Annex 4-Draft Electrical Design Theme Phase 2-Marius

DESIGN THEME
PROJECT NAME: Electrical and automation installation for the equipment from
cereal silo from berth 42 Constanta Harbor- Phase 2
Technical requirements for designing the equipment triggering installation
1. All the electrical motors >18.5 kW will be triggered by a soft

starter, besides the equipment which will be triggered with a
frequency converter:
a. Auto and CF pit conveyors;
b. Belt conveyors from under the cells so that the product

flow could be adjusted between 400T and 800T.
2. For all electrical motors there will be drawn tables with the
cable sections used depending on the length of the electrical
route. All the cables will be written in the cable journal.
3. The soft starters will be SCHNEIDER ELECTRIC.
4. All other triggering, command and signal equipment will be a

combination of various brands like Siemens and Wago, the
special relays will be Finder, the multimeter Siemens, the PLC
Siemens, and the UPS APC,latest version available on the
market.
5. All sensors ,instruments, dust filters controllers, elevator

controllers , I/O modules must be latest version available on the
market.
6. The frequency converters will be SCHNEIDER ELECTRIC, latest version

available on the market.
7. The electrical motors of the belt conveyors, chain conveyors
and elevators will be provided with absorbed current control
system which will be recorded as a graphic.For maintenance
purpose ,all these motors can have same size?
8. The electrical motors of the belt conveyors, chain conveyors

and elevators will have a meter which will record the hours of
functioning.
9. The motors will be protected by motor circuit breaker, which will

protect the motors against thermal overload or short circuits at
nominal current In.
10. All the Motors except the motors for slide gates and flap boxes
will be provided with thermistors, which will be connected to
the system to protect all motors from raising temperatures
inside the stator coils.
11. All electrical motors will have a safety switch.

12. 24 VDC distribution should be separated on each el. cabinet by electronic
fuses. ETA fuse breaker fault isolator to be install on each cabinet.Also,the 24
VDC power supply should be provided , separate, for each el.cabinet (parallel
connection ,different than what we did in phase 1).
13. All 24 VDC power sources must be protected by a voltage stabilizer .
14. 230Vac distribution should be separated on each el. cabinet by circuit

breakers. Schneider circuit breaker fault isolator to be install on each cabinet.
15. WAGO D/O connected to field using interface relays in order to protect in
case of overload/ shortcircuit.
16. 230Vac sockets to be provided on each el. cabinet fitted with inverters for
service purpose.
17. All el.cabinets should be provided with A4 size documentation (drawings,

diagrams,etc.) support installed on the doors.
18. 24VDC distribution sensors drop voltage less than 3%. Number of power
supply should be assigned in order to satisfied specified request (3%) and
power supply separation for different system (e.g. bus system, field sensors ).
19. Each el. cabinet should have phisical reserve arround 20% in order to add
more electrical equipment just in case.
20. Spare parts .Provide 20% of installed spares for field sensors,dust filter
controllers,elevator controllers ,I/O modules, diaphragm
valves ,magnetventils,VDC power source,PLC‘s,fieldbus coupler,small size
motors (up to 50 kw ),soft starters, frequency converters ,circuit
breakers,contactors,motor circuit brakers,light fittings,.The spare parts must be
tested and certified in factory QA/QC dept. as well as at site before handing
over to our store.
Technical requirements for designing the Emergency Stop installation
1. In the Emergency Stop system are connected all the buttons,

arranged in a logical system on all the transport system,
according with the flow diagram, including the explosion vents
system for the elevators, the dedusting filters and the vacuum
cleaning for the entire system.
2. Emergency Stop system will have to be organized by transport systems as

follows:
a. reception and siloing ( CF, Auto, Barge);
b. emptying the silos and loading ships;
c. drying system.
3. In the Emergency Stop system will have to be included the
explosion vents, which, when triggered will shut down the entire
silo, as a general protection.
4. Emergency stop pushbuttons should be assigned max 10 pcs per safety chain
loop in order to reduce downtime in case of fault.
5. The exact Emergency stop button pushed must be seen in SCADA.
Technical requirements for designing the temperature control system of

the bearing of the equipment which is inside ATEX zone (tunnels,
machine houses)
1. All the machinery situated in ATEX zone must be provided with

temperature sensors for bearings and the oil in the reducers,
where the producer of the reducer will deliver with this sensor.
Reducers/ gearbox should be provided with oil level glass.
2. The system will be set so that each bearing to have two

alarming stages, afterwards will intervene and will stop the
equipment that has problems.
3. A graphic will be made with the evolution of the temperature on

each bearing/reducer for the month that passed.
4. In SCADA, only the alarming stages must be visible. The

temperature graphic and the temperatures from the bearings and
the oil from the reducers must be visible when accesed, in
another window. In another words, the temperature from the
bearings and the oil from the reducers, must be seen only when
an information is wanted about a specific equipment by clicking
on it.
SCADA program
Technical requirements of the program
1. The SCADA operating program will be operational and will be accessed from
a PC.
2. The program will contain all the machinery from the diagram
and all the signals which are coming from all the sensors from
the mechanical equipment and from the electrical motors
(thermistors and circuit breakers).
3. There will be two programs, MANUAL MODE and AUTOMAT

