ENGINEERING

ELECTRICALSTANDARDS
STANDARDS
JULY 2014
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 Electrical Standards

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Section 3 Electrical Standards
Electrical standards apply to the installation of all major electrical equipment and sensors on site. Including the
provision of electrical power from the local utility to plant and machinery, i.e. Electrical Panels and motors.

EE_EL_01 General Electrical Specification 2

EE_EL_02 Electrical Induction Motors 20
EE_EL_03 Electrical Components of Packaged Equipment 24
EE_EL_04 MCC Specification 30
EE_EL_05 Variable Speed Drive Specification 35
EE_EL_06 nstrument Tube and Fittings 45
EE_EL_07 Instrument and Protective Devices for Packaged Equipment 48
EE_EL_08 Instrument Cable and Gland Specification 58
EE_EL_09 Supply of Process Control Systems 65
EE_EL_10 Specifications for Electronic Access Control Systems 86
EE_EL_11 Fire Detection, Alarm & Suppression Systems 89
EE_EL_12 Specifications for Closed Circuit Television (CCTV) 97
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General Electrical Specification

1. Scope
1.1 This specification covers the requirements for the supply, installation and testing of electrical equipment
and materials within Diageo Beer OpEx sites.
1.2 The products works or services to be procured are described in the technical specifications and drawings
and have been formulated by reference to European standards, European technical approvals, common
technical specifications, international standards or, where these do not exist, national standards or
national technical approvals, as appropriate. Notwithstanding the foregoing, equivalent standards and
specifications are acceptable. Where the technical specifications are formulated in terms of performance
or functional requirements, the tenderer must comply with these requirements.
1.3 Where the technical specifications and drawings, where necessary, are formulated by reference to
detailed descriptions, proposals by the tenderer will not be rejected on the grounds that the products
works or services do not comply with the technical specifications and drawings, provided the tenderer can
show, by an appropriate means, that his proposals satisfy in an equivalent manner, the requirements
defined by the technical specifications and drawings. Where trade names / product names may be used,
if any, in describing the products works or services to be procured, these are used as information only for
the purpose of more fully describing the specification and drawing requirements. In relation to all
descriptions and references used for products works or services to be procured, equivalent products
works or services are acceptable, except in such instances, if any, where equivalent products works or
services would be incompatible with existing equipment already in use or would entail disproportionate
cost or technical difficulty, in which instances, the particular products works or services shall be identified
in the technical specifications and drawings as being mandatory.
1.4 It shall be the Contractor’s responsibility to provide a completely safe and workable installation in
accordance with the requirements of this specification, the Particular Electrical Installation Specification,
Construction Drawings, Datasheets and Schedules, all to the entire satisfaction of the Engineer.
1.5 All electrical equipment, materials and parts used, shall be new and unused, of current manufacture, of
the highest quality and free from defects or imperfections. All electrical equipment installed outdoors shall
be weather-proof and corrosion resistant.
1.6 The Contractor shall protect all electrical equipment, materials and parts during storage and during
construction against the ingress of moisture, contamination or corrosion.
1.7 The Contractor shall be responsible for checking and co-ordinating the electrical installation with all other
services disciplines prior to the commencement of each section of the work.
1.8 Copies of the detailed electrical specifications for the equipment to be free-issued to the Contractor will
be provided to the Contractor.
1.9 Unless indicated otherwise in the Particular Electrical Installation Specification the Contractor will be
responsible for taking delivery, off-loading, handling, installing in final location, supporting, fixing, levelling,
protecting, assembling, connecting, testing, commissioning and setting to work all free-issue equipment
to the satisfaction of the Engineer.
1.10 The Contractor shall visit the site prior to tendering to familiarise himself with all aspects of work, as
claims for unforeseen work shall not be entertained by the Engineer.
1.11 The Contractor shall include for marking of openings, chases etc. including the preparation of builder’s
work drawings, and co-ordination drawings.

2. Standards and Codes

2.1 The entire installation shall be completed in accordance with the following regulations:-
2.1.1 The “Requirements for Electrical Installations”, BS 7671, 2008 (IEE Wiring Regulations
seventeenth Edition) where such regulations are not in variance with or included in ETCI
rules).
2.1.2 IEC 60079, 2007 (All Parts) Specification and Installation of Electrical apparatus for explosive
gas atmospheres.
2.1.3 61241(All Parts): Electrical apparatus for use in the presence of combustible dusts.

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2.1.4 EU Directive 94/9/EC (Atex100a) equipment and protective systems intended for use in
potentially explosive atmospheres.
2.1.5 I.S.3217 “Code of Practice for Emergency Lighting “
2.1.6 I.S.3218 “Code of Practice Fire Detection and Alarm Systems for Buildings Systems Design,
Installation and Servicing”.
2.1.7 EN 60598, 2006 (All Parts) - Luminaires general and particular requirements
2.1.8 EN 61557, 2008 (All Parts) - Electrical safety in low voltage distribution systems up to 1000 V
ac. and
1500 V dc.
2.1.9 BS 729:1971 Specification for hot dip galvanized coatings on iron and steel articles.
2.2 The entire installation shall be fully compliant with the following EU directives:
2.2.1 EMC Directive (89/336/EEC).
2.2.2 L.V. Directive (73/23/EEC).
2.2.3 Machinery Directive (98/37/EC).
2.2.4 EU Directive 94/9/EC (Atex100a) equipment and protective systems intended for use in
potentially
explosive atmospheres.
2.3 All equipment supplied or employed to complete the electrical installation shall conform to the
requirements of the latest editions of the relevant European CENELEC Standard, British Standard
Specifications and IEC Standards as applicable.
2.4 The entire installation and all components used shall be to the satisfaction of the National Authority for
Occupational Health & Safety (Health & Safety Authority).
2.5 In the event of a discrepancy between the above codes and standards the ETCI version shall be followed.
In any case of conflict or uncertainty in the application of the above refer to the Engineer for clarification.
2.6 Generally recognised Good Engineering Practices shall be adhered to at all times during the installation.

3. LV Wiring And Cable Installation Systems

3.1 Cables shall be fully detailed on the particular specifications, cable schedules, single line diagrams,
panelboard schedules and the drawings.
3.2 All cables shall be new and unused and shall be delivered to site with manufacturer’s seals, labels or
other proof of origin intact. Identification trademarks (cable type, insulation level, conductor size, etc.)
shall be embossed or indelibly printed on the surface of the PVC sheathing of the cables.
3.3 In general the wiring and cabling shall conform with the following:
3.3.1 Single Core PVC: Single core non-sheathed cable with plain annealed copper stranded
circular conductor and PVC insulation rated to 450/750V. These cables shall comply with
IS201: 2001. The cables shall be installed in totally enclosed conduit or trunking systems.
Cu/PVC
3.3.2 Single Core LSF: Single core non-sheathed cable with plain annealed copper stranded
circular conductor and non-sheathed thermosetting low smoke and fume insulation rated to
450/750V. These cables shall comply with IS276: 1994. The cables shall be installed in totally
enclosed conduit or trunking systems. Cu/LSF
3.3.3 Single Core Armoured Cu/XLPE/PVC/AWA/PVC: Voltage rating of 600/1000 V constructed as
follows: Stranded copper conductor, cross-linked polyethylene (XLPE) Insulation, extruded
PVC bedding, aluminium wire armour, and extruded PVC oversheath. The cables shall
conform to BS5467. The cables shall be rated for a maximum conductor operating
temperature of 90 deg. C.
3.3.4 Single Core Armoured Cu/XLPE/LSF/AWA/LSF: Voltage rating of 600/1000 V constructed as
follows: Stranded copper conductor, cross-linked polyethylene (XLPE) Insulation, extruded
LSF bedding, aluminium wire armour, and extruded LSF oversheath. The cables shall conform
to BS 6724. The cables shall be rated for a maximum conductor operating temperature of 90
deg. C.

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3.3.5 Multi-Core Armoured Cu/XLPE/PVC/SWA/PVC voltage rating of 600/1000 V constructed as

follows: Stranded copper conductor, cross-linked polyethylene (XLPE) insulation, extruded
PVC bedding, galvanised steel wire armour, and extruded PVC oversheath. The cables shall
conform to IS273 or BS5467. The cables shall be rated for a maximum conductor operating
temperature of 90 deg. C.
3.3.6 Multi-Core Armoured Cu/XLPE/LSF/SWA/LSF voltage rating of 600/1000 V constructed as
follows: Stranded copper conductor, cross-linked polyethylene (XLPE) insulation, extruded
LSF bedding, galvanised steel wire armour, and extruded LSF oversheath. The cables shall
conform to BS 6724. The cables shall be rated for a maximum conductor operating
temperature of 90 deg. C.
3.4 Any other types of cables not described above but specified in drawings, schedule or particular
installation specification shall meet the relevant IEC codes and the approved by the engineer.

3.5 Only cables and flexible cords permitted by the ETCI, National Rules for Electrical Installations may be
installed. They shall be in accordance with the latest Irish Standards and shall carry the Irish Mark of
Electrical Conformity (IMEC).
3.6 The outersheath shall be embossed with the manufacturer's name, year of manufacture, voltage rating,
insulation, number of conductors and cross sectional area, at two metre intervals along the length of the
cable.
3.7 Cables feeding items of plant and equipment are described in the electrical cable schedules or on the
drawings. In all cases cable installations shall be suitable for the hazard classification as indicated on the
area classification drawings or panelboard schedules.
3.8 Cables are described in the electrical cable schedules or on the drawings. In general, cables to electrical
services (lighting, small power, FA etc.) may not be detailed on the cable schedule, but described on
drawings.
3.9 All cables shall be installed generally along the routes and in the manner indicated on the drawings and
in accordance with the notes and instructions thereon.
Notwithstanding the above requirement, all cable routes shall be approved by the engineer before any
work is commenced.
3.10 All cables shall run directly from point to point without joints. No cable joints shall be permitted. However,
if certain installation demands cable joints, a specific approval from the Engineer shall be obtained in
writing. In such a case, the engineer shall approve the position of each and every joint.
3.11 Where cables are run on tray/rack, cable ties and cleats/clamps shall be used at intervals as follows :
Maximum Spacing of Clips/Cleats/Tie-Wraps

Non-armoured Cable Armoured cable

Overall Diameter of
Cable Horizontal
Vertical Horizontal Vertical

mm mm mm mm mm

<=9 250 400 - -

>9 <=15 300 400 350 450

>15 <=20 350 450 400 550

>20 <=40 400 550 450 600

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3.12 All single wire armoured, multicore cables 70 sq. mm and larger, shall be fixed to ladder rack/tray using
cable cleats. All single core power cables shall be laid in trefoil groups and fixed to ladder rack using
cable cleats. Cleats shall be of BICC manufacture, type 370BA/376AB, or equivalent, as appropriate.
3.13 For multicore cables 50 [Link] and below, heavy duty nylon 66 tie-wraps as manufactured by BICC, type
BB120S, or equivalent, shall be used. Tie-wraps shall be suitable for outdoor use and shall be resistant to
ultraviolet light.
3.14 Where a cable is indicated on the drawings to be clipped to steelwork the Contractor shall use “HIT”
Spring Steel Clips “BCCT” series, of “Emlux Holdings Ltd” manufacture or equal and approved. Steelwork
shall not be drilled unless approval is obtained from the Engineer.
3.15 Cables clipped to steelwork or to structures shall be supported at intervals in accordance with Annex
52B-2 of the National Rules for Electrical Installations ET101.
3.16 The minimum internal radius for any cable bend shall be in accordance with Annex 52B-1 of the National
Rules for Electrical Installations ET101.
3.17 All SWA power cables shall have a separate earth cable (yellow/green). The size of this conductor shall
be as follows :
S ≤ 10 mm2 - 10
10 < S < 16 mm2 - S
16 < S ≤ 35 mm2 - 16
S > 35 - S/2
Where S = CSA of conductor
3.18 The minimum internal radius for any cable bend shall be 8 x cable diameter or as stated by the
manufacturer if greater.
3.19 All cables shall be identified by means of non-deteriorating type cable tags, strap on type.
3.20 Cables shall be grouped to follow routes as indicated on the layout drawings.
3.21 The minimum sizes of cables are as follows:
Power 2.5mm2
Control 1.5mm2
Lighting 2.5mm2
3.22 Colour coding of cable cores and internal wires shall be as follows:

Power:
Phase 1 Brown
Phase 2 Black
Phase 3 Grey
Neutral Blue
Earth Green/Yellow
Control
110V AC Live Brown
Neutral Blue
DC Positive Brown
DC Earthed Negative Blue
DC Earthed Positive Blue
DC Negative Grey
DC Positive Brown
DC Negative Grey
DC Earthed Mid Wire Blue

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3.23 Control cable cores shall be identified by a number printed in black ink on white PVC insulation.
3.24 Cables shall be purchased with the colour codes identified correctly. Sleeving shall not be used to identify
cable cores.
3.25 Cables passing through floors or other positions where they are liable to mechanical damage, shall be
protected up to 300mm above floor level. Cables passing through cladding shall be run in Conduit.
3.26 In the case of supplies from VSDs, the contractor shall ensure that the continuity of the protective
conductor and the screen are maintained throughout.
3.27 Fire resistant cables shall only have glands approved by the cable manufacturer used with these cables
and approved by the engineer. The glands shall be installed in accordance with manufacturer’s
instructions.
3.28 All “Unistrut” used to support cables and protect cables shall be provided with pre-galvanised steel snap-
in cover strip (lid). The “Unistrut” shall be hot dipped galvanised.
3.29 LSF insulated single core cables shall run in conduit and/or trunking. Wiring shall be loop-in style without
joints.
3.30 Cables passing through floors or other positions where they are liable to mechanical damage shall be
protected up to 300mm above floor level by installing cable in GI conduits.
3.31 Where no cable ladder rack or tray is provided for cables dropping from high level, the cables shall
generally be installed in either galvanised or stainless steel cable containment as per the typical
installation details.
3.32 Unless otherwise specified, all materials, supports, fixings, attachments and other items associated with
the installation of cables, together with all of the work involved, shall be provided by the Contractor
whether or not specifically mentioned in this Specification.
3.33 It shall be the responsibility of the contractor to protect the cables, even after installation, from
mechanical damage to the satisfaction of the engineer till the total construction phase of the area is
complete and is handed over to the purchaser. If cables are damaged during this phase before hand over,
the contractor shall replace the cables at his own expense.

4. Cable Terminations
4.1 When terminating to equipment that may require removal or replacement as part of on-going
maintenance, SWA cable should be run to a local isolator and SILFLEX used to connect to the equipment.
4.2 Glands shall be made of brass and comply with BS6121 and EN50262 and in the case of glands used in
Hazardous Areas have ATEX certification. Glanding of cables shall comply with manufacturer instructions.
Use the correct size metric cable glands. Use adapters only with prior approval by the Buyer.
4.3 Terminate armoured cables with compression brass gland fittings, type E1W in non-hazardous areas and
type EIWF in hazardous areas per BS6121. Use LSF shrouds and brass earth tags with cable glands.
Glands, earth tags and shrouds shall be Hawke Cable Gland Limited OR CMP manufacture or equal
AND as approved by the Buyer. PCP shrouds may be used for non-LSF cables.
4.4 Mineral insulated copper sheathed cables with copper conductors shall be fitted with glands approved by
the cable manufacturer, and the glands shall be installed in accordance with manufacturer’s instructions.
Glands shall be RGM type with screw-on seal type RPS, of “BICC” manufacture, or equivalent.
4.5 Terminate unarmoured cables in brass type A1/A2 gland fittings per BS6121.
4.6 Glands shall have ISO, R68 series thread, 1.5mm constant pitch. Use brass adapters for threads other
than ISO.
4.7 Earth the case of glands for armoured cables, the brass armour-earthing ring shall be incorporated in the
gland. This earthing ring shall be connected to the earth bar or earth point by means of earthing cables.
4.8 All non-metallic enclosures are to be glanded with an internal locknut and earth tag. This shall be
connected to all metal parts within the enclosure to maintain earth continuity.
4.9 The inner sheath of all cables shall not be removed until it is necessary to spread or loom the cable cores
for termination. The maximum amount of inner sheath shall be retained in all circumstances and at least
20mm shall be retained clear of the cable glands in the worst cases.

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4.10 The cable conductors shall not be subjected to undue pressure or sharp bending during termination. All
conductors shall be fitted with crimp type terminal lugs of “BICC / Burndy” manufacture, or equal and
approved unless indicated otherwise.
4.11 All cable lugs shall be supplied and installed by the Contractor, strictly in accordance with the
manufacturer’s instructions and using the manufacturer’s recommended crimping dies and compression
tools.
4.12 All cables shall be adequately supported and clipped to within 200mm of the cable glands at both ends.
4.13 All cables shall be identified by means of non-deteriorating, strap-on type cable tags, fitted on each
termination point.

5. Underground Cable Installation

5.1 Underground cables shall be laid direct in the ground or drawn into pipe ducts as indicated on the
drawings.
5.2 Unless otherwise specified all underground electrical cables shall be installed in underground cable ducts
except earthing cables which shall be directly buried.
5.3 The underground cable ducts, drawpits, draw wires, trenching etc. shall be installed by others.
5.4 The contractor shall supply a tripod and all other PPE which may be required for underground cable
installation.
5.5 The contractor shall ensure that all cables in one duct as indicated on drawings are pulled one at a time
using the draw wires installed in ducts. Maximum care shall be taken to ensure that cables are not
damaged while drawing through ducts.

6. Cable Ladder Rack and Tray Systems

6.1 Cable containment shall be either hot dip galvanized or stainless steel as noted on the drawings.
6.1.1 Hot dip galvanized cable containment shall be hot dip galvanized after manufacture to
ENISO1461/ASTM A123M/BS129.
6.1.2 Stainless steel cable containment shall be 316L stainless steel to EN1008- 2.
6.2 All cable trays shall be mounted in the vertical plane to minimise the accumulation of dust and debris. A
distance of at least 25mm shall be maintained between the back of the tray and the wall. Tray support
brackets of galvanised P1000 Unistrut shall be used for dry areas and stainless steel for wet areas,
spaced at 1200mm intervals for the support of the cable tray. Brackets to extend the full width of the tray.
Where purpose made brackets are used, these shall be slot blasted and treated with 2 coats of cold
galvaniser.
6.3 Only manufacturer’s bends, reducers, tee pieces and accessories shall be used in conjunction with cable
tray, except where the tray may be neatly formed by corrugation of the flange.
6.4 Cable drops to equipment shall be rigidly supported using cable rack/tray or “Unistrut”, or equivalent, or
sleeved in conduit and fixed to plant/pipework support steelwork or walls. Refer to standard installation
details. The cable drops shall be 316L stainless steel where specified on drawings.

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6.5 The minimum external wall heights for various types of cable trays and ladders shall be as specified in
the following tables unless otherwise specified in Particular Installation specification or on drawings:
6.5.1 Heavy Duty Cable Ladder

Width Height
1200 110
900 110
600 110
300 110
150 110

6.5.2 Heavy Duty Cable Tray

Width Height

300 50
150 50
75 50

6.6 The maximum spacing between rungs (for cable ladders) shall not be more than 400mm.
6.7 Cable tray or cable ladder shall be adequately sized to house the cables with at least 30% spare capacity.
Sizes are specified on the drawings.
6.8 Where possible, at least 300mm working space shall be reserved between stacked racks/trays and
above the top rack/tray to facilitate cable installation. The minimum allowable distance shall be 250mm to
provide adequate ventilation of loaded cables.
6.9 Manufacturers‟ standard bends, tees and accessories shall be used throughout the installation. Only
where these are inadequate to meet special local conditions will fabricated fittings be accepted subject to
the approval of the Engineer.
6.10 Tray and ladder supports shall be spaced at regular intervals as recommended by the manufacturer but
not more than 1500 mm unless otherwise specified. Supports shall be means of P1000 Unistrut standoff
and fixings to the fabric of the building.
6.11 Where cable tray is slotted for cabling purposes, all cut edges shall be protected by the manufacturer’s
approved method. Damage to the galvanised finish, and cuts made on site, shall be protected by 2 coats
of cold galvaniser as soon as practicable after installation.
6.12 Cable tray of minimum size 100mm shall be used in all locations where 2 or more SWA cables follow the
same route. Separate cable tray to be installed for power and control/instrumentation cables. Cable tray
shall not be used for the support of cables exceeding 4 x 25sqmm. There cables shall be run on ladder or
cleated with approval by the Engineer.
6.13 Cable rack used for routing cables should have good electrical bonding between components. This shall
be achieved by use of an earth bond at joints along the complete run of racking.
6.14 All cable trays and ladder installed externally shall be provided with manufacturer’s standard covers
unless otherwise specified.
6.15 Separation between cable trays/ladders of different services shall be strictly as indicated on drawings or
specified in the particular installation specification.

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7. Conduit And Trunking Systems

7.1 Conduit and conduit fittings shall be heavy duty, welded, screwed type to BS4568, Parts 1 and 2, Class 4
unless otherwise noted. The protective coating on conduit and associated fittings shall be hot dipped
galvanised inside and out. Care shall be taken to make watertight all screwed joints by means of a
metallic paint.
7.2 Screws used shall be of brass or cadmium plated steel of the correct length and without excessive
projection.
7.3 No conduit having an outside diameter of less than 20mm shall be used.
7.4 Inspection and non-inspection type elbows, bends or tees shall not be used. A draw-in box shall be
provided in all conduit runs exceeding 15m in length or containing more than two right - angle bends.
7.5 Conduit boxes, both standard and adaptable, shall be fixed to the structure or the building independently
of the conduit.
7.6 Where conduit is exposed to different air temperatures e.g. if a conduit is run outside a heated building,
the section of the conduit at the higher temperature shall be isolated from the section at the lower
temperature by means of a conduit box filled with approved plastic compound.
7.7 Conduit shall be secured to apparatus by means of a hexagon male smooth brass bush and brass
compression washer screwed from the inside of the apparatus into the conduit to make a tight joint.
7.8 The length of thread on the ends of the conduit shall suit the length of internal thread in the end of the
fitting or accessory. Excess length of thread will not be permitted.
7.9 No burr shall be left on the conduit ends after cutting and screwing. All joints in an assembly of conduit
shall be treated with cold galvaniser.
7.10 Runs terminating flexible conduit shall be fitted with special adaptors in accordance with the
manufacturer’s recommendations to ensure a waterproof connection. Flexible conduit shall not be relied
on as the sole means of earth continuity and a separate earth cable shall be run inside the conduit or
wrapped externally.
7.11 Where conduit and trunking passes through fire break walls, it shall be fire stopped using the
manufacturers proprietary materials.
7.12 The wiring capacity of conduits shall be as indicated in Annex 52A of the National Rules for Electrical
Installations, 3rd Edition.
7.13 Conduit shall be supported at regular intervals not exceeding 1200mm on horizontal and vertical runs, for
surface work, all metallic conduits through the building shall be fixed by spacer bar saddles to give not
less then 6.25mm clearance between conduit and face of structure.
7.14 Particular attention shall be paid to the continuity of all conduit etc. The impedance between any point in
the installation and the earth terminal on the main switchboard shall not exceed 0.5 ohms.
7.15 Conduits shall be adequately ventilated and provided with drain holes at the lowest point in each conduit
run. The length of thread on the ends of conduit shall suit length of internal thread in the fitting or
accessory. Excess length of thread on the conduit shall not be permitted. Where running couplings are
unavoidable, the exposed threads and any damaged portion of the protective coating shall be effectively
rust proofed by the application of 2 coats of cold galvaniser as soon as possible after installation.
7.16 Conduit shall normally be installed on the surface, unless otherwise specified, and shall be spaced away
from the walls, etc., by means of distance saddles, so as to prevent the accumulation of dust or moisture.
The saddles shall not be more than 1,200mm apart. Only galvanised case iron distance saddles shall be
used for supporting conduit in dry areas & stainless steel in wet areas. Conduit boxes shall be of the
raised back type with spouts lineable with the conduit saddles providing a clearance of approximately
6mm between the back of the conduit and wall face.
7.17 Cable trunking shall be installed as per the drawings.
7.18 Cable Trunking shall be supported at regular intervals not exceeding 1200mm on horizontal and vertical
runs.
7.19 Cable trunking shall only be used indoors.
7.20 Cable trunking and fittings shall have removable lids extending over their entire lengths. The lids shall be
of the same material and finish as that of the trunking.
7.21 Metal partitions in trunking and fittings shall be provided as required by the IEE Wiring Regulations. They
shall be of the same material and finish as those of the trunking.

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7.22 Cable trunking shall be run neatly on the surface or suspended as indicated on the drawings and the
specifications. Runs shall be truly vertical, horizontal or parallel with the features of the building.
7.23 Cable trunking shall be supported at regular intervals not exceeding 1750mm on horizontal and 2000mm
on vertical runs.
7.24 Manufacturer’s standard fittings shall be used. Only where these are inadequate to meet special local
situations will the fabricated fittings be accepted subject to approval by the Engineer.
7.25 Where special fittings or sections of trunking are fabricated, they shall be prepared and finished to the
same standard as manufacturer’s standard items.
7.26 Standard manufacturer’s couplings shall be used to terminate trunking at points where it is desired to
connect one section of trunking to another.
7.27 Connections between trunking and apparatus shall be by a screwed conduit coupler, bush and locknut or
a standard flanged coupling. Direct attachment of trunking to apparatus will only be permitted if cable
entries are provided with bushings and the return edge of the lid of the trunking is left intact.
7.28 The wiring capacity of trunking shall conform to local standards and legislation
7.29 Inspection points, elbows and tees shall not be used. Standard galvanised conduit boxes of a suitable
type shall be used wherever drawing in or inspection points are required in dry areas and stainless steel
in wet areas. All conduit boxes to be independently secured.
7.30 A substantial metal box shall be provided wherever a conduit terminates.
7.31 All bends in conduit shall be made on site by means of a standard bending machine. Factory made
bends and pressed steel boxes of all types shall not be employed without the prior approval of the
Engineer.
7.32 Compression type connections, installed in accordance with the manufacturers’ instructions shall be used
for the termination of all cables unless otherwise specified.

8. Isolators
8.1 All motors shall be provided with on-load isolators, which are lockable in the off position and protected to
IP65. These isolators shall be provided with an early opening switch for opening the control circuit or
alternatively a switch in an extra low voltage segregated compartment to enable the control system to
monitor the isolator position.
8.2 Details of the isolators shall be scheduled in the design drawings.

9. Panelboards
9.1 Lighting and distribution panelboards shall be provided as indicated on the drawings. They shall be
surface mounted type, fitted with hinged front door and shall enclose all equipment, circuit breakers,
isolators, residual current devices etc., all suitably shrouded for safe working conditions.
9.2 The Panelboard shall be Form 2 as per IEC 60439-1.
9.3 The feeder cable to the incomer shall be connected through a three-pole (unless indicated otherwise)
MCCB to EN 60947-3. The switch shall have provision for padlocking in the “Off” position. The current
rating shall be as indicated on the Distribution Boards schedule or drawing.
9.4 Residual current devices (RCDs) shall conform to IEC 61009.
9.5 Residual current devices (RCBOs / RCDs) shall be differential type with a tripping fault current not
exceeding 30mA. They shall be supplied for all circuits supplying socket outlets and heat tracing circuits.
In each case a separate RCBO/RCD shall be supplied for each circuit.
9.6 MCBs shall be rated for use as switches and shall conform to EN 60898, and EN 60947 as appropriate
and have a short-circuit fault rating greater than the perspective short circuit fault current value as given
on the associated distribution board schedule or drawing.

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9.7 MCBs shall be selected as follows:

9.7.1 Type B: General circuits with a moderate inrush such as controls
9.7.2 Type C: Fluorescent lighting, battery chargers, socket circuits.
9.7.3 Type K: Motors (To IEC60947-2)
9.7.4 Type D: Circuits with high inrush currents such as transformers, solenoid valves, capacitors,
voltage transformers and semiconductor devices
9.8 Circuit breakers shall be rated for use as switches and shall conform to IEC 60947-2.
9.9 Residual current devices (RCDs) shall be differential type with a tripping fault current not exceeding
30mA. They shall be supplied for all circuits supplying socket outlets and heat tracing circuits. In each
case a separate RCD shall be supplied for each circuit.
9.10 All panelboards shall be suitable for continuous operation. The insulation level of the boards shall be
1000 volts and the fault level shall be adequate to withstand the maximum fault conditions at the part of
the system where they are installed.
9.11 Neoprene gaskets shall be provided for doors / detachable covers, gland plates etc.
9.12 All panelboard doors shall be fitted with recessed hinges and combination catch and lock suitable for one
common key operation. If the door is divided in such a manner that it gives access to operate circuit
breakers only the remaining section of the door shall act as a safety barrier. The safety barrier shall be
removable only by the use of a tool or special key.
9.13 All distribution boards shall be suitable for top cable entry unless otherwise specified in the
schedules/single lines. Distribution boards shall be fitted with header trunking of adequate size to allow
for incoming and outgoing cable glanding and/or trunking fitting, crossover and easy distribution of
cables/wiring. The minimum height of header trunking shall be 200mm.
9.14 The minimum steel thickness used in the construction of panelboards shall be 18 gauge (S.W.G.) with
framed returned or 16 gauge (S.W.G.) for flat steel panels.
9.15 All panelboards shall be fully labelled in screwfixed ‘Traffolyte’ or similar material - black on white - and
shall be fitted with typed sub-circuit charts in waterproof heavy clear polythene envelopes fixed to the
back of each door. All warning labels shall be in ‘White’ background with „Red‟ lettering and shall be
clearly visible. All 400V compartments shall have a label reading “Danger 400 Volt”.
9.16 Supply cable dividing/spreading boxes shall be fitted to panelboards where necessary to avoid undue
bending of cables and to give adequate clearance of the cable lugs to earth and between phases.
9.17 All indoor panelboards may be fitted with header trunking of adequate size to allow the crossover and
easy distribution of cables/wiring where necessary.
9.18 The busbars and other necessary accessories shall be fitted to accommodate future (spare ways) circuit
breakers.
9.19 All panelboards shall be fitted with a main copper earth bar so that all cable armouring and earth
continuity conductors shall be readily bonded together and to the metal frame of the enclosure, including
the door. An external earth stud shall be provided which shall be bonded to the main earth bar.
9.20 Panelboards shall be fitted with suitable fixing brackets to enable the panelboard to be wall mounted.
9.21 Panelboards shall be supplied with undrilled removable gland plates at the top and bottom of the
enclosure to facilitate termination of the incoming supply and the outgoing circuit cables.
9.22 The outgoing circuit breakers shown as ‘spare’ in schedule/single lines shall be fitted and wired up to the
terminals.
9.23 All panelboards shall comply with the requirements of IEC 60439
9.24 Contactors supplied as part of the distribution boards shall be installed within the same enclosure and
shall be AC3 category class 1 duty to IEC 60947. Control supply shall be derived internally. 1 N/O and 1
N/C auxiliary contacts shall be provided as a minimum.
9.25 The busbars and other necessary accessories shall be fitted to accommodate future (spare ways) circuit
breakers. This arrangement shall be provided to accommodate 25% future circuit breakers.
9.26 Wherever possible, provision shall be made for the subsequent installation of additional circuits, up to the
full capacity of each fuseboard. All unused entries shall be stopped with galvanised hexagon headed
plugs. All outlets from fuseboards shall be provided with tapped holes.

