 HV Substations and Switchrooms

HV substation earth grids shall be designed to consist of an array of electrodes

(maximum spacing is 20m between electrodes) interconnected with 120mm2 bare
annealed underground copper conductors with minimum cover of 600mm. The grid
spacing shall not be larger than 5m squares where practical to install. A minimum of
two 120mm2 PVC earth cable connections shall be run from the HV switchroom
internal wall mounted earth bar to the new underground earth grid. All localised earth
grids at equipment such as RMU’s, transformers compounds etc shall be bonded to the
main substation earth grid by minimum 2 off 120mm2 earth PVC cables. For
substations containing LV and HV switchrooms there shall be a separate LV and HV
switchroom earth bar provided.

4.13.4 Existing Earth Systems

The physical condition and extent of the earth system components installed for existing
assets cannot always be easily verified and the As Built design documentation is not
always available or accurate. The design for new earth grids at existing sites shall not
rely on or take credit for the performance of any existing earth grid members in near
vicinity of the proposed new earth grid.

For modifications to earth grids at existing facilitates, the building foundations and all
other underground structures in the vicinity of the proposed new earth grid shall NOT
be considered when designing and modelling the performance of the new earth grid.
The new earth grid design shall not rely on the connections to the existing earth grids
and other underground structures to meet safe step and touch voltage levels. This
condition must be clearly stated in the Earth Grid Design Report.

The As Built earth grid design drawings must show all bonds to existing structures and
existing earth grid members that can be located at the site and are assessed by the
Contractor as being in adequate physical condition for continued service. The
Contractor shall de-commission and remove all earth system members that are no longer
in service as a result of works performed under the Contract. The Contractor shall not
bond existing earth grid components to the new earth system where the location and
condition of the existing components cannot be verified and documented on the AS
Built drawings. All existing equipment must have more than one earth bond installed to
the new earth grid.

4.13.5 Equipment Earthing

Refer to TMS1200 Electrical Installation Technical Specification

4.13.6 Transfer Potentials

The effect of transferring potential rises due to earth faults shall be considered as per
TEM336 PSA Guideline during the earthing system design.

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The means of transferring potentials to be considered include:

• Metal fencing
• Piping
• Cable sheathing
• Earth and equipotential bonding

Insulated copper earth cables shall be run from the main HV switchroom earth bar to
each distribution substation HV earth bar at the site. Where applicable the earth grid for
a HV installation shall include a site perimeter underground loop located one metre
outside the fence line and bonded to the fence at maximum 15m intervals, bonds are
also required to gates and all metal structures within the facility.

Insulated copper earth cables shall be run from the main LV earth bar in each plant area
to each LV switchboard in the same plant production area.

Metal pipes, fences and cable ladder crossing a substation boundary shall be provided
with insulated sections at the boundary to prevent transferred potential.

Particular care shall be taken with design and bonding of electrical cable screens
crossing a substation boundary that may bridge earth systems.

In any case the transferred potential shall not exceed safe levels.

4.13.7 Equipotential Bonding

Refer to TMS1200 Electrical Installation Technical Specification

All non-current carrying metallic parts and enclosures of electrical equipment and
metallic structures used for mounting electrical equipment shall be effectively bonded to
the earth grid throughout the site so as to ensure that all exposed conductive parts are at
equal potential during normal operation and under fault conditions. All exposed
conductive parts of equipment, piping, vessels and structural items shall be effectively
bonded so as to prevent the accumulation of static charge. The Contractor shall provide
standard earthing installation drawings for the types of equipment to be installed.

Unless otherwise required, metal sheaths and steel armouring of cables shall be
connected at both ends to the switchboard earth bar via cable glands and gland plates.
The continuity of metal sheaths and armouring shall be maintained across cable
branches or joints.

To bridge the insulating effect of the anti-vibration mountings on mechanical packages,

bonding conductors shall be used to connect the insulated equipment to the adjacent
structural steel.

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4.13.8 Low Frequency Induction

Assets including pipelines in vicinity of HV transmission of distribution lines can be

exposed to Low Frequency Induction (LFI). CDEG modelling software shall be used to
determine LFI voltage levels and an LFI design report shall be provided unless
otherwise specified in the Project Documentation. LFI voltages imposed on equipment
must be considered for both steady state and fault conditions in the HV lines.

4.13.9 Instrumentation Earthing

Instrument earth design shall be in accordance with the requirements of AS/NZS3000

and TMS1201 Instrumentation Installation - Design Requirements.

Conventional instrument earthing systems shall be designed such that each instrument
control loop system is earthed at a single point and only at the instrument earth bar,
through the cable screens/shields at the PLC or RTU control panel.

Screen earths shall be separated from ‘dirty’ equipment earths. Equipment earths are for
electrical safety earthing only.

Field instrument bodies, junction box housings and any other control system enclosures
shall be solidly earthed to the equipment earth. In addition, and not as a substitute for
cable shields, cable armour shall be continuous and earthed via the glands at a junction
box, instrument, and panel end of the cable.

Where earths are to be terminated in a junction box earth terminals shall be provided.

Instrument loop surge protection devices shall be connected to the control panel
instrument earth bar as per the manufacturer’s recommendations. Refer to other sections
of this document for additional surge protection device design requirements.

4.13.10 Static Electricity

Static electricity shall be controlled in accordance with the requirements of AS 1020 by

the provision of secondary earthing supplemented by the provisions of this section.

Particular attention shall be given to the provision of adequate paths to earth preventing
the build-up of potentially hazardous static charge levels arising from the flow of gas
and fluids under both normal and abnormal operating conditions.

All parts of metallic piping systems shall be earthed with a resistance to ground not
exceeding 10 ohms regardless of whether the fluid being transported is conductive or
not. Bonding is not required across joints in the metallic piping system, except for
flexible, swivel or sliding joints. If the resistance across pipe connections is greater than
1MΩ, the pipes on either side of the connection shall be bonded together by a suitable
conductor and earthed.

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In HA’s, all electrically isolated parts of metallic piping and components shall be
bonded to the remainder of the piping system and earthed.

Any earthing shall not compromise sections of pipe that are to be electrically isolated,
for example, insulating flanges on cathodic protection systems.

4.14 EARTH SYSTEM DESIGN DOCUMENTATION

The following is a list of the minimum design deliverables required for an earth system
design:-

• Earth Grid Design Report including soil test results, step and touch and transfer
potentials. Design report must state the test methods and pass/fail criteria for
each test and the report shall be updated with As Built information.
• Earth Grid Layout Drawings showing earth bars, above and below ground earth
conductors, earth tails to equipment and structures, joints and electrodes and
MEN locations.
• Earth bar general arrangement drawings showing size, all conductor connections
and tagnames and mounting details.
• Detail installation drawings for new electrodes and earth connection types.

4.15 LIGHTING

4.15.1 General

Light fittings shall be designed to provide illumination for safe access for operation and
maintenance purposes in low natural light conditions. The Contractor shall design and
supply lighting system to comply with the relevant Australian Standards.

Energy efficiency, ease of maintenance and reliability of the lighting system

components shall be taken into consideration in the design. Light fittings shall be
selected from suppliers listed in TMS62 Preferred Electrical and Instrumentation
Equipment List. The lighting design shall ensure the luminaires can be installed in
accordance with TMS1200 Electrical Installation Technical Specification.

In general, high bay and area lighting shall be LED. Low level lighting for switchrooms,
control rooms, etc shall also be LED lighting.

All light poles greater than 1.8metres in height (e.g. walkways, outdoor work areas and
general plant areas) shall be designed such that maintenance of light fittings may be
carried out from the ground or walkways without the use of an elevated platform
workstation or ladders.

All lighting columns shall be of the lowering type and shall not require an elevated
platform to access the light fittings. The lowering apparatus shall be operable from

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outside the fall zone. Any control gear associated with lighting poles shall be mounted
at the base of the pole so that it is accessible from the ground for maintenance. Control
equipment shall have a dedicated CB’s provided at the base of the pole for local
isolation. Poles which support multiple luminaires shall have an individual protective
device per luminaire located at base of the pole.

Lighting levels in vicinity of CCTV cameras shall be selected so as to not diminish

night vision of the cameras. Light fittings shall also be positioned to minimise glare and
illumination of neighbouring properties.

Lighting lux level plots shall be provide for each site area using AGI32 or similar
lighting design software. The luminaire locations shall be superimposed on the site
layout drawings and indicate mounting height, angle of inclinations, fouling and aging
factors allowed.

4.15.2 Lighting Intensities

The following (in-service) average lighting intensities are generally based on AS1680
series of standards. In order to allow for ageing and fouling, the initial average lighting
intensities shall be 1.20 times the values shown in below table:-

Plant Area/Location Minimum LUX Level

General Outdoor Process Areas 10
Compressor, large blowers and fans(indoors) 150
Interconnecting pipe ways and cable ladders 20
Open stairways (exterior) 55
Local control panels and operating points 150
Indoor facilities for personnel and other amenities 200
Switchrooms (interior) 300
Walkways and access areas (outdoors) 20
Walkways and access ways to buildings 40
General work areas 160
Pump House and Plant Rooms 160
Process plant items(occasional attendance) 80
Workstations (permanently occupied) 160
Control Room, measuring stations, control platforms and 320
observation posts
Storage routinely involving reading tasks 160
Office General 320
Office Background 160
Office for Drafting Tasks 600
Computer/Control Rooms 320
Meeting Rooms 320

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Plant Area/Location Minimum LUX Level

Reception Area: 240
Photocopying / printing 240
Filing areas 160
Entrances 160
Waiting rooms 160
Gate houses 320
Corridors / passages 80
Loading bays 80
Stairs (interior) 160
Staff kitchen/dining areas 240
Staff rooms:
• Locker 80
• Changing rooms 80
• Cleaners rooms 80
Store rooms 80
Car Parks 15
Vehicle Access Roadways 10

Lighting levels shall be measured 1m above floor level. Outdoor areas without buildings
plant and equipment and no access pathways shall not be illuminated.

The design of pedestrian pathways including outdoor covered walkways shall comply
with AS1158.3.1.

4.15.3 Gate Approach Lighting

At STP sites and other permanently manned sites a 3m pole mounted LED light at the
maintenance gate entrance shall be operated by motion sensor activated by an
approaching maintenance truck. An IP66 rated Automatic / Manual lighting selector
switch box shall be installed at the gate post with local control switches to plant general
area lighting and maintenance lighting circuits. The enclosure shall be designed to
comply with TMS1222 Control Panel – Technical Specification.

4.15.4 Plant Area Lighting

Flood lighting luminaries for larger sites shall be fitted with LED lamps complete with
integral control gear.

Outdoor car parks and vehicle roadway lighting luminaries shall comply with
AS1158.3.1 and shall be HPS or LED lamps complete with integral control gear unless
specified otherwise in Project Documentation.

Plant area lighting circuits shall be controlled by contactors located at lighting

distribution boards as appropriate. All external lights shall be able to be switched

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ON/OFF using the site control system SCADA system either in total or by plant area.
The site control system shall automatically switch external lighting off in daylight hours
via a day/night switch, with an override facility for testing purposes.

All external lighting shall also include manual direct switching facilities adjacent to the
relevant local light and power distribution board. This switching shall operate
independently of the site control system.

All external lights shall be able to be switched off after an adjustable time delay
function (0-60 minutes) via SCADA operator control. External lighting SCADA
controls shall also include the facility to select automatic operation of the lights
whenever an area security alarm is active at night (as determined by a day/night switch).

Lighting poles shall not be fixed to handrails.

The preferred type of lighting is LED mounted to dedicated galvanised steel pivot poles
that can be easily accessed for maintenance. Aluminium poles are required in corrosive
environments.

Lighting poles shall be located outside HA’s where possible and shall be designed and
tested to comply with the requirements of AS 1170 when subjected to the site service
conditions.

