BECHTEL CHILE LTDA.

GENERAL SPECIFICATION 24017-GE-002

FOR

ELECTRICAL CONSTRUCTION AND INSTALLATION FOR MINERA ESCONDIDA LIMITADA PHASE IV EXPANSION PROJECT

0 A REV.

07/09/00 23/12/99 DATE

Issued for Construction Issued for Coordination & Approval REASON FOR REVISION

CZ CZ BY

WK WK CHECK

CZ CZ EGS VEM

CL CL PE

GR GR PEM

SIGNED CLIENT

JOB No. 24017 BECHTEL CHILE LTDA. GENERAL SPECIFICATION No. 24017-GE-002

SHEET 1 OF
REV.

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General Specification for Electrical Construction and Installation 24017-GE-002 Rev. 0

TABLE OF CONTENTS

Section 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

Description GENERAL SCOPE OF WORK CODES AND STANDARDS SITE CONDITION ELECTRICAL ENCLOSURES CONSTRUCTION LABELING AND NAMEPLATES TESTS AND INSPECTIONS STANDARD SAFETY LOCKOUT SYSTEM AS-BUILT DRAWINGS MISCELLANEOUS

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1.0

GENERAL 1.1 This specification establishes the minimum quality requirements for furnishing materials, equipment, installation assembly, labor and supervision, and equipment testing for the complete electrical installation for the Escondida Phase IV Expansion Project. Clarifications regarding quality or interpretation of a Contractors scope of work, the drawings, the documents or any other issues, shall be made by the Field Engineering Group of Bechtel-FEG). FEG decisions shall be final. When reference is made to "approved equal, approval by FEG shall be obtained. Electrical installations shall be safe to operate and maintain under all operating and environment conditions. All electrical rooms shall have legible as built latest editions of the applicable one line diagrams installed at clearly visible locations. These diagrams shall be protected by clear plexiglass (or equivalent). 1.6 1.7 All low, medium and high voltage equipment and exposed raceway systems shall have danger warning signs separate from the equipment nameplates Turnkey contracts shall be the responsibility of the turnkey contractor. FEG responsibility shall ensure that these contracts are completed in compliance with the terms and conditions of the contract documents.

1.2

1.3 1.4 1.5

2.0

SCOPE OF WORK The Contractor shall be responsible for the following: 2.1 Furnishing of all labor, supervision, equipment, and tools required for the installation, and testing of the complete electrical system as shown on the contract documents. Furnishing, delivery, unloading, handling, storage, installation and testing of all equipment and materials not specifically indicated as being furnished by others. Unloading, handling and storage of all electrical equipment and materials provided by others. Materials or equipment damaged from handling or installation shall be replaced and/or repaired at Contractorss expense. Material and equipment received in damaged condition shall be brought to the attention of the FEG. 3

2.2 2.3 2.4

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3.0

CODES AND STANDARDS The installation and testing of the electrical installations shall conform to the applicable provisions of the latest editions of the following standards and codes: ANSI ANSI-C2 ASTM AWS ETG-1015 IEC ICEA IEEE MSHA NEC NEMA NFPA OSHA SEC RSM UL American National Standards Institute National Electrical Safety Code American Society for Testing and Material American Welding Society Endesa Seismic Specification (220kV equipment) International Electrotechnical Commission Insulated Cable Enginners Association Institute of Electrical and Electronics Engineers Mining Safety and Health Administration National Electrical Code - 1999 National Electrical Manufacturer's Association National Fire Protection Association Occupational Safety & Health Administration Superintendencia de Servicios Electricos y Combustibles (Chilean Regulation) Reglamento de Seguridad Minera D.S. N72 Underwriters Laboratories, Inc.

The construction and assembly work shall be performed in compliance with the Construction and Industrial Safety standards of Minera Escondida Ltda. (MEL) Asociacin Chilena de Seguridad. With regard to discrepancies or interpretations arising from the above codes and standards, the most severe shall apply.
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FEG shall be informed of all noted discrepancies and interpretations. 4.0 SITE CONDITIONS 4.1 ENVIRONMENTAL CONDITIONS For information on environmental conditions, refer to Section 4 Site Specific Information included in the material requisition, Tab 5.19 of the Project Procedures Manual. 4.2 SPECIAL ENVIRONMENTAL CONDITIONS In general, all areas except for the following will be considered to be subject to fine abrasive dust: control rooms, electrical equipment rooms, offices, and warehouses. Control rooms, electrical equipment rooms, and offices will be considered to be clean areas after the completion of construction. The following indoor areas will be considered to be wet and subject to hosedown: Open areas of the concentrator grinding facility operating platform and below. Open areas of the concentrator flotation facility below the flotation bay crane. Open areas of the pumping stations. Open areas of the concentrate filtering facility operating platform and below.

4.3

ALTITUDE CORRECTION FACTORS Altitude correction factors will be applied for derating the equipment to be located at the plant site based on the altitude of 3200 m above mean sea level (m.a.m.s.l.) in accordance with the applicable ANSI/NEMA standards and codes. No altitude correction factor need to be applied for the equipment located at Coloso Filter Plant.

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5.0

ELECTRICAL ENCLOSURES 5.1 All electrical equipment furnished outside of control rooms and electrical rooms shall have enclosures approved for the environmental conditions, such as rain, dust, etc., in which the equipment is to be installed and used. All enclosures shall be primed and painted. The enclosures listed below are minimum requirements for the various non corrosive operating areas and are as follows: 5.1.1 Indoor - Control Rooms and Electrical Rooms. - NEMA 1 gasketed or NEMA 12. - Other Rooms - NEMA 12 or 13. 5.1.2 Indoor and outdoor process areas - NEMA 4 5.1.3 Corrosive Areas - Provide stainless steel or fiberglass enclosures with NEMA classifications as per 5.1.1 and 5.1.2 above.

6.0

CONSTRUCTION 6.1 General All electrical materials and equipment shall be installed and shall be connected in a complete and workman like manner in accordance with the Project specifications and drawings, the manufacturer's installation instructions and the applicable codes and standards. 6.1.1 All electrical equipment shall be covered with protective material during the painting of structures, pipes, vessels, tanks and other equipment. Special care shall be taken to prevent damage to electrical materials and equipment due to welding or other fabrication or installation operations.

