PT.

Nestl Indonesia Lentera Project

EQUIPMENT STANDARDS AND SPECIFICATION (ELECTRICAL, INSTRUMENTATION & CONTROL AUTOMATION)

1. Electrical Installations
1.1. General Specification Voltage Frequency Earthing System : 380 V (3 phase) 220 V (1 phase) : 50 Hz : TN-S 5 Wire system (R-S-T-N-PE) from transformer, MDB upto MCC/SDP, and each 3 phase load (non motor), including for 3 phase socket. 4 Wire system (R-S-T-N/PE) from MCC to motors.

1.2. Cables and Wiring 1.2.1. Type and sizing In general, all cable must be a LSZH (Low Smoke Zero Halogen) type, as per IEC Standard (IEC 332-1, IEC 332-3, IEC 754-2, IEC 1034), with minimum operating temperature resistant is 75 C. Power Cables : Rated at 0.6/1 kV Solid-stranded copper Minimum size 1,5 mm2 >70 mm2 must be single core In Process area Dia. 25/35sqrmm NYY

Grounding Cable Control Cable

: Rated at 0.6/1 kV Flexible, fine stranded copper : Rated at 0.6/1 kV Shielded/Screened Flexible, fine stranded copper 0,75 mm2 : Shielded Twisted Pair (STP), category 6 (support 1 GHz speed)

Instruments cable

Communication Cable

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1.2.2. Color Code Three phase four wire + PE (380V 50Hz - Power) For cable feeder < 95 sqrm (5 core cable) : Phase R Brown Phase S Black Phase T Grey Neutral N Blue Grounding Yellow/green insulated cable For cable feeder >= 95 sqrm (single core cable) : Phase R/S/T Black Neutral N Black Grounding yellow/green insulated cable For Motors (4 core cable): Phase R Brown Phase S Black Phase T Grey Grounding Yellow/green Single (220V ; 50Hz - Power) Phase Brown Netral Blue Grounding Yellow/Black 24VDC (inside the Control Panel) 24V + Red 24V White 24VDC (field wiring - 3 wiring system) 24V + Brown/Black 24V White/Blue 24VDC (field wiring 2 wiring system) Signal Brown /Brown 24V + Yellow-Green /Black 24V Blue /Grey

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1.3. Motors 1.3.1. Type

All motors must be a premium efficiency type motors (EFF1). Totally enclosed fan cooled type, the sealing of end covers and junction box shall comply with IP56. Motor above 200 w shall be driven by 220/380Vac, 3 phase power, Where D.C. motors are to be used, they must be of the brushless type. If any application need motor run below 25Hz, separate/auxillary cooling fans are needed.

1.3.2. Motor Start and protection Direct On Line start up to 11 kW, For motor greater than 11 kW, Soft Starter or frequency converters For motor above 30 kW, PTC sensor need embedded in the stator winding (TBD w/ Nestle Engineers) For motor above 150 kW, vibration sensor shall be provided to each sleevetype bearing (TBD w/ Nestle Engineers). Each motor to be equipped with Isolation Switch/Safety Switch : o Up to 7,5 kW 3 phase power isolation o > 7,5 control circuit/contactor coil isolation

1.3.3. Main Distribution Board (MDB)

Type of Equipment ACB Air Circuit Breaker Current Transformer TYPE Supplier Merlin Gerin Voltage 400

Capacitor Bank MCCB - Plant protection Power-energy meter Mounting System Contactor&Motor Protection Motor Protection Contactors Miniature Circuit breaker Terminals Relays Isolators/Safety Switch (w/ Lock Out Tag Out feature) Safety relays

Clamp (no need to disconnect cable for replacement) Metal casing Capacitor NS for =/> 630 Amp NSX for < 630 Amp ION 750 Tesys U (For motors =< 32 A) GV7 (For motors >32 A) LC (For motors >32 A) MG Multi 9

Merlin Gerin Merlin Gerin Moller/Wohner/TBD Telemecanique Telemecanique Telemecanique Merlin gerin Telemecanique/Weidmuler/ Phoenix Telemecanique Moller

400 400

400 220 (coil) 400 400 220 400 24DC 400

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1.3.4. Motor Control Center (MCC)

Type of Equipment MCCB - Plant protection Power-energy meter Mounting System Contactor&Motor Protection Motor Protection Contactors Miniature Circuit breaker Terminals Relays Isolators/Safety Switch (w/ Lock Out Tag Out feature) Switch Plugs Safety relays Soft Starter Variable Speed Drive Servo Drive
*)

TYPE NS for =/> 630 Amp NSX for < 630 Amp PM 810 Tesys U (For motors =< 32 A) GV7 (For motors >32 A) LC (For motors >32 A) MG Multi 9