4.15.5 Maintenance Lighting

Illumination level at maintainable equipment including process areas for safe access and
walkthrough shall be as per section 4.15.2.

Visual inspection or manual intervention of plant equipment shall be provided by task

lighting. Lights shall be installed for maintenance lighting and task lighting located on
2.2m aluminium lamp posts attached to structures or mounted on platforms.

4.15.6 Emergency Lighting

Emergency and evacuation lighting shall be provided to comply AS 2293 standard and
Australian Building Code requirements.

The site emergency lighting system shall employ standalone single two hour battery
backed up maintained lighting luminaries. UPS’s dedicated for emergency lighting
circuits are not accepted unless specified otherwise in the Project Documentation.

Manual testing facility shall be provided at the plant lighting distribution boards as
appropriate to comply with AS 2293 standard requirements.

Luminaires shall comprise, but not be limited to, batteries, automatic charger, supply
failure relay and control switch.

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The lights shall comprise LED lamps forming part of a luminaire containing 230 Vac
lamps. All emergency light fittings shall be dual rated charge type for maximum battery
life. Fittings shall have integrated battery cell in each luminaire.

4.15.7 Prefabricated Switchroom Lighting

Refer TMS1188 Demountable Switchroom Technical Specification

4.16 LIGHTNING PROTECTION

All major steel structures, platforms, equipment, machinery and other non-conducting
metallic components of electrical equipment and instrumentation in buildings and plant
sections shall be connected to the site earthing system via earthing and bonding in
accordance with AS 1768 standard requirements.

Lightning risk assessment studies shall be undertaken to determine the level and extent
of lightning protection. No separate earth connections are required for equipment, items,
vessels and machinery which are bolted or welded to earthed steel structures.

Lighting protection design is required for all new assets and modifications to existing
assets unless specified otherwise in the Project Documentation. The Contractor shall
undertake a Risk Assessment (RA) to AS1768 and provide a Lightning Protection (LP)
Design Report for the site. A RA is required for each production area on a large
distributed site. Network sites can be covered by one common RA for the site.

For the purpose of the RA all sites and plant areas contained within shall be classified as
industrial properties or premises in accordance with AS1768.

The RA and LP Design Report shall include all equipment on the site and extends to the
perimeter inclusive of the site perimeter security fence.

The LP Design shall include drawings containing the following details:-

• Overhead earth wires and finials ( air terminals) installation details and locations
• Down conductor installation details and locations
• LP test links installation details
• Earth grid bonds installation details
• Elevations and site plan view of the rolling sphere zones of protection

Overhead earth wires and finials are not to be proposed unless these are the only
alternative to achieve acceptable level of risk. Finials and down conductors must be
provided to roof of masonry buildings and structures in exposed areas and the rolling
sphere method used to demonstrate coverage. An earth electrode with test links shall be
provided in proximity to each down conductor. Steel structures are inherently self-
protected and do not require additional finials and down conductors installed.

Printed at 7:26 AM on 21/01/19 Page 51 of 96

All structural steel work, hand rails, platforms, steel pipes, steel vessels etc. shall be
equipotential bonded to the site earth grid throughout the site as per TMS1200 Electrical
Installation Specification.

Dynaspheres and other LP methods, not recognised by AS1768 are not accepted.

All LV Switchboard, DB’s and control panels with LV supply shall have surge arrestors
on their incoming power supply regardless where located and surge arrestor status shall
be monitored by a local PLC input and a surge arrestor general fault alarm configured to
SCADA.

All above ground instruments (analogue, digital signals and power supply signals) in
exposed areas shall have surge protection devices installed at the control panel.
Instruments located underground or indoors or in sheltered areas (instrument and wiring
not exposed) do not require surge protection on the PLC inputs. Sensitive analyser type
instruments in exposed area shall have additional surge protection located at the
instrument and connected to a purposely designed low impedance earth path.

All copper communications cabling routed exterior of building (above and below
ground) shall be installed with surge protection devices with minimum 20 kA rating. All
control system analogue input signals shall have surge protection installed within the
marshalling panel with a current discharge capacity of 20 kA.

Pipelines with weld-neck flanges and screwed socket joints are regarded as electrically
continuous. Piping does not require additional earthing connections, providing the pipe
terminates to an item of equipment or machinery that is equipotential bonded to the site
earth system.

Insulating spool pieces in pipelines or joints with slip-on flanges may be electrically
bridged with transient suppressors.

Refer TMS1595 Cathodic Protection Pipelines and Structures Technical Specification

for design of surge protection on cathodic protection systems.

4.17 ELECTRICAL EQUIPMENT

4.17.1 HV Switchboards and Ring Main Units

Refer TMS1186 HV Switchboard Technical Specification.

4.17.2 LV Switchboards

Refer TMS60 LV Switchboard Technical Specification which applies to all LV

switchboards including DB’s, MCC and also includes LCP’s.

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All design modifications that include additions or enhancements to the enclosure shall
ensure the installation works when complete complies with the current version of
AS3000 Wiring Rules and the relevant regulations and standards.

4.17.3 Variable Speed Drives and Soft Starters

VSD’s can be wall-mounted when installed inside switchrooms. VSD’s with minimum
IP4x enclosure can be directly wall mounted where the arc flash incident energy at the
VSD power terminals is less than or equal to 1.2 cal/cm2. VSD’s with incident energy
exceeding 1.2 cal/cm2 shall be installed in a dedicated control panel.

VSD’s and soft starters shall only be installed inside switchboards that comply with
TMS60 LV Switchboards with specific consideration to the validity of the Switchboard
Design Verification Report.

VSD’s and soft starters are only accepted to be installed in outdoor located
switchboards at Network assets as per QUU standard design drawings.

Refer TMS1406 LV Variable Speed Drive Technical Specification for detail design
requirements of VSD’s.

Soft starters in STP’s are generally only required on larger motors typically exceeding
30kW and if required shall be wall or floor mounted in a purpose built enclosure located
in a switchroom. The control panel design constraints shall be similar for a VSD and
refer to TMS1406 LV VSD Technical Specification.

4.17.4 Transformers

The design requirements for oil insulated transformers are included in TMS1185
Distribution Power Transformer (Less than 5MVA) – Technical Specification. The
additional design requirements are as follows:-

• Transformer compounds shall have security fence with lockable access gates,
and the transformers mounted on a concrete plinth within a bund area. The bund
capacity shall be sized to hold 110% of the total tank volume and sized to
capture any leaks from the tank in accordance with AS1940.
• Transformer compound clearances shall be in accordance with AS2067.
• Transformer enclosures shall have a sump pit to facilitate removal of oil and/or
water from the transformer bay.
• A 2-hour fire rated wall shall be provided between adjacent transformers.
• Where transformers are installed adjacent to a non-fire rated building, a 2-hour
fire rated wall shall separate the building and the transformer compound.
• The transformer compounds shall be filled with aggregate and the aggregate
shall be retained by concrete retaining walls. The depth of aggregate shall be a
minimum of 150 mm.

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• Transformers may be enclosed “kiosk” padmount type, totally enclosed with an

integral bund. A fence is not required for this type of installation.
• Noise walls shall be provided where required to meet the site noise emission
constraints.

Where cost effective and practical to meet the project requirements dry type
transformers are accepted and design requirements are included in TMS1625 Dry Type
Distribution Transformer - Technical Specifications.

Special consideration for adequate ventilation is required where transformers are

mounted in outdoor enclosures.

Pole mounted transformers are not accepted.

4.17.5 Motors

A general guideline for selection of motor ratings and voltage level is outlined in the
following table:-

Voltages Minimum Motor Rating Maximum Motor Rating

230V 1ph - 0.5kW

400 V 3ph 0.75kW 300kW
3.3kV 3ph 300kW -
6.6kV 3ph 300kW -

For motors of a given size range or for certain equipment furnished with speciality
motors, the above voltage-motor size assignment may vary.

LV motors exceeding 300kW can be considered for particular projects. The Contractor
shall provide a design report outlining the proposal to install LV motors in excess of
300kW and shall consider the alternative HV motor option. The report shall include
sufficient detail to fully ascertain the relative benefits of an LV and a HV solution. A
full life cycle cost analysis is required covering capital cost, maintenance costs,
operating costs (energy), installation and cutover costs as part of the HV and LV options
analysis. Following acceptance of the design report the detailed design shall progress
with either the LV or HV motor solution.

Motor starting analysis shall be undertaken to determine the voltage drop when starting
large motors as per TEM336 PSA Guidelines.

4.17.5.1 HV Motors

Refer TMS1404 HV Motor - Technical Specification

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4.17.5.2 LV Motors

Refer TMS1637 LV Motor - Technical Specification

4.17.6 Diesel Generators

Refer TMS1589 LV Diesel Generators – Technical Specification

Permanently installed generators shall consider the arc flash incident energy at the
alternator terminals. The generator local HMI shall be located external of the arc flash
boundary. Typically the generator components including the alternator and on-board
switchgear are not contained within arc fault contained enclosures.

Refer TEM336 PSA Guidelines for additional requirements on arc flash hazard
mitigation associated with generators.

4.17.7 Junction Boxes

For electrical equipment junction boxes refer TMS1200 Electrical Installation -

Technical Specification.

For junction boxes associated with instrumentation refer to TMS1201 Instrumentation

Installation - Technical Specification.

4.17.8 Uninterruptible Power Supplies

Refer TMS1187 AC Uninterruptible Power Supply – Technical Specification

The input power supplies shall be a solidly earthed three phase and neutral system, 400
V AC, 50 Hz or single phase and neutral, 230 V AC, 50 Hz fed from an essential supply
bus. UPS’s with rating exceeding 7.5kVA shall be three phase 400VAC input.

The UPS shall generally have operating output voltage level of 230VAC single phase.

A Battery Monitoring System shall be provided unless specified otherwise in the Project
Documentation.

UPS systems shall include bypass circuitry to allow for maintenance/emergency

activities.

A permanently installed label in close proximity to the UPS shall be installed that
outlines the operating procedures for all modes of operation of the UPS and associated
bypass switch.

At STP sites all new and modifications required to existing instrumentation, protection,
control systems and communications equipment shall be 24VDC and the power supply
fed from an upstream 230VAC or 400VAC UPS. All safety related equipment

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excluding emergency lighting shall be fed from the UPS. This requirement extends to
new switchboard control circuits. Process control and monitoring equipment operating
at LV shall not be fed from general power and lighting DB’s.

Typically each switchroom requires a dedicated UPS suitably rated to power all
equipment mentioned above associated with the switchroom. Small dedicated UPS’s for
specific equipment and distributed throughout the site are not preferred and will only be
considered where the localised load is small and it is not economically feasible or
practical to install an LV supply fed from a larger centralised UPS in the nearest
switchroom.

4.17.9 DC Power Supply

4.17.9.1 HV Switchrooms

The design requirements for the DC Power Supply for HV installation are specified in
TMS1221 DC Power Supply Systems - Technical Specification.

The input AC power supply shall be fed from an Essential Services supply at 400VAC,
three-phase, 4-wire, 50 Hz, for loads in excess of 7.5kVA and 230VAC 50Hz single
phase for smaller size loads. The DC Power systems shall have an output voltage of
24VDC unless specified otherwise in the Project Documentation.

All the equipment associated with the HV installation shall be fed from the DC Power
Supply with integrated 24VDC DB. This included PLC, HMI, IED, communications
equipment, control and monitoring circuits associated with the HV switchroom.

4.17.9.2 Miscellaneous

DC power supplies for new installations (excluding HV switchrooms) shall be

230VAC/24VDC units selected from TMS62 Preferred Equipment List – Electrical and
Instrumentation and fed from an UPS. Multiple power supplies shall be connected in
parallel to offer N+1 redundancy. A redundancy module shall be installed on the output
and located in the same enclosure as the power supplies.

