Section 15

SPECIAL SYSTEMS

SPECIAL SYSTEMS ADDRESSED IN THIS SECTION ARE: appliances, facility fire safety controls, and
supplementary equipment. Depending on system
FIRE DETECTION PG 1 design, the fire alarm signaling function may
HEAT TRACING PG 12 provide for one or more of the following:
LIGHTNING PROTECTION PG 19 • Notify all facility occupants simultaneously
COMMUNICATIONS PG 21 • Notify occupants in certain portions of the
LIGHTING PG 28 facility who are in immediate danger
CATHODIC PROTECTION PG 41 • Notify key facility personnel
PLANT SECURITY PG 42 • Notify the local fire department
480V PLANT POWER & MAINTENANCE PG 43 • Notify the on site fire department and plant
TEMPORARY CONSTRUCTION POWER PG 43 operations group
PLANT SYSTEMS & FACILITY TURNOVERS PG 46 • Activate facility fire safety control and
supplementary functions during fire
emergencies
FIRE DETECTION AND ALARM
Control Unit Operation
General
A fire alarm control unit may be a simple, single-
All fire alarm systems consist for the following basic zone unit providing for one alarm initiating circuit
parts: and one or two alarm notification circuits. However,
• Control unit most control units are modular in construction and
• Initiating device circuits are designed to accommodate multiple zones of
• Notification appliance circuits detection and alarm signaling, as well as the
• Power supply selection of other modular components to perform
any of the system functions listed above.
The applications of fire alarm systems can be broken
down into four broad categories: Fire alarm systems must perform in an emergency.
• Protected premises (local) fire alarm For this reason, the control unit constantly monitors
systems (supervises) the integrity of the primary (main)
• Auxiliary fire alarm systems power supply, the secondary (standby) power supply,
• Remote supervising station alarm systems and the installation wires and the connections of the
• Proprietary supervising station fire alarm alarm initiating devices and alarm notification
systems appliances to the initiating and notification circuits.
The control unit will sound a trouble signal to alert
Although NFPA specifies the installation operating personnel when a fault condition exists on
requirements for the four categories of systems, the any of the monitored circuits which prevents normal
requirements of the local municipality and state fire circuit operation.
authorities having jurisdiction must also be met. In
addition, care should be taken to install equipment in The trouble signal normally will sound to indicate
strict accordance with manufacturer’s instructions. any of the following types of faults.
• Loss of primary (main) power
Control Unit • Loss of secondary (standby) power
• An open in a monitored wire
The control unit is the brain of the system. It • A ground on a monitored wire if a ground
provides power to the system and electrically can cause the system to be inoperative or
monitors its circuits. The control unit contains the ground detection is supplied
logic circuits to receive signals from alarm initiating • Loss of an audio amplifier, tone generator,
devices and transmit them to alarm notification or preamplifier

Rev. 0 Electrical Handbook 15-1

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Section 15
SPECIAL SYSTEMS

• A short across an alarm notification circuit Performance of Circuits

• Loss of connection between any installation
wire and any alarm initiating device wire or Initiating device, signaling line and notification
terminal necessary to sense an alarm indicating appliance circuits are classified in NFPA
• Loss of connection between any installation 72 according to their ability to perform under a
wire and any alarm notification wire or single open or ground fault, a combination single
terminal necessary to indicate the presence open and ground fault or a short-circuit fault
of an alarm. condition. Though Class A and Class B
classifications are most commonly used, they are
Any one of the foregoing faults could interfere with only defined by their performance under single open
the proper transmission or receipt of an automatic or or ground fault conditions. Short-circuit faults are
manual alarm signal. ignored. Though short-circuit faults occur less
frequently than opens or grounds, their effect can be
The trouble signal is an audible appliance, with a more catastrophic. A short-circuit on an initiating
distinctive sound. A visible trouble indication or device circuit results in a false alarm which can
display may be provided also locally and/or remote. have serious consequences where certain types of
Depending upon control unit design, a trouble signal occupancies are unnecessarily evacuated. Of even
silencing switch may to provided. If the trouble can greater consequences are short-circuit faults on
be silenced in this manner, a trouble light which signaling line and notification appliance circuits
must remain lighted until the cause of the trouble is which could cause the loss of the entire fire alarm
corrected must be provided. The audible trouble system or the accidental energization and subsequent
signal will sound if the switch is in the silence discharge of the mechanical fire protection system
position and no trouble exists. In addition to the (e.g. halon, co2, deluge).
foregoing trouble indications, the control unit may
contain additional trouble lamps which pinpoint the For this reason, NFPA 72 classifies these circuits
particular circuits or zones which are in trouble. both as Class A or B as well as by styles which also
Trouble conditions also may be recorded on a system take short-circuit faults into consideration. NFPA 72
printer, if used. divides initiating device circuits into Styles A
through E, signaling line circuits into Styles 1
The requirement for a fire alarm system to monitor through 7 and notification appliance circuits into
(supervise) the integrity of its interconnecting wiring Styles W through Z.
and connections is the major difference between the
installation of a fire alarm system and the Initiating Device Circuits
installation of the more general wiring of a facility.
Most problems encountered during the startup of a Initiating device circuits are those to which
fire alarm system are traced to errors made in the automatic or manual initiating devices are
installation wiring or connections, or both. It is connected. The commonly used types of circuits are:
therefore, extremely important to follow the
manufacturer’s explicit installation instructions • Two-Wire Using Normally Open Contact
when installing any fire alarm system component. Initiating Devices and an End-Of-Line Device.

The control unit is usually installed in a surface or This is termed a Class B circuit. Monitoring of
flush wall-mounted cabinet, a floor-mounted cabinet, this circuit is accomplished by passing a low
or a desk-type console, depending, upon the size of current through the installation wires and end-
the system and the manufacturer. Normally a lock of-line device. Any interruption of this current
and/or tamper switch is provided for security of the will cause the trouble signal to sound.
controls or cabinet doors.

Rev. 0 Electrical Handbook 15-2

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Section 15
SPECIAL SYSTEMS

• Two-Wire Using Normally Closed Contact both, are carried. Systems with this type of circuit,
Initiating Devices. use signaling from a multiple number of individually
identifiable initiating devices or circuits over a
This circuit uses bias resistors across the common circuit or path compared with systems
contacts, and an end-of-line device in order to using initiating device circuits which deals with a
differentiate between alarm and trouble single identifiable circuit of initiating devices.
conditions. This is also a Class B circuit.
Notification Appliance Circuits
• Two-Wire with Both Polarized Normally Open
Contact Initiating Devices and Oppositely Notification appliance circuits are those which can
Polarized Notification Appliances. operate a variety of appliances such as bells, horns,
chimes, buzzers, or speakers to signal an alarm
In this circuit, the appliances are connected on condition. Visible appliances such as strobes,
the same circuit and terminate in an end-of-line beacons, or other lamp-types also may be used on
device. This is also a Class B circuit. these circuits. Appliances used in fire alarm systems
should be listed for such use. Common notification
• Four-Wire Circuit Using Normally Open circuit types can be as follows:
Contact Initiating Devices.
• Series Circuits
The initiating devices are connected across two
of the wires. After the last device these two In these circuits the current flows through a
wires are brought back directly to the control continuous wire loop from the control unit
unit. If the wires terminate within the control through the coil of each connected signal
unit with only an end-of-line device, the circuit appliance in turn and then finally back to the
is termed a Class B. Additional circuitry may be control unit. Monitoring of this circuit is
provided which allows the operation of the accomplished by passing a low current through
circuit despite the occurrence of a single open or the lines. Any interruption of this current will
ground in that circuit. With this additional cause the trouble signal to sound. The series
circuitry, the circuit is termed a Class A circuit. alarm notification circuit no longer meets code
It may be necessary to refer to the requirements.
manufacturer’s operating manual or drawings to
determine whether a circuit is four wire Class B • Parallel Circuits
or a true Class A circuit.
These circuits normally have polarized alarm
• Four-Wire Circuit with Both Polarized Normally notification appliances wired in parallel and
Open Contact Initiating Devices and Oppositely equipped with diodes in series with each coil
Polarized Alarm Notification Appliances. and an end-of-line device. Monitoring current
is allowed to flow in one direction through the
In this circuit, the initiating devices and the end-of-line device to monitor the circuit wires.
notification appliances are connected on the Upon reversal of the current flow, the signaling
same circuit. appliances are now allowed to sound while the
end-of-line device limits the current flow.
Signaling Line Circuits
Parallel circuits are used also for speaker
Signaling line circuits are those which provide a circuits when the fire alarm control unit is
circuit or path between any combination of circuit designed to sound electronic tones or to give
interfaces, control units, or transmitters over which recorded or live voice messages. The most
multiple system input signals or output signals, or common method of monitoring used in this

Rev. 0 Electrical Handbook 15-3

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Section 15
SPECIAL SYSTEMS

application is to have a capacitor in series with e) Guard’s tour supervisory service

each speaker transformer coil so as to block and f) Industrial process monitoring
DC voltage used for monitoring. The audible
signal, being AC, will pass through the • Auxiliary Fire Alarm System.
capacitor and energize the speaker coil.
There are two types of auxiliary systems in
Power Supplies common use. One is a local energy auxiliary
alarm system which uses power from the
Fire alarm systems are required to have two sources protected premises system to automatically trip a
of electrical power, a primary (main) power supply transmitter or master box connected to the
to operated the system, and a secondary (standby) municipal public fire service communications
power supply to operated the system in the event of system.
failure of the primary power supply. The trouble
signal power supply must be able to sound trouble The other is a shunt auxiliary alarm system with
signals in the event of loss of the primary power. isolated closed contacts controlled by the
protected premises fire alarm system or alarm
Supplementary Circuits initiating devices connected directly to a
municipal system or master box. Power from
Supplementary circuits may consist of the following: the municipal system loop is used to trip the
• Annunciators transmitter.
• Signal sounding appliances not required by
code • Remote Supervising Station Fire Alarm System.
• Printers
• Fan shutdown The remote supervising station system provides
• Motor stop an alternative method of connecting a fire alarm
• Elevator capture system directly to the municipal
communications center over lines other than the
These circuits may be unmonitored, provided they municipal fire alarm circuits. Usually this
are designated as supplementary by the applicable means a separate pair of telephone wires, leased
authority having jurisdiction, and a short circuit, a from the telephone company, between premises
break, or a ground fault does not prevent the and the municipal communications center.
required operation of the fire alarm system.
• Proprietary Supervising Station Fire Alarm
Types of Control Systems System.

• Protected Premises (Local) Fire Alarm System. A proprietary supervising station fire alarm
system serves from a central supervising station
A protected premises fire alarm system provides either single or multiple contiguous or
alarm signal indications at the protected noncontiguous properties under one ownership.
premises and, in addition, it provides for one or Trained operators are required to be in constant
more of the following: attendance on this type of system. The operator
a) Manual fire alarm service may alert an in-house fire brigade or the
b) Automatic fire alarm service municipal fire department, or both. All signals
c) Automatic detection of waterflow or received by the central supervising station that
abnormal conditions in sprinkler systems show a change of status must be automatically
d) Automatic discharge or abnormal and permanently recorded, including time and
conditions in extinguishing systems such as date of occurrence.
CO2 or Halon

Rev. 0 Electrical Handbook 15-4

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Section 15
SPECIAL SYSTEMS

• Central Supervising Station Fire Alarm System. listed for fire alarm use where it does not
perform a required fire alarm system function.
A central supervising station fire alarm system Where common wiring is used between the fire
receives signals from alarm and supervisory alarm and nonfire alarm systems, short circuits,
signaling devices at a protected premises. The open circuits, or grounds on the shared wiring
response to the signals is determined by the type or within the nonfire alarm equipment should
of service provided. A central supervising not prevent normal operation of the fire alarm
station fire alarm system can provide or more of system.
the following services:
a) Water-flow Alarm - Dispatch fire New Technology Systems
department upon the activation of a
sprinkler system. New technology has given manufacturers the
b) Sprinkler Supervisory - Notify facilities opportunity to apply computer controlled devices
maintenance personnel when a fire that can work much faster and perform more work to
sprinkler system has been disabled by make people in a facility safer from the danger of
actions such as closing a valve. fire.
c) Guard’s Tour Supervisory - Notify facilities
personnel when a guard’s tour is not The new technology systems, for the most part, use
completed on time. the basic capabilities of computers and borrow
d) Manual Fire Alarm - Dispatch the fire heavily from telephone signaling methods.
department when a manual fire alarm box Some of the new technology devices and systems are
has been activated. as follows:
e) Automatic Fire Alarm Detection -Dispatch
the fire department when an automatic fire • Multiplexing.
detector goes into alarm.
Multiplexing is a signaling method
• Fire Safety Control Functions. characterized by simultaneous or sequential
transmission, or both, and reception of multiple
NFPA 72 contains requirements that apply to signals on a signaling line circuit or a
equipment within the protected premises that do communication channel including means for
not detect fires nor notify people but do make positively identifying each signal.
the premises safer for the occupants from the
fire’s effects. The function that multiplex system have added
to fire alarm signaling systems is the capability
Previously, many of these functions were to construct systems that use a common
frequently classified as supplementary. In most signaling line circuit to gather information from
cases, these control functions are required by many types of input devices (such as manual fire
local codes and ordinances and, therefore, must boxes, fire detection devices, and supervisory
have their installation wires monitored for devices) and distribute appropriate control
integrity and meet the requirements of NFPA action commands to output devices (such as
72. relays and alarm notification appliances) at very
high speed. In addition, the new signaling
• Combination Systems. technology has made the use of radio signaling
paths practical because it made it possible to
Combination systems are systems where the fire monitor signaling pathways that do not use
alarm system shares components, equipment wires with a high degree of reliability.
and circuitry with nonfire alarm systems. The Functionally, the signals passed back and forth
nonfire alarm equipment does not have to be in a multiplex fire alarm system permits the

Rev. 0 Electrical Handbook 15-5

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Section 15
SPECIAL SYSTEMS

system to identify the type of device reporting, interface. The term transponder is also used to
its location and status. In addition, in the case describe this unit. A circuit interface may have
of outputs, the signals must direct action one or more initiating devices, notification
commands to specific locations. appliances, or control circuits connected to it.

Many multiplex systems place a tone on the Each circuit interface must have the capability
signaling line and then shift the tone in of separately indicating the status of each
accordance with some particular code. Digital connected initiating device circuit. All
or alpha characters can be sequentially connected notification appliance circuits and
represented and decoded by various pieces of control output circuits can be individually
equipment along the signaling line circuit as actuated and monitored by the control unit.
required to perform the system functions. Other
systems may use the length of a particular tone Normally, the circuit interface is an assembly of
as having some significance such as a solid state components capable of working at
quantitative value. high speed. The high speed permits the system
to report individual alarms and other conditions
It can be seen that the signals on these modern in a short time, thereby, making it possible for a
multiplex signaling line circuits cannot be large number of initiating devices, notification
received and interpreted without special appliances and control circuits to be connected
compatible equipment designed for that purpose to a signaling line circuit.
on the particular system involved.
• Multiplex Outputs.
Today’s modern multiplex systems use what the
industry refers to as “active” multiplex. Each In most fire alarm systems, the input (initiating
reporting point in the system is required to send device circuit) transmits data from initiating
its status signal at periodic intervals. The lack devices that is received by the control unit which
of receipt of at least an “OK” or “normal” signal interprets it and sends out data to specific circuit
from a reporting point is interpreted by the interfaces to actuate the outputs. However, on
control unit as an abnormal condition for the more complex systems, using today’s
reporting point. This contrasts greatly from the communications techniques, it is possible for
old mechanical systems where a spring-wound data at any point on the signaling line circuit to
transmitter could be bound up and unable to be interpreted and acted upon at any circuit
send an alarm signal and not cause this to be interface location to create a programmed
indicated by a trouble signal. output.

While it is relatively easy to depict fire alarm system • Addressability.

installation wiring, or even imagine that the
signaling paths could be optical fiber cables or radio An addressable device is a system component
waves, it is not easy to visualize the actual signal with descrete identification that can have its
itself in today’s new technology systems. status individually identified or that is used to
Specialized test equipment can be used for this individually control other functions. These
purpose. devices must be compatible with the other
system devices and the control unit so that the
• Circuit Interfaces (Transponders). whole system can function as required.

The assembly that connects each of the The addressable devices do not have to be
initiating, notification and control circuits to the limited to smoke detectors. They may be other
signaling line circuit is know as a circuit initiating devices such as heat detectors,

Rev. 0 Electrical Handbook 15-6

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

sprinkler waterflow alarm switches, manual fire or all the techniques. With a sophisticated
alarm boxes, etc. control unit, a system can have the ability to
manually or automatically shift the sensitivity of
• Analog Sensors. detectors at selected locations. Such systems are
frequently referred to as “intelligent systems”.
Heretofore, fire detection has been primarily an Intelligent systems can also monitor the buildup
on/off type of function. Normally a contact or of contaminates in a sensor and indicate the
its equivalent closed and initiated a signal need for maintenance (cleaning or replacement)
indicative of a fire condition. before a sensor indicates an unwanted alarm.
The algorithm used may also improve the
With the advent of economical components and system’s ability to give warning of an incipient
the power of digital signaling unleashed, it is alarm condition at a threshold below the alarm
possible for fire detecting sensors to signal how level.
much heat (temperature) or how much smoke
(percent obstruction) is being sensed by a While used principally for heat and smoke
detection device. Such devices are known as detection, any value that can be sensed and
“analog” sensors. encoded into the signal can be sent to the control
unit for any other location on a signaling line
In the industry, the term “intelligent” or “smart” circuit where equipment capable of interpreting
devices is frequently heard when describing the signal may be located.
these sensors. There are two types of intelligent
sensors: • Displays.
a) Sensors that only send quantitative data
back to a central or subcontrol unit where Most existing fire alarm systems use individual
the alarm level decision is made. In this lamp or LED type annunciators. Many new
case, the sensing device is relatively dumb systems are also using the same technique.
when compared to conventional smoke However, displays are available that give
detectors that can both sense smoke and manufacturers the capability to display more
decide that an alarm level has been reached. information in an alpha-numeric format.
b) Sensors employ a microprocessor that
analyzes the signal for alarm and pre-alarm These displays have taken three basic forms, flat
levels and makes decisions on when or what screen displays made with light emitting diodes
sort of information should be sent to the (LED), liquid crystal display (LCD), and
central or subcontrol unit. In this type of cathode ray tubes (CRT).
intelligent system both the sensor and
control unit contain CPU decision makers. • Digital Alarm Communicator Systems (DACS).
The benefits of this concept are that the
communications on the signaling line The signaling technique previously used for
circuit is greatly simplified and alarm remote supervising station fire alarm systems
reporting is still possible even if the control required telephone lines between the protected
unit fails. premises and the remote receiving point. These
physical wires are becoming less and less
• Intelligent Systems. available. The telephone service companies
have steadily been converting to optical fiber
Assuming computer type circuitry is used in a cable and radio communication links that cannot
control unit, the designer can design an be used to carry the DC current required.
algorithm using rate of rise, level, time delays,
multiple sensor logic or a combination of some

Rev. 0 Electrical Handbook 15-7

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

A new fire alarm system component called a • Protection - fixed or portable fire fighting or
digital alarm communicator has been employed mechanical extinguishing equipment and
to overcome the application problem of the components or a fixed system to extinguish,
disappearing physical copper paths. control, or contain the presence of a fire.
• Prevention - programmatic regulations and/or
A digital alarm communicator system consists of established means, methods, practices, and
one or more digital alarm communicator resources to retard, restrict, educate, and prevent
transmitters (DACT) and at least one digital the occurances, circumstances, and situations
alarm communicator receiver (DACR). which could or will create a combustible
atmosphere, environment, or conditions for a
The DACTS are designed to connect to the potential fire.
standard public switched telephone networks. Engineering companies that specialize in the design,
The DACT units send appropriate coded signals testing, and installation of fire detection systems
to a remote receiving location and are designed routinely are subcontracted to design, and possibly
to automatically dial up the particular receiving install and/or just test, their (or these) fire detection
station to which they are to report. Since they systems. These designs; in conjunction with the
are designed to use the public switched P&ID’s for the fire protection systems, applicable
telephone network, the signals will go through regulatory fire, safety, and building codes or
whatever type of signaling path the telephone standards, client and/or site specifics, are the basis
company puts in place for its normal voice for the overall site fire detection system.
communications services. A DACT protecting a
particular area can send an alarm signal to any Some fire protection systems (wet/dry sprinkler,
location that can be reached by a voice telephone deluge) may be designed and installed by similar
circuit. subcontracted engineering or construction
companies.
Putting all the above together, a system with the use
of computer techniques, high speed signaling line Fire detection system devices and components are
circuits, binary (on/off) as well as analog sensing identified on the following fire protection system
devices, and modern information display systems, P&ID’s:
such as color video or LCD screens and printers, can • HVAC.
provide a sophisticated new technology system. • Cardox or Halon Systems.
• Fire Protection Piping, Pumps, Diesel Engine
Fire Prevention, Detection, and Protection. and Controls, and/or Generator.
• Wet or Dry Sprinkler and Deluge Systems.
The Fire Detection system should never be confused • Fire House and/or Watchman Stations.
with the Fire Protection system. These two systems
perform two independent functions though they are Fire Detection field mounted electrical devices that
closely interrelated systems. Akin to these two are commonly installed in support of a fire system
systems is Fire Prevention. By simple explanation include:
each means: • Smoke, heat, fire, thermal detectors or sensors.
• Detection - performs early warning or actual • Manual hand pull or push stations.
alarm notification, has supervisory controlled • Horns, bells, beacons, alarms.
circuits, provides zone or area indication, • Instruments (local/remote), indication, switches.
causes personnel response, or the intended
• Controller, cabinets, panels, monitors, consoles.
actuation of a fire extinguishing system to
• Emergency, egress, and exit lighting.
control, contain, or extinguish the existance of a
fire.

Rev. 0 Electrical Handbook 15-8

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

Supplemental equipment, components, and devices Heating and Ventilation - identified on these
that are commonly associated with a Fire Protection drawings are:
System are: • Fire damper locations.
• HVAC - fire dampers, exhaust or ventilation • Exhaust, intake, roof fans and ventilators.
fans. • Supply and return ducts, vents, and registers.
• Piping - valves, flow and pressure switches.
• Mechanical - pumps, generators, elevator Fire Prevention and Safety.
shutdown and capture, fire doors.
Though not directly associated with any true
Supplemental Design Drawings. electrical or mechanical installation system the Field
Engineer’s primary or supporting role associated
Supplementing the primary fire detection electrical with Fire Prevention and Safety during normal day-
design layout and wiring drawings and schematics to-day construction work activities could/will
are the interfacing disciplines design drawings and involve:
specifications. The Field Engineer should become • Generation of Hot Work Permits in supporting
familiar with their relative importance to the fire welding, cutting, and grinding activities.
detection and protection systems. Interface • Fire Impairment or Breaching Permits to pull
discipline drawings and information included are: cables through fire rated walls, block open fire
doors, Tag out of service an operable fire
Architectural - identified on these drawings are: system or component.
• Hourly fire ratings for: blockwalls, drywalls, • Acquire the services of a Fire Watch Person to
floor slabs, rooms, zones, and areas. continuously monitor or “rove about” to ensure
• Fire doors and hourly ratings. no fires are started resultant of spark generating
• Personnel egress paths, stairwells, elevators. normal work activities.
• False ceiling layout grid (lighting, sprinkler • Ensure fire retardant blankets are utilized to
heads, duct vents and registers, smoke detectors, protect cables in trays or that are exposed to
paging speakers). overhead or nearby welding activities.
• Buildings and walls expansion joint boundaries. • Review welding work areas for combustible
• Structural steel fire proofing criteria and details. materials and that “flash” screens, and
• Office areas, bathroom or lavatory facilities, protective clothing and equipment is being used.
laboratories, change or meeting rooms layouts. • Ensure compliance to the site Safety and Fire
• Painting, wall or slab texture. Prevention procedures and specifications are
being implemented in daily work activities.
Civil and Structural Layout - identified on these
drawings are: Fire Detection Raceway and Cable.
• Ceiling heights and slab or wall thicknesses,
ceiling and wall configuration, steel sizes. Raceway associated with a fire system is commonly
• Slab or wall openings, blockouts, embeds. installed as “a dedicated raceway” system and
typically is installed using EMT or rigid conduit.
Plant Design - identified on these drawings are: Typical too, is the “indelible” painting or use of
• Hose reel station locations. “red” condulet covers, red nameplate labels, or red
• Fire pumps locations and generators. terminal and junction box covers uniquely
identifying them as being associated with the fire
Yard Layout - identified on these drawings are: detection or protection system.
• Fire hydrant locations.
• Fire Pump House. Raceways and cable trays that pass through fire rated
walls and slabs must be sealed at the entrance point
of the wall, blockout, or slab. Typical fire rated

Rev. 0 Electrical Handbook 15-9

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

walls and slabs are 1 to 4 hours. These seals prevent

the seepage or spread of smoke and/or fire from
using the raceway or trays as a travel path to an
adjoining area. These internal conduit or tray seals
(and damming or compound materials utilized) must
be installed comparable to the hourly wall or room
fire rating to ensure the rated integrity is maintained.
Typical fire seal applications include:

• Conduit plugs and damming material for

“spare” sleeves, stub ups, or underground Firestop Sealant utilized at fire rated wall sleeve.
raceways.
• Fire stop putty, sealant, “pillows”, or compound
around “core bored” walls, or busted out
blockwalls, encapsulating cables in conduit or
trays through blockouts, condulets, or boxes.
• Multi-cable transit frame.
• Marinite board or 12 guage sheet steel.

Firestop compound used at fire rated floor opening.

MCT Multi-Cable Transit wall detail

Firestop pillows utilized at fire rated tray opening.

Firestop putty application utilized through a fire

rated wall. Firestop coatings utilized to protect exposed cables.

Rev. 0 Electrical Handbook 15-10

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

as a whole. Safety of personnel should always be

first and foremost while performing work associated
with operable fire systems.

Testing Scenarios.

As a minimum the following guidelines should be

adhered to:

• An approved or established test procedure

Non-metallic pipe fire rated sealing blanket. defining all particulars relative to the test.
Identifying precise test scope, signoffs, sequence
of events, and expected test results. Identifies
test personnels responsibilities and actions.
• Affords sites fire department and operations
personnel inclusion. With any applicable
regulatory agency personnel, or sites fire brigade
direct involvement and applicable inspectors
required to witness, verify, or certify the test.
• The test must identify what impaired fire
systems, devices, or components will be “out of
service or under test” and appropriate “back up
Firestop fire rated “marinite” board with overall fire protection or detection contingencies” that
sheet steel cover and fire rated sealing compound. will be required are in place.
• Acquire plant operations, clients fire and safety
Fire stop materials and usage varies. Prior to design, departments, and applicable site personnels “buy
procurement, and installation the following in” on the performance and acceptance of the
considerations must be made: test and its parameters.
• Ensure continuous communications are planned,
• Toxic nature. established, and maintained prior to and during
• Shrinkage. the test. Ensure all on-site plant personnel are
• Weather resistance, pressure resistance. informed prior to and during the test.
• Cable de-rating effects. • All applicable specialty equipment (e.g. smoke
detector cannisters, personnel protective
• Uniformity and adhesiveness.
clothing, and equipment), material, and tools
• Application, fire and temperature ratings.
are readily available.
• Damming material, fiber, installation materials.
• Perform a pre-test walk-thru and briefing prior
• Economics, ease of installation, shelf or storage
to the performance of the test with all personnel
life.
associated with the test.
Operating Fire Protection and Detection Systems.
Work Activities on an Energized Fire System.
Fire detection or protection systems that are “in an
Performing any construction activity that in whole
operational” or “testing” mode require a different
or in part “impairs” the operational integrity of any
mind set, approach to work, and work methodology
fire detection device, circuit, or fire protection
by the craft and the Field Engineer. Conditions or
system or component places the fire systems integrity
work activities can and do have a profound effect on
in jeopardy. Prior to commencing any work that is
the reliability and operability of the system in part or

Rev. 0 Electrical Handbook 15-11

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

related to an energized or active fire system, device, elements to current flow (I2R). Other specialized
or component the Field Engineer should: electric tracing systems make use of impedance,
• Contact the site clients Fire and Safety induction, and skin conduction effects to generate
Personnel as appropriate. and transfer heat.
• Contact the local fire regulatory agency or
person as appropriate. Electric Resistance Heat-Tracing
• Contact the site client operations department as
appropriate. Significant commercial use of electric heat-tracing
• Acquire necessary permits, clearances, and began to take hold in the 1950’s. Electric heat-
authorizations prior to commencing work. tracing served as a viable alternative in situations
where steam could not be used or was impractical.
Relative to most operational facilities and sites, the At the outset, hardware had to be adapted from other
clients site Fire and Safety Personnel respond to resistance heating applications. Lead-sheathed soil
conditions related to their site and advise the local heating cable was used extensively for waterline
authorities and fire authorities as necessary. freeze protection while longer runs of pipe were
Consistent with that each client has their own site traced with mineral-insulated copper-sheathed cable.
fire and safety programs, procedures, and For higher temperature service, tubular heaters
requirements that all contracted personnel shall normally used for immersion and clamp-on
adhere too. Generally, this is in addition too applications were converted for pipe tracing and
Bechtel’s own established procedures, practices, and controllers were adapted from furnaces and
fire response or prevention measures. consumer appliance in order to control temperature.

• Self-Regulating Heaters. Since their

HEAT-TRACING SYSTEMS introduction in 1971, self-regulating heaters
have become the most popular form of electric
General heat-tracing and are currently offered by most
major vendors for industrial heat-tracing. Self-
The term heat-tracing refers to the continuous or regulating heat-tracing has an advantage with
intermittent application of heat to a pipeline or respect to other heat-tracing products because
vessel in order to replace heat loss. The major uses this technology eliminates the possibility of
of heat-tracing include freeze protection, thawing, heater burnout due to an inability to dissipate
maintaining fluids at process temperature or internally generated heat - the most common
pumping viscosity’s, preventing fluid components cause of failure.
from separating, and preventing condensation of
gases. Self-regulating tracers are usually provided in
the form of a heater strip consisting of two
Heat-tracing systems can be divided into two broad parallel 20 to 10 AWG bus wires embedded in a
classes, electric and fluid. Fluid heat-tracing conductive polymer core which serves as the
systems utilize heating media at elevated heating element and over which a polymeric
temperatures to transfer heat. The fluid is usually insulator is extruded. The entire assembly may
contained in a tube or small pipe attached to the then be covered with a metal braid, and
surface being traced. Electric heat-tracing systems additional polymer jacket, or both. The heater
convert electric power into heat and transfer it to the core consists of carbon particles embedded in a
surface being traced. The majority of commercial polymer matrix. Heat is generated by resistance
electric heat-tracing systems in use today are of the to current flowing through the conductive
resistive cable type. When current flows through the polymer heating element. As the temperature of
resistive elements, heat is produced in proportion to the conductive core increases, so does the
the square of the current and the resistance of the electrical resistance. The result is a diminishing

Rev. 0 Electrical Handbook 15-12

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

output of heat for each successive increment of The parallel circuit configuration of zone
temperature elevation. Since power output is a heaters means that output is independent of
function of temperature at any location in the cable length and systems can be designed and
element, the conductive core behaves like a adapted by purchasing cables of specific wattage
temperature sensitive rheostat guarding against which are cut to length in the field. Zone
low- as well as high-temperature failure. heaters use standard voltages, and their parallel
circuitry preserves system function in the event
Self-regulating tracers can be cut to any desired of individual heater element failure. It is
length and field installed within the limitations important to remember that the length of cable
of the voltage drop on the hot wires. They have between the cut and the nearest node will not
good impact resistance and are routinely receive power and should not be depended upon
handled in the field. The self-regulating feature for heater service.
provides a tremendous boost to operational
reliability while cutting installation, Zone heaters use thinner resistive wires than
maintenance, and energy costs. It also adds a series heaters and are more susceptible to
dimension of safety unavailable with any other damage from impact. Perhaps the biggest
form of electric resistance tracing product drawback is their susceptibility to burnout.
because the heater cannot be destroyed by its With their combination of constant wattage and
own heat output. polymer insulation, zone heaters are vulnerable
to destruction from self-generated overheating.
The only serious drawback of self-regulating As with all constant-wattage heaters, zone
tracers is the upper limit on operating heaters to be used in hazardous (classified) areas
temperatures, 366°F (188°C) for constant require factory calculations to determine if the
exposure and 420°F (215°C) for intermittent system conforms to the prescribed “T” rating.
exposure. Self-regulating tracers can fail as a
result of exposure to excess heat. • Mineral-Insulated Cable (Constant Wattage
Series) Heater. Mineral-Insulated (MI) cable
• Zone Heaters. First introduced in 1971, zone was introduced in the early 1950’s as an
heaters were initially the most popular form of electrical-powered alternative to steam and
parallel resistance heaters and by the late liquid heat-tracing. MI cable is a constant-
1970’s, were being used in a large percentage of wattage, series resistance heater in which the
electric heat-tracing applications. Since that entire circuit acts as a continuous heating
time, they have been increasingly replaced by element. Heat is generated by current flowing
self-regulating heaters. through a nichrome, copper, or other metal
conductor, insulated with magnesium oxide and
A typical zone heater consists of two insulated encapsulated in an outer metallic sheath of
bus wires wrapped with a small-gauge (38 to 41 copper, stainless steel, Inconel, or other suitable
AWG) nichrome heating wire, covered with metals.
polymer insulation, and optionally sheathed in a
metallic braid covered with a polymer jacket. MI cable is capable of carrying high heating
The heating wire is connected to alternate bus loads, and given the proper conductor and
wires at nodes every 0.3 meters (1 foot) to 1.2 sheath alloys, it can be used in applications up
meters (4 feet), and the distance between to 1500°F (800°C). Its high impact resistance
connections constitutes a heating zone. Heat is and general ruggedness allows it to stand up to
generated by current flowing between the bus rough handling in the field. Circuits usually are
wires through the heating wire. factory fabricated to length prior to installation,
which can be a source of problems when piping
changes are made since installations are difficult

Rev. 0 Electrical Handbook 15-13

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

to field modify. Field fabrication of circuits is Skin Effect Tracing

sufficiently complex that the training of
installation personnel should be supervised by a Skin effect systems are primarily applicable to the
trained factory representative. MI cable system tracing of long pipelines. The “skin effect” is based
circuits must be individually designed, or on the tendency of an alternating current to flow in
variable-voltage controls must be used to se the layers near the surface (skin) of a current-
circuit parameters. Voltage control may also be carrying ferromagnetic conductor. In a typical skin
required for short lengths due to the low effect tracer, the heating element is a carbon steel
resistance. pipe of small diameter welded to the fluid-carrying
pipeline to be traced. Running through the heat tube
As with all series circuits, a single break in the is an insulated, low-resistance copper wire. The
cable causes the entire system to fail. Breaks in alternating magnetic field created by this
the outer sheathing can cause failure due to alternating-current-carrying conductor causes the
absorption of moisture and subsequent loss of return current in the small heat tube to be
insulating properties. Another disadvantage of concentrated toward the inner wall of the tube. This
MI cable is the risk of overheating from phenomenon is called the “proximity effect”.
excessive currents or poor thermal dissipation. Because almost no current flows on the outer surface
Hazardous area installations must be factory of the heat tube, there is no measurable potential
calculated to ensure conformance with the there and the entire piping system can be grounded
proper “T” rating. at any number of points.