Supplier Merlin gerin Merlin Gerin Moller/Wohner/TBD Telemecanique Telemecanique Telemecanique Merlin gerin Telemecanique/Weidmuler/ Phoenix Telemecanique Moller

Voltage 400

400 220 (coil) 400 400 220 400 24DC 400

Jung MCD FC 300 *) Danfoss Danfoss Allen Bradley

400 400 400 400

With internal RFI Filter version

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1.4. Lightings 1.4.1. Illuminations Level

Type of room Offices - General - Drafting - Conference Rooms - Reception, Lobbies, Lounges Social block - Restrooms, Washrooms, - Toilets - Cloak-rooms, Locker rooms - Medical, First aid - Canteens, Cafeterias - Lodging Facilities, Guest Houses Industrial services - Boiler Room - Transformer/Utility Rooms - Compressors (Refrigeration) Workshop - Gen. Maintenance Workshop - Electrical /Instrumentation - Machine Shop Laboratories - Microbiology - Tasting Warehouse/Storage Rooms - Tools, Technical Materials - Rough/Bulky Items - Small Items - Raw materials, Finished Goods Others - Staircase, Corridors - Truck Loading Dock - Parking, External Security
2 1

Illumination Level [Lux] 300-500 350-500 200-300 150-200

Type of room Milk Processing - Reception - Standardisation - Evaporation - Egron: supervisory floor top floor (spray nozzle) intermediate floors Coffee Processing - GC Cleaning/Drying - GC/RC Transport, Roasting - Extraction - Egron (see milk) - Cold room 40 C general - Cold room 40 C granulation Chocolate Processing - Refining - Conching - Moulding - Mixing - Cocoa Press - Roasting - Wrapping and Packing Culinary and Frozen Food - Culinary preparation - Culinary filling and Packing - Frozen Prep. FoodProcessing - Frozen Food inspection - Frozen Food filling and packing - Casing and palletizing

Illumination Level [Lux] 200-300 200-300 150-200 200-300 200-300 150-200

150-200 100-150 150-200 300-400 150-200 200-300

200-300 200-300 200-300 150-200 200-300

150-250 150-250 150-250

300-500 300-500 300-500

200-300 200-300 200-300 200-300 200-300 200-300 300-500

500-750 1'200 2'000 150-250 100-150 200-300 100-150

200-300 300-500 300-500 300-500 300-500 150-300

75-100 200-300 30-50

1 2

Additional light on equipment or working place Warehouses shall only be lit in the traffic aisles. For this area the illumination level mentioned in the table is given at the floor level.

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1.4.2. Type and specification The below specification from PHILIPS is to be used as referrence 2 x 36W Polycarbonate IP66 Luminaire Pacific for production area 2 x 36W Louvre type for offices 1 x 250W Metal Halide High Bay with wide beam Reflector and polycarbonate cover standard for Warehouse and external usage. The possibility of using LED/other extra energy saving lamp type is under detail review and study with Philips Lighting. Other option than above need to be confirmed with Nestle Engineer.

1.5. Electrical Panel

Panel MDB-Main Distribution Board MCC/Sub Distribution Panel Control Panel Remote IO Dimension (WxDxH) H = 2200 mm, Width and Depth TBD 800 x 600 x 2000 (or TBC) 800 x 600 x 2000 (or TBC) As per requirement (TBC) Material Powder Coated Mild Steel Powder Coated Mild Steel Powder Coated Mild Steel SS (for High Hygiene and Wet Area) Powder Coated Mild Steel (for Basic Hygiene Area) Powder Coated Mild Steel Remarks Bottom Entry

Top Entry

Top Entry Bottom Entry

Lighting Panel

As per requirement (TBC)

Bottom Entry

All above electrical panels must use the following locking device (cylinder type) Rittal 3524 E, with all are the same/identical keys :

1.6. Safety Requirement related to Fire Protection Cable Insulation Resistance : 1000 Ohms/Volt

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2. Instrumentation
2.1. Analog Instruments
Type of Instrument Temperature RTD Temperature Thermo couple Pressure Type 3 wires PT100, TMT182 Type J, Supplier Endress + Hauser Connection 1.5" Tri-clamp for process " NPT for service Sanitary, transmitter mounted in wellhead 3051 & 1151series Signal To PLC

Analog (4-20mA) Analog (4-20mA)

Mass Flow

Differential Gauge Absolute Coriolis massflowmeter Promag

Fisher Rosemount Endress + Hauser Endress + Hauser

Analog (4-20mA) Sanitary Analog (4-20mA) and Pulse for totalizer Analog (4-20mA) and Pulse for totalizer Analog (4-20mA) Analog (4-20mA) Analog (4-20mA) Analog (4-20mA) Analog (4-20mA) Ethernet/IP

Magnetic Flow

Endress Hauser

Vortex Flow Steam Flow Mass Air Flow Density Level Level Weight

Humidity Conductivity Control Valves Damper and flaps

Prowirl Prowirl Prowirl Promass Pressure Radar 0958 Flexmount and terminal is IND331/Panel Relative

Endress Hauser Endress Hauser Endress Hauser Endress Hauser Endress Hauser Endress Hauser Mettler Toledo

D type sensor

Rotronics Endress Hauser Samson Keystone

Analog (4-20mA) Analog (4-20mA) Analog (4-20mA) Analog (4-20mA)

Note: Hart Protocol to be applied wherever possible.