For large installations the power supplies shall be installed in a dedicated enclosure (not
contained within an LV switchboard or MCC) and fed from an upstream UPS with
provision to isolate individual power supplies both input and outputs so a faulty unit can
be removed from service without interrupting the operation of the other power supply
units. Smaller DC power supply systems can be installed in the PLC control panel
where space permits.

DC Power Supply design for Network assets shall be provided to QUU standard
drawings. Network sites have a single battery back-up rather than a dedicated UPS.
Refer to TMS60 LV Switchboards Technical Specifications for further design criteria.

Printed at 7:26 AM on 21/01/19 Page 56 of 96

The status of all DC power supplies shall be monitored by the local control system.

4.17.10 Batteries

Due considerations shall be given to size, number, location, ventilation, and temperature
rise in the battery bank design. Lithium Ion or VRLA battery cell technologies only are
accepted by QUU. Battery banks shall consist of multiple parallel strings of cells.
Battery cells should be designed to offer 2 x 50% battery capacity unless specified
otherwise in the Project Documentation.

Refer TMS1221 DC Power Supply Systems - Technical Specification for batteries

required in HV switchrooms.

Refer TMS1185 AC Uninterruptible Power Supply – Technical Specification for UPS

battery requirements.

4.17.11 Packaged Plant Equipment

Equipment packages may include, but not limited to the following skid mounted
equipment:-

• Blower skids
• Centrifuge skids
• Multi Pump Manifold Pump Skids
• Waste Gas Burners(enclosed flares)
• Air Compressors
• Instrument Air Driers

Low voltage motor starters, instrumentation and proprietary control systems are
generally supplied as part of the packaged equipment.

Refer to TMS1645 - Package Plant EI&C - Technical Specification for specific design
requirements.

4.17.12 Socket Outlets

Circuits for socket outlets rated at 20A or less shall be protected by a separate circuit
breaker with RCD at the point of supply. Outdoor socket outlets shall have IP66 rating
as minimum. External socket outlets shall be installed in minimal quantities to avoid
hazards associated with unauthorised hot live works.

RCD shall have 30mA setting for each individual circuit.

Unless otherwise specified, the following mounting heights shall apply.

• Socket outlets (Switchrooms) - floor level (200mm).

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• Socket outlets (other) - 1000mm.

• Service outlets to water boilers etc. - 1300mm.
• Air conditioner and fixed high level equipment outlets 1800mm.

Three phase outlets shall be 4 pin for motors and 5 pin for connection of other speciality
loads. The outlets shall be rated for maximum 63A and protected by a 30mA RCD
installed upstream at point of supply. Three phase outlets shall have IP66 rating with
integral cover facility.

Earth leakage protection shall be selectable up to 250mA for each individual welding
outlet circuit.

4.17.13 Transportable Switchrooms

Refer TMS1188 Transportable Switchroom - Technical Specification. This

specification shall be utilised for sea container switchroom enclosures with all
departures nominated to QUU prior to contract award.

4.18 SWITCHROOM HVAC SYSTEMS

HVAC shall be installed in all new HV and LV switchrooms and where specified in
Project Documentation for modifications to existing switchrooms. The HVAC system
shall offer N+1 redundancy meaning if one HVAC unit is unavailable then the heat load
of the switchroom under all operating conditions can be met by the other HVAC unit(s).
HVAC units shall be inverter type and units in excess of 8kW rated electrical load shall
have 3ph, 400VAC 50Hz supply.

On general power failure to the switchroom all the HVAC units can be shut down and
shall restart automatically without operator intervention, when power is re-established
to the building. The HVAC units are not considered an essential load and shall be fed
from the general power and lighting switchboard in the switchroom.

On a confirmed fire the HVAC units must be shut down immediately. A confirmed fire
is when the FIP and the VESDA both detect a fire and a voltage free contact shall be
wired direct from FIP to the distribution board containing the HVAC unit power supply
contactors.

Ventilation ducts between rooms (if any) shall be fitted with fire dampers controlled by
the FIP.

The HVAC units shall be individually monitored by the control system. Voltage free
contacts shall be provided for HVAC Running and separate input for HVAC General
Fault. The signals shall be wired to the local PLC control panel for alarms to be
provided at SCADA.

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The HVAC units shall be provided with their own inbuilt temperature controllers. A
battery powered portable remote controller for each unit shall be wall mounted near the
switchroom personnel access door. Fixed hardwired wall mounted controller panel in
the switchroom is also accepted.

The switchroom shall be provided with a wall mounted temperature sensor to provide
an analogue 4-20mA temperature signal to the local PLC. The room temperature shall
be displayed at SCADA and warning alarms produced if temperature exceeds 30°C in
the switchroom.

The Contractor shall determine the maximum heat load on the building and the
calculation and selection of HVAC units shall be approved by an RPEQ Mechanical
Engineer. Engineering design software such as CAMEL or equivalent shall be utilised
for the calculation.

The switchroom HVAC system shall be designed to maintain the switchroom at 24°C
when external ambient temperature is between -5°C and 45°C and under maximum heat
load conditions inside the switchroom i.e. all equipment operating maximum load rating
simultaneously. Switchrooms are not permanently occupied by personnel. The heat load
generated from personnel access can be ignored, unless the switchroom is provided with
a permanently installed SCADA terminal. In this case the heat load from two persons
must be considered in the calculation.

HVAC units shall be conformal coated where installed in switchrooms located on STP
sites. HVAC units shall be procured from reputable supplies to meet design service life
of minimum 15 years.

Conduits and cable supports from the building to condenser units shall be provided with
a flexible gap to allow for differential movement of the building and condenser units.
The condensers shall be mounted on rubber feet on a concrete pad or column mounted
and shall be accessible from ground level with local isolator provided adjacent. The
Contractor shall assess flood level when determining the final location of the condenser
units. Refer to TMS1200 Electrical Installation Technical Specification for further
information regarding the installation of HVAC units.

Refer TMS1188 Demountable Switchroom Technical Specification for HVAC

requirements in demountable switchrooms. The HVAC design report and switchroom
HVAC layout drawings must be accepted by QUU before commencing the demountable
switchroom manufacture.

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4.19 FIRE DETECTION SYSTEMS

A fire detection system shall be installed in all new HV and LV switchroom buildings
and where specified in Project Documentation for modifications to existing
switchrooms, buildings and plant process areas. The fire detection system shall be
networkable and microprocessor based with a Fire Indication Panel (FIP) hardwired
signals to the site PLC control system.

The fire detection system including VESDA, MCP’s and smoke detectors shall be fed
from the FIP. The FIP shall be fed from the Essential Services LV Distribution Board
which shall have a UPS back-up supply.

Fire suppression systems are not required unless specified otherwise in the Project
Documentation. Facilities shall be provided at the FIP for Emergency Warning System
functions. An I/O interface card shall be provided in the FIP to connect to the site PLC
control system.

A battery backup power supply housed within the FIP shall be provided for the fire
detection system. The battery shall be rated to provide maximum demand of all
connected equipment to the FIP such as smoke detectors, MCP’s etc. A maximum
demand calculation in accordance with TEM336 PSA Guidelines shall be provided to
determine battery size required.

The FIP shall be constructed to AS1670, AS1603.4 and AS1428.1. It shall be capable of
a minimum of 8 inputs, 8 outputs and a redundant path network module suitable for
multi-mode fibre optic connection to the Master FIP and shall incorporate emergency
warning facilities to AS2220. The existing site master FIP may require modification to
allow communications to any new FIP’s. The Contractor shall provide all dedicated
fibre optic communication cables between FIP’s and the site Master FIP.

The FIP shall monitor:

• Manual call points
• Smoke detectors
• Other input devices such as VESDA

The FIP shall have direct control over the switchroom building. The status displayed on
the FIP local indicator such as warning alarms, faults etc shall be wired through volt-
free contacts rated at 24VDC to the PLC Control System.

The site PLC control system shall monitor the following FIP signals as a minimum:-
• FIP Power On,
• FIP General Fault,
• FIP Battery Fail

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• FIP Fire Alarm.

• VESDA General Fault
• VESDA Smoke Alarm
• Any MCP Activated
• Smoke Detector Activated

Two spare unused volt free fire alarm contacts in the FIP shall be provided for
interfacing other signals to the site control system in future.

The switchroom shall be provided with at least two off smoke detectors, actual number
and location shall be indicated on the Project Drawings. Status and alarms shall be
configured to SCADA and at the local HMI in the switchroom.

The FIP shall be installed inside the switchroom building in a metal wall mounted
enclosure complete with digital display and LED indicators and control pushbuttons.
The enclosure shall be key lockable.

The condition for a confirmed fire in the switchroom is when any one of the following
occur:-
• MCP is activated or
• VESDA system detects smoke and one smoke detector is activated

On confirmed fire detected in the switchroom the fire systems shall:

• Shutdown all HVAC units in the switchroom
• Activate a local strobe light mounted external above the switchroom access
doors
• Activate a local siren
• Activate PAGA speakers through PLC/ SCADA interface

Refer TMS1188 Demountable switchroom – Technical Specification for fire detection

systems in demountable switch rooms.

4.19.1 Manual Call Points

Where manual call points are specified they shall be located at each exit door to HV and
LV Switchrooms and wired to the switchroom FIP. MCP’s located internal to
switchroom shall be to AS 1603.5, and surface mounted. All cable penetration to
MCP’s shall be bottom entry.

Refer TMS1188 Demountable switchroom – Technical Specification for fire detection

systems in demountable switchrooms.

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4.19.2 PAGA Speakers

PAGA speakers shall be provided in the switchroom and shall be wired individually for
connection to the local PLC network. Wiring from the PAGA Speakers to the PLC shall
be of minimum type WS51W in accordance with AS1670.4.

4.19.3 Very Early Smoke Detection Apparatus

The VESDA system shall consist of a highly sensitive laser based smoke detector
complete with an aspirating fan and filter connected to a network of pipe and sampling
points and detector displays. The VESDA shall only sample air within the switchroom
and NOT within switchboards or other enclosures.

The system shall be modular in design and the detector shall be monitored by a display
dedicated to a specific detector to show a visual representation of smoke levels detected
by a particular detector.

The VESDA shall be of a type designed, manufactured and tested to comply with
AS1603. The detector shall be provided with LED indicators.

Each detector shall provide the following features at a minimum:

• Independent high intensity alarm indicators for Pre-Alarm and Fire (Alert
indicated by the Pre-Alarm LED flashing) corresponding to the alarm thresholds
of the detector:
o Fault indicator
o OK indicator
• Isolate indicator
• Controls supporting the following features:
• Reset – Unlatches all latched alarm conditions
• Isolate – Isolate (inhibits Alarm and Fault relays and initiates the Fault relay)
The unit shall be equipped with configurable relays for signalling
alarm and fault conditions. Initial settings for the alarm levels
shall be determined by the requirements of the fire zone.
Default settings of the unit shall be:
• Alarm Level 1 (Alert) 0.08% Obs/m with a delay of 10 seconds
• Alarm Level 2 (Pre-Alarm) 0.14% Obs/m with a delay of 10 seconds
• Alarm Level 3 (Fire) 0.2% Obs/m with a delay of 10 seconds

The detector fault relay shall be connected to the addressable interface device located in
the FIP in such a way that a detector fault would register a fault condition on the FIP.
The fault relay shall also be connected to the appropriate control system.

The VESDA System shall be powered from regulated 24V DC supply from the FIP.

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The response time for the least favourable sampling point in the system shall not exceed
90 seconds.

Refer TMS1188 Demountable switchroom – Technical Specification for VESDA

requirements in demountable switchrooms.

4.19.4 Smoke Detectors

Smoke detectors shall comply with AS3786.

4.20 SOLAR PHOTOVOLTAIC SYSTEMS

4.20.1 General

The design of photo voltaic power system shall be undertaken to Australian Standards
and by Clean Energy Council accredited Engineers. The Clean Energy Council has
compiled a list of approved products - including solar PV modules (panels) and grid-
connect inverters that meet the relevant standards. Contractors must use equipment on
the Clean Energy Council list of approved products in order for QUU to qualify for
government incentives for solar PV systems.
www.solaraccreditation.com.au/approvedproducts

The Contractor shall design and install the PV system in accordance with the Clean
Energy Council’s Installation Guidelines for Accredited Installers and Supervisors. The
design deliverables shall be approved by an electrical RPEQ with the nominated
accreditation. Where grid connection is required the Contractor is responsible for all
applications, negotiations with Energex and other costs required to connect the PV
system to the grid.

4.20.2 Inverters

Inverters shall be 3 phase, 400VAC, 50Hz output and transformerless type and in
compliance with AS4777. Inverters shall be sourced from OEM with registered
supplier outlets in Australia. The warranty offered for the inverter shall be unconditional
and minimum 10 years for industrial use. The inverter enclosure must be minimum
IP4X and be wall mounted inside a building not exposed to the weather or direct sun
light. Inverter enclosures with IP rating less than IP4X shall be installed in a purpose
built forced ventilated metal enclosures. Inverters shall not be installed in outdoor
exposed locations.

Inverters shall accept multiple strings of PV panels. A minimum 2 off MPPT channels
rated up to 1000V is required per inverter. The total harmonic voltage distortion at the
inverter LV terminals shall not exceed 2%.

A full load current DC isolator and AC isolator shall be provided adjacent to the
inverter or located on the front door of the inverter panel. The inverter shall connect
directly to the site LV main switchboard through a 400VAC 3 pole CB.

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Inverters shall be provided with CAT 6 communications port and support Modbus /TCP
and shall be interfaced to the site control system for diagnostics and status monitoring to
SCADA.

Hybrid inverters to charge batteries are not required, however the PV system shall be
expandable to include battery connection in future as well as additional inverters to
increase generation capacity.

4.20.3 Photovoltaic Panels

PV panels shall be mono crystalline type and comply with AS5033 and IEC62941.
Panels shall have minimum unconditional 12 year warranty in industrial installation.
Panels with unconditional warranties exceeding 12 years are preferred.

PV panels shall be high power density type available from Tier 1 manufacturers and
sourced from OEM with registered outlets in Australia. Panels shall comply with the
following minimum specifications:-

• 20 year design life

• Electrical connections minimum IP65
• Power output degradation maximum 0.25% per year
• Power temperature co-efficient < -0.4%/°C
• Power tolerance maximum +5%/-0%
• Voltage temperature co-efficient <180mV/°C
• Current temperature co-efficient <4mA/°C
• Panel efficiency > 20%
• Salt Spray test compliance IEC61701 (maximum severity)
• Impact resistance minimum 25mm diameter hail at 23m/sec
• Wind rating minimum 2400Pa, 240kgm2 front and back

The design shall include PV panels connected in multiple strings and each string shall
have a DC isolator located adjacent to the panel strings.

Panels shall be mounted on fixed permanently installed galvanised steel structures.

Other mounting methods can be considered and must be accepted and fully costed
before Contract award. Small kW systems (not exceeding 10kW) are permitted on
building roof tops where roof space permits. Permanent access to the roof top must be
provided to the relevant design standards and included as part of the design.

Panel arrays shall be arranged for optimum solar exposure and design must avoid direct
reflection onto residential dwellings and road ways. The area under and around the
panels shall be a low maintenance surface treatment and accessible to control weeds.
Equipment shall not be susceptible to mechanical damage from machinery and power
tools required to control vegetation under the structures.

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4.21 PROTECTION PHILOSOPHY

The Contractor shall provide a Protection Philosophy Report for the power distribution
network. The document must be specific to the site and outline how any proposed
network changes will integrate with the existing protection schemes. An existing asset
may not necessarily have a Protection Philosophy Report available and the Contractor
shall discover and document the existing as installed protection schemes as required.

The topology of the HV and LV network shall be described in detail and the protection
schemes discussed for each equipment type. All operating scenarios including
emergency generation shall be disclosed and outline what operational limits are
proposed. The Protection Philosophy is a key document that shall be submitted early in
the design phase of the project.

Refer to QUU for typical Protection Philosophy Reports for indicative minimum
content and detail required.

Network sites are typically LV installations and do not require a Protection Philosophy
Report and in this case the Protection Co-ordination report is adequate documentation.

4.21.1 HV Protection Schemes

4.21.1.1 HV Incomers and Feeders

For protection schemes applicable to HV switchboards refer TMS1186 HV Switchboard

Technical Specification and following table provides further clarity of the minimum
requirements:-

Equipment Metal Clad Switchboard RMU

Single Incomer 3 phase OC and EF Fuse only
3 phase OC and EF plus
Two Incomers and
directional OC. Auto transfer N/A
Bus coupler
scheme and bus differential
3 phase OC and EF plus 3 phase OC and EF plus
Feeder SEF(configure as alarm and SEF(configure as alarm and
trip) where CB installed trip where CB installed
3 phase OC and EF plus 3 phase OC and EF plus
Transformer Feeder
SEF(configure as alarm and SEF(configure as alarm and
(less than 1MVA)
trip) where CB installed trip) where CB installed

Transformer Feeder 3 phase OC and EF plus 3 phase OC and EF plus

(greater than and SEF(configure as alarm and SEF(configure as alarm and
equal 1MVA) trip), REF (secondary side) trip), REF (secondary side)

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Equipment Metal Clad Switchboard RMU

Transformer Feeder 3 phase OC, EF plus 3 phase OC, EF plus
(greater than 2.5 differential protection and differential protection and
MVA) thermal protection thermal protection
TCS Required Required
Required and utilise IEC 61850
CBF Required and utilise IEC 61850
where CB installed
Required and utilise IEC 61850
Blocking Schemes Required and utilise IEC 61850
where CB installed

4.21.1.2 Transformers

For protection schemes applicable to distribution transformers refer to TMS1185

Distribution Transformers(less than 5MVA) – Technical Specification and TMS1625
Dry Type Distribution Transformers – Technical Specification.

HV Feeder CB’s shall be installed where the transformer nameplate rating exceed
500kVA.

4.21.1.3 HV Motors

For protection schemes applicable to HV motors refer TMS1404 HV Motor Technical

Specification. DOL HV motor starters are not accepted unless specified otherwise in the
Project Documentation.

4.21.1.4 Circuit Breaker Fail

To enhance the HV protection scheme, the CBF protection in the outgoing feeder IED’s
shall be used to back trip the incomer CB. The scheme design shall back trip all of the
CB’s connected to a common section of Bus-bar in the event of one breaker failing.
When CBF is triggered by protection functions, blocking signals on the IED shall be
removed. This scheme requires status of bus –ties to operate effectively to isolate bus
sections.

4.21.1.5 Trip Circuit Supervision

A standalone trip circuit supervision relay and hardwired circuit can be accepted rather
than the TCS configured in the IED. Under healthy conditions a constant low level
supervision current is maintained regardless if CB is open or closed to avoid nuisance
tripping.

4.21.1.6 CB Lock-out

CB lockout shall be provided to main incomers and feeder CB’s.

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4.21.1.7 Thermal Overload

Thermal overload protection utilises RMS load current to model the heating of the
connected loads and shall trip both incomer and feeder CB’s as required. Thermal
overload protection of HV cables is required.

4.21.1.8 Negative Sequence

Provide trip signal to site main incomers.

4.21.1.9 Bus Zone Protection

Bus Zone Protection shall be provided for all HV switchboards and shall utilise IEC
61850 goose messaging exchanged between incomer and feeder IED’s. Bus bar
blocking shall be implemented for faults external of the bus zone.

4.21.1.10 Under Voltage and Over Voltage

Alarm only shall be provided for main incomers to local HMI and SCADA.

4.21.1.11 Transformer Feeder 2nd Harmonic Blocking

Second harmonic blocking shall be provided where required to distinguish between

fault current and transformer inrush current due to the different natures of both current
types. An inrush current waveform is rich in harmonics (particularly the second),
whereas an internal fault current consists only of the fundamental.

Second harmonic blocking shall be applied where required to the following overcurrent
protection types:
• Phase Over Current
• Earth fault

The setting for 2nd Harmonic Blocking should not be too low, because the 2nd
harmonic blocking may prevent tripping during some internal transformer faults. If the
setting is too high, the blocking may not operate for low levels of inrush current which
could result in undesired tripping of the over current element during the energisation
period. In general, a setting of 15% to 20% is suitable.

4.21.1.12 HV Generators

HV generators are not preferred and where required the protection scheme shall be to
the generator manufacturer’s standard offering configured in the generator on-board
control system. The generator protection schemes shall be co-ordinated with the site
protection schemes and suitable for the site earth grid.

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4.21.2 LV Protection Schemes

4.21.2.1 Motors

Refer TMS1637 LV Motors Technical Specification, TMS1406 LV VSD – Technical

Specification and TMS60 LV Switchboard - Technical Specification.

4.21.2.2 LV Main Incomers and Feeders

Refer TMS60 LV Switchboard Technical Specification

4.21.2.3 LV Generators

For protection schemes required for LV Diesel Generators refer to TMS1589 Diesel
Generator - Technical Specification.

Permanent installed generators shall be connected to the site LV switchboard through a

4 pole ATS in the switchboard. A 4 pole MTS shall be provided where provision is
made for a mobile generator to be connected to the LV switchboard.

The MEN shall reside in the LV switchboard and a warning label shall be provided at
the switchboard connection point to disconnect the MEN from onboard the mobile
generator.

Refer TMS60 LV Switchboard Technical Specification for other requirements when

connecting generators to LV switchboards.

For permanently installed generators the load shedding or pre-determined maximum

demand control shall be provided where required to minimise the rating of emergency
generators required. Unless specified otherwise the load shedding algorithm for non-
essential loads shall be programmed in the site PLC control system. The control system
shall be delivered in accordance with TMS1202 Control System Implementation -
Technical Specification.

4.21.3 Metering

4.21.3.1 Check Metering

Check metering data for HV switchboards shall be accessed from the IED’s and
displayed at the local HMI and site SCADA.

Refer TMS1186 HV Switchboard Technical Specification for data to be accessed.

Check meters shall be provided on all main LV Switchboards in a metering section of

the switchboard. Check meters shall be provided in other LV switchboards and DB’s
exceeding 250A rating, unless specified otherwise in the Project Documentation. The

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meters shall be selected form TMS62 Preferred Electrical and Instrumentation List. The
metering data shall be displayed and trended at the STP site SCADA.

4.21.3.2 Revenue Metering

Utility owned revenue meters and instrument transformers shall be located in a

standalone panel in accordance with Energex standard design.

Revenue meters for new outdoor LV switchboards at Network Asset sites shall be
integrated into the switchboard in accordance with the Utilities’ requirements and QUU
standard design drawings. Where the switchboard is installed indoors a standalone
metering panel shall be installed on the external wall of the switchroom building that is
readily accessible by the Utility.

Revenue metering sections of a new switchboard require provision of an upstream and

downstream isolator that can be both pad locked in the “isolated/off” position.

4.22 COROSION PROTECTION

Refer to QUU technical specifications listed in section 1.3 for corrosion protection and
paint systems accepted for EI&C equipment.

4.23 CATHODIC PROTECTION

For the design of cathodic protection systems refer to TMS1595 Cathodic Protection
Pipelines and Structures - Technical Specification.

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5 INSTRUMENTATION DESIGN

5.1 GENERAL

Instrumentation signal types shall comply with following table:-

Parameter Signal Type

Operating Voltage 24VDC
Analogue I/O Signals 4-20mA
Digital I/O signals 24VDC volt free
Process Communication Modbus TCP
Signals DNP3
HART
Ethernet/IP

Note 1: LV single phase supply to instruments, process control solenoids and motorised
actuated valves shall only be proposed where the 24VDC supply option is not cost
effective or practical due to cable length voltage drop or other constraints and must be
accepted by QUU in writing. An RCD shall be provided at the point of supply to all
equipment that requires an LV supply
Note 2: Profibus and Profinet are only accepted where minor modifications to an
existing control system network are required and only where the protocols are already in
service at the site.

5.2 INSTRUMENT OPERATING RANGE

Instruments shall be factory calibrated, unless specified otherwise in the Project

Documentation. The operating range and set points shall be included in the project
instrument schedule. Refer QUU for a typical instrument schedule template.

Refer to QUU for standard instrument data sheet templates to be completed by the
Contractor. In the absence of a QUU instrument template the instruments shall be
provided with the manufactures generic data sheet and information on the data sheet not
relevant to the instrument supplied shall have strike through text or other method
accepted by QUU.

For instrumentation installed at various Network Asset types refer to the asset type
functional specification documents listed in section 1.3 of this document.

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5.3 INSTALLATION AND INTERCONNECTIONS

The design and selection of instruments shall ensure compliance with TMS1201
Instrumentation Installation - Technical Specification. Typical instrument process
connection or hook-up drawings shall be provided by the Contractor for all instruments
to be supplied or modified under the project.

P&ID’s shall be provided for all projects where new or modification to existing
instrumentation is required. Unless specified otherwise in the Project documentation the
Contractor shall produce As Built P&ID drawings for existing assets where QUU is
unable to provide the P&ID drawings.

5.3.1 Tubing and Fittings

Polyethylene tubing and compression fittings may be utilised for instruments to general
purpose electromechanical actuator valves and other equipment.

Tubing and fittings shall be in imperial sizes and SS316 Swagelok® compression
fittings for instrument air supply to API 607 fire rated control valve installations and
compressed air tubing up to the air dryer. The tubing shall be seamless cold drawn,
annealed and pickled, ASTM A269 TP316/316L with a minimum molybdenum content
of 2.6% (hardness maximum of 80 HRB), unless another material is required for
corrosion or other reasons. Alternatives tubing and fitting materials shall require QUU’s
acceptance.

5.3.2 General Requirements

For non-specified instruments in the Project Documentation the instrumentation

selection shall be based on TMS62 Preferred Equipment List Electrical and
Instrumentation Technical Specification. Any deviations from this list must be accepted
by QUU based on equipment with field proven ability for the application and
manufacturer’s technical support.

Smart HART analogue transmitters shall be used in preference to digital switches

wherever possible. Process variable alarming or switching shall be achieved via
software alarms and switches configured in the local PLC.

Instrumentation in safety applications shall be provided with dedicated instrumentation

and process tapping points that are separate from instrumentation and tapping points in
normal control services.

Monitoring and recording of data of all process variables shall be performed by the site
PLC control system.

Field transmitters shall be provided with integral digital indication except where
specifically noted otherwise in the Project Documentation.

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Loop powered local indicators that are required to be mounted externally to the
transmitters shall be series connected local to the transmitter and not reside in cable
junction box or local control panels.

Local PLC based control systems shall be utilised. Local field controllers shall only be
used where accepted by QUU.

The materials of construction shall be suitable for the process conditions. Where there is
a conflict between suitable materials of construction and this document, the suitable
material shall take precedence, unless otherwise approved by QUU.

DC relays shall be fitted with free-wheeling diodes. Solenoid coils shall also be fitted
with suppression protecting diodes, located within the local control panel.

Instruments shall be installed to enable calibration and testing without shutting down
the process.

Instruments shall be lagged, or heat traced and lagged, where the process liquid would
otherwise condense, solidify or be otherwise adversely affected by low or high ambient
temperatures.

The methods to be used for density measurement shall be accepted by QUU and shall
have a track record of reliability and repeatable measurements in similar service
conditions in the water industry.

All analogue field instrumentation shall be individually fused at the point of supply by a
suitably rated CB.

5.3.3 Flow

5.3.3.1 Vortex Meters- Volumetric Flow

Particular attention shall be paid to the minimum flow of a vortex installation to

determine suitability for application. Where vortex flow-meters are used, the Reynolds
number at minimum flow shall not be less than 20 000.

5.3.3.2 Differential Pressure - Volumetric Flow

Flow orifice plates and orifice plate flow meter installations shall comply with AS 2360.
The material for orifice plates should be compatible with the fluid handled. The
preferred material is type 316 SS.

For liquids with entrained solids, eccentric orifice plates may be used subject to the
acceptance of QUU. Alternate design (multi-hole) orifice plates which may reduce the
straight run piping requirements may be used subject to the acceptance of QUU. No
drain or weep holes shall be made in any flow orifice plate. Square root extraction shall

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be performed in the transmitter. Use of straightening vanes shall be subject to the

acceptance of QUU.

The flow rates and choice of differential pressure transmitters shall be as follows:

• Normal flow rate shall be between 70% and 80% of the full scale flow provided
that the anticipated minimum and maximum flow rates shall be between 33%
and 95% of the full scale flow and the accuracy of the transmitter is at least
0.2% of the calibrated span.
• Where the required range is required to be between 33% and 95%, a single
transmitter may be used.
• Where the required range is exceeds 33% and 95%, dual transmitters may be
required and shall be submitted for approval.
• Where a differential pressure transmitter is used as a flow input to safety system,
the transmitter range shall be such that the trip point is at least 33% of the full
scale calibrated span.
• Orifice plate Beta ratios (orifice diameter/pipe inside diameter) shall be limited
to values between 0.3 and 0.7.
• The preferred DP cell range is 25 kPa. Common alternatives are 10 kPa & 50
kPa and shall be subject to acceptance by the QUU correspondent.
• Orifice size, flange size, flange rating and instrument number shall be stamped
on the upstream side of each orifice plate and shall be visible when the orifice
plate is installed.

Orifice plate flow meter flanges shall have the following requirements:

• Flanges shall be in accordance with ASME B16.36.

• Flanges shall be weld neck type.
• Pressure taps shall be equipped with round head or stock plugs.
• Flange rating, facing and finish shall be as per the piping specification, or
ASME Class 300 minimum, whatever is greater.
• Flange tapping arrangement shall be utilised for all orifice plate installations.

Differential pressure (DP) transmitters shall be remote mounted to minimise or

eliminate vibration issues and lengths of impulse piping should be kept to a minimum.

The following guidelines shall be used to determine limitations for direct mounting of
transmitters:

• DP transmitters to be direct mounted in lagged service up to process temperature

of 250°C.
• DP transmitters installed on process temperatures above 250°C shall require
remote seals of fill fluids suitable for such temperatures.
• DP transmitters to be direct mounted in flushed services for process
temperatures of flush fluid within the Vendor supplied temperature limits for the

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transmitter fill fluid (no dead legs exist for these installations and therefore no
cooling).
• For installations in vertical pipelines the direction of flow shall be downwards
for wet gas or saturated steam and upwards for liquids.
• Upstream straight length requirements shall be in accordance with AS 2360.
• DP transmitters in gas service shall be mounted above the flow element.
• DP transmitters in liquid service shall be mounted below the flow element.
• DP transmitters for use in flow applications shall have a five-valve manifold

5.3.3.3 Magnetic Flow Meters

Magnetic flow meters may be used in water and sewerage services. Magnetic flow
meter excitation shall not exceed 24 VDC. The flow transmitter shall be mounted
remotely in a suitable electrical enclosure and not integral to the meter body. An
earthing ring with protecting edge shall be supplied and installed as per the flow meter
manufacturer’s recommendations. The electrodes shall be fixed type. The electrode
material of construction shall be 316 SS, unless other material is required for corrosion
resistance.

5.3.3.4 Other Flow Meters

Ultrasonic flow meters are the preferred measurement technique for flow measurement.
Alternatives to ultrasonic flow meters shall be subject to the acceptance of QUU.

Averaging pitot tubes or thermal dispersion meters may be used in particular

applications is subject to QUU acceptance. Installation of averaging pitot tubes shall be
such that they are removable on line, unless indicated otherwise.

In-line variable area flow meters shall only be used on non-critical processes and these
shall have 316 SS bodies with magnetic followers (unless other material is required for
corrosion resistance). The use of glass tube type shall be subject to the acceptance of
QUU. In-line variable area flow meters shall be installed in the vertical position.

Positive displacement flow-meters may be used for local flow indication/totalising in

non-critical process lines.

5.3.3.5 Mass Flow

Coriolis type mass flow-meters are preferred for liquid mass flow applications. Straight
tube-type Coriolis mass flow-meters are preferred over bent tube type.

5.3.4 Level

Where more than one level transmitter is required on a vessel, both shall be calibrated to
the same operating span and level wherever possible. Where level gauges (magnetic or

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glass) are installed alongside other level instrumentation the level gauge span shall
match or exceed that of the vessel operating range. Where vessels have both level
instruments in control and shutdown applications, different types of level transmitters
shall be installed to reduce common mode failures.

For continuous level measurement, the following level transmitter types are the
preferred choice:

• Magnetic follower style gauges with magneto-restrictive level transmitters for

use in shutdown applications
• Hydrostatic Pressure
• Ultrasonic
• Capacitance
• Conductive liquid
• Guided wave radar level transmitters

Use of capillary filled DP transmitters with diaphragm seals may be considered subject
to the acceptance of QUU. The lower connection point to a vessel shall not be taken
from the bottom of the vessel to minimise fouling of tappings and ensure full range of
measurement. Where bottom of vessel nozzle connections cannot be avoided, an up-
stand in the vessel should be installed.

All level instruments shall be located such that they are visible and accessible for
calibration, maintenance, or repair from grade or from a permanent platform.

All continuous level measurement instruments shall be provided with a means of in-situ
range checking and testing.

On liquid/liquid interface service the vessel top instrument connection shall be

submerged in the lower density fluid under all normal operating conditions. Level in
vessels and equipment shall be displayed in terms of 0-100% working range unless
specified otherwise by QUU. Operating range must be less than the working range
capacity of the vessel.

Any special applications for a level switch (e.g. sump pump auto-start/stop) shall be
accepted by QUU.

5.3.4.1 Guided Wave Radar

Radar level measurement shall only be considered where the relative dielectric constant
of the measured medium is suitable for this technology and other level measurements
are considered not suitable for the application. Radar transmitters shall be installed in a
manner that allows the instrument removal on line without impact on the process.

Installation of radar element shall meet manufacturer’s criteria for clearance from
sidewalls and internal obstructions.

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5.3.4.2 Level Bridles

Level bridles shall be utilised to minimise the connections on a vessel and to facilitate
instrument testing. Sufficient block, vent, and drain valves shall be installed to permit
in-place testing of instruments without the need to shut down the process.

Where several level instruments are required on a vessel, a separate bridle shall be used
by each level instrument.

Bridle process interfaces shall be via DN50 flanges having a minimum rating of ASME
class 300. Level bridle material of construction shall be 316 SS unless another material
is required for corrosion resistance. Bridles shall be equipped with DN20 (minimum)
vent and drain valves.

No bridle may connect across more than two adjacent phases on a three-phase vessel. In
this event, a third balancing connection is required to accommodate the middle phase.
Careful consideration must be given to the placement of the taps in relation to the
normal location and range of the interface. In some cases, additional taps may be
required to ensure continuous and correct measurement of the interface No vertical dog-
legs shall be permitted in making level connections to bridles.

Bridles shall not be used under the following circumstances:

• In service at low temperature (<0 °C)

• In viscous service and in applications where materials being handled contain
high concentrations of solids.

Level bridles and gauges shall be supplied with vent and drain valves.

5.3.4.3 Differential Pressure (DP) Level

Response times and temperature effects shall be calculated (as % of span) for each
remote seal application by the instrument supplier, over the range of process and
ambient temperatures for the application. In particular, the effects on accuracy shall be
reviewed for the case when the top seal temperature increases suddenly as the hot
process liquid rises. Where the effects on accuracy are unacceptable alternative
measurement techniques shall be provided.