• Series Resistance Polymer-Insulated Cable. The requirement for custom system design makes
Polymer-insulated series resistance cables can be skin effect systems costly. It is generally not cost-
used with various conductor materials. effective for pipelines shorter than 1500 meters
Nichrome is suitable for short circuits, but the (5000 feet), its upper temperature limit of
length must either be predetermined to suit the approximately 400°F (204°C) is set by the maximum
available voltage or field cut and provided with exposure temperature of the conducting wire
a variable voltage supply. Conductors such as insulation, and the method is not adaptable to
copper offer a measure of self-limiting heater complex piping. Installations cannot be modified,
properties, since their resistance increases with and the complete system fails with a single line
temperature. This allows greater latitude of use, break.
and copper conductors with their 600 volt
limitation and relatively low cost are especially Impedance Heat-Tracing
favored for long-line applications with this type
of heater. In impedance heating, the pipe itself becomes the
heating element. The generation of heat is produced
The circuits must be designed and controlled to by resistance to current flow. Impedance heat-
minimize high temperature, because a failure at tracing has the ability to reach very high operating
one spot disables the complete circuit. The temperatures. limited only by the design and
possibility of catastrophic failure due to contents of the piping system. Since the pipe is the
overheating and melting of the polymer heating element, it is the supply cable and
insulation puts this type of tracing in connections which can be vulnerable to burnout.
unfavorable competition with parallel resistance This technique has high heat-transfer rates and
heat-tracing systems which dominate in the low- uniform heat distribution and provides excellent
to moderate-temperature application ranges. temperature control at the control point, using any
one of several automatic control methods.

Rev. 0 Electrical Handbook 15-14

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

Impedance tracing is costly and has limited of the combustible atmosphere. By comparing the
application. Systems are almost exclusively vendor “T” rating to the area classification, and assessment
designed, and the engineering cam become can be made as to heater eligibility for a particular
complicated, especially in attempting to achieve system.
electrical balance in piping systems with multiple
branches. Because current flows through the pipe, Environmental Considerations
the entire pipeline must be electrically isolated from
the support structure and shielded from personnel Environmental factors include whether the area is
contact. As a precaution, impedance-traced dry, wet, moderately or severely corrosive or
pipelines are normally operated at 30 volts or less. noncorrosive and whether the tracing will experience
Voltages at 80 volts are allowed if ground fault rough handling or mechanical abuse during
protection is supplied. installation, operation, or maintenance. These
considerations are primarily related to the
Induction Heating performance of electrical heat-tracers. Electrical
heaters exposed to any of the environmental stresses
Induction heat-tracing uses a metallic pipeline as a listed above should be protected accordingly: a
heating element by placing it in the magnetic field of metal sheath of a material able to withstand the
an alternating current source. Low-resistance wire is corrosive agent for MI cable; a braided sheath
wound around a conductive pipeline or vessel, and covered by a polymer jacket and formulated for
the alternating current flowing through the coils protection from particular classes of corrosives is
generates a rapidly changing magnetic field that recommended for polymer-insulated types of heating
induces eddy currents and hysteresis losses in the cables. The heater must be rated to withstand
pipeline wall. Induction heating has been most anticipated maximum exposure temperatures.
frequently employed for melting metals and would
most likely be considered for high-temperature, Heat Tracing System Design.
high-power, heat-tracing applications. The absence
of thermal resistance between heat source and General mechanical systems or components that
pipeline allows very rapid heating. Present systems predominantly will require tracing include:
would involve considerable expense, custom design,
and require power inputs at short intervals along the • Chemical process piping lines.
pipeline. Induction methods do not easily lend • Water - potable, well, service, waste.
themselves to the production of uniform heating and • Above ground tanks, valves, pumps, pipes.
provides only moderate system efficiency. • Natural gas, ammonia, caustic acid pipes.
• Instruments and instrumentation tubing.
Area Classification • Salt piping.
• Vents and drains.
Areas are classified according to their potential fire • Below ground pipes within a sites “frost line”.
hazard as defined by Article 500 of the National
Electrical Code. Under this system, ordinary areas Piping, instruments, instrumentation tubing, pumps,
are those not classified as hazardous. valves, vessels, and tanks requiring to be traced are
identified on the P&ID’s associated with the system,
In order to ensure that the heat-tracing system applicable pipe line and equipment lists, or vendor
selected will operate safely in a hazardous drawings. These project P&ID’s or documents
environment, it must also be classified according to usually “flag” the pipe line, vessel, or component
its NEC temperature identification number or “T” that is required to be traced with specific markings
rating. This code specifies that the temperature of (e.g. ET or with “dots” ..... below the pipe or around
the exposed surface of the electrical equipment not the tank). Tracing limits or boundaries, for a line to
be in excess of 80 percent of the ignition temperature be traced, are also identified on these drawings.

Rev. 0 Electrical Handbook 15-15

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

Where these tracing “boundaries” extend to or component, line, or tank. This provides the Field
encompass vendor provided equipment skids or pipes Engineer with specifics as to:
review the vendors P&ID’s or drawings to determine
the tracing boundaries for their respective supplied Heat Tracing Line Matrix
piping, pumps, or equipment.
Heat tracing designs, and sometimes installation too, • Assigned system or start-up system number.
are subcontracted to engineering, manufacturers, or • Line is released for tracing and/or insulation.
construction companies that specialize in the design, • Pipe line number, size, P&ID or isometric
installation, and testing of heat tracing systems. number, equipment or vessel numbers.
Heat tracing designs typically consider the following: • Instruments and tubing numbers.
• Panel and circuit number and traced cable type.
• Client preferences and/or project specifications • Estimated wattage and circuit length. Actuals
• Heat tracing system approach and application upon installation and testing.
• Pipe (or component) service or operating • Insulation type, size, and class.
temperatures to be maintained, size and wall • Pipe line service temperature to be maintained.
thicknesses • Tank connection and/or valve numbers.
• Piping type hangers, valves, flanges, instrument
taps, pipe configuration Heat Tracing Isometric Layout
• Insulation class, thickness, and type
• Sites “frost line”, ambient climate, environment • Panel, breaker, and heat trace circuit number.
• Material surface composition (e.g. steel, PDVC) • Heat tracing cable type, estimated length, layout.
• Pipe system or process application • Estimated wattage, amperage.
• Hazardous area classifications • Supporting bill of material requirements and
• Cable type, cable length, wattage, and heat loss. quantities for “this” particular traced layout.
Suitablility, application, and cable rating • Diagrammatic locations for: end seals, splice,
• Instruments and instrumentation tubing tee, or power connection boxes, line sensing or
• Plant layout for panel locations, sizing, quantity, ambient thermostats.
load, classification and application, spare • Generic or specific application or installation
breakers for future expansion of system notes.

Note: In estimating heating cable length the design Heat Tracing Equipment.
normally considers 4’ (feet) to trace a large size
“gate or globe” valve, 2’ (feet) for most “pipe shoe or The typical heat tracing design utilizes the following
pipe guide” supports, and 4’ (feet) for most flanges. equipment:
What is important is that any heating cable estimate • NEMA 4 Control Panel - main breaker, 3∅,
must consider these components and their unique 4W, 208-120v distribution panel.
complexity and individual characteristics. • Dry type Transformers (30kVA-75kVA are
common) indoor or outdoor.
For designs that are not “subcontracted” out; the • Ambient and/or line sensing thermostats.
designers utilize heat tracing manufacturers • Controllers, ammeters, voltmeters, relays.
engineering manuals, handbooks, and guidelines • Indication, alarms, selector switches, push
which provide detailed application, selection, and buttons, and engraved legend plates.
installation instructions considering the
aforementioned minimum requirements. Optional equipment or design features include:
• DCS I/O points.
Consistent with most tracing installations is the field • Panel heater and light, GFCI breakers.
generation of a heat tracing “line matrix” and a
• Panel purge and pressure, weather shields.
detailed “isometric” layout of the “to be traced”

Rev. 0 Electrical Handbook 15-16

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

• Continuous service panel. (panel not controlled these materials “on demand or need”. Heat tracing
by ambient thermostats). materials commonly utilized include:
• Specific NEMA characteristics and rating.
• Dual ambient thermostats. Usually the ambient • Heat tracing cable type, wattage, and voltage.
thermostat(s) are preset. If, only one (1) is used • Prefabricated cables to line length.
it usually is set at 40°F, if two (2) are used, the • Ambient or pipe line sensing thermostats.
first is set at 10°F higher than the secondary • Power, splice, tee, end seals connection “kits”.
backup. Common application in cold climates. • Glass or “deflective” tape, pipe mounting straps,
• Underground piping. Piping systems that are steel tie-wire, heat trace warning labels.
below the sites “frost line” the installation of
heating cables unique to this application may be Note: The typical purchased “kit” includes the
designed. Traditionally, they are a redundant required supporting bill of material and instructions
service for maintenance and service reliability to complete the installation of “that” style kit only
and the heating cable is installed at the 11 or 1 and individual pieces lost etc. must be purchased
o’clock positions. separately. These kits normally contain:

Note: The sites “frost line” (ground grade freezing • Grommet(s).

temperature depth in-inches) is based on climate • Tubing or wire sleeving.
studies for the region. It is sound heat tracing • Butt end or closed end insulated connectors.
practice to design and install tracing to this depth for • Pipe attachment strap (sizes vary based on pipe
below ground piping systems that extend up above diameter) and must be so noted on purchase.
grade level.
Note: The correct type tracing cables “hold down”
Typically, ambient thermostats are used to energize tape must be used in regions that experience constant
the main control panel and line sensing thermostats ambient temperatures below 40°F. The glass tape
or voltage controls for individual branch circuit utilized must be suitably rated for both the ambient
control, though this is usually based on the client and attaching cable components surface temperature.
and/or project design specifics. Variable temperature rated tapes are available.

Prior to installing any tracing the responsible Note: Installation of a “deflective” aluminum type
mechanical discipline should “release” the “to be tape (over the heating cable) must also be purchased
traced” component, line, or equipment to ensure that and used when tracing non-metallic piping (e.g.
all the hangers, welds, tests, joints, flanges, valves PDVC) to aid the heating cable in evenly
and applicable “hydro’s” are completed. This distributing the heat to avoid damaging the pipe
significantly prevents removing the heat tracing, to surface due to localized heating.
enable the commodity to be completed.
Upon receipt of tracing cable an “initial” megger
Tracing Bill of Materials. check should be performed to verify that received
cable wasn’t damaged and to provide a base line for
Purchasing of miscellaneous tracing components or insulation resistance checks later.
materials commence upon a completed design and
should be available for installation prior to the Heat Tracing Installation Methods.
component being released to avoid start-up turnovers
delays or the installation of temporary heat tracing to Principly three (3) types of tracing will be addressed:
support the schedules. In designs that are performed
by heat tracing engineering or manufacturing • Auto Trace
companies it isn’t unusual for them to also provide • Self or Non Regulating
• Mineral Insulated (MI)

Rev. 0 Electrical Handbook 15-17

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

Auto Trace Cable • Flanges - typical to the installation of a valve.

• Pipe Guides or shoes style hangers - a service
Installation of auto trace type cables are generally loop that “doubles” back is typical for these style
used in conjunction with instrumentation tubing. pipe hangers.
These cables are essentially a “tubed bundle” where • Pipe elbows - traced on the bottom or the back
instrument tubing (quantities and size varies) are side of the fitting.
enveloped with an overall polyvinyl type jacketing Additional heating cable installations used are:
with an enclosed heat traced cable, usually self
regulating. • Spiral wrapping - heating cable is installed on
piping similar to the figure eight (8) or the
These bundles, used in conjunction with instruments infinity symbol (∞∞ ) dependent upon whether the
and instrument taps off pipes, are prefabricated and application is in the vertical or horizontal plain.
field bent (by instrumentation fitters) in accordance • Multiple cables - installed at 5 and 7 o’clock or
with the applicable instrumentation installation in equal degrees if more than two (2) cables this
details ensuring slope, hangers, and tie-ins are ensures the most efficient heating coverage.
correct. The cable tracing usually includes the
instrument valve taps and is terminated at the Installation Activities
instrument location utilizing a “power connection
box”. Insulation of the bundle itself is not necessary Self regulating heating cables should be:
because of the outer polyvinyl protective jacket.
• Adequately taped down to the pipe with no air
Self Regulating Heat Cable gaps and cables bend radius is maintained.
• Not in physical contact with itself or with other
Self regulating cable tracing is installed according to heating cables that may be attached to the pipe.
the “detailed isometric” layout of the pipe, tank or • “Kinked” or installed on end.
vessel, and instrumentation tubing. Installation of
• In contact or exposed to concrete or grout unless
this type heating cable is usually in accordance with
cable is approved for the purpose.
manufacturer installation manuals and guidelines
• Must be insulated over. With no portion of the
factoring in the configuration of the pipe and its
heating cables exposed to the ambient elements.
system installed components (valves, flanges).
• Heat trace warning labels affixed on insulation.
• Meggered immediately after heating cable
Common installation practices and guidelines
installation and again after final insulation is
consider heat loss areas, effectiveness of heating
installed and/or in accordance with the
coverage, and maintenance activities they include:
manufacturer’s recommended practices.
Meggering and recorded readings should be to:
• Heating cable is usually installed in the 5 or 7
• 500vDC
o’clock position with respect to the pipe. This
provides the most efficient heat coverage and • 1000vDC
avoids hangers that support the pipe and • 2500vDC
prevents possible cable damage from above. • Documented “as built information” after
• Valves - a service loop is typical for most valves installation should update the following:
where the cable envelops, both the sides and the • Actual cable length installed and wattages
bottom of, the main body of the valve and to • Revised circuit information or changes
support maintenance to the valve without • Revised cable type
requiring the complete removal of the heating • Megger readings
cable. A properly installed cable will “unravel” • Updated circuit and transformer loads
when maintenance work is required on the • Updated panel circuit schedule
valve.

Rev. 0 Electrical Handbook 15-18

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

• Updated isometric layout changes showing Specialty valve jackets made of two (2) piece steel
new cable route, device locations and bolted together are available for high heat
• Updated bill of material lists mineral-insulated cable heating applications.

Mineral-Insulated Heating Cable For instruments; low wattage heaters are installed on
the bottom of the instrument, with a fiberglass “flex
Installation of MI (mineral insulated) cable utilizes pac”, or their mounted inside an enclosure when an
stainless tie wire in lieu of glass tape. Additional enclosure is required to be used. These enclosures
differences include: (normally NEMA 4x) “trade name O’Brien” boxes
provide an environmental or hazardous area
• “Cold lead” - as part of the prefabrication of this protective addition to the instrument. Typically;
cable a portion will not be placed in contact with these enclosures have a “plexiglass” face to enable
the pipe and is referred to as: the cold lead. This instrument readings and are maintenance accessable
portion is exposed (outside the insulation) and is with removable or hinged covers.
usually a prefabricated distance and is connected
to the termination connection box. The low-wattage (120v) heater circuit is commonly
• “In line sensing bulb” - the “to” end of the fed from the heat tracing control panel.
prefabricated cable is complete with a self
contained bulb which also serves as the end seal. Heat Trace Testing (Warm Weather)
• Usually is multiple heating cables to support the
requirements of the high heat loads. Ensuring the operability of the heat trace system in
• Unique identification “tag” is attached at the “warm weather” conditions is accomplished by:
exposed portion of the cable identifying cable
type, length, and cold joint specifics. • Simulating cold weather conditions to ensure
the ambient thermostats energize the panel and
Supplemental Heat Tracing Design and Activities perform or monitor for: power on, lamp and
light indication test, breaker trips, actuation of
Associated design, procurement, and installation any heating circuits, ammeter and current
activities that are frequently required to support the readings.
heat tracing effort are: • Performing circuit checks by “open or closing”
contacts to ensure they “make or break” the
• Valve, tank, or pump heating jackets or blankets circuit.
• Instrument “flex pacs” or enclosures • Simulating an in line “fault” condition.
• Low-wattage (120v) heaters • Simulate line sensing thermostat actuation by
resetting the pre-set temperature.
Procurement and installation of heating jackets, “flex
pacs” (for instruments), or blankets are generally
treated as individualized specialties for one (1) time LIGHTNING PROTECTION
applications and are ordered as such. These jackets
are normally fiberglass insulated and are fabricated Nature of Lightning
with “slits”, seams, or openings to accomodate
protruding pipes, instrument taps, valve handles, et Lightning is a gigantic spark of DC current. A
al. After installation the jackets openings are typical destructive lightning flash consists of a
secured with “velcro” flaps or with “laced closures”. current flow of 25,000 amps or more at a potential of
Upon request, some of these heating jackets are 30 million volts or more.
ordered with heating tapes interwoven inside the
fabric lining ensuring an even distribution of heat. A “cold bolt” is made up of at least one leader
stroke, usually negative, and a positive return stroke

Rev. 0 Electrical Handbook 15-19

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

during which the negative charge laid along the should consider such lightning-induced transient
lightning’s ionized path flows to ground in voltages.
milliseconds. There can be 20 or more component
stroke sequences, each bringing a massive discharge Lightning Protection Theory and Practice
to ground. A typical cold bolt consists of three
leader-return strokes occurring in less than half a Lightning protection theory is premised on the
second. behavior of two components of the typical flash - the
stepped-leader stroke of free electrons and the point-
A “hot bolt” includes a long-duration final stroke, discharge currents of positive polarity straining
during which current flows at a rate of about 900 upward from grounded objects toward the
amperes. Enduring for tenths of a second, this long downcoming leader. The step-leader’s path is
tail of current develops enough heat to ignite wood unpredictable as it zigzags to earth. It might pulse
or other flammable materials. erratically in one direction, and then turn and stab a
crooked path a half mile in the other direction.
The typical “thunderbolt” is initiated when a small Several incomplete ionized channels might branch
discharge at the base of a charged cloud frees off the main electron flow path. However, when the
electrons that are drawn downward to the electron- main channel is at “striking distance” above earth or
deficient (positively charged) earth. The negative grounded objects such as building, trees, and poles,
stepped-leader stroke of freed electrons usually zags the discharge path becomes somewhat predictable.
downward in descrete steps averaging about 150 feet.
There are two basic approaches to lightning
As the stepped leader nears the ground, positive protection:
point streamer currents are attracted by it and strain
upward from roof edges, gable ends, chimney (1) Remedial or Collector-Diverter. This design
corners, trees, poles, and other pointed or sharp diverts the stroke channel and neutralizes the
objects. When the leader is about one step’s distance secondary effects.
from electrical ground, a positive point-discharge (2) Preventive. This design prevents the buildup
current rushes to meet it, completing an ionized path of charge in the area of concern and thereby
to ground. A massive positive return stroke prevents the lightning strike.
immediately rises along the channel at a speed of
one-half to one-tenth the speed of light. The theory of operation of these two approaches is:

How Lightning Causes Harm • Remedial or Collector-Diverter approach. This

conventional lightning strike protection system
Lightning traditionally causes harm in four ways: is based on the premise that any stroke to the
(1) Fire. protected area must be collected and diverted via
(2) Air-pressure blast. a safe path to earth. To accomplish this
(3) Shock injury. objective, the system must perform the following
(4) Electrical damage caused by direct strike to functions:
conductors. (a) Provide an effective collector to capture
the stroke.
The proliferation of sensitive electronic equipment (b) Divert the energy around the
has added a fifth dimension to the manner in which protected equipment.
lightning causes harm. Even faraway lightning (c) Establish a low impedance interface with
strokes can, by electromagnetic induction, induce ground.
high transient voltages on power lines, damaging (d) Eliminate any secondary effects.
electronic equipment or causing it to malfunction.
Complete protection against the effects of lightning

Rev. 0 Electrical Handbook 15-20

 Bechtel Corporation 1997. 11/26/97
Section 15
SPECIAL SYSTEMS

There are three system concepts used in this Lightning Protection system are predominantly
approach which provide three basic components - subcontracted out to specialized engineering
Air Terminal, Downcomer, and Earth Interface. companies. They will perform a site assessment,
Each concept performs as follows: study, analysis, and subsequent design. Installation
(1) Air Terminal. Air terminals, commonly is commonly performed by the field with vendor
referred to as lightning rods, are placed to representatives possibly overseeing the installation.
protect any facility within a “cone-of-
protection”. The premise is that anything Lightning Protection Equipment and Raceway
within the cone is protected against a
lightning strike. The air terminal is Equipment and installation activities associated with
designed to attract and divert the stroke the lightning protection system include:
leader to ground.
• Lightning arresters, poles, rods and bases.
(2) Early Streamer Generators. These devices • Non-metallic conduit (PVC).
are suppose to generate collective • Spark gaps and surge protectors.
streamers long before the conventional • An external grounding system.
lightning rod. The theory is to reach out
and bring in strikes from long distances,
thus claiming a larger area of protection. IN-PLANT COMMUNICATIONS
The first of the “Early Streamer
Generators” was the Radioactive Air General
Terminal developed in Europe. Later,
such devices as the “Prevectron”, Various in plant, or on site, communication systems
“Preventor”, “System 3000” and others are utilized and basically serve separate and
have been introduced in the marketplace. individualistic functions in support of the overall site
communication network or system. Most industrial
(3) Dissipation Array System. This system is sites will utilize most or all of the following:
based on the use of the point discharge • Telecommunications.
principal as a charge transfer mechanism • Emergency broadcast, evacuation, or alarm.
from the protected site to the surrounding • Priority and general plant personnel paging or
air. The electrostatic field created by the “over the air general information”.
storm cell will draw that charge away from • CCTV - Closed Circuit Television and
the protected site, leaving the site at a Surveillance (Reference Security System).
lower potential than its surroundings. • SCADA - Supervisory Control and Data
Acquisition.
Lightning Protection Installation • Sound Powered.
• UHF/VHF (radio).
Lightning protection technology is a specialty
• LAN/WAN Data Communication.
discipline requiring qualified specialists to design
and supervise the installation. Lightning protection
Telecommunications
system design should conform with NFPA-78,
Lightning Protection Code, or Lightning Protection
The common telephone consists of a device
Institute (LPI) Standard Practice LPI-175.
(transmitter) for transforming speech sounds into
electrical currents which traverse a connecting
Lightning Protection Design
medium (line or channel) and react in another device
(receiver) in such manner as to convert the electrical
Design specifics as to location, installation details,
currents into the original speech sounds.
equipment and material requirements to support the

Rev. 0 Electrical Handbook 15-21

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Section 15
SPECIAL SYSTEMS

Telecommunications; or the telephone system, as it Specific applications of use or features of an in-plant

applies to an in-plant communication system, begins telecommunication designed system include:
with the sites and/or clients PBX (Private Branch
Exchange). This PBX, commonly referred to as • Over the air plant page.
“board(s)”, ranges in system size or complexity • Emergency response or awareness.
dependent on the quantity of phone extensions and • Elevators.
required service needs. This telephone (PBX) • Multiple party lines.
system; could be housed within its own telephone or • High decibel areas with remote lights or bells.
communication building, floor, and/or be located • Remote outlying buildings.
throughout various designated “telephone
equipment” rooms known as “PBX trunk” locations. Telecommunication Design
From these points the system extends (branches) out
to eventually reach or service an individual or groups Basic design of the in-plant telephone system is
of phones on a floor, area, or room. The PBX system typically laid out on a one-line diagram or an overall
is typically “non-manned or manually” controlled. site telephone layout. Which generally provides:

PBX Equipment • Phone symbol of type (e.g. desk, wall, station).

• Applicable room, building, or column location.
The initial installation of a sites operating PBX’; • PBX equipment and room locations.
equipment, cabinets, racks, trays, devices, cables and • Low voltage (120v) wiring needs (e.g. a duplex
interconnecting wiring and terminations are receptacle at the PBX board, an interface box).
predominantly performed by the local central
• Voice data or jack symbols.
telephone companies service network of technicians.
• Cable and/or raceway specifics.
• General Notes and Installation Guidelines (e.g.
Designated on-site personnel or site service
mounting heights).
representatives are available to contact the “local
telephone” company to perform extentions to service,
Complementing the one-line diagram is the
repairs, any wiring or switching work that may be
telephone layout drawing which could be inclusive
required at the PBX board(s). Localized or
with the lighting layout or the overall raceway and
individual office phone hookups, changes, wiring, or
communications drawings. The drawing will show:
service problems may be performed by these on-site
service representatives. Typically, the on-site craft
• Phone symbols.
(electricians) do not perform these tasks though they
may assist in the physical work (routing of cables) in • Voice data or jack symbol and wall or room
an office setting, if required. location.
• Sound proof booths (acoustic booth) locations.
Common field or office telephone features and • Telephone interface box locations.
service capability are strictly client related and • Remote located telephone terminal boxes.
generally are based on:
The Communication General Notes and Details,
• Phones on-site field location and acoustical unless a telephone specification is a site document,
background. will generally provide the raceway information
• Restrictive use limitations or requirements. required to support the installation.
• Cost, practicality, and maintenance.
• Size of PBX system. Installation Guidelines
• Plant personnel, maintenance, or staff’s need to
Construction installation activities that are unique to
use and/or responsibilities.
the telephone system include:

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Section 15
SPECIAL SYSTEMS

• Duplex receptacle at the PBX board(s) location. Emergency and Alarm - a pronounced resonant
• Raceway system is installed generally as a sound, voice, tone, siren, or signal requiring and/or
“dedicated” system. Raceway labels identifying then providing explicit:
the telephone system is usually “Tele”.
• Specific communication cables for specified • Immediate silence and individual attention.
applications and use are required. Multiple • Predetermined course of action or response.
paired cables (2 up to 3600) for main PBX • Instruction then adherence.
equipment locations may require oversized pull
boxes and raceway to support the cable bend Common illustrations include:
radius, diameter, and fill requirements. • Fire alarm.
• Installation parameters are generally limited too: • General Plant or a localized evacuation.
• Raceway only. Usually is EMT indoors. • Chemical hazard or spill.
• Cable pulls or “pulling in of a pull string” • Emergency medical treatment.
only. • Environmental hazard.
• All termination of cables are performed by • Explosion or an in-plant accident.
the local telephone service technicians. • Extreme weather conditions.
• No significant field construction testing is • Breach of plant security.
performed.
• Outlet boxes, PBX rooms “backboard”, or Public Address System - a system for amplification
remote terminal and pull boxes only. of speech or music whether indoor or outdoor. Also,
is referred to as a sound-reinforcing system. This
Note: The “backboard” associated with most PBX form of audible communication is generally the least
system equipment rooms is traditionally a “fire utilized and is predominantly an existing in-plant
retardant” sheet of 3/4” or 1” plywood. system or used for “mobile” or temporary situations.
This system will not be addressed further after these
The Field Engineer typically is responsible to set up basic points are made concerning their site use.
and ensure the service technicians terminate all
cables and provide an operable telephone system. Common industrial illustrations of this system are:

Purchasing of the desired specific phone(s), with Indoor:

appropriate requested or desired features, and colors • (Some) Main office buildings, floors, or rooms.
also are the responsibility of the Field Engineer. • General meeting area (auditorium) setting.

Outdoor:
In-Plant Party Page and Emergency and Alarm • Designated site general meeting area:
1. Daily safety meeting or exercises.
Utilization of this form of audible communication in 2. Special visitors or speakers.
an industrial setting is primarily associated with: 3. Planned site wide or specific events.

• Emergency and Alarm. One-Way Plant Channel or Broadcast - system

• Public Address System. whereby, when activated, broadcasts pre-recorded
• One-Way Plant Channel or Broadcast. tones, speech, or live voice messages over the plant
• Two-Way or Multiple Plant Channel Page. page/party system. Could be used at pre-timed
intervals, “override” all normal page/party
A simplified definition and explanation of each communication, and/or activate visual remote
utilized audible system would be: devices.

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Section 15
SPECIAL SYSTEMS

Typical applications of where this system in an • Decibel levels. Unit of sound. Ratio of relative
industrial, chemical, or utility generating station will sound pressure to a reference sound pressure.
be used are: • Acoustical background.
• Reverberation.
• Main Operations Control Room Complex. • Weather.
• Time whistle. • Distance.
• Emergency Warning and Notification. • Tone and amplification.
• Immediate access to local authorities or • Impeding obstructions.
agencies. • Environmental surroundings.

Two-Way or Multiple Plant Channel Page - To maximize the human ears capacity to discern
system whereby all stations are wired in parallel singular or multiple tones and engage in intelligble
enabling two-way conversation either on single or speech the following studies, site analysis, or plant
multiple channels. This system is the most survey’s need to be performed at the onset:
common form of in-plant communication and
conversation in an industrial, utility generating • Measure sites dB (decibel) levels (see figure).
plant, and chemical process plants. Systems • Identify objectives of the sound system.
versatility enables: • Identify coverage area of sound system.
• Override capability and broadcast in emergency • Identify plant zones and major equipment.
scenarios. • Identify “high noise areas”.
• Enables tones, speech, or voice messages. • Determine regional weather characteristics.
• Telephone tie-in. • Identify potential obstructions and sound affects
• Adjustable tone or amplification. resultant from reverberation.
• Auxiliary jack receptacles for headset use.
• Adaptable to a “sound powered” system.
• Hazardous area or weather adaptable.
• Hearing disabled compatible.
• Expandable or unlimited system.
• Controllable and Maintainable.

For purposes of this Handbook Section this In-plant

form of two-way communication will be addressed
because of its wide spread use in the construction
industry.

Two-Way Audible Communication

Significant concerns in the selection of this form of

Decibel levels for normal speech at one (1) foot is
communication that must be considered, evaluated,
70. By contrast threshold of pain dB levels are 130.
calculated, and factored in prior to, during, and after
construction are the inherent characteristics
Communication Equipment
associated with the human’s ability to hear. Hearing
any emitted sound is done with both ears (binaurally)
Proper selection of the two-way communication
and is indispensible for the localization or
systems equipment will significantly enhance the
perspective of that sound. Impeding the ears
quality, transmission, reception, efficiency, cost, and
capacity to listen, concentrate, understand, discern,
optimization of the overall system. Placement, type,
and detect are influenced greatly by multiple means,
location, direction, amplification, and coverage are
including:

Rev. 0 Electrical Handbook 15-24

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Section 15
SPECIAL SYSTEMS

essential ingredients to ensure sound signal levels • Impedance - Ohm output (8 or 16) which may
and sound quality are maintained while reducing or affect quantity of speakers/horns per amplifier
avoiding signal loss due to obstructions, signal and feeder cable/wire size.
interferences, or poor acoustics. • Frequency response - in Hz (hertz). See figure
and note below:
A primary two-way complete communication system • Efficiency - input power vs. output power
equipment utilized could include or portions thereof: expressed in dB per 1 meter in distance with
one (1) watt of input. See figure below:
• ZCU - Zone Control Unit. Components that • Dispersion angle - 90° is normal. Efficiency dB
comprise of this equipment include: decreases by 6 dB as the dispersion angle
1. Alarm control panel(s). increases or decreases below 90°. In essence, as
2. Communication control panel(s). the lateral distance increases from the sound
3. Alarm annunciator panel(s). source the coherence or sound level decreases.
4. Modular card unit. See figure below:
• Speaker performance - proper setting should be
Principal usages with this form of a system are: 10dB louder than the surrounding area and
• Programmed pre-recorded high quality speech located near the source in a “high noise area”.
messages, visual indication, alarm silencing.
• Prioritized alarm acknowledgement.
• Override normal page/party communication.
• Interconnected to other communication
networks.

• Speakers - typical selection types are:

1. Pole mounted clusters.
2. Directional loud speaker.
3. Constant direction horn.
4. Two-way or remote wall mounted speaker.
5. Ceiling tile cone speaker.
6. Hazardous or explosion-proof.