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6.1.2

All electrical materials and equipment shall be aligned with surrounding structural members and installed in such a manner as to present a neatly finished installation. All electrical materials and equipment shall be installed in a manner to provide easy access for personnel safety, operation, service and maintenance. Code clearances shall be interpreted as being minimum.

6.1.3

6.1.4 6.1.5

All electrical materials and equipment shall be properly secured to prevent damage due to normal operation, weather or seismic activity. All installation details for mounting of electrical equipment and materials shall be fabricated to withstand a combined horizontal and vertical seismic acceleration relevant to a UBC seismic Zone 4. Welding procedures shall be in accordance with AWS D1.1, Structural Welding Code, and carried out by a qualified welder.

6.1.6 6.2

Conduits 6.2.1 6.2.2 6.2.3 6.2.4 PVC conduits shall be suitable for direct burial and concrete encasement. PVC conduits, fittings and PVC cement shall be of the same manufacture. Rigid steel conduits and fittings (where specified) shall be heavy wall, hot dip galvanized, UL listed, rigid steel conduits. For 4, 5 and 6 conduits, conduit elbows shall have 0.9 meter minimum bending radius unless shown otherwise on installation drawings. Conduits shall be so installed that the required cables or wires can be drawn in without excessive strain or risk of mechanical damage. Conduit shall not be installed in locations where they interfere with clean-up. Where conduits enter boxes they shall be secured by galvanized locknuts and insulating bushings. Bushings made of thermoplastic material such as polyethylene or other flammable materials shall not be used. "Myers" hubs shall be used in wet or washdown areas.

6.2.5

6.2.6

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6.2.7

In general, conduit shall be securely fastened at least every 3 meters. Supports or fasteners shall be provided on each side of conduit bends, and no more than 0.9 meters from any outlet. Conduit supports shall be secured to concrete work by approved expansion anchors or bolts, or by inserts set at the time the concrete is placed. Wood, lead, or other makeshift plugs driven into holes shall not be used. Exposed conduit shall be run parallel to column lines in all cases, and must present a neat and workmanlike appearance and shall be without kinks or sags. No more than the equivalent of three 90 degree bends shall exist in a single conduit run, including bends located immediately at the conduit termination. Where more bends are required, additional pull boxes shall be installed. Any unbroken conduit run more than 10m in length shall contain a pull wire. Conduit shall be laid out to avoid water and heating pipes. In no case shall conduit be within 150mm of such pipes except where crossings are unavoidable, in which case the conduit shall be at least 25mm from the covering of the pipe. Conduits shall not be mounted on or supported from heating or plumbing pipes, or ducts. All conduit and cable fastenings on concrete block shall be made with toggle bolts, tampins or ramsets using Unistrut channel support or approved equal. The use of running threads on conduit is prohibited, and ends must be properly reamed. Single runs of exposed conduit when run along steel, concrete or masonry structures shall be spaced to avoid the accumulation of dirt. Connections to equipment subject to vibration or removal shall be made with galvanized flexible steel conduits with an outer liquidtight jacket. Fittings shall be of the watertight compression type.

6.2.8

6.2.9

6.2.10

6.2.11

6.2.12

6.2.13 6.2.14 6.2.15

6.2.16

Conduit and conduit fittings shall not be directly welded to supports, rebar, or any structure.

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6.2.17

Conduits in location where foreign material may enter shall be plugged or capped during construction. Ends of spare conduits shall be plugged or capped. Threaded connections of conduit shall be tightened so that the ends of joining conduit or the end of the conduit and shoulder of the fitting butt tightly together. A corrosion-resistant, anti-seize lubricant shall be used on threads at all connections of dissimilar metals.

6.2.18

6.3

Cable Tray and Fittings 6.3.1 Minor deviations in routing of cable trays to avoid interferences may be allowed, except where locations are dimensioned, subject to the approval of FEG. The completed work shall be straight, plumb and true, without kinks or sags. 6.3.2 6.3.3 Cable tray shall be supported as indicated on the detailed drawings. Supports shall be at a maximum of 3 meters intervals. Care shall be exercised during installation to ensure that the trays are installed without distortion and that they are properly aligned and supported. They shall only be supported on permanent members of the buildings and shall not be affixed to roof decks or temporary walls. Before the installation of any cable tray network, the area shall be checked and coordinated for interference with other trades, lighting, piping and ventilation. If interferences occur, the Contractor shall notify FEG in writing before any part of this network is installed. 6.3.5 The Contractor shall identify all cable tray systems using 75mm (3 in.) letter size stencils and black paint. All identification of trays shall be clearly visible and spaced no more than 9 meters apart on the same tray system. Trays shall be numbered in accordance with the numbering system shown on the drawings. Cable trays shall be installed in such a way as to ensure that no damage is caused to the PVC outer covering of the cable by sharp edges. Trays shall generally be routed through clean, dry areas away from washdown locations. Where cable trays are installed in washdown 9

6.3.4

6.3.6

6.3.7

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areas or an area susceptible to mud or rocks, then either an inverted "V" shaped cover shall be installed on top of the tray or the tray installed laid on edge. 6.3.8 Where any trays pass through concrete block walls, or into electrical rooms, the wall openings shall be sealed with approved fire stops. (Ref. 6.6) The drawings do not show all details of clips or mountings for cable trays. When it is necessary to do so, the Contractor shall install additional clamps, brackets, channels, angles, or other supporting members necessary to provide a rigid and continuous support for the cable trays. The ends of all cut pieces of tray or hangers shall be painted with primer or zinc-rich paint before installation. Field fabricated fittings, elbows or bends will only be accepted where job conditions do not permit the installation of manufacturer's standard fittings, elbows or bends, or as otherwise shown on the drawings. Deflection of installed cable trays shall not exceed 13mm between any two supports. Supports shall be installed at all bends, tees and fittings. Trays shall not be used as walkways or platforms by construction personnel. 6.3.13 6.4 In general, trays shall have a spare capacity of 20%.

