-
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
Issue Rev
Issue or Revision Description Origin By
Date Chkd By
Date Appd By
Date Appd By
Date
Document Number
Philosophy for
Lighting and Trace Heating Onshore
TO-HQ-02-018-00
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Revision Description of revisionA1 Issued for
Comment/Approval
A2 Client Comments Incorporated
00 Final Issue
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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
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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
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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
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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:
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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
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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.
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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.
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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.
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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.
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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;
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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.
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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).
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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.
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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%
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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.
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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).
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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
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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.
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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.
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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
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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
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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.
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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
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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
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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.
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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
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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.
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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
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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)
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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:
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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.
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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.
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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.
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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
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Location Emean (Lux)
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
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Location Emean (Lux)
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.
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APPENDIX 2 TYPICAL POWER SUPPLY AND DISTRIBUTION DIAGRAM
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APPENDIX 3 TYPICAL EXAMPLE OF HEATER DISTRIBUTION
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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