REFERENCE REVISION

EEAM-Q-012
0

SA Port Operations
DOCUMENT TYPE AUTHORISATION DATE: Date signed
by CEO
SPECIFICATION
TITLE:
SPECIFICATION FOR GENERAL ELECTRICAL
PAGE 0 of 14
EQUIPMENT
COMPILED BY REVIEWED BY REVIEWED BY

EQUIPMENT ENGINEERING
AND ASSET MANAGEMENT SENIOR MANAGER SENIOR MANAGER
(GENERAL MANAGER) (PROJECT MANAGER) (ASSET MANAGER)
ACCEPTED BY AUTHORIZED BY

CHIEF FINANCIAL OFFICER CEO

FUTURE REVISION DESCRIPTION OF APPROVAL DATE
RECORD NUMBER REVISION 01/04/2003

-1-
CONTENTS
Page
1.0 SCOPE 04
2.0 FACTORY BUILT ASSEMBLIES (FBA) OF SWITCHGEAR AND CONTROL GEAR 04
3.0 AC CONTACTORS 05
4.0 SWITCH DISCONNECTORS 07
5.0 INDICATING INSTRUMENTS AND PROTECTION RELAYS 08
6.0 CONTROL SWITCHES 08
7.0 LIMIT SWITCHES 09
8.0 RATING PLATES AND LABELS 09
9.0 MOULDED CASE CIRCUITS BREAKERS 10
10.0 FUSES 10
11.0 RESISTANCE UNITS 10
12.0 POWER FACTOR CONNECTION AND HARMONIC FILTERING EQUIPMENT 11
13.0 WIRING AND CABLING 11
14.0 PROTECTION AGAINST CORROSION 15

KEYWORDS DATE OF LAST REVIEW: N/A

SPECIFICATION
DATE OF NEXT REVIEW 01/06/2005

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DETAIL CONTENT

Title Page

1.0 Scope 03

2.0 Factory Built Assemblies (FBA) Of 03

Switchgear And Control Gear
2.1 Electronic Control Modules 03

2.2 equipment shall be housed in a FBA 03

2.3 Protection against shock 03

2.4 Electrical personnel Operations 04

2.5 Maintenance Accessibility 05

2.6 Panels 05

2.7 Anti-condensation heaters 05

3.0 AC Contactors 05

4.0 Switch Disconnectors 06

5.0 Indicating Instruments And 07

Protection Relays
6.0 Control Switches 07

7.0 Limit Switches 08

8.0 Rating Plates And Labels 08

9.0 Moulded Case Circuit Breakers 09

10.0 Fuses 09

11.0 Resistance Units 09

12.0 Power Factor Correction And Harmonic 10

Filtering Equipment (If Asked For In The
Main Specification)
13.0 Wiring And Cables 10

13.1 Cables for fixed installation 10

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13.2 Steel wire armoured cables 10

13.3 Armouring of Cables 11

13.4 Spare cores and terminals 11

13.5 Standard Methods for Numbering 11

13.6 Colour coding of cables 11

13.7 Cable Installation on structures 11

and in electrical rooms etc
13.8 Internal panel wiring shall be in 12
accordance with BS 158 and/or
BS 162
13.9 Terminals and connections 13

13.10 Flexible Connections 14

14.0 Protection Against Corrosion 14

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GENERAL ELECTRICAL EQUIPMENT SPECIFICATION HE8/2/2

[Version 4]

February 1997

1. SCOPE

1.1. This Specification covers SAPO’s requirements for low voltage general
electrical equipment and must be read in conjunction with the main
specification.

2. FACTORY BUILT ASSEMBLIES (FBA) OF SWITCHGEAR AND CONTROL

GEAR

This section shall be read in conjunction with BS 5486 Part 1 and /or IEC 439.

2.1. All electronic control modules, printed circuit boards, electrical control
and protection equipment etc. shall be housed in robust enclosures with
minimum protection of IP 55 for indoor and IP65 for outdoor usage and
shall be designed to protect the equipment from mechanical damage as
far as possible.

2.1.1. All enclosures used indoors shall be manufactured from mild

steel and enclosures used outdoors shall be manufactured
from 3CR12 or stainless steel, and shall be painted in
accordance with Specification HE9/2/8.

