to-hq-02-018 rev 00 philosophy for lighting and trace heatin

OMV Exploration & Production

00 Final Issue JS 27/5/05 JEA 31/5/05 PZ 31/5/05 MF 3/6/05

A2 Client Comments Incorporated AS/RW

A1 Issued for Comment/Approval AS/RW 10/2/05

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Philosophy for

Lighting and Trace Heating Onshore

TO-HQ-02-018-00

OMV Exploration & Production GmbH

Document Number Rev Page Philosophy for Lighting and Trace Heating

OnshoreError! Reference source not found. TO-HQ-02-018 00 2 of 41

Revision Description of revisionA1 Issued for Comment/Approval

A2 Client Comments Incorporated

00 Final Issue




Contents

1.0 PREFACE .......................................................................................................................5

2.0 DEFINITIONS .................................................................................................................5

3.0 ABBREVIATIONS...........................................................................................................6

4.0 INTRODUCTION.............................................................................................................6

5.0 APPLICABLE CODES, STANDARDS AND REGULATIONS........................................6 5.1 Codes and Standards list.......................................................................................................... 6 5.2 References ................................................................................................................................. 8

6.0 SYSTEM GOAL ..............................................................................................................8

7.0 SYSTEM BOUNDARIES ................................................................................................8

8.0 DESIGN PHILOSOPHY..................................................................................................8

9.0 LIGHTING.......................................................................................................................9 9.1 Design Considerations.............................................................................................................. 9 9.2 General ....................................................................................................................................... 9

10.0 TRACE HEATING.........................................................................................................15 10.1 Design Considerations............................................................................................................ 15 10.2 General ..................................................................................................................................... 15 10.3 Site Conditions ........................................................................................................................ 16 10.4 Degree Of Protection............................................................................................................... 16 10.5 Electrical Supply System ........................................................................................................ 16 10.6 Heating-Up Requirement......................................................................................................... 17 10.7 Start Load ................................................................................................................................. 17 10.8 Performance Requirements.................................................................................................... 17 10.9 Spare Or Over-Capacity .......................................................................................................... 18 10.10 Operation And Maintenance ................................................................................................... 18 10.11 Special Applications/Conditions............................................................................................ 18 10.12 Heater Selection....................................................................................................................... 19 10.13 Self-Regulating/Self-Limiting Heaters ................................................................................... 19 10.14 Constant Wattage Parallel Heaters ........................................................................................ 19




10.15 Power Limiting Heaters........................................................................................................... 20 10.16 High Temperature Polymer Insulated Series Cable Heaters ............................................... 20 10.17 Temperature Control ............................................................................................................... 20 10.18 Energy Saving.......................................................................................................................... 22 10.19 Temperature Limitation For Safety Reason .......................................................................... 23 10.20 Temperature Limitation For Protection Against Overheating ............................................. 23 10.21 Power Supply And Distribution.............................................................................................. 24 10.22 Installation................................................................................................................................ 25 10.23 Testing And Commissioning .................................................................................................. 29 10.24 Commissioning........................................................................................................................ 30

11.0 DOCUMENTS ...............................................................................................................30 11.1 General ..................................................................................................................................... 30 11.2 Information Required From Omv ........................................................................................... 31 11.3 Documents To Be Submitted By The Contractor ................................................................. 32 11.4 Database................................................................................................................................... 34 11.5 Documents ............................................................................................................................... 34

12.0 REGULATORY AUTHORITY REVIEW REQUIREMENTS ..........................................35




1.0 PREFACE

This Philosophy defines the OMV Exploration & Production GmbH corporate policy on the design of Lighting and Trace Heating for onshore hydrocarbon production and processing facilities. The document specifies basic requirements and criteria, defines the appropriate codes and standards, and assists in the standardisation of facilities design across all onshore operations.

The design process needs to consider project specific factors such as the location, production composition, production rates and pressures, the process selected and the size of the plant. This philosophy aims to address a wide range of the above variables, however it is recognised that not all circumstances can be covered. In situations where project specific considerations may justify deviation from this philosophy, a document supporting the request for deviation shall be submitted to OMV E&P for approval.

Reference should be made to the parent of this philosophy, document number TO-HQ-02-001 for information on deviation procedures and Technical Authorities, general requirements and definitions and abbreviations not specific to this document.

2.0 DEFINITIONS

The following definitions are relevant to this document

Ambient Temperature

The temperature surrounding the object under consideration. Where electrical heating cable is enclosed in thermal insulation, the ambient temperature is the temperature exterior to the thermal insulation.

Branch Circuit

That portion of the wiring installation between the overcurrent device protecting the circuit and the trace heater unit(s).

Cold Lead

Electrically insulated conductor or conductors used to connect a trace heater to the Branch Circuit and designed so that is does not produce significant heat.

Parallel Heating Cable

Heating elements that are electrically connected in parallel, either continuously or in zones, so that watt density per unit length is maintained irrespective of any change in length for the continuous type or for




any number of discrete zones. Self-Regulating/Self-Limiting Heating Cable

A parallel heating cable with a semi-conductive element, which responds to temperature variation by adjusting the thermal output to finally reach equilibrium.

3.0 ABBREVIATIONS

There are no abbreviations with particular relevance to this document.

4.0 INTRODUCTION

This document describes the philosophy to be used for the design, engineering and installation of lighting and trace heating for onshore plants.

5.0 APPLICABLE CODES, STANDARDS AND REGULATIONS

Codes, standards and regulations referred to in this philosophy shall be of the latest edition and shall be applied in the following order of precedence:

Local Regulations, The provision of this document, International standards (e.g. ISO, IEC etc), National standards.

Design of the safety system shall comply with the standards listed within this philosophy, however, for instances where local standards are more onerous local standards shall apply.

5.1 Codes and Standards list NFPA 70 National Electrical Code API RP 540 Electrical Installations in Petroleum Processing Plants Institute of Petroleum Model Code Of Safe Practice, Part

1, Electrical Safety Code The Convention on International Civil Aviation, Volume 1

Chapter 6 of Annex 14

European Standards

Electrical apparatus for potentially explosive atmospheres:




EN 50014 General requirements EN 50015 Oil immersion "o" EN 50016 Pressurized apparatus p EN 50017 Powder filling q EN 50018 Flameproof enclosure d EN 50019 Increased saftey e EN 50020 Intrinsic safety i EN 50028 Encapsulation m EN 50039 Intrinsically safe electrical systems i

International Standards IEC 60079 Electrical apparatus for explosive gas atmospheres IEC 60529 Degrees of protection provided by enclosures IEC 60947-2 Low voltage switchgear and controlgear, Part 2: Circuit

breakers IEC 62086-1 Electrical apparatus for explosive gas atmospheres

Electrical resistance trace heating, Part 1: General and Testing requirements

IEC 62086-2 Electrical apparatus for explosive gas atmospheres Electrical resistance trace heating, Part 2: Application Guide for design, installation and maintenance

IEC 60529 Classification of degrees of protection provided by enclosures (IP Code)

IEC 60445 Identification of apparatus terminals and general rules for a uniform system of terminal marking, using an alphanumeric notation

IEC 61140 Protection against electric shock Common aspects for installation and equipment maintenance

IEC 61558 Safety of power transformers, power supply units and similar

NEMA 250 Enclosures for electrical equipment (1000 Volts Maximum)

NEMA ICS 1 General standards for industrial controls and systems NEMA ICS 2 Industrial control devices, controllers and assemblies IEEE Std 515 Recommended practice for the testing, design,

installation and maintenance of electrical resistance heat tracing for industrial applications




European Community Directives. (Applicable with the EEC) 89/336/EEC The Electromagnetic Compatibility (EMC) Directive

73/23/EEC The low voltage equipment (safety) regulations 94/9/EC The Antmospheres Explosibles (ATEX) directive.