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9.27 Distribution boards shall be fitted with suitable fixing brackets to enable the board to be wall mounted.
The larger size board shall be suitable for floor mounting. In this case a plinth of 100mm height shall be
provided.
9.28 Distribution boards shall be supplied with undrilled removable gland plates on the header trunking to
facilitate termination of the incoming supply and the outgoing circuit cables. The clear space (minimum
150 mm) between terminal block and gland plate shall be provided for ease of termination and
connection of cables / wires.
9.29 Where the load fed from an MCB is located in a hazardous area single phase MCBs shall be two pole
while three phase MCBs shall be four pole.

10. Electrical Equipment Installation

10.1 A preliminary inspection of the equipment shall take place to ensure that the equipment to be installed is
in a satisfactory condition.
10.2 The Contractor shall be responsible for identifying the equipment in accordance with
Manufacturer/Vendor drawings and for all handling in so doing.
10.3 The Contractor shall be responsible for sorting all equipment into order for installation and for transporting
from storage to place of installation including cranage, low loaders etc. as required.
10.4 The correct and accurate placing, setting, levelling and fixing of all equipment and accessories shall be
the Contractor's responsibility.
10.5 The equipment shall be placed correctly on the bases or foundation prepared for the same. In the case of
switchgear consisting of a switchboard with a number of panels bolted together, all sections of the
switchboard shall be placed correctly and shall be bolted together to form one continuous switchboard
after aligning them.
10.6 The switchgear shall be secured to the foundation by means of nuts and bolts or foundation bolts grouted
in the base. The inter-section bus / wiring connections shall be carried out as per the vendor's wiring
diagrams.
10.7 After equipment is properly installed, the Contractor shall maintain the equipment as recommended by
the Manufacturer/ Vendor until such time as the care, custody and control is handed over.
10.8 The correct and accurate placing, setting, levelling and fixing of all equipment and accessories shall be
the Contractor's responsibility.
10.9 Steelwork required for the support of distribution boards, starters, etc., shall be of ample section to secure
rigidity. Where possible, all supports are to be vertical to prevent the accumulation of dust and debris. All
such steelwork shall be either galvanised channel section or be protected by 2 coats of cold galvaniser
before erection and one coat of paint of approved colour after erection, in dry areas. All cuts shall be
painted with zinc paint before painting. In wet areas it shall be stainless steel.
10.10 The full and complete installation shall be the responsibility of the Contractor. The Contractor shall
adhere to the equipment manufacturer's installation instructions and follow the instructions of any
specialist erection supervisor at all times.

11. Variable Speed Drive Installations

11.1 360˚ High Frequency earthing should be undertaken at either end of the motor cable, i.e. in the motor
terminal box and into the VSD unit. This involves the use of unpainted gland plates, conductive tape
around the cable cores/shielding up to point of termination and short tails to termination points.
11.2 If a motor isolator or junction box needs to be installed in the motor cable, then the continuity of the 360˚
earth must be maintained by using a metallic box and the general termination technique as detailed in
above.
11.3 The entire installation of the VSD cables, glanding, terminations, and earthing shall comply with the EMC
regulations. The recommendations of the VSD unit supplier shall be followed throughout the installation.

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12. Lighting Installation

12.1 The lighting installation shall be carried out in accordance with the drawings.
12.2 Lighting wiring circuits, when installed in conduit and or trunking shall be wired in LSF insulated cables
with a separate earth wire unless otherwise specified on drawings, in the Particular Installation
Specifications or on the panel board schedules. Lighting wiring circuits, when installed in cable ladders or
trays shall be wired with XLPE/LSF/SWA/LSF cables on cable racks unless otherwise specified on
drawings, in the Particular Installation Specifications, or on the panel board schedules. Outdoor lighting
wiring circuits shall be wired in XLPE/PVC/SWA/PVC cable.
12.3 The location of luminaries, fixings and elevations shall be as indicated on the lighting layout drawings,
subject to final positioning at site.
12.4 The centre line of all switches shall be at 1300mm above finished floor level unless specified otherwise
on the drawing.
12.5 Final location and positioning of light fittings shall be determined on site.
12.6 Surface mounted fittings, where recessed conduit installation is not specified, shall be mounted on a
network of lighting trunking or „Unistrut‟ as specified on drawings or in the particular installation
specification.
12.7 Surface mounted fittings, where recessed conduit installation is specified, shall be secured with metal
threaded studs complete with washers, two lock nuts. The threaded metal studs shall penetrate into the
hard concrete to a depth of not less than 32 mm and shall ensure that it will not hit concealed conduit or
any other concealed services.
12.8 For pendent fittings, the down rods shall be securely fixed to the ceiling with conduit terminating boxes
(and not teak boxes).
12.9 Recessed fittings in safe area shall be supported to the ceiling slab independently by means of
galvanised steel wires tied to metal studs penetrated into the concrete to a depth of not less than 32 mm,
as detailed in the relevant drawings. There shall be no noticeable ceiling deflection when the fittings are
installed. The fittings shall not be supported or impose weight on the false ceiling.
12.10 For safe area recessed mounted light fittings all wiring shall be carried out on the „loop-in/loop-out‟
principle with plug-in type ceiling connectors of MK or approved equivalent. The connector shall be of
such construction that the earth connection is first to make and last to break. The plug and socket
connector shall be type tested to comply with the relevant clauses of BS 5733: General Requirements for
Accessories.
12.11 The recessed mounted light fittings in hazardous area shall not be supported from the ceiling slab, but
shall be supported from the recessed ceiling itself. An adjustable channel provided along with the
recessed fittings shall be used for supporting these fittings on the recessed ceiling.
12.12 All wiring shall be carried out on the „loop-in/loop-out‟ principle.
12.13 The switches for industrial/safe area lighting control shall be as specified on the drawings or in the
particular installation specification. The switches shall be of approved manufacturer conforming to BS
3676.
12.14 Where flush switches are required the boxes shall, unless otherwise specified, be of the adjustable lug
pattern. Efficient means shall be provided to ensure that the switch rocker is effectively earthed to the box
and to conduit.
12.15 Switches in office areas shall be single-pole, one way or two ways, rocker operated and of white square
plate pattern unless otherwise specified in particular installation specification or on drawings. Where two
or more switches are to be fixed adjacent to each other, multi-gang switches on a single cover plate shall
be used. Multigang switches shall not be used for different phases. Separate switches shall be provided
for different phases.
12.16 Dimmer switches shall be flush mounted or surface mounted as specified on the drawings or in the
particular installation specification. Dimmer switches shall be single gang or multi-gang, as required and
specified. The dimmer switches shall be rated for 250W or 400W as required.
12.17 Hazardous area lighting shall employ Ex-rated two pole switch complete with external earth/gland plate
with two cable entries unless otherwise specified in the Particular installation Specification or on the
drawings and datasheets. The current rating of the switches shall be as per drawings, schedules or as
specified in the particular installation specification. The minimum current rating of the switches shall be
10A.

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12.18 At all positions where lighting switches are grouped, multiple gland boxes shall be used unless otherwise
specified.
12.19 Ceiling switches unit, where specified, shall be of the 5 amp rating, suitable for mounting on a conduit box
and be quick make and break action by a pull cord.
12.20 All lighting switches unless otherwise specified, shall be protected to IP 54 in dry areas and IP65 in wet
areas.
12.21 Where lighting are installed above a height of 5 metres, the method of access to the lighting for
maintenance and lamp replacement must be agreed with the Engineer.
12.22 All fluorescent lighting switches shall not be loaded more than 70% of the steady load current.
12.23 Where sub-circuits of different phases are present, separate light switches shall be provided. Light
switches with phase barrier protection shall not be provided.
12.24 High frequency control gear shall be used on all fluorescent fittings
12.25 All light fittings and light switches shall be fitted with labels indicating distribution board number, circuit
number and switch number.
12.26 The lighting installation shall be carried out in accordance with the drawings.
12.27 Wiring shall be carried out in accordance with section 3.0.
12.28 The location of luminaries, fixings and elevations shall be as indicated on the lighting layout drawings,
subject to final positioning at site.
12.29 The centre line of all switches shall set at 1300mm above finished floor level unless specified otherwise
on the drawing.
12.30 Switches shall be 20A unless the load to be switched is less than 500W, in which case 10A switches may
be used.
12.31 All brackets, fixings etc shall be stainless steel.
12.32 All Luminaires shall be supplied complete with lamps.
12.33 Weather-proof switch units shall be to IP55, unless otherwise specified.

13. Luminaires
13.1 All fluorescent light fittings shall have high frequency type electronic ballast. This requirement applies to
all fittings where fluorescent lamps are used.
13.2 All light fittings shall be provided with internal ‘PE’ earthing terminal.
13.3 Each light fitting shall bear a CE mark and comply with all applicable EU directives.
13.4 All light fittings shall be provided with minimum two cable entries of sizes as specified in the datasheets
with one cable entry provided with blind plug.
13.5 All surface mounted light fittings shall be provided with arrangement for suspending/hanging the fitting
from ceiling with two nos. conduits. Recessed fittings shall be also provided with a similar arrangement
for suspension from ceiling.
13.6 All light fittings shall be wired with loop-in/loop-out features. Adequately sized terminals pre-wired for this
arrangement shall be provided completely within the light fitting enclosures.
13.7 The degree of ingress protection shall be as specified in the datasheets.
13.8 For fluorescent light fittings, in case of failure of one fluorescent lamp the other lamps shall remain in
operation independently.
13.9 All light fittings shall be supplied with lamps. However, the lamps shall be supplied loose. High efficiency,
low energy light bulbs are to be used, to meet local lighting requirements.
13.10 The contractor shall furnish complete technical datasheets and polar curves (luminous intensity
distribution diagrams) for review and approval by the engineer.
13.11 The emergency and EXIT light fittings shall comply fully with the requirements of IS 3217. The exit
sign/emergency light fittings shall be supplied from the plant central battery system.

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13.12 The EXIT fittings shall bear the legend EXIT together with directional arrows as required. The exact
requirement of arrows shall be furnished at the time of purchase.
13.13 All emergency light fittings shall be provided with a RED neon lamp or LED to indicate the health of the
unit.
13.14 The contractor shall include supply of all mounting accessories required and special tools.

14. General Services

14.1 General service circuits, when installed in conduit and or trunking shall be wired in LSF insulated cables
with a separate earth wire unless otherwise specified on drawings, in the Particular Installation
Specifications or on the panel board schedules. General service circuits, when installed in cable ladders
or trays shall be wired with XLPE/LSF/SWA/LSF cables on cable racks unless otherwise specified on
drawings, in the Particular Installation Specifications, or on the panel board schedules. Outdoor General
service circuits shall be wired in XLPE/PVC/SWA/PVC cable.
14.2 Socket outlets shall be provided as indicated on the drawings.
14.3 All socket outlet circuits shall be protected by residual current devices set to operate at 30mA.
14.4 Socket outlets shall generally be mounted 300mm above finished floor level unless indicated otherwise
on the drawings. The exact height and location will be agreed with the Engineer on site.
14.5 All outlets shall be fitted with labels indicating panel number and outlet circuit number.
14.6 Socket outlets in indoor areas shall generally be mounted 300mm above finished floor level and 600mm
above finished floor level when installed in outdoor areas unless indicated otherwise on the drawings or
in the Particular Installation Specifications. The exact height and location will be agreed with the Engineer
on site.
14.7 All socket outlets, spurs, switches, isolators, etc. shall be fitted with labels indicating distribution
board/MCC tag number, circuit number and way or outlet circuit number.

15. Earthing and Bonding System

15.1 The requirements and methods for electrical system earthing and bonding shall be in accordance with
ET101 AND BS 7430:1991.
15.2 The value of resistance of the combined electrodes in the earthing system for each area shall be 1Ω or
less. Additional earth electrodes shall be driven to achieve the earth resistance as specified above.

15.3 Measures to prevent the accumulation of static charge on all fixed and portable equipment and structures
shall be provided.
15.4 All underground joints for earthing shall be carried out by using exothermic welding process of Furse or
equivalent approved by the Engineer.
15.5 Anti static flooring shall be earthed at regular intervals as shown on drawings/details and in the Particular
Installation Specification.
15.6 The earth cable used for bonding and earthing shall be green and yellow insulated as per ET101. In the
case of multi-core cables, when one of the cores is used for the purpose of earthing, the core when
exposed within MCC or DB and in equipment terminal box shall be covered with a PVC sleeve with a
green and yellow colour. The sleeve shall be heat shrinked on to the core used for earthing. For e.g. the
fourth core of motor power cable is used for earthing, this core shall be covered with heat shrink PVC
green/yellow sleeve in MCC and in motor terminal box.
15.7 In general, all glands of armoured cables must be earthed. Where glands are terminated in a non-metallic
gland plate, a separate earth lug should be brought from the gland and earthed to the main earthing
system.

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16. Testing And Commissioning

16.1 The verification, inspection and testing of the electrical installation shall comply with the requirements of
ET101 Part 6.
16.2 Field testing shall be required for all cables and electrical equipment furnished, installed or connected by
the Contractor.
16.3 Testing shall ensure the installation is in accordance with the schematics, plans, specifications and
manufacturer’s recommendations.
16.4 Testing shall be conducted in the presence of the Engineer when necessary or under the supervision of
the equipment manufacturer’s field engineer.
16.5 Testing shall include any additional tests issued by the Engineer deemed necessary because of field
conditions to determine that equipment, material and systems meet the requirements of the specifications
16.6 The Contractor shall furnish qualified personnel to conduct all testing and shall furnish all testing
equipment and labour required for, and incidental to testing.
16.7 The Contractor shall maintain in quadruplicate a written record of all tests showing date, personnel
making test, equipment or material tested, tests performed and results. Three copies of test records shall
be given to the Engineer.
16.8 The Contractor shall notify the Engineer one week prior to commencement of any testing, except for
“meggering”.
16.9 The Contractor shall be responsible for any damage to equipment or material due to improper test
procedures or test apparatus handling, and shall replace or restore to original condition any damaged
equipment or material.
16.10 Safety devices such as rubber gloves and matts, locks, tags protective screens and barriers, danger
signs, etc., shall be provided by the Contractor and shall be used to adequately protect and warn all
personnel in the vicinity of the tests.
16.11 The Contractor shall carry out Earth Continuity tests on main pieces of equipment and on various parts of
the piping installation. The Contractors shall mark the results on P&ID‟s provided. These shall be
presented to the Engineer when complete. The selection of pipework for testing shall be representative of
the entire installation .
16.12 Tests shall include but shall not be limited to:-
a) Continuity of the protective conductors and of equipotential bonding conductors.
b) Insulation resistance tests.
c) Protective earthing system
d) Polarity
e) Continuity of conductors in ring circuits
f) Functional Tests
g) Electrical separation of circuits from one another
h) Phase Rotation
i) Bonding Verification
16.13 Insulation resistance for circuits up to 400V a.c. shall be measured at a voltage of 500 Volts d.c. or a.c.
(RMS), applied from a rectifier (preferred) type or motor driven type tester. The insulation resistance shall
be considered to be satisfactory, if a value of not less than 1Megohms is achieved.
16.14 Insulation resistance tests which show a lower value than stated in clause 16.13 above or unsteady
values shall be thoroughly investigated to determine and correct the cause before equipment is energised.
16.15 The line earth loop impedance of all circuits shall be measured and shall not exceed the values given in
Table 61C-1 and 61C-2 of the ETCI Regulations.
16.16 Tests on 400 Volt switchboards and motor control centres shall include the following:-
a) Check and measure equipment earth resistance value. Notify the Engineer if more than 0.25 ohm.
b) Clean all busbars, insulators, etc., remove or draw out all potential transformers; high voltage test
all switchboard or motor control centre busbars. Use test voltage of 2.5 kV (50 Hertz for 1 minute).
c) Megger all control busbars for freedom from earths or short circuit. Do not megger earthed a.c.
circuits (current or potential transformers circuits); do not megger instruments or fuses.
d) Check all incomer metering circuits for compliance with drawings.

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e) Check starter overload relays for proper current range with motor nameplate full load current. Adjust
relays for manual or automatic reset as directed by the Engineer.
f) Check starter, fuse ratings in accordance with the drawings.
g) Check that all local and remote controls, interlocks and alarms of each starter, functions in
accordance with the schematic drawings.
h) Torque all connectors.
i) For timing relays, adjust the timing cycle for proper equipment operation, as furnished by the
Engineer.
j) Check switchfuse, fuse ratings in accordance with the drawings.
k) Test over-current and earth fault relays (where installed) to ensure -correct operation and
discrimination.
16.17 Ammeters shall be tested as follows:-
a) Check connections from current transformers for a.c. ammeter.
b) Check ammeter scale accords with current transformer ratio.
c) Set pointer on zero scale with no load.
16.18 Voltmeter tests shall include the following:-
a) Check voltmeter scale accords with potential transformer ratio.
b) Set pointer on zero scale with no voltage.
c) Check voltmeter reading with test voltmeter when energised.
16.19 Wattmeter and watt-hour meter tests shall include the following:-
a) Check with current transformer and potential transformer ratio.
b) Set wattmeter pointer on zero scale with no load.
c) Check rotation on watt-hour meter.
16.20 Test on current and voltage transformers shall include the following:-
a) Physically check polarity mark orientation on all CT’s and PT’s with manufacturer’s drawings.
b) Check all CT polarity markings where CT is used for Watt, Watt-hour, or VAR metering, or
protection as follows:-
1) Connect a D.C. permanent magnet ammeter with a scale less than 5 Amperes across the CT
secondary terminals with meter “plus” terminal attached to marked lead of CT.
2) Attach the “negative” lead of a 6 volt dry cell to the unmarked terminal of the CT primary.
3) Momentarily touch the “plus” lead of dry cell to marked CT primary leads. If the polarity as
marked is correct, the meter will “kick” upscale, and on breaking the connection the meter will
“kick” down scale.
c) Check all PT polarity markings as follows:
1) Connect a D.C. permanent magnet voltmeter with scale appropriate to PT ration (0-150 Volts
or higher) across the high voltage terminal of the PT with the meter “plus” terminal connected
to the marked terminal of the PT secondary.
2) Attach the “negative” lead of a 6 Volt dry cell to the unmarked terminal of the PT secondary.
3) Momentarily touch the “plus” lead of the dry cell to the marked secondary terminal of the PT if
the polarity as marked is correct the meter will “kick” upscale, and on breaking the connection
the meter will “kick” down scale. Avoid touching the meter or its leads during this test.
d) Disconnect the secondary connections at each current transformer, and inject approximately 2
amperes A.C. into the circuit. With clip-on ammeter (or test plug and ammeter) check to see that
current is present in each instrument, relay, switch, auxiliary equipment, etc., that should be
connected to the CT being tested. Repeat for every CT.
e) Disconnect secondary connections from each PT and apply 110 Volt, A.C. with voltmeter, check for
voltage at relays, instruments switches, auxiliary transformers, etc. that should be connected to the
PT being tested.
16.21 Tests on power cables shall include the following:-
a) Check effectiveness of earth continuity and verification of polarity.
b) Insulation Resistance Test.
c) Insulation Resistance Test readings shall be one minute duration.

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16.22 Tests on 400 Volt motors shall include the following:-

a) Check equipment earth to assure continuity of connections.
b) Measure the insulation resistance of the stator winding before applying voltage. Compared this
measured value against the manufacturer’s value furnished by the manufacturer, compare readings
against the value given in Clause 16.13 If measured resistance values are lower that above, record
ambient temperature and humidity and submit readings to the engineer. Dry out motors as required
by approved method of application of external heat and do not apply voltage to motor until
substandard resistance condition is corrected. “Megger” readings are to be one minute duration.
c) Apply voltage momentarily and note direction of rotation; if direction of rotation is reversed,
interchange two of the primary leads at the motor terminals. Reconnect motor to driven equipment.
d) After being placed in operation, observe the motor for heating at the bearings of windings. If the
motor appears to be running hot notify the Engineer.
16.23 Tests on power transformers shall include the following:
a) Visual check of transformer and fittings
b) Megger check on windings
c) Continuity test of the tap changer
d) Earthing connection check for neutral connection and equipment earth
16.24 Tests on the earthing and bonding installation shall include the following:
a) Check the earthing and bonding connections for tightness and corrosion.
b) Check earthing pits for tight connections and corrosion.
c) Measure the earthing resistance of electrodes.
16.25 Tests on lighting system installation shall include the following:
a) Measure the insulation resistance of the lighting circuit cables.
b) Check the termination arrangement.
c) Check the lamps and ballast and operation.
d) Check and test the switching operation as per the single lines and schedules.
e) Check and verify illumination level in line with the design.
f) For emergency light fittings with integral battery units check the operation simulating power failure
also check and verify the Central test Unit operation.
g) For emergency light fittings with integral battery units check the battery duration tests (2 hours).
h) For emergency light fittings operating on central battery system, assist the system supplier for
commissioning of the system (all tests on the wiring as described above shall be carried out by the
contractor)
16.26 Tests on general service socket outlet installation shall include the following:
a) Measure the insulation resistance of the circuit cables.
b) Check the termination arrangement.
c) Test the earthing continuity
d) Check the operation.
e) Check and test the switching operation
16.27 Some of the electrical equipment will be tested and commissioned by the equipment/system supplier.
This equipment, however, will be installed and wired by the contractor when specified in the particular
installation specifications. The contractor shall carry out following tests on the installation and wiring:
a) Check the installation is in line with the vendor drawings and installation details.
b) Check the wiring and termination with vendor drawings/schematics.
c) Check the wiring continuity and measure insulation resistance tests.
d) Assist the vendors in testing and commissioning of the equipment (the contractor shall have to
provide required manpower and machinery).
e) All other tests as specified in the particular installation specifications

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Some of these equipment/systems are:

a) Fire Alarm systems.
b) Telecommunication systems.
c) CCTV systems
d) UPS units
e) Central battery systems.
f) Low voltage switchgear and MCCs
g) Vendor supplied equipment panels
h) All other items as specified in the particular installation specifications

17 Nameplates, Labels and Tagging

17.1 The contractor shall supply and install a label on all local isolators and push button stations. The label
shall have following descriptions:
• Equipment/Motor Tag Number
• Equipment Description
• Equipment Rating (kW Rating)
• MCC Number along with feeder and section number.
17.2 All light fittings and light switches shall be fitted with labels indicating distribution board number, circuit
number and switch number.
17.3 All socket outlets, spurs, switches, isolators, etc. shall be fitted with labels indicating distribution
board/MCC tag number, circuit number and way or outlet circuit number.
17.4 Labels shall be engraved black on white background, “Traffolyte”, or similar.
17.5 Labels shall be fixed with non-ferrous rivets or screws.
17.6 Lettering shall be a minimum of 4mm high.
17.7 All cables shall be identified by means of non-deteriorating type cable tags of “Critchley” manufacture, or
equal and approved; fitted on each termination point and on each side of a cable transit or barrier. The
cable numbers shall as per cable schedules and/or schematics and/or as specified in particular
installation specifications.
17.8 All earth cables connected to earth bars shall be tagged and labelled at both ends.
17.9 Labelling and tagging for telecommunications outlets shall be as agreed on site with the engineer.

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Electrical Induction Motors

1. Scope
1.1 This specification defines requirements of for the provision of low voltage squirrel cage induction motors
for use on any Diageo Global site.
1.2 The products works or services to be procured are described in the technical specifications and drawings
and have been formulated by reference to European standards, European technical approvals, common
technical specifications, international standards or, where these do not exist, national standards or
national technical approvals, as appropriate. Notwithstanding the foregoing, equivalent standards and
specifications are acceptable. Where the technical specifications are formulated in terms of performance
or functional requirements, the tenderer must comply with these requirements.
1.3 Where the technical specifications and drawings, where necessary, are formulated by reference to
detailed descriptions, proposals by the tenderer will not be rejected on the grounds that the products
works or services do not comply with the technical specifications and drawings, provided the tenderer can
show, by an appropriate means, that his proposals satisfy in an equivalent manner, the requirements
defined by the technical specifications and drawings. Where trade names / product names may be used,
if any, in describing the products works or services to be procured, these are used as information only for
the purpose of more fully describing the specification and drawings requirements. In relation to all
descriptions and references used for products works or services to be procured, equivalent products
works or services are acceptable, except in such instances, if any, where equivalent products works or
services would be incompatible with existing equipment already in use or would entail disproportionate
cost or technical difficulty, in which instances, the particular products works or services shall be identified
in the technical specifications and drawings as being mandatory.

2. Standards and Codes

2.1 Materials and equipment shall be new and meet the requirements of all the applicable standards of the
authorities, but no limited to, listed below:
• IEC60034 (All Parts): Rotating electrical machines
• BS 4999 (All Parts): General requirements for rotating electrical machines.
• IEC60072 (All Parts): Dimensions and output series for rotating electrical machines
• IEC60529: Degrees of protection provided by enclosures (IP Code)
• IEC60079 (All Parts): Electrical apparatus for explosive gas atmospheres
• IEC 61241(All Parts): Electrical apparatus for use in the presence of combustible dusts.
• EU Directive 94/9/EC (Atex100a) equipment and protective systems intended for use in potentially
explosive atmospheres.
• Motors shall bear CE mark and comply with applicable EU directives.

3. Application
3.1 The motors shall be suitable for use in areas defined by the mechanical specification data sheet and in
accordance with this specification.

4. Submittals
4.1 The Seller shall submit a completed motor data sheet (blank copy attached) and one outline drawing,
both certified by motor manufacturer for each motor. The motor data sheet is to be submitted with the
quotation and after an order is placed, resubmit when certified.
4.2 Motors shall be CE marked. A CENELEC certificate of conformity to the required standard shall be
delivered with each motor.
4.3 Submit product data and test results.
4.4 Electrical and mechanical data, inclusive of speed, torque, power, efficiency, power factor characteristics
etc. for each motor.

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4.5 Include general arrangement drawings, bearing data including replacement sizes and lubrication
instructions.
4.6 Foundation loadings.

5. Service & Performance Conditions

5.1 Motors shall be capable of delivering rated output power under the local climatic conditions without
injurious overheating:
5.2 Motors shall be suitable for continuous operation at the specified rating and speed.
5.3 Motors may remain unused for a long period after installation. The vendor shall supply instructions
detailing such items as shaft turning, protection of bearings, insulation resistance tests etc., to ensure that
the motors are fully serviceable at all times.
5.4 Motors shall be capable of continuous operations with:
• rated voltage +/-10%
• rated frequency +/-5%
• combined variation of voltage and frequency +/-10%
5.5 Rated output power of motors shall exceed by at least 10% the maximum input power required by driven
equipment under any conditions of normal continuous operation, without overloading, or exceeding the
temperature rise stated above.
5.6 Guaranteed motor rating for pumps shall exceed pump-operating curve at any point including runout.
Pump curve used shall be based on pump being equipped with impeller capable of delivering rated flow
at 110% head and motor having service factor of 1.0.
5.7 It shall be the manufacturer’s responsibility to match motor torques with driven equipment torques, so
that adequate starting, accelerating, pull-up, break-down and full load torques are available for the
intended service in accordance with the requirements of the driven equipment.

6. Construction
6.1 Motors shall comply with sound engineering practices to result in an expected lifetime period of a
minimum 20 years. All motors shall be capable of an uninterrupted initial service period of a minimum of 4
years (under the site conditions defined within this specification), prior to any periods of major
maintenance.
6.2 Totally enclosed fan ventilated (TEFV).
6.3 The motors shall have minimum IP55 degree of ingress protection to IEC-60529 unless otherwise
specified in the equipment datasheets..
6.4 Motors shall be designed for continuous duty type S1, in accordance with IEC-60034- 1. Other duties to
be selected based on load type and mode of operation.
6.5 Motors shall be suitable for direct-on-line starting up to and including 55kW, and star-delta, Soft Starter
aided, or VSD starting for 55kW and greater.
6.6 Single speed, single voltage motors above 3kW shall be provided with six (6) terminals to permit star-
delta starting if required. Busbar links shall be provided so the motors may be connected as DOL without
any site modifications.
6.7 Class F insulation with Class B temperature rise.
6.8 Cast iron construction, including frame, feet, bearing housings and end bells. Fan covers may be of sheet
steel construction. Stainless steel enclosures shall be used where specified in the mechanical / process
specification. Aluminium may only be used in exceptional circumstances, subject to approval of the
Engineer. The construction should be robust, and designed to enable routine maintenance of the motor
with ease of access, and covers etc, not fragile.
6.9 Anti-friction ball bearings sealed for life type or where not available 50,000 hour minimum and facility for
new grease.
6.10 Terminal box shall be suitable for PVC or XLPE insulated, single wire armoured, PVC over-sheathed
cable. Cable entry to have threaded hole suitable for gland with ISO metric thread (BS 3643, R68 series,
constant pitch 1.5mm, class 6g fit). Terminal box shall be located on right hand side facing shaft end.
Gland plate cable entry size shall be as specified.