6.3.9

6.3.10 6.3.11

6.3.12

Wire and Cables 6.4.1 6.4.2 Tray type cables shall be used on cable tray and conduit runs. Normal recommended practices shall be followed when installing, so as to avoid damage to cable sheaths, conductors, insulations, or jackets. The Contractor shall take measures to ensure that cables will not be damaged by excessive tension when pulling. Suitable rollers, pulleys and other devices for pulling cable around sharp corners shall be provided, to maintain the recommended bending radius. Any damaged cables shall be rejected and shall be replaced at no extra cost to the Owner.

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6.4.3

All bends shall be so made that the cable will not be injured, and the radius of the curve of the inner edge of any bend shall not be less than that specified by the NEC. All power and control cables installed in cable tray shall be held in place by using "Ty" cable ties. The ends of all cables shall be sealed against the entry of moisture or other contaminants immediately after cutting. Where cable enters motor control centers, the cable sheath shall be carried as close as possible to the first point of termination. The Contractor shall ensure that conductor insulation is not nicked or damaged when removing armor and cable inner jacket. Any cables with damaged conductor insulation shall be rejected, and replaced at no extra cost to the Owner. Connections of conductors in terminal boxes and equipment shall be made with extra length. Spare conductors shall be neatly bundled and secured by lacing, or straps.

6.4.4 6.4.5 6.4.6 6.4.7

6.4.8

6.4.9

All power and control cables shall be permanently identified with the cable and wire numbers as shown on the drawings and cable schedules in all control panels, control devices, distribution panels, pull boxes, junction boxes, etc., at the terminals to which they connect. Cables shall be installed in trays in a logical order, such that they do not cross each other and that they lie flat in trays and shall be spaced in accordance with the NEC. Cable shall be unrolled from reels, or removed from cartons, in a manner which will prevent kinking, undue tension and crushing of the conductors. External protective sheathing, or jacket shall remain intact and undamaged. Cable shall be drawn into conduit or duct only after all work of any nature that might cause injury to the cable is completed. Conduit system shall be complete, snaked and cleaned before pulling in any cable. Cable pull-in lubricant shall be used to minimize pulling stresses on cables pulled into conduit.

6.4.10

6.4.11

6.4.12

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6.4.13

Power feeder and power distribution conductors shall be one continuous unbroken length unless a splice or tap is specifically shown on the contract drawings. Prior approval from FEG shall be obtained before commencing work on any power conductor splice or tap.

6.4.14

Raychem or approved splices and/or taps shall be made up following the standard methods and procedures recommended by the cable manufacturer. Cutting and/or splicing of cable shall be done during dry weather or under cover which will ensure dry working conditions. Cut ends of cable shall be immediately and effectively sealed in accordance with manufacturer's recommendations. Splicing of conductors in current transformer leads, in potential transformer leads or in protection circuit leads is not allowed. Splices and/or taps in control conductors shall be made at approved terminal blocks in terminal boxes. Connections shall be both mechanically and electrically secure. Instrumentation and communication cables shall be installed only in conduit systems designed and assigned for the purpose. Insulated cable or wire shall not be installed if at any time during installation it may be subjected to a temperature below freezing. Each insulated cable shall be tagged at each end and each insulated conductor shall be marked at each end with the tags and markers as shown on schematic, diagrams or circuit schedule. Conductors in tray shall be protected during the construction period against damage. The Contractor shall provide appropriate measures to protect cables from welding arc burn splattering. All insulated conductors whether used or spare shall be terminated on terminal blocks or equipment terminals. Terminations shall be aligned at devices and terminal blocks to provide maximum electrical clearance and a minimum of crossovers. Turns shall be 90 bends. Wires shall leave terminal points at right angles to terminal posts and lie parallel or perpendicular to each other and to the terminal blocks. Conductor insulation shall be stripped back from the wire and a 1

6.4.15

6.4.16 6.4.17

6.4.18 6.4.19 6.4.20

6.4.21

6.4.22

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distance which shall allow the undisturbed insulation to butt against the shoulder of the terminating lug or connector. Removing insulation shall be done with care to prevent damage to conductors. Lugs and connectors shall have ample contact area between conductor and device. They shall be applied with tools recommended by the manufacturer of the lugs and connectors. 6.4.23 Within equipment, wires from cable termination to terminal connections shall be neatly trained, bundled, and supported. Spare wires shall be separately identified. In wiring gutters, wires shall be laid without lacing. Wires shall not be drawn tight to be under tension, but shall not be loose and sag outside the gutter when the cover is removed. 6.4.24 6.4.25 Shields on instrumentation cables and on high voltage cables shall be grounded only at the location as shown on the drawings. Stress cones on high voltage cables shall be Raychem or approved equal and shall be made up in accordance with the cable manufacturer's recommendations. Underground cable shall be installed with a minimum of 3 meters of space from buried piping.

6.4.26 6.5

Grounding 6.5.1 6.5.2 Grounding shall be installed in accordance with the Grounding Notes and Details 0000-E-007. Grounding conductors exposed to mechanical damage shall be protected by rigid steel conduit sleeves with bushings. Ground conductors installed along beams or columns shall be routed on the inside of the flange adjacent to the web. Before grounding connections are made, all contact surfaces shall be thoroughly cleaned. Connections shall be both mechanically and electrically secure. In general, exposed or accessible grounding connections shall be made with bolted pressure or compression type connectors. All underground or embedded grounding connections shall be made by the exothermic welding process.

6.5.3

6.5.4

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6.5.5

Grounding conductor "pig tails", which are extensions of the underground grounding grid, shall be connected as shown on the contract drawings to equipment, machinery, building steel, etc. All electrical apparatus supplied from the resistance or solidly grounded alternating current systems operating at higher than 220 volts shall be provided with one ground fault return path. Miscellaneous electrical equipment enclosures, boxes, etc., shall each be provided with one equipment grounding post for termination of a grounding conductor. Cranes are considered to be adequately grounded through the rails. Therefore each rail shall be grounded to building columns at two or more points and rail sections shall be bonded. In Areas where equipment grounding conductors can come in contact with copper concentrate, the conductor shall be protected from corrosion using epoxy painting.

6.5.6

6.5.7

6.6

Fire Stops 6.6.1 6.6.2 Fire stops shall be provided for all raceways and cables penetrating electrical rooms, as shown on the layout drawings. The fire stops shall provide a method of completely sealing off all air spaces around cables penetrating walls or floor and shall be U.L. listed, silicone foam. The fire stops shall not be installed until all cables are installed and each cable has been tested for grounds, continuity, and short circuits.

6.6.3 6.7

Buried Cables All buried cables shall be installed in RGS conduit, unless otherwise specified.

6.8

Underground Duct Banks and Tunnels 6.8.1 Excavation and backfill shall be performed in accordance with General Specification 24017-GC-012, Structural Excavation and Backfill, and as noted herein. Water in excavations shall be controlled. Adjacent property shall be protected and shored as necessary to prevent damage. 1

6.8.2 6.8.3

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6.8.4

Excavations in established areas shall be done in a manner to leave the areas clean of earth and debris and in the original condition. When the excavation is performed on compacted and graded backfill, all surplus excavated material shall be removed from the site. Backfill shall be compacted to a density equivalent to that of the excavated material. Where practical, trenches for encased duct banks shall be cut with near vertical sides and of a width approximately equal to the required width of the duct bank envelopes so that the undisturbed earth may be used as the forms for bottom and sides of the concrete envelopes. Where this procedure is impractical, sides of duct bank envelopes shall be formed and formwork removed before backfilling operations commence. Backfill shall be made such that the original grades and elevations or grades and elevations shown are maintained at the completion of the work. Any settlement shall be restored to grade. Backfill for conduit banks shall be trench backfill and for underground conduits shall be sand backfill. Manholes, handholes, junctions boxes and pull boxes shall be located and constructed as shown and as follows: a. b. c. Manholes shall be installed in duct banks at the locations shown on the drawings. Handholes shall be installed at distribution points as indicated on the drawings and 0000-E-009, Raceway Notes and Details. Pulling irons shall be installed in the manholes on opposite side of the conduit bank openings, 300mm above bottom of the manhole. Ladder rungs shall be installed in duct bank manholes in the adjacent wall to the wall the duct bank is located.

6.8.5

6.8.6

6.8.7 6.8.8

d. 6.8.9

Locations indicated on drawings for conduit, manholes, handholes, junction boxes and pull boxes will be approximate only and shall be altered slightly, as directed, to avoid local obstructions, except for conduit terminating at specific equipment which shall be placed in accordance with tolerances shown.

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6.8.10

Depths shown for trenches and conduit will be minimum requirements, unless otherwise noted for coordination with other underground utilities. In areas where conduits cross, conduits shall be laid deeper than the nominal depths shown to maintain adequate clearance, as directed.

6.8.11

Buried conduit banks and box locations shall be posted by concrete marker monuments. Monuments shall be installed at a minimum of every 15 meters along underground conduit banks, at every point where a change in direction occurs and at every buried box location. A white plastic warning tape printed in red, designed for marking underground cables in conduit or duct banks, shall be run at each side of the cable trench at a depth of 150mm below ground level. If the cable trench is less than 300mm wide, one warning tape placed in the center of the trench run at a depth of 150mm below ground level will be acceptable. Minimum size of below-grade PVC conduit shall be 2". Conduit and fittings shall be new. No warped, deformed or otherwise defective conduit shall be used in construction. Ferrous items which have become corroded or rusted shall be thoroughly cleaned and treated with a coat of Galvanox, manufactured by Subox, Inc., or as approved, prior to installation. All work shall be performed in accordance with manufacturer's instructions.

6.8.12

6.8.13

6.8.14

6.8.15 6.8.16

Horizontal terminations of PVC conduits within manholes, handholes or buildings shall be made with end-bells flush with the surface. Vertical terminations of conduits in buildings shall extend 75mm above the finished floor elevation and shall be cut-off evenly and neatly after the floor has been finished, unless otherwise shown. Conduit terminations shall be installed in a manner that allows connection with above grade raceway installations. a. b. Non-metallic conduit to be extended with metallic conduit shall be terminated and fitted with appropriate adapter. Flush surface terminations of metallic conduit shall be made by terminating conduit with standard conduit couplings. Open ends 1

6.8.17

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of couplings shall be plugged with standard countersunk iron plugs. Cup grease shall be applied to threads of plugs and couplings to assure easy removal. Recessed socket holes of plugs shall be filled with Duxseal or equivalent compound. Plugged ends of couplings shall be set so that they are perpendicular and flush with finished surfaces to produce flush, concealed conduit terminations until such conduit is put into service or is extended. c. Projected terminations of metallic conduit shall be made by extending conduit approximately 75mm beyond finished surfaces. Exposed portions of conduit shall be perpendicular to surfaces with ends threaded. Conduit shall be capped with a galvanized pipe cap of proper size. Cup grease shall be applied to the threads of the cap and conduit to assure easy removal. 6.8.18 Conduit cuts shall be made square with an approved cutting tool. Plastic conduit cuts shall be made using a miter box with a fine tooth handsaw. The inside and outside of a cut conduit shall be carefully reamed and trimmed to eliminate internal burrs and sharp and rough edges. After reaming and trimming the conduits shall be wiped clean of dust, dirt and shavings. Joints between lengths of conduit and between conduit and couplings fittings and boxes shall be made by a method specifically approved for the purpose and as follows: a. Where a conduit enters a box or other fitting, a bushing or adapter shall be provided to protect wires from abrasion unless the design of the box or fitting is such as to provide equivalent protection. Tapered ends on cut lengths of non-metallic conduit shall be made with an approved type of tapering tools. Field threading of metallic conduits shall be done with a standard conduit cutting die providing 62mm taper per meter. Running threads shall not be used on conduit. Threaded connections of metallic conduit shall be treated with red lead and threaded so that the ends of joining conduit or the 1

6.8.19

6.8.20

b. c.

d.