5.2 References

TO-HQ-02-011 Philosophy for General Electrical Design Onshore

TO-HQ-02-012 Philosophy for Main Generators and Switchboard Onshore

TO-HQ-02-039 Philosophy for Rotating and Reciprocating Equipment Onshore

6.0 SYSTEM GOAL

The lighting system is intended to provide the correct level of illumination in all areas and, in the event of emergency, to provide sufficient illumination and direction to allow escape. The aim of trace heating is to maintain fluid temperatures at the correct level to allow processes to proceed as intended.

7.0 SYSTEM BOUNDARIES

The boundaries of the Lighting and trace heating systems are the:

interface to the main electrical system Interface to the PCS and HMI luminaires and heating tape.

8.0 DESIGN PHILOSOPHY

The general philosophy for lighting is to provide sufficient lighting to allow safe working and allow personnel to safely escape in the event of emergency. The general philosophy for trace heating is to safely maintain fluid temperature to allow processes to continue uninterrrupted as designed.




9.0 LIGHTING

9.1 Design Considerations Lighting levels are as prescribed in Appendix 1. Proportions of luminaires required to be supplied from an emergency power source are detailed in section 9.2.7. It should be noted that the CE Mark, or CE marking as it is officially named, is an obligatory product mark for the European market, which indicates compliance 'certification' according to the requirements formulated in the approximately 22 European 'CE Marking Directives' and subsequent European standards.

9.2 General 9.2.1 General lighting requirements

General lighting shall provide the required level of illumination in accordance with Appendix 1. It shall be fed from the normal site power supply and shall comply with the requirements of Section 9.2.2, except that maximum use shall be made of floodlights where possible. The preferred type of floodlight is high pressure sodium, which shall be used except where instant relight is required, e.g., on helipads. Typical areas where floodlights can be employed in preference to fluorescent luminaires are open or production and utility areas. Industrial fluorescent lighting in 'white' colour shall in general be used for illumination. Where special requirements regarding colour distinction exist, these shall be met. Long life lamps in combination with electronic ballasts shall be used in new installations, and for upgrading old installations, so as to take advantage of their increased lumen efficiency and economic life. Incandescent lighting shall be applied only for decorative lighting. High pressure discharge lamps should be used to light tall buildings or large areas. In view of the restarting time of this type of lighting after a voltage dip, sufficient fluorescent luminaires shall be installed for basic lighting requirements of the area, equivalent to emergency lighting requirements as detailed in Section 9.2.7. Consideration shall be given to the use of floodlighting, especially around the perimeter of process and production plants. Care shall be taken to ensure that this does not result in shadows, especially at operating locations. Maintenance free, sealed for life discharge lamps and associated luminaires may be considered with account being taken of their total life-cycle cost. These types of luminaires are available in industrial and Ex protected executions.




Low pressure sodium discharge lamps shall not be used, as they constitute a fire hazard in the event of breakage.

9.2.2 Plant lighting

In Zone 1 and 2 hazardous areas, fluorescent luminaires with type of protection Ex'e' shall be used. Luminaires for level gauge lighting shall be of the fluorescent type, bracket-mounted. High pressure discharge luminaires in hazardous areas shall have type of protection Ex'd'. An isolating switch shall be included within the fitting to prevent the luminaire from being energised when it is not fully assembled. For standardisation reasons the same type of Ex'd' or Ex'e' luminaires should be used in all plant areas, whether classified Zone 1, Zone 2 or non-hazardous. Plant lighting circuits shall be fed from dedicated lighting distribution boards installed in the plant substations. Plant lighting circuits shall be single phase and neutral or three phase and neutral, protected with maximum 16 A fuses or MCBs, but not be loaded higher than 12 A. Plant lighting distribution boards shall include 10 % spare outgoing circuits. Adjacent luminaires shall not be supplied from the same circuit, or in the case of three phase circuits, from the same phase. As far as practical, fluorescent lighting shall be used throughout the plant installations. The lighting system shall be designed to give illumination levels as shown in Appendix 1. Lighting installations shall be designed to obviate stroboscopic effects. Luminaires on structures shall be located so that maintenance and lamp changing can be effected without the use of ladders or scaffolding, where possible. Where a luminaire mounted from an elevated walkway or platform does not overhang it, the lamp post shall be arranged to swivel for maintenance purposes. In tall buildings, such as compressor and turbo-generator houses, maintenance and lamp-changing by means of the overhead crane shall be possible. In view of EMC requirements, all metallic parts of the lighting installation shall be properly bonded or earthed. Where no structure is available to support luminaires, fixed lighting poles of adequate length with high pressure discharge floodlighting shall be used to supplement the fluorescent luminaires. Lighting poles shall be hot-dip galvanised. NOTE: For fixed floodlighting columns, lamps will be changed with the aid of a mobile platform, e.g., vehicle mounted. Alternatively, hinged lighting columns may be used, if space is available for the columns to be lowered.




Plant lighting circuits shall be designed for automatic switching via photo-electric relays. Control circuits for photo-electric relays shall be 'fail-safe', i.e., they shall switch the lights on if a fault occurs in the photo-electric relay. The plant lighting shall be designed in such a way that in daytime the lighting of furnaces, boilers and the ground level plant can be switched on by means of a switch overriding the appropriate photo-electric relay contact. The remaining photo-electric relay-operated plant lighting shall be able to be switched off at night-time. These override switches shall be located either outside the plant substation or in the control room, as required by plant operations. Moreover, the lighting distribution board shall be provided with an override switch for maintenance purposes. Level gauge lights shall not be switched by the above-mentioned photo-electric relays and shall have no maintenance override switches. Level gauge lights shall normally be on. Internal lighting of non-process buildings and substations shall be switched inside the building. The lighting installation in the control rooms shall be designed so that ceiling lighting groups can be switched off independently to suit operators' needs. Electronic dimmer control shall be provided to adjust the illumination level smoothly down to 20 % of the specified illumination. The luminaires shall be situated in such a way that reflection on VDUs, instrument windows and displays is avoided. Attention shall be paid to the selection of the correct category of luminaire so that low glare units are provided without compromising the lighting quality.

9.2.3 Building lighting

Luminaires in closed buildings that are classified non-hazardous areas, e.g., control rooms and substations, shall be fluorescent bi-pin, switch-start, industrial pattern. Non-industrial luminaires may be used in control rooms, offices, etc.

9.2.4 Street and fence lighting

Street and fence lighting shall be fed from lighting distribution boards installed in a conveniently located plant substation. These lighting distribution boards may either be dedicated to street and fence lighting, or be one or more sub-sections of a plant lighting distribution board. This lighting shall also be photo-electric relay controlled and provided with a maintenance override switch, as for ground level plant lighting. Generally, for street/fence lighting three phase and neutral LV supply shall be used. Each lighting pole shall include a fuse box as well as a four pole terminating box for looping the feeder cable. Teed cable joints are not allowed. Adjacent luminaires shall not be supplied from the same phase.