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6.11 External earthing terminal shall be provided. Earthing terminal inside the terminal box shall be provided.
6.12 External surfaces shall be properly cleaned and primed with zinc chromate red oxide primer and finish
coated with a full gloss epoxy enamel paint which shall protect against such things as acid and alkaloid
fumes, salt air, solvents and moisture. Finish colour shall be manufacturers standard.
6.13 Lifting eye bolts.
6.14 Dual windings are required where two speed operation is specified. Dahlander connection is not
acceptable
6.15 Energy efficient design, complying with IEC 60034-2, with efficiency class EFF1 (as defined by CEMEP,
the European Committee of Manufacturers of Electrical Machines and Power Electronics) and high power
factor. Lower efficiencies may be acceptable for specialised fractional kW motors, subject to approval of
the Engineer.

7. Variable Speed Operation

7.1 Where a motor is used with a Variable Speed Drive (VSD), the manufacturer shall provide certification to
prove the suitability of the motor for use in conjunction with the VSD and state the acceptable operating
frequency range. The rating plate shall be stamped “VSD Rated” in addition to normal rating plate
information. The frequency range and the motor rating at 50Hz should also be stated on the rating plate.
Insulation rating shall be 1,400 Volts minimum.
7.2 Motors shall be suitable for operation with AC VSDs (pulse width modulation design – IGBT technology)
as per Specification No. 00/E02A/0003, Variable Speed Drives.
7.3 Each VSD operated motor shall be fitted with one set of positive temperature coefficient (PTC)
thermistors rated 140 degree C for trip and 120 degree C for pre-warning, embedded in the winding
prospective hotspots. The set shall comprise three PTC thermistors connected in series, one in each
phase of the stator winding. The thermistors shall be spaced at approximately 60 degrees around the
stator winding.
7.4 Motors shall be capable of continuous operation at low speeds without injurious overheating or nuisance
tripping of over temperature thermostats. The manufacturer shall ensure motor heat dissipation meets the
above criteria while producing full load torque, required by load over its entire speed range. Operational
limit shall be 12.5Hz minimum.

8. Construction of Motors in Hazardous Areas

8.1 Where the motor is located in a hazardous area the following paragraphs shall apply in addition to those
described in 6.0 above.
8.2 Hazardous Locations (Zone 1, Zone 2)
• All motors in hazardous area shall be rated Zone-1
• The motors shall conform to IEC60079
• EExde flameproof motor with increased safety terminal box.
• The motors shall have a minimum IP55 degree of ingress protection to IEC-60529 unless otherwise
specified in datasheets.
• Gas group IIB/IIC (as defined in mechanical equipment datasheets).
• Temperature class T4 135 oC (or better).
8.3 Dust Hazard Locations (Zone 21, Zone 22)
• All motors in dust hazard area shall be rated Zone-21.
• The motors shall conform to IEC 61241
• The motors shall have IP65 degree of ingress protection to IEC-60529.
8.4 Where the motor is located in a Hazardous Locations (Zone 1, Zone 2, Zone 21 or Zone 22) the Zone
shall be noted on the equipment datasheet.

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9. Voltage / Starting Characteristics

9.1 Motors 0.37kW and larger: 400V ± 6%, three phase, 50 Hz.
9.2 Motors below 0.37kW: 230V ±6%, single phase, 50 Hz. Process pumps and agitators are frequently
rated 400V, three phase, 50Hz.
9.3 Unless indicated otherwise in the Performance Criteria, motor starting characteristics shall be design
letter „N‟ for DOL starting and “NY” for star/delta starting as detailed in IEC60034-12. VSD motors shall
be designated as per Section 7.0 above.

10. Tests
10.1 Routine check tests in accordance with BS4999, Part 143 or equivalent shall be carried out on the motors
at the motor manufacturer’s works.

Project No. 79-2030-10

Equipment No. Specification No.
Supplier: Purchase Order No.
LOW VOLTAGE CAGE INDUCTION ELECTRIC MOTORS DATA SHEET
Manufacturer
Model No.
Rated Output
Rated Voltage 400V (230 below 0.37kW)
Rated Frequency 50 Hz
Number of Phases 3 (1 below 0.37)
Insulation Class
Full Load Current (FLC)
Locked Rotor Current (LRC)
Full Load Torque (FLT)
Locked Rotor Torque (LRT)
Minimum Starting Torque
Minimum Breakdown Torque
Full Load RPM
Full Load Power Factor
Full Load Efficiency
Maximum Ambient Temperature
Bearing Type
Frame Size
Mounting Method
IP Rating: Motor & Auxiliaries
IP Rating: Terminal Boxes/Bearing Housings
ISO thread sizes on Entry Hole(s)
ATEX Rating (Where Applicable)
Temperature Group
Gas Group
Time for type of protection “e”
FOR VARIABLE SPEED DRIVES
Minimum Maximum Standard
Output Frequency 50 Hz
Motor Output

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Electrical Standards: Electrical Components of Packaged Equipment

Electrical Components
of Packaged Equipment
1. Standards and Codes
1.1 Electrical components, wiring and enclosures shall comply with CENELEC standards, Euronorm
Standards, I.E.C. Publications, ISO and British Standards. Equipment shall comply with relevant EU
directives.
1.2 If Seller’s equipment deviates from these standards or codes, the proposal should define in detail these
differences, and submit in writing for the engineer’s approval.
1.3 All packaged electrical equipment shall bear a CE mark and comply with applicable EU directives.

2. Controls
2.1 Where starters form an integral part of a control package and are furnished with equipment the following
should be provided:
a) Motor starters shall be direct on-line type or VSD for motors up to 55kW.
b) For motor starters above 55kW variable speed drives, Soft Starter or Star Delta starters shall be
provided.
c) Contactors shall have inherent under-voltage release and 110 VAC, 50 Hz operating coils.
e) Starters shall be of reputable manufacture and approved by the Buyer.
f) Moulded case circuit breakers shall be in accordance with IEC 60947-4-2 (Low Voltage Switchgear
and Control-gear).
g) The equipment shall be rated for a three-phase symmetrical short-circuit level (Ics) of 40kA rms
unless otherwise stated on the datasheet.
h) Triple pole hand reset adjustable ambient temperature compensated thermal overload relay with
single phase protection.
i) Local start, emergency stop pushbuttons and green run indicating light.
j) Run, stop, fault, supply on and supply available indicating lamps or a digital display covering all
these indication.
k) Hand-Off-Auto selector switch, complete with ‘volt-free’ contact to be wired out to terminals for
control system Auto position indication.
l) For each starter, provide a door-mounted rotary handle operator for the circuit breaker, with
provision for padlocking in the "Off" position.
m) Co-ordination of circuit breaker contactor/overload relay starter combination shall be type ‘2’ in
accordance with IEC 60947-4-1 (Safety of Machinery) and shall be fully proven by certified tests
including ‘p’ and ‘q’ tests.
n) Starters shall be rated for utilisation category AC3 as a minimum and intermittent duty Class 1 to
EN 60947-4-1, or equivalent. Category AC4 shall be used where more onerous duties such as
plugging, inching etc. have to be met.
2.2 A main switch shall be provided on the panel to disconnect the incoming power supply. This switch shall
be mechanically interlocked with the door and shall have provision for padlocking in the "Off" position.
Where it is required to have the control system operating on an external backup UPS system, the control
system wiring and components shall be completely segregated from the rest of the wiring and
components. A separate power on-off switch shall be provided for the UPS control power supply.
2.3 Indicating lamps shall be neon or LED type and the colour code shall be as follows:
Green - motor running, or contactor closed
Red - motor stopped
Amber - motor tripped, or fault alarm
Blue - supply available
White - power on

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2.4 All equipment shall operate fail-safe in case of loss of power supply. The starting signal shall be removed
if there is a power failure, if the motor overload trips, if a lock-stop or emergency stop is activated, if the
motor disconnector is switched off, or if the H-O-A switch is changed from the ‘Auto’ position. The
recovery of power, the release of a lock-stop or emergency stop pushbutton, the closing of a motor
disconnector, or the resetting of a motor overload relay should not result in equipment immediately re-
starting. A system manual reset shall be included so that the restarting of equipment by automatic
controls shall be initiated and carried out in a controlled and predictable manner after a system failure or
switching operation.
2.5 Motors 75kW and greater shall have earth fault protection.
2.6 Pushbuttons and selector switches shall be heavy-duty type.
2.7 Instrumentation supplied with the package shall be rated according to the specification, **Hold for
Reference Number**, “Instrumentation and Protective Devices For Packaged Equipment”.
2.8 Control voltage shall be 110VAC.
2.9 Both the instrumentation and control voltages shall be supplied from a power source within the control
panel.
2.10 Provide volt-free contacts wired out to terminals for motor run and trip signals. Provide other digital and
analogue I/O signals for interfacing with other systems as specified in the relevant mechanical equipment
specifications.
2.11 Provide two (2) normally open and two (2) normally closed spare contacts wired to outgoing terminals.
2.12 If a motor is remote from the package equipment control panel, provide adjacent to each motor, a
disconnect-switch with provision for padlocking in the ‘OFF’ position and a turn to reset lock-stop
pushbutton. The disconnect switch shall be equipped with an early-break auxiliary contact which shall be
wired into the motor’s control circuit.

3. Enclosures
3.1 The control panel shall be flush-fronted, industrial cubicle type of 1.5mm thick sheet steel construction,
welded and bolted to form a rigid structure, totally enclosed, dust-tight and damp-proof, finished in stoved
enamel or epoxy paint finish. Control panel doors shall be hinged and shall open a minimum of 180
degrees.
3.2 Refer to section 9.0 for IP ratings of the enclosures.
6L Stainless steel enclosures shall be provided where specified on the equipment datasheet.
3.4 Internal equipment shall be mounted no less than 300mm from the bottom of the panel. All devices
(starter, switches, pushbuttons, relays, pilot lights, etc.) shall be identified with nameplates in accordance
with Section 10. Panels shall be mounted with top of panel at 1500mm above floor.
3.5 For control panels and equipment installed in non-hazardous area, enclosures shall be fitted with
removable blank gland plates and gaskets. Adequate space shall be allowed within the enclosure for
glanding and spreading power cables. Gaskets shall be manufactured from neoprene or synthetic rubber
or similar.
3.6 For control panels and equipment installed in hazardous area, taped hole shall be provided for cable
entry. The Buyer will advise on number of such holes and cable entry sizes. Prior to despatch suitable
flameproof plugs shall be provided for all unused entries.
3.7 Enclosures shall be fitted with removable blank gland plates and gaskets. Adequate space shall be
allowed within the enclosure for glanding and spreading of the power cables. The cable termination
arrangement, top or bottom, shall be agreed with the Engineer before the equipment is manufactured. A
cable termination gland plate shall be provided at the top or bottom of the enclosure to suit the field cable
terminations to be agreed with Engineer.
3.8 A warning label shall be provided on each compartment in which an external source is terminated.

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4. Wiring
4.1 Wiring for Buyer’s connections shall be brought to an identified junction box, provided with adequately
rated shrouded terminal strips for external interface. Internal wiring shall be 1.5sqmm minimum. The
minimum size terminal shall be capable of accepting two 2.5sqmm conductors. The internal wiring shall
be individually numbered and crimped at both ends. Extra low voltage wiring and terminals shall be
segregated from low voltage wiring and terminals.
4.2 Seller’s arrangement drawings shall show location of Buyer’s cable entries to electrical equipment and
junction boxes.
4.3 Barriers shall separate terminals of different voltages.
4.4 All terminal blocks shall be Din rail mounted.
4.5 The text on wire and terminal labels shall be typewritten or stamped on the markers. Handwritten labels
are not acceptable.
4.6 Colour coding of cable cores and internal wires shall be as follows:

Power: Phase 1 Brown

Phase 2 Black

Phase 3 Grey

Neutral Blue

Earth Green/Yellow

Control 110V AC Live Brown

Neutral Blue

DC Positive Brown

DC Earthed Negative Blue

DC Earthed Positive Blue

DC Negative Grey

DC Positive Brown

DC Negative Grey

DC Earthed Mid-Wire Blue

4.7 All panel wiring shall be routed in cable ducting with removable clip-on lid. Looming of wiring shall be
permitted where the use of ducting is not possible.
4.8 Wiring between fixed portions and hinged doors shall be enclosed in flexible, PVC tube.
4.9 Wiring passed through internal holes shall be fully protected by correctly fitting grommets.
4.10 Intrinsically safe cabling shall be coloured blue and shall be segregated from all other wiring.

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Electrical Standards: Electrical Components of Packaged Equipment

5. Cable Terminations
5.1 Glands shall be made of brass and comply with BS6121 and EN50262 and in the case of glands used in
Hazardous Areas have ATEX certification. Glanding of cables shall comply with manufacturer instructions.
Use the correct size metric cable glands. Use adapters only with prior approval by the Buyer.
5.2 Terminate armoured cables with compression brass gland fittings, type E1W in non-hazardous areas and
type EIWF in hazardous areas per BS6121. Use LSF shrouds and brass earth tags with cable glands.
Glands, earth tags and shrouds shall be Hawke Cable Gland Limited OR CMP manufacture or equal and
as approved by the Buyer.
5.3 Terminate unarmoured cables in brass type A1/A2 gland fittings per BS6121.
5.4 Glands shall have ISO, R68 series thread, 1.5mm constant pitch. Use brass adapters for threads other
than ISO.
5.5 Earth the case of glands for armoured cables, the brass armour-earthing ring shall be incorporated in the
gland. This earthing ring shall be connected to the earth bar or earth point by means of earthing cables.
5.6 All non-metallic enclosures are to be glanded with an internal locknut and earth tag. This shall be
connected to all metal parts within the enclosure to maintain earth continuity.
5.7 Use LSF glands and shrouds for LSF cables.
5.8 The inner sheath of all cables shall not be removed until it is necessary to spread or loom the cable cores
for termination. The maximum amount of inner sheath shall be retained in all circumstances and at least
20mm shall be retained clear of the cable glands in the worst cases.
5.9 The cable conductors shall not be subjected to undue pressure or sharp bending during termination. All
conductors shall be fitted with crimp type terminal lugs of “BICC / Burndy” manufacture, or equal and
approved unless indicated otherwise.
5.10 All cable lugs shall be supplied and installed by the Contractor, strictly in accordance with the
manufacturer’s instructions and using the manufacturer’s recommended crimping dies and compression
tools.
5.11 All cables shall be adequately supported and clipped to within 200mm of the cable glands at both ends.

6. Earthing
6.1 All electrical equipment shall be provided with a suitable terminal earth stud, complete with a nuts and
washers.
6.2 All equipment and metalwork shall be properly bonded.
6.3 Metallic equipment inside control panels shall be connected to the earth stud or bar using yellow/green
earth wire, minimum size 4sqmm.
6.4 An earth bar shall be provided inside control panels, insulated from the panel, for power earths and
bonding earths. This earth bar to be tagged as’ Main Earth’.
6.5 An earth bar shall be provided inside control panels, insulated from the panel, for signal earths and
screens of external cables. This earth bar to be tagged as’ Instrument Earth’.
6.6 Each skid associated with an equipment package shall be provided with an earth stud, complete with
nuts and washers.

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Electrical Standards: Electrical Components of Packaged Equipment

7. Site Conditions
7.1 The equipment shall be suitable for use in areas defined by the mechanical specification and in
accordance with this specification.
7.2 Electrical Rooms:
Enclosures for equipment located indoors in an electrical room shall be IP42 minimum in accordance with
IEC 60529.
7.3 Process Areas and Utility:
Enclosures for equipment located both indoors and outdoors in process or utility areas shall be IP65
minimum in accordance with IEC 60529. Provide space heaters for dew point control if subject to
condensation. Heaters shall be accessible for replacement and provided with personnel protective
screens. Protect each space heater with MCB protection and thermostatic control.
7.4 Hazardous Areas
Equipment shall be suitable for use in Zone 1 areas, temperature class T4 and gas group IIB or IIC, and
in case of locations where Dust Hazard is present equipment shall be suitable for use in Zone-21,
certified by the appropriate national authority of an E.U. member country. Where hazardous zones are
present they shall be detailed in the equipment datasheet.

8. Labels
8.1 All items of electrical equipment shall be identified in accordance with Purchaser’s tag numbers with
necessary non-corroding labels having black letters on white backgrounds. All wiring in control panels,
etc, shall be identified in accordance with the seller’s schematic and wiring diagrams. All wiring and
danger labels shall be non-corrodible having white letters on a red background. All labels and lettering
shall be of sufficient size to provide easy reading from the normal operating or maintenance positions.
Fixing labels shall be by means of non-ferrous screws.
8.2 All items of low voltage equipment shall be fitted with warning labels showing a black “lightning” symbol
inside a black triangle against a yellow background.
8.3 All labels shall be reversed engraved to provide a smooth, edgeless and cleanable surface on the
nameplate.
8.4 The equipment shall be marked with the fabricator’s name, trademark or other identification symbol.
8.5 A permanent nameplate containing the following information shall be affixed to the control equipment
enclosure where plainly visible after installation:
10.5.1 Machine/system serial number
10.5.2 Supply voltage, phase and frequency (of each incoming circuit)
10.5.3 Full load current (of each incoming circuit)
10.5.4 Ampere rating of the largest motor and load
10.5.5 Short circuit interrupting capacity of the equipment
10.5.6 Electrical schematic drawing number or drawing number for index of electrical diagrams
10.5.7 CE Mark
8.6 The full load current shown on the nameplate shall not be less than the sum of the full load currents for
motors and other equipment which operate concurrently under normal conditions of shall be reflected in
the full load current indicated on the nameplate.

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9. Voltage Supply
9.1 A single source of 400V, 3 phase, 50 Hertz, 3 or 4 wire plus earth, or 230V, 1 phase plus earth (with
neutral solidly earthed) supply will be supplied by the Buyer. Should control panel, by providing suitably
rated control transformer or other electrical devices.
9.2 Requirement for UPS power shall be detailed on the equipment datasheet.

10. Drawings And Data

10.1 To meet consideration, all bids must be returned with the following drawings and data:
a) Preliminary dimensional outline and arrangement of equipment and panel layouts.
b) Preliminary details of equipment foundation requirements.
c) Full descriptive and technical details of components that the Seller proposes to use in his control
panel.

11. Scheduled Requirements

11.1 The Seller shall also provide the following after receipt of order:
a) 1 copy – dimensional outlines of all equipment and panel layout for approval with one reproducible.
b) 1 copy – certified dimensional outlines of all equipment and panel layouts with one reproducible.
c) 1 copy – schematic diagram of the control system with description of operation or approval with one
reproducible.
d) 1 copy – certified schematic diagram of the control system with one reproducible.

11.2 The Seller shall indicate clearly if any required electrical components must be installed remote from the
packaged equipment and the extent of field electrical work to place the packaged equipment in operation.
11.3 The Seller shall provide interconnecting wiring diagrams with terminal numbers.
11.4 All other documents detailed in the technical requisitions.

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Electrical Standards: MCC Specification

MCC Specification

1. Purpose
The purpose of this document is to define the minimum requirements for design, supply, delivery, ingress,
installation and commissioning of MCCs at Diageo production sites.

2. Standards
All MCCs to be supplied to the site will be required to meet the latest Irish, British and European standards. These
standards include:
ET201:2005 – Code of Practice for the design, selection and erection of low voltage switchgear assemblies.
ET204:1995 – Code of Practice for control systems involving programmable electronic products and systems.
ET101:2008 – National Rules for Electrical installations
IEC60947 - Specification for Low Voltage Switchgear and Control gear
IEC60439 – Specification for Low Voltage Switchgear and Control Gear Assemblies.
IEC 60044-1 – Instrument Transformers – Part 1: Current Transformers
IEC61000 – Electromagnetic Compatibility (EMC)
IS201 – PVC type insulated cables and flexible cords of rated voltage up to and including 0.6/1.0KV

3. General Requirments
• All materials shall be new and of excellent quality
• All MCCs are to be Form 2. (Busbar is separated by a Rittal standard plastic channel.)
• MCC Panels shall be designed for installation into dry areas only - MCC Rooms, Plant rooms etc. Note that if
the panel is to be installed outside these areas a panel of suitable manufacture for those areas is required, i.e.
generally stainless steel and IP65 rated.
• Overall Panel height of 2,100mm made up of a 100mm plinth and 2,000mm MCC chamber. Note the busbar
should be included in to the Control Cabinet.
• Cable entry via the top or bottom of the panel as required. Top entry is generally only applicable in a sealed
building where there is no risk of water ingress. Agreement with the Diageo engineer required for confirmation.
• Cable entry shall be protected by a Rittal standard steel plate with foam rubber. All cables which enter the top
of the panel shall be glanded and be installed with rubber shrouds.
• All cables are wires must be marked at each end
• In general MCC’s shall be limited in size to 800A supplies. See Section 10 below for distribution line diagrams.
• Each MCC must have a suitably rated mains isolator
• Each Mains Isolator must be housed in its own Cabinet and the Isolator must be door interlocked. Steel
partition required to separate the Mains Isolator from the Starter sections.
• The main incoming cable shall be terminated directly onto the terminals of the main isolator switch.
• All internal components shall have permanent nameplates highlighting their instrument tag numbers.
• Panel design shall take into account suitable glanding space for the mains incomer cables when laying out the
main incomer section.
• The MCC to be made of a series of Rittal or equivalent cabinets all bolted together to form a composite suite
• All main incomers to have a door mounted Siemens Centron PAC3200 with Profibus DP interface. Dirius A40
Profibus DP Energy Meter may be used on agreement with the Diageo engineer.
• Panel colour shall be RAL 7035 (Grey Colour)
• Type of Rittal Lock: Rittal 3524
• Panel design shall take into account MCC Room dimensions and access to the MCC Room.
• Incoming Power = 400v 3ph & N & E, 50Hz
• Internal panel cable core labelling to be a white marker with black letters

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• Labels containing the following information shall be permanently mounted on the outside of the panel in a
visible position.
• Warning Labels
• Panel Name
• Supply Voltage and frequency
• MCC Control Voltage = 24vdc
All digital outputs shall be fused. Fusing arrangement to be agreed with the Diageo engineer at pre-
manufacture drawing approval stage.
Colour Coding:
AC Voltages
400v L1 = Brown
400v L2 = Black
400v L3 = Grey
400v N = Blue

230v L = Brown
230v N = Blue

110v L = Brown
110v N = Blue

24vac L = Purple
24vac N = Black

DC Voltages
24vdc+ = Grey
24vdc- = Black

Others
4-20mA+ = Red
4-20mA- = Blue

• Earthing, Protective and Bonding Conductor = Green / Yellow

• Measured signals = Number on each core for identification
• 35 kA Busbars rated for the total full load current plus 20% to be run left to right the entire length of the MCC in
the Busbar chamber.
• A steel internal partition to be inserted between each row of Control Cabinets
• Air inlet filters of similar size to the fans to be fitted on the door of the MCC’s
• Panels to have a 230vac Rittal strip light controlled by a switch activated by the door
• Each MCC shall include a double RCD socket (3 pin BS)
• Transformer required for control voltage and shall take into account motor cable length, spare capacity and
voltage drop.
• Screw Type terminals to be used = Weidmüller
• All terminals to be Weidmüller dinrail type with terminal side covers installed where required.
• Panel rail shall be dinrail
• Allow for robust Rittal type drawing pockets on all MCC’s
• Fully type tested and rated to IP 42, or higher if located outside of an MCC Room. (Rittal standard)
• Adequate spacing must be allowed to allow glanding and routing of cables for incoming and outgoing circuits.
• Earth and neutral connections must be in accessible positions and are not to be located such that they will be
obscured by cabling.
• All components must be accessible from the front for maintenance or replacement.

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• Wireways are to be sized with sufficient room to house outgoing cables and leave 40% spare – subject to
space availability in MCC Room
• Raceways shall not be filled more than 60% – subject to space availability in MCC Room
• All boards must be extendible with a minimum modification.
• All main busbar, including neutral to be rated for FLC of the board. Connections from main busbars to starter
sections to be sized for full load of starter. Busbars shall be insulated with a plastic or screwed metal cover with
warning notice on the cover.
• All panels to be supplied with 15% spare space – subject to space availability in MCC Room
• All contactors / overloads / isolators shall be Siemens. Alternatives such as Schneider can only be used on
agreement with the Diageo engineer.
• The assembly must be CE compliant and bear the CE logo.
• Panels must be designed to avoid overheating under full load conditions. Compartments must have adequate
space to dissipate any heat generated. Air conditioning should be provided on all panels installed outside of
the UK and Ireland unless located in an air-conditioned MCC Room.
• Panels are to be provided with lifting lugs and are to be delivered in sections that will ensure access to the
MCC Room.
• All separate metal sections of the panel shall be bonded to the main earth bar. All removal metal parts such as
gland plates / doors etc to be bonded to earth.
• All boards shall have a main board label located in the middle of the assembly above the main switch. Each
compartment is to have a label indicating the equipment tag name and description.
• Covers to all busbar chambers must be clearly labelled “Danger Live Busbars”.
• All equipment not isolated by the main incoming switch to be clearly labelled using a red label with black text.
• All equipment, terminals and wires to be clearly labelled with typed, permanent labels. Equipment labels to be
traffolyte, with black text on a white background, wire numbers to be slip on.
• All wiring shall be ferruled.
• Depending on the application, 230vac distribution sections should be considered in each MCC. General
guidance is to allow 12-off 10amp breaker in each MCC. In addition, all breakers and neutral wires need to be
connected to terminals at the top of the panel. Allow an earth terminal for each circuit. (This is not a mandatory
requirement)
• Allow ample space between contactors / relays / VSD’s / trunking etc. All equipment must be easily removed
without impacting equipment on other circuits.
• Panel layout drawings shall be approved by the Diageo engineer before panel build.

4. Motor Starters
4.1 General
Motor starters shall be of type Siemens. Alternatives such as Schneider can only be used on agreement
with the Diageo engineer.
Motor starters must be lockable in the OFF position.
In general starters are to be DOL up to a maximum of 15kW, soft starters above 15kW until 200kW and
Star-Delta above 200kW.
Soft starters may be used for motors sizes of 5.5kW and above.
Any parts of the compartment that remain live when the door is open must be shielded to minimum IP20
and be appropriately labelled.
DOL Motor starter can be either Type A or B below. Type A is an intelligent type system and Type B is a
conventional RIO type. The type used must be approved by the Diageo engineer.
Type A – Intelligent
• Simicode 3UF7 type.
• This design shall use the Siemens intelligent overload on Profibus DP.
• The design shall allow all DOL / Star-Delta motors to be controlled by Profibus and allow the current
to be monitored.
• Each simicode shall have its own DP node number.
• Each starter shall have its own simicode interface and current measuring module.
• The start / running and trip signals can be monitored over the Profibus network.

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Type B – Conventional
• Et200s remote I/O used to control the starters.
• Each motor shall have a start output and a run and trip signal back to the ET200s station.
• An ammeter is required on the door for each motor 7.5kw and installed on the door OR wired to the
PLC with display on the control monitor.
• MCC panel to contain the ET200s station.
• Partition required to separate the I/O section from the power section
• Allow for the following type card in each MCC:
• 1-off IM151-1 ET200s Interface
• 2-off Power supply module
• 4-off 4 channel DO cards and Bases (To energise the Contactor)
• 8-off 4 channel DI cards and Bases (Run and Trip Signals)
• The number of cards will depend on the number of DOL starter in each MCC.
• Allow 1-off digital output and 2-off digital inputs per DOL motor. Note maximum 4-off Do cards per
power module

5. Starter Sections:
• MCB - magnetic only coil.
• Contactor - AC3 rated
• Appropriately sized adjustable electronic overload relay shall be used
• Star-Delta starters to be equipped with electrical and mechanical interlocks.
• Stat controlled cooling fans to be fitted to the panel doors capable of extracting all heat generated by the VSD’s
/ Softstarters / DOLs etc when all running at full load.
• Run and trip lamps are not mandatory. However they may be used if appropriate for a particular application,
e.g. extension of an existing system
• All DOL field wiring power / isolator cables / water solenoids etc shall be wired to terminals at the top or
bottom of the panel.
• Coil suppressors required across contactor coils
• All VSD’s must be located in the panel. They must be stacked in such a way which will allow for easy removal.
• All VSD’s shall have thermistors. The thermistor circuit to be wired into the VSD from the field through
terminals at the top or bottom of the panel.
• All VSD’s to be Danfoss FC302 Type
• VSD’s to incorporate the safe stop system Sil 2
• All VSD’s power connections will be wired directly to the VSD terminals from the field and the cable screen
connected directly to the earth. MCC manufacturer to allow a EMC screen connection at the VSD.
• All VSD Isolator cables / Water solenoids / Thermistors etc wired to terminals
• VSD Keypad located on the VSD - minimum one per cabinet
• PLC communication with all VSD’s will be on Profibus DP
• Allow an earth terminal for each DOL / SS Motor
• Vendor is to provide heat calculations to ensure that there is sufficient space allowed for cooling for VSDs.
Fans and louvers are to be installed in the panels to provide adequate airflow.
• Control transformers are to be located in the panel. Secondary side of transformer to be grounded on one leg
and both sides to be fused.
• Power and control terminals to be segregated.

6. Power Monitor
Power monitors are to be provided on the incoming switch. The monitor type shall be Siemens Centron PAC3200
with Profibus DP interface. The Profibus connection needs to be a 9 pin connection type. Alternatives such as Diris
A40 on Profibus DP may be used on agreement with the Diageo engineer.

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7. Earthing
A separate "clean" earth system shall be provided for each instrumentation and computer system. This shall be by
means of a separate copper bar.
Every panel shall have main earth connections to the main panel metalwork.
Earthing of doors. Reliance shall not be placed on hinges for earthing. Removal of any component from the door
must not break the earth continuity to any other component on the doors.
Cable shields (e.g. filter to frequency converter, frequency converter to motor) must be connected directly to the
panel earth on both sides with sufficient cross sectional area.

8. Lightning Protection
Each board is to be provided with lightning protection.
The surge device is to be located in the power supply panel close to the main switch with suitable MCCB.
The surge device to be capable of discharging both lightning strikes and surges.
A terminal to be provided to allow fault signal to be fed to monitoring equipment.
Indicating LED to be provided on the door of the cubicle for indication of a fault.

9. Installation And Testing

Tests shall be carried out in the manufacturers premises per EN 60439-1 and shall be witnessed by the client.
Certificates verifying all test results are to be provided as part of the project documentation.
The manufacturer is responsible for reassembly of the board on-site.
After reassembly on site, the manufacturer is to carry out functional tests on protective circuits and dielectric tests on
the board.
2500VAC and continuity tests on busbars circuits may be carried out at the panel manufacturer’s premises prior to
delivery or on site prior to commissioning.

10. Documentation
The supplier shall provide the following design documentation to the client:
• Approval drawings to include general arrangement, schematics and equipment layouts – prior to manufacture.
• As built datasheets for all equipment
• As-built general arrangement and layout drawings
• As-built wiring diagrams indicating all terminal and wire numbers
• Records of all tests certificate, including type tests.
• Declaration of conformity to the low voltage directive and CE compliance.

11. Warranty
The equipment shall be guaranteed by the supplier against all defects arising from faults in design, material and
workmanship for a period of twenty four months after commissioning.

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Variable Speed Drive Specification

1. Scope
1.1 This specification defines requirements of for the provision of Variable Speed Drives for use on any
Global Diageo site.
1.2 Where the technical specifications and drawings, where necessary, are formulated by reference to
detailed descriptions, proposals by the tenderer will not be rejected on the grounds that the products
works or services do not comply with the technical specifications and drawings, provided the tenderer can
show, by an appropriate means, that his proposals satisfy in an equivalent manner, the requirements
defined by the technical specifications and drawings. Where trade names / product names may be used,
if any, in describing the products works or services to be procured, these are used as information only for
the purpose of more fully describing the specification and drawings requirements. In relation to all
descriptions and references used for products works or services to be procured, equivalent products
works or services are acceptable, except in such instances, if any, where equivalent products works or
services would be incompatible with existing equipment already in use or would entail disproportionate
cost or technical difficulty, in which instances, the particular products works or services shall be identified
in the technical specifications and drawings as being mandatory.
1.3 The Seller shall be required to design, fabricate, supply and deliver, assemble, test and commission the
Variable Speed Drives in accordance with this specification and the attached drawings.
1.4 All necessary lifting lugs etc., for transportation, lifting and erection purposes shall be included.
1.5 The electrical contractor shall offload the Various Speed Drives and place them in position. The seller
shall be responsible for all other on site works including but not limited to assembly and testing.
1.6 The Seller shall commission the equipment. Installation will generally be by the Electrical contractor or
package vendor.
1.7 All labour, materials, appliances, tools, equipment facilities, transportation, and services necessary for
and incidental to performing all operations in connection with furnishing, testing and delivery of the work
of this specification, complete, as shown on the drawing and specified herein. Work includes, but is not
necessarily limited, to the following:
1.7.1 Examine all other specifications for work r elated t o those other specifications as required to
be included as work under this specification.
1.7.2 Furnish, test and deliver the Variable S peed D rives complete as shown on the drawings and
as specified. The Variable Speed Drives shall be built, tested, and shipped by the
manufacturer who will assume total responsibility for the unit and for all components of each
variable speed drive.

2. Standards and Codes

2.1 Variable Frequency Drives shall meet the requirements of all the applicable standards of the authorities,
including but not limited to the list below:
2.1.1 EN 61800 (All Parts) Adjustable Speed Electrical Power Drive Systems.
2.1.2 EN 60439-1: Low voltage switchgear and control gear assembles.
2.1.3 ET [Link] Code of Practice for the Design, Selection, Testing and Erection of LV
Switchboards for Commercial and Indus trial Applications, published by the Electro-Technical
Council of Ireland.
2.1.4 EN 50178: Electronic equipment for use in power installations.
2.1.5 EN 60529: Specification for degrees of protection provided by enclosures (IP Code).
2.1.6 European Union Directives relating to product safety and CE marking.
2.1.7 IEC 61000 -1-1 Title: Electromagnetic Compatibility ( EMC) – Part 1 General – Section 1 .
Application and interpretation of fundamental definitions and terms.
2.1.8 IEC 61000 -5-1 Title: Electromagnetic Compatibility ( EMC) – Part 1: Installations and
Mitigation Guidelines – General Considerations Basic EMC Publications.
2.1.9 EMC Directive 89/336/EEC.

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2.1.10 Electrical components, wiring and enclosures shall comply with European Standard E N
60204 -1 – “Safety o f Machinery – Electrical Equipment of Machines Part 1: General
Requirements”.
2.1.11 Safety, Health and Welfare at Work Act, 2005 and the Safety, Health and Welfare at Work
(General Application) Regulations 1993 ( Statutory Instrument S .I. N o. 44 of 1993) , P art V
III r elates to Electricity and Amendment Regulations S.I. No. 188 of 2001 and S.I. No. 53 of
2003.
2.2 Electrical components, wiring and enclosures shall be in accordance with the standards published by the
International Electrotechnical Commission ( IEC), European Committee for Electrotechnical
Standardisation (CENELEC), National Standards Authority of Ireland (NSAI) and The British Standards
Institute (BSi). If the Seller’s equipment deviates from these standards or codes the proposal shall define
in detail these differences.
2.3 Variable S peed D rives s hall comply with the requirements of the E MC Directive 2004/108/EC and EN
61800-3. The Seller shall demonstrate in his bid how this has been achieved.
2.4 The entire assembly shall be CE compliant and shall bear the ‘CE’ logo.

3. Service & Performance Conditions

3.1 All VSDs shall be designed to be suitable for the indoor environmental conditions defined in IEC60439-1
section 6. Refer to the datasheets for the details of each VSD.
3.2 A TN-CS system is used throughout the plant as defined by ET 101.
3.3 The following are the site standard voltages:

Motors above 0.37kW 400V ± 10 %, 50 Hz ± 2% 3 Ph 3 wire

Motors 0.37 kW and below 230V ± 10 %, 50 Hz ± 2% 1 Ph 2 wire

Non-motor loads 400V ± 10 %, 50 Hz ± 2% 3 Ph & N 4 wire

3.4 Prospective Fault Level shall be stated on the datasheet or single line drawings.

4. General Requirements
4.1 The solid-state VSDs shall be of the pulse width modulated (PWM) type, designed to convert 400 Volt,
three-phase, 50 Hz input power to variable-frequency output power. The output voltage of the inverter
shall also be variable and controlled by the value of output frequency such that a constant Volts-to-Hz
ratio may be maintained throughout the operating range.
4.2 The VSDs shall be used to operate both variable-torque and constant torque loads. The drives shall,
however, be suitable for constant or variable torque applications and the Manufacturer shall determine
the size of variable-frequency drive to meet this requirement.
4.3 The V SDs shall include power conversion components, power control logic devices, and regulator
circuitry. The regulator shall provide full digital control of frequency and voltage.
4.4 All components are to be mounted in an enclosure properly sized to dissipate the heat generated by the
VSD within the limits of the specified environmental operating conditions. The Manufacturer of the VSD
enclosure shall provide Heat Dissipation calculations to verify that the enclosure can dissipate all heat
generated by the VSD and any other hardware mounted within the enclosure. The degree of enclosure
protection shall be IP 21 minimum in accordance with E N 60529 unless other wise stated on the
datasheet.
4.5 All components shall be removable from the front. With all components fitted, the VSD enclosure shall
facilitate maintenance access and not be overcrowded. Extra- low voltage equipment and terminals shall
be accessible with low voltage equipment covered.

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4.6 The V SD shall be fitted with an output choke/filter device w here any of the following conditions apply or
where the supplier deems it necessary:
4.6.1 For each motor with a shaft power rating ≥ 18.5 kW.
4.6.2 For installations where there are long field power cables from the VSD to the motor.
4.6.3 Where required or recommended by the VSD manufacturer.
4.6.4 The Buyer shall provide the relevant motor and cabling installation da ta i n order for the
Manufacturer to size the VSD and advise of filtering requirements
4.7 The frequency resolution of the VFD shall be 0.1 Hz.
4.8 All V SD adjustments and custom programming shall be capable of being stored in non-volatile memory
(EEPROM).
4.9 The VSD s hall be designed to protect itself against instantaneous current levels above 200 percent of its
rating. The V SD s hall continue to operate through instantaneous current spikes below 200 percent.
4.10 The VSD shall be immune to line notching from other VSDs.
4.11 The VSD shall be capable of operating with the output open circuited.
4.12 The VSD is to have electrical isolation between the power and logic circuits as well as between the
control power and the static digital display.
4.13 The VSD controller shall be rated for 150 percent continuous current for 1 minute.
4.14 The VSD shall be able to withstand the RMS symmetrical short circuit current at the line terminals to the
prospective fault level shown on the datasheet.
4.15 Where VSD units mounted within a MCC,unit components shall be factory mounted and wired within the
MCC enclosure by the MCC seller. A VSD key pad interface panel and display unit s hall be mounted on
the door see also 9.0 below. Adequate ventilation, with fans if recommended by the V SD manufacturer,
shall be provided.

5. Main Power And Control Components

5.1 Where specified in the associated equipment specification, datasheet, or as required for safety or
maintenance purposes, the VSD shall be provided with a bypass starter and manual by pass s witch to
permit motor operation during VSD failure or maintenance procedures. Bypass starters shall be direct on
line (DOL) for VSD’s rated up to 50 kW and electronic soft start for VSD’s greater than 50 kW. The
bypass start facility s hall be initiated locally using the panel by pass s tart pus h button, and shall be fully
interlocked with the VSD.
5.2 The VSD shall have the functional components listed below:
5.2.1 Main disconnect with the handle interlocked with the door for safety. The unit shall be a non-
automatic circuit-breaker complete with a door-mounted handle. A tool operated interlock
defeat mechanism shall be located on the side of the door mounted handle.
5.2.2 Input ac contactor for emergency stop function.
5.2.3 Main HRC fuses, rated for the protection of semiconductors.
5.2.4 Input diode bridge rectifier to supply fixed dc bus voltage.
5.2.5 Smoothing reactor for dc bus.
5.2.6 Diode bridge motor over-voltage protection.
5.2.7 DC bus capacitors.
5.2.8 Single control logic board with full digital control circuitry capable of accepting 4 to 20 mA, 1 to
10 Volt dc signal, 250 Ohm maximum load.
5.2.9 The VSD shall be equipped with a hardwired control interface option or a control bus interface
using Profibus D P or DeviceNet or equivalent and approved by the Buyer. The clients
required option s hall be stated on t he data sheet.
5.2.10 Integrated serial interface (RS232) in door mounted operator panel.
5.2.11 Terminal block for operator controls separated from power terminals.

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5.2.12 Power semiconductor section for generation of the sine-weighted PWM output waveform.
Main semiconductors are to be transistors.
5.2.13 Terminal blocks for incoming power and motor termination suitable for top or bottom cable
entry, as agreed with the Buyer.
5.2.14 Built-in thermal overload protection in all three phases suitable for long ramp times where
applicable.
5.2.15 Direct input for motor winding PTC thermistors for thermal protection.
5.3 All VSDs shall operate fail-safe in case of loss of power supply and shall not restart automatically.

6. VSD Operating Characteristics

6.1 The VSD shall have the features listed below:
6.1.1 Output Frequency Range: 0.1 to 200H z for constant torque configuration and 0.1 to 75Hz for
variable torque configuration.
6.1.2 Control voltage shall be 110Vac.
6.1.3 Active current limit function to provide nominal 110 per cent torque for 1 minute.
6.1.4 Minimum efficiency of 95 percent at rated load and speed, and minimum of 90 percent at any
other speed and load.
6.1.5 Minimum incoming line power factor throughout the load an d s peed range of 0.95.
6.1.6 Bus discharge to 50V maximum within 60 seconds or less per referenced British and Irish
standards.
6.1.7 In the event of a short duration input power failure/dip (less than 20 milli- seconds), t he V SD
s hall s hut down safely without component failure and then automatically restart the motor
when the input power is restored. If the motor is still rotating when power is restored, the VSD
will sense the speed of the rotating motor and ramp to the appropriate frequency.
6.2 Where required for safety or operational reasons, specific V SDs s hall be provided with a “Maintained
Output Ride-Through” facility for defined input voltage dips.

7. VSD Protection Features

7.1 The VSD protection functions are to include:
7.1.1 Overload protection.
7.1.2 Short circuit protection consisting of HRC gG type fuses to IEC 60269.
7.1.3 Monitoring of the V SD heat sink temperature via the serial interface providing separate pre-
set levels for cooling fan control, temperature alarm level and temperature trip level.
7.1.4 The enclosure cooling-fan s hall be controlled directly from a temperature sensor in the VSD.

8. VSD Diagnostics
8.1 The following faults/indications are to be displayed on the main enclosure front programming panel.
8.1.1 Overload or short circuit (overcurrent).
8.1.2 Earth fault.
8.1.3 Under voltage.
8.1.4 Overvoltage.
8.1.5 Over temperature alarm
8.1.6 Over temperature shutdown.
8.1.7 Semiconductor fault (each leg).
8.1.8 Power on
8.1.9 Bypass on (if installed).

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9. Local VSD Operator Control

9.1 A VSD operator control and programming panel with protective visor shall be mounted on the front door
of the main enclosure or shall be accessible from the front of the main enclosure, and shall include the
following functions:
9.1.1 Start.
9.1.2 Stop.
9.1.3 Manual speed adjust.
9.1.4 VSD/Off/Bypass selector switch (if bypass is installed).
9.1.5 Ability to increase or decrease local speed reference using door mounted potentiometer or
keypad (accuracy to 0.1 Hz).
9.1.6 Provide a digital display for monitoring the following functions:
• Frequency reference.
• Motor load, calibrated in Amperes.
• Output frequency.
• Output voltage.
• Fault diagnostic messages.
• VSD status messages.
• Remote speed reference from PCS.
• DC Bus Voltage
• Push to Test LCD.

10. Remote Controls

10.1 Inputs to VSD:

10.1.1 An external input signal to start and stop the VSD when the enclosure mounted H/O/A switch
is in auto mode.
10.1.2 Analog VSD input for speed remote setpoint reference signal shall be 4 to 20 mA, 24V DC
loop powered
10.2 Outputs from VSD:
10.2.1 Analog V SD output signal for VSD output current shall be 24V DC, 4 to 20mA. The loop
circuit shall be powered from the VSD.
10.2.2 Auto-Off-Hand s elector switch. Additional ‘ volt-free’ contact t o be wired out to terminals for
Auto position indication.
10.2.3 VSD fault signal: ‘volt-free’ contact wired to terminals.
10.2.4 Main contactor closed and VSD in operation: ‘ volt-free’ contact wired to terminals for
connection to BAS or PCS.
10.3 The VSD shall be fitted with a DeviceNet, profibus, protocol or similar as specified on datasheet interface
card for transmitting output signals to an external control system.

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11. VSD Parameter Adjustment

11.1 The following setup adjustments are to be provided as a minimum:
11.1.1 Minimum speed.
11.1.2 Maximum speed.
11.1.3 Independent acceleration rate (adjustable).
11.1.4 Independent deceleration rate (adjustable).
11.1.5 Adjustable dc boost.
11.1.6 VFD shall have the capability to avoid up to five critical operating ranges.
11.1.7 Constant or variable torque.
11.1.8 Output voltage at minimum speed.
11.1.9 Output voltage at maximum speed.
11.1.10 Line di p r ide through time for operation in the non -maintained output m ode (maximum time
for the VSD to stay active).
11.1.11 Remain running following loss of analog speed reference signal. The VSD is to retain the last
speed setting, + or -2 percent in the event of loss of the analogue speed setpoint or bus
interface.

12. Internal Wiring

12.1 Internal wiring s hall have switchgear rated insulation with a minimum of 1.5m m2 stranded copper
conductors. All internal wiring shall be high temperature tri rated cable to BS6231.
12.2 All wiring for Buyer’s connections shall be brought to identified, adequately rated enclosed terminal s trips.
2
The minimum size terminal shall be capable of accepting 2No 2.5m m conductors. All internal wiring s
hall be individually numbered and crimped at both ends. Wiring for different voltages shall be colour
coded accordingly.
12.3 The terminal strips shall be arranged so that the panels are suitable for top or bottom entry as specified
on the datasheet.
12.4 Circuits, wiring and terminals operating at different voltages shall be segregated and marked with the
relevant voltage with adequate protection against accidental contact during termination of external control
wires etc. Starters that contain intrinsically safe devices shall have the IS terminations completely
segregated.
12.5 VSD s hall be supplied with gland plate and accessories suitable for E MC rated glands & cables.

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12.6 Colour coding of cable cores and internal wires shall be as follows:

Power Phase 1 Brown

Phase 2 Black
Phase 3 Grey
Neutral Blue
Earth Green/Yellow

Control 110V AC Live Brown

Neutral Blue

DC Positive Brown
DC Earthed Negative Blue

DC Earthed Positive Brown

DC Negative Grey

DC Positive Brown
DC Negative Grey
DC Earthed Mid-Wire Blue

12.7 The phase sequence of the supply shall be L1, L2, L3 and the power conductors shall be arranged to
follow this sequence, reading from left to right or top to bottom, when observed from the front of the Panel.
12.8 Wiring to door mounted equipment shall be arranged so that it cannot possibly be trapped in the door or
become mechanically strained.
12.9 All wires shall terminate in approved type terminals and shall be identified at both ends using white plastic
core ferrules. Numbering of wires and terminals shall be in accordance with the schematic wiring
diagrams.
12.10 Field power cables shall be armoured, screened, E MC type VSD cables, 600/1000V grade stranded
copper.
12.11 Incoming cable cores shall be terminated in “Klippon” type clamping terminals or with compression type
lugs. Terminals of the type where the screw itself grips the core shall not be used. A separate terminal
shall be used for each external cable core.
12.12 Control / indication terminals shall be screw / clamp type, properly sized for the corresponding conductor.
12.13 Cable terminations shall be of the solderless crimped type. Stud type terminals shall use spring loaded
clamp type terminals.
12.14 Wiring shall be neatly arranged in looms of not more than 25 cores. The wiring shall be positioned and
routed to minimise the possibility of mechanical damage.
12.15 Each terminal block s hall be supported at frequent intervals to prevent damage caused by the normal
use of a screwdriver. All cables and looms must be retained with cable ties or strapping, designed to
prevent damage to the c able insulation and to provide adequate support to the cables and cable looms.
Alternatively, cables may be installed in cableways adequately sized to al low the installation o f 50% m
ore cables at a future date.
12.16 Terminal blocks s hall be arranged and positioned to afford easy access for carrying out external cable
terminations, testing, inspection and maintenance. Where equipment is located on any hinged or sliding
panel section or door, it shall be wired i n a P VC insulated flexible cable holder suitably supported and
protected against undue strain and chafing.

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12.17 Proprietary type cross-connecting links shall be used where conductors are to be “commoned” together.
12.18 Terminations s hall be arranged in functional groups, each group being clearly labeled. Intrinsically safe
terminations shall be coloured blue.

13. Labels
13.1 The VSD shall have a main data label bearing the following minimum information:
13.1.1 Manufacturers name or identifiable trade mark.
13.1.2 Type, designation, number or code.
13.1.3 Rated voltage and frequency.
13.1.4 Rated current.
13.1.5 Light overload use in kW.
13.1.6 Heavy duty use in kW.
13.1.7 Date of manufacture.
13.1.8 Short-circuit rating in kA.
13.1.9 Country of origin.
13.1.10 Degree of protection.
13.1.11 Dimensions and weights.

13.2 Labels shall be white “Traffolyte” with black letters .

13.3 All warning labels shall be engraved red on white background "Traffolyte", or similar. Covers to busbar
chambers shall be fitted with warning labels and engraved with 6mm high letters as follows "DANGER
LIVE BUSBARS".
13.4 Labels shall be clear and concise and shall be engraved in the English language.
13.5 The numbering system to be adopted for the V SDs, cables, panel s and terminal boxes shall be as per
the single line diagrams.
13.6 Labels shall be fastened with non-ferrous screws or rivets. Adhesive or tape shall not be used for
fastening purposes.

14. Documentation
14.1 The Seller shall provide documentation as per the attached VDR. These s hall include but not be limited
to the following:
14.1.1 Fully dimensioned, general arrangement drawings, including elevations showing front, s ides
and back views with locations and dimensions of the cable chambers, including the bottom
cable entries.
14.1.2 Weights of the equipment
14.1.3 Wiring Diagrams
14.1.4 Schematic Diagrams
14.1.5 Logic Diagrams
14.1.6 VSD User Manual and Programming Instructions
14.1.7 Location of available parts and service
14.1.8 List of sub-assemblies, devices and part numbers
14.1.9 Base plan, show dimensions of base with anchoring
14.1.10 All component catalogue cut sheets
14.1.11 Characteristics of protective devices

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14.2 Shop drawings and product data shall be submitted in electronic form as well as hard copy whenever
possible.
14.3 Manufacturers “ type test” certificates s hall be provided for all V SDs. Type tests results shall be for
VSDs of the exact same type/model/design and construction.
14.4 The seller shall provide three complete bound and covered sets of operating and maintenance manuals
for the V SDs and al l of the accessories. In addition to hard copies the seller shall supply in disc form the
manuals in Adobe Acrobat format.
14.5 The O&M manuals shall also include the test records for the VSDs.
14.6 It is emphasised that a collection of standard pamphlets of general nature unaccompanied by Drawings
and descriptive matter relating to items of Plant as installed will not be acceptable. In particular,
information supplied by sub-contractors and manufacturers employed by the Contractor s hall be co-
ordinated into the comprehensive Manuals. Cross-reference of descriptive matter, drawings and spare
part lists must be complete.
14.7 The Manuals shall be of A4 size and loose-leaf binders. Drawings shall be of extended A3 size: large
drawings, except circuit diagrams, being reduced photographically as necessary. The binder shall be
clearly marked with the name of the installation. The Manuals shall have contents sheets at the front and
a comprehensive index at the back.
14.8 The seller shall provide three complete hard copies and one CD ROM copy of the operating and
maintenance manuals.
14.9 Approval of drawings by the Buyer does not relieve the Vendor of any responsibility in respect to faulty
design, materials or workmanship.
14.10 All documents shall be supplied in the English language.

15. Testing And Installation

15.1 Test records shall be provided for the factory tests and type tests as defined in EN61800-2 Section 7.
15.2 The VSDs shall be completely assembled, wired, and tested at the Sellers’ plant. The following routine
tests will be subject to witnessing by the Buyer: These tests shall be at both the Sellers manufacturing
plant and on site after installation. The Seller should allow in his bid for such testing.
15.2.1 Factory test the VSD system, including a motor for functional performance, proper operation,
and proper wiring.
15.2.2 Verify proper operation of all controls, instrumentation, and protective functions.
15.2.3 The Buyer reserves the right to witness any or all of the a fore mentioned tests. Where the
Buyer waives the right of witnessing a test or tests, the Vendor shall in no way be relieved of
the responsibility for the performance of such tests.
15.2.4 Operate the VSD with a motor throughout its specified speed range and at rated power supply
load for at least 10 hours.
15.3 Records of the test results shall be furnished on completion and included in the O&M Manuals.
15.4 The Purchaser shall have the right to refuse to accept the VSDs if the test results do not comply with the
standards/values specified and information/data given in the enquiry.
15.5 Both Factory Acceptance Tests ( FAT) and Site Acceptance Tests ( SAT) s hall be subject to witnessing
by the Owner/Engineer.

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16. Deviations
16.1 Deviations from the specification, datasheets, schedules and drawings must be stated in writing at the
quotation stage.
16.2 In absence of such statement, it s hall be assumed that the requirements of the specification are met
without exception.

17. Warranty
17.1 The V SDs including all components and accessories shall be guar anteed by the Supplier against all
defects arising from faults in design, material and workmanship, for a period of 12 months from the date
of commissioning.
17.2 Should any design fault which would lead to a forced outage of VSDs, become apparent to the Purchaser
or to the Supplier after the expiry of the above period, the Supplier shall deliver all components necessary
to correct the fault, together with any necessary instructions and specialist assistance, free of charge.
17.3 If the VSD has to be returned to the Supplier’s works for repair under this guarantee clause, the Supplier
shall c over the cost of transport from site to works and back to site again.

18. Start-Up Assistance

18.1 The Seller shall include for the following site services:
18.1.1 Service of a factory trained engineer or technician to approve the V SD installation, attend
meetings with the buyer and Engineer to agree philosophy and consistency of drive settings
prior to implementation.
18.1.2 VSD start-up, test and adjustment for proper operation.
18.1.3 Provide final programmed VSD parameters in a format for downloading to the VSD and hard
copy. The parameter file name shall be the same as the VSD number.
18.2 Provide instruction and training for the buyer personnel i n programming, operation and maintenance of
the V SD systems; minimum of four hours of training for each type of VSD.

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Electrical Standards: Instrument Tube and Fittings

Instrument Tube and Fittings

1. Scope
1.1 This specification covers the requirements for the provision of Instrument Tubing and associated fittings
for the any Global Diageo Site.
1.2 Where the technical specifications and drawings, where necessary, are formulated by reference to
detailed descriptions, proposals by the tenderer will not be rejected on the grounds that the products
works or services do not comply with the technical specifications and drawings, provided the tenderer can
s how, by an appropriate means, that his proposals satisfy in an equivalent manner, the requirements
defined by the technical specifications and drawings. Where trade names / product names may be used,
if any, in describing the products works or services to be procured, these are used as information only for
the purpose of more fully describing the specification and drawing requirements. In relation to all
descriptions and references used for products works or services to be procured, equivalent products
works or services are acceptable, except in such instances, if any, where equivalent products works or
services would be incompatible with existing equipment already in use or would entail disproportionate
cost or technical difficulty, in which instances, the particular products works or services shall be identified
in the technical specifications and drawings as being mandatory.
1.3 All instrument tube and fittings, materials and parts used, shall be new and unused, of current
manufacture, of the highest quality and free from defects or imperfections. All instrument tube and fittings
installed outdoor s shall be weather-proof and corrosion resistant.

2. Technical Requirements
2.1 Pneumatic Tubing and Fitting
Tubing shall typically be utilised for the instrument air supply from a manifold to a pneumatic actuator.
Check with engineer for guidance on specific locations for preference to stainless or polyethylene and for
quick release fitting requirement.
2.1.1 Single Polyethylene Pneumatic Tube - (Location specific - UV rating and Chemical
Resistance) Single O.D. x 1mm wall thickness high-density flame retardant polyethylene tube
with 1mm thick PVC Green overall sheath. (if high uv or chemical exposure define tubing with
engineer) Preferred Tube sizes • 6mm • 12mm
2.1.2 Stainless steel Compression Fittings All stainless steel compression fittings used shall
manufactured by Festo or approved equal.
2.2 Process Impulse or Sampling Tubing
Tubing s hall typically be utilised w here Process/Instrument interface is required e.g. the process
connections for an off-line flow transmitter or the sample line connection to a process analyser. The
tubing shall conform to ASTM A269
2.2.1 Single Stainless Steel Impulse Tube Description
• All tube fittings require the tubing to be softer than the fitting material. The maximum
hardness of tubing allowed shall be no greater than 80HRB.
• The tube is to be free of scratches and suitable for bending O.D. tolerances.
• Standard tube sizes shall be O.D; 4, 6, 8, 10, 12, 14, 15, 16, 18, 20, 22, 25mm.
• The tube shall not contain any imperfections or irregularities and shall have a concentric
section.
• Finished tubes shall be reasonably straight and have smooth ends free of burrs.

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• Wall thickness for standard tube sizes shall be taken from the table below.

Minimum Minimum
Tube O.D Nominal wall Tube O.D Nominal wall
Thickness Thickness

4 0.8 15 1.5
6 0.8 16 1.5
8 1 18 1.5
10 1 20 1.8
12 1 22 2
14 1.2 25 2

Materials
The tube shall be high quality, fully annealed, seamless type, 316L SS or Alloy C-276
(Hastelloy) depending on process requirements.
2.2.2 Stainless Steel Tube Fittings
Description
• Fittings shall be two-ferrule flareless design.
• Standard tube fittings shall be compatible with the following O.D. tube sizes; 4, 6, 8, 10,
12, 14, 15, 16, 18, 20, 22, 25mm.
• Forged and Straight fittings shall have a machined shoulder or hex to allow for gagging
of the fitting.
Materials
• The fittings shall be manufactured from 316 Stainless Steel (as a minimum) or Hastelloy
depending on process requirements.
• The fittings shall be manufactured from forgings or blanks
• 316L SS type fittings shall be manufactured from 316 Stainless Steel with a carbon
content of .05% to improve corrosion resistance
• The fittings shall not contain Mercury or Molybdenum Disulphide
• Stainless steel straight fittings shall be shall be machined from bar stock material
procured to ASTM A-276.
Design
• The fitting shall not torque the tube during make-up.
• The fitting shall not require disassembly for inspection during make-up.
• A standard tube to pipe fitting shall consist of four machined pieces.
• The sealing and gripping power of the installed fittings shall be such that a
compensation action between ferrules will overcome commercial variations in tubing wall
thickness, hardness and diameter specifications.
Inspection
• Stainless steel and Hastelloy fittings shall allow for inspection on correct fitting pull-up,
after assembling the fitting by the use of a “no-go” gauge or spacer between the fitting
nut and body. This gauge shall be designed and supplied by the same manufacture as
the fittings.
• There shall be no radius at the point where the shoulder meets the neck of the fitting
body that will interfere with proper gauging.
• The “no-go” gauge should not be permitted to enter the space between the shoulder and
the nut.
Fitting Assembly
• Normal make-up procedures shall be to tighten the nut a prescribed number of turns as
specified in the manufactures literature.

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Manufactures Identification
• All components of fittings shall be marked with the manufactures name or trademark.
• Markings s hall be roll s tamped in a location that will not affect the performance of the
fitting.
• Markings shall not affect the corrosion resistance of the fitting.

2.2.3 FE and PFA Tubing

• This tubing shall typically be utilised where Process/Instrument interface is required e.g.
the sample line connection to a process analyser. The tubing shall be natural in colour
i.e. have a milky white appearance.
• PFA tubing shall be manufactured from 450 HP resin to ASTM-D-3307 Type II.
• Stainless steel or Hastelloy fittings as described in 3.2.2 may be used with TFE or PFA
tubing.
• PFA/TFE fittings shall not be used in conjunction with PFA/TFE tubing due to the low
coefficient of friction between both materials.
• The tube is to be free of scratches and suitable for bending. O.D. tolerances.
• The tubing s hall be supported along its entire length by suitable stainless steel supports.
The supports used shall not damage or restrict the tubing in any way.
• Standard tube sizes shall be O.D; 3, 6, 8, 10, 12mm.
• The tube shall not contain any imperfections or irregularities and shall have a concentric
section.
• Wall thickness for standard tube sizes shall be taken from the table below.

Minimum Nominal wall

Tube O.D
Thickness

6 0.8
12 0.8

3. Related Documents
This specification has been developed with due consideration of other documents and should be read in conjunction
with the following project specification documentation:

Document Title Doc. No.

Instrument & Protective Devices for Package Equipment TBA

Control System Panel Specification TBA
Instrument Cable and Gland Specification TBA
Hazardous Area Layout Drawings TBA

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Electrical Standards: Instrument & Protective Devices for Packaged Equipment

Instrument and Protective Devices

for Packaged Equipment
1. Scope
This specification defines the type and quality of instruments, control equipment and safety devices suitable f or the
operation and control of self-contained “ Packaged” equipment

2. Seller’s Responsibility
2.1 The Seller shall be responsible for the correct design, installation and operation of all such equipment as
affects the operation of the “Package” to which they are fitted.
2.2 Approval of the Seller’s drawings by the Buyer shall in no way relieve the Seller of any of the
responsibility set out in Section 2.1.
2.3 Components, sub-assemblies, documentation and drawings shall be audited, inspected, and tested as
required by the Buyer to ensure quality in accordance with this specification.
2.4 The Buyer reserves the right to inspect equipment, documentation, and witness test software at any
stage during manufacturing and development of the “Package”.
2.5 The Seller s hall supply full details of all instrument and control equipment at t he bi d stage, listing
manufacturer’s name and model number, type, range, electrical certification, and duty for each item.
2.6 Wherever possible instruments shall comply with the Buyers approved vendor list. Seller shall advise
Buyer of all non-compliance’s with this list.
2.7 The Seller shall ensure that a method exists for the transfer of data from his equipment to a plant control
system for alarm and status monitoring of the “Package”. The plant control system shall be supplied by
others. The preferred method of data transfer shall be defined by the buyer. Any deviation must be
brought to the buyer’s attention prior to construction.
2.8 The Seller shall where necessary allow for critical alarms to be hardwired from his “Package” to the plant
control system.
2.9 The Seller s hall where necessary allow for a Siemens ProfiNet or Profibus DP communications link for
status monitoring of his “ Package” by the plant control system. The Seller shall also refer to the following
specifications
• Cable Specification
• Tubing Specification
2.10 The Seller shall submit with his quote a ‘ Compliance with Specification Statement’ against each item of
this specification noting areas where the Seller is in compliance and/or exception. Quotes submitted
without same shall be deemed invalid.
2.11 The Seller shall be responsible for supplying all spare parts during commissioning of the “Package” on
the client’s premises.
2.12 The Seller s hall be responsible f or providing a full comprehensive set of documentation, which s hall
certify the instruments suitability for the project requirements.
2.13 The Supplier shall provide all instrumentation directly connected t o t he supplier’s equipment. All
instruments shall be supplied (where applicable) with a process block valve in accordance with the
applicable piping class.
2.14 Terminations to be made at skid-edge junction boxes or local skid mounted panel with clearly identifying
tubing, bulkhead, connections and terminals. It will be buyer’s responsibility to cable from skid-edge on-
wards.
2.15 Where any equipment supplied generates noise, supplier will provide sufficient information for noise risk.

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3. Reference Codes And Specifications

3.1 The following codes and standards shall govern the selection of instrument equipment, as applicable:
a) Instrument Society of America “Standards & Practices for Instrumentation” - sixth edition.
b) ‘Boiler and Pressure Vessel Code, Section VIII, Pressure Vessels’ American Society of Mechanical
Engineers (ASME).
c) Current applicable BS standards.
d) ‘Pipe Flanges and Flanged Fittings’ - ASME/ANSI B16.5 American National Standards Institute (
ANSI ).
e) ATEX 95. Directive 94/7/EC
f) ‘CE Marking’ The Electromagnetic Compatibility (EMC) Directive 89/336/EEC.
g) Good Automated Manufacturing Practice (GAMP), version 5.0.
h) PED Directive

4. Design Requirements
4.1 The Seller shall ensure that the following units of measurement are used as applicable, other units not
indicated shall conform to the SI standard.

Temperature deg C
Pressure Bar
Flow m3/hr or kg/hr
Level %
Oxygen %
Speed rpm
Viscosity cP

4.2 Local mechanical type indicators shall read between 50% and 75% of full scale f or normal conditions of
operations, with over range protection to 125%.
4.3 All analogue signals shall be 4-20mA, digital signals shall be 24 VDC.
4.4 All wiring terminations s hall be by means of fixed s crew terminals, coloured blue t o indicate intrinsically
safe wiring. All spare cable pairs to be terminated.
4.5 All equipment shall be suitable for use in a Zone 1, IIB T4 area.
4.6 All instrumentation shall be certified as intrinsically safe ( EEx-i) in accordance with ATEX 95. Other
certification deemed suitable by t he Seller s hall be submitted f or approval. The general method for
junction boxes shall be EEx-e, any other form shall be approved by buyer.

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4.7 The Seller shall comply with the following for field junction boxes:
IS Circuits in Hazardous Areas

Manufacturer Rittal Or Weidmuller

Type Vta
Application I.S. Circuits In Hazardous Areas
Material Stainless Steel (304)
Finish Brushed
Lid Fixing 2 No. Bayonet Type Locks
Gasket Neoprene
Earthing Internal M6 Stud (Base And Lid)
Enclosure Class Ip-65 (With Glands)
Gland Plates Vta
Dimensions Vta
Mounting 4 No. External Lugs
Sak2.5 Exe Blue I.S. Terminals. Rows Identified As”Tb-1” And “Tb-2”. No
Terminals
Of Terminals To Allow For Termination Of Buyer Cables & 20 % Spares.
Suitable For Hazardous Area / Cable Type. Seller Shall Be Responsible
Glands
For Gland Sizing.
Certification Cat Atex 2g Eex-E Iib T4
Id Number Tba
Label ”This Box Contains Intrinsically Safe Circuits”

Non IS Circuits in Hazardous Areas

Manufacturer Rittal Or Mcc

Type Vta
Application Non I.S. Circuits In Hazardous Areas
Material Stainless Steel (304)
Finish Brushed
Lid Fixing 2 No. Bayonet Type Locks
Gasket Neoprene
Earthing Internal M6 Stud (Base And Lid)
Enclosure Class Ip-65 (With Glands)
Gland Plates Vta
Dimensions Vta
Mounting 4 No. External Lugs
Sak2.5 Ex-E Beige Terminals. Rows Identified As ”Tb-1” And “Tb-2”. No Of
Terminals
Terminals To Allow For Termination Of Buyer Cables & 20 % Spares.
Suitable For Hazardous Area / Cable Type. Seller Shall Be Responsible
Glands
For Gland Sizing.
Certification Cat Atex 2g Eex-E Iib T4
Id Number Tba
LABEL None

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4.8 All circuits for IS equipment shall be installed separate from non-IS equipment.
4.9 The Seller shall en sure t hat all instrument cable and tubing shall be supported t o within 200mm of the
primary instrument.
4.10 The Seller shall leave a 300mm helix in the cable or tubing before final termination.
4.11 The Seller shall comply with the following tubing specifications
Single Pneumatic Tube

Manufacturer TBA

Type Single Pneumatic Tube

Tube Material High Density Polyethylene

Tube Colour Green Overall Sheath

Tube O.D. 6mm

Burst Pressure Rpm 80 Bar G

4.12 Transmission Signals

Transmission signals to the Utilities Control System (UCS) shall be electronic analogue signals 4 -20mA
( 2 w ire), 0 -24v D C ( for switched contacts). All transmitters unless otherwise stated shall be SMART
type using HART protocol. All communication links shall be via agreed protocol. Communication links
shall be used only for communication between systems, e. g. U nit Control Panels to Utility Control
System. Communication links shall not be used for safety related signals, e. g. Unit Control Panels to
Process Shutdown Systems unless otherwise agreed by the Engineer. Other transmission signals shall
only be considered if it is not possible to utilise the above. This will be considered on a case by case
basis.
4.13 Flow Instruments
Mass f low applications shall be coriollis type. Other applications shall b e vortex or electromagnetic.
Local flow indicators shall be variable meters (VA). Local indication shall be by digital indicator if on a
transmitter loop. Installation including straight pipe requirements shall be in accordance with ISO 5167.
Deviations may be allowed after application to and approval by the Purchaser. Materials for all measuring
instruments process wetted parts shall be compatible with relevant piping class.
4.14 Pressure Instruments
All process wetted parts materials s hall be compatible with the requirements of applicable piping class.
All pressure instruments shall be fitted with block and bleed valves.
Pressure Gauges
• Pressure gauges shall be to BS 1780.
• Element Type: Bourdon for general use and diaphragm for duties less than 0.8 barg
• Chemical seals: to be 25 mm in case of gauges and 50mm in case of transmitters, flanged to ANSI
standards, to the applicable piping class. Gauge adapters to be provided by seller.
• Element material shall be compatible with requirements of applicable piping c lass (AISI 316
stainless steel minimum). Case shall be stainless steel and be fitted with anti-vibration movement
for applications subject to vibration.
• Connections: 1# 2” BSP male. Dial : Size as applicable - white with black numerals
• Ranges to BS 1780: Part 2, over-range protection to be provided where required. All gauges to be
provided with shatterproof glass and blow out device.
Differential Pressure Gauges
Gauges to be capable of withstanding maximum static pressure as a differential in either direction.
Element type: Bellow or Diaphragm, Dual element gauges should only be used when differential pressure
exceeds 10% of available pressure.

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Pressure Transmitters (including Differential Pressure Transmitters for Flow and Level)
• Electrical transmitters are to be of capacitance piezo-resistance or strain gauge types with integral
indicator.
• Differential pressure transmitters to be capable of withstanding maximum static pressure as a
differential in either direction.
Pressure Switches
• Element type, element material and connections shall be as per pressure gauges. Enclosure
material to be stainless steel. Switch to be provided with calibrated scale and to be adjustable over
the full range. Contacts shall be double pole, double throw (changeover) type rated 0.2 amp min. at
24 v DC hermetically sealed.
• Contact metal: Noble metal suitable for I.S. circuits
4.15 Level Instruments
The method of level detection to be used shall be reviewed on a case by case basis. Vessel design may
preclude the use of certain type of detection and previous experience must be taken into account
wherever possible. Types of level detection, which may be considered, are Radar, tuning fork,
capacitance, displacers, ultrasonics and differential pressure. Level gauges are to be used for local
indication. All level instruments shall be externally mounted where possible. All process wetted parts
materials shall be compatible with the requirements of the applicable piping class. Level Gauge shall be
provided with visible length to cover operating range of level transmitters, controllers and level switches.
In general magnetic level gauges shall be used. If Radar are unacceptable and the level range to be
covered is over 3000mm or where viscous fluids are involved, DP cells shall be used. Diaphragm seals
should be considered on dirty and/or corrosive duty. If external float type switches are deemed
necessary they shall be magnetically operated (glandless) with flanged chamber. Float shall be
compatible with applicable pi ping specifications and shall withstand vessel test pressure. Connections
shall be 2” flanged swaged down to meet the requirements of each individual instrument Switch
enclosure material to be subject to Purchasers approval. Contacts shall be double pole, double throw
(changeover) type rated 0.2 amp min at 24v DC contained in a hermetically sealed micro switch. Contact
material shall be noble metal suitable for I.S. circuits.
4.16 Temperature Instruments
• All process wetted parts materials shall be compatible with the requirements of the applicable piping
class. Thermowells shall be provided for all intrusive measuring elements.
• Material: As per the requirements of the applicable piping class (AISI 316 stainless steel as a
minimum).
• Style: Thermowells to be manufactured as single drop forged units with pipe connection as per t he
requirements of the applicable piping specification with tapered shank. Element connection t o be
1# 2 ” N PT Female entry.
• Dial Thermometers shall be Bi-metallic type with 100mm dial, 1# 2” BSP(F) connection- union type
and everyway adjustable head. The case material shall be stainless steel. Thermocouples
characteristics s hall comply with B S 4937 to tolerances specified i n BS 1041: Part 4, Insulated tip
type.
• Thermocouple type shall be Type K for range 0 to 1100°C and Type T for range below 0°C.
• Construction shall be mineral insulated min 304 stainless steel sheath (to BS 2765), ungrounded,
6mm Dia element with union and stainless steel weather-proof terminal head (IP55).
• Thermocouple Compensating Cable Type Copper/copper nickel for Type K thermocouples and
Copper/copper nickel for Type T thermocouples.
• Resistance Bulbs shall be Platinum pt 100 complying with BS 1904 Grade A/B, 3 wire type .
Calibrated range shall suit the application.
• Head mounted transmitters to be used where possible.
• Transmitters to be S MART t o al low “ on-site” calibration and re-ranging via “ laptop” personal
computer or equivalent (Handheld) which will be supplied by the Purchaser. Software required to be
supplied by the Supplier.
4.17 Speed Measurement
Tachometers shall provide indication at the package unit control panel. The tachometers pick-ups shall
be replaceable without stopping the machine. Vibrating reed tachometers shall not be used.

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4.18 Pushbuttons And Indicating Lights

Pushbutton Colours

Red Stop or De-energise

Green Start or Energise
Black Miscellaneous

Indicating Light Lens Colour

Red Stopped or De-Energised

Green Running or Energised
White Information

Stop pushbuttons must stay put in the stop position and require manual release to return to the running
position. They shall be provided with shields or caps to prevent inadvertent operation.
4.19. Control Valves
4.19.1 General
Control valves shall generally be globe valves however supplier w ill advise on suitability.
Shut-off valves shall be ball valves, or type compatible with requirements of applicable piping
class.
Connections
Valve end connections and rating shall be as per the applicable piping specification.
Valve face to face dimensions for valves shall be in accordance with ANSI Standard.
Seat Leakage
To be specified by Supplier in accordance with A NSI, but generally will be Class IV minimum.
Trim Material
Compatibles with requirements of applicable piping class ( 316 stainless steel as a minimum
as applicable).
Characteristic
Generally the package supplier shall determine the valve characteristic to be used in particular
instances. Historical data should b e used to determine the most suitable characteristic
however the Purchaser will assist if requested to by the Supplier.
Seller shall be responsible f or selection of type of control valve best suited to the application.
Position indicator shall be provided on valve stem to show position of inner valve.
Proximity switches for remote indication shall be provided for power actuated isolating valves.
Proximity switches to be suitable for I.S. circuits.
4.19.2 Sizing
Sizing shall be based on BS 5793. In general valve capacity shall be 120% to 140% of design
for linear trim and 130% to 160% for equal percentage trim.
In general valves should not be required to operate outside the limits of 10% - 90% of their
stroke. Any deviation from this shall be approved by the Purchaser.
Seller shall be responsible for sizing of control valves. Control valve sizing calculation shall be
done for all sizing cases.
4.19.3 Noise
All valves shall be assessed for their noise level under all operating conditions. Passages in
low noise trims shall be large enough to prevent plugging in service.
Noise limit shall be no greater than 85 dBA at 1.0m.
4.19.4 Actuators

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Regulating control valves shall generally be operated by spring return pneumatic diaphragm
actuators. Piston actuators may be accepted if benefits can be shown to Purchaser or to
provide longer strokes or greater thrust than is available from spring diaphragm units and be
sized to operate to 5.0 barg air supply.
Actuator sizing shall be based on atmospheric pressure downstream and maximum inlet
pressure upstream, or more stringent if they exist.
Bench setting to be avoided by using adequately sized actuators. Any deviation from this to be
approved by Purchaser.
Actuators pneumatic circuits shall be sized such that the valve can be operated from open to
closed “stops” and from closed to open at a speed of 2 seconds per inch of end connection
size. That is a valve with 4” end connections shall be capable of travelling from open to close
in a maximum of 8 seconds and from closed to open in a maximum of 8 seconds. Any
deviation from this shall be by approval of the Purchaser.
Seller shall be responsible for selection of type & size of the actuator for the control valves
being used in the application.
4.19.5 Accessories
Positioners s hall be “ Smart” un its which a re “ on-site” configurable. T hey s hall incorporate
the current to pneumatic converter and provide outlet pressure indication. For any end of
stroke indication intrinsic proximity s witches will b e t he preferred method.
Air Filter/Regulators shall be provided by Supplier. Units are to be piped up to all users on
valve by Supplier. Purchaser connection to valve pneumatic circuit shall be via Air
Filter/Regulator. Purchasers preferred connection is 1# 2” BSP Female however deviation from
this will be accepted where requirements of valve air demands require a larger entry.
Handwheels to be side mounted and shall be provided when identified by the Package
Supplier where they are required to provide suitable control on their package.
4.20 Solenoid Valves
Body material shall be 316 stainless steel. Body connection sizes shall be 1# 4” thread size min. and 1# 2”
thread size max.
Solenoid valves with threaded entries larger than 1# 2” shall be subject to approval by Purchaser.
Valve design shall be direct acting and action shall be de-energised to shut down.
Reset requirements shall be “ Automatic” for all control system applications and “Manual” f or
shutdown/trip system applicable. Solenoid c oils shall operate o n 24V D.C. (nominal) with coil insulation
to Temp Class A, BS 2757 (minimum).
Coil shall be rated for continuous operation and provided with suppression di odes across the coil.
Solenoids shall be certified ATEX 2G EEx i IIB T4 minimum, and have a protection rating of IP65
minimum.
4.21 Relief Valves
4.21.1 General
All process wetted parts materials t o be compatible with t he requirements of t he applicable
piping class.
Body material shall be compatible with the applicable piping class, and trims shall be stainless
steel 316 as a minimum.
Type of end connection shall be compatible with the applicable piping class. Valves shall
conform to API Std 526 and seat leakage to API RP 527.
4.21.2 Sizing
Sizing and specification shall be in accordance with A PI R P 52 0 and A PI R P 2000 (Atm.
storage tanks) for s ingle-phase vapour or single-phase liquid. Seller shall be responsible for
sizing & selection of Relief valve with required capacity.

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5. Site Conditions
5.1 Non-Hazardous Areas
Enclosures for equipment located both indoors and out doors shall have I P-54 minimum in accordance
with IEC-144.
5.2 Hazardous Areas
All equipment shall be suitable for use in a Z one1 area, g as group I IB with temperature classification T4
( min), certified t o A TEX standards by the appropriate national authority. All enclosures for equipment
shall be IP-65 minimum in accordance with I EC-144. All safety barriers f or, intrinsically safe circuits shall
be Galvanic Isolators. Zener Barriers are not acceptable.

6. Identification
Each instrument shall have a Stainless steel tag securely fixed by the Seller via single strand stainless
steel wire, and stamped with easily identifying letters (A) and numerals (N), Format being AAA – NNN –
NNN. Tagging convention shall be in accordance with project standards. The Seller shall supply spare
tags.
All instrument panels and enclosures supplied by the Seller shall be fitted with suitably sized traffolyte
labels, black background (blue for IS) with white text. Labels shall be developed as per Seller panel
drawings, which shall be approved for construction by the Buyer.

7. Testing
7.1 All instruments s hall be factory tested and calibrated in accordance with the manufacturers
recommended guidelines. Calibration documentation s hall be turned over to the Buyer. Each instrument
shall have its own Calibration Sheet. Minimum work of this nature shall be performed on site.
7.2 An approved national testing authority shall certify all test equipment used by the Seller. The Seller shall
submit these certificates as part of the final document handover package to the Buyer.
7.3 Where “ Packaged” equipment contains control devices such as Programmable Logic Controllers (PLC),
the Seller shall invite the Buyer to a Factory Acceptance Test (FAT) at the Sellers works prior to shipment.
It is the Sellers responsibility to have tested the system prior to confirming a FAT date to the Buyer. The
Seller shall document said in- house testing, and make same available for inspection by the Buyer.
7.4 Where “ Packaged” equipment does not contain control devices such as Programmable Logic Controllers
(PLC), but contains microprocessor based proprietary control equipment, then the Seller shall submit a
reference list of sites where such units are installed, and operating satisfactorily.
7.5 The Buyer reserves the right to back charge the Seller for abortive visits. The Seller shall give at least two
weeks notice in writing for the FAT, and shall confirm and demonstrate at that time that he has completed
his own tests satisfactorily.
7.6 The FAT shall consist of a visual inspection to ensure that equipment is free from defects, and is
complete as per the Purchase Order and associated documentation. A full functional check shall take
place to prove that all components both hardware and software are correctly installed, and functional.
Buyer shall al so inspect all in-house test sheets to ensure system is prepared prior to commencement of
approved FAT.
7.7 The Seller shall prepare the Factory Acceptance Test procedure. The FAT procedure shall be submitted
to the Buyer for both pre and post test approval. The document shall be to cGMP standards detailing all
the tests to be performed, the expected result (i.e. pass or fail) with each test initialled and dated. All tests
shall be witnessed, and signed off by the Buyer.

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8. Installation
8.1 All instrumentation fittings, where possible shall be factory fitted (inc. cable and tubing installation) before
dispatch. All loose equipment shall be listed separately, an d packaged accordingly for shipment.
8.2 No free issue or loose items shall be provided other than instruments removed on a temporary basis for
packing and transportation. The Seller shall ensure that a full set of clear concise installation instructions
is provided for these instruments.
8.3 All instruments shall where possible face the same direction and are readily visible to the equipment
operator.
8.4 Mounting positions shall be designated to facilitate ease of operation and maintenance.

9. General
9.1 The quality of instrument equipment supplied s hall be consistent with the main mechanical device of
which it forms an integral part.
9.2 Asbestos and Mercury are prohibited without exception. The use of glass to contain fluids is prohibited.
The Seller shall pay particular attention to these specific safety requirements.
9.3 The Buyer reserves the right to reject any item that he considers either sub-standard or over-specified,
and to require substitution with suitable equipment.
9.4 The Seller shall indicate as part of his bid the amount of installation and wiring to be carried out by the
Buyer on site.
9.5 The Seller shall ensure that the cable installation is in accordance with good engineering practice for the
elimination of electrical noise pickup. However, as a minimum the following guidelines apply:
Parallel runs of instrument cables and power cables shall be avoided. Where parallel runs are
unavoidable, adequate cable spacing shall be maintained.
Where instrument cables and power cables cross in close proximity, the cross shall be at right angles.
Unless advised otherwise, the Seller shall segregate signal types. Analog and digital signals shall not be
routed in the same multicore cable. Separate junction boxes shall also be used. This concept shall be
reviewed on an individual case by case basis and shall be clarified before order placement.

10. Submittals
10.1 A completed Instrument Specification sheet (ISA S20 format or equivalent) is required for each proposed
instrument. W here instrument manufacturers/type differs from clients preferred vendor listing, Seller to
provide reasons and recommend spare parts for 1 year of operation.
10.2 The Seller shall provide serial numbers for all instruments being supplied.

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11. Documentation
11.1 The Seller shall supply complete instruction manuals, spare parts lists, recommended spare parts
quotations for each type of instrument supplied.
11.2 Seller shall supply calibration certificates, and material certificates for all instruments. Seller shall ensure
that all package mounted Instrumentation is bench calibrated prior to installation and that appropriate
bench calibration certificate and installation check sheets are produced.
11.3 Certificates of conformity shall be supplied f or all instruments located in hazardous areas.
11.4 Wiring and interconnection details shall be supplied for all panels and instruments on the package. This
shall include as a minimum:
• Instrument Block Wiring Diagrams
• Cable/Tubing Schedules
• Panel Termination Details
• Panel Layouts, Front and Back of Panel
• Instrument Termination Details
• Loop Diagrams
11.5 Where “ Packaged” equipment contains control devices such as Programmable Logic Controllers (PLC),
the Seller shall also supply the following documentation to GMP standards,
• Functional Design Specification
• Detailed Design Specification
• Factory Acceptance Test Procedure
• Site Acceptance Test Procedure
• Application software on CD/diskette

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Electrical Standards: Instrument Cable & Gland Specification Equipment

Instrument Cable and Gland

Specification
1. Scope
1.1 This specification covers the requirements for the supply of Instrument cable and glands at any Global
Diageo Site.
1.2 Where the technical specifications and drawings, where necessary, are formulated by reference to
detailed descriptions, proposals by the tenderer will not be rejected on the grounds that the products
works or services do not comply with the technical specifications and drawings, provided the tenderer can
show, by an appropriate means, that his proposals satisfy in an equivalent manner, the requirements
defined by the technical specifications and drawings. Where trade names / product names may be used,
if any, in describing the products works or services to be procured, these are used as information only for
the purpose of more fully describing the specification and drawing requirements. In relation to all
descriptions and references used for products works or services to be procured, equivalent products
works or services are acceptable, except in such instances, if any, where equivalent products works or
services would be incompatible with existing equipment already in use or would entail disproportionate
cost or technical difficulty, in which instances, the particular products works or services shall be identified
in the technical specifications and drawings as being mandatory.
1.3 All instrument cable and glands, materials and parts used, shall be new and unused, of current
manufacture, of the highest quality and free from defects or imperfections. All instrument cable and
glands installed outdoors s hall be weather-proof and corrosion resistant.
1.4 Cables shall be packed and packaged so that with customary handling they shall be protected from
damage during shipment. Special handling instructions shall be conspicuously indicated on all cables
requiring special handling and shipping care.
1.5 Under no circumstances shall any asbestos, or any material containing asbestos, be used in the
production (or packing) of any items in this specification.

2. Standards And Codes

2.1 The seller shall be responsible for all engineering, design, fabrication, and materials of construction,
inspection, testing and certification of the material specified. The cables and c able glands supplied shall
conform to relevant IE C, C ENELEC, European, British and Irish standards and the below listed
specifications
• BS5308 Instrumentation Cables P art 1: Specification for Polyethylene Insulated Cables
• BS5308 Instrumentation Cables Part 2: Specification for PVC Insulated Cables
• BS 6724 Electric cables. Thermosetting insulated, armoured cables for voltages of 600/1000 V and
1900/3300 V, having low emission of smoke and corrosive gases when affected by fire
• BS 6121 Mechanical cable glands. Armour glands.
• EN 60529 Specification for degrees of protection provided by enclosures (IP code)
• BS 5501 P art 1, P art 5 and P art 6 Electrical apparatus f or potentially ex plosive atmospheres.
• ANSI/EIA (American National Standards Institute/Electronic Industries Association) Standard 568
• IEC 1158-2 Transmission Technology

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3. Technical Requirements
3.1 Digital Cable Intrinsically Safe (I.S.) to BS 5308 Part 1 Type 1
Collective Screen, Unarmoured 300/500V PE/PVC/OSCR/PVC
3.1.1 Conductors 0.75mm2, Stranded (Class 2) conductors shall be used to BS 6360.
3.1.2 Insulation Polythene Insulation Type 03 to BS 6234
3.1.3 Pair Identification
Two-pair overall screened cable shall be terminated as follows; Black, Blue, Green, Brown.
All other overall screened cables shall be terminated as given in the chart below.

Pair Number A-Wire B-Wire

1 Black Blue
2 Black Green
3 Blue Green
4 Black Brown
5 Blue Brown
6 Green Brown
7 Black White
8 Blue White
9 Green White
10 Brown White
11 Black Red
12 Blue Red
13 Green Red
14 Brown Red
15 White Red
16 Black Orange
17 Blue Orange
18 Green Orange
19 Brown Orange
20 White Orange

3.1.4 Outer Sheath

PVC Blue outer sheath to BS 6724
Flame Retardant to BS4066 Part 3 NMV 1.5
The preferred cable sizes are as follows,
• One Pair
• Two Pair
• Three Pair
• Five Pair
• Ten Pair
• Twenty Pair
3.2 Analogue Cable Intrinsically Safe (I.S.) to BS 5308 Part 1 Type 1
Individual and Collective Screen, Unarmoured 300/500V PE/PVC/OSCR/ISCR/PVC
3.2.1 Conductors 0.75mm2,Stranded (Class 2) conductors shall be used to BS6360.
3.2.2 Insulation Polythene Insulation Type 03 to BS 6234
3.2.3 Pair Identification
Pairs shall be numbered, each pair containing one Black and one Blue core.

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3.2.4 Outer Sheath

PVC Blue outer sheath to BS6724
Flame retardant to BS4066 Part 3 NMV 1.5
The preferred cable sizes are as follows,
• One Pair
• Two Pair
• Five Pair
• Ten Pair
• Twenty Pair
3.3 Digital Cable Non Intrinsically Safe (N.I.S.) to BS 5308 Part 1 Type 1
Collective Screen, Unarmoured 300/500V PE/PVC/OSCR/ISCR/PVC
3.3.1 Conductors 0.75mm2,Stranded (Class 2) conductors shall be used to BS6360.
3.3.2 Insulation Polythene Insulation Type 03 to BS 6234
3.3.3 Pair Identification
For details of pair identification, refer to the colour chart in section 3.1.3.
3.3.4 Outer Sheath
PVC Black outer sheath to BS6724
Flame retardant to BS4066 Part 3 NMV 1.5
The preferred cable sizes are as follows,
• One Pair
• Two Pair
• Five Pair
• Ten Pair
• Twenty Pair
3.4 Analogue Cable Non Intrinsically Safe (N.I.S.) to BS 5308 Part 1 Type 1
Individual and Collective Screen, Unarmoured 300/500V PE/PVC/OSCR/ISCR/PVC
3.4.1 Conductors 0.75mm2,Stranded (Class 2) conductors shall be used to BS6360.
3.4.2 Insulation
Polythene Insulation Type 03 to BS 6234
3.4.3 Pair Identification
Pairs shall be numbered, each pair containing one Black and one Blue core.
3.4.4 Outer Sheath
PVC Black outer sheath to BS6724
Flame retardant to BS4066 Part 3 NMV 1.5
The preferred cable sizes are as follows,
• One Pair
• Two Pair
• Five Pair
• Ten Pair
• Twenty Pair
3.5 Digital Cable Intrinsically Safe (I.S.) to BS 5308 Part 1 Type 2
Individual and Collective Screen, Armoured 300/500V PE/PVC/OSCR/ISCR/PVC
3.5.1 Conductors
0.75mm2,Stranded (Class 2) conductors shall be used to BS6360.
3.5.2 Insulation
Polythene Insulation Type 03 to BS 6234
3.5.3 Pair Identification
For details of pair identification, refer to the colour chart in section 3.1.3

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3.5.4 Outer Sheath

PVC Blue outer sheath to BS6724
Flame retardant to BS4066 Part 3 NMV 1.5
The preferred cable sizes are as follows,
• One Pair
• Two Pair
• Five Pair
• Ten Pair
• Twenty Pair
3.6 Analogue Cable Intrinsically Safe (I.S.) to BS 5308 Part 1 Type 2
Individual and Collective Screen, Armoured 300/500V PE/PVC/OSCR/ISCR/PVC
3.6.1 Conductors
0.75mm2,Stranded (Class 2) conductors shall be used to BS6360.
3.6.2 Insulation
Polythene Insulation Type 03 to BS 6234
3.6.3 Pair Identification
Pairs shall be numbered, each pair containing one Black and one Blue core.
3.6.4 Outer Sheath
PVC Blue outer sheath to BS6724
Flame retardant to BS4066 Part 3 NMV 1.5
The preferred cable sizes are as follows,
• One Pair
• Two Pair
• Five Pair
• Ten Pair
• Twenty Pair
3.7 Digital Cable Non Intrinsically Safe (N.I.S.) to BS 5308 Part 1 Type 2
Individual and Collective Screen, Armoured 300/500V PE/PVC/OSCR/ISCR/PVC
3.7.1 Conductors
0.75mm2,Stranded (Class 2) conductors shall be used to BS6360.
3.7.2 Insulation
Polythene Insulation Type 03 to BS 6234
3.7.3 Pair Identification
For details of pair identification, refer to the colour chart in section 3.1.3
3.7.4 Outer Sheath
PVC Back outer sheath to BS6724
Flame retardant to BS4066 Part 3 NMV 1.5
The preferred cable sizes are as follows,
• One Pair
• Two Pair
• Five Pair
• Ten Pair
• Twenty Pair

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3.8 Analogue Cable Non Intrinsically Safe (N.I.S.) to BS 5308 Part 1 Type 2
Individual and Collective Screen, Armoured 300/500V PE/PVC/OSCR/ISCR/PVC
3.8.1 Conductors
0.75mm2,Stranded (Class 2) conductors shall be used to BS6360.
3.8.2 Insulation
Polythene Insulation Type 03 to BS 6234
3.8.3 Pair Identification
Pairs shall be numbered, each pair containing one Black and one Blue core
3.8.4 Outer Sheath
PVC Black outer sheath to BS6724
Flame retardant to BS4066 Part 3 NMV 1.5
The preferred cable sizes are as follows,
• One Pair
• Two Pair
• Five Pair
• Ten Pair
• Twenty Pair
3.9 System Cables
These cable types shall be utilised for cabling between items of the site Control Systems.
3.9.1 Ethernet Cables.
CAT 5E Cable
EIA/TIA 568 A Category 5E, 4 pair 0.5mm2 (24 AWG) solid conductors, with plastic foil
wrapping. It is characterised by supporting transmission at frequencies up to 100 MHz and
giving transmission rates of up to 100 Mbps Overall screen to consist of aluminium bonded
polyester tape and tinned copper wire. Overall sheath shall be Black PVC.
CAT 6 Cable
EIA/TIA 568 A Category 6, 4 pair 0.5mm2 (24 AWG) solid conductors, with plastic foil
wrapping. It is characterised by supporting transmission at frequencies up to 250 MHz and
giving transmission rates of up to 1000 Mbps Overall screen to consist of aluminium bonded
polyester tape and tinned copper wire. Overall sheath shall be Black PVC.
CAT 7 Cable
EIA/TIA 568 A Category 7, 4 pair 0.5mm2(24 AWG) solid conductors, with plastic foil wrapping.
It is characterised by supporting transmission at frequencies up to 1.2 GHz and giving
transmission rates of up to 1000 Mbps Overall screen to consist of aluminium bonded
polyester tape and tinned copper wire. Overall sheath shall be Black PVC.
3.9.2 Fibre Optic Cable for Site Network.
62.5/125 Micron Multimode, graded index, glass silica fibre core, Mechanical protection
provided by corrugated steel/polymer laminated tape layer over inner sheath. Overall sheath
shall be Green polyethylene.
3.9.3 Profibus Data Cables.
Belden 3079A, 22AWG Shielded Profibus Cable or approved equal. Overall sheath shall be
Mauve PVC.
3.9.4 Coaxial Cable - (ThinNet)
10-Mbps baseband Ethernet specification, using 50-ohm thin coaxial cable approximately 5
mm in diameter. 10Base2, which is part of the IEEE 802.3 specification, has a distance limit of
185 meters per segment.
3.9.5 Coaxial Cable – (ThickNet)
10-Mbps baseband Ethernet specification, using standard (thick) 50-ohm baseband coaxial
cable approximately 12 mm in diameter. 10Base5, which is part of the IEEE 802.3 baseband
specification, has a distance limit of 500 meters per segment.

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3.10 Power Cables

3.10.1 24VDCPowerSupplyCable.
Various cross sectional areas shall be used as required.
In Accordance with BS 6724. XLPE/LSF/SWA/LSF, 600/1000Volts, stranded class 2 copper
conductors and Black outer sheath.
Core Identification
2 Core: Brown, Blue

3.10.2 110VACPowerSupplyCable. Various cross sectional areas shall be used as required .

In Accordance with BS 6724/IS 273. XLPE/LSF/SWA/LSF, 600/1000Volts, stranded class 2
copper conductors and Black outer sheath.
Core Identification
2 Core: Brown, Blue
3 Core: Brown, Blue. Green/Yellow
3.10.3 230VACPowerSupplyCable. Various cross sectional areas shall be used as required.
In Accordance with BS 6724. XLPE/LSF/SWA/LSF, 600/1000Volts, stranded class 2 copper
conductors and Black outer sheath.
Core Identification
2 Core: Brown, Blue
3 Core: Brown, Blue. Green/Yellow
5 Core and above, the core number shall be printed on the cable core
3.10.4 Underground Cables. All buried cables shall be armoured.

3.11 Glands
3.11.1 The cable glands utilized shall conform to BS6121 and be manufactured by Hawke or CMP or
equal and approved.
3.11.2 The cable glands utilized for the above cables shall provide some or all of the following in the
cabling system.
• Mechanical Connection: Locate and anchor the cable to the panel or instrument
• Earth Continuity: Armour Termination
• Ingress Protection: Protect against dust and liquids, minimum protection to be IP54.
3.11.3 The IP (IngressProtection) rating for the cable gland shall conform to EN60529.
3.11.4 The cable gland utilized shall be ‘Fit for purpose’ and shall be correctly sized for the cable.
3.11.5 Plastic metric compression glands shall be utilized for non-armoured cable
3.11.6 Brass metric cable glands shall be utilised for armoured cable. This gland must be capable of
providing full earth continuity.
3.11.7 The gland thread form shall match equipment threaded cable entries directly where possible
without the use of adapters. Cable entries shall be BSPT (1/16” pitch) thread form wherever
possible.
3.11.8 Glanding of cables shall be done only by a skilled crafts man. A very high standard of
workmanship is particularly required in relation to glanding of all cables.
3.11.9 All gland nuts and locknuts are to be properly secured, cable glands should not be dismantled
(by hand) without the use of proper tools.
3.11.10 Glands are to be correctly sized as per the manufacturers charts. The Instrument Contractor is
responsible for ensuring that all glands are correctly sized for all cables.
3.11.11 All non-metallic enclosures are to be glanded with an internal locknut and earth tag. This shall
be connected to al l metal parts within the enclosure to maintain earth continuity.
3.11.12 The inner cable sheath shall extend into the enclosure by a minimum of 6mm to prevent
damage to cable cores.

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3.12 Increased Safety Glands (EEx e)

These glands shall be utilised in hazardous areas and comply with EN 50014 and EN 50019. (BS 5501
Part 1 and Part 6). These glands shall be fitted with fibre washers to achieve the IP rating.
3.13 Flameproof Cable Glands (EEx d)
These glands shall be utilised in hazardous areas and comply with EN 50014 and EN 50018 (BS 5501
Part 1 and Part 5). These glands shall not be fitted with fibre washers.
3.14 Barrier Cable Glands (EExd)
These glands shall be utilised in hazardous areas to maintain integrity between panels installed in the
hazardous area where cables are glanded to panels in the safe area and comply with EN 50014 and EN
50018 (BS 5501 Part 1 and Part 5). These glands shall not be fitted with fibre washers..
3.15 Shrouds
PVC shrouds shall be used on all armoured cable glands, both internally and externally. The shroud shall
match the cable colour.

4. Related Documents
This specification has been developed with due consideration of other documents and should be read in conjunction
with the following project specification documentation:

Document Title Doc. No.

Instrument & Protective Devices for Package Equipment TBA

Control System Panel Specification TBA

Instrument Tube and Fitting Specification 00/J.02A/9500

Hazardous Area Layout Drawings TBA

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Electrical Standards: Supply of Process Control Systems

Supply of Process Control Systems

1. Purpose
This specification covers the requirements for the supply of process control systems and related components.

2. Scope of Specification
2.1 General
This specification covers the minimum requirements for control system hardware and software. Specific
application details shall be stated in the User Requirement Specification (URS). Where there is a conflict,
this standard shall take priority.
A defined procedure must be in place to justify new technology selected for installation with a stringent
approval process followed for any non-standard components. All exemptions to this standard must be
documented and ratified and the source of spares verified.
The following general guidelines for the selection of up to date electrical devices, components, new
technologies, should be applied:
• No new systems or machines supplied with obsolete components
• Nothing obsolete within five years from date of installation
• Track discontinuation, phase out dates, and obsolescence of equipment versus projected system
/machine life and consider in life cycle analysis
• Design system to facilitate projected upgrades without re-engineering
An objective evaluation system for selection of contractors should be applied. They should be assessed
to ensure they are suitably qualified and accredited, technically competent to deliver in prescribed time
and will take full technical and legal culpability for their equipment. Migration to Performance Levels (PL)
and Safety Integrity Levels (SIL) evaluation and competency. Interface and coordination requirements
must be mandatory between machines at controls and safety levels.
2.2 Materials and Material Quality
Materials supplied by the Vendor shall be in accordance with the appropriate sections of this specification.
All materials shall be of the best quality for the application and to be new unless otherwise specified.
Dismantling, replacement and re-erection of work rejected under this clause will be at the cost of the
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3. Terms and Abbreviations

High Voltage Voltage in excess of 1000 V
Standard utility low voltage at which most industrial equipment operates; 3-phase: 380-
Low Voltage
415V / single phase: 230-250V.
The Project Manager or the engineer designated by Diageo PLC to be responsible for
Diageo Engineer
the automation system.

CD Compact Disc
CFC Continuous Function Chart
CIP Clean In Place
DDS Detailed Design Specification
DVD Digital Versatile Disc
FAT Factory Acceptance Test
FDS Functional Design Specification
FRL Unit Air Filter Regulator Lubricator
FSR Final Status Report
GA's General Arrangement Drawings
HDS Hardware Design Specification
HMI Human Machine Interface
IEE Institute of Electrical Engineers
IS Intrinsically safe
IS Department IQ Information technology department Installation Qualification
KPI Key Performance Indicator
LAN Local Area Network
MES Manufacturing Execution System
O&M Operation and Maintenance Manual
OQ Operational Qualification
OP Operator Panel
PLC Programmable Logic Controller
PQ Performance Qualification
QM Quality Manual
RAM Random Access Memory
SAT Site Acceptance Test
SCADA Supervisory Control And Data Acquisition
SDS System Design Specification
SOP Standard Operating Procedure
SWA Cables Steel Wired Armoured cables
TS Test Schedule
URS User Requirement Specification
USB Universal Serial Bus
VLAN Virtual LAN loops
Wet Area Any area that is routinely cleaned by wet means

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4. Control Panels
4.1 Control Panels General
All panels must comply with the latest editions of the relevant Irish, European or British Standards and
ETCI Regulations. Compliance with same must be stated in the suppliers proposal with each identified by
their unique identifier such as Directive number, IEC number, EN number etc, which will also be quoted
by the supplier on their Declaration of Conformity (or Incorporation). All panel design drawings and an
associated schedule of all panel components shall be submitted to Diageo for approval, prior to
construction.
• The equipment shall operate under the following conditions:
• Europe: Average ambient 25°C, max 30°C: Relative Humidity 40%.·
• Rest of the world: Average ambient 35°C, max 40°C: Relative Humidity 95%.
Where necessary, the panel must be equipped with heating or cooling to suit the operating limits of
components contained therein.
4.2 Construction
Panels
All main panels shall be the latest appropriate Rittal type or similar, mounted on a 200 mm Plinth (if floor
standing in a wet area), removable for transporting separately and providing easy access to foundation
bolt holes. In dry areas these shall be painted coated steel (e.g. Zintec) with an ingress protection rating
of IP45 as a minimum. In wet areas these shall be stainless steel with an ingress protection rating of IP65
as a minimum. All field mounted control panels shall be of the Rittal enclosure range, in stainless steel
and rated to IP66, wall mounted or frame mounted. All cables shall be bottom entry and suitably sealed
against moisture ingress. Where trunkings or welded stainless conduit entries are not used appropriately
sized cable glands shall be used on cable entries to the panel. Glands shall maintain the overall IP rating
of the panel.
Panels must be:
• Vermin, damp and dust protected and include a sloping top for hygienic installation
• Intrinsically rigid, not dependent upon external frameworks, wall or floor to maintain their integrity or
shape.
• Constructed of sheet steel, thickness of not less than 2 mm.
• Provided with top covers capable of supporting the weight of a person of 100 kg without affecting
the assembly.
• Layout and size to allow installation and maintenance of the components to be carried out with
ease from the front, giving access to all points requiring maintenance without any dismantling of
functional elements.
• Possess a height not more than 2400 mm and depth not more than 600 mm.
• Provided with removable lifting angles or lifting eyes positioned to ensure that the unit to be lifted is
rigid and the load evenly spread. The panel will be designed with 20% free panel space in all
voltage sections, PLC racks, terminals, safety rack MCB space, etc.
Doors
Doors should have:
• A minimum swing of 120o
• Their movement limited to prevent damage to door mounted equipment.
• Neoprene seals and lockable door handles with cam fasteners to ensure a tight seal.
Doors must remain rigid and capable of carrying the devices fixed to them without flexing, particularly
where there are large area cut-outs.
All doors and covers on electrical and control equipment shall either:
• Require a tool to be opened. (to include triangular section inner stub)
• Have handles with barrel locks.
Where a panel has multiple doors or a suite of panels is supplied, locks shall have a common key for all.
Switches, push buttons and instruments shall be positioned between 400 mm and 1900 mm from floor
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Reliance must not be placed on hinges for earthing. All hinged doors and components mounted on doors
must be effectively bonded to the main body of the panel using a flexible multi-strand copper conductor of
minimum 2.5 mm2 cross-section.
Removal of any component from the door must not break the earth continuity to any other component on
the doors.
4.3 Isolation
A main isolator is to be provided which is interlocked with the door unless otherwise specified. Where no
door interlocking is required a suitable notice prohibiting entry to unauthorised persons, is to be provided.
Where external supplies greater than 24 VDC enter from other systems, they shall be switched by the
main isolator unless otherwise agreed. If they are not isolated, then the terminals for those external
supplies shall be shrouded and labelled to say where they may be isolated. External labelling on the
panel should indicate that parts of the panel remain live after isolation and indicate the location of the
isolation of the secondary power source
4.4 Identification
Each panel section door shall be fitted with an engraved legend plate mounted centrally at the top of the
door referencing the function or tag number of the equipment therein e.g. "FILLER CONTROL PLC". The
text height shall be 25 mm minimum.
Labels are to be,
• Manufactured from 2 or 3-ply, pvc laminate.
• Placed on the front of the item unless insufficient space.
• Fixed with screws or rivets – not adhesive alone.
Cables shall be colour coded (see Appendix 1), terminating in spade type lugs or pins. All cables shall be
identified with appropriate PVC cable markers. The ferrule numbering system used in the Control Panel
shall continue as far as possible through all junction boxes etc. to the field connections and terminal
junction positions shall be numbered accordingly. A label with 4 mm high lettering shall identify individual
lamps and pushbuttons . All major components e.g. relays, solenoids, electronic enclosures etc. shall be
identified with the same references as the schematic diagrams.
4.5 Terminals
Terminals shall be DIN rail mounted and be permanently identified with a unique number. Terminals shall
be located to give easy access for incoming cables and for maintenance staff. Approximately 20% spare
unwired terminals shall be provided. Terminals of different voltages and signal types shall be segregated
All incoming control cables from the field equipment and the MCC's shall be terminated in the marshalling
section of the control panel. Terminals in this section shall be “knife edge” type disconnect terminals.
4.6 Wiring General
All panel wires must be ferruled at both ends. All panel wires must be numbered at both ends using
resistor type cable markers, using I/O numbers throughout with associated leading network address
(where applicable). All internal panel wiring shall be run in plastic trunking. External cabling core colours
will be as specified in Appendix 1.
All network address numbering shall be logged with and controlled by the Diageo IS department.
Preferred Internal Panel Wiring Sizes and Colours
The supplier is required to ensure that all wire sizing is appropriate for the design voltage/current rating
and circuit recommended by the applicable national and European standards. The design must include
analog wiring specifications, covering aspects such as:.
• Cable lengths, screening, capacitance
• Belden types or equivalent, twisted pairs,
• Choice of current transmission-long lengths or voltage transmission-short lengths.

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All panel wiring must be at least 0.75 sq. mm. diameter, except for high density 32 Input / Output PLC
cards where 0.5 mm2 may be used. The minimum sizes permitted and colours are shown in this table .
Function X-Section mm2 Colour

3 phase power wiring 2.5 Black

220/110/50 VAC general wiring 1 Grey
24 VAC 1 Yellow
24 VDC general wiring 0.75 Light Blue
Earth cabling 2.5 Green/Yellow
High Density Cards 0.5
Analogue 4-20 mA wiring 0.5 White
PLC Inputs/Outputs 0.75

Fuses and Links

Fuses and their carriers must always be rated for the fault level at the point of use. All PLC signal cables
are to be fused. Fuses and their carriers shall be to a design and standard recognised by the IEC.
4.7 Trunking
Internal wiring shall be enclosed in plastic trunking. Trunking shall be installed with approximately 50%
spare capacity allowed for future use. Cabling carrying different voltages and signals, e.g.. Analogue &
digital signals, shall be run in segregated trunking where possible without cross overs between cables.
Trunkings shall be laid out to take account of incoming cables. Panel manufacturer shall ensure that
there is space allocated in internal trunking or install dedicated trunking to contain field wiring.
Where it is necessary to leave excess length to instrument and control cables, the excess shall be looped
back in trunking or enclosed in plastic or stainless steel boxes (not tied in loops or coils).
4.8 Other Components
All components shall be DIN rail mounted where possible. All panels shall be fitted with a thermostatically
controlled panel heater of sufficient rating. All panels shall be fitted with a steel panel drawing pocket. All
panels shall be fitted with a door-operated fluorescent light. All panels shall be fitted with an early warning
smoke detector, which shall be connected into the local intelligent system. All main panels will be
protected by a fire suppression system, either dedicated or as part of a wider area system.
Additional spare boards and relays or space for some extra 10% extra relay capacity shall be provided.
Where agreed, alarms shall be provided with accept/mute facility: A lamp test facility is required. Surge
Protection Units shall be fitted to inter-panel cables, where the panels are located in different buildings.
Surge / Lightning protection shall be fitted on main panels where mains cables are run externally.
Reset facilities must not be installed inside electrical panels, but should be door mounted for easy access.
4.9 Earthing
Earthing and bonding shall be as per the ETCI regulations. Where panels are fed using SWA cables the
SWA must be bonded to the earth bar in the panel. The armour of a cable can not be used as the only
earth. A separate protective conductor must be installed with the mains cable.
The contractor shall provide a safety earth bar in the control panel for bonding the SWA of incoming
cables and connection to the main earth.
The contractor shall provide an instrument (clean) earth terminal in the panel to accept an incoming clean
earth cable and to which all the instrument screens shall be linked. The instrument earth shall be
insulated from the panel and safety earth.
T

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The resistance to earth must not exceed the values shown below.

Maximum Resistance
System
(Ω)

Electrical Power 5

Lightning Protection 10

Electrostatic Discharge 10

5. Intrinsically Safe (IS) Systems

Installation of Intrinsically safe systems must comply with appropriate ETCI regulations and the ATEX regulations.
IS barriers and terminals for IS cables shall be installed in a separate section from the rest of the control equipment.
This may be a separate barrier box or a separate compartment within the control panel. The IS compartment or box
shall be clearly labelled to identify it. All IS terminals and trunkings within the panel shall be blue. IS components
requiring a clean earth shall be connected to the instrument earth. Cables for intrinsically safe circuits shall be
armoured or screened.

6. Pneumatic Panels and Components

6.1 Panels
Pneumatic equipment shall be housed in an enclosure, with the exception of some steam valve control
equipment, separate from the control panel. The enclosure shall be constructed as per section 4.1.
Location
Pneumatic panels, isolators, filter regulators and pressure gauges shall be located outside machine
guarding to give personnel safe and unhindered access to them.
Pressure Relief
Panels containing compressed air equipment shall be fitted with suitable pressure relief systems to
ensure that in the event of a line leakage, over pressurisation of the control panel cannot occur.
6.2 Components
Pneumatic panels shall be fitted externally with a Local Isolator, a Filter Regulator and a Pressure Gauge.
Solenoids
Solenoids shall have manual over-rides and integral position indicator LED's. and shall be supplied on
supplied in the latest proven technology such as 'Solenoid Islands'. Each set of solenoids shall have an
individual isolating valve. Solenoid vent ports shall be manifolded and vented at one point to the outside
of the panel and fitted with an exhaust silencer. Provision for additional 25% solenoids shall be allowed in
each panel. All solenoids shall use the latest multi-node technology such as Profibus or ASI-bus.
Instrumentation
All pneumatic instrumentation (i.e. positioners, I/P converters) must be fed via a separate filter regulator
unit which can be adjusted to the desired pressure and which incorporates a mist separator to remove
moisture in the air supply. Solenoids for pneumatically operated stream control valves may be located
local to plant if they have been included to provide a lock-up facility or if they have been included to serve
a locally mounted I to P or E to P converter.
6.3 Pipework
Pneumatic pipework shall be identified at both ends and shall terminate on a gland plate with bulkhead
type fittings. Pipework shall be a minimum of 6 mm poly-ethylene tubing.

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6.4 Electrical Components

All components shall be DIN rail mounted where possible. Panel wiring, trunking, identification and
terminations shall be as specified for control panels in section 4.
The contractor shall use a Profibus interface to the PLC where the pneumatic panel is remote from the
PLC processor.

7. Programmable Logic Controller Hardware

7.1 Processors
The processor shall be of the type specified in Appendix III System Hardware. The CPU should be sized
such that it fulfils the requirement of the supplier control system and additional integrated SCADA and
MES/MIS requirements. The processor shall be supplied, post 'Factory Acceptance Test', with at least
50% spare memory capacity.
The controllers should be members of the S7-4xx or S7-3xx series, dependent upon the project
performance requirements.
7.2 Local Human Machine Interface (HMI)
Where appropriate, the local Human Machine Interface will be from the range specified in Appendix 3
Preferred Hardware and Software
7.3 Input/Output Cards
All valves, pumps, meters, levels, temperature probes, pressure probes, conductivity probes etc. shall be
connected to the PLC. All input and outputs shall be wired to terminals, including spare I/O, except where
internally wired to components. Provision for an additional 25% input/outputs cards and associated
terminal space for each I/O type shall be allowed for in all panels.
The PLC I/O shall have the provision to be expanded by a further 50% without upgrade of the processor
or other components. All I/O shall be 24 V dc, unless otherwise agreed with the Diageo Engineer.
Interface relays shall be provided between PLC outputs and contactors. Outputs to field equipment shall
be individually fused, but internal items may be fused in suitable groups. Inputs/Outputs shall be assigned
in a manner that will maximise safety , assist maintenance and reduce the number of single points of
failure e.g. duty and standby equipment I/O shall be on different cards.
Remote Input / Output cards shall be from the ET200 distributed I/O range communicating via Profibus.
If I/O card failures are detected by the system then the appropriate failsafe action shall be initiated.
7.4 Communications
All systems must have either Ethernet networking capability or have Profibus links to a system running an
Ethernet network. All IP-address numbering shall be logged with and controlled by Diageo IS department.
All bus communications must be checked by the system and failsafe action initiated in the event of a
problem. This includes 'Heartbeats' between redundant Servers.
7.5 Power Supplies
The PLC power supply shall be 120 VAC dedicated to the PLC only, unless otherwise agreed by the
Diageo Engineer. The control voltage shall be 24 VDC throughout, unless otherwise agreed by the
Diageo Engineer.
Analogue loops shall have a dedicated 24 VDC power supply. PLC panels shall be fitted with a single-
phase socket suitable for a programming unit (220 VAC with RCD protection).
7.6 Push Buttons, Indicating Lamps
All panel front operators and indicators should as far as possible be selected from the same range from a
single manufacturer. Emergency stop buttons must be mushroom headed, hand or reset via a key.
Indicating lamps should be of the LED cluster type.

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8. Programmable Logic Controller Software

8.1 General
The PLCs shall be autonomous, such that a failure of the Human Machine Interface or the integrated
SCADA systems shall not jeopardise the control of the plant. The PLC’s shall monitor all bus
communications for failure. In the event of a problem an alarm shall be raised and appropriate failsafe
actions shall be carried out. The software shall include the control of the equipment, plant condition
monitoring and operator interface. Programs may be started, stopped, halted, continued and ended from
the human machine interface or the integrated SCADA system. All operator or remote commands shall
pass through an arbitrator, in the software, that will check for plant availability, safety regarding execution
of the command (both to plant and personnel) and control stability. Should an operator command fail,
then the arbitrator shall reject the command, giving the reason for the rejection to the operator.
During all programming work at site, strict adherence to site software modification control procedures
must be maintained throughout the development and commissioning phases of any project.
8.2 Performance
The system should react to any exceptional process or plant condition within 1 second. The system must
display any alarm condition or change in plant status within 2 seconds of occurrence. The overall system
must react to any operator command within 1 second.
8.3 Code Structure
The preferred languages are Ladder Logic Programming Language (LAD) or Function Block Diagram
Programming Language (FBD). These will be suitable for most applications. Least favoured is Statement
List Programming Language (STL).
Only programming methods detailed within the PLC supplier’s manual shall be used. The use of higher
level languages or third-party software packages is not to be used without the written approval of the
Diageo engineer.
All custom built software should be supplied in function block diagram or ladder logic format wherever
practical. Standard functions and control blocks already in Statement List will be accepted. The program
shall be divided into easily identifiable sections and should be well documented using comments and
synonyms. The software and data structure shall be planned in a manner that will allow changes without
affecting unrelated items and overall software control structure.
Linear programming of large sequences is to be avoided. The programs should be clearly structured into
appropriate functions and function blocks.
All programs shall be written in such a way as to permit easy addition of extra steps, modifications,
activations, etc. Indirect addressing is only permissible in sub-routines, and must not form part of the
main sequence control program. Indirect addressing is to be kept to a minimum.
Outputs shall be controlled only via control modules. The software shall be written in a manner that
allows for ease of resolution of problems. The operator shall be given prompts, alarms, etc., so that the
point of failure can be quickly identified.
8.4 Documentation/Annotation
All software shall be supplied on DVDs or on the server hard disk.
All code must be annotated using descriptive names for each component and titles and descriptions for
each module of code. All software application programs, comments, symbol and assignment lists shall be
documented in the English language.
A comprehensive Function Design Specification (FDS) must be provided for each individual major item of
equipment in the system in English on DVD. Each step description shall be accompanied by a marked-up
equipment drawing to illustrate the particular step.
As a minimum the FDS must contain for each step
• Start, Stop and Step ON/to information should be provided for the equipment.
• Fault conditions and actions taken on each fault.
• Pre-conditions.
All necessary Operator Interventions and inputs.

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8.5 Analogues Handling

Analogue values shall be scaled in engineering units in the code, before subsequently being used within
the code. Analogue signals shall have out of range detection <4 mA and >20 mA, which shall produce a
derived alarm. Analogue trip values used within the code must be scaled in engineering units. They shall
have alarm limits (i.e. HH, H, L and LL).
8.6 Alarm Generation
All non-latching digital alarms shall be de-bounced using timers to ensure they are genuine. .Analogue
signals under and over-range detection shall generate a derived “Failed” alarm, for each analogue value.
All drives shall be monitored for failed to start and failed to stop, and signal discrepancy (e.g. running and
stopped). These shall produce a derived “Failed” alarm, for each drive. All isolating valves shall be
monitored for failed to open and failed to close, and signal discrepancy (e.g. opened and closed). All
positioned or control valves shall be monitored for failed to move and signal discrepancy (e.g. closed and
not 0% open). In all cases these shall generate a derived “Failed” alarm for each valve. Any PLC
component failure shall generate a unique alarm for diagnostic purposes. All step changes which are
dependent on instruments must have override timers to prevent problems due to instrument failures.
These failures must be treated as alarms.
Time and date stamping must be exclusively generated by the PLC or remote controller.
8.7 Remote Assistance
The vendors authorised software engineers shall be given access to installed programs via a secure VPN
access link into a suitable access point, most probably a Server, for the purpose of monitoring, fault
finding and downloading changes.
Procedures must be agreed with the local engineering management regarding the level of access and
must be under their control. This is to ensure that changes to the systems are properly tracked and the
appropriate backups of the original and modified systems can be kept.
8.8 Standalone Plant
Stand alone proprietary plant items and machines may be connected to an integrated overall SCADA and
MES/MIS system. The software in all plant control systems must therefore be developed to facilitate this
requirement. The integrated overall SCADA and MES/MIS system development must complement the
requirements for stand alone proprietary plant items and machines. The following points relate to stand
alone proprietary plant items and machines:
• The PLC software should contain contiguous data words in a unique data block containing the
management information required for transmission to a supervisory system such as WinCC,
Infoplus 21 etc.
• Any OP information (i.e. keystrokes, parameter inputs, recipes etc.) not accessible to the
supervisory system via the PLC must have a separate transmission mechanism included to a
supervisory system.
• The PLC software should contain contiguous data words in a unique data block containing the
information required for display of mimics, analogue values, alarms etc. on a supervisory system
such as WinCC, Infoplus 21 etc.
8.9 GUI Formats
Standard devices are to be represented on the graphic interface screens as per the HMI Design
Specification. The graphical screen must give the user access to the following attributes devices as a
minimum requirement;
Digital Devices:
• Device Tag
• Device Name
• Device Address
• Device Status
• Access to Manual Control
• Access to Manual Activation and Deactivation
• Access to Maintenance Control
• Access to Interlock Control
• Access to Error Override Control
• Access to Set Input Value
An area where the operator can attach notes to the device.

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Analogue Instruments:
• Device Tag
• Device Name
• Device Address
• Device Status
• Input Value
• Associated Alarm and Error Limits
• Associated Error Status and Control
• Instrument Range
PID Control Loops;
• Device Tag
• Device Name
• Device Address
• Device Status
• Associated Alarm and Error Limits
• Associated Error Status and Control
• Instrument Range
• Process Value
• Set Point Value
• Output Value
• Proportional Setting
• Integral Setting
• Derivative Setting
• Manual Control of Loop Set point
• Manual Control of Output Value
The general representation of data and the specific data to be displayed on lines and vessels is to be
agreed with Diageo prior to screen development.
8.10 Parameter Access
All Parameters must be accessible through the SCADA system. Parameters are not to be hard coded at
PLC level unless agreed by the Diageo Engineer. It must then be clearly indicated in the FDS. This
includes all timers, counters and set points. All parameters are to be listed in the FDS to which they
pertain. The location of each parameter on the SCADA system is to be listed in the FDS. Parameter
access and levels of authority for change needs to be clearly defined. All parameter changes that have
taken place at all levels within the control system are to be trapped in an event log, which can be
electronically searched and made available in printable format.
8.11 Alarm Handling
A historical alarm page is to be provided. The information on this page for each alarm should include
alarm text, associated program, type of alarm, time and date generated, time and date acknowledged,
time and date cleared. The text for alarms is to be approved by Diageo.
An alarm banner is to be displayed on each screen. The alarm banner should display only alarms
relevant to the area where the terminal is located.
It must be possible to acknowledge selected alarms from the alarm banner or from the alarm page. This
functionality should be available for individual alarms, selections of multiple alarms and the ability to
acknowledge all with a single button.
Time and date stamping is permitted in the SCADA system only for those alarms generated exclusively in
the SCADA system itself. Time stamping at the SCADA level of alarms generated in the PLC level is not
acceptable.
• The system must have comprehensive diagnostic and fault logging capability so that:
• The system is equipped with sufficient messages, pointing to the cause of programme and/ or field
device errors / failures.
• Tools are provided that enable diagnosis of problems.
• Modifications or diagnosis of problems that require access to the PLCs can be carried out from a
central location.
• Communications between the system components are monitored and alarms are generated as a
result of failure.

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8.12 Data Update Frequency

It is a requirement that the availability of data to a SCADA or MES/MIS be based on a real-time update,
i.e. as the data is received and processed by the SCADA layers of the proposed system it should be
made available without delay. It is required that the delivery to the SCADA and/or MES/MIS should not
exceed 5 seconds.

9. Hardware for PCs and Servers as well as the MES/MIS

9.1 General
PCs and Servers form the central pillar of any control system. This equipment should be from the
preferred Diageo suppliers detailed in the Appendix.
9.2 PC Clients
The client hardware and software should be of a type specified in the Appendix Preferred hardware and
software. The PC processor is to be based on Intel Dual Core/Celeron or higher in either single or multi-
processor configurations. AMD processors are not acceptable. The PCs must have a minimum of 160GB
hard disk memory (partitioned in C-Drive for the OS and applications and D-Drive for local data). Each
system must also have 2GB or greater RAM memory installed, along with the usually peripheral devices
(DVD reader/USB ports, network card, etc.).
9.3 Operator Terminals
Operator terminals are to be supplied with high quality 19” high-resolution flat panel screens as a
minimum. Servers are not to be used as operator terminals. Operator terminals must have access to all
available software modules in the system. Access to and rights over the data will be controlled via the
user profile.
9.4 Server
Servers must be of a type specified in Appendix 3 Preferred Hardware and Software.
The Operating system must be in compliance with that specified in Appendix 3 Preferred Hardware and
Software. (Diageo Engineer agreement required).
Each server must be based on Intel processor technology, include redundant network interface cards,
power supplies (minimum 2), Remote Insight Board, RAID disk technology using multiple spindles. The
disk controllers must be fit for purpose with both write and read caches. The disk array chassis must have
spare slots for additional disks.
The Server is required to have a data backup/recovery system installed.
9.5 Switches
These are to be in compliance with the type specified in Appendix 3 Hardware and software. Servers and
Clients, as well as PLC systems will be connected through a suitable set of switches and are to be the
latest models as well as suitable for the task. Sufficient spare capacity (ports) is to be designed into the
system.
Whether these switches are fibre-optic capable and/or redundant will depend upon the project at hand.
9.6 Redundancy
Full redundancy is required of the system above the PLC layer; this is to include all networks, exceptions
to be agreed by the Diageo Engineer.
The system as a whole must be designed to ensure a controlled shutdown to a safe status for the plant
under the control of the system, in the event of a single component failure or a loss of power to the
system or parts of the system.
9.7 Software Back Up
All system software must be accessible for back up using a purpose designed back up facility which is
both robust and user friendly.
9.8 Anti-Virus Software
The latest anti-virus software (as recommended by Diageo) is to be installed on the Servers and Clients,
exceptions to be agreed by the Diageo Engineer. Systems without Anti-Virus protection must be fully
closed networks with all DVD/CD and USB ports on all Clients and Servers disabled in the BIOS boot file.

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10. Documentation
10.1 All documentation and drawings shall use English language. All components on drawings shall be
identified with tags and be referenced in a legend. All panel drawings shall be provided as AutoCAD or
equivalent files. Diageo will supply title blocks, on disc, and allocate drawing numbers.
The documentation to be provided by the contractor for approval by the Diageo Engineer shall include,
but not be limited to, the following:
• Quality Plan or Validation Master Plan (where required in the URS)
• Functional design Specification (FDS)
• HMI Design Specification (SCADA)
• Network Design Specification (NDS)
• System Design Specification (SDS) (where required in the URS)
• Factory and Site Acceptance Test documents
• Test Schedule (TS)
• Validation documentation (see below in section 12 Validation)
• Final Status Report (FSR)
• Panel General Arrangement (front panel and back plane)
• Panel Electrical Schematics
• Panel Component Schedule
If the contractor is responsible for the instrument supply then they shall supply the following as well:
• Loop Drawings
• Process Connection Drawings (Hook Ups)
10.2 Quality Plan / Validation Master Plan
This document should describe how the contractor intends to manage compliance with all applicable
standards, design specifications, the URS and ensure good software practices are maintained throughout
the project execution. The plan must encompass all work to be performed that is the responsibility of the
contractor and therefore include all elements of the system contributed by sub contractors and third party
specialists.
It shall detail the test procedures to be carried out throughout the system build, installation and
commissioning and in particular shall include:
• Regulatory Requirements and Guidelines.
• Project Scope.
• References (S88, etc.).
• Validation Objective/Strategy/Responsibility.
• Validation Lifecycle.
• Vendor Audit.
• Design Qualification.
• Code Reviews and Reports.
• Test Plan
• FAT/SAT.
• IQ/OQ/PQ.
• Responsibility Matrix.
• Project Schedule.
• Agreed KPI’s.
•
The quality plan will outline the methodology to be used at each phase of testing, the pass/fail criteria and
clearly assign the associated responsibilities for protocol generation, execution, review and approval.
The quality plan will list all documents to be generated throughout the course of the project, outlining the
content, intent and responsibilities for the generation of each document
10.3 Functional Design Specification (FDS)
The FDS shall describe in clear English how the contractor intends to meet the users requirements
specified in the URS. It shall detail the hardware and software that will be used to implement the solution.
The description shall be broken down into the functional units, both hardware and software. It shall also
include the following (where relevant to scope of supply):
• Process Description
• Signal Communication

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• Alarm, Process and Fault Messages

• Sequence Descriptions
• Recipes
• Parameters
• Route Control
• Equipment Control and Operation
• Background Control (Temp / Press)
• Route Selection
• Modes (Active/Inactive)
• Automatic/Manual/Override/Inhibit/Pause
• Queuing
The FDS shall be a maintained document. Hardware procurement and building shall not proceed until the
FDS is approved by the GIGT Engineer, unless at the contractor’s own risk. The “As Commissioned” FDS
shall be submitted within 4 weeks of hand-over.
10.4 HMI Design Specification (SCADA)
The HMI specification shall detail the design of the SCADA systems in each of the individual control
systems. This should be a single document and detail the site-wide and control system specific features.
These features include but are not limited to:
• Overview
• Basic System Functions (Start-up / Shutdown / Redundancy / Diagnostics / Security / etc.)
• Remote Access
• Screen Structure (Recipes / Process / Programme)
• Operator Interface
• Navigation
• Alarm/Event/Messaging Banners
• Pop-ups / Tooltips
• Logon Access Control/Authentication
• Process Signal Handling
• Colour Definitions (Display Standards)
• Standard Icons
• Mimic Displays
• Trending/Bar Charts
10.5 Network Design Specification (NDS)
The NDS shall detail the design for the site-wide network system inter-connecting all Ethernet, Profibus
and other multiple node connected objects. The document should specify the equipment to be installed,
proposed IP addressing, types of cabling and the protocols used. This should be a single document and
detail the site–wide specific features. These features include but are not limited to:.
• System Configuration (LAN / Port / IP Routing / Network Time)
• Equipment (Cabling {Copper/FO} / Switches / etc.)
• DNS Client
• Servers
• Clients
• VLAN/RSTP
• Hardware
• Software
10.6 System Design Specification (SDS)
The SDS shall detail the design for both the hardware and software used by the contractor to build the
hardware and programme the application software. This shall include the software structures, address
allocations, peer-to-peer communications, databases, flow diagrams and other documentation that is
used in the final design.

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10.7 Final Status Report (FSR)

The contractor shall submit a Final Status Report within one week of the completion of the SAT. It shall
detail any failures noted during the SAT that cannot be resolved due to work outside the scope of the
project (e.g. Instruments or signals not working). In addition it shall list all the Technician, Operator and
Administrator settings (e.g. set points, timers setting, control loop parameters, etc.) used on the control
system at hand-over.
10.8 Other Drawings
Panel General Arrangement, Panel Schematics, Panel Component Schedule and typical loop drawings
and hook-ups, shall be submitted to Diageo for approval prior to starting the hardware build. A full set of
Loop drawings and Process connection drawings shall be submitted to the Diageo Engineer for approval,
prior to site installation.
Panel General Arrangement (front panel and back plane) – drawings shall detail all the panel
components, panel dimensions and panel weight
Panel Electrical Schematics – drawings shall detail the electrical distribution and control wiring in a
schematic form using standard electrical symbols. All components to be shown in de-energised state.
Panel Component Schedule – shall list all the components of the panels with manufacturer's name,
component number and the drawing number of the GA and Schematic showing that component. This
may be incorporated in to the Panel GA's.
Loop Drawings – shall show the complete loop (digital and analogue) starting from the PLC terminals on
the left side of the page through to the instrument or controlled device in the field. All cable nos., core nos.
and terminal nos. used by the loop shall be indicated, plus any intermediate junction boxes, indicators,
trips, barriers or other devices.
Process Connection Drawings (Hook Ups) – shall be in accordance with BS 6739 and shall indicate the
connection to the process, any intermediate (impulse) pipes and the mounting details. If a drawing is
common to more than one device then only one common drawing is required with a list of instruments
(tag number and duty description) to which it applies.

11. Testing and Commissioning

11.1 Factory Acceptance Testing
The contractor shall carry out their internal testing and provide satisfactory proof of this testing prior to the
Factory Acceptance Test. The contractor shall make the system available for Factory Acceptance Testing
prior to installation. The system can only then be installed on site once the Diageo Engineer is satisfied it
has passed the FAT. This will be outlined in a FAT summary Report to be issued by Diageo. Minor issues
can be forwarded to the SAT.
11.2 Installation and Commissioning
The contractor shall at all times seek the permission of the Diageo Engineer to carry out installation work
which may disrupt production. Disruption shall be kept to a minimum by scheduling work on equipment
that is not due to be used by production. The contractor shall provide a Commissioning programme in
cooperation with production scheduling, which will detail the work on site. This will be regularly up dated
to fit in with production schedules.
11.3 Site Acceptance Testing
The contractor shall make the system available for Site Acceptance Testing after their installation and
commissioning and prior to handover. The contractor shall provide satisfactory proof of their internal
testing prior to the SAT. The system can only then be taken over once the Diageo Engineer and
Operations are satisfied it has passed the SAT. This will be outlined in a SAT summary Report to be
issued by Diageo.

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12. Validation
12.1 Definition
Validation is defined to be the verification of the system that it is fit for purpose and complies with
Diageo's requirements as laid out in the project specific URS.
Validation of the system follows on from the installation and commissioning of a system and
encompasses both hardware and software installations.
Validation is a process of qualifying the system against written protocols that measure the actual
demonstrated performance under specific test conditions against pre set criteria for quality, range and
performance in system operation and process execution. The written protocols will include:
• Installation Qualification (IQ).
• Operational Qualification (OQ).
• Performance Qualification (PQ).
12.2 Installation Qualification (IQ)
This protocol is intended to verify that the installation of either hardware or software is of the required
standard and satisfies the written and pre-approved specifications produced during the project. These
include for the hardware:
• URS,
• Functional Design Specification (FDS)
• Hardware Design Specification (HDS) (if separate from and FDS)
• Schematics for digital I/O and motor circuits.
• Loop drawings for all analogue devices.
They include for the software:
• URS,
• Functional Design Specification (FDS)
• Software Design Specification (SDS) (if required in the URS).
• Detailed Design Specification (DDS) (if required in the URS).
12.3 Operational Qualification (OQ)
This protocol is intended to verify that a system operates according to the written and pre-approved
specifications, produced during the project, throughout the specified operating ranges.
12.4 Performance Qualification (PQ)
This protocol is intended to verify that a system is capable of performing the activities of the process it is
required to perform, according to the written and pre-approved specifications, produced during the project,
within the scope of the business process and operating environment.
12.5 Validation Requirements
The URS produced for the project will specify whether one, several or all the validation protocols are
required to be implemented.

13. Key Performance Indicators

Tests will be set in the URS to test the performance of key equipment within the system. These will include but are
not limited to:
• Control system SCADA update delays,
• PLC data communication rates to higher and lower level equipment
• PC and server boot-up times,
• Network loading between PLC's, Clients and Servers
• Frequency of network collisions.
• Overall system speed.
• These KPI's will form part of the overall system tests before validation begins.

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14. Archiving
Every PC and PLC based system running software will require regular backing up to preserve the latest set of
software and data. These backups are essential to be able to restore the system to operational capacity should part
of the system suffer a catastrophic failure. The procedures for backing up a system should be specified in an O&M
which would form the backbone of a SOP developed by Diageo for the system. The following backup strategies, as
well as the required hardware, should be included in any computer controlled system:
Server:
Backups to a remote tape / hard drive across a network of critical and important data on a "Grandfather-Father-Son"
basis (i.e. Monthly / Weekly / Daily backups).
Server:
Entire disk backup using for example the MS-Server Utility(Monthly).
Client:
Ghost image of entire disk (Monthly).
Client:
Backups across network to Server related tape of any critical data kept on the client with the same frequency as in
Item 1. (it is, however not recommended to keep any critical data on clients).
PLC:
Backup of PLC programmes across network on a regular basis (monthly)
PLC:
Immediate backup of all PLC programmes whenever a change is made.
Other controllers: Same procedure as the PLCs.

15. Training
The contractor shall include for training of the Operations and Maintenance Staff for all equipment within the scope
of supply. The contractor shall submit a training proposal to the Diageo engineer for approval prior to Site
Acceptance Testing. The contractor shall then use this to form the basis of a training booklet to be issued by the
Contractor at training sessions. The contractor’s proposal shall take into account the constraints on availability of
personnel for training due to the shift patterns of the Operations staff. The training documents and the content of the
training programme will comply with the requirements of the DGS Training Standard. (See Section X.X References)

16. Support
The contractor shall provide support for the control system following handover to the end user where specified in the
URS.

17. Recommended Spares

The contractor shall provide with the tender a list of recommended spares for the maintenance of the control system.
This list shall be updated by the Contractor prior to hand-over.

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18. Programme
18.1 Project Programme
The contractor shall submit a project programme detailing, as a minimum, the following key activities,
with the Tender submission. This programme shall be maintained by the contractor and reviewed at each
project meeting.
• Design Phase
• FDS and Drawings Submissions for approval
• System Development
• Test Schedule Production
• Test Schedule Submission for Approval
• Factory Acceptance Test
• Hardware Installation
• Commissioning
• Site Acceptance Test
• Issue of Draft O&Ms
• Training
• Hand-over
• Final Documentation and O&Ms Submission for Approval
18.2 Commissioning Programme
The contractor shall develop a detailed programme for the Commissioning, prior to the Factory
Acceptance Testing. It shall detail the hardware and software on site activities for each part of the control
system (e.g. PLC, SCADA, etc.). The programme shall highlight critical activities, which require
“downtime” on any part of the Plant or existing control system.
The programme shall be flexible to enable the sequence of the activities to be re-ordered to suit
production schedules. The programme shall be regularly reviewed with the Operations Team and Diageo
Engineer, so as to avoid conflicts.
18.3 Progress Meetings
The contractor shall hold frequent (at least monthly) progress meetings at their works to which the Diageo
Engineer shall be invited. Once the system is delivered to site, meetings will be held weekly to review
progress and plan the coming week's activities around the production schedule.

19. Project Deliverables

Within 4 weeks of the ‘Project Hand-over’ the contractor shall submit the following Final Documentation to the
Diageo Engineer.
FDS “As Commissioned”
SDS “As Commissioned” (if required in the URS)
Panel G.A.'s
Panel Electrical Schematics
Test Schedule passed at FAT &and SAT
Final Status Report
Software back-ups of all the PLC’s and the OP system
O&M Manuals
Where the supply of instruments was part of the scope the Final Documentation shall include:
Loop Drawings
Hook-up Drawings
Documentation Listed in General Spec for Instrumentation

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Appendix 1
Cable Colours
Cable Core Colours
Cable and core colours are to be as detailed in ETCI regulations ET101:2008

380 Volts ac
First Phase of a 3 Phase Circuit Brown
Second Phase of a 3 phase Circuit Black
Third Phase of a 3 phase Circuit Grey
Neutral Conductor of a 3 phase Circuit Blue
Earthing, Protective and Bonding Conductor Green / Yellow

220 Volts ac
Phase of single Phase AC. Circuit 220 VAC. Brown
Neutral of single Phase AC. Circuit 220 VAC Blue

110 Volts ac

Phase of single Phase AC. Circuit 110 VAC Brown

Neutral of single Phase AC. Circuit 110 VAC Blue

24Volts ac
Phase of single Phase AC. Circuit 24 VAC Brown
Neutral of single Phase AC. Circuit 24 VAC Blue

24Volts dc Earthed Negative

Positive of 24 VDC. circuit Brown
Negative of 24 VDC. circuit Blue

24Volts dc Earthed Positive

Positive of 24 VDC. circuit Blue
Negative of 24 VDC. circuit Grey

24Volts dc Neither Pole Earthed

Positive of 24 VDC. circuit Brown

Negative of 24 VDC. circuit Grey
Mid Point (may be earthed) Blue

Earth
Earth Green/Yellow

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Cable Sheath
Colours

Black Power, Control and Instrumentation cables

Grey Low voltage e.g. telephones, computer networks, etc.
Blue Intrinsically safe circuits
Mauve Field bus (e.g. Profibus)
Orange MICC Fire Alarms in buildings
Red Fire Alarms outside buildings
White Intruder

Sleeving of blue cores

Note: Do not assume that existing cables carry the services or voltages indicated by the above colours.

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Appendix 2
URS Guidelines
1.1 System Attributes
The vendor must ensure that the system has all the capabilities to allow the plant to be partially run in
manual mode. This means that the valves can be operated manually, pumps driven, automatic routes
overridden and error messages overruled. This requires the following attributes to be designed into the
control system:
1.2 Manual Interlocks
Any object in the control system can be operated manually in the correct circumstance. This may,
however may not be desirable from a product or equipment safety point of view (e.g. opening a CIP valve
into a product line) and will require manual interlocks to be defined that the system takes account of when
a manual activation request is made. The system will refuse to activate the object when it violates this
manual interlock. This does not apply to automatic operation since it will be assumed and consequently
tested that the automatic system cannot cause safety related activation problems in the course of its
normal programmed sequencing. The exception to this is the ‘Interlock Override’ function detailed below.
1.3 Automatic Override (Phase Enable Bypass)
Any object enabled by the automatic system to complete a route must have the attribute to override this
status and switch it to a manual mode without the entire automatic route being disabled. This capacity
must be access level controlled and only available to those granted access by the system. Activations of
the automatic overridden object by the operator are entirely the responsibility of that operator and the
automatic system must continue as if that object were in automatic mode. Safety control functions must
not be overridden by this facility.
1.4 Error Override
An object showing an error may not actually be in physical error. Therefore the ability to allow the
operator to override the error, if it is clear that this object is actually responding correctly and only the
feedback is in error, and restart the automatic operation is crucial to contiguous production. This capacity
must be access level controlled and only available to those granted access by the system. Activations of
the error overridden object by the operator are entirely the responsibility of that operator and the
automatic system must continue as if that object were responding normally mode .
1.5 Interlock Override
An object running in either automatic mode or not phase enabled, may require a manual activation to
allow an out of sequence action to take place (i.e. opening a drain valve out of sequence is a typical
example). These objects must be activated manually to achieve this and the system may not allow this to
happen due to the defined set of manual interlocks applying to that object. Therefore a ‘Manual Interlock
Override’ function (IO) is required to set this block out of action for this particular object. Activating the IO
will allow the operator to activate the object despite the manual interlocking function. This capacity must
be access level controlled and only available to those granted access by the system. Activations of the
interlock overridden object by the operator in manual mode (may also require that object to be automatic
overridden) are entirely the responsibility of that operator and the automatic system must continue as if
that object were in automatic mode. Safety control functions must not be overridden by this facility.
1.6 Object Simulation
Setting the simulation attribute on an object effectively simulates the feedback from that device without
actually activating that device. Therefore it is possible to show an object as activated without actually
driving that object.
1.7 Override Rescinding
An object in either automatic error or interlock override must have this status rescinded at a sensible time
point after the operation has moved on.
In a batch scenario, this will be when a particular batch has moved on to the next vessel.
In a non-batch scenario, this will be when the particular function or programme where this override
became necessary has completed.
The reason for the requirement for rescinding the override is to avoid multiple instances of overrides
occurring and to place pressure on the site operations to repair the offending object. Simulated objects
will not have the status rescinded in this way. Simulation must be manually removed by the operator.

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Appendix 3:
Preferred Hardware and Software
1.1 Hardware
Electrical panel:
Rittal
Or similar to be agreed with Diageo engineer
PLC:
Siemens S7 range
HMI:
Siemens OP range PC:
HP with Intel processor technology.
IBM with Intel processor technology.
Server:
HP with Intel processor technology.
IBM with Intel processor technology.
Network:
Cisco Switches or industrial equivalent.
1.2 Software
Operating System (with latest approved SP):
• Windows XP Professional
• Windows Server 2008
• Anti Virus:
To be agreed with Diageo engineer

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Electrical Standards: Specifications for Electronic Access Control Systems

Specifications for
Electronic Access Control Systems
1. Background
1.1 In order to ensure that all Diageo`s staff, sites and premises are protected from the risk of crime in the
most efficient way, it is vital that all available security resources are deployed in a coordinated and
efficient manner.
1.2 This means that CCTV cameras, lighting, access control systems and where deployed, Security Guards
should be deployed in a manner which:
1.2.1 acts as a deterrent to unlawful activity
1.2.2 detects any unauthorised activity at the earliest opportunity
1.2.3 provides real time information to allow incidents to be managed safely and efficiently
1.2.4 provides best value for money

2. Justification for installation of an Electronic

Access Control system
2.1 Controlling access to any Diageo premises is the most fundamental aspect of security since it ensures
that:
2.1.1 Only authorised persons are within the premises
2.1.2 Details of all persons within are known
2.1.3 Access to areas which require higher levels of security can be controlled
2.1.4 n the event of the need to evacuate, accurate records are immediately available in relation to
whether persons are accounted for or otherwise
2.2 Manual methods of controlling access and recording details of persons entering or leaving a site are
only appropriate if less than 30 persons are normally based on site and numbers of daily visitors do not
exceed 30. Any premises where numbers exceed these limits should install an electronic access control
system.

3. Specifications for Electronic Access Control Systems

3.1 Any premises which uses an existing electronic access control system (other than the type now
approved) should continue to utilise that system until such time as it reaches end of life however
thereafter and in respect of an new installation, the only system which is type approved for use in any
Diageo premises will be as follows :-
3.1.1 Tyco – Software House - C- Cure 9000.
3.1.2 I-Star controllers which must be installed within secure areas.
3.1.3 I-Class swipe access cards will be used (a list of approved suppliers is available)
3.1.4 I-Class readers to be installed on all main entrance and exit points and on areas which require
higher levels of security i.e. server rooms.
3.1.5 Biometric readers or swipe card readers and PIN numbers may be installed where additional
confirmation of identity is required.
3.1.6 Biometric systems must be compatible with local Data Protection legislation and the selection
of a particular system should be discussed with a member of Corporate Security.

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3.2 The system shall be installed so that all persons entering and leaving the premises are required to swipe
“in” and “out” thereby allowing the system to be used for roll call purposes. Turnstiles are considered the
most suitable equipment to achieve this requirement
3.3 Muster points, must be installed at Fire Assembly areas (mobile I-class readers are acceptable at muster
points if the permanent placement of a reader is not feasible).
3.4 Cards may be printed on site using an approved printer or remotely using HID remote card printing
services.
3.5 The system must be installed and maintained by contractors who are C-Cure accredited and where
possible of “Enterprise Integrator” status. There are 3 levels of accreditation – Certified, Advanced and
Enterprise (highest). Installation companies and their Engineers, who are not accredited, will not be
permitted to work on the system.
3.6 Access control system controllers should be mounted in a tamper proof manner and not be capable of
being deactivated from outside the secure area.
3.7 The system should be connected to a back-up electrical power source capable of maintaining the system
for a period of not less than 4 hours so that in the event of power loss, key external doors remain closed.
3.8 All external doors shall be fitted with Door Status Monitors.
3.9 All Emergency doors shall also be fitted with a Door status monitor plus a local sounder. An alarm event
should be created if a door is left open for more than 60 seconds. Such doors will be fitted with a hard
wired link to the Access Control System. Unlock time should normally be set at 5 secs.
3.10 All doors must be continuously monitored by the Access Control System.
3.11 Locks on doors will be Magnetic locks or where a higher level of security is required, an Assay Abloy lock
will be fitted.
3.12 Magnetic locks where used shall be installed in conjunction with Emergency Door Release buttons or
equivalent. The use of the button shall be monitored and recorded by Access Control System and shall
cause a local audible alarm to be activated with each use of the button. The magnetic lock should be of
adequate power in relation to the size and weight of the door.
3.13 Any perimeter area that has glass greater than 96 sq in (619 sq cm) shall have a glass break detector
fitted. This will have a separate input onto the Access Control Panel.