Speakers and horns are not the same and both have
distinct differences, application, limitations, and
usages. By description:

Speaker: has an integral driver, is not normally

hazardous area classified. Choicing a loudspeaker is based on: efficiency and
coverage (dispersion angle). High efficiency equates
Horn: separate driver, hazardous area classified. to high acoustic output (dB) with low disturtion.
Coverage angle equates to directivity and “beam”
Both are available in wide-angle (> 90° dispersion) width as a function of frequency for all the intended
or narrow-angle (≤ 90° dispersion). Typically, the broadcast area.
driver and supports brackets are required to be
ordered separately. Note: Frequency response (Hz) for normal speech
intelligibility is between the 500 to 4000 Hz range.
Proper selection of either a speaker or horn must
consider: • Handsets - also known as stations are available
for single or multiple channel paging. Power

Rev. 0 Electrical Handbook 15-25

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Section 15
SPECIAL SYSTEMS

requirements are 120vAC and 24vDC. Handset which are used in applications where “false ceiling
types commonly available are: grids” are to be installed and aid in the installation
• With or without an amplifier. location of “cone style” speakers mounted in the
• Wall mounted or Desk top. ceiling “tiles” or the installation of concrete pads,
• Hazardous classified. bases, or foundations for outdoor communication
• Mobile unit. poles.
• Used as a receiver only.
• Remote mounted “subset”. Communication Raceway and Cable Installation

Supplemental components used with two-way The raceway installation for this system is generally
communication systems include: installed as a “dedicated” raceway system. Cables
• Line Balancer. specific to this type of system are usually purchased
• Adjustable volumn and speaker control. with the equipment supplier and approved for the
• Sound power adapter and jack for headsets. purpose and installation location. The insulated
• Acoustic booth (sound proof enclosure). cable usually is complete with power and
communication conductors. See cable types below:
• Multiple mounting assemblies.
• Tone Speech Generator.

Two-Way Communication System Design.

This form of communication system design is

typically laid out on a one-line diagram. Which
generally provides:
• Handset symbols depicting type of set required.
• Horn or speaker symbols. Inclusive with this
symbol are “sub symbols” which depict size of
speaker or other significant information. Installation specifics relative to this form of
• Diagrammatic layout of “subsets” and/or communication system include:
speakers and from which handset or amplifier.
• Room, elevation, area, or column coordinates. • Mounting heights for handsets: design and
• Supplemental communication devices (e.g. line installation must consider applicable codes
balancer, tone speech generator). (ADA - American Disabilities Act) which may
• Cable type and general raceway, termination “override” standard installation heights in areas
information. (e.g. offices, hallways, ADA rated stairwells),
• General Notes and Symbols, and Details relative where this Act may take precedence.
to the installation of this system. • Speaker mounting locations and heights.
• Low-voltage power (120v) is fed commonly
Communication Raceway Layout Design from normal lighting panels or distribution
power panels.
The general raceway layout drawing in conjunction • Ensure the maximum number of handsets from
with the one-line diagram usually locates the two (2) a branch panel circuit is not exceeded. Typical
principle components of this system: handset amperage is less than 1 amp.
• Horns and Speakers. • Ensure the maximum number of speakers also
• Handsets or subsets. does not exceed the amplifier.
• Installation of “localized” termination boxes
Supplemental design drawings that may be required where system is sometimes “split” off may be
include the Architectual and Civil design drawings required and purchased.

Rev. 0 Electrical Handbook 15-26

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Section 15
SPECIAL SYSTEMS

• Some speakers require an “in line splice” as Sound Powered Communication

some are provided with “pigtails”.
• Raceway is typically Galvanized rigid steel and Installation of a sound powered communication
when a duct bank is utilized the raceway is system is primarily associated with two-way
normally dedicated for only communication communication where high noise levels are a
cables. constant and an area is traditionally a high
maintenance area. This system is adaptable to the
Testing of the two-way in-plant page/party page-party system or could be installed as a separate
communication system comprises of balancing the system.
system, ensuring amplification and speech levels are
above an areas decibel levels, ensuring all speakers, The principle uses of a sound powered system are:
horns, handsets are tied in, operable and two-way or
override characteristics can be achieved. System test • Freeing up of page-party system from constant
primarily follows the vendor manual and uses the use when an “equipment or system is
manual to “troubleshoot” problems. undergoing a prolonged or dedicated test”.
• Use of head sets “plugged” into sound powered
“jacks” affords remote location communication
SCADA from hand set station.
• Hazardous area classification adaptable.
SCADA - Supervisory Control and Data Acquisition • Affords tie-in to multiple remote handsets.
Communications system, according to the IEEE, is a
serial digital transmission form of communication UHF/VHF
which utilizes dedicated communication channels
(e.g. private microwave or leased telephone lines) Sites utilizing UHF (Ultra-High Frequency between
which are limited to data rates less than 10,000 300MHz and 3000MHz) or VHF (Very-High
bits/s. By definition, a data rate is a rate at which Frequency 30MHz and 300MHz) require
data path carries data, measured in bits per second. government licenses and permits for use of an
Wideband local networks used for “high speed” data operating frequency. Sites that use this form of radio
acquisition and control functions are excluded. communication is usually limited to daily field
construction communication or start-up and testing
Advantages associated with the use of a SCADA activities and is normally a temporary system.
system are to reduce message errors across a
transmitted communication channel caused either by On some sites (e.g. nuclear power plants) this form
passive or active means. Passive errors are the result of radio communication may include the installation
of channel noise on the transmitted message and of a permanent UHF/VHF antenna and cable system.
active the willful attempt by a “third party” to alter a
transmitted message. LAN/WAN DATA COMMUNICATION

The SCADA system is usually a vendor provided Resultant of the continuous evolutions of high-speed
package, inclusive of design and major equipment, data communication network technology, the
and is normally associated with sites where “high multitude of manufacturers and system types, and
levels of security” are required to be maintained to the diverse needs or use of a particular client or site
prevent data message communication breaches, it is quite impractical to highlight any relative
intrusion, or disruptions of normal data system specifics to the size, complexity, use, and cost of this
transmission or reception (e.g. nuclear plants). form of data communication except to apprise the
Field Engineer of the systems basics.

Rev. 0 Electrical Handbook 15-27

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Section 15
SPECIAL SYSTEMS

LAN (Local Area Network)

• Bus - has a main cable path carrying the signal
A network of integrated computers and devices in both directions with drop lines to local
connected by communication cable(s) and used for workstations.
transmitting data throughout an: • Ring - workstations are connected in a closed
• Office ring.
• Site • Star - easiest to install and maintain and utilizes
• Localized Area or Region a central control which connects to workstations
in a “star” formation.

Installation of either coax, fiber optic, twinax,

twisted pair or a combination of cables dependent on
system is typical. Prior to purchase, exact cable
specifications must be addressed as well as unique
specialty tools, test equipment, and connectors.

Supplemental cable considerations must factor:

• Type of network.
• Network application.
• Distances between devices.
• Electromagnetic and RF interferences.
• Environmental or hazardous classified areas.
• Accessories and hardware.

WAN (Wide Area Network)

Connectivity between a construction site and the

design office is typically through the use of a Wide
Area Network (WAN).

LIGHTING

Lighting General

For the principles of illumination, light is defined as

visually evaluated radiant energy. Visible energy
(seeing or being able to discriminate color) radiated
by light sources is found in the middle band of the
electromagnetic (wavelengh) spectrum
(approximately from 380 to 770 nanometers). At the
near and far bands of this spectrum are ultraviolet
and short-wave infrared. These three (3) bands are
the principle bands of the electromagnetic spectrum
with which an illumination and lighting design are
most commonly based upon.
These are the three (3) basic type LAN (site)
configurations, referred to as “topologies”, they are:

Rev. 0 Electrical Handbook 15-28

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Section 15
SPECIAL SYSTEMS

The effect of light upon the eye gives us the • Flourescent

sensation of light. The impression of color depends • HID - High Intensity Discharge
on the wavelength of the light falling upon the eye. • Gaseous-discharge
The three (3) colors of light that have the longest or
shortest wavelength of radiant energy to which the • Incandescent Lamps - Filament
eye is sensitive to are referred to as the primary
colors. These three (3) primary colors (red, green, The incandescent filament lamps produces light by a
violet) cannot be produced by combining light of filament heated to incandescence by an electric
any other color, but lights of other colors can be current. This type of lamp affords the lowest initial
produced by combining in proper proportion light cost, has the lowest ratio of lumens to the total power
from any two or three of these primary colors. input (watts), shortest life span and is characterized
by four (4) primary features:
Rays of light travel in straight lines unless interfered
with by another medium that either absorbs or • Filament - forms, sizes, and construction are
deflects them. Three (3) effects occur when light designated by a letter or group of letters
encounters this other medium: followed by an arbitrary number. Tungsten is
• Absorption - dissipates in the form of energy the most widely used filament because of its
• Reflection - transmitted through the substance in high melting point.
the same direction or is reflected back in the
same direction at which it impinged the surface
• Refraction - transmitted through the object but
in an altered direction or reflected back in an
different direction.

In most scenarios all three (3) situations in some

form take place.

Lighting Sources

Lighting sources are a flow of light (i.e. light energy

or waves) originating from some source of light
either natural or man-made and is measured in
lumens. Intensity is the source of light in a given Letter characters C - helical coil. CC - coiled
direction and is measured in a unit called candela, coil (double helical coil). S - straight uncoiled
formally the candle. Illuminance is the density of wire. Coiling the filament increases the lamps
the light source on a surface and is measured in luminous efficacy (power to produce effect).
footcandles when the “foot” is taken as a unit of Coiling the coil further increases the efficacy.
length. Brightness refers to the intensity of sensation
resulting from viewing light sources and surfaces. • Bulb - shape, size, material, and finish vary
according to application. Bulbs are designated
Electric-Light (man-made) sources are classified as: by a letter (referring to shape) and by a number
• Visible-light sources which is the maximum diameter in eighths
• Ultraviolet-light sources (1/8”) of an inch. Common bulbs are made of:
• Infrared 1. Lead
2. Lime soft-glass
For this Handbook Section only the Visible-light 3. Frosted on the inside for moderate diffusion of
sources will be addressed and include: light without appreciable reducing light output
• Incandescent 4. Clear

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Section 15
SPECIAL SYSTEMS

5. Fused quartz and high-silica • Fill Gas - used to reduce the rate of evaporation
of the heated filament. Typical inert gases used
include nitrogen, argon, krypton, and halogen.

Additional characteristics of incandescent lamps are:

• Lamps rated over 150w are “pear shaped”

versus standard-line shape for general-lighting
service lamps.
Note: When incandescent lamps are used for
temporary lighting (light stringers) a tough skin
finish should be ordered to prevent broken glass.
• Performance is influenced by voltages, bulb
position, size, construction, environment,
ambient temperatures and manufacturer quality.
• Specialty Lamps. Examples of specialty
incandescent lamps include:
1. Low-voltage service lamps - rated as low as 6
volts to 64v.
2. Tough-service lamp - used in heavy construction
environment where protection from accidental
breakage of bulb is a consideration.
3. Aviation-service - beacon, warning, or runway.
Purchasing of bulbs to suit application must
4. Multi-filament - three lite-lamp.
include the letter, number, desired wattage and
5. Spot or Floodlights.
voltage. Installation notes and details generally
6. Decorative and/or color specific.
reference what bulb and wattage is required.
• Flourescent Lamps
• Bulb base - also vary according to application.
Ranges from screw types, bipost, and prefocus.
Are low-pressure mercury electric-discharged lamps
Size varies with lamp wattage, for heat
in which a phosphor coating transforms some of the
dissipation, and voltage.
ultraviolet energy generated by the discharge into
light. This lamp consists of a long straight, U-
shaped, or circular tube and when proper voltage is
applied across the ends of the lamp, an arc is
produced by current flowing between the electrodes
through the fill gas (mercury vapor). Flourescent
lamps operate via hot-cathodes (electrodes) and are
started with either hot-cathode or cold-cathode
action.

Distinctions between hot-cathode and cold-cathode

action are:
Hot-cathode is associated with:
• Preheat or rapid starting
Screw type - general-service. Prefocus and bi-
post are used where a high degree of accuracy in Cold-cathode is associated with:
lamp positioning is needed (e.g. projectors). • Instant starting

Rev. 0 Electrical Handbook 15-30

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Section 15
SPECIAL SYSTEMS

Preheat or rapid-starting lamps are usually only bi- • Phosphors - the chemical composition of the
pin whereas the instant-starting lamps are either bi- phosphor coating on the bulb interior surface
pin or single pin. The clear distinction in use is that determines the color of the light produced.
the instant-start bi-pin will not operate on the same
ballast circuits as those employed for preheat or Flourescent lamps require a ballast assembly
rapid-starting lamps. (ballast) due to the mercury arc in the tube having
varying unstable resistance which requires a high
The typical flourescent lamp is between 5/8” to 2- voltage to start the arc. Pre-heat start lamps also
1/8” in diameter with ranges for straight lengths require starting switches
from 6” to 96”. This form of flourescent lamp is
typically the most common used in construction • Ballasts - have two (2) prime purposes and types
designs and installation and typically are either 48” vary by circuit voltage, class, power rating, noise
or 96” in length. classification, thermal protection devices or
rating, wiring practices.
The principle components of a flourescent lamp are: 1. Produces a high induced starting voltage for
• Bulb - designated by a letter (indicates the tube striking the arc.
cross section shape) and a number (indicates the 2. Stabilizes the operating impedance of the circuit
diameter in eighths of an inch (1/8”). to maintain the operating current at a steady
• Electrodes - two (2) electrodes in each value.
flourescent lamp, one at each end, designed to • Starting switches - for (preheat) rapid starting
operate as either “hot” or “cold” electrodes lamps closes the circuit between the two
(cathodes). filaments when the lamp is energized or opens
• Fill gas - droplets of liquid mercury which the circuit after a sufficient lapse of time for the
vaporize to a very low pressure during lamp filaments to be heated to the proper temperature.
operation. Other fill gases that are added or Typically four (4) different types of switches are
used in combinations include: used dependent on the lamp.
1. Argon
2. Argon-krypton mix Auxiliary devices and luminaire styles associated
3. Argon and neon or zenon with flourescent lamps are:
• Bases - lamps associated with instant-start
operation generally have a base at each end with • Pin locks - inserted between the pins and the
a single pin connection. These lamps with two base this lock effectively prevents the bulb from
(2) pins are electrically connected. Lamps for accidentally falling out.
rapid-start have two (2) pins. Circline lamps • Tube sheets or guards - slip on plastic guards
have four (4) pins. over the bulb aid the prevention of accidental
bulb breakage.
• Shields, covers, louvers, baffles, and troffers.

• High-Intensity Discharge Lamps

The HID (high-intensity discharge) lamps that

closely relate to this type of lamp consist of mercury,
metal halide, and high-pressure sodium lamps. A
mercury lamp is an electric discharge lamp in which
the major portion of the radiation is produced by the
Group A - regular flourescent lamp base.
excitation of mercury atoms. A metal halide lamp is
Group B - compact flourescent lamp bases.
an electric discharge lamp in which the light is

Rev. 0 Electrical Handbook 15-31

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Section 15
SPECIAL SYSTEMS

produced by the radiation from an excited mixture of distance the lamp appears to emit a daylight white
a metallic vapor (usually mercury) and the products light.
of the dissociation of halides (e.g. halides of sodium,
thallium, indium). A high-pressure sodium lamp is Phosphor-coated mercury lamps - more widely
an electric discharge lamp in which the radiation is used of the mercury lamps. Distinctive from other
produced by the excitation of sodium vapor. All mercury lamps by its inner phosphor “coating”
three (3) lamp types produce light from an arc tube which emits a “softer” white light.
which is usually contained in an outer glass bulb.
Metal halide lamps - similar to mercury lamps in
Characteristics unique to each are: construction, in that the lamp consists basically of a
quartz arc tube mounted within an outer glass bulb.
High-pressure mercury lamp - consists of a quartz However, in addition to the mercury, the arc tubes
arc tube sealed with an outer glass jacket or bulb. contain halide salts, usually sodium and scandium
Note: It is not good construction practice to utilize iodide. This HID is more commonly used than the
this type lamp near or around “stainless steel” piping mercury lamps due to its increased light output and
or stainless piping components because of the greater wattage ranges.
adverse reaction mercury has on stainless steel.
High-pressure sodium - commonly referred to as
HPS has the highest light-producing efficiency of
any commercial source of white light. This lamp
consists of an arc tube enclosed within an outer glass
bulb.

The HPS is the most commonly used HID lamp due

Wattage ranges vary from 40 - 1000w. Light output to its increased long-life, greater efficacy, and
is reduced when this lamp is installed in positions burning position. Wattage ranges from 35 - 1000w.
other than vertical. The mercury lamp is the least
used HID in industrial facilities. When viewed at a

Rev. 0 Electrical Handbook 15-32

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Section 15
SPECIAL SYSTEMS

All HID lamps consist of a cylindrical transparent or Lighting System Design

translucent arc tube with a distinctively
characteristic “dimple top” of the outer glass bulb. The typical construction lighting system designs are
The arc tube contains the electric discharge and the often classified with their layout or location with
associated gases. That tube is further contained in respect to the visual task or object lighted and
an enclosed outer glass bulb or jacket to exclude air comprise principly of:
to prevent oxidation of the metal parts and to
stabilize operating temperatures and significantly • General Lighting
reduce ultraviolet radiation emitted by the excitation • Localized general lighting
of the vapors. HID lamps also require ballasts. • Local lighting (supplemental)

Ballasts associated with these HID lamps are Supplementing these basic lighting systems are the
classified into three (3) categories, dependent on the luminaires (a device which directs, diffuses, or
circuit involved, and provide three (3) basic modifies the light given out by the illuminating
functions: source) and their effects associated with:

Catagories • Direct lighting

• Nonregulating - line balance • Semi-direct lighting
• Lead-type regulating - constant wattage • General diffuse
• Lag-type regulating - autotransformer plus a • Direct-indirect
reactor in a single structure • Semi-indirect
• Indirect
Function
• Control lamp current to the proper value By description each lighting system or luminaire
• Provide sufficient voltage to start the lamp effect means:
• Match the lamp voltage to the line voltage
• General lighting - a lighting system which
Ballasts associated with HID luminaires are designed provides an approximately uniform level of
inside the luminaire. illumination on the work plane over the entire
area.
Consistent with all HID lamps are the “slow” warm- • Localized general lighting - consists of a
up and/or restart times for the arc to stabilize at its functional arrangement of luminaires with
operating value and achieve full light output. This is respect to the visual task or work area(s). This
normally referred to as “in rush” or starting is more traditionally referred to as task lighting.
amperage currents and must be a consideration in • Local lighting - a local lighting system which
the design circuit loads to avoid designing to many provides lighting only over a relatively small
luminaires to an individual branch circuit. This area occupied by the task and its immediate
initial starting current is usually higher than the surroundings. Typically this form of task
normal operating current of the lamp and varies with lighting requires heightened illumination levels.
the line voltage.
• Direct lighting - luminaires that direct 90 to
Also, the HID’s ballast wattage associated with each 100% of their output downward.
lamp must also be factored into the branch circuit • Semi-direct lighting - luminaires that direct 60
load. to 90% of their output downward with some
small upward illumination.
• General diffuse lighting - surface mounted or
suspended luminaires that equally distribute
light upward and downward.

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Section 15
SPECIAL SYSTEMS

• Direct-indirect lighting - luminaires that emit

very little light at a horizontal angle.
• Semi-indirect lighting - luminaires that direct
60 to 90% of their light upward.
• Indirect lighting - luminaires that direct 90 to
100% of its light upward.

Supplemental Lighting System Design Factors

The overall lighting system design typically is

augmented by non-design engineering factors and/or
by the the designs associated with the interfacing
engineering disciplines. Most commonly they are:
• Material costs and vendor supplier agreements.
• Local or national codes and standards.
• Testing laboratories or certifications.
• Client preferences, specifications, or by contract.

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Section 15
SPECIAL SYSTEMS

• Task or maintenance illumination levels. Lighting System Design Objectives

• Emergency, standby, or egress lighting, needs or
established requirements. The general objectives of the engineering design of
• Hazardous area classifications. the overall lighting system is to primarily satisfy four
• System maintenance, luminaire life expectancy. (4) primary purposes. They are:
• Environment, combustible material or zones. • Site or project goal - an overall conceptual plan
• Safety. of the entire project which will affect or could
• Energy conservation. influence the lighting system design.
• Illumination criteria - by visual task(s) their
The lighting system designs are influenced frequency or location, by space or distance
significantly by the other engineering disciplines. dimensions, reflectances, daylight availability,
Their role in the electrical lighting design greatly temperature and dirt conditions, cost and
determines luminaire selection, location, and service. schedule, power and energy budgets, voltage
requirements, codes and standards, client
Architectural. preferences or specifics.
• False ceiling grid layout plans. • Illuminance criteria - illuminance levels, safety,
• Block wall or interior room layout (e.g. offices, visual comfort, light-loss factors.
partitions, rest rooms, meeting areas). • Design decisions, approach, or philosophy -
• Egress paths, ADA areas. luminaire selection, location, and mounting,
• Area room fire classifications. control (switching, dimming), calculation
• Building details or specifics (e.g. paint color, methods, maintenance and cost, energy
wall or floor tile, siding, flashing details). consumption.
• Windows locations, door types and details.
Persuant to the issued design, and subsequent
Civil installation, is the evaluation of the design (as
• Yard lighting pole base details. installed) installation. Common evaluation methods
used in supporting this effort include:
• Roadway layout and grade elevation.
• Illumination checks and “as built” drawings.
• Grid or column locations.
• Circuit verification checks and actual loads.
• Floor or slab elevations.
• Life-cycle and maintenance costs.
• Concrete wall locations.
• System walkdown with client maintenance,
work task disciplines, safety, applicable local
Structural
regulatory agencies or inspectors.
• Steel or column locations, elevations, sizes.
• Circuit schedule and drawing updates.
• Platforms, ladders, stair details and locations.
• Overall system constructability.
• Grating type and details.
• Monorails and rigging beam locations.
Lighting System Design Drawings and Layout
Plant Design
The lighting system layout is identified on a series of
• General plant, building, or yard layout.
(or a) one-line diagram(s) and/or individual lighting
• Plant equipment layout.
raceway or general raceway layout drawings. The
raceway layout drawings will locate and identify;
HVAC either by fixed location or diagrammatically the
• Humidity levels. luminaire (e.g. fixture), receptacles, or switches by:
• Room or area air pressure, displacement,
movement, exhaust, transfer. • Fixture type - using a defined lighting symbol.
• Room or area heat levels, temperature control or Which when cross referenced back to supporting
variances. design documents or specification, manufacturer

Rev. 0 Electrical Handbook 15-35

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Section 15
SPECIAL SYSTEMS

catalogs, detail or cut sheets, or the Lighting control, circuit number, height and location,
General Notes and Details will provide all the accessories (e.g. cover, dimmer, color, GFCI).
relative information for that fixture inclusive of: • Weather or environment - weatherproof, area
1. Line voltage, wattage, amperage rating(s). classification, sealing criteria.
2. Accessories (e.g. ballast, control switch(es),
reflector, refractor, troffer, color globe, Associated with all lighting or distributed power
glass, guard, bulb(s), covers, batteries). systems are panel schedules drawings. Panel
3. Position, plane, angle. schedules for lighting systems identify the following:
4. Mounting base, brackets, poles, stands.
5. Wiring information. • Lighting panel schedule - usually identifies each
6. Manufacturer fixture or device data. lighting panels design information (low-voltage
• Elevation - mounting height, tolerances or power distribution panels also).
lateral variances. 1. Power source - transformer and/or MCC.
• Directional arrow(s) - fixture head position, sign 2. Main breaker rating.
face view(s), photocell placement. 3. Number of phases and wire (e.g. 3∅ 4W).
• Support detail - restraints, material, mounting. 4. Voltage rating (e.g. 277v, 208-120v).
• Illumination level(s) - general area or room, 5. Total branch circuit breakers required,
equipment areas, egress or emergency. inclusive of spare(s), and “blank” spaces.
6. Individual branch circuit breaker rating,
• Circuit - phase(s), neutral, ground wire or cable position, and pole(s).
size, quantity, type, panel and circuit number. 7. Individual circuit description of service (e.g.
control room lights, stairwell #2, yard area).
Note: Circuits - depicted by “hash” marks on 8. Individual phase and total estimated load.
the raceway. These hash marks represent the
total number of phases, neutral, and ground Lighting Systems Designs
wires. If, more than three phases are utilizing a
raceway the phases are separated by the neutral Dependent on client requirements, project specifics,
hash which is represented larger than the phase or applicable regulatory agencies (e.g. NRC Nuclear
hash(es). (example: ‘/ “‘/ G). Regulatory Commission) the principle lighting
systems that are designed are:
• Cable - traditionally is multiple 1C - #14, 12,
10 AWG stranded though larger AWG wire is • Normal lighting (non-essential)
use. • Low-voltage power (e.g. 208/120vAC)
• ∅ panels Black (Hot), White
Cable colors - For 1∅ • Emergency lighting (essential)
(Neutral). For 3∅∅ panels: • Emergency standby and/or lighting
Phase A: Black (breakers 1,2, 7,8 13,14, .......)
Phase B: Red (breakers 3,4, 9,10, 15,16, ....) Normal lighting - (also known as “non-essential
Phase C: Blue (breakers 5,6, 11,12, 17,18, ..) lighting”) its primary system service is usually just
Neutral: White for general, task, or localized area lighting and if a
Ground: Green (typical for 1∅) total loss of incoming panel power was experienced,
no automatic switching or transfer activation of a
• Raceway - size, layout, boxes. back up or standby lighting system would occur to
• Lighting equipment - contactor, transformer reestablish or supplement this lighting system.
type and voltage rating, panel “guts”, NEMA
rating, and classification. Note: Emergency lighting luminaires that derive
• Switches and receptacles - type, NEMA rating, their primary source of power from these “normal”
mounting and type box, fixture or device lighting panel branch circuits must have some hourly
rated battery tie-in (usually 4 or 8 hours) that will

Rev. 0 Electrical Handbook 15-36

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Section 15
SPECIAL SYSTEMS

automatically activate (or reactivate) the luminaire • An independent raceway and circuited lighting
(e.g. exit signs, egress light). Most lighting systems system but is a part of the overall site or area
where this condition is present is usually the lighting layout plan.
exception and not the rule and is usually limited to • Operable through a photocell.
outlying or remote buildings or locations where the • An emergency light (luminaire) or circuit(s)
cost of an independent lighting system is not may or may not be installed with an hourly rated
practical and the continuous prescence of DC battery back up (e.g. outdoor multi-tiered
maintenance or plant personnel (and/or essential facilities that are not a totally enclosed building or
plant operating equipment) is not required or exists. structure). Subsequently, with the loss of an
individual branch circuit(s) the emergency light(s)
Low-voltage 208/120vAC distributed circuitry’s on the effected circuit may or may not be (or remain)
primary service is usually for general-service or lit.
dedicated duplex receptacles, small 208/120v devices • On luminaires that do utilize a DC battery the
or equipment (e.g. motors, tools), subpanels (e.g. re-energization of the circuit or panel will recharge
vendor panels, lights,), appliances (e.g. office the battery and de-energization of the circuit will
kitchenettes, stationary electric water coolers), or energize the fixtures low-voltage DC battery circuit.
miscellaneous systems (e.g. plant-page system).
Specific design features of an emergency egress
Note: Per the NEC general-use receptacle outlets, lighting system include:
that have no defined load, must assume a value of
180 volt-amperes which should be considered as part • Dedicated raceway and lighting equipment.
of that individual branch circuit load. • Exit signs.
• Low-voltage DC battery type fixtures or remote
Note: Instrument(s) 120vAC power requirements mounted fixtures tied to a main fixture or pack.
traditionally either have their own 120vAC power
distribution panel or are fed via the UPS system. Note: HID (high intensity discharge) fixtures
(luminaires) utilized for this system should always be
The Emergency lighting system is also typical to “instart restart” because of the HID slow warm up
the normal lighting system. This designed lighting period when de- than re-energized.
system is sometimes referred to as the “essential
lighting system” which provides lighting to essential Applicable code requirements to egress paths may or
plant equipment that may be necessary for the commonly require 1fc (footcandle) of illumination
continued plant operability or reliability in event along the egress (exit) path (normally for indoor
there’s a total loss of normal lighting. Too, is areas).
principly associated with emergency egress (exit)
path lighting or emergency equipment (e.g. elevator On some sites or projects (e.g. nuclear) the design of
controller, fire) circuits. an Emergency Standby and/or lighting system may
be required. Sites where this system is designed and
Akin to the normal lighting system in operation, used predominantly utilize diesel generators to
except in the event of total loss of primary incoming provide alternate power to safely bring an operating
power than the automatic switching or transfer to a facility down or to continue to maintain the facility
back up system or diesel generator will reenergize in a safe condition.
this emergency lighting system.
Alternate uses of this system are for fire protection
Dependent on client specifics or the emergency equipment (e.g. diesel fire pumps, fire engine
lighting system design operable approach the system controls) and as an alternate lighting designed
can be installed to serve the following applications: system to augment the emergency or normal lighting
systems.

Rev. 0 Electrical Handbook 15-37

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Section 15
SPECIAL SYSTEMS

Lighting System Scope Note: Due to their “high” cost it is advisable to

order multi-tap ballast/voltages.
The lighting system begins from the individual • Roadway lights - typically are 30’ mounted on
branch circuit(s) breaker of the lighting and/or the concrete pole bases and are photocell controlled.
miscellaneous low-voltage power panel. Common to • Emergency egress lights - single or double faced
most electrical (turnover) systems the, primary, directional exit signs, single or double
incoming power supply to the lighting or low-voltage directional “head” wall packs with a low-voltage
120vAC panel is traditionally another electrical DC battery back up (usually rated for 4 - 8
scoped system and the individual branch circuits that hours), remote single or double head fixture
are associated with the lighting, receptacle, or device (powered from a main DC wall pack).
are either related to the Facility turnover schedule or • Floods or spot lights.
the branch circuit devices turnover system.
Low-voltage 208/120vAC system or lighting
Facility turnover versus systems turnover will be components comprise mainly of:
addressed later in this handbook section. • Duplex receptacles or outlets - hazardous or
environment classified, various NEMA
Lighting Equipment and Components classifications, various mounting, types, and
styles.
Though associated with the electrical power systems
the principle equipment that is required to be Lighting System Installation Constructability
installed to support the lighting system comprises of:
• Dry type transformers - usually 30 to 75kVA 3∅ Pitfalls to avoid during the constructability review or
4W 480v primary and either 277 or 208/120v installation of a lighting system design include:
secondary. Weather shields required for outdoor
transformers or NEMA rated for use. • Obvious interferences or obstructions that block
• Lighting panelboards - NEMA rated “can”, or hinder the effectiveness or usefulness of a
internals, individual breakers, main, trim, dead fixture.
front. Commonly either 12 to 42 circuits. • Overloaded or underloaded or utilized circuits.
• Lighting contactors - auto or manual selector • No “future” branch circuit panel expansion. No
switch. spare breakers or an inadequate quantity of
“blanks” or “spares” available or allocated
Supplemental lighting devices include: (panel too small).
• Remote mounted photocells. • Unbalanced phases.
• Timers. • Fixture mounted adjacent to pipe or components
• Switches. that expand due to heat or will be insulated.
• Dimmers. • Panels individual circuits “too” far from
• DC batteries. fixtures. Voltage drop concerns.
• Panel or transformer location not optimized to
Luminaires that are commonly installed are: best available location for installation, fixture(s)
• Flourescent fixtures - multiple types, styles, raceway routes, panel maintenance, hazardous
voltage ratings. Myriad of accessories and area classification, or accessability.
mounting conditions or locations. • High-bay or suspended fixtures located where
• Incandescent fixtures - multiple types, styles, maintenance is impractical or lack sufficient
voltage ratings. Myriad of accessories and moving air thereby reducing service life.
mounting conditions or locations. • Fixture not hazardous classified, is incorrectly
• HID - typically are only High-pressure sodium rated for service voltage, or areas environment.
(HPS).

Rev. 0 Electrical Handbook 15-38

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Section 15
SPECIAL SYSTEMS

• Receptacles and outlets are blocked, located too • Replacement burnt out or damaged incandescent
far away from equipment that is required to be or flourescent bulbs.
serviced or maintained. • Replacement for damaged fixtures, guards,
Note: a maintenance mechanics rule of thumb globes, shades, refractors, reflectors, troffers,
on receptacle location is 50’ optimum from primary covers, lenses.
equipment or general plant areas. Which usually is • Bad or burned up ballasts.
the length of their power cord for small power tools. • Incandescent or flourescent fixtures and bulbs
used for temporary power or as temporary light
Lighting System Review and Evaluation or outlets for work tables, offices, trailers, lunch
areas.
As a field engineering and construction aid the Field • Lighting wire also used for temporary power or
Engineer should ensure the lighting design considers lighting needs.
consequences or field conditions that could reduce
overall construction installation costs and materials. It is good field engineering practice to assume a
• Isolated (orange) receptacles are primarily for “loss and replenishment percentage” of these
UPS systems. consumables and to purchase sufficient extras to
• Consider what NEMA male “plug” and type avoid repeated purchases and to avoid potential
manufacturer the clients or sites maintenance installation schedule delays due to “material
personnel use versus whats designed to be unavailability” or “its on order”.
installed.
• Panels used for temporary power or powered for Lighting System Installation Philosophy
temporary or individual circuit energization.
• The total circuit wattage on an individual Lighting system installation practices that require
branch circuit (fixture or outlets) is much less Field Engineering planning, sequencing, scheduling,
than the code or the site allows. This enables or for consideration should include:
the field electrician the flexibility to add or
change the circuit without exceeding the branch • Whether it is “more costly” to initially install
circuit rating. portions of a designed lighting system or to
install “temporary” construction lighting to
Note: During the installation verification augment daily contruction activities, safety, or
checks the design circuits will always not be as temporary power needs.
shown on the design drawings and most times
can significantly save field rework by “as • Properly plan and schedule when, how many,
builting” the “as installed” circuit condition. A and what supplemental fixture parts and
field engineering rule of thumb is: as a components are necessary to order. Consider
minimum allow for 1 added light of the highest the fixtures delivery dates that are a “long lead
rated wattage on that circuit (e.g. 150w vs. time” to support supervisions lighting system
100w) or for 1 additional outlet. installation schedules. Always bulk order
whenever conceivable. Ones and two’s cost
Lighting Consumables significantly more and take longer to receive.

No system will continuously require consumable • Most lighting designs will consistently undergo
purchases more than the lighting system. The Field revisions, changes, additions, or deletions
Engineer should be mindful that the lighting system whether by design or by construction and
belongs to “construction” until its turned over to the require constant vigil to avoid an “end of the
client. Because of this, and the fact that eventually lighting installation massive as built”. Update,
the lighting system will be used in lieu of temporary monitor, and review documents and drawings as
lighting, conditions may require the purchases of: the installation activities transpire.

Rev. 0 Electrical Handbook 15-39

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Section 15
SPECIAL SYSTEMS

• Mount an appropriately sized “central” pull or

• Perform a lighting material takeoff that as a “splice” box somewhere above the panel - this
minimum addresses fixture type, mounting enables a central feed raceway from the panel to
components or fixture accessories, switches and the box, from where circuits can than
outlets, breakers, equipment. “effectively” split out without installing multiple
conduits.
• Ensure a proper fixture storage area is • Avoid installing raceway directly under steel or
established and a receipt accountability centrally to vertical columns - install off sides
inventory is maintained to avoid an excessive this avoids other disciplines hangers or pipes.
surplus of fixtures or unplanned shortages due to • Install additional central pull or splice boxes
damage, missing, or being lost. approximately at mid points in the raceway run
to enable circuit cut-ins (splices) or circuit
Lighting Installation and Material Costs extention for that area of service.
• Mount boxes at each floor level when run is
Installation of just lighting fixtures, outlets, and their vertical through slabs.
supports consists of only 20% of the overall lighting • Decide if its “more costly” to route the larger
system but approximately 45% of the installation sized “trunk” or “home run” longer than split
budget. Installing the raceway, hangers, wire, and off with smaller pipes or the reverse (run the
terminations comprise the balance. By contrast, the larger shorter than run numerous smaller pipes).
lighting fixtures and their accessories (bulbs, globes, • Flex to all or most ceiling tiled fixtures. This
refractors, mounting brackets, etc.) represent 80% enables light to be lifted into the ceiling without
of the material costs. From this the Field Engineer hinderance from the raceway or requiring
should get a sense of the overall significance pre- determination of the light.
planning, reviewing the design, performing proper • Coil some “slack” wire (12 - 18”) in condulets at
material take-offs, identifying and resolving fixture fixtures. Affords the feasibility to relocate a
and circuit concerns and problems before work starts light or repair “crystallized” or damaged wiring
will save on the lighting systems overall budget. in a fixture without pulling new wire.
• Install some “X” (cross condulets, plug unused
Lighting Raceway Installation Basics ends) at central locations in the run. Enables
extention of raceway without cutting in or going
Installation of the lighting raceway design is not an back to a box.
exact science and is mostly subjective to how the • Review costs between “multi-tap” alike fixtures
field electrician plans and visualizes the raceway and “dedicated” 120, 277etc. fixture. Multi-tap
routes with respect to the fixture(s), circuiting, or fixture enables fixture to be used regardless of
lighting device(s) that the raceway serves. In voltage especially if designs use various voltage
conjunction with this the electrician will utilize the lighting systems and fixtures are the same type
design drawings to get an “overall” feel for the except for voltage. Purchasing this type fixture
designers intentions, lighting circuit methodology, affords greater use flexibility.
and fixture service. • Route raceway under trays, in groups, or in
“save zones” where other disciplines are less
Some common design or field installation guidelines likely to be installed.
that will aid in the maintenance of the lighting • Install panel and circuit designations on outlets
system, reduce installation schedule and costs, will and boxes, condulet fittings, splices, fixtures.
avoid field questions and/or rework, and enable • Install terminal boxes in areas where fixtures,
circuit or fixture changes, resultant of additions or receptacles, or raceway’s are required to be
deletions, without unduly disrupting installed removed for maintenance (e.g. removable
circuits are: platforms, handrails).

Rev. 0 Electrical Handbook 15-40

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Section 15
SPECIAL SYSTEMS

• Consider installing cord reels, from high bay • Using a light-meter - verify illumination levels
ceilings for portable receptacles, when or where are in accordance with codes, standards, or
removable shelters are required or to be design for the area, room, egress path,
installed. equipment location. Record levels and is best
• Use “high-temperature” rated wire where the performed at night or before dawn. Most sites
potential for excessive heat build-up or lack of will accept results from “desk top” height (30”)
moveable air, or high heat exists (e.g. high-bay, readings and perform most checks at night.
high-wattage lights, boiler areas).
• Emergency lighting raceway and normal Note: More commonly a “field walkdown” with
lighting raceway are considered dedicated the clients representatives from maintenance,
systems. operations, safety, and engineering is done and
mutual agreements on low-light, dark areas, or
Lighting Material high-visibility areas requiring more light are
addressed their and than precluding the need for
Common material usages associated with the a “formal light-meter check.
lighting design and installation include:
• Wire spools and wire caddy - typical lighting • Perform emergency egress lighting check -
wire reel is a 500’ spool mounted on a multiple depress the fixtures test button to verify if lamp
spool caddy to enable multiple lighting wires to will come on, if battery is working or “wired”,
be pulled simultaneously. performs per manufacturers specifications.
• Wire nuts - twist mechanical connectors 600v • Circuit verifications - at night verify photocell
rated and colored for common 1C lighting wire controls the lighting circuits as designed.
terminations of multiple AWG sizes. • De-energize individual branch circuit breakers
• Armored or MC cable in lieu of raceway is and verify from the design drawing that the
commonly used on some sites. correct receptacles and lights are wired per the
• Use of EMT conduit is not uncommon though design drawing(s).
aluminum and galvanized rigid are more • Perform amperage readings on the individual
traditional. branch circuits that are suspected of being
• 4 - 11 outlet box, octogon box , extention rings, “overloaded”.
FS cast iron boxes. • As built changes, update schedules, drawings.

Lighting Fixture Support Hardware

CATHODIC PROTECTION
Common support hardware associated with fixtures
include the use of: Cathodic protection as an electrical system is the
• Drop chain. reduction or prevention of corrosion of metal(s). This
• Fixture hooks, hangers, clamps, swivels. is accomplished by making the metal a cathode in a
• Ceiling saddle, beam clamps. conducting medium by means of a direct current
• 1/2” all thread bolt rod, channel. (which is either impressed or galvanic). By
definition, corrosion is the deterioration of a
Lighting Level and Design Circuit Checks substance (usually a metal) because of a reaction
with its environment. This environment could
Performing a lighting system test, illumination level include mild or harsh indoor or outdoor areas
check, or lighting circuit verifications are principly subjected to salt water (water intake structures,
the responsibility of the Field Engineer and condensers, piping systems), atmospheric conditions
comprises of all or some of the following: (rain, wind, etc. on steel or bridges) or more
common to industrial facilities the effects of an
electrically connected dissimilar metals environment

Rev. 0 Electrical Handbook 15-41

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Section 15
SPECIAL SYSTEMS

which forms a galvanic cell which then directly • Low-voltage rectifiers or drainage panels
influences the rate of corrosion to underground • Active DC impressed current protected metal(s)
pipes, raceway, or tanks, or above ground tanks and
steel. These designs are supplemented by the project
piping or mechanical system designs that require the
Cathodic Protection Designs necessary protection.

Basic principles used in the design philosophy of a PLANT SECURITY SYSTEM

cathodic protection system include:
• DC-voltage potential difference between the two Complexities of a sites security system design vary
metals. The greater the potential the greater the with each site or specific client requirements and/or
current and subsequent rate of corrosion . federal regulatory guidelines (NRC Nuclear
• The resistance of the electrolyte (earth) which Regulatory Commission for nuclear plants).
limits the current flow. The lower the resistance Consistent with most industrial sites these designs
the greater the corrosive current. comprise of:
• The base end (anodic - ) and the noble end • CCTV (Closed Circuit Television) surveillance
(cathodic +) of the metals. Anodic (-) end cameras
represents the metals that will corrode and the • Guard shack, house, security building or central
Cathodic (+) are the protected metals and not command center
subjected to corrosion. • Fence perimeters
• Components external protection (coatings). • Motion detectors, x-ray machines and/or
explosive monitors and sensors.
Common anodic (-) end metals include: • Infrared and heat sensors or monitors.
• Iron • Card readers for restrictive or secured doors.
• Aluminum
• Zinc Nuclear Plant Specific (Security Design)
• Lead
Accessing security documents, design drawings, et al
Common cathodic (+) end metals include: for nuclear plants require specific security
• Copper (one reason ground cables are copper) clearances, authorization, review, and strict
• Silver compliance to all specifications, procedures, and
• Mercury federal regulatory guidelines. In addition, these
• Gold documents and drawings will be “security classified”
and closely monitored for compliance during usage.
Typically sizeable cathodic protection system designs
are usually sub-contracted to engineering or Non-Nuclear Facilities
contractors specializing in cathodic protection, soil
testing and/or studies. Inclusive of this are: For non-nuclear facilities these documents and
• Principle equipment (anodes, test stations or drawings could be classified or regulated by site or
boxes, rectifiers, control panels) client specifics relative to sensitivity, control, and
• System checkout, functionality, testing usage. Traditionally, for these facilities the
• Cable(s) in ample lengths adherences and compliance to requirements are not
• Installation layout drawings, notes and details as sensitive as for nuclear plants. In either event the
• Manuals, design basis, calculations, test results Field Engineer must be sensitive to the nature of this
• Technical advice and services system and its effect on the integrity, reliability, and
operability of a clients site.
Specifics as to cathodic protection means include:
• Consumable anodes (sacrificial)

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Section 15
SPECIAL SYSTEMS

A typical security design and installation is akin to What Is Construction Power?

most any raceway or circuited cable schematic with
the aforementioned notable exceptions. Construction power is a safe, pre-planned, and
adaptable 480v electrical power distribution system.
480v In Plant Power Outlets Which is principly used to supply, complement, or
support a sites day-to-day construction work forces
Installation of fixed 480v remote power outlets (akin electrical needs, requirements, and demands without
to a 120v receptacle) is commonly a client specific unduly impeding a users work schedule or creating
design additive or plant feature. Typically, this manpower inefficiencies due to a lack of electrical
design and installation is used in nuclear or heavy power in any plant area or construction work
industrial complexes where a high level of location.
continuous plant maintenance or upgrades and/or
where major plant mechanical or electrical system Planning for Temporary Power Needs
outages are “taken out or service” requiring a means
to maintain or provide temporary power and lighting Commonly a sites first electrical construction work
in remote buildings, areas, or multiple floors. activity is the initial installation of the overall
temporary electrical power system. But, prior to
Usages of this system commonly are for or by: this initial construction activity, evaluating the needs
• Portable welding or stress relief machines of all the electrical kw (kilowatt) power requirements
• 480v temporary power panel, transformer and a project or site will need from conception to
disconnects completion should be accomplished. Working in
• In-plant, client, or site maintenance groups, on- tandem with:
site plant modification contractors personnel • Electrical Supervision
• Temporary lighting and/or small power tools fed • Site electrical craftsmen
from a temporary 480/208-120v panel • Design Engineering
• temporary or portable 480v power equipment • Other field engineers or supervisors
• Remote outlying buildings or yard areas where • Client representatives (maintenance, etc.)
temporary power services are necessary
and/or utilizing:
The design is normally a one-line diagram and the
location of outlets are identified and located on the • Field Engineer’s prior experiences, practices,
raceway layout drawings. and knowledge of “what equipment and tools
will be required to be electrically powered”
Temporary Construction Power and Site Services • Drawings - Sites overall construction plot plan,
projects plant design layout, and equipment plan
Though this is not a scheduled system or design the • Existing sites electrical distribution systems one-
continuous site demands, needs, requests, evolution, line and equipment layout drawings
and uses of temporary construction power during all • Underground commodity and utility drawings
phases of the construction project requires the Field
Engineer to support field supervision and the a formalized preliminary electrical distribution and
electricians in ensuring a safe, reliable, and adequate raceway/equipment layout plan can be based.
temporary power distributed system is maintained,
upgraded, and removed. The preliminary plan should include as a minimum:

The temporary power system must comply with all • Site budgeting - based on initial setup and
applicable local and national codes and standards needs, maintaining, upgrading, or revising, and
with emphasis on Safety to equipment and user removal after project completion.
personnel.

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SPECIAL SYSTEMS

• Material costs - major equipment, cable, and • Material costs, supplier availability and delivery,
other electrical commodities. Cost to maintain use of surplus electrical equipment versus newly
system, make upgrades, and removal. Inventory purchased, resale of same, ample in stock
surplus, sell, or disposition used site equipment. inventory and electrical apparatuses that can be
• Miscellaneous system purchases - sundry items used for permanent installation.
(bulbs, fuses, breakers, cable ties, wire, conduit, • Adaptable system without constantly requiring
PVC, fixtures, cords, adapters, receptacles). to be relocated due to normal work installation
• Basic one-line diagram of elecrical distribution. activities that may interfere.
• Electrician manpower requirements to maintain • Use of underground raceway or above ground
system, modify, or remove as necessary. cable and raceway installation or a combination
• Equipment installation or storage requirements, of both. Above ground cables free from
review project construction schedule. overhead cranes, “pickers”, load lifts, or
• Subcontractor or vendor equipment power needs equipment paths. Below ground free from
for trailers, work tables, or tools and equipment. known or future commodity trenching work.
• Sites construction layout for trailers, offices,
lunch or meeting areas and kw load demands. Construction Power Order of Magnitude
• Regional weather considerations cold weather
(heating, freeze protection), summer (AC, fans, To achieve a “broad perspective” of the overall
ventilation), off-shift work (lighting). construction sites temporary power needs the Field
• Each disciplines unique power tools, equipment, Engineer can plan and execute a temporary power
machinery, fab shop(s) power requirements. system by following these simple guidelines:
• Safety requirements (e.g. confined space • Anticipate power needs by the various
lighting, GFCI outlets, periodic power cord or construction phases of the project.
tool inspection and/or repair). • Anticipate power needs by respective discipline
• Code requirements and/or client site specifics. with respect to their installation schedule and
• Power outages or tie-ins and their affects on site manpower loading.
installation work activities due to “revamping or • Anticipate power needs by equipment, vendor or
relocation of temporary electrical equipment”. subcontractor.
• Anticipate power needs by construction
Distribution system must consider as a minimum: budgeting.
• Anticipate power needs for AC voltages but
• Available primary sources of main incoming consider what equipment may require DC.
temporary power (e.g. use of spare 480v MCC
or Switchgear buckets or cubicles, local utility Construction Power Guidelines
poles, portable generators, present equipment
loads, demands, ratings, capacity). Common sense guidelines used in the development,
• Estimated total kw load and amperage of overall implementation, stategy, and cost containment or
service: on transformers, panels, phases. By affordability of most construction sites temporary
location, area, elevation, building, zone, or floor power systems usually consider:
with consideration to the various voltage levels • Multiple originating sources of primary power
needed to support all discipline work activities. (800A preferable) to multiple centrally located
• Quantity and type of major equipment factoring distribution panels or racks (400A preferred).
in all the necessary variables (e.g. ratings, Whereby, the anticipated maximum loads, for
voltage, NEMA class, hazardous areas, etc.). that (or a given) area is not exceeded at any one
• Disconnect and safety switches, fuse ratings, point of distribution requiring alternative power
placement or location, quantity, voltage and solutions or “work arounds”, avoidable rework,
amperage ratings. partial or temporary loss of power or requiring

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Section 15
SPECIAL SYSTEMS

excessive manpower or material demands to • Consider purchasing previously used and

resolve any load or availability problems. “surplused” distribution power boards, racks,
• Fabricate as required temporary power boards disconnects, transformers etc. from other sites
and disconnects centrally placed by area or use that are still in generally good repair or
(example 480v temporary power boards below) condition.
• Consider alternatives to temporary power:

1. Install permanent receptacles or lights and feed

from temporary sources.
2. Install permanent lighting system and power
from permanent equipment sources or augment
with temporary power.
3. Use portable diesel generator lights - shift
lighting needs or area flood lighting.
4. Consider feasibility of using sites or clients
existing installed lighting system to augment
temporary system or request to use in remote
locations, buildings, or areas.
Temporary 480v Power Board • Utilize permanent duct bank installations (spare
400A 600v Fused Disconnect supplying (5) five raceway’s).
100A Fused Disconnects via a common gutter.
Temporary Power Equipment and Material

Common electrical equipment and material needs

associated with a temporary power system include:

Major Electrical Equipment

• Transformers (various voltages 1∅ and 3∅)

• Load Centers, panelboards, (w/ internals)
• Disconnects (fused/non fused 1∅ and 3∅ )
• Welding leads, clamps, cable, ground
• 480v male/female plugs

Common Low-voltage material

• 50’ SO type cord - multiple conductor 600v

• 600v Power and control cable - single and
multiple conductor
• Gutter, raceway, PVC, flex, condulets, fittings
• Light stringers - “toughskin” bulbs, guard, globe
• 120v Twist-lock plugs - male/female, adapters
• Breakers, fuses, nuetral/ground kits, connectors
480v Temporary Power Board w/ 100A 208- • Luminaires
120v load center via 120/240 transformer • Danger live voltage tags, phasing tape, cable ties
mounted on a common frame. • Receptacles, switches, outlet boxes, connectors

Rev. 0 Electrical Handbook 15-45

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Section 15
SPECIAL SYSTEMS

Common Construction Equipment Typically, only complex mechanical and/or electrical

systems will have both a primary assigned system
Common construction equipment utilized that number (SUS) and an associated sub-system (SUSYS
requires temporary construction power are: start-up system) number when used for sub-defining
portions or sections of the primary mechanical or
480v Equipment electrical system.

• Welding machines (8 banks, single) Example: from the mechanical system scoping
• Stress relief machines (P&ID) drawings. An installed mechanical plant
• Hydrolazers system (i.e. SUS) is Mainsteam (i.e. MS). To further
• Compressors/Generators define this mainsteam mechanical systems
• Large bore pipe bevelers/cutters “boundaries” for a particular operating unit or
• Air Conditioners/Fans building it could be sub-defined by assigning a start-
• Heaters/Blowers up system number (i.e. SUSYS) say MS1A meaning
• Furnaces/Boilers (Mainsteam unit 1, turbine building areas).
• Motors/Pumps/Valves
• Cranes/Hoists Facility items (and/or turnovers) by definition; are
• Construction elevators/Roll-up doors related to the operating plants civil structure(s),
buildings, yard, and any of its associated plant cable
• Fab Shop - sheet metal breaks, punches, presses,
systems are not directly required to support the
table saws
normal or intended operations of the plant. Instead
they are primarily used to augment the overall plant
DC Power
design or to support the clients maintenance or plant
personnel in daily tasks (lighting/communications).
• Batteries
• Torque driven equipment
Facilities (buildings or areas) are normally assigned
• Motors
facility code numbers, sub-defined by room number
or elevation.
PLANT SYSTEMS and FACILITY TURNOVER
Plant System Scoping (Package Turnovers)
By definition; plant systems are a pre-defined series
Any mechanical or electrical plant system that is
of mechanical and/or electrical equipment,
required to support either the sites start-up group or
instruments, components, apparatuses, or integral
clients responsible system representatives are
devices necessary to satisfactorily commission or
“system scoped” (by either group). Scoping
enable an operational plant to successfully perform
identifies system boundaries, parameters, and/or
to its designed intention safely and reliably.
power origination locations. These boundaries and
power origination points are uniquely defined by
To uniquely define all the various plant systems, they
“marked up or highlighted” plant P&ID drawings
are “system scoped” into specific systems or sub-
(commonly referred to as scoping drawings), for
defined into “start-up systems” and turnover
mechanical systems, and by scoping either the
packages. These systems (packages) are by plant
electrical one-line and/or single line-diagrams for
system function, application, group(s), or plant
the electrical power origination points to support the
operational service. Each of these independently
electrical energization systems.
designed mechanical and electrical systems are
integrated together to primarily support the overall
Commonly; these scoped systems are integrated into
operations of the plant while performing segregated
the overall project completion schedules for start-up
plant functions, application or service.
and client turnover dates based on the clients or

Rev. 0 Electrical Handbook 15-46

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Section 15
SPECIAL SYSTEMS

start-ups testing, checkout requirements, system • Equipment connection or wiring diagrams.

energization and/or actual service need date(s). • Schematics or one-line diagrams.
• Design change documentation or “as built”
Eventually, these system turnover schedule dates will documentation.
become the “driving” force of the projects overall • Exceptions to turnover items (work not
completion schedule. completed, material statuses/delivery dates)
• Punch-listed “to go” items
From these scoped P&ID’s and one-line drawings
either the Field Engineer or the designer can than Electrical Plant Systems
subsequently enter into the SETROUTE database
(reference Handbook Section 5) the appropriate Plant systems that are typically, electrically specific
(SUS system number and SUSYS start-up system and generally are the first plant systems that are
number) for the respective cables, raceway’s, required to be “turned over” to start-up or to the
equipment, terminations, and jumpers that applies to client to support plant energization schedules are:
each “scoped” systems equipment and components. • Medium or Hi-Voltage electrical systems (2.4kV
and greater) equipment and cables.
As subsequent system scoping changes, additions, or • Low-voltage Switchgear or MCC’s (480v and
deletions are experienced only the SETROUTE data greater) electrical equipment and cables.
base needs to be updated so an accurate status of the
systems can be “tracked” or defined. Commonly, these electrical systems are scoped to the
line side of the electrical equipment from single or
Start-up system packages are commonly turned over one-line drawings to an electrical energization
with each system either to the start-up group and/or system. Thereby, enabling the load side to be “sub-
the client. These packages typically contain all the scoped” into its appropriate mechanical or electrical
documentation related to that particular system or start-up system. Too, any control related load side
start-up system. Electrical required documentation circuitry is sub-scoped accordingly.
associated with these packages usually contain all or
parts of the following; dependent on site, client, Associated equipment metering or relay circuits and
start-up group, contractual agreements, and compartments, un-related to the load side, are also
responsibility of testing or circuit checks: commonly scoped to the primary electrical system.
• Recorded megger and/or Hi-pot data sheets and
readings. Note: some sites do not accept ∞ Subsequent single or one-line diagrams scoped
(infinity) as an acceptable value. electrical systems line side systems include:
• Motor run-in tests and results, motor data, no- • UPS system (includes batteries) but not
load amp readings. individual branch circuits associated with any
• Equipment rotation direction and records. panelboard(s) these are usually sub-scoped
• Instrument Loop check verification records • DCS/PLC equipment and interrelated
(related commonly with electric motor circuitry) cabling/circuits
instrument loop packages for instruments are • 125vAC and DC distribution equipment
sometimes separate or integrated together. • 480v distribution equipment
• Low-voltage controls circuit tests, checklists, • 24 or 48vAC or DC equipment
and results. • Heat tracing (freeze protection) equipment
• Motor maintenance records. • Cathodic Protection
• Purchase order manuals, diagrams, documents. • Lightning Protection
• Spare parts lists. • Fire Detection (fire protection devices will be
• Scoping drawings. associated with a mechanical system)
• Setroute lists of system included cables. • Communication system cables and devices
• Applicable equipment or cabinet keys.

Rev. 0 Electrical Handbook 15-47

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Section 15
SPECIAL SYSTEMS

Mechanical Systems (Electrical Connected) Freeze Protection Circuits

The preponderance of systems scoped and associated Typically, the load side of the individual branch
most commonly with industrial construction sites are heating circuit (inclusive of tracing) is system scoped
mechanical systems. These mechanical systems; to the mechanical system that the process pipe,
scoped from plant P&ID’s, will include instruments, equipment, vessel, instrument, or tank is assigned
DCS/PLC components, and devices. From these too.
scoped drawings all associated electrical and
instrumentation cables, terminations, jumpers, and System Construction Completion and Walkdown
equipment will be subsequently scoped to their
respective mechanical system or start-up system. The Field Engineer should perform periodic system
walkdowns prior to the system being considered
Generally mechanical systems are derivatives of: “construction complete”. An initial walkdown
• Piping systems relative to the operation or should be performed approximately six (6) weeks
specific design function of the plant. prior to the assigned scheduled system construction
• HVAC related. completion turnover date. A comprehensive formal
• Vessel, boiler, or vendor provided mechanical or informal written “punchlist” of incompleted work
equipment and/or piping systems related. activities associated with the system should be
generated at this time and presented to the applicable
Raceway System Scoping and Reports craft supervisor(s) apprising them of what is required
to satisfactorily complete that system. This
Raceways, inclusive of trays, get assigned a system comprehensive system/start-up system “punchlist”
number also. This is accomplished simply and should include as a minimum:
efficiently by assigning the raceway to a cable system
that is scheduled to be turned over at the “earliest” • Incompleted raceway’s, equipment, cables,
date. This then requires that individual raceway/tray terminations “to go” or required to be installed.
to be installed to support that early scheduled system • Grounding items required to support the system.
turnover. SETROUTE’s database is capable of • Outstanding design issues that are unresolved or
automatically performing this function and only require response, action, or completion.
requires the cable to be assigned a system/start-up • Devices or components needing repair, rework,
system number from the scoping drawings. or replacement due to being damaged or
missing.
To support supervision in meeting system turnover • Equipment or device legend plates or labels not
installation schedule dates the Field Engineer needs present or containing incorrect information.
only to “issue” reports to supervision by system/start- • Outstanding material deliveries and dates
up system by commodity (e.g. raceway/equipment/or inclusive of “purchase order number”.
cable). • Inspections, tests, data records not completed.
• Identify instruments, electrically connected
Grounding components, and devices that are not installed.
• Vendor or subcontractor related material issues,
Grounding is considered associated with any plant warranties, open backcharges, or work concerns.
system via its scoped or associated equipment
(grounding is not scoped). It is required to be A subsequent walkdown should be performed by the
installed, prior to the system turnover, and must Field Engineer two (2) weeks prior to the scheduled
provide a “ground-fault return path” and have an system construction completion turnover date re-
effective “equipment ground”. evaluating outstanding concerns, issues, construction
work activities and formally documenting these
incompleted activities on a system punchlisted form.

Rev. 0 Electrical Handbook 15-48

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Section 15
SPECIAL SYSTEMS

These outstanding system punchlist items can than • Facility system cables are not generally scoped
be utilized for system meeting discussion, review, to P&ID’s. If, they are, they are denoted with a
and/or to apprise all interested system participants of system number than affiliated with a facility
where the system stands with respect to electrical turnover number. Common examples could
construction completeness. include:
1. Plumbing devices (electrically connected)
Prior to the system construction completion turnover 2. Sewage Treatment/Disposal pumps/panels
date the Field Engineer may be requested to attend 3. Waste Water Treatment components
(mechanical systems) or perform a system walkdown 4. Storm floors and drains (alarm devices)
(electrical systems) with start-up, and/or with the 5. Emergency eye-wash stations (alarms)
clients system engineer(s), operations, maintenance,
safety personnel, and/or with the designers to review • Facility system cables and components are
for plant concerns, construction completeness, mostly associated with civil, architectural, or
system familiarity, and for design issues. Identified structural buildings or areas and commonly are:
items, concerns, and issues are noted and added to 1. Elevators
the existing issued punchlisted system. 2. Roll-up doors
3. Cranes/Hoists
System Cable Delineation 4. Electric fences, gates
5. Fire Detection (not associated with the plant fire
A rule of thumb used on scoping branch circuited protection piping system)
wiring or cables to individual or multiple devices or 6. Roadway lighting
instruments is to scope the cable/wiring to the 7. General or emergency plant lighting
applicable cables “to end” and scope the cable to the 8. Plant communications (telephone, paging, etc.)
“earliest” assigned devices system turnover date and 9. General receptacles or area outlets
identify the additional devices system against the 10. Plant 480v welding outlets
cable in SETROUTE in event schedule turnover
dates change. Facility Completion Activities

Associated primarily with facility completion and

FACILITY SCOPING turnover are the electrical work activities un-related
to facility system cables. These electrical work
Akin to system scoping except, general plant layout activities include the final completion or walkdown
drawings are used defining facility turnover items to punchlist for:
boundaries and numbers. Some plant system cables
can be assigned a system number but, are “turned • General plant grounding - equipment, building,
over” with a facility, floor, room or an area (referred grid, miscellaneous steel/column grounds.
to as facility system cable). Scoped facility system • Supports all raceway and trays - approved,
cables also utilize one-line diagrams identified with properly constructed, in compliance, grouted,
a facility turnover number. material type, protective coating, installed.
• Support bolting and hardware - proper bolt
Facility vs. Systems engagement, threads, torque, size, type, material
compatibility, washers, nuts, missing, damaged.
Consistent with most construction projects is the • Raceway conduit - lubricated, not in contact or
question of delineation between what is a facility conflicts with thermal expansion piping, flex not
scoped cable or component versus what is a scoped damaged, flex length adequate, expansion joints
plant system cable or component? Delineation installed, properly grounded, properly spaced or
between facility and plant systems generally follow separated, adequately supported, labeled.
these basic guidelines.

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Section 15
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• Raceway (conduit fittings) - gasketed and • Start-up personnel are commonly not involved
covered, screws aren’t missing, flex connectors with facility walkdowns or turnover activities.
secured, drain plugs installed. • Perform and record lighting illumination and
• Boxes - grounded, supported, labeled, rated for circuitry verification.
area/location, missing screws/cover, openings • Ensure plant communication systems was tested
sealed, interior debris cleaned out. and is operable.
• Trays - cable edge guard, tray covers, barriers • Perform and record grounding resistance or ohm
installed, labeled, grounded, supported, cables checks that may be required.
tied down, debris cleaned out, cable fill • Walkdown items should also identify:
acceptable, expansion plates installed. 1. ADA (American Disabilities Act) concerns.
• Seals (tray, raceway, equipment) - fire, tray, 2. Clients Safety, Health, Fire and egress concerns.
environmental, smoke, hazardous classified 3. Equipment load path or maintenance concerns.
completed and rated for the purpose. 4. OSHA violations or concerns.
• Housekeeping - general area, internal cabinets, 5. Housekeeping concerns.
false floors, internal panels and equipment free 6. System turnover items not previously identified.
from debris. 7. Safety Tagging or Locks are transferred to
• Temporary power - de-energized and removed. start-up or client personnel and are no longer
• Openings, sleeves, stub ups - grouted, sealed, under site constructions jurisdiction.
plugged, capped.
• Duct Banks - manhole covers are set to grade,
grounded, sealed, pumped out, labeled. Facility Turnover Packages
• Equipment - panel schedules are updated, panel
branch circuit breakers and remote devices are Documentation similar to plant system turnover
labeled, drain seals, trim, and covers are packages with one notable difference:
installed, holes sealed, touch-up painting • “As builted” raceway layout (communications,
completed, labeled. grounding, lighting, general raceway) and plant
• Lighting - bulbs aren’t burnt out, fixtures, layout equipment drawings may be required to
circuits, refractors, globes and guards, switches, be “turned over” to the client.
receptacles, photocells are installed, supported,
egress fixtures visible, lights are not in conflict Construction Activities on Turned Over Systems
with thermal expansion piping or are blocked,
inaccessable. Once cables and equipment are turned over, either to
• Communications - devices installed, adjusted start-up or the client, the rules of the game change
for amplification and angle, supported. drammatically. Typically; the way construction
• Fire Detection - devices installed, wall alarms activities are performed to support or complete
visible or audible, painted “red” (identifiable). punchlisted system or facility work, design changes,
or warranty issues are site specific or more
Facility Turnover Schedule and Walkdowns commonly by client preference as to how work may
proceed. Consistent to most industrial sites are these
Treated the same as plant systems, whereby the Field basic guidelines in the performance of construction
Engineer should perform the requisite facility “to work on turned over systems or facilities:
go” work walkdowns, generate facility punchlists,
and perform (or attend) a walkdown with the clients Energized turned over cables or equipment:
representatives. The Field Engineer’s facility “to
go” walkdown should be similar to the system • Utilize clients Tagging and Lockout Safety
walkdown with these notable differences: Procedure or Programs to “take any
equipment or systems out of service”.

Rev. 0 Electrical Handbook 15-50

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Section 15
SPECIAL SYSTEMS

• Require plant operations and/or maintenance

personnels notification, authorization, and a
direct interaction or interface with these
individuals is normal and expected.
• Descriptive reason of what work is required to
be accomplished, individuals involved, and a
duration of time to complete task may be asked.
• Utilize established plant permits, key control or
room access policies, utilize existing or
established plant procedures, safety program,
sites inspection (or inspector) guidelines.
• Personnel protective clothing, tool and material
control progams must be followed.
• Documentation, drawings, test or inspection
records, procedures, and effects to plant
operation conditions while performing work
must be made known or available to craft
personnel.
• Maintain a “professional” attitude and
remember your actions reflect the company
not just yourself.

Rev. 0 Electrical Handbook 15-51

 Bechtel Corporation 1997. 11/26/97