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end of the conduit and shoulder of the fitting butt tightly together. 6.8.21 No more than the equivalent of three 90 degree bends shall exist in a single conduit run, including bends located immediately at the conduit termination. Runs exceeding 60 meters shall not have more than the equivalent of two 90 degree bends. Where more bends are required, additional pull boxes shall be installed. Any unbroken conduit run more than 30 meters in length shall contain nylon pull wire. Bends shall be in accordance with the following requirements. a. Bends of rigid metal conduit and plastic conduit shall be so made that the conduit will not be damaged, flattened or cracked and that the internal diameter of the conduit will not be effectively reduced. The radius of curvature of the inner edge of any field bend shall not be less than 0.9 meters. b. Non-metallic PVC conduit shall be laid with tight joints, sealed with approved joint compound. Bends shall be made with even sweeps having as long a radius as practical and using short straight lengths of duct to accomplish the bend. The angle of offset of each short length shall not exceed five degrees. Underground conduit termination at finished grade shall consist of rigid steel bend and fittings as shown on the drawing.

c. 6.8.22

Conduit shall be accurately spaced on conduit spacers in accordance with the conduit bank cross-sections shown. Conduit shall be securely tied in place to prevent displacement or floating while being encased. Conduits shall slope toward the manholes. There shall be no dips in conduits, in which water may stand.

6.8.23

Junction pull boxes shall be securely mounted within the envelope area so that their coverplates will be exposed and flush with the surface of the concrete enveloped. Galvanized surfaces damaged during handling and installation shall be treated with one touch-up coat of Galvanox as manufactured by Subox, Incorporated or as approved. Underground metallic conduit not encased in concrete shall be painted with two coats of Gilsonite asphaltite protective paint or be PVC-clad rigid steel and buried to a depth of at least 1 meter. After the runs are 1

6.8.24

6.8.25

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6.8.26 6.8.27

assembled, all paint scars, couplings and fittings shall be retouched with two coats of asphaltite paint. Spaces between conduits and sides of trenches shall be carefully filled with sand back-fill which shall be well tamped under and around the conduit to hold it firmly in position. Each conduit shall have full solid bearing along its entire length. Backfilling shall be continued by placing and tamping backfill, being careful not to disturb the conduit, until trenches are backfilled with excavation material over top of conduit. There shall be no foot traffic on or over conduit during installation or backfilling operations until a minimum of one foot of backfill has been placed. Metallic conduit encased in concrete shall have 75mm minimum cover of concrete envelope. Non-metallic conduit shall be encased in red oxide-dyed concrete envelope. A minimum of 75mm of concrete envelope shall exist between the outside surface of any conduit and the surrounding earth. Reinforcing shall be as shown. Where non-metallic conduit banks pass through or under building walls or foundations the concrete envelope shall be reinforced with four feet lengths of #4 reinforcing steel. Reinforcing steel shall have 75mm minimum cover of concrete. A bare copper 120mm2 (4/0 AWG) ground wire shall be installed on top of concrete. Concrete for concrete envelopes shall have a minimum compressive strength of 150 kg/cm2 (2,000 psi) at 28 days, with a maximum aggregate size of 19mm, as specified for Class H20 concrete in Specification 23137-GC-005, Reinforced Concrete. Concrete for duct bank envelopes shall have an approved red color additive mixed and blended into the mixture in accordance with the manufacturer's instructions.

6.8.28

6.8.29

Concrete for manholes and handholes shall have a minimum compressive strength of 200 kg/cm2 (3,000 psi) at 28 days, with a maximum aggregate size of 19mm and have a slump of 75 to 125mm unless otherwise shown. Placing of concrete for envelopes shall be done in such a manner as to avoid damage or displacement of the conduit. Care shall be taken to prevent voids under and around the conduit. Concrete for each conduit bank shall be placed from bottom to top and from end to end in one continuous operation.

6.8.30

6.8.31

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6.9

Installation of Major Electrical Equipment 6.9.1 General Each piece of equipment has been designed to be bolted to the floor or wall. All bolts and nuts provided by the Contractor shall be electrogalvanized or cadmium plated. 6.9.2 Preassembled Electrical rooms, Power Transformers, Neutral Grounding Resistors, Non Segregated Phase Bus, Switchgear, Motor Control Centres, Variable Frequency Drives, I/O racks, Panelboards, etc. Assembly requirements for this equipment shall be undertaken by the Contractor from manufacturer's final certified drawings and from the installation manuals. Except for electronic components and sensitive equipment such as protective relays, meters and instruments, cleaning the interior of this equipment shall be done with vacuum equipment by the Contractor after all installation work is completed. No equipment shall be tested or energized until cleaning is completed. 6.9.3 Batteries, Battery Chargers and Uninterruptable Power Supplies Batteries, battery racks, battery chargers and uninterruptable power supplies shall be installed in accordance with the manufacturer's installation instructions. 6.9.4 Motors 6.9.4.1 Prior to installation, all motors shall be checked to verify that they are in accordance with the applicable motor data sheets which have been completed by the manufacturer. 6.9.4.2 When installing larger motors with sleeve type bearings the Contractor shall strictly follow the manufacturer's instructions concerning the bearing insulation requirements to prevent shaft circulating currents. All materials provided by the manufacturer for this purpose must be used and installed in the prescribed manner.

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6.9.4.3 The Contractor shall follow manufacturer's instructions when cleaning commutators and slip rings that have been adversely affected by weather or storage. Brushes shall be checked for freedom of movement and springs checked for correct pressure in accordance with manufacturer's instructions. 6.9.4.4 The Contractor shall provide a temporary power supply to all motor heaters during the storage and installation phases of the contract in accordance with manufacturer's instructions. No permanent installation materials shall be used for these supplies until final connection, immediately prior to commissioning of the motor. 6.10 Installation of Lighting Fixtures 6.10.1 6.10.2 6.10.3 Lighting shall be installed in accordance with Lighting Notes and Details, 0000-E-008. All Fixtures shall be installed as detailed on the drawings or the accompanying notes and details. All fixtures shall be properly cleaned at the time of installation. Any fixture showing marks or scratches due to handling or tool marks shall be replaced at the Contractor's expense. All fixtures shown in continuous rows or broken lines shall be carefully aligned so that all rows appear as straight lines. Crooked lines or incorrectly placed fixtures shall not be accepted. All fixtures shall be installed complete with lamps and tubes of the approved type and size. All hi-bay lighting fixtures will be serviced from the overhead crane platform. Fixtures shall be provided with chains for holding and plugs for easy disconnect. (See Lighting Fixture Schedule 0000-E-005) All other fixtures shall be mounted for easy access from the ground. Recessed or semi-recessed fixtures shall be wired with 1.2 meters of flexible steel conduit 13mm minimum or "AC" type BX cable to adjacent outlet boxes placed above the finished ceiling. At least 13mm of free air space shall be allowed between fixture enclosures and any combustible material other than that to which they are attached. A suitable gasket shall be provided between fixture frames 2

6.10.4

6.10.5

6.10.6 6.10.7

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and ceiling to prevent light leaks, unless the gasket is supplied with the fixture. 6.10.8 Receptacles and local switches for lighting circuits in offices and hollow partitioned rooms shall be flush mounted in switch boxes with covers and wired with wires in EMT conduit. Receptacles and local switches for lighting circuits in other indoor locations, shall be surface mounted in cast metal FS conduit fittings with phenolic brown covers.