4. Maintenance
4.1 It is essential that a maintenance contract is implemented for regular maintenance and repairs. A central
maintenance contract exists for the maintenance of the server and also software however this does not
extend to hardware installed on site or card printers.
4.2 As with installation of the system, only C-Cure Enterprise Partners or a suitably qualified C-Cure
accredited partners will be used for maintenance of the system.

5. Administration
5.1 For each site or premises that uses an electronic access control system, there must be a nominated
person(s) depending upon the size of the site who oversees the administration of the system and who will
undertake such functions as:
5.1.1 Issuing access cards
5.1.2 Altering levels of access
5.1.3 Removing persons from the system
5.1.4 Ensuring that regular maintenance is carried out
5.1.5 Reference may be made to the Diageo C-Cure Standard Operating procedures (attached).

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6. Data Protection
As with any electronic system which contains personal data relating to persons, it is imperative that such data is
properly managed. In respect of an electronic access control system, this means that the requirements of the Diageo
Physical Security Access Control Data & CCTV Footage Records Retention Policy must be complied with.

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Electrical Standards: Fire Detection, Alarm & Suppression Systems

Fire Detection, Alarm &

Suppression Systems
1. Background
1.1 Early fire detection is considered vital for safe evacuation and to allow time for in-house fire teams to
tackle a fire while it is still possible to control it with the fire-fighting skills and resources on site.

2. Introduction and Scope

2.1 The purpose of this document is to specify the functional and installation requirements for Fire Detection
& Alarm (FDAS) Systems for Diageo production, packaging and storage facilities within Diageo’s Brewery
Facilities.
2.2 This specification is not intended to be prescriptive. Suppliers/installers of FDAS Systems are
encouraged to propose new equipment and methods where they can add value or reduce costs while
being mindful any change have sighed approval by the responsible person(s) within Diageo.

3. General Requirements
Systems Overview:
3.1 The supplier shall discuss, with Site Management, the particular needs for each site. The latest Site Fire
Risk Assessment shall be consulted and provision made for any additional or specific fire risk mitigation
measures.
3.2 As a general principal the system will be comprised of a Master Fire Zone Station in a suitable location,
typically the site Gate House or Security Control Room. This Master Fire Zone station will be linked to
Local Fire Zone panels placed in strategic locations within each area of the site.
3.3 Systems shall include a mimic panel with a fire alarm graphical user interface (GUI) showing a full
graphical layout of the site. It shall have individual LEDs indicating each fire zone. The colour used for
indicating lights shall be red to simulate a fire.
3.4 Fire Supervision CCTV will similarly be installed in the gate house or control room where fire fighting
operations may be directed.
3.5 In general, manual alarm call points shall be installed in accordance with BS5939-1: 2002+A2:2008 (Fire
Detection and Fire Alarm Systems for Buildings, part 1).
3.6 Sounders should be installed in all buildings to ensure a sound pressure level of 65 dB(A), or 5 dB above
the sound pressure level of the background noise. Visual alarm devices (red flashing beacons) should
also be located in areas where the ambient noise is 60 dB(A) or above. All internal sounders should have
similar sound characteristics and should be of the “banshee” type.
3.7 Cable sheaths shall generally be coloured red. Where cable containment is required, red μVPC trunking
should be used. To avoid the risk of mechanical damage to the cables, they should not be installed within
the same conduct as cables of other services. Where cables share common trunking with other cables a
separate from other compartments by a strong, rigid and continuous partition should be reserved solely
for fire alarm cables. In areas prone to acid or alkali attack consideration should be given for suitable
protection to the cabling.
3.8 Gas extinguishing shall be installed in business-critical rooms such as IT rooms, CTR Rooms, PLC
Rooms, Server Rooms, MCC rooms, Substations and any other high-risk areas as determined by the site
fire risk assessment.
3.9 A CCTV system shall be installed within critical areas to allow security to decide on appropriate action to
take in the event of a fire.
3.10 Remote control shut of switch shall be provided for the main electrical circuit breaker which can be used
to isolate the electrical supply to the building in the event of a fire.
3.11 In Substations and other critical areas, consideration given to install a two-stage manual system.

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3.12 Training for Fire teams and Security personnel to enable the effective response time and action taken
shall be delivered as part of the project scope.
3.13 Maintenance plans to regularly test and maintain the installed fire detection suppressant equipment shall
be provided as part of the project scope.
3.14 In practice the category of system that is specified for any particular premises depends primarily on three
factors:
3.15 The requirements of legislation, as imposed, or enforced, by the relevant authorities or GRMS.
3.16 The requirements for protection of property which are often ‘driven’ by the property insurers. The
requirements may, equally arise from desire on the part of the property owner or occupier to protect the
property against fire.
3.17 Requirements for protection of the business against business interruption to its operations. These
requirements often arise from management policies of the business, but may sometimes be driven by
business interruption insurer.

4. Civil works
4.1 The Contractor shall be required to provide drawings, loadings and all technical information required by
the Purchaser to enable civil works to be specified for the project.
4.2 Where civil works are progressed, they shall be suitably finished and inspected by a Diageo engineer as
part of the handover inspection. Where cable penetrations are to take place, methods of penetration and
sealing shall be agreed between the supplier and the Diageo engineer.

5. Mechanical & Electrical installation

5.1 The Contractor shall be required to provide drawings, loadings and all technical information required by
the Purchaser to enable mechanical and electrical works to be specified for the project.
5.2 Diageo shall be responsible for the supply/installation of any fused 240 V spurs required for the Fire
Alarm installation. However, by prior agreement, this may be done by the supplier.
5.3 The Contractor shall also be responsible for removing all redundant fire system equipment and cabling.
5.4 The safe disposal of hazardous materials – e.g. Mercury Switches and Ionisation Smoke Sensors and
any other redundant equipment is a site responsibility. An area need to be nominated were redundant
equipment should be securely stored.

6. Electrical Switch rooms (MCC), Transformer Rooms

and Computer Rooms
6.1 The standard for Electrical Switch rooms and Transformer Rooms is BS 5839. These areas shall be
protected by OPTICAL smoke detectors to Category P1 or as determined by the Site Fire Risk
Assessment. Business-critical MCC Rooms shall be protected with a gas suppression system using, e.g.,
Novec 1230 as the fire extinguishant.
6.2 The standard for Computer Rooms is BS 6266. Detection in these areas will be determined by Site Fire
Risk Assessment and also the number of air changes in the room and presence of floor and ceiling voids.
The areas shall be protected by OPTICAL smoke detectors to Category P1/M. Business-critical
Computer Server Rooms shall be protected with a gas suppression system using, e.g., Novec 1230 as
the fire extinguishing medium.

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7. Fire Main & Hydrants

7.1 The Fire main (water) installation should conform to the British Standard.
7.2 This system should provide a Fire Pump house, a Fire ring Main including Fire Hydrants. The hydrants
should be positioned not more than 90 m from an entrance and not more than 90 m apart
7.3 The means of supply for wet fire mains is essential. The pressures and flows are at all times adequate to
serve two fire–fighting jets. This is irrespective of the source of water supply
7.4 When the town’s main supply is not sufficient to provide the right capacity and pressure the fire main
should be feed from an onsite water supply with a minimum capacity from 45 m3. The tank should be
automatically supplied from a town’s main or borehole.
7.5 The solution requires two automatic fire pumps to feed the wet fire main, one of which should act on
standby, and be arranged so that when acting as duty pump it will operated automatically, i.e. on a flow of
water or fall of pressure on the installation. The secondary pump should be so arranged that it will
operate automatically on a failure for any reason of the duty pump. Both pumps should be primed
automatically at all times. The pumps should be driven by diesel engines.
7.6 Each pump should be capable of providing a flow of water of at least 1500 l/min in the fire main i.e.
sufficient to serve lines of hose from two separate landing valves simultaneously. A running pressure
from 8bar should be maintained at each landing valve when fully opened
7.7 To keep the systems pressure an electric jockey pump will be installed. This will prevent the pumps
kicking in during small pressure drops, when the pressure drops below set pressure the main pump will
kick in. The system will not depend on electrical power only for the jockey pump. During power failure the
pressure drops the diesel pump automatically will kick in.
7.8 The two diesel pumps, jockey pump and suction and delivery pipe work should be housed in a pump
house. This can be an existing or purpose build pump house. The pump house should have a main
power supply and fuel tank or refill facility for the fuel tanks of the diesel pumps.
7.9 The pumps control panel should have a dry connection, if the system requires to be connected to the fire
detection system
7.10 It is foreseen that redundant equipment would need to be removed during the installation of this Fire
Pumps and Hydrants project. This equipment will be stored at a predetermined place organized by the
site.

8. Design Standards
8.1 General Codes and Standards
8.1.1 The DIAGEO Category for design of Fire detection and Suppression is P2/M with Variations
as per BS5839-1:2002 + A2 2008 Fire Detection and Fire Alarm Systems for Buildings.
8.1.2 Variations from the design may be necessary; bearing in mind compliance with the standard
P2/M should be applied where reasonably practical. Variations shall have sighed approval by
the responsible person(s) within Diageo.
8.1.3 All equipment will conform to the relevant standards. Where exceptions occur, these must be
clearly highlighted and approved before placing of any order otherwise it will be assumed the
standards are followed.
8.2 Additional Codes and Standards:
8.2.1 FDAS Systems shall be installed to meet the requirements of Global Risk Managements
Standard or the requirements of the country where the system is installed. If those
requirements are higher that the GRMS, those standards will apply
8.2.2 To meet this requirement the design, manufacture, and installation of FDAS Systems shall be
in accordance with the latest revision of all relevant European Union Directives, as well as
European and British Standards.
8.2.3 All equipment will conform to the attached Diageo standards. Exceptions to this must be
clearly highlighted and approved before placing of any order otherwise it will be assumed the
standards are followed.

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8.3 Fire Alarm & Emergency Site Evacuation Systems

8.3.1 BS5839-1:2002 + A2 2008 Fire Detection and Fire Alarm Systems for Buildings - Code of
practice for system, design, installation, commissioning and maintenance
8.3.2 BS7671 lEE wiring to17th Edit of the Regulations.
8.3.3 BS EN54 Part 2 Fire alarm control panels
8.3.4 BS EN 54 Part 3 Fire Alarm Sounders
8.3.5 BS EN54 Part 4 Power Supplies
8.3.6 BS EN54 Part 5 Point type Heat Detectors
8.3.7 BS EN54 Part 7 Point type Smoke Detectors
8.3.8 SANS 10139 (Derived from BS5839) Fixed Extinguishing Systems
8.3.9 BS EN15004 Fixed Fire Gaseous Extinguishing Systems
8.3.10 BS EN 6266 2002 COP Fire protection of electronic equipment installers
8.3.11 BS EN 7273 COP for operation of protection measures
8.3.12 BS EN 7273 Part 1 2006 Electrical actuation of gaseous total flooding extinguishing systems
8.3.13 BS EN 7273 Part 2 1992 Mechanical actuation of gaseous total flooding extinguishing
systems
8.3.14 BS EN 7273 Part 3 2008 Electrical actuation of water mist and sprinkler systems
8.3.15 BS EN 7273 Part 4 2007 Actuation of release mechanisms for doors
8.3.16 BS EN 7273 Part 5 2008 Electrical actuation of water mist system (except pre-action systems)
8.3.17 BS EN 9999 2008 COD for fire safety in the design, management of buildings
8.4 Recommended Gas use:
8.4.1 Computer Room - Telephone Rooms Novec 1230
8.4.2 BS 5306/4 2001 Fixed Extinguishing Systems 2001
8.4.3 HV Rooms 11 - 15KV Novec 1230 local application
8.4.4 Control & MCC Rooms Novec 1230 local application
8.4.5 Electrical LV Rooms Novec 1230 local application
8.5 Electrical Control of automatic extinguishing systems:
8.5.1 BS6266: 2002 - Code of practice for fire protection of electronic equipment installations.
8.5.2 BS7273-1:2006 - Code of practice for the operation of fire protection measures: Electrical
actuation gaseous total flood extinguishing systems.
8.6 Approving Organisations:
8.6.1 All supplied equipment shall be approved by at least one of the following organisations:
8.6.2 Loss8Prevention Council (LPC),
8.6.3 British Standards Institution (BSI),
8.6.4 Underwriters Laboratories (UL),
8.6.5 Factory Mutual (FM).
8.7 Installer Certification Standards:
The Fire Detection and Alarm System contractor shall be LPS 1014 or BAFE certified.
8.8 ATEX Compliance Standards:
All equipment must have CE certification and be marked accordingly and fully ATEX137 compliant.
8.9 Fire Main and Fire Hydrants:
8.9.1 BS EN 9990:2006 - Code of practice for non-automatic fire fighting systems in buildings

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8.9.2 BS EN 5041-1:1987 - Fire hydrant systems equipment. Specification for landing valves for wet
risers
8.9.3 BS EN 14384:2005 - Pillar fire Hydrants
8.9.4 BS EN 5839-8:2008 - Fire detection and fire alarm systems for buildings; Code of practice for
the design, installation, commissioning and maintenance.
8.9.5 Equipment Design Life:
[Link] The supplier shall state the design life for all major parts of the system and should
draw attention to items with an inherently short design life: for example, the system
batteries.
[Link] The supplier shall guarantee the availability of all system spares for a period of not
less than ten years.
[Link] The supplier shall ensure that a record of all new equipment is passed to their
maintenance department and also to the relevant Diageo engineer to enable
testing and maintenance records to be kept up to date.
[Link] The supplier shall maintain accurate site records for all maintenance, repair and
change works to the installation. These records shall be kept in the document box
and be available to site management.
8.9.6 Manual Control and User Interface:
[Link] The control panel shall incorporate a keyswitch to prevent unauthorised use of the
manual controls.
[Link] The control panel shall be provided with the following push buttons:
[Link] EVACUATE (actuates ALL alarm sounders in the system)
[Link] SILENCE (stops all currently actuated alarm sounders)
[Link] RESET(returns the control and indicating equipment to quiescent condition)
[Link] LAMP TEST (tests all LEDs)
[Link] A simple to operate keypad to enable a user to access the various built-in functions,
and interact with the information displayed on the LCD shall be provided. For
security reasons, the control panel shall provide a customer configurable password
code facility.
8.9.7 Cabling:
[Link] Generally, “standard” fire resisting cables shall be used in Diageo Fire Detection
and Alarm Systems -. The use of cables with “enhanced” fire resistance shall be
used where recommended by BS 5839-1 or as required by the Diageo engineer.
[Link] Standard fire resisting cables shall be type FP200 Gold. Enhanced fire resisting
cables shall be type MICC/LSF.
[Link] Additional mechanical protection shall be provided in areas where necessary.
FP400 cables shall be installed in underground ducts.
[Link] Fire resisting cables in hazardous areas shall be either FP200 Gold with additional
mechanical protection or, preferably, MICC/LSF.
[Link] Cable sheaths shall normally be coloured red. An exception is the FP400 type
where this is used underground: the sheath shall be the standard.
8.9.8 Sounders:
[Link] Sounders shall be IP rated for the area in which they are located and should be
capable of producing the audible levels for that area. All sounders shall have the
same banshee style sound throughout the complete site.

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9. Installation and Commissioning

9.1 General
9.2 A method statement and risk assessments shall be submitted to site, and copied to the Diageo engineer,
at least one week prior to works starting.
9.3 The supplier should ensure that any third party contractor they wish to utilise for the installation of
equipment has been approved as suitable for working on Diageo sites – i.e. they should also be on the
Diageo Approved Contractors List.
9.4 Installation engineers working in hazardous areas shall be CompEx (or equivalent) trained.
9.5 All equipment supplied (e.g. cable, call points, sounders, interface modules, etc.) should be installed in
accordance with the guidelines set out in BS 5839-1:2002+A2:2008, BS 7671:2008 and the installation
instructions provided by the manufacturer.
9.6 All equipment and components should be correctly located as per the design drawings. Any deviations to
locations shall be agreed with Diageo before installation.
9.7 All equipment and components installed should be as originally specified. Any changes to this shall be
subject to prior approval by Diageo.
9.8 The FDAS System mains power connections to the fire controller equipment should be accordance with
the guidelines set out in the relevant British Standards and the installation instructions provided by the
manufacturer.
9.9 The FDAS System mains power-isolating switch shall be coloured red and clearly labelled “FIRE ALARM:
DO NOT SWITCH OFF”.
9.10 Each circuit of the system shall be connected to the fire controller via associated fuse or circuit breaker
devices located within the fire controller unit.
9.11 Cable and Field Equipment Installation:
9.11.1 Cable and wire entries in all equipment shall be fitted with grommets to prevent possible
damage to the insulation.
9.11.2 Wiring used for driving devices requiring high currents, (e.g. bells, etc.) shall limit the voltage
drop to less than 10% of the nominal operating voltage.
9.11.3 Cables used for the transmission of system data and alarm signals shall be in accordance with
the types recommended by the manufacturer of the fire detection and alarm equipment.
9.11.4 The ends of all cables shall be sealed by means of proprietary seals and associated glands
that are suitably rated for the application and area. No heat should be applied to any seal or
termination. Cable tails shall be insulated by means of blank PVC sleeving anchored and
sealed into the seal.
9.11.5 All cabling and wiring shall be tested before they are connected to the fire controller and
associated devices.
9.11.6 Where protection of the cable glands is required, or terminations are on display, the glands
shall be enclosed in red coloured shrouds of the appropriate British Standard colour.
9.11.7 Where cable(s) are to be attached to cable trays they shall be neatly run and securely fixed at
suitable intervals. Metal or plastic-coated metal ty-wraps cable fixings shall be used.
9.11.8 At detector and sounder locations, cables shall be terminated in approved black
enamelled/galvanised BESA or MI Clamp type junction boxes. All other devices forming part
of the system shall utilise dedicated /custom back boxes.
9.11.9 All detector bases shall be securely fixed to BESA boxes and allow for easy fitting and
removal of detectors.
9.11.10 Cable and wire strain relief clamps shall be provided at entries to control devices, associated
modules and the control panel as required.
9.11.11 All cables from the fire controller equipment to the detection and alarm devices shall be clearly
labelled as part of the fire detection and alarm system.
9.12 Equipment in Hazardous Areas:
9.12.1 Equipment must be selected, installed and maintained in accordance with DSEAR (Dangerous
Substances and Explosive Atmospheres Regulations 2002) / EPS Regulations (Equipment

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and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations
1996), BS EN 60079 (various parts) (Electrical Apparatus for Explosive Gas Atmospheres)
and BS EN 61241-14 (Electrical Apparatus for Use in the Presence of Combustible Dust:
Selection and Installation) and 61241-17 (Maintenance and Inspection). Local Hazardous
Area Classification drawings should also be consulted.
9.12.2 Electrical equipment for use in hazardous vapour areas should meet the requirements for
ATEX G Category equipment.
9.12.3 The equipment must also be selected with the correct temperature classification. This is the
temperature which will not be exceeded by exposed hot surfaces of the equipment in normal
operation and is governed by the auto-ignition temperature of the vapour in question – ref.
Section 10.
9.12.4 Electrical equipment for use in hazardous dust areas should meet the requirements for ATEX
D Category equipment.
9.12.5 The apparatus must also be selected according to an appropriate temperature classification
and this depends on the combustion characteristics of the dust in question. The T rating must
be selected on the basis that the maximum surface temperature of the equipment will not
exceed two-thirds of the ignition temperature of the flammable dust cloud and a value of 75oC
below the minimum ignition temperature of a 5mm dust layer.
9.13 Testing, Commissioning and Handover:
9.13.1 The supplier shall be responsible for the complete inspection, testing and commissioning of
the system to the requirements of the relevant British Standards, manufactures guidelines and
the design specification. The supplier shall record details of all tests and commissioning
results.
9.13.2 As part of the commissioning activity, the supplier shall demonstrate the successful operation
of the system to Diageo.
9.13.3 After successful commissioning, the supplier shall arrange for a walk round the installation
with site management as well as the Diageo engineer. If there are no snagging items to be
addressed, the supplier shall handover the system. At this time, all handover documentation
referred to above should be issued to Diageo.
9.13.4 The supplier shall also present an Acceptance Certificate for signature by the customer.

9.14 Training
9.14.1 As noted above, the supplier shall provide training for Diageo personnel as part of the contract.
The scope of the training should be discussed and agreed with site management. Suitably
competent personnel shall carry out training. Certificates of attendance issued to all site
personnel who attended. A comprehensive training package shall be provided for each system
installed. A copy of this shall be left on site for subsequent training of new personnel.
9.14.2 Authorised people such as Permit writers, Site Engineers, Facilities manager and team need
to be trained in issuing General and Hot work permits. Issuing permits and completed the
isolation process and putting the system back online is a very important part to prevent
unplanned activations. This will save production interruption and unnecessary evacuation.
This training need to take part during the commission period.

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10. Documentation
10.1 Tender Documentation:
10.1.1 At the tender stage the supplier shall produce layout drawings and outline system specification
documents to enable Diageo to review design concepts and scope.
10.1.2 The supplier shall also provide a project plan detailing design, installation and commissioning
activities.
10.2 Order Documentation:
10.2.1 Diageo shall provide the supplier a copy of site CAD drawings with the enquiry. Where these
are not available, Diageo shall inform the supplier so that they can cost for the relevant
drawings to be created.
10.2.2 The supplier shall provide all documentation and drawings necessary for the correct
installation, operation and maintenance of the system. Drawings shall comply with the Diageo
CAD Code of Practice, which should include the following as a minimum:
• System description
• System schematic diagram
• Cabling and wiring diagram
• Detailed equipment connection diagrams
10.2.3 A building plan shall be provided showing zoning and location of fire controller, detectors, call
points, sounders and ancillary devices. The supplier shall ensure that this plan details all
buildings required, and that each individual floor is detailed.
10.3 Handover Documentation:
At the time of handover, the supplier shall provide the following information:
10.3.1 Copy of commissioning report (to include all setting and adjustment details)
10.3.2 As-fitted system design drawings
10.3.3 As-fitted system schematic diagrams
10.3.4 As-fitted loop diagrams, including calculations, for all Intrinsically Safe (IS) circuits
10.3.5 Calibration Certificates for all test equipment
10.3.6 Category certificate plus variations
10.3.7 Training and certification records for personnel trained during/after the commissioning period
10.3.8 Control Panel manual – including a laminated single-page sheet showing the basic
instructions.
10.3.9 Handover documentation shall be in the form of two paper copies and one electronic copy.

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Specifications for
Closed Circuit Television (CCTV)
1. Background
In order to ensure that all Diageo`s staff, sites and premises are protected from the risk of crime in the most efficient
way, it is vital that all available security resources are deployed in a coordinated and efficient manner.
This means that CCTV cameras, lighting, access control systems and where used, Security Guards should be
deployed in a manner which:
• Acts as a deterrent to unlawful activity
• Detects any unauthorised activity at the earliest opportunity
• Provides real time information to allow incidents to be managed safely and efficiently
• Provides best value for money

2. Justification for installation of CCTV equipment

Prior to installing any CCTV or other recording equipment on any premises, consideration must be given to the
provisions of Human Rights and Data Protection legislation. Whilst legislation varies from country to country,
generally CCTV systems should only be installed for the purposes of crime prevention and detection and not in
areas where private activity may be monitored (i.e. toilets etc). The installation of CCTV systems must be justified,
proportionate and not recording public areas or areas which should remain private!
2.1 Where any doubt exists, consultation should take place with members of the Corporate Security Team or
Legal
2.2 Where additional cameras are installed for Health & Safety reasons this should be documented and
access to recordings limited accordingly.
2.3 Image storage arrangements must be in compliance with Diageo and local data protection legislation
2.4 Adequate signage advising all persons of the presence of CCTV shall be displayed.

3. Networking
All CCTV systems will be installed using Local Area Networks (LAN`s) linked to on site Networked Video
Recorder(s) (NVR`s) Where remote monitoring is required this will be achieved using broadband connects
Consultation must take place with local IS personnel to agree any networking issues.

4. CCTV Equipment
4.1 In order to ensure that all CCTV equipment installed is of a type and design which fulfils the above criteria,
the following “technical specification” has been created and will be applied to all new installations or
upgrades effective immediately.
4. 2 Any new installations which do not comply with these specifications will require specific approval from a
member of the Corporate Security Team

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5. CCTV Cameras
CCTV cameras must be of a type which is “open protocol” and may be either
Panasonic or American Dynamics make (or other suitable equivalent)
Fixed Cameras – IP 65
Resolution: Maximum resolution supported by camera on the recording system
Codec: MJPEG, H264, JPEG
Recording Mode: Event based on VMD detection.
When there no VMD detected, the camera will record at 5 frames per second.
Event Pre and Post Alarm: 10 Seconds
Video Motion Detection: VMD sensitivity should be as sensitive as possible without generating false alarms
Irrelevant items in the cameras field of view should be masked.
Each camera’s VMD should be tested in daylight and low light conditions to ensure correct and satisfactory object
detection. The furthest relevant part of the cameras field of view should be able to correctly detect motion during day
time and low light conditions.
Power: POE+ if local configuration dictates this otherwise then a local 230 volt spur will be installed with distributed
low voltage power.
Fully Functional cameras – IP 66
Resolution: Maximum resolution supported by camera on the recording system
Codec: MJPEG, H264, JPEG
Zoom Capability: 35x Optical, 12x Digital
Recording Mode: Event based on VMD detection, when no VMD is detected the camera will record at 5 frames per
second.
Event Pre and Post Alarm: 10 Seconds
VMD: VMD sensitivity should be as sensitive as possible without generating false alarms,
Each camera’s VMD should be tested in daylight and low light conditions to ensure correct satisfactory object
detection. The furthest relevant part of the cameras field of view should also be able to correctly detect motion
during day time and low light conditions.
Power: 230 volt spur will be installed for each camera location.
5.1 Suitable Verizon PoE switches shall be employed.
5.2. Apart from cameras dedicated to site Main entrances, Reception areas or other areas which require a
dedicated fixed camera, all cameras should be fitted with motion detectors (software or hardware) and
should be static Dome or Dome PTZ design.
5.3 They should provide a minimum of five (5) frames per second when not active increasing to fifteen (15)
when active. They should be set to record on motion only.
5.4 Images obtained from CCTV systems must be securely stored with only authorised persons able to
access images.
5.5 Such images should be capable of being stored for a minimum of 30 days at all sites or such longer
period as is operationally necessary and can be justified.
5.6 To allow interface with the C-Cure 9000 access control system, all CCTV systems shall use INTELEX,
HDVR or Videoedge Recording systems.

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6. Surveillance System
6.1 The CCTV surveillance system must be able to capture images of persons entering or leaving a
controlled area such that the image is of sufficient quality to be used in evidence. Low light level CCTV
cameras and or artificial lighting may be used to ensure recognizable images are captured at all times.
6.2 The CCTV surveillance system must provide an accurate date/time stamp on every frame.
6.3 The CCTV surveillance system clock must be synchronized with the Diageo server clock.
6.4 The CCTV surveillance system appliance(s) will be limited to no more than 100 cameras per appliance.
6.5 The CCTV surveillance system components must be mounted in a tamper-proof manner and not be
capable of being deactivated from outside the secured area.
6.5 The CCTV surveillance system (network switch(s) and appliance(s) only) must be connected to a back-
up electrical power source capable of maintaining the system for a minimum of 4 hours.
6.7 All main entrance and exit doors or gates especially those which exit directly into public areas should be
monitored by CCTV cameras. In addition turnstiles and gates which are controlled by an electronic
access control system and areas such as receptions, server rooms and other areas where sensitive
information or material is stored should also be covered by CCTV cameras.
6.8 Wide Dynamic Range cameras must be used on all rollup/delivery doors.
6.9 Where shipping /receiving areas are covered by CCTV, cameras should be positioned so that they
capture a clear view of the inside of the trucks/containers and what is being loaded into them.
6.10 Where perimeter security is required and in the absence of a perimeter barrier, where possible, cameras
should be installed to establish a 100-150’ perimeter around the facility.
6.11 Where a perimeter barrier is present and coverage is required then CCTV should monitor the entire
perimeter. This may be done using Fully Functional cameras with inbuilt or external motion detection
devices.
6.12 1 or 2 way audio may also be employed on selected cameras. This may only be employed following an
Environmental impact study in relation to noise level limits for the site.

7. Installation
7.1 It is essential that all CCTV systems are installed by accredited and Diageo approved companies. All
installations should be according to the relevant industry standards as a minimum.
7.2 Full commissioning and testing of the system must take place prior to sign off.

8. Maintenance and Quality Assurance

8.1 There must be a service agreement in place which ensures that all equipment is regularly serviced and
cleaned commensurate with local environmental conditions by an accredited and Diageo approved
company.
8.2 The CCTV surveillance recording system must be checked at least once a month for quality assurance
by a member of Diageo personnel.
8.3 For facilities that store, process or transmit sensitive data, components of the video surveillance system
must be tested once per calendar quarter and a documented record must be kept for a period of two
years.
8.4 For non-production offices, components of the video surveillance system must be tested semi-annually
and a documented record must be kept for a period of two years.

9. Advice or assistance
Please contact any member of the Corporate Security Team for advice or assistance

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SIX PILLARS
ONE STANDARD

SUSTAINABILITY

INNOVATION

CONSISTENCY

QUALITY

VALUE

SAFETY

SOME ARE
MADE OF MORE