Fence lighting shall be placed in such a way that the fence as well as the area outside the fence will be illuminated, leaving the patrol road in comparative darkness. Normally fence lighting intensity shall be equivalent to the street lighting intensity stated in (Appendix 1). If special security fence lighting is required, a floodlight installation shall be designed based on HP discharge lighting with a minimum illumination of 5 lux at any point in the area between the fence and 5 m outside the fence, unless otherwise specified.

9.2.5 Special lighting

Special lighting such as, obstruction warning lights and aircraft warning lights shall comply with the applicable national and/or international rules and standards. Special lighting, e.g., obstruction warning lights and aircraft warning lights, shall be installed in accordance with international and/or national standards. Long-life lamps or normal lamps at reduced voltage shall be used. The installation shall be supplied from an interruptible, maintained source.

Aviation warning lighting Aviation warning lights shall be installed in accordance with Volume 1 Chapter 6 of Annex 14 to the Convention on International Civil Aviation. The luminaires shall each consist of a double lamp unit with automatic changeover to the stand-by lamp upon failure of the operating lamp.

Illumination of areas to be observed by means of CCTV monitors The lighting installation for areas that require surveillance by closed circuit television monitors shall be designed in particular with regard to uniformity of the level of illumination as well as to the location of the individual luminaires. The direct visibility of light-emitting bodies and/or reflections from covers of the luminaires shall be checked before commissioning of the plant.

9.2.6 Portable lamps

Hand-held lamps shall be rated for maximum 50 V a.c. supply. The types of portable equipment to be used in both industrial and non-industrial areas (except in restrictive conductive locations as referred to below) shall be one or more of the following:

double or reinforced insulation equipment, compliant with IEC 61140, connected to the mains via a 30 mA RCCB, protecting both the supply cord and the equipment;




42 V equipment, compliant with IEC 61140, connected to a safety extra-low-voltage circuit by using double-wound safety isolating transformers, complying with IEC 61558 (SELV system).

9.2.7 Emergency and escape lighting

Fixed emergency lighting shall be installed at strategic points in the installations, including control rooms, switchrooms, fire stations, first-aid rooms, watchmen's offices, the main entrances, and all other buildings and areas where required for safety reasons. Location and electrical arrangement shall be such that danger to personnel in the event of a power failure is prevented, and escape routes are lit. The emergency lighting system shall consist of a number of standard luminaires of the normal lighting installation, which shall be fed via circuits having a stand-by supply from an emergency generator or from an inverter having a battery with an autonomy time of at least 1 h. In remote areas, where only a few fittings are required, self-powered emergency luminaires may be used, subject to economic considerations. If power is supplied by an emergency generator, a number of luminaires in the control room, as well as field auxiliary rooms, shall have a stand-by supply from an independent source with battery back-up to avoid complete darkness during start-up of the diesel engine. The number of emergency luminaires in relation to the total number of fittings shall be determined as follows:

- utility area 20 % - process area 10 % - administrative area 5 % - control room and auxiliary rooms (including 10 % connected to inverter

system) 50 %

- substations, field auxiliary rooms, compressor

and generator buildings 30 %

The escape luminaires shall generally be part of the emergency luminaire installation, but the luminaires shall have integral batteries rated to maintain the lighting for at least 30 min. Escape luminaires shall be provided in all buildings to light the way for personnel leaving the building along defined escape routes to defined muster points, which shall also be illuminated.




NOTE: Where emergency lighting is fed from a distribution system classed as vital or essential, due care shall be taken to avoid harmful overvoltages due to lightning strikes which could affect the instrumentation and control systems. Emergency lighting shall provide sufficient level of illumination to permit minimum operation of the site. The emergency lighting luminaires shall comprise up to 25 % of the total number of luminaires. They shall be fed from the emergency switchboard but shall also have a stand-by supply from an independent source with battery back-up to avoid complete darkness during start-up of the emergency generating set. Emergency lighting shall be provided to allow limited operational lighting for inspection, testing, emergency support, and the starting of the emergency generator. Typical applications are obstruction lights on vent stacks and crane booms, perimeter lights on helidecks, and key operational areas such as the control room, radio room, and crane access ladders. The luminaires shall be suitable for Zone 1 areas. Emergency lighting shall also be installed in main switchgear and generator rooms, accommodation and workshop areas. Portable emergency lighting units shall be provided at the exit doors of all non-hazardous area modules, e.g., installation control centre, switchrooms, utility areas, and emergency team muster points. Each unit shall comprise a fixed wall-mounted battery charger and hand lamps suitable for use in Zone 1 areas. The unit shall be kept on float charge when not in use and be fed from the emergency lighting switchboard. The battery shall be rated to energise the hand lamp for not less than 6 h. Escape lighting shall form part of the emergency lighting system and be located so as to illuminate the escape routes, ladders and walkways to allow safe movement of personnel to the muster points, etc. Escape lighting shall be fed and equipped in the same fashion as the rest of the emergency lighting except that, for normally unmanned installations, a central uninterrupted maintained power supply should be provided with battery back-up for a 24 h autonomy time. Escape luminaires shall be installed at the following locations:

every exit doorway; in sleeping accommodation, if provided; external escape ways (stairways and walkways); internal escape ways (escape routes in modules or deck areas,

accommodation area corridors, and galley);

embarkation areas (access to helipads); muster areas (helicopter waiting room, cinema, lounge, dining room

and the emergency response team muster points).




Escape luminaires installed in any sleeping quarters shall only illuminate on loss of the a.c. supply to the integral battery charger. Escape lighting shall be suitable for Zone 1 areas.

10.0 TRACE HEATING

10.1 Design Considerations The aim of trace heating is to safely maintain fluid temperatures at the correct level to allow processes to proceed as intended in accordance with appropriate Standards. It should be noted that the CE Mark, or CE marking as it is officially named, is an obligatory product mark for the European market, which indicates compliance 'certification' according to the requirements formulated in the approximately 22 European 'CE Marking Directives' and subsequent European standards. The selection and installation of Equipment shall be in accordance with the requirements of the applicable code or standard, as determined by the relevant regulations. It is required, for plant within the European Economic Area (EEA), that Equipment be compliant with the requirements of the two ATEX Directives, 94/9/EC: The approximation of the laws of Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres (the Equipment Directive) and 1999/92/EC: Minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmospheres (the User Directive).

10.2 General 10.2.1 Safety

For safe and reliable application of electrical heating systems, the climatic, environmental and operating conditions shall be taken into consideration. As far as practical, the electrical equipment should be located in non-hazardous areas or in the least-hazardous areas. It shall not be located in Zone 0 areas. The trace heating equipment shall comply with IEC 62086-1.

10.2.2 Hazardous Areas

When installed in a hazardous area, the construction of electrical equipment shall comply with the relevant parts of IEC 60079 or with the relevant parts of EN 50014, EN 50015, EN 50016, EN 50017, EN 50018, EN 50019, EN 50020, EN 50028 and EN 50039. The application of standards other than those above is subject to the approval of OMV.




For installations in Zone 1 and Zone 2 areas, the following types of protection shall be used:

Connection boxes: Ex "e" enclosure Local switches: Ex "d" or Ex "m" switches, or a

combination of these two, with Ex "e" terminals and enclosure

Thermostats: Ex "d" or Ex "m", or a combination of these two, with Ex "e" terminals and enclosure

Temperature control systems: Ex "i" for e.g. PT 100 connections For the above-mentioned electrical apparatus, a Declaration of Conformity shall be obtained from the Manufacturer.

10.2.3 Non-hazardous areas

For standardization, material as specified for Zone 1 and 2 areas should be used in non-hazardous areas. Industrial type equipment may be used, subject to the approval of OMV.

10.3 Site Conditions The parts of a heating system installed outdoors shall be suitable for outdoor use in a relative humidity of 100%, and exposed to direct sunlight, without protective shelter. The atmosphere shall be considered saliferous, sulphurous and dusty as commonly encountered in hydrocarbon production and processing facilities located close to open water. The possibility of condensation, as experienced during large temperature fluctuations in a humid atmosphere, shall be taken into account. Extremely corrosive and saliferous conditions shall be taken into consideration.

10.4 Degree Of Protection As a minimum, the enclosures shall have a degree of protection IP 55 in accordance with IEC 60529.

10.5 Electrical Supply System The AC supply to the heating system shall be either single phase or symmetrical three-phase, + neutral, with a nominal voltage and frequency as indicated in the requisition. The supply variations at the distribution board under steady-state conditions shall be limited to: - Nominal system voltage: 10% - Nominal system frequency: 2%




In addition to the above, input voltage variations may be subject to temporary voltage variations of +10% and -20% of the nominal voltage, caused by e.g. motor starts. Transient high-frequency voltages of 2 kV peak may also be superimposed on the input voltage because of system switching operations, etc.

10.6 Heating-Up Requirement In most applications, trace heating is used for temperature maintenance and not for heat-up. However, it is often of interest, at initial start up or after a power shutdown, to see how long it will take the system to reach its maintained temperature. This depends mainly on how much heat capacity is available. For critical applications where heat-up time is an important factor during start-up or after a power shutdown, extra heating capacity of the trace heating in addition to that required for temperature maintenance becomes an important factor and shall be taken account of in the design. Apart from compensation heating, there may be a need to heat-up (to melt) the contents of a pipeline within a certain period. This may be required for example when the product is solid under ambient conditions (e.g. wax). Additional heating capacity would need to be installed to perform such a duty. This can be done by increasing the capacity of the compensation heating or by installing additional heaters dedicated for this duty, provided consideration is given to the maximum heat density allowed under those circumstances. The most economic solution shall be chosen.

10.7 Start Load The start-up temperature determines the in-rush current (start-up load). This temperature determines the rating of the electrical protection (circuit breaker). Since self-regulating heaters have higher power outputs at lower temperatures; the lower the selected start-up temperature the higher the power demand will be and the rating of the protective device will have to be increased accordingly. If the electrical protection rating is already known, then the maximum length of the heater circuit has to be limited to a value where the start-up load does not exceed the circuit breaker rating.

10.8 Performance Requirements The system (materials, components and assembly methods) shall have a design life of at least 20 years. Heating equipment used for piping and equipment that will undergo periodic steam cleaning shall have a minimum withstand temperature of 190 C, for a cumulative exposure time of at least 1000 hours, with the Power OFF.




Heating equipment shall be designed to withstand a temperature of not less than the maximum operating temperature + 20 C, which can occur under all process conditions. The heat density of the heating elements shall be such that the temperature limits for pipe, heaters or product are not exceeded.

10.9 Spare Or Over-Capacity The design of initial spare or over-capacity of the heating system shall be considered if for critical applications the power output is not allowed to drop below the design values. A minimum of 20% additional design heat requirement shall be taken into account. This may not be applicable if Self-Regulating Cable is used. The safety factor used in the design shall be stated in the heat balance calculations (8.3).

10.10 Operation And Maintenance All electrical equipment subject to operating and maintenance activities shall be easily accessible wherever possible and shall allow for safe and convenient performance of such activities with minimum use of scaffolds and ladders. System components shall be standardized as much as possible.

10.11 Special Applications/Conditions The following typical applications require special attention in design:

loading arms; lines that require tracing from above ground to underground; preformed rugged insulation like cellular glass or calcium silicate; flexible parts like compensators; short time heat-up requirements; exposure to special chemicals (e.g. sulphur).




10.12 Heater Selection 10.12.1 General

For winterising and compensation heating the following heater types may be used:

self-regulating/self-limiting heaters; constant wattage parallel heaters; power limiting heaters; high temperature polymer insulated series cables; mineral Insulated heaters (M.I. cable). In the case of welded pipelines (i.e. without flanges), a system of skin effect

current tracing heaters shall be considered.

10.13 Self-Regulating/Self-Limiting Heaters Self-regulating/self-limiting heaters shall be utilized where possible, within the restrictions of heat output and operating temperatures. They can be used for all winterising and the majority of compensation heating requirements. Heating tape shall consist of two parallel copper conductors, both being in contact with a self-regulating/self-limiting semi-conductive material. This basic element shall be insulated by one or more non-hygroscopic jackets, and shall be covered with a braided metal screen covering at least 70% of the surface and a fluor-polymer outer jacket. The braided metal screen shall have an electrical conductivity not less than the conductivity of one of the conductors. The heaters shall vary the power output in response to the sensed temperature at every point of the surface. As the temperature increases, the heater output shall decrease automatically and vice versa. The natural reduction in heat output by increasing temperatures shall be at least so much that the heater will not be damaged due to overheating as result of e.g. overlapping, irrespective of the application. Self-Regulating Cable shall be capable of being overlapped on itself (but this should be avoided wherever possible) without causing hot spots.

10.14 Constant Wattage Parallel Heaters Constant wattage parallel heaters may be utilized when the required heat output or the operating temperature is beyond the capabilities of self-regulating/self-limiting heaters. A constant wattage Parallel Heating Cable shall consist of two insulated copper conductors. Heating elements (wires or other types of elements) are connected to the two conductors at certain distances, forming heated zones. The maximum length of a heating zone shall not be more than one metre. The conductor and the heating elements shall be provided with one or more layers of insulating material. All insulating material shall be heat resistant and




non-hygroscopic, and shall be covered with a braided metal screen covering at least 70% of the surface together with a polymer outer jacket. The electrical conductivity of the braided metal screen shall be not less than the conductivity of one of the conductors. The heating pad shall have an external metal earth screen or foil over the entire surface for mechanical and personnel protection. The heaters (both cables and pads) shall provide a constant power output regardless of the operating temperature. In the event of a hot spot, the affected element(s) may burn out leaving, however, the remaining part of the heater in operation.

10.15 Power Limiting Heaters Power limiting heater cables shall be used where the maximum allowable temperature of Self-Regulating / Self Limiting Heater Cables will be exceeded OR if high outputs are required. This type of cable can reduce considerably the use of mineral insulated heating cables. Power limiting heater cables consist of a metal-alloy heating element, which is helically wrapped around a fibre substrate, electrically disposed between two copper conductors. The element has a Positive Temperature Coefficient characteristic and reduces its output with increased temperature.

10.16 High Temperature Polymer Insulated Series Cable Heaters Series cables shall be used where the length of the heating circuit is beyond the maximum allowable length of parallel heaters. This will help to reduce the number of power points and/or junction boxes at non-reachable locations. Such cables shall be used for pipe bridges, etc. High temperature polymer insulated series cable heaters consist of one or more conductors insulated by non-hygroscopic insulation material (e.g. Teflon), low ohmic protective braid metal screen covering at least 70% of the surface and non-hygroscopic outer jacket (e.g. Teflon). The heaters (cables and pads) shall provide a constant power output regardless of the operating temperature. The maximum watt density shall be 25 W/m, with voltages up to 400 V.

10.17 Temperature Control 10.17.1 General

Each process will impose a unique set of constraints on achieving proper temperature control. Such constraints may include maintenance and operating flexibility, energy efficiency, acceptable temperature span, time and manpower available to correct deficiencies, and the cost assignable to lost production.




The installation and selection of temperature control depend on the following criteria:

process/product considerations; energy saving; temperature limitation for safety reasons; protection against overheating of the heating elements.

If Self-Regulating Cable is used (e.g. for winterisation) on impulse lines, the power off point shall be below the temperature at which the impulse line liquid starts to strip/evaporate.

10.17.2 Process/Product Considerations

For convenience, three basic process types, along with probable tracing constraints, are covered herein. It should be recognized, however, that each specific application may involve a combination of considerations.

Type I A process where the temperature should be maintained above a minimum point. An ambient sensing thermostat is acceptable. Equipment might consist of a mechanical thermostat and few, if any, alarms. Large blocks of power might be controlled by means of a single thermostat, a contactor, and a panel board. Since heat input will be provided unnecessarily at times, wide temperature excursions should be tolerable, and maximum energy efficiency is not essential. Energy efficiency can be improved through the use of dead leg sensing control.

Type II A process where the temperature should be controlled within a moderate band. Pipeline temperature sensing devices, along with some facilities for monitoring and alarming, are typical. Redundant equipment is not generally specified, and the tracing requirement would be sufficiently seasonal to permit planned maintenance and repairs.

Type III A process where the temperature should be controlled within a narrow band. Pipe sensing controllers using thermocouple or resistance temperature detector (RTD) inputs will facilitate field calibration and provide maximum flexibility in the selection of alarm and monitoring functions. Redundant equipment may be warranted where maintenance and repairs need to be performed without a process shutdown. Heat input capability may be provided to warm and/or melt the fluid within a specified range and time interval. Type III considerations require strict adherence to flow patterns and thermal insulation systems with the highest integrity.




10.18 Energy Saving 10.18.1 General

In a winterising installation, an Ambient Temperature-sensing device shall be used to activate the heating installation when the temperature drops below 4 C. One single device can control all winterising heating circuits of an area (see Appendix 1, circuit B). Piping with compensation heating does not normally need to be heated when in operation. Only at low or zero flow rate will the heating system be used to compensate for the heat losses. Consequently, the heating system shall only be activated when required, and shall be controlled by local thermostats. The number and location of the thermostats shall be selected to ensure that the heating requirements of all piping and equipment involved will be maintained under all process conditions.

10.18.2 Group Control and Monitoring Device (Station)

A Group Control and Monitoring device (Station) should be considered if this adds value to the tracing system. This system can be applied to complex trace heating systems (type II or III). The capabilities of the device should contribute to:

low-cost temperature control and monitoring; lower maintenance cost; optimising and simplifying tracing design; reduced energy cost; networking to plant control systems.

The station should be capable of central control of the relatively large tracing system. The number of low stations provided shall be as low as possible (one per system). The Manufacturer shall provide the accessories and software for the group control and monitoring device. The Manufacturer shall provide the RS-485 card(s) for communication and alarm annunciation and RTD temperature sensing elements.

10.18.3 Proportional ambient sensing controller (PASC)

As part of a complex control system, a proportional ambient sensing control system can be adopted. Design heat loss and consequently design heat output are based on extreme operating conditions, i.e. minimum Ambient Temperature. For most of the time the actual ambient will be much higher and heat loss will be correspondingly less, so that heaters do not need to be energised 100% of the time. PASC works by measuring the Ambient Temperature, comparing this to the




pre-set design minimum Ambient Temperature and then proportioning the heater output required to compensate for the actual heat loss. A control group containing all lines to be maintained at a process or winterisation temperature is defined and these are all switched together by the controller. As many groups can be defined as there are process or winterisation maintain temperatures. If certain lines require accurate temperature control or monitoring, this should be accommodated into the controller infrastructure. Line mounted PT-100 devices should be wired back to the main controller via field-mounted remote monitoring modules and RS-485 connection(s). Selected lines should be energised according to this line-sensed temperature rather than via the main group control system.

10.19 Temperature Limitation For Safety Reason Controlled design applications, which require the use of a temperature control device to limit the maximum pipe temperature, shall comply with a) for zone 1 and either a) or b) for zone 2: a) For zone 1 or zone 2 applications: controlled design applications, which require the use of a temperature control device to limit the maximum surface temperature, shall utilize a protective device that will de-energize the system after the maximum operating temperature has been exceeded, and reset shall only be possible by hand after the defined process conditions have returned. In case of an error by, or damage to the sensor, the heating system shall be de-energised before the defective equipment is replaced. The setting of the protective device shall be secured and sealed to avoid tampering. The protective device shall operate independently from the temperature monitoring system. b) For zone 2 applications: a single temperature controller with failure annunciation may be used. If so, adequate monitoring of such annunciation, such as 24-hour surveillance, shall be provided. Alternatively, automatic reset may be used if the temperature limiter gives an alarm in a manned control room when the heater is switched off. The decision as to which option is to be applied shall be made with the agreement of OMV.

10.20 Temperature Limitation For Protection Against Overheating It is sometimes required to install thermostats that monitor the surface temperature of the heaters and disconnect the system from the supply if the temperature is too high. This high temperature could be damaging to:

the material used in the heater and in particular the self-regulating/self-limiting semi-conductive material. Examples of this are




highly insulated small bore tubing and piping in which a product could flow with a temperature higher than the maximum exposure temperature of the heater when energised;

the material used in the process piping or equipment (e.g. plastic); personnel, e.g. supply piping of safety showers, which may contain

water at too high a temperature. The maximum allowable temperature when the heater is de-energised, as stated by the Manufacturer, shall not be exceeded. The requirement of such temperature limiters shall be discussed with the Manufacturer in the detailed design stage.

10.21 Power Supply And Distribution 10.21.1 Distribution Panel

The heating system shall be connected to a distribution board which should be installed in the plant switch house. It may be economically attractive to install the distribution panel or a sub-distribution panel nearer to the heater installation; for this, OMV's approval is required. These panels shall be suitable for outside installation. The incoming feeders of such panels shall be protected by short circuit limiting devices having a maximum nominal current of 355 A. These (sub-) distribution panels shall be installed in a non-hazardous area. The outgoing panels of the distribution board shall consist of a number of three-phase fused main circuits, with an isolating switch which is padlockable in the off position. Fuse sizes shall be selected to limit the short circuit currents to the capacities of the downstream circuit breakers. Each main circuit shall be divided into a number of circuits, each provided with a padlockable miniature circuit breaker (MCB). The circuits may be single phase or three phase with neutral. In the case of single phase, the circuits shall be equally divided over the three phases. If the heating system is not controlled by local thermostats but via an Ambient Temperature device or via a process control system, contactors shall be incorporated either in the main circuit or in each of the circuits (Appendix 2, circuits B, C and D).