2.2. Digital/Discrete Instruments

Type of Equipment Proximity Switches (Inductive) Proximity Switches (Infra-red) Limit Switches Pressure Switches Flow Switches Level Switches Emergency Stops Selector Switches Push Buttons Indicating Lights Supplier Telemecanique/Sick Telemecanique/Sick Telemecanique Danfoss Danfoss Endress Hauser Telemecanique Telemecanique Schneider Telemecanique Schneider Telemecanique Schneider

Note: Since PLC cards will be current sinking; All switches etc should be of PNP configuration.

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2.3. Pneumatics
Type of Equipment Solenoids (installed in control box) Fittings Regulators I/P Converters Air Lines Control Valve Positioners Damper Actuators Damper Positioners Supplier Festo Ethernet/IP: terminal CPX Valves terminal: 32 MPA Festo Festo Festo Festo Samson/Burkert Burkert/Keystone Burkert/Keystone

2.4. ASI modules (applicable only for Egron)

Type of Equipment ASI Scanner ASI Power Supply I/O Splitter Box Branching Flat Cable Flat Cable Seal ASI addressing unit Supplier IFM Type: AC1337 IFM IFM IFM IFM IFM IFM Type: AC1144

2.5. Others
Type of Equipment Stand alone PID controller **) Hardcopy recorders **) UPS Power Supply Self acting temperature regulator Computer Network equipment
**)

Supplier Honeywell Yokogawa BSPower/ICA/APC Siemens/Meanwell Spirax Sarco HP Cisco

Normally this kind of stand alone instruments are avoided, instead it is integrated in HMI application.

3. Automation
3.1. Programmable Logic Controller (PLC) 3.1.1. PLC Hardware
All PLC equipment shall be Allen Bradley. The following is a list of recommended equipment Type of Equipment Controller (For processing and filling machine) ControlLogix Family Control Logix Family 1756 - L62, L72, L73, L75 (L72 & Flex I/O

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Chassis Power Supply ControlNet bridge Ethernet bridge 24V Digital Input 24V Digital Output Analog Input Analog Output 20 pins terminal 36 pins terminal Controller (For packing line and other simple stand alone machines) Power Supply

L74 estimated AFC Jan 2011) depend on application size (TBD) 1756-A7, A10 or 1756-A13 1756-PA75 1756-CN2, CN2R 1756-EN2T, EN2TR, EN3TR, EN2F 1756-IB16 1756-OB16E 1756-IF16 1756-OF8 1756-TBNH 1756-TBCH Compact Logix Family 1768 L43, L45 1768-PA3

1794-TB3

1794-PS3, PS13
1794-ACN15, ACNR15 1794-AENT, (1794-AENTR estimated AFC Q4 2011) 1794-IB16 1794-OB16 1794-IE8 (HART) 1794-OE4

In case it is still needed to be Flex I/O as above (not Points IO) Ditto as above for Control Logix ditto ditto ditto ditto ditto

Ethernet bridge 24V Digital Input 24V Digital Output Analog Input Analog Output Controller (For simple, stand alone, non-extendable system with less than 16 digital I/O, with NOanalog I/O) ETAP for Device Level Ring (DLR) Ethernet Switch from CPU CLx to Remote IO modules/devices

1768-ENBT 1769-IQ16 1769-OB16 1769-IF16C/V 1769-OF4CI Micrologix series 1763 - 1100, 17661400

1756-EN2TR, 1783-ETAP EN3TR Stratix 8000 : 1783-MS10T (Base Switch only)

Stratix 8300 (Layer (Base Switch only)

3 Routing)1783-RMS10T

3.1.2. PLC Operator Interfaces The following may be considered in presenting operator interfaces that do not have SCADA requirements.
Type of Interface Process equipment : Panelview Plus 1000 color, Touchscreen Type 2711P- T10C4A1 (PanelView Plus) or 2711P-B10C4A9 (PanelView Plus 6 -new released) Network Ethernet

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Stand alone equipment (Fill/Pack, AHU etc) : Panelview Plus 600 color, Touchscreen

2711P-T6C

Ethernet

Should there is any doubt on the selection, always consult Nestle E&A engineer in charge 3.1.3. PLC Network All PLC configurations must be thoroughly discussed with Nestle Engineers before commencing design.
Type of Communication PC and PC, Controller and PCs Between PLC controllers Field IO : Remