Job No. Doc. No. Rev.

Project Specification RG6-S-91-1388-003 2

Date : 29, May., 2006 Sheet 1 of
10
RasGas Onshore Expansion Project Phase 2 Prp'd : T. Konda

(Train 6&7 EPC and AKG-2 EPC) Chk'd : R. Kaida / S. Onodera

Electric Heater System App'd : Y. Okazaki

CONTENTS
Pages
1.0 SCOPE................................................................................................................................................................................. 2
2.0 REFERENCES.....................................................................................................................................................................2
3.0 GENERAL........................................................................................................................................................................... 3
4.0 HEATER CONSTRUCTION...............................................................................................................................................3
5.0 ELECTRIC HEATING ELEMENTS...................................................................................................................................4
6.0 THERMOCOUPLES............................................................................................................................................................4
7.0 TERMINAL BOX................................................................................................................................................................4
8.0 ELECTRICAL AND CONTROLS......................................................................................................................................5
9.0 FLANGE FACE FINISH.....................................................................................................................................................6
10.0 MISCELLANEOUS.............................................................................................................................................................6
11.0 INSPECTION AND TESTING............................................................................................................................................6
12.0 VENDOR DATA................................................................................................................................................................. 7
13.0 PREPARATION FOR SHIPMENT.....................................................................................................................................7
ATTACHMENT-1 CONCEPT FOR SCOPE OF SUPPLY BY VENDOR.........................................................................8
ATTACHMENT-2 CONCEPT OF HEATER CONTROL AND PROTECTION (6.6KV SUPPLY).................................9
ATTACHMENT-3 CONCEPT OF HEATER CONTROL AND PROTECTION (415V SUPPLY).................................10

FOR AS BUILT

For Information For Review For Approval For Construction x For As Built
RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 2 of 11

Rev Date Page Description Prpd Chkd Appd

E Mar.,10, 2006 All Issued for Approval T. Konda S. Onodera Y. Okazaki
R. Kaida /
0 May., 29, 2006 All Issue for Construction T. Konda Y. Okazaki
S. Onodera
Issue for Construction(Applied to AKG-2
1 Sep., 28, 2006 All T.Takeno H.Konno H.Inoue
also)
2 Feb., 26, 2008 All AS BUILT for Train-6 K.Iwasa H.Yatabe S.Onodera
1.0 SCOPE

This specification covers the minimum technical requirements for the design, material selection
and supply, and testing of the Electric heater system to be used for RasGas Onshore Expansion
Project Phase 2 (Train 6&7 EPC) and Al Khaleej Gas Project Phase 2 (AKG-2 EPC).

2.0 REFERENCES

2.1 Electrical facilities shall be designed and installed in accordance with the following standard and
specifications.

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

Electric heater system shall be referred to the latest following IEC standards. The latest edition
and addenda up to Year 2004 shall apply without updating edited year, title and number.

IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres

IEC 60529 Degrees of protection provided by enclosures (IP Code)

IEC 60811 Common test methods for insulating and sheathing materials of electric cables
and optical cables

AMERICAN SOCIETY of MECHANICAL ENGINEERS (ASME)

ASME B46.1 Surface Texture, Surface Roughness, Waviness and Lay.

AMERICAN PETROLEUM INSTITUTE (API)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

API 660 Shell-and-tube Heart Exchangers

ISO 16812 Petroleum and natural gas industries-Shell-and-tube heat exchangers

THE INSTITUTE OF PETROLEUM (IP)

IP PART 15 AREA CLASSIFICATION.CODE FOR INSTALLATIONS HANDLING

FLAMMABLE FLUIDS

Project Specifications

RG6-S-91-1381-001 Electrical Design Criteria

RG6-S-91-1548-001 Testing and Commissioning of Electrical Systems

RG6-S-00-1380-001 Classification of Hazardous Locations

RG6-S-00-1380-002 Certification Requirements of Electrical, Instrumentation and

RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 3 of 11

Telecom Equipment / Materials.

RG6-S-91-1380-001 Common Requirements for Electrical Equipment

　　 　　RG6-S-91-1380-002 Electrical Requirements for Package Equipment

　　 　　RG6-S-91-1381-031 Oil-Filled Transformer

RG6-S-91-1381-032 Neutral Grounding Resistors

RG6-S-00-1353-001 Technical Specification for Design & Fabrication of Shell &

Tube
Exchanger

3.0 GENERAL

3.1 The system shall be complete from the point of power supply and shall provide all necessary
functions, including electric heater system, distribution, protection, alarms, temperature
sensing, temperature monitoring, and control . This specifications shall define the minimum
technical requirements for the Electric Heater System for the RAS GAS ONSHORE
EXPANSION PROJECT PHASE 2 (TRAIN 6 & 7 EPC) and Al Khaleej Gas Project Phase 2
(AKG-2 EPC).