10.21.2 Circuit Protection Requirements For Branch Circuits

Miniature circuit breakers in the circuits shall be either double pole for single-phase circuits or four pole for three-phase circuits, and shall have trip characteristics corresponding thermally and electro-magnetically to IEC 60947-2, Category B or C.




The maximum rating of the circuit breakers for parallel type heaters shall be 25 A, and the minimum short circuit breaking capacity shall be 10 kA with current limiting capabilities. Auxiliary contacts wired up together for one common trip signal to a manned control room shall be provided. It shall be ensured that the protective devices will operate effectively regardless of the location of a possible fault in the heating cable. The breaker shall be suitable for the inrush current of the heating elements. The heater Manufacturer shall approve the type and rating of the circuit breakers. In a three-phase heater cable, an unbalanced protection relay shall be provided with a trip setting of maximum of 20% of the nominal current with a maximum of 5 A. For TT and TN-S systems: Each Branch Circuit shall be equipped with a circuit breaker with a residual current protection device with an operating current not greater than 300 mA. The device shall have a break time not exceeding 150 ms at five times the rated residual operating current. Values of 30 mA and 30 ms are preferred unless there is evidence that this will result in a marked increase in nuisance tripping. For IT systems: An electrical insulation monitoring device shall be installed to disconnect the supply whenever the electrical resistance falls below 50 /V of rated voltage.

10.21.3 Field Distribution

The supply cabling between the distribution board and the heaters shall have a cross section adequately rated for the maximum load, and restricting the voltage drop over the cable under full load conditions to maximum 5% of the nominal voltage. The cables shall have copper conductors and a steel wire armouring or braiding and, if required, lead sheathing. Cabling and heaters shall be connected via connection boxes. Individual heaters or groups of heaters of no more than five segments on the same pipeline shall be provided with a local switch, padlockable in the 'Off' position and installed near the supply point of the heater(s). Other configurations shall be subject to the approval of OMV. Heaters integrated in instruments along the pipelines shall also be connected to a heater supply circuit.

10.22 Installation 10.22.1 Heater Distribution




Heaters shall be distributed and grouped logically in order to minimize the number of switches, thermostats and power cabling required. In installations where the process flow can follow different routes (for example manifolds and A/B pump lines, bypass circuits and safety showers), each independent part of the system shall be controlled separately and supplied via separate MCBs. Where the same conditions apply in a pipeline, the heaters shall be controlled from one point unless they are connected to different circuits (see Appendix 2). Heating systems of duplicated process control instruments shall not be connected to the same circuit. Heater circuits shall be loaded with maximum 20 A for single-phase circuits and 3 x 20 A for three-phase circuits. For the operating current rating of self-regulating/self-limiting heaters, the minimum operating temperature shall be taken into account. To prevent overloading of the heater conductors, the maximum length of a Parallel Heating Cable shall be limited in accordance with the specification of the Manufacturer. Some heating cables are available with additional power supply conductors integrated in the tape. This will allow extended heater lengths without using separate power feeding points. Through connections or 'Tee-offs' shall not be made underneath the pipe insulation; only end-seals and 'cold-lead' connections may be used. All other connections shall be made in connection boxes. Sufficient heater capacity shall be installed to ensure that, towards the end of the heating cable, the output does not drop below the minimum design value owing to the voltage drop in the heater conductors.

10.22.2 Local Switches

Local switches shall have a minimum switching capacity of 16 A and shall be double pole for a single-phase circuit and four pole for a three phase, + neutral, circuit. The switch shall not be loaded with more than 75% of its nominal rating to allow for future extension. The switches shall have a clear 'ON - OFF' indication. The 'OFF' position shall be padlockable. Local switches shall be installed in the direct vicinity of the associated heating equipment in an easily accessible position and have the cable glands at the bottom.

10.22.3 Local Thermostats




Capillary type The capillary shall be no more than 5 m long. The contacts of thermostats used for direct switching shall have a minimum rated capacity of 16 A, which may be obtained by an integrated local contactor. Each contact shall not be loaded with more than 75% of its nominal rating. The temperature setting accuracy shall be better than 5% of the set value, with a maximum of 10 C. The switching hysteresis shall be between 5% and 10% of the actual setting or between 4 C and 10 C whichever is the smaller.

Electronic thermostats with PT-100 sensor If highly accurate control is required, electronic thermostats with PT-100 sensor should be used. The contacts of the thermostats used for direct switching shall have a minimum rated capacity of 16A, which may be obtained by an integrated local contactor. Each contact shall not be loaded with more than 75% of its nominal rating. The maximum switching accuracy shall be within 1 C for an actual setting between 0 C and 100 C, or 2% for higher temperature settings. The switching hysteresis shall be within 3%. Local thermostats shall only be adjustable with the use of tools. Thermostats installed as temperature limiters for safety reasons shall be of the fail-safe type.

10.22.4 Connection Boxes

Connection boxes shall be used for: a) the connections between supply cable and heater cable; b) the distribution of supply from one circuit of the distribution board to sub-circuits. Only the supply from one circuit of the distribution board shall be allowed in a connection box; NOTE: Combinations of a) and b) are also possible. c) splitting of a three-phase circuit into three single-phase circuits. Connection boxes shall contain sufficient terminals for all the connections to be made. Individual terminals shall be provided for each conductor. The terminals shall be of non-loosening construction and of the wedge type or cage clamp type, obviating the use of cable lugs and constructed in such a way that direct contact between screw and conductor is avoided. Terminals shall be identified in accordance with the related diagram. In addition, sufficient earth terminals or an earth bar with sufficient earth connection points shall be provided to earth the metal screens of all cables and heaters. All cables connected to the box shall enter the box through the bottom or the sides, not the top. Sufficient cable glands, suitably sized for the associated cables, shall be installed.




10.22.5 Heater Installation

Extreme care shall be taken to prevent heater cables and pads absorbing water during transport as well as during and after installation. During transportation from the Supplier to the site, the ends of the cables or the connection leads shall be suitably sealed by heat shrinkable adhesive end-seals, which shall remain fitted until the final connection is made in the junction box, switch, etc. The heater cables or the Cold Leads shall be terminated in the junction boxes, switches, etc. in such a manner that any ingress of water through the cores, braiding or in between insulation layers due to the capillary effect is excluded. Heaters shall be installed in accordance with the Manufacturer's instructions. All heaters shall be fixed to ensure continuous and permanent contact with the surface to be heated over the entire (hot) length. Especially when constant output heaters are used, this shall receive special attention since lack of contact will cause hot spots, which may damage the heater. Unrolled heating cable has the tendency to rewind, and unrolling the drum in a certain direction can improve the contact with the heated surface (see Appendix 4, Fig. 4). Heating cables shall normally run straight along the lower quadrant of the pipes (see Appendix 4, Fig. 1). If spiralling of tapes is necessary, this shall be done as shown in Appendix 4, Fig. 2, in order to ensure that the cable can easily be removed. Constant wattage output heaters shall not overlap or touch each other. Where heaters run close together, special retaining fixings shall be used to prevent the heaters from touching. Overlapping of self-regulating/self-limiting heaters shall be avoided wherever possible. Entry kits shall be used where heating cables, Cold Leads or temperature leads enter the thermal insulation, to prevent damage and to ensure weatherproofing. The entry kits may consist of special entry brackets, cable glands or conduit type entries. Cable glands or conduit type entries shall be fixed to the bottom part of the pipeline. The design and the installation of the entry brackets shall be such that ingress of water is excluded. Cold-lead joints including a small portion of the Cold Lead shall be fixed to the heated surface to ensure a good contact of the heater. Heating cable fixed to pumps, valves, flanges etc. shall allow easy removal of the equipment without damaging the cable. To obtain good contact between heater and heated surface, additional metal tape or foil can be used. Additional fixing straps shall be provided on both sides of the pumps, valves, flanges, etc. to avoid loosening of the heater from the associated pipes. Special measures shall be taken to prevent sharp edges or rough surfaces damaging the heaters. Fixing materials for heaters shall ensure continuous and permanent contact between heater and heated surface. They shall be non-corrosive and suitable for




the relevant operating temperature, and shall not damage the heater mechanically or chemically. In general, for heaters with a polymer outer jacket, self-adhesive plastic or glass-fibre tape shall be used. For heaters with a stainless steel outer sheath, stainless steel straps or bands shall be used.