6.10.9

6.10.10 Receptacles or local switches in locations exposed to weather or in areas subject to hose down shall be surface mounted in FS condulets with gasketed weatherproof covers. 6.10.11 Mounting height of electrical devices, shall be as follows: Local Switches Office Convenience Outlets Plant Convenience Outlets Lighting Panels Fixtures Above Doorways Centerline 1.4 meters above finished floor Centerline 0.5 meters above finished floor Centerline 1.4 meters above finished floor Top 2 meters above finished floor 0.3 meter above door opening to bottom of fixture

6.10.12 High and low bay mounted lighting fixtures shall be switched from the breakers located in the lighting panels. 6.10.13 220V convenience receptacles shall not be on the same circuit as lighting. 6.11 Installation of Fittings, Boxes and Enclosures for Lighting System 6.11.1 6.11.2 Conduit fittings without mounting lugs needs not be separately supported. Conduit fittings with mounting lugs, pull boxes, junction boxes, terminal boxes, equipment enclosures, etc., shall be securely fixed in place prior to the installation of raceways.

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6.11.3

Unused hubs in conduit fittings, etc., shall be closed with recessed head, galvanized conduit plugs. Unused holes in sheet metal boxes shall be closed by a method suitable for the location. Outlet boxes shall be cast feraloy, galvanized, for wiring devices, supporting lighting fixtures and for junction boxes.

6.11.4 6.12

Clean-Up, Touch-Up and Painting The Contractor shall clean, prior to painting, all exposed raceways, fittings, boxes, supports, etc., by removing all oil, grease, dirt, etc. The Contractor shall touch up all surfaces of switchgear, bus ducts, motor controllers, transformers and similar electrical apparatus which are scratched or marred during shipment or erection. The materials used shall match exactly the surface being touched up. Precautions shall be taken during touch-up and painting to prevent the spattering or obscuring of any nameplates, insignia, etc., on any equipment.

7.0

LABELING AND NAMEPLATES 7.1 All electrical equipment such as panelboards, disconnect switches, circuit breakers, junction boxes, terminal boxes and field devices, shall be permanently identified with an engraved laminated plastic nameplates bolted to cover plate with stainless steel hardware. The nameplate legend shall denote name or description and tag number; serial number, date of manufacture, voltage, phase, amperage, device controlled, etc., shall be indicated, as applicable. See drawing details for specific items. 7.3 All field devices such as push-button stations, selector switches, hand-off-auto switches, receptacles, shall have nameplates denoting device served, function position(s). Nameplate colors shall be as follows: 7.3.1 7.4 White lettering on Lightgreen background for all equipment and control devices (except as listed in 5.3.2).

7.2

Character sizes shall be at least 5mm high.

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7.5

Stick-on tape (typewriter, etc.) types of name- plates will not be acceptable. Indoor plates may be attached by self-tapping screws. All outdoor nameplates shall be bolted in place. Where required, special metal backplates shall be provided and bolted to device or tack welded to device supporting steel. All cable, conduit and cable tray runs shall be tagged at each end of run and on both sides of all intermediate splice or tap locations with a Type 316 stainless steel tag. Tags shall be slotted at each end and secured to the cable, conduit or cable tray with Type 316 stainless steel bands. Lettering for cables and conduit shall be 5mm high and for cable tray shall be 13mm high, permanently embossed on the tag. All wires and cable conductors shall have identification markers at their terminations. The markers shall be permanent sleeve type, flame retarded, heat shrinkable, white with black lettering, Raychem TMS system or equal. The lettering shall be applied by typewriter or printer. Warning Signs Warning signals shall be installed according to the following: - On all the fences (enclosures) and accesses to substation yards. Signs shall read PELIGRO DE MUERTE and shall be standardized. Sign size shall be 450 x 300 mm. - On equipment and circuits over 400V. Signs shall read PELIGRO ALTA TENSION and the sign size shall be 175 mm x 400 mm. All letters shall be 25 mm high, except for the word PELIGRO which shall be 38 mm high. - On disconnect switches. Signs shall read NO ABRIR BAJO CARGA (Do not open when loaded) and the sign size shall be 175 mm x 400 mm. All letters shall have a minimum height of 25 mm. Danger signs shall be of a standard design, made from stainless steel sheet, gage N 18, red and have white letters. The sign dimensions stated above are minimum. Caution signs shall be yellow with black letters.

7.6

7.7

7.8

8.0

TESTS AND INSPECTIONS 2

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8.1

General 8.1.1 FEG shall be notified at least three (3) days prior to planned commencement of tests so that a representative can be present to witness the tests. Tests and inspections shall be made after the installation is completed in accordance with all applicable specifications, codes and regulations. Inspections shall include verification that all protective relays and trip devices have been set in accordance with the settings approved by FEG. 8.1.3 Tests and calibrations that require special equipment and skills (such as calibration of switchgear relays) may be performed by an independent testing Company which must be approved by FEG. A test format such as input/output matrices, test procedures and test equipment shall be provided by the Contractor and approved by FEG. 8.1.4 All equipment shall be inspected, cleaned, checked for electrical and/or mechanical operation, and all circuits shall be free of short circuits, ground faults or loose connections before being energized. Temporary power shall be provided by the Contractor as necessary to perform the required tests. All temporary power shall be connected with the proper phase sequence, as mentioned earlier in this specification. In making any test on equipment, the equipment manufacturer's instructions regarding recommended test and check-out procedures, special precautions and the like shall be strictly observed. Where the test provisions of this specification conflict with the manufacturer's recommended instructions, the latter shall take precedence. Records shall be maintained for all electrical tests. Recorded data shall include, but not be limited to, the following: o o o o Date of test Description and identification of the equipment tested Type of test and method of application Test equipment used 2

8.1.2

8.1.5

8.1.6

8.1.7

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o o o 8.1.8 8.1.9 8.1.10

Tabulated test data and results Name of company and person making test Environmental conditions at the time and place of test and any other pertinent information.

All test reports and records shall be submitted to a representative of FEG for certification, final approval and signature. All materials, equipment, and utilities required to perform the tests and inspection shall be furnished by the Contractor. When a test indicates the possibility of a fault within specific equipment, the Contractor shall locate the cause of such faults and replace such wires or equipment as may be necessary, retest, and show elimination of fault. All parts, components, etc., found to be faulty as a result of the tests and check outs shall be brought to the attention of FEG. The tests and inspections of the electrical facilities shall include, but shall not necessarily be limited to, the following:

8.1.11

8.2

Cable and Wiring 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 Visually check all cables for damage along entire exposed sections. Check all cable and wiring connections for conformity with latest construction drawings and manufacturer's information. Check all AC and DC control circuits for short circuit and/or ground faults. Check continuity of all connections from one end of conductor to another. Check for proper phase sequence, color code and wire gauge as mentioned earlier in this specification. Medium voltage cable shall be tested with a high-potential DC test set. Tests shall be performed in accordance with cable manufacturer's recommended test procedures. This high-potential DC test shall exclude transformers and medium voltage motors. Before applying high-potential tests check that the cable shield grounding has been properly carried out. 2

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8.2.7

Before end terminations are made, conductors with 600 V insulation shall be "meggered" with a 1,000 V insulation tester. Each circuit, each conductor-to-ground and each conductor between each pair of conductors shall be meggered. After the installation is complete and end terminators are made up, all wire and cable shall be tested. This shall be a "megger" test of each conductor-to-ground and between each pair of conductors. Conduit seals in hazardous areas shall not be poured until completion of wire testing and release by FEG. Ground resistance tests shall be performed to determine the resistance between the grounding system and ground. Readings shall be taken at each equipment grounding conductor that is connected underground and at each accessible ground rod that can be isolated from the ground grid. All resistance values shall be recorded for field inspection. Ground resistance shall not exceed a maximum value of 5 ohms at the main substation as well as the overall plant grounding resistance. If requested values are not reached, the procedure explained in dwg. 0950-E-201 shall be followed to mitigate the high resistance (deep wells, soil treatment).

8.2.8

8.2.9 8.2.10

8.2.11

8.3

Power Transformers 8.3.1 220 kV / 23 kV Power Transformers The 220 kV / 23 kV power transformers shall be inspected, tested and be prepared for energization in accordance with the manufacturer's instructions and under the direction of a representative of the FED. This procedure shall include, but shall not necessarily be limited to, the following: 8.3.1.1 Transformers shall be visually checked to verify oil level, setting of taps, and adequacy of terminations. 8.3.1.2 Transformers shall not be given a high- potential test. 8.3.1.3 Dielectric strength of the transformer insulating oil shall be checked by carrying out a breakdown test. 8.3.1.4 Before primary and secondary connections are made, megger the windings primary-to- tank, secondary-to-tank and primary-to- secondary.

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8.3.1.5 During installation prior to energizing the power transformers, the Manufacturer of the transformers shall send an authorized representative to the site to ensure the transformers have been installed checked and tested to the Manufacturers requirements. The Manufacturers representative shall sign off that the transformers are ready to be energized and shall witness energization. The Manufacturers representative shall authorize and witness loading of the transformers. 8.3.2 Balance of Plant Transformers 8.3.2.1 The balance of plant transformers shall be inspected, tested and be prepared for energization in accordance with 8.3.1 above except that FEG shall determine whether or not a Manufacturers representative is required for energization.

8.4

23 kV Switchgear The 23kV switchgear shall be inspected, tested and prepared for energization in accordance with manufacturer's instructions and under the direction of a representative of the FEG. This procedure shall include, but shall not necessarily be limited to, the following: 8.4.1 8.4.2 8.4.3 DC high-potential tests of 23kV bus in accordance with manufacturer's recommended testing procedure. Calibrate and set all protective relays according to the protections coordination report data sheet. Functionally check proper tripping of each circuit breaker from all associated relays with current applied to secondary wiring of the current transformers. Functionally check all control power circuits. Check polarity of all current and potential transformers, transformer ratios and continuity of secondary circuits. 2

8.4.4 8.4.5

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8.4.6

Disconnect (or draw out) all potential transformers and megger the main bus, each phase to ground and phase to phase.

8.5

Medium Voltage Switchgear and Motor Control Centers Medium Voltage Switchgear and Motor Control Centers shall be inspected, tested, and prepared for energization in accordance with manufacturer's instructions and under the direction of a representative of FEG. This procedure shall include, but shall not necessarily be limited to, the following: 8.5.1 8.5.2 8.5.3 8.5.4 Conduct DC high-potential test of 7.2 or 4.16kV bus in accordance with manufacturer's recommended testing procedure. Calibrate and set all protective relays according to BF-FEG instructions. Check polarity of all current and potential transformers, transformer ratios and continuity of secondary circuit. Functionally check proper tripping of each circuit breaker and contactor from all associated relays with current applied to the secondary wiring of the current transformers. Functionally check all control power circuits. Check that all power fuses, potential transformer fuses and control fuses are the correct size and are installed. Disconnect (or draw out) all potential transformers and megger the main bus each phase-to-ground and each phase-to-phase.

8.5.5 8.5.6 8.5.7 8.6

460V Switchgear The 460V switchgear associated with the unit substations shall be inspected, tested and prepared for energization in accordance with manufacturer's instructions and under the direction of a representative of FEG. This procedure shall include, but not necessarily be limited to, the following: 8.6.1 8.6.2 Megger test 460V bus. Check phase rotation of 460V bus.