3.2 Ambient air temperatures and humidity

3.2.1 For outdoor locations

- Maximum ambient air temperature : 49 ℃ at 90% humidity.
- Minimum ambient air temperature : 4 ℃

3.2.2 For indoor locations

- Maximum ambient air temperature : 40 ℃ at 90% humidity
- Minimum ambient air temperature : 10 ℃

3.3 Degree of protection

3.3.1 The degree of protection shall be in accordance with the classification given in IEC 60526 as
appropriate.

3.3.2 The degree of protection to environmental conditions for equipment located outdoors shall be at
least IP55.

3.3.3 The degree of protection to environmental conditions for equipment located indoors shall be at
least IP41.

3.4 System components shall be approved by a nationally recognized testing laboratory, such as
BASEEFA, for the specified area classification. Heater system equipments that located
outdoor shall be approved for Zone 2, Group IIA, Temperature class T3 locations, as a
minimum.

4.0 HEATER CONSTRUCTION

4.1 Heaters may be installed either horizontally or vertically. CONTRACTOR to advise mounting
orientation.

4.2 All heaters shall be provided with suitable spacers and supports to maintain the elements in proper
alignment and from direct contact with the shell wall. The spacing of supports shall not exceed
508mm. Spacer and support material shall be the same as the heating element sheath. No
segmental baffles are allowed inside the shell.
RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 4 of 11

4.3 Except where specified, the number, length, and arrangement of heating elements shall be by
VENDOR. Heating elements shall be evenly distributed across the shell cross section.

4.4 All radial process connections to the heater shell shall be the same diameter as the shell. This
shall
be accomplished by the use of welding tees. This requirement applies to single stage units or the
interconnecting piping for multiple stage units. Axial interconnecting piping between multiple stage
units shall also be the same diameter as the shell.

4.5 Lifting lugs shall be provided.

4.6 Heater shell design and fabrication shall be based on design metal temperature.

5.0 ELECTRIC HEATING ELEMENTS

5.1 Heating elements shall consist of 80 Ni-20 Cr alloy heating wire packed with magnesium oxide
(MgO) insulation enclosed in a tubular element sheath. The element O.D. shall be 12mm nominal
size (10mm minimum - 15mm maximum). Heating element shall be designed for 100,000 hours
continuous operation at design conditions.

5.2 All sheaths (both heating elements and thermocouples) shall be welded to the heater flange. Silver
solder, sleeves or bushings connections are not acceptable. Bite coupling construction is not
allowed for hydrogen or hydrocarbon services.

5.3 The heating elements to flange seal welds shall be given a pneumatic or hydrostatic pressure test
for 2 hours in the shop. The minimum test pressure shall be 25 psig(1.76 kg/cm 2 (g)) or 1.5 times
the design pressure, whichever is greater.

5.4 The unheated element length shown in this specification is that portion of element occupying the
space from the heater flange face to the nearest tangent line of the welding tee opening. This
length shall be determined by CONTRACTOR and transmitted to the heater VENDORs. Provide a
minimum of 2 full solid baffles in the unheated section to reduce the heat loss through the heater
flange.

5.5 All heating element sheaths shall be of seamless tube construction. The tube thickness shall be
1.25mm minimum.

5.6 Heater shall be designed taking into account no less than 6% increase in resistance due to element
temperature change.

5.7 All terminals of the heating element shall be sealed with epoxy for moisture resistance.

6.0 THERMOCOUPLES

6.1 All heaters shall be equipped with two duplex type over-temperature thermocouples welded to the
sheaths of two heating elements located in the area of highest anticipated sheath temperature (at
the process fluid exit end). If the heater comprises multiple heating element bundles, each heating
bundle shall be provided with two thermocouples.

6.2 Thermocouple construction shall be grounded-junction chromel-alumel in a mineral oxide insulated

sheath. Thermocouple sheath to be of the same material as heating element sheath.
Thermocouple wire shall be 0.5sqmm minimum. The sheathed thermocouple shall be brought out
through the heater flange and shall terminate in a transition splice. Extension wires (1.5sqmm
minimum), from the transition fitting, shall terminate in a thermocouple junction box separate but
adjacent to the terminal box. The over-temperature cut off actuating will be supplied by others.

6.3 Thermocouples shall be provided with HI temperature alarm contact and HI HI trip contact.
RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 5 of 11

6.4 Heating elements with thermocouples welded shall be clearly identified (tagged) in the terminal box.

7.0 TERMINAL BOX

7.1 Terminal box and thermocouple junction box shall be spaced 150mm minimum apart from
flange for cooling purposes. VENDOR shall advise if high temperature wiring is required at the
terminal box.

7.2 When the line current exceeds 50 Amps, high temperature lead wire from each circuit shall be
directed to terminal boards which are to the terminal box.

7.3 All terminal boxes shall be by heavy duty moisture-resistant, stainless steel and shall be suitable for
out door installation as per paragraph 3.4.

7.4 Terminal box covers shall be removable for access to terminal connections. Terminal blocks shall
be
provided in the terminal box for the power cable connections.

7.5 Heating elements shall be arranged to form a balanced ‘Delta’ connected load. Spacing between
terminals of differing phases in the terminal junction box shall be designed by VENDOR considering
adequate shielding to prevent arcing.

7.6 All terminal boxes shall be certified flameproof by an approved independent third party authority per
IEC 60079 or equivalent.

7.7 Provide radiation heat shield between the terminal box and the heater flange.

7.8 Provide the hook on the terminal box to pull out heater bundle.

8.0 ELECTRICAL AND CONTROLS

8.1 VENDOR shall provide power control system.

8.2 Power control system configuration shall be of Contactor control or SCR-zero crossover.

8.2 Concept of Scope of Supply by Heater vendor shall be refered to Attachment-1.

8.3 Concept of Heater Control System and Protection (6.6kV supply and 414V supply) shall be refered
to Attachment-2, 3.

8.4 Location of the control panel shall be in indoor.

8.5 CONTRACTOR shall advise both maximum and minimum RMS voltages to be anticipated at
the site. Heater and controls shall be designed for voltage fluctuation of ±5% minimum. VENDOR
shall determine the expected wattage developed at the maximum voltage including any allowances
for manufacturing to tolerance. All heaters shall be designed to operate reliably at the maximum
voltage and be capable of delivering the specified wattage at the minimum voltage.

8.6 Type of control signal is 4 – 20 mA and shall be supplied by Instrument.

8.7 The heater control panel shall be provided with the minimum acceptable protections : Manual trip
reset key switch, Over temperature protection, Short circuit protection and Mechanical interlock
type.

8.8 VENDOR shall provide ground fault interrupt protection to shut down the heater in the event of
heating elements shorting to the ground.
RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 6 of 11

8.9 Method of ground fault interrupt protection and short circuit protection shall be required. Method of
earth leakage protection and short circuit protection shall be by VENDOR.

8.10 Electrical system design and installation shall meet the requirements of RASGAS specifications
mentioned in paragraph 2.1. The area classification shall be established by CONTRACTOR in
accordance with IP PART 15.

8.11 A lug for external grounding shall be affixed to each shell and bundle. It shall be the same material
as the shell to which it is attached.

9.0 FLANGE FACE FINISH

Type of flange gaskets shall be selected as per RG6-S-00-1353-001 (Design & Fabrication of Shell &
Tube Exchangers) and Flange surface finish shall be selected as per API 660 / ISO 16812. Finishes
shall by judged by visual comparison with surface finish roughness standards conforming to ASME
B46.1.

10.0 MISCELLANEOUS

10.1 VENDOR shall advise pressure drop, inlet to outlet, including entrance and exit losses.

10.2 All exceptions to this specification shall be clearly indicated by VENDER in his quotation.

11.0 INSPECTION AND TESTING

The equipment shall be tested in accordance with the applicable standards and codes section. Copies of
certified test reports shall be provided to the purchaser. The purchaser will witness a functional test with
the actual equipment and will inspect the equipment prior to shipment. The equipment will be inspected for
conformity with specification, workmanship, and completeness. The manufacturer shall give at least 10
working days notice prior to the anticipated completion date in order that arrangements for inspection may
be made by the purchaser. Equipment cannot be shipped until released by the inspector. Inspection will
not be made of equipment, which is incomplete as determined by the purchaser.

Manufacturer's quality control inspections of the equipment shall as a minimum address the following
items:

- Ensure that the physical arrangement of components is as shown on drawings and is per this
specification.

- Ensure that provisions for incoming and outgoing cable connections is as shown on drawings and
is per this specification.

- Verification of components and materials as shown on drawings and called for in this specification.

- Verification of the proper operation of moving parts including breaker operating mechanisms,
racking mechanisms, auxiliary switches, shutter mechanisms, mechanical safety devices and
interlocks, etc.

- Proper fit of doors, safety barriers, cover plates, etc.

- Proper tightness of electrical power and control connections.

RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 7 of 11

- Proper tightness of bolts used to mount components.

- Proper nameplate labeling of components.

- Proper labeling of wiring.

- Prior to covering or encasing the conduit, it shall be pressure tested by dry nitrogen at
1.05 bar G with a soap solution applied at joints.
RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 8 of 11

12.0 VENDOR DATA

12.1 Documents submitted with the bids shall include the following information:

(a) Heater arrangement and circuit drawings, including number of zones for separate control,
heater spacing, and location.
Drawings shall give all heater, conduit and equipment tag data.
(b) Heater control scheme, including duty cycle, location of sensors, temperature control
criteria, and any provision for a forced frequency cycle.
(c) Calculated heat leak, heat flux, watt density of heating cable, and conductor and sheath
temperatures for each zone.
(d) Assumed thermal conductivity of the various layers on which the calculations are based.
(e) Heater rating service factor.
(f) Total kilowatts used for each zone.
(g) Component specifications, descriptive literature, and proposed VENDORs and sub
CONTRACTORs.
(h) General QA/QC procedures.

12.2 Additional documents following the bid award shall include:

(a) Shop and field testing and inspection procedures.

(b) Installation and heater replacement instructions.
(c) Instructions on raising the control temperature of adjacent heaters when one heating
circuit fails, when required.
(d) Heating calculations, by zone, including tank heat leak, steady state and transient
temperature distribution, transient power and temperature curves during heat startup and
shutdown, and sketches serving as the models (with boundary conditions) for calculations.

12.3 The CONTRACTOR shall provide the following drawings that are necessary to install the heating
systems. (But not be limited as below);

(a) Heater control panel arrangement drawings.

(b) Heater control panel equipment schedules (temperature controller, heater cable lengths,
junction boxes, temperature detectors, cable gland, etc.).
(c) Heater control panel schematic diagrams.
(d) Heater cables installation and connection drawings.
(e) Power supply cable arrangements.

13. 0 Preparation for Shipment

Preparation for shipment shall be in accordance with manufacturer's standards, unless otherwise noted
on the request for quotation and/or purchase order. The manufacturer shall be solely responsible for the
adequacy of the preparation for shipment provision employed in respect of materials and application, to
provide materials to their destination in ex-works condition when handled by commercial carrier systems.
This equipment shall be adequately protected and secured to withstand environmental conditions during
transportation, storage, and handling.
 RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 9 of 11

ATTACHMENT-1 Concept for Scope of Supply by Heater VENDER

POWER
SUPPLY

By
CONTRACTO
R

TRANSFORMER By VENDER
6600 / 415 V
(If required)
Drum with nozzle

Safe Area

HEATER
THYRISTER
CONTROL PANEL

TE1 TE1 TE1

TT1 TT1 TT1

Heater Flange Gasket Bolts & Nuts

By VENDER

By Instrument Panel
CONTRACTOR

TE : Temperature Element
TT : Temperature Transmitter

Note : External Power and control cables will be supplied by CONTRACTOR

 RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 10 of 11

ATTACHMENT-2 CONCEPT OF HEATER CONTROL AND PROTECTION (6.6kV Supply)

POWER SUPPLY TRIP

FROM SWGR
6.6 kV +- 5% BY
CONTRACTOR

TRANSFORMER BY VENDER
TRANSFORMER FAULT
6600 / 415 V

BY
CONTRACTOR
R 10A

HEATER CONTROL PANEL

Instrument Panel
Grounding Earth
51G
MCCB Fault Protection OUTPUT
Relay Remote / Local
FUSE PT FUSE Common Alarm
CONTROL POWER Shut down Alarm
SUPPLY ON / OFF Status
Power demand (kW)
V VOLT METER (4 – 20 mA)
INPUT
A AMMETER ON / OFF Command form
CT x 3
DCS

CONTACTOR Emergency Shut Down

TRIP
Temperature Control
Signal (4 – 20 mA)

Control System

ZCT EARTH FAULT

ELEMENT OVER
TEMPERATURE (TRIP)

HEATER ELEMENT OVER

TEMPERATURE (ALARM)

Note : External Power and control cables will be supplied by CONTRACTOR

 RasGas Onshore Expansion Project Phase 2 (Train 6&7 EPC and AKG-2 EPC) RG6-S-91-1388-003 Rev. 2
Electric Heater System Sheet 11 of 11

ATTACHMENT-3 CONCEPT OF HEATER CONTROL AND PROTECTION (415V Supply)

POWER SUPPLY
FROM SWGR
415V +- 10% BY
CONTRACTOR

BY VENDER

BY
CONTRACTOR

HEATER CONTROL PANEL

Instrument Panel
MCCB OUTPUT
 Remote / Local
FUSE PT FUSE  Common Alarm
CONTROL POWER  Shut down Alarm
SUPPLY  ON / OFF Status
 Power demand (kW)
(4 – 20 mA)
V VOLT
METER INPUT
A AMMETER ON / OFF Command
CT x 3
form DCS

CONTACTOR Emergency Shut Down

TRIP
Temperature Control
Signal (4 – 20 mA)

Control System

ZCT EARTH

ELEMENT OVER
TEMPERATURE (TRIP)

HEATER ELEMENT OVER

TEMPERATURE (ALARM)

Note : External Power and control cables will be supplied by CONTRACTOR