MODE, which will work independently. If an automatic line is
running, all the equipment that are turned on automatically,
cannot be switched to manual mode during functioning, but
the equipment that is not integrated in the automatic flow can
be switched to manual mode and tested. If an equipment from
an automatic line stopes due to fault, the equipment upstream
downstream ( from the equipment in fault towards the delivery point) is
working, but the equipment downstream upstream ( from the
source until the equipment in fault) are stopped. The equipment due
to which the line stopped, can be switched to manual mode
and tested.
4. Safety switch feedback position to be indicated on Wincos SCADA. Safety
switch off position will be indicated on mimic, no interlock need it and the
operator cannot select the equipment in an automatic flow for which the safety
switch is on.
5. I/O pop up menu by right click, to be specified where is connected to I/O Wago
on details window. Now we have only I/D information ( e.g. =A-1611-BTE67,
location +C11 +F14).
In MANUAL MODE, all the machinery can be started and is the

maintenance control mode for all the equipment.
In AUTOMAT mode, the flows start.
SCADA must have a list of technological programs which are:
I. Reception with siloing in one of the cells 1-6 from auto pit 1;
II.Reception with siloing in one of the cells 1-6
from auto pit 2;
Ill. Cereal delivery at ship loader no.1/2 from
one of the cells 1-6;
IV. Cereal delivery from any line, of many cells

simultaneously from the same row, at SL01/02;
V.Direct transfer CF pit - Ship loader
VI. SCADA system will allow the functioning of more flows simultaneously.
These programs will be selected by the operator and SCADA will

start the machinery in cascade or will shut them down.
SCADA system will have a list of alarms, information which will be

stored for at least 30 days and a list of the programs accessed by
the operator, list which will be stored at least 30 days.
In SCADA, each failure must be defined and seen by the operator.

Each sensor triggered (overflow elevator, level sensor elevator, level
sensor scale, belt deviation sensor elevator left right, belt deviation
sensor belt conveyor left right, overflow chain conveyor and so on)
must be seen as such in SCADA, so that the failures could be easier
to be identified by the operator and communicated to the mechanics
in the field.
The train intake to the flat storage will be operated manually. Before
the transport will be started, the movable belt conveyors at the flat
storage needs to be placed in the correct position.
Due to safety reasons it is requested that the positioning of the belt
conveyors will be done fully guarded by the operator.
The belt conveyors will be controlled by radio remote control, which

allows the operator to have free insight for the relevant plant section.
After reaching the final position, the intake line can be

started. Following intake lines can be started (and
stopped):
1. train intake to berth 35 or 42
2. train intake to flat storage 1 or 2
3. train intake to flat storage 3 or 4
4. train intake to silo bins
The detailed functional description of this plant section needs to be

defined during an automation design meeting at a later stage.
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DESIGN THEME

Technical requirements for designing the equipment triggering installation

1. All the electrical motors >18.5 kW will be triggered by a soft

a. Auto and CF pit conveyors;

b. Belt conveyors from under the cells so that the product

3. The soft starters will be SCHNEIDER ELECTRIC.

4. All other triggering, command and signal equipment will be a

5. All sensors ,instruments, dust filters controllers, elevator

6. The frequency converters will be SCHNEIDER ELECTRIC, latest version

8. The electrical motors of the belt conveyors, chain conveyors

9. The motors will be protected by motor circuit breaker, which will

11. All electrical motors will have a safety switch.

14. 230Vac distribution should be separated on each el. cabinet by circuit

17. All el.cabinets should be provided with A4 size documentation (drawings,

Technical requirements for designing the Emergency Stop installation

1. In the Emergency Stop system are connected all the buttons,

2. Emergency Stop system will have to be organized by transport systems as

a. reception and siloing ( CF, Auto, Barge);

b. emptying the silos and loading ships;

Technical requirements for designing the temperature control system of

1. All the machinery situated in ATEX zone must be provided with

2. The system will be set so that each bearing to have two

3. A graphic will be made with the evolution of the temperature on

4. In SCADA, only the alarming stages must be visible. The

Technical requirements of the program

3. There will be two programs, MANUAL MODE and AUTOMAT

In MANUAL MODE, all the machinery can be started and is the

In AUTOMAT mode, the flows start.

SCADA must have a list of technological programs which are:

II.Reception with siloing in one of the cells 1-6

from auto pit 2;

Ill. Cereal delivery at ship loader no.1/2 from

one of the cells 1-6;

IV. Cereal delivery from any line, of many cells

V.Direct transfer CF pit - Ship loader

These programs will be selected by the operator and SCADA will

SCADA system will have a list of alarms, information which will be

In SCADA, each failure must be defined and seen by the operator.

The belt conveyors will be controlled by radio remote control, which

After reaching the final position, the intake line can be

The detailed functional description of this plant section needs to be

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