10.22.6 Identification

Electrically heat traced piping and equipment shall be clearly identified with suitable durable weatherproof caution signs, visible from all sides. Signs on traced pipelines shall not be more than 5 metres apart and positioned on alternate sides of the sheathing/cladding. Traced branch pipes, instruments, etc. shall carry individual signs. The elements of a circuit such as local switches, thermostats, connection boxes and heaters shall be provided with permanent labels, which shall consistently indicate the number of the circuit to which the elements are connected. The labels shall be fixed on a non-removable part; for heaters the labels shall be fixed on the sheathing of the associated pipelines or equipment.

10.23 Testing And Commissioning 10.23.1 Factory Testing

The distribution board shall be tested in accordance with the requirements of Document No TO-HQ-02-011 Philosophy for Electical Design Onshore. On request, the Manufacturer shall supply type test certificates of the trace heaters quoted. The Type testing of the trace heaters shall be done in accordance with section 5.1 of IEC 62086-1. The Routine testing of the trace heater shall be done in accordance with section 5.2 of IEC 62086-1. If Manufacturer's testing is based on other codes, this shall be stated in the quotation. Before leaving the Manufacturer's works, each length of cable or panel shall be subject to inspection, dielectric testing and verification of rated output. Results shall be recorded in test reports, which shall be distributed as specified in the purchasing documents. Prefabricated control panels should be completely checked at the Manufacturers shop prior to shipping to verify correct wiring, layout and function. If such a check is not feasible by the user, documentation should be obtained from the Manufacturer, stating that such tests have been performed.




10.24 Commissioning After the control panels have been received, a general inspection should again be made with attention to controllers and other devices that may have been damaged in shipping. Heating cables and surface heaters should be visually checked for damage incurred during shipping and handling. Continuity and insulation tests may be made as a final quality check. Prior to the application of thermal insulation, the insulation resistance of the heating cable shall be measured under normal dry conditions and before associated wiring or control equipment is connected. The measured value should not be less than 20 M at 500 V(dc). For heating devices provided with a non-metallic over jacket, an insulation resistance test should be performed between the metallic covering and ground at 500 V(dc) after:

installation of the heating device on the pipe/vessel, and installation of the thermal insulation.

These tests are used to detect damage to the over jacket during the installation process. If no process temperature measuring system is installed on the traced pipeline, temperature test points shall be installed at crucial points (for example near heat sinks) for checking the performance of the trace heating system. It is recommended that the insulation resistance of the entire Branch Circuit, after the thermal insulation is complete, should not be less than 10 M measured at 500 V(dc). For Type II and Type III, if required, the operation of each electric heating cable should be checked by applying rated voltage and recording current and pipe temperature at steady-state conditions. Time should be allowed for the current to stabilize, as the starting current is sometimes higher than the operating current.

11.0 DOCUMENTS

11.1 General Documents, including drawings, required for the installation shall form an integral part of the design. The documents shall be distributed as specified in the purchasing documents. The documents shall show the relevant order and item numbers and the Manufacturer's reference number. To ensure a workable heat-tracing design, the designers concerned should be furnished with up-to-date




piping information and should be notified of any revisions of items and drawings that pertain to the heat-tracing system. All documentation shall be submitted in the form of an Electrical Trace Heating Manual.

11.2 Information Required From OMV The engineering information required from OMV in order to design a heat tracing system is listed below. The data should be provided by the various disciplines, as follows: These disciplines are:

Process (A) Mechanical (B) Electrical (C) Instrumentation (D)

The information required:

Country and/or local standards (A) Climatic and environmental conditions (A) Hazardous area classification information (A) Piping and Instrumentation Diagrams (A) Trace heating philosophy (A) Insulation specification (B) Pipe support details (B) Line list for heat tracing only (B) Piping Isometrics (B) Plot plans (B) Equipment drawings (tank, filter, columns and pumps) (B) Instrument list (D), including:

- service - process liquid - fill liquid in the impulse line (if applicable) - size of the impulse line (if applicable)

Trace heating specification (C) Power supply philosophy (C)




11.3 Documents To Be Submitted By The Contractor As well as any additional instructions in the requisition/purchase order, the following detail design documents shall be submitted:

thermal design parameters (heat balance calculations used for the design);

system flow diagram (isometrics showing the configuration of the heating circuit);

equipment layout drawings (plans, sections, etc.); schematic and connection diagrams covering the complete trace heating

installation;

pipe drawings (plans, isometrics, line lists, etc.); piping specifications; thermal insulation specifications; equipment detail drawings (pumps, valves, strainers, etc.); electrical drawings (single-line, etc.); bill of materials; general arrangement information showing location of all main boxes; electrical equipment specifications; equipment installation and instruction manuals; equipment details (technical catalogue data of each item of the tracing

installation);

thermal insulation schedules; area classification drawings; ignition temperature of gas or vapor involved; process procedures that would cause elevated pipe temperatures, e.g.

steam out or exothermic reactions;

Manufacturer's installation manual; Manufacturer's test reports, certificates of conformity, declarations of

compliance;

Completed design data summary sheet Each heater circuit should be shown on a drawing depicting its physical location, configuration, and relevant data for the heating cable and its piping system. The drawing and/or design data should include the following information:




piping system designation; pipe size and material; piping location or line number; heating cable designation or circuit number; location of power connection, end seal, and temperature sensors as

applicable;

heating cable number; heating cable characteristics such as the following:

- temperature to be maintained; - maximum process temperature; - minimum Ambient Temperature; - maximum exposure temperature (if applicable); - maximum sheath temperature (if required); - heat-up parameters (if required); - length of piping; - trace ratio of heater cable per length of pipe; - extra length of heater cable applied to valves, pipe supports, and other

heat sinks; - length of heating cable; - operating voltage; - watt per unit length of heating cable at desired maintenance

temperature; - heat loss at desired maintenance temperature per unit length of pipe; - watts, total; - circuit current, start-up and steady-state; - thermal insulation type, nominal size, thickness, and k-factor; - area classification, including the lowest auto ignition temperature for

each area (if applicable); - bill of material.

The drawing should also indicate the power distribution panel number or designation, the alarm and control equipment designation, and set points.