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8.6.3 8.6.4 8.6.5 8.6.6

Check polarity of all current and potential transformers, transformer ratios and continuity of secondary circuit. Functionally check all control power circuits. Set all solid state trip devices and timers according to FEG's instructions. Functionally test and check the safety interlocks and the open and close operations of each mechanical and electrically operated circuit breaker. Functionally check proper tripping of each breaker from all associated relays by applying appropriate test currents and/or voltages to the sensing circuits.

8.6.7

8.7

460V Motor Control Centers The 460V motor control centers shall be inspected, tested and prepared for energization in accordance with manufacturer's instructions and under the direction of a representative of FEG. This procedure shall include, but not be limited to, the following: 8.7.1 8.7.2 8.7.3 8.7.4 Megger test 460V bus. Check phase rotation of 460V bus. Measure insulation resistance of each control circuit with respect to ground. Functionally check motor overload units by primary injection, or secondary injection if CT's are fitted. Trip times shall be monitored and checked to verify they are in accordance with manufacturer's tolerances. Perform operational tests by initiating control devices to affect proper operation of the starter control circuits. Check motor nameplate data with motor starter nameplate and component ratings and verify compatibility. The Contractor shall provide a list of additional required overload units to FEG and shall install the overloads after purchase by FEG.

8.7.5 8.7.6

8.8

Motors 3

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All motors shall be inspected, tested and prepared for energization in accordance with manufacturer's instructions and under the direction of a representative of FED. This procedure shall include, but not be limited to, the following: 8.8.1 Check for correct clearances, alignment and lubrication. If required, lubricate in accordance with the manufacturer's instructions. Special tests as suggested by manufacturer, such as gap spacing and pedestal alignment shall be made where applicable. For ratings over 110kW a dielectric absorption test shall be made on motor and starter circuit and a polarization index shall be determined for the motor winding by a test of 10 minute duration. If no test voltages are given by the motor manufacturer, then a test voltage of 1,000V shall be used for motors with voltage rating 150-660V, 2,500V test for motors of 1000-5,000V rating and 5,000V test for motors over 5,000V rating. Polarization index readings less than 3 shall be investigated and reported to FEG. 8.8.3 For motor ratings of 110 kW and below a dielectric absorption test shall be made on the motor windings. The thirty/sixty (30/60) second ratio shall be determined. Ratio readings of less than 1.4 shall be investigated and reported to FEG. Pedestal bearing insulation shall be tested per manufacturer's instructions. An over-potential test between the winding and ground shall be carried out. This shall be made at 80% of twice rated voltage plus 1,000V. A rotation test shall be made to verify proper shaft rotation. A motor run-in test shall be carried out in accordance with manufacturer's instructions. The time of run-in is generally two to three hours or until motor temperatures stabilize. Measurements of starting, no load and full load currents should be recorded and compared with nameplate data. 8.8.8 A motor vibration test shall be carried out, firstly if possible with motor uncoupled, and then with motor coupled. 3

8.8.2

8.8.4 8.8.5

8.8.6 8.8.7

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Refer to manufacturer's instructions for maximum allowable amplitudes. 8.8.9 8.9 All RTD's shall be checked for proper connection and for wiring continuity.

Underground Conduits 8.9.1 Before any section of conduit is covered with concrete or buried, each conduit shall be tested for obstructions or flattening by drawing through a mandrel of the size specified in the following table: Conduit Size (Inches) 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5 6 8.9.2 Mandrel Diameter (Inches) 0.78 1.03 1.20 1.55 1.85 2.30 2.50 3.50 3.75 4.50 Mandrel Length (Inches) 1.25 1.50 1.75 2.25 2.75 3.50 3.75 4.25 5.25 6.25

Immediately after a conduit bank has been covered or encased with concrete and before initial set takes place, the proper mandrel shall again be run through each conduit to determine if any obstructions or defects exist. Defects shall be immediately corrected. Exposed ends of conduit shall be sealed with plugs or caps after testing to prevent the entrance of vermin, moisture and debris until the conduit is put into service or extended.

8.9.3

8.10

General Inspection 8.10.1 All equipment and areas (refer to 4.9.2) shall be inspected for a complete and vacuum-clean installation. All equipment enclosures, doors, covers, nameplates, and tags shall be securely installed and all conduit seals shall be properly poured and marked. Perform all conduit inspection as required by FEG. 3

8.10.2

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8.10.3 8.11

Perform grounding and bonding of equipment inspection as required by FEG.

Checkout and Acceptance It is intended that each system will be operated as completely as possible during the checkout and acceptance phase. Temporary connections for fluids, power, control systems, etc., will be made. All equipment and each system will be tested and operated as a complete electrical installation.

8.12

Startup Following equipment and installation tests, inspections and verifications, functional tests of equipment and systems shall be performed. The startup of equipment and systems shall be executed in a planned orderly practical manner. Safety systems shall be commissioned first. A startup schedule detailing the operations to be carried out, sequences, etc. shall include verifying proper equipment and system operations. The startup date shall be agreed to with FEG.

9.0

STANDARD SAFETY LOCKOUT SYSTEM To prevent the accidental operation of mechanical or electrical equipment during startup, when operation of that equipment would present a hazard to life or material; the Contractor shall establish a standard safety lockout procedure subject to FEG's approval.

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10.0

AS-BUILT DRAWINGS 10.1 As a condition to certification of completion and prior to final acceptance of the facilities by the Owner, the Contractor shall deliver to FEG one complete set of record as-built drawings. This include as-built relay settings. A complete set of blueline working drawings shall be reserved for use as record prints and retained on the jobsite throughout the progress of the work. All variations from the contract drawings and any additional information required by these specifications or by instruction from FEG shall be entered on this record set of drawings to be used to make as as-built drawings.

10.2

11.0

MISCELLANEOUS 11.1 Electrical Bulk Materials Bulk materials are specified in document 24017-GE-009, Electrical Bulk Materials. Any deviation from this specification shall require FEG approval prior to the installation. 11.2 Raceway for Lighting

Contractor shall be responsible to generate the detail raceway systems for lighting based on the information provided in lighting layout drawings. 11.3 Setroute Program

Contractor will install all scheduled equipment, cables, wiring and raceway based on installations cards generated from the Setroute program. Contractor will return as-built installation cards no later than one week after the installation.

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