2.2. All equipment shall be housed in a FBA in terms of the following:-

2.2.1. A multi-cubicle-type design shall be used;

2.2.2. The FBA shall be for in- or outdoor installation according to

use;

2.2.3. The FBA shall be of the stationary type;

2.3. Protection against shock shall be by means of:

2.3.1. By using protective circuits;

2.3.2. By discharging of electrical devices;

2.3.3. Barriers or enclosures noting that:

Where it is necessary to make provision for the removal of

barriers, opening of enclosures, or withdrawal of parts of
enclosures (doors, casings, lids, covers and the like), this shall
be in accordance with the following requirements:

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[Link]. Removal, opening or withdrawal shall necessitate the

use of a key or tool;

[Link]. All live parts which can accidentally be touched after

the door has been opened shall be disconnected
before the door can be opened. This shall be by
interlocking the door or doors with a switch
disconnecter so that they can only be opened when
the disconnecter is open and that the disconnecter
cannot be closed when the door or doors is/are open.

If, for reasons of operation, the FBA is fitted with a

device permitting authorised persons to obtain access
to live parts while the equipment is switched on, the
interlock shall automatically be restored on re-closing
the door or doors.

[Link]. For withdrawable equipment:

The FBA shall include an internal barrier or shutter

shielding all live parts in such a manner that they
cannot accidentally be touched when the door is open.
It shall either be fixed in place or shall slide into place
the moment the door is opened. It shall not be
possible to remove this barrier or shutter except by the
use of a key or tool.

[Link]. Where applicable, warning labels shall be used.

Where any parts beyond an enclosure need

occasional handling (such as replacement of a lamp
or a fuse-link), the removal, opening or withdrawal
without the use of a key or tool and without switching
off shall be possible only if the following conditions is
fulfilled:

A second barrier shall be provided inside the

enclosure so as to prevent persons from coming
accidentally into contact with live parts not protected
by another protective measure. However this barrier
need not prevent persons from coming intentionally
into contact by by-passing this barrier with the hand.
It shall not be possible to remove the barrier except
through the use of a key or tool.

2.4. It shall be possible for competent electrical personnel to perform the

following operations while the assembly is in service and live:

Visual inspection of switching devices and other apparatus;

Adjusting and resetting of relays and releases;

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Certain fault location operations, e.g. voltage and current measuring

with suitably designed and insulated devices.

2.5. Accessibility for maintenance shall be provided by use of barrier

protected sub-sections for each functional unit or group.

2.6. All panels shall have an internal fluorescent light as well as 230 V 3
point plug fitted.

2.7. Anti-condensation heaters shall be fitted when called for by the main
specification.

3. AC CONTACTORS

3.1. Contactors shall comply with IEC 947-4-1/latest.

3.2. Contractors shall be chosen by taking the following factors into

account:-

3.2.1. Load to be switched;

3.2.2. Utilization category, e.g. AC1, AC2, AC3, AC4, AC11;

3.2.3. Electrical life (Clause 3.3);

3.2.4. Short circuit immunity;

3.2.5. Starting time;

3.2.6. Mechanical life:- All contactors shall have a mechanical life of

at least 10 million operations. (1 operation equals 1 make and
1 break).

3.3. The electrical life shall be not less than that laid out below for the
following utilization categories:-

Utilisation Category Electrical Life In Hours

AC 1 8 000
AC 2 6 000
AC 3 8 000
AC 4 2 500
AC 3/4 5 000

The category AC 3/4 is defined as one where the usual operation is in

category AC 3 with more than 1% of total operations occurring in AC 4.

For the purpose of determining life in this category the percentage

operations in category AC 4 shall be equivalent to the expected value,
but shall in any case not be less than 20% of the total.

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3.3.1. The duty class shall be at least class 3. Should the operating
class exceed that of class 3, i.e. 300 cycles per hour, the actual
value shall be used when computing the expected electrical
life.

3.4. Block type contactors shall be used for all low voltage motor control
applications.

3.5. The maximum thermal current rating shall be at least 1.25 times the
rated full load current.

3.6. Auxiliary contacts shall be contained in a separate unit directly

operated from the main armature.

3.7. Visual indication by means of a pin or protrusion that the contactor is

energized must be provided.

4. SWITCH DISCONNECTERS

4.1. Switch disconnecters shall comply to BS 5419 and/or SABS 152.

4.2. The rating of the disconnecter shall suit the system fault level and the
breaking capacity of the associated moulded case circuit breaker
(where used), or fuses, and shall be rated for fault make load break
operation.