11.4 Database As part of the detailed design a database, in the format specified by OMV, shall be submitted to OMV for inclusion in a (computerized) management system. This database shall contain as a minimum the following information for each individual heater circuit:

type of heating system (winterising, compensation, heating-up, etc.); length of the heating cable(s) and number of circuits; type of the heating cable; maximum, minimum and maintaining temperature; power demand per circuit at maintaining temperature; type and thickness of the insulation; list of lines selected for steam cleaning; list of switches and junction boxes, cross-referenced with the marking of the

installation at site;

data on thermostat(s) and or temperature control system; also indicating for what purpose they are installed.

11.5 Documents The Manufacturer shall provide technical manual(s) and drawings in accordance with the purchase order requirements, which shall include at least the following documents (preferably on a CD ROM):

single line diagram of the unit;

general arrangement drawings;

main and control circuit schematic diagrams;

equipment lists;

recommended spare parts lists to cover startup and two years operation;

test reports and performance curves, including oscillograms of output ripple;

operating manuals incorporating installation, commissioning, operating and maintenance instructions, and fault-finding procedures;

battery calculation sheet. CD ROMs shall incorporate all viewer software necessary to access the information provided.




12.0 REGULATORY AUTHORITY REVIEW REQUIREMENTS

Generally, works test certificates showing compliance with the relevant constructional and performance standard(s) will be required for all equipment.




APPENDIX 1 ILLUMINATION LEVELS The required illumination levels, measured at the working plane or 1 m above the floor level in a horizontal plane, are shown in the table below. These values are mean values and the uniformity ratio (Emin/Emean) is for normal installations. These values shall be used as a basis for the design of new installations unless higher illumination levels are required by national or local regulations in the country of installation. The tabulated illumination levels apply when the luminaires are dirty, i.e., after taking account of the following fouling factors:

Location fouling factor

Plant areas (both indoor and outdoor):

0.80

Non-plant areas (outdoor): 0.80 Non-plant areas (indoors): 0.85

REQUIRED ILLUMINATION LEVELS

Location Emean (Lux)

Notes

CONTROL ROOMS General, including front of panel

300/500

1, 7

Rear of panels 150 Auxiliary rooms 150/30

0 2

Outside, near entrances 150 PLANT AREAS Operating areas requiring regular operator intervention

pumps, compressors, generators, drivers, valves, manifolds, loading arms, etc.

150 3

Local control and monitoring points

indicating instruments, gauges and control devices

75

Level gauges (see-through) to be lit from behind by single tube fluorescent luminaries

Access ways: walkways, 25





Notes

platforms, stairways, ladders.

Plant and jetty approaches and road intersections 5 Non-operational areas with limited attendance, e.g., tank farms without equipment requiring regular operator intervention.

0.5

Loading gantries: top loading, walkways and top of tankers

150

bottom loading (coupling handling area)

150

Road tanker parking area

25

NON-PLANT AREAS

Switchrooms, including relay and auxiliary rooms 150

Workshops and garages

indoor general 250 3

local on workbenches and machine tools

400 4

outdoor storage and handling areas

50

Warehouses and stores

indoor between storage racks

150

bulk storage 50 outdoor storage areas 5

Laboratories and analyser rooms

400

Street lighting and fence lighting

lit by twin 40 W fluorescent or single 70 W HP sodium (SON) luminaires on standard 8 m poles at, typically, 50 m spacing

5, 6

NON-INDUSTRIAL AREAS Canteens (dining areas) 100 Car parks 1 Catering areas (food preparation and serving) 300 Communications rooms 400 Computer rooms 400 7 Conference rooms 400





Notes

Corridors and stairways 100 Drawing offices 400 7, 8 First aid rooms 400 Libraries and reading rooms 400 Lifts 100 Offices 400 Plant rooms 150 Print rooms 250 Reception areas 150-

400

Recreation rooms and lounges 300 Store rooms 150 Toilets and locker rooms 100

NOTES:

1. 300 lux applies at night and 500 lux during the daytime. Control of the

illumination level down to 100 lux should be possible either by switching off rows/groups of luminaires, or by use of electronic dimmers, or both.

2. 150 lux applies for normal access and 300 lux for maintenance activities. The illumination level should be controlled by switching each lamp in a twin fitting from separately controlled circuits or by switching alternative fittings.

3. Where overhead travelling cranes are installed, floodlights should be fitted under the crane beam to provide an illumination level of 400 lux for better illumination during maintenance.

4. In areas where very fine work is carried out, local lighting with higher illumination levels may be required, e.g., 750 - 1000 lux on an instrument workshop bench.

5. Higher illumination levels apply where security fence lighting is required, e.g., for use with video camera surveillance. These shall be specified to be compatible with the video system utilised.

6. At the security barrier and check point in front of site entrance gatehouses, higher illumination levels may be required.

7. In rooms where VDUs are permanently installed, the lighting shall be designed to avoid reflections and glare from the screens.

8. Local lighting shall be provided to give an illumination level of 700 lux on drawing boards.




APPENDIX 2 TYPICAL POWER SUPPLY AND DISTRIBUTION DIAGRAM




APPENDIX 3 TYPICAL EXAMPLE OF HEATER DISTRIBUTION




APPENDIX 4 TRACE HEATING INSTALLATION EXAMPLES

PREFACEDEFINITIONSABBREVIATIONSINTRODUCTIONAPPLICABLE CODES, STANDARDS AND REGULATIONSCodes and Standards listReferences

SYSTEM GOALSYSTEM BOUNDARIESDESIGN PHILOSOPHYLIGHTINGDesign ConsiderationsGeneralGeneral lighting requirementsPlant lightingBuilding lightingStreet and fence lightingSpecial lightingAviation warning lightingIllumination of areas to be observed by means of CCTV monito

Portable lampsEmergency and escape lighting

TRACE HEATINGDesign ConsiderationsGeneralSafetyHazardous AreasNon-hazardous areas

Site ConditionsDegree Of ProtectionElectrical Supply SystemHeating-Up RequirementStart LoadPerformance RequirementsSpare Or Over-CapacityOperation And MaintenanceSpecial Applications/ConditionsHeater SelectionGeneral

Self-Regulating/Self-Limiting HeatersConstant Wattage Parallel HeatersPower Limiting HeatersHigh Temperature Polymer Insulated Series Cable HeatersTemperature ControlGeneralProcess/Product ConsiderationsType IType IIType III

Energy SavingGeneralGroup Control and Monitoring Device (Station)Proportional ambient sensing controller (PASC)

Temperature Limitation For Safety ReasonTemperature Limitation For Protection Against OverheatingPower Supply And DistributionDistribution PanelCircuit Protection Requirements For Branch CircuitsField Distribution

InstallationHeater DistributionLocal SwitchesLocal ThermostatsCapillary typeElectronic thermostats with PT-100 sensor

Connection BoxesHeater InstallationIdentification

Testing And CommissioningFactory Testing

Commissioning

DOCUMENTSGeneralInformation Required From OMVDocuments To Be Submitted By The ContractorDatabaseDocuments

REGULATORY AUTHORITY REVIEW REQUIREMENTSAPPENDIX 1 ILLUMINATION LEVELSAPPENDIX 2 TYPICAL POWER SUPPLY AND DISTRIBUTION DIAGRAMAPPENDIX 3 TYPICAL EXAMPLE OF HEATER DISTRIBUTIONAPPENDIX 4 TRACE HEATING INSTALLATION EXAMPLES

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