5.3.4.4 Level Gauge Glasses

Excess flow type isolation cocks shall be fitted as standard Reflex type gauges are only
suitable for clean liquid services. Transparent sight glasses shall be used for other
services. No vertical dog-legs shall be allowed in making level connections to gauge
glasses.

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Gauge glass shall be of such quality that it shall break with an interlocking crystalline
fracture without loose, flying particles (normally referred to as tempered glass).

Gauge glasses shall be equipped with DN20 vent and drain valves. Drain valves shall be
piped into the facility drain system.

5.3.4.5 Nuclear Level

Nuclear type level measurement shall be used only when other methods cannot provide
the required accuracy or reliability. The use of this type of measurement requires
QUU’s acceptance..

Compliance with the statutory and site requirements for handling radioactive devices
shall be ensured at all times. Al lspecific design documentation and regulatory
approvals shall be provided by the Contractor. The operations and maintenance
requirements of the instrument must be accepted by QUU.

5.3.5 Pressure

5.3.5.1 General

Pressure elements shall be specified such that the steady normal operating pressure does
not exceed 75% of the maximum range.

Pressure elements shall be such that the process pressure does not exceed the maximum
rating of the element. If the process pressure can exceed the instrument rating pressure
then an adequate overpressure protection technique shall be provided. For each
application, QUU shall accept the technique proposed to be implemented.

Pressure sensor material of construction shall be 316 SS unless another material is

required for corrosion resistance. Pressure instrument process connections shall be ½”
BSP.

In corrosive services where a direct mounted pressure element is not appropriate, a

diaphragm seal shall be used. Where the pressure element shall be subjected to pulsating
pressures (e.g. inlets and outlets) the following steps are to be taken:

• Element shall be specified such that normal operating pressure does not exceed
60% of maximum range.
• A pulsation damper shall be used. Dampers shall be of the non-adjustable type.

Unless specified otherwise in the Project Documentation a method to depressurise the

process line or vessel to gain access to disconnect the instrument shall be provided.

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5.3.5.2 Pressure Gauges

Pressure gauges shall comply with AS1349 and have the following features:

• ½ ” BSP bottom entry

• 316 SS movement
• Oil filled housing
• 100 (or 115) mm diameter dial
• Weather proof 316 SS (IP65 rating or better)
• Solid front
• Shatter proof glass
• Blow out back (or pressure relief vent for the cases)
• White dial with black lettering and black pointer
• Isolation valve

Pressure gauge measuring elements shall be the C-type or helical Bourdon type. The
measuring element shall be 316 SS, unless process fluid requires the use of other
materials.

Pressure gauges shall be selected so that the normal operating pressure is 50-70% of the
full range of the gauge. Pressure gauges shall be able to withstand over-ranging to a
pressure of 1.3 times the maximum scale reading without a permanent set that affects
gauge calibration. In moderate vibration service (e.g. centrifugal pump suction), the
gauges are to be liquid filled with glycerine or equivalent.

5.3.6 Temperature

All temperature instruments (dial thermometers, thermocouples and RTDs) shall be

installed in flanged thermowells. Exceptions (e.g. skin temperatures) can be proposed
for QUU review. Temperature instruments shall be ranged to include start-up and
abnormal operating conditions unless otherwise specified by QUU.

5.3.6.1 Dial Thermometers

Field temperature indicators (dial thermometers) shall be of the bimetallic type, with a
125 mm dial size unless otherwise specified. Dial thermometers shall have adjustable
every-angle heads. The element diameter is nominally 6mm with a ½” BSP connection.

In applications where bi-metallic thermometers are not suitable, filled systems may be
used. The preferred materials for filled systems are 316 SS wetted parts with gas fill. All
such applications are to be accepted by QUU.

Where required for readability or protection from vibration, indicators shall utilise a
fully compensated filled system with a 316 SS armoured capillary tube and with a
remote reading dial.

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Mercury thermometers shall not be used. Where possible, dial thermometers shall
comply with the manufacturer’s standard ranges.

5.3.7 Temperature Elements and Transmitters

Dual sensor 3-wire Pt100 RTDs are the preferred option. 4-wire RTDs may be used
where required. The use of 2-wire RTDs requires acceptance by QUU. Where RTDs are
not suitable, i.e. due to required measuring range, Type K thermocouples can be used.

Where process temperatures allow, elements shall be direct connected to the

temperature transmitter. Where remote indication is required a loop powered indicator
shall be installed.

RTD’s shall have 6mm O>D316 SS sheaths. Sensors shall feature spring loaded heads
in their assemblies. Thermocouples shall be mineral insulated metal sheathed (MIMS).
These thermocouples shall be 6 mm O.D with insulated junctions and 316 SS sheathed.
Thermocouple terminal heads shall be spring loaded.

When Vendor packages include the supply of tube skin thermocouples (e.g. fired
heaters) the thermocouples shall be installed with thermocouple heads to allow remote
mounting of temperature transmitters. Where tube skin thermocouples during plant
shutdown.

Use of high temperature rated cable shall be considered if thermocouple extension and
RTD cables are run close to hot surfaces.

5.4 ANALYSERS

The design and selection of analysers is viewed as warranting special consideration. All
proposed analysers, including sampling handling systems must be accepted by QUU.
Unless the actual analyser model number is currently proven on QUU sites, no analyser
or sampling handling and recovery system shall be introduced to a QUU site without it
first complying with a guaranteed Performance Test; in agreement with QUU and the
equipment Vendor. The Performance Test shall be carried out on site by the analyser
supplier, or their nominated agents, and all the costs shall be included in the Contract
for the analyser supply.

If the initial Performance Test fails, all modifications and subsequent Performance Test
shall be undertaken by the analyser Supplier at no additional cost to QUU. Lab sample
points shall be provided on all analysers. Auto changeover manifolds to be provided on
carrier gases. Low carrier gas pressure shall be alarmed to SCADA. Low sample flows
shall also be alarmed to the SCADA.

In general, analyser outputs shall be 2 wire 4-20 mA loops. Where an analyser reports
multiple analyses the use of a communication link shall be provided. Refer TMS1202
Control System Implementation – Technical Specification for acceptable

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communication protocols. Common hardware alarms for each analyser shall be

provided and alarmed to the site SCADA.

Liquid samples shall be returned to process. Only where accepted by QUU shall bio-gas
be vented to site flares or the atmosphere.

Analysers shall be mounted as close as practical to the sample point in a weatherproof

naturally vented shelter or prefabricated enclosure subject to acceptance by QUU. Local
flow, pressure and temperature indications shall be provided on analyser sample
handling systems. Analysers shall have power isolators mounted adjacent to each
analyser in the field.

The analyser shall have a local shutdown and start-up facility, allowing the operator to
take the analyser out of service during unit upsets etc.

Where product sampling is required the sampling shall be continuous and independent
of the main process.

5.5 INSTRUMENTATION AND CONTROL CABLES

5.5.1 General

Refer TMS1201 Instrumentation Installation - Technical Specification

High Frequency pulse signals shall be transmitted via a dedicated cable wired direct
from the field device to the end device e.g. flow computer. Intermediate cable breaks,
i.e. wiring via junction boxes, shall be avoided to maintain signal integrity.

5.5.2 Process Control Network Cabling

Refer TMS1202 Control System Implementation - Technical Specification.

Fibre Optic (FO) cables shall be multi-mode fusion splice terminated with Straight Tip
(ST) connector break out boxes by specialist contractors.

Dedicated FO cables shall be provided for fire system communications. Signals for the
fire detection system shall not be run in the same cables used for the process control
network and other site communications.

5.5.3 Junction Boxes

Refer to TMS1201 Instrumentation Installation Technical Specification and TMS1203

General Requirements for Hazardous Area Installation – Technical Specification.

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6 CONTROL SYSTEM DESIGN

This section is intended to complement information contained in TMS1202 Control

System Implementation – Technical Specification. The information provides further
clarity for the control system design associated with particular electrical and
instrumentation equipment types.

6.1 CONTROL PANELS

Control Panels shall be designed to comply with TMS1222 Control Panel Technical
Specification. All new standalone control panel enclosures shall have minimum
dimensions 1800mm(H) x 900mm(W) x 450mm(D) and floor mounted on a plinth
unless specified in the Project Documentation.

The PLC control panel shall not be integrated into the same enclosure as the LV
switchboard at STP sites. Control panels associated with HV and LV Switchboards at
STP sites shall contain a 15” touch screen terminal for remote control and monitoring of
the switchgear items. The HMI shall be selected from TMS62 Preferred Equipment List
Electrical and Instrument unless specified otherwise in the Project Documentation.

6.2 SWITCHBOARDS

The control system for new LV switchboards shall be designed to comply with TMS60
LV Switchboard Technical Specification.

The reference to LV switchboards applies to MCC’s and vice versa throughout all
Project Documentation.

6.2.1 LV Switchboards for STP’s

Motor Protection Units (MPUs) shall be installed in each 3 phase DOL motor starter for
new switchboards to be installed at STP sites. Refer TMS62 Preferred Equipment List –
Technical Specification for MPU model numbers preferred. The site PLC control
system shall communicate with the motor starters MPU’s over a standard industrial
network protocol accepted by QUU.

Remote I/O modules shall be provided in the switchboard for I/O signals not related to
DOL motor starters and these would normally be located in a separate compartment of
the switchboard.

MPU’s shall communicate over a copper cable bus or star network topology to the local
PLC control system. All motor starter diagnostics including control and status is
provided over the network to the PLC and signals displayed at the local HMI and site
SCADA. The design intent is to minimise control wiring between the switchboard and
the PLC panel and to streamline FAT of the control system.

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All motor process control functions shall reside in the PLC processor. No control logic
shall reside in the MPUs or other programmable devices. Exceptions to this rule would
be considered for Packaged Plant equipment supplied with proprietary control systems.

6.2.2 LV Switchboards for Network Assets

The control system for new LV switchboards for Network Assets shall be designed as
per QUU standard design drawings. The standard designs are based on conventional I/O
control wiring between motor starters and the PLC or RTU control system and suitable
for Arc Flash Category 0 switchboards.

For new switchboards exceeding Arc Flash Category 0 PPE, the PLC, RTU and other
control system components shall be in a separate standalone Control Panel. The control
panel shall be manufactured to TMS1222 Control Panel Technical Specification.

6.2.3 HV Switchboards

HV switchboard remote control and status monitoring by the site control system shall be
implemented unless specified otherwise in the Project Documentation.

This includes the following:-

• Monitoring and trending of voltage, current, frequency, power, power factor etc.
of all incomers and feeders at local HMI and SCADA. Trends only provided at
SCADA terminals.

• Monitoring of the status of all devices including CB’s, LBS’s, and ESW’s,
IED’s, surge diverters etc at local HMI and SCADA

• Remote Control (Open and Close) of CB’s and LBS’s at the local HMI only.
The local HMI shall not have control capability of HV equipment located in
other plant areas

6.3 DOL MOTOR STARTERS

For outdoor switchboards the local control and monitoring functions shall be provided
for DOL individual motors using start/stop pushbuttons on the escutcheon of the motor
starter functional units unless advised otherwise in the Project Documentation.

For indoor switchboards located at STP’s a local HMI terminal is required for remote
control and monitoring of all components installed in the LV switchboard including
motor starters. The HMI shall be mounted on the PLC control panel located within the
same switchroom as the switchboard. Mounting the local HMI terminal on the front
door of an arc fault contained switchboard is NOT accepted. The control and monitoring
features of the local HMI shall be replicated at SCADA.

Printed at 7:26 AM on 21/01/19 Page 82 of 96

Auto control of motors is by the site control system sequence logic programmed in the
PLC. The Auto/Manual and Remote/Local mode selections shall be performed at the
local HMI and at SCADA.

Summary of motor control features as follows:

Control Mode Control Facilities

Auto Process control from PLC sequence logic
Control using motor START/STOP pushbuttons at the local HMI
or
Motor START/STOP pushbuttons at motor starter escutcheon
Remote Manual
or

Motor START/STOP pushbuttons at SCADA

Local Manual Control using motor START/STOP pushbuttons at the LCP

When selected in Auto mode all START/STOP pushbuttons for manual control are
disabled.

Emergency stop pushbuttons and other safety function devices shall be hardwired to the
motor starter and monitored by the local control system for deploy of alarms at the local
HMI and SCADA. Refer TMS1651 Machine Safety Implementation – Technical
Specifications for implementation of emergency stop circuits.

Refer TMS60 LV Switchboard Technical Specification for further design requirements

related to control and monitoring of motor starters.

6.4 VSD AND SOFT STARTERS

VSD and soft starters for motors shall have facility to be controlled similar for DOL
motors. The manual speed control for VSD’s shall be provided at the local HMI or at
the VSD starter panel using a potentiometer. All process control functions shall reside
in the PLC processor. No control logic shall reside in the VSD or soft starter unless
otherwise accepted by QUU.

VSD’s supplied with Packaged Plant equipment can be located on the skid with the
mechanical equipment and provided with a UCP. It is preferable to have VSD’s located
within air conditioned switchrooms.

Emergency stop pushbuttons and other safety function devices shall be hardwired to the
VSD and soft starter and monitored by the local control system for deploy of alarms at
the local HMI and SCADA. Refer TMS1651 Machine Safety Implementation –
Technical Specifications for implementing emergency stop circuits.

Printed at 7:26 AM on 21/01/19 Page 83 of 96

Refer TMS1406 LV VSD – Technical Specification for other VSD control system
design requirements.

6.5 EMERGENCY MOTOR CONTROL

Where operation of a motor is considered critical to safety of personnel, plant or is

essential for production availability the MPU display or VSD keypad may have
facilities to select LOCAL mode of operation to override the HMI and SCADA mode
selection. The LOCAL mode may also be selected at the LCP using a hard wired
LOCAL/OFF/REMOTE selector switch to the MPU.

The intention is to operate the motor under an emergency scenario from the field LCP
control pushbuttons and/or pushbuttons on the MPU. This feature would be utilised
when the PLC is out of service or local HMI and SCADA is unavailable. Other
equivalent design solutions can be proposed for emergency local mode of control.

6.6 SINGLE PHASE MOTORS

Controllers for single single-phase motors shall be manual controls and located near the
motor and provided with CB short circuit protection and thermal overload protection
relay mounted in a suitable enclosure. The enclosure shall be SS316 where located
outdoors or in corrosive environments with STOP/START pushbutton controls. For
packaged plant the motor starters can be located in close proximity to the mechanical
equipment.

6.7 LV SWITCHING

LV switchboard incomers, bus ties and feeder CB’s and isolators exceeding 400A rating
shall be remotely operated using the local HMI. Local control pushbuttons mounted at
the switchboard escutcheon to open and close the motorised Isolators, MCCB’s or
ACB’s shall be provided. The switchboard mounted controls are intended to be only
used in an emergency if the local HMI or control system is unavailable.

Operation of LV protective devices and isolators exceeding 400A while energised shall
be performed with personnel removed outside the arc flash boundary using the local
HMI. The PLC panel containing the local HMI shall be located external of the
switchboard arc flash boundary. A warning label shall be provided at the switchboard
that directs operators to use the HMI rather than the switchboard controls for LV
switching operations.

MCCB’s and isolators rated up to maximum 400A can be manually operated and do not
require motorised control facilities. PPE as specified on the switchboard arc flash label
shall be used when performing manual switching tasks at the switchboard.

Printed at 7:26 AM on 21/01/19 Page 84 of 96

6.8 HV MOTOR CONTROL

Where the HV motor is part of a large vendor package such as air blowers the control
shall be from the package UCP. The control system shall be delivered in compliance
with TMS1645 Package Plant EI&C Requirements - Technical Specification.

6.9 AUXILIARY DEVICES

The control system shall supervise and acquire data from auxiliary devices such as
UPS’s, DC Supply Systems, battery monitoring systems and other diverse equipment
such as vibration monitoring systems directly via Modbus TCP Ethernet
communications or other accepted communication protocols. Accepted protocols are
listed in TMS1202 Control System Technical Specification.

6.10 LOCAL CONTROL STATIONS

The design requirements for motor LCP are outlined in TMS60 LV Switchboards -
Technical Specification.

Motors shall have a dedicated LCP installed adjacent to the motor unless specified
otherwise in the Project Documentation.

The LCP START/STOP pushbuttons are only enabled when the motor is selected in
Local mode. The LCP STOP pushbutton can be omitted and replaced by an Emergency
Stop pushbutton where accepted by QUU. Refer TMS1651 Machine Safety
Implementation – Technical Specifications for machine safety design requirements.

HV motors and large LV motors (greater than 30kW) shall generally not have
STOP/START pushbutton controls provided at the LCP unless specified otherwise in
the Project Documentation. The Local Manual control facilities of HV and large LV
motors must be carefully considered in the design phase with input from QUU
operators.

Local Emergency Stop pushbutton(s) shall be provided at all motors. Refer TMS1651
Machine Safety Implementation – Technical Specifications for emergency stop circuit
design requirements.

6.11 EQUIPMENT INTERLOCKING

An Interlocking Technical Specification shall be developed for all new HV

switchboards, RMU’s and LV switchboards with multiple incomers, ATS or MTS. The
document shall describe the following in detail:-

• Mechanical interlocks between CB, ESW and LBS, as well as between incomers,
bus ties and feeders. The interlock key system shall be simple and easy to

Printed at 7:26 AM on 21/01/19 Page 85 of 96

follow. The preferred key type is RONIS for new switchboards and RMUs. The
implementation of lock boxes and complicated key interlocking schemes is not
preferred and the Contractor shall offer simple and effective key interlock
systems where possible.
• Hardwired electrical interlocks
• Control System software interlocks programmed in IED devices. Software
interlocks should not be programmed in the PLC.

All the mechanical, electrical and control system interlocks must operate to reinforce
each other. Hard-wired electrical and mechanical interlocks shall also be programmed
where possible in the IED devices. The PLC control system shall not be used alone to
implement interlocks that can impact safety of persons. For new HV installations the
reliance only on administration procedures is not accepted in order to prevent HV
equipment being operated to an unsafe mode or cause an unexpected trip.

The interlocking specification must provide step by step tasks for how to isolate and de-
isolate equipment safely under all operational scenarios. The interlocking specification
must be complemented by interlocking drawings showing hardwired and key interlocks
superimposed on the switchboard SLD.

Interlocks between upstream and downstream devices must be provided and is

applicable to interlocks between LV and HV network devices.

The Contractor is responsible to design and install interlocking to all existing equipment
upstream and downstream of new equipment provided under the Contract. The
Contractor shall also make adequate provisions in the design for potential future
expansion of the site when designing the interlocking system.

6.12 FUNCTIONAL SPECIFICATIONS

Refer to TMS1202 Control System Implementation Technical Specification for

minimum content and detail to be included in a control system functional specification
document. The QUU templates for functional specification documents are listed in
section 1.3 of this document.

6.13 IEC 61850 IMPLEMENTATION

New HV Switchboards shall be fully compliant with the IEC 61850 standard. This
encompasses communications, control, protection and monitoring of the switchboard’s
operation.

New IED’s shall be provided with an IEC 61850 communications port and linked with
CAT 6 communications cables through to an IEC 61850 network switch. The network
switch shall be located in a dedicated communication panel in the HV switchroom.

Printed at 7:26 AM on 21/01/19 Page 86 of 96

IEDs shall be networked in a star network topology using the IEC 61850 protocol.
Goose messaging shall be used for communications between IEDs for protection
schemes. The site PLC control system shall supervise, control and acquire data from all
IED’s also over the IEC 61850 communications network. MMS messaging shall be
used for communications between IED’s and the site control system.

For new HV installations a dedicated HV PLC shall be provided to control and monitor
the HV switchboard and associated components inside the HV switchroom. The PLC
shall be located inside the HV switchroom in a full height floor mounted control panel
with 15” touchscreen HMI mounted on the door. The HMI shall be configured to
control and monitor all equipment associated with the HV installation on the site
including switchboards, transformers, RMU’s and building services equipment
associated with the HV switchroom. The PLC Panel shall be designed to comply with
TMS1222 Control Panel Technical Specification.

The IEC 61850 network can be extended to include an IEC 61850 to Modbus/TCP
gateway device if required to allow the PLC to communicate with the IED’s, however
direct IEC 61850 communications between IED’s and PLC is preferred. The PLC and
HMI shall not be configured to provide any HV or LV protection functions. The
protection scheme shall be configured in the IED’s. Failure or unavailability of the PLC
or HMI shall not diminish in any way the capability of the HV protective devices to
clear faults in the power network.

All new HV switchboards and RMUs shall be provided with capability under normal
operation to remotely operate CBs and LBSs with operators removed from the arc flash
hazard. The switchgear devices shall also be possible to be operated locally (from the
front of the HV switchboard) under emergency situations if the control system is
unavailable.

The HMI must provide adequate information and diagnostics for HV Authorised
Persons to perform HV switching operations. Only persons with HV Authorisation are
permitted to perform HV switching tasks and the HMI terminal shall be secured behind
a security key lockable panel door so that the panel touch screen is only accessible by
HV Authorised Persons. The local HMI only has control capability of the local HV
switchgear and has monitoring capability of all other HV switchgear and associated
equipment located elsewhere on the site.

Where IED’s have limited I/O capacity, the switchboard shall be fitted with IEC 61850
Block I/O located in the same tier as the IED. Block I/O shall also be provided in a
common area of the switchboard to gather I/O signals that are not associated with any
particular feeder or incomer. Control wiring between feeders and incomer tiers shall be
minimised.

The following functions shall be provided at the local HMI and the control and
monitoring capability shall be replicated at the site SCADA.

Printed at 7:26 AM on 21/01/19 Page 87 of 96

CBs and LBSs shall be motorised and have facility to be remotely operated from the
local HMI. Status shall be provided at the local HMI and SCADA.

ESW’s shall be operated manually at the switchboard and the status of the switch
position displayed at the local HMI and SCADA.

The local HMI shall display extensive fault finding information. All interlocks that are
preventing a device from operating shall be displayed. All signals and alarms associated
with the HV equipment, switchroom facility shall be displayed at the local HMI and
SCADA.

The CB Trip Circuit Supervision (TCS) can be a dedicated relay separate from the IED.
The status of the TCS relay shall be provided at the local HMI and SCADA. The TCS
scheme shall be tested and faults reset using controls on the TCS relay accessible from
the front of the switchboard with doors closed. The TCS can be incorporated into the
IED and in this case testing and monitoring shall be undertaken using the IED keypad
with status also provided at the HMI and SCADA.

Refer TMS1186 HV Switchboard - Technical Specification for other design features

required in HV Switchboards.

Refer to TMS1185 Distribution Transformer(less than 5MVA) - Technical Specification

for status signals to be connected to the PLC for oil insulated transformers.

Refer TMS1625 Dry Type Transformers – Technical Specification for status signals to
be connected to the PLC for dry type transformers.

Time stamping for Sequence of Events data is not required unless specified otherwise in
the Project Documentation.

The IED’s shall be programmed from the local communications port and are NOT
required to be configured remotely over the IEC 61850 network. The data log and other
information stored in the IED’s will be accessed if required from the communications
port on front of the IED using a portable programming terminal.

The Contractor shall design and deliver all control system works in compliance with
TMS1202 Control System Implementation - Technical Specification.

6.14 CLOSED CIRCUIT TELEVISION

A Closed Circuit Television (CCTV) system shall be provided where specified in the
Project Documentation. The CCTV cameras with night vision capability shall be
installed at key process points and site access ways.

Refer TMS117 Security, Access, Control and CCTV – Technical Specification for
specific design requirements. The CCTV design must ensure the equipment can be
installed as per TMS1200 Electrical Installation Technical Specification.

Printed at 7:26 AM on 21/01/19 Page 88 of 96

CCTV system shall not utilise spare network switch ports or spare fibre cable cores
which are used for process control or other services. Dedicated network switches and
fibre cables shall be installed for all new and modifications to CCTV systems.

Printed at 7:26 AM on 21/01/19 Page 89 of 96

7 COMMUNICATION SYSTEMS

7.1 GENERAL

This section is intended to complement information contained in TMS1202 Control

System – Technical Specification. The information provides further clarity for the
communication network design associated with particular electrical and instrumentation
equipment.

Communication links may be used between component parts of a proprietary control

and information system for data gathering, operator commands and supervisory control.

Communication links shall not be used for equipment basic stop/start, reset of faults or
for any automatic shutdown functions related to safety systems.

7.2 COMMUNICATION CABLES

Communications cables that are routed external of switchrooms and building in process
areas shall be multi–mode fibre optic cables. The cable installation shall comply with
TMS1200 Electrical Installation – Technical Specification. The fibre cables shall be
metal sheathed rodent proof or SWA cables.

CAT 6 and other screened copper communications cables are only accepted where both
ends of the cable terminate in the same building or switchroom. For short
communications links, not exceeding 5m between equipment in process areas, copper
serial or CAT 6 communication cables can be installed.

Rugged multi-mode fibre optic patch leads or rugged CAT 6 cables shall be installed
when patching signals between enclosures separated by short distance of less than 5m.
Rugged patch lead data sheets must be accepted by QUU.

7.3 COMMUNICATION PANELS

New communications equipment where installed in switchrooms at STP sites and

switchrooms at other larger assets shall be mounted in standalone rack unit type
enclosures. The communications panel shall be 42 rack units unless specified otherwise
in the Project Documentation and accessible from front and rear. Only communications
equipment shall be installed in the communications panel and this includes termination
facility for communication cables.

Communications Panels shall be designed to comply with TMS1222 Control Panel

Technical Specification.

Printed at 7:26 AM on 21/01/19 Page 90 of 96

New communications equipment installed at Network Assets or located in the field,

such as within the process areas of STP’s may have the communications and control
system equipment integrated into a PLC control panel or switchboard compartment.

7.4 PRIVATE RADIO AND 3G/4G COMMUNICATIONS

QUU has an existing extensive private radio telecommunications network. QUU’s

private radio network is the preferred communications link for RTU/SCADA sites.

Two communication options exist within QUU, with private radio being the preferred
link and 3G or 4G are viable options if the radio solution is found not to be feasible for
the site.

The Contractor shall design new and modifications to existing radio networks so as to
not degrade the current performance and reliability of the existing network. New
equipment shall be selected from TMS1151 Control Systems Preferred Equipment List.
The equipment must be designed to comply with TMS1202 Control System
Implementation – Technical Specification.

For the replacement of “like for like” remote radio sites where the new antenna will be
located in the same position as existing, monitored path loss diagnostics can be utilised
to provide a suitable radio signal strength.

For new sites or where the new radio antenna cannot be mounted in the same position as
the existing antennae, a radio network desktop design must be performed by the
Contractor to determine which repeater within the area will provide a suitable
communications link. From the desktop design and once a suitable link is proposed a
radio signal site survey shall be performed to confirm the proposed radio design
solution.

The preferred option is for the desktop design to achieve a target RSSI of -80dB or
better and the antennae pole height to not exceed 6m in height from finished ground
level of the site. A 6m pole is the maximum height which a pole mounted on the side of
a switchboard will be accepted by QUU.

Standalone poles should be located in near vicinity the switchboard and generally be
installed 2m higher that the local council Town Plan building height restriction so as to
allow the antennae to be mounted at the maximum height possible and reduce radio
signal interference and loss from any nearby tree foliage or buildings.

The Contractor shall only proceed with a Telstra 3G or 4G communications design

solution for a site where the Radio Network Desktop Design Report demonstrates that a
private radio network link is not feasible and the report is accepted by QUU or the site
requires dual communications links based on site criticality. A desk top determination
if 3G or 4G communications to the site is feasible shall be performed by the Contractor

Printed at 7:26 AM on 21/01/19 Page 91 of 96

that utilises the Telstra network coverage map followed by a site survey by the
Contractor to confirm the Telstra network signal strength.

A 3G/4G site survey shall be performed at each site and whenever a radio signal site
survey is performed at the site. A 3G site survey and design solution shall only be
required where a site does not have Telstra 4G signal coverage.

7.4.1 Radio Network Desktop Design

When modifying existing radio networks or proposing new radio networks, the
Contractor shall undertake a radio network desk-top design analysis. The analysis shall
be undertaken using one of the radio network design software packages accepted by
QUU as follows:-

• ICS Telecom,

• Mentum Planet

• Pathloss

Alternative modelling software can be proposed by the Contractor and must be accepted
in writing by QUU before any design commences.

Prior to radio network design commencing the Contractor shall enquire with QUU and
request the existing radio network software model. QUU will only provide the model(s)
where available and the information contained in the model must be verified by the
Contractor.

The Contractor shall produce the model when is not available from QUU. The
Contractor when compiling the model shall provide GPS co-ordinates, radio type,
antenna heights etc and shall allow for all necessary site visits to collect and verify the
required data.

The minimum base station data required to be confirmed by the Contractor is as

follows:-

• Transmit power
• Antenna gain
• Antenna model and coverage pattern file
• RF feeder type and length
• Antenna height

In order to get consistent results with the radio path modelling software, the Contractor
shall utilise digital terrain databases accepted by QUU.

Printed at 7:26 AM on 21/01/19 Page 92 of 96

The Radio Network Desktop Design Report shall detail the repeaters within the area, a
path profile view and a link detail table with a recommendation table. The engineering
calculations showing path loss, cable loss, transmit power, antennae types/gains, length
of transmission paths, obstructions, RSSI for different antenna heights etc shall be stated
in the report for the proposed radio frequencies.

QUU will provide the existing QUU private radio base station locations and frequencies
upon formal request by the Contractor. The digital terrain models shall be nominated
within the report to understand the level of accuracy for the terrain. Clutter shall be
included in the point to point link which can be manually inputted if no clutter data is
available.

QUU must accept the Radio Network Desktop Design Report before the radio signal
site survey is commenced.

QUU will provide TEM596 Radio Network Desktop Design Report Template and is
issued for information only to the Contractor.

7.4.2 Radio Signal Site Survey

The Contractor shall attend the site to undertake site measurements of the radio signal
strength and confirm the parameters calculated in the Radio Signal Desktop Design
Report. The location of the switchboard containing the radio equipment and antenna
location shall have been generally accepted by QUU before the site survey commences.
The Contractor shall consider the removal of trees and foliage that may impact or cause
future interference with the radio signal. Contractor must also consider proximity to
overhead power lines and public road ways to ensure adequate access to maintain and
inspect the antenna.

The Contractor shall test at a range of antenna heights, above and below the height
calculated in the Radio Network Desktop Design Report. If it was found within the
desktop design that more than one repeater was available, signal strengths shall be
recorded for each repeater.

The Contractor shall prepare a Radio Signal Site Survey Report and shall submit the
report to QUU for review. The report shall as a minimum nominate the radio
frequencies assessed on the site, antennae heights and RSSI recorded at each antennae
height. The report shall contain photos of the testing as performed and shall reference
the test plan document.

The Contractor shall only proceed with a 3G or 4G communications network design

solution for a site, where the Radio Site Survey Report demonstrates that the private
radio network link is not feasible and this is accepted by QUU. On all sites the
Contractor shall measure the 3G or 4G signal strength using the Cybertec 2455 modem
which is specified by QUU for the Telstra mobile network. The site measurements must
verify the feasibility of a 3G or 4G design solution if it is required for the site.

Printed at 7:26 AM on 21/01/19 Page 93 of 96

QUU will provide TEM597 Radio Signal Site Survey Report Template and is issued
for information only to the Contractor.

7.4.3 Communications Network Design Report

The Communications Network Design Report is relevant to a private radio and/or a

3G/4G communications solution. The report shall nominate the proposed mast height,
the actual antenna mounting height, assess susceptibility to network frequency
interference from external noise sources and consider the feasibility of erecting the
antenna mast in the proposed location.

Antenna masts shall not be proposed in vicinity of HV transmission lines. Section

clearance as per AS2067 must be maintained during installation and while accessing the
antenna and mast for maintenance.

Provision for lightning protection of the network components shall also be detailed in
the design report. All coaxial cable connections to antennas shall have a suitable surge
arrestor installed in the switchboard or control panel.

An options section shall be provided in the report that details the communication path
options available, details possible alternative antenna heights, antenna
supports/structures and radio link signal strengths for each option. The report shall also
contain a recommendation that details the preferred solution. The report and
recommendation must be accepted by QUU before the Contractor proceeds to finalise
the design drawings and procure the radio equipment for the project.

The Communications Network Design Report shall be updated to As Built status and
this shall require a final signal survey undertaken by the Contractor during the site
commissioning phase of the project. The radio software model shall also be updated to
As Built and provided to QUU with the As Built documentation for the site. The radio
network software model filenames and versions shall be nominated in the report.

QUU will provide TEM598 Communications Network Design Report Template and is
issued for information only to the Contractor.

Printed at 7:26 AM on 21/01/19 Page 94 of 96

8 HAZARDOUS AREAS

8.1 GENERAL REQUIREMENTS

Plant areas where the formation of gases, vapours or mist that may occur in such
quantities that explosive mixtures with air are likely to occur, shall be classified as
Hazardous Areas (HAs) in accordance with AS60079.10.1.

Electrical equipment and instrumentation shall as far as practicable, be located in the

least hazardous area zone. Switchrooms and instrument air packaged plants shall be
located in non-hazardous areas.

HA installations shall be designed to ensure compliance with TMS1203 General

Requirements for Hazardous Area Installation - Technical Specification. Projects with
HA scope shall be delivered in compliance with MP183 HA Management Plan.

8.2 CLASSIFICATION

The HA Classification shall be completed to the latest edition of AS 60079.10.1. QUU

requires to standardise on the HA Classification Report content and layout and will
provide a report template that shall be utilised by the Contractor. The HA Classification
Report minimum contents are specified in MP183 HA Management Plan and TEM518
HA Verification Dossier Template. Existing HA Classification Reports shall be
updated by the Contractor to comply with TEM518 where required.

8.3 EQUIPMENT EX CERTIFICATION

Refer to TMS1203 General Requirements for Hazardous Area Installation - Technical

Specification for equipment Ex certifications.

8.4 PROTECTION TECHNIQUES

The Ex protection techniques for new equipment that are accepted by QUU are outlined
in TMS1203 General Requirements for Hazardous Area Installation - Technical
Specification..

8.5 HAZARDOUS AREA DOSSIER

The site HA Verification Dossier shall be updated for any equipment located fully or
partially within HA’s. The site HA Verification Dossier shall be updated by the
Contractor in compliance with TEM518 HA Verification Dossier Template.

The Dossier shall be issued to QUU prior to the commencement of the project
commissioning phase. All equipment decommissioned shall have the relevant

Printed at 7:26 AM on 21/01/19 Page 95 of 96

information removed from the site HA Dossier. The Contractor is responsible for the
completeness and accuracy of the HA Dossier.

The information provided in the HA Dossier shall not be duplicated in any other
documentation deliverables provided by the Contractor.

Printed at 7:26 AM on 21/01/19 Page 96 of 96

E:\QUU\Specifications\E,I and C Design Criteria\TMS1648 Electrical, Instrumentation & Control Sytems Design Criteria- Rev2.docx

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