4.3. The mechanical endurance shall not be less than:-

10 000 operating cycles for rated currents between 0 and 63 A;

3 000 operating cycles for rated currents between 63 and 250 A;

1 000 operating cycles for rated currents exceeding 250 A.

4.4. The electrical endurance in the appropriate utilization category shall not
be less than 20% of the mechanical endurance.

4.5. Where the neutral link is external to the disconnecter and is removable
without first opening the disconnecter it shall be labelled in terms of
SABS 0142.

4.6. The disconnecter shall be interlocked with the front cover of the
enclosure in a way to prevent opening of the cover if the switch is "ON".
The switch must be able to be switched on with the cover open, only by
a competent electrician for maintenance purposes.

4.7. The disconnecter shall be suitable for padlocking in the off position.

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5. INDICATING INSTRUMENTS AND PROTECTION RELAYS

5.1. All indicating instruments shall be flush-mounted industrial type that

comply with the relevant clauses of IEC 51-1, IEC 51-2, IEC 51-7, IEC
51-8 and IEC 51-9 and shall have a minimum accuracy of 3% or better
and shall have a scale length of not less than 90 mm.

5.2. All scales except for thermal ammeters shall be linear and shall be
marked in accordance with BS 3693 with the scale selected for the
accuracy class.

5.3. All instrument glass shall be glare free.

5.4. All current operated instruments and protection relays shall be protected
against continuous over current of up to 120% of the nominal value as
well as short circuit currents that may be experienced.

5.5. Ammeters shall be marked with the ratios of the associated current
transformer.

5.6. Ammeter full-scale deflection shall be 120% of primary current of the

associated current transformer.

5.7. Voltmeter scales shall indicate 80%-120% of the nominal system

voltage. Where 0-120% indication is needed the nominal voltage shall
be approximately 75% of full scale. The nominal voltage shall be
marked with a red line.

5.8. If required by the system or main specification ammeters shall

incorporate a thermal maximum demand indicator with a time lag of 15
minutes. A built in saturation current transformer shall be provided to
protect the indicator against the maximum fault currents that may be
experienced. A resettable pointer shall be provided to indicate the
maximum value reached.

6. CONTROL SWITCHES

6.1. Control switches shall comply with BS 4749.

6.2. "Emergency-stop" push buttons shall be of red colour, shall have one
normally closed and one normally open contact and shall be of the
mushroom head twist lock type and be lockable in the "off" position.

6.3. All push buttons shall have non corrosive appropriately engraved and
anodized escutcheon plates fitted.

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7. LIMIT SWITCHES

7.1. All "end" or "ultimate" limit switches (e.g. slow down, end of travel,
maximum travel etc.) shall be of the rotary cam operated type, housed
in an extremely rigid cast iron enclosure with a minimum protection of IP
55, with large roller levers of the spring return-to-neutral action. It is
stressed that the entire limit switch must be of an extremely robust
construction.

7.2. All limit switches shall be mounted in easily accessible positions to

facilitate adjustment, maintenance and replacement.

7.3. Magnetic or inductive proximity type limit switches are preferred and are
to be used wherever possible.

8. RATING PLATES AND LABELS

8.1. Rating plates complying with the relevant requirements of IEC 298
showing the following information shall be provided:-

8.1.1. Manufacturer's name;

8.1.2. Manufacturer's type number;

8.1.3. Manufacturers serial number

8.1.4. Portnet contract number;

8.1.5. Year of manufacture;

8.1.6. Rated values, etc.

8.2. Identification labels is required on or adjacent to all electrical control

equipment, switches, relays, instruments, meters, fuses, MCCB's, test
blocks, terminal strips etc. The text shall be in black letters on a white
background and shall be at least 5mm in height.

8.2.1. These identification labels shall correlate with the

corresponding schematic and wiring diagram and the wording
shall be in English.

8.3. All labels shall be of a corrosion resistant material and shall be securely
attached.

8.4. Labels shall be placed adjacent to all fuses and circuit breakers to
indicate their rating.

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8.5. All switching devices shall be provided with labels that indicate ON,
OFF, EARTH, as required. These labels shall be permanently marked
with characters at least 10 mm in height, and shall be visible to the
operator in a normal operating position, in a fixed position or located on
a moving component of the switch that is visible through an opening
and shall be as follows:-

8.5.1. I - white lettering on black background for the ON position;

8.5.2. O - white lettering on a green background for the OFF position;

8.5.3. Earth symbol in black on a yellow background for earth

position.

9. MOULDED CASE CIRCUIT BREAKERS

9.1. Moulded case circuit breakers shall comply with SABS 156.

10. FUSES

10.1. Fuse links shall be of a high rupturing capacity type complying with
SABS 172 and/or BS 88. Fifty percent spare fuse links of each size
shall be supplied loose at handover of the equipment.

11. RESISTANCE UNITS

11.1. Resistance units shall be made up of standard modules (mill-banks).

These shall be to Nema 26.5" dimensional standards and each bank
shall be made up of grids of one size only. The grids shall be of the
heavy duty stamped chromium steel or nickel chromium alloy corrosion
resistant grid type. There must be a terminal tap on every second grid.

11.2. Modules must be easily removable without the need to dismantle any
part of the enclosure.

11.3. All taps and terminations shall be clearly identified with relevant
numbers, which must correspond to the numbering shown on the
schematic and wiring diagrams.

11.4. The resistance banks shall be enclosed in robust well ventilated drip-
proof enclosures with louvred side and rear fixed covers. All units shall
be accessible from the front only by "lift-off" type doors. Exterior and
interior surfaces of the enclosure shall be painted with a suitable heat-
resistant paint.

11.5. The resistance enclosed shall be arranged for floor mounting and
bottom entry of electrical cables.

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11.6. When resistance enclosure doors are removed, all terminals on

resistance tappings, the terminal blocks, cable terminations and the
individual grid banks must be readily accessible.

11.7. Resistance units shall be mounted in accessible positions as near to

their motion panels as is practical. Cast iron, sheradized mild steel, or
wire wound resistances are not acceptable. All insulation used in the
construction of the resistances must be fire proof and non-hygroscopic.
Soldered joints must not be used in connection to resistances.

11.8. The resistances must be designed to at least Nema Class 174 P rating
for hoist drives and Nema Class 94 rating for permanently connected
resistances and shall be capable of prolonged operation in service
without overheating.

NOTE: Resistances mounted in or on top of the control panels will

definitely not be acceptable.

11.9. Resistance units shall be individually designated to indicate to which

motion they apply.

12. POWER FACTOR CORRECTION AND HARMONIC FILTERING

EQUIPMENT (IF ASKED FOR IN THE MAIN SPECIFICATION)

12.1. Capacitors must comply with BS 1650 or IEC 70 and shall have passed
the routine tests specified.

12.2. Capacitors must be of the "dry" metallized film or paper "self sealing"
type, impregnated with an non PCB, fully biodegradable non-toxic
dielectric.

12.3. Each capacitor must be fitted with an external HRC fuse rated at 2
times capacitor full load current, for protection.

12.4. Capacitors must be fitted with discharge resistors to discharge the

capacitor voltage to less than 50 V in one minute.

12.5. Inrush currents of capacitors must be kept to an acceptable level by

using reactors or resistors. Details of actual and allowable inrush
currents to be given in tender documents.

13. WIRING AND CABLES

13.1. All cables for fixed installations must comply with SABS 1507, except
where special cables have otherwise been specified.

13.2. Steel wire armoured cables must be used where the possibility of
mechanical damage exists.

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13.3. Armouring of cables will not be used for earthing purposes or any return
circuit but shall be bonded to earth. An earth conductor shall be
provided in each cable for earthing purposes. If an earth core is not
provided a separate, appropriately coloured, insulated earth wire shall
be run.

13.3.1. Metallic structures shall not be used for any return or earthing
circuit under normal operating conditions but all structures shall
be electrically bonded together with welding type cables..

13.4. Spare cores and terminals for all control cables shall be provided as
follows:

Number of Conductors/Cables Spare Cores

3-6 1
7 - 12 3
Over 12 4

13.5. The standard method for numbering small wiring shall be as indicated in
NRS 003, Annex A.

13.6. Colour coding of cables

13.6.1. Unless otherwise agreed to the colour of all auxiliary and

control wiring (except earth wires) shall be grey. The colour of
earth wires shall be green/yellow.

13.6.2. All three phase supplies shall be colour coded red, white and
blue.

13.6.3. Single phase supply cables shall be blue for neutral and brown
for live.

13.6.4. DC supply cables to motors, fields, magnets etc. shall be

orange.

13.6.5. If the correct colour cables are not available cable ends may be
marked with "air-shrink" or "heat shrink" type insulation material
for ± 200 mm. Colour coding of cables with insulation or
marking tape is not acceptable.

13.7. Cable Installation on structures and in electrical rooms etc:

13.7.1. Except where otherwise specified, the entire electrical

installation including the wiring, shall where applicable, be in
accordance with the "Code of Practice for the Wiring of
Premises" (SABS 0142-1978) or the IEEE Wiring Regulations
for Electrical Installations.

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13.7.2. The cables must be installed by the following methods:

[Link]. In cable ducts or hollow floors with covers;

[Link]. On structures, strapped to cable trays or in electrical

conduits, with protection against mechanical
damage where necessary.

[Link]. No loop-in wiring shall be permitted. All limit switch

and field wiring shall return to junction boxes for re-
marshalling.

[Link]. All cable glands shall be corrosion resistant glands

of the "Posi" or "Pratley Envirogland", Exe type, or
similar.

[Link]. Junction and connection boxes must be

manufactured in glass fibre reinforced polyester with
threaded brass inserts and earthing continuity rods,
and must be suitable for threaded (minimum 8
threads) glands. The minimum enclosure protection
must be IP65. Pratley "EZEE-FIT" ir similar boxes
will be preferred.

[Link]. The number and size of cables that may be

accommodated in cable ducts, trays or conduits
shall be in accordance with the manufacturer's
recommendations and the temperature rise
permissible for the cables used for the load that may
be carried.

13.8. Internal panel wiring shall be in accordance with BS 158 and/or BS 162:

13.8.1. All instruments and control wiring shall be carried out in

minimum size of 1.5mm² cross section, with stranded copper
conductors. Wires connected to current transformers shall
have a minimum cross sectional area of 4 mm².

13.8.2. The communication cores of screened cable shall have a

minimum area of 1 mm².

13.8.3. The wiring shall be done in a neat and orderly manner using
any of the two methods below:

[Link]. In covered switchboard type wire channels or,

[Link]. Suitably strapped with approved strapping material.

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13.8.4. When wiring is looped from the cubicle interior to the door or to
the back it must be suitably strapped and enclosed in a flexible
conduit.

13.8.5. Cable Trays:

[Link]. Cable trays shall be of "Unistrut" or similar and equal

manufacture and shall consist of butting sections
made from stainless steel of minimum thickness of
1.2 mm. Cable trays shall be painted according to
Specification HE9/2/8 for colour coding purposes.

[Link]. Cable trays shall be bolted to structures on both

horizontal and vertical runs at centres recommended
by the number and mass of cables carried.
Maximum distances 1.3. metre for steel.

[Link]. Each section of metal cable tray must be provided

with a stainless steel connection tab/lug at each
end prior to being painted, for continuous earthing
purposes.

13.9. Terminals and connections:

13.9.1. All terminal connections shall be done with good quality

connectors and/or lugs and each wire end shall be marked
with durable tags or clips on which shall be clearly and
indelibly marked, the identifying code numbers of each wire,
corresponding to the wiring diagrams.

13.9.2. The system of wire and terminal numbering shall be provided

in the terminal boxes for possible additional wiring.

13.9.3. A minimum of 20% but not less than 4 spare terminals shall
be provided in the terminal boxes for possible additional
wiring.

13.9.4. Box type rail mounted terminals complying with EN 50035

with a pressure pad between the conductor and clamping
screws shall be used. Cage clamp systems may also be used
except in areas where high shock forces exist, e.g. on
spreader beam or headblock equipment.

13.9.5. Moulding and insulation materials shall be resistant to flame

or self extinguishing as required by IEC 216.

13.9.6. Access to all terminals shall be through doors, covers etc.

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13.10. Flexible Connections:

13.10.1. Where wiring crosses from one structure to another and

relative motion between the structures is possible, a welding
type cable earth bond shall interconnect the two structures.

13.10.2. Flexible connections shall be made with heavy duty flexible

cord using watertight terminators. Where the length of cable
is greater than 1.6. metres a basket type cable grip shall be
provided at each end.

13.10.3. Flexible cables shall run in free air and shall not contact other
cables or structures.

14. PROTECTION AGAINST CORROSION

14.1. All enclosures, cabinets etc. shall be manufactured from 3CR12 or

similar stainless steel sheeting, as called for in the main specification
and shall be painted according to Specification HE9/2/8 for
identification.

14.2. All fixing screws, bolts, nuts, washers, clips, terminals, brackets, etc.
shall be stainless steel.

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END OF SPECIFICATION HE8/2/2 [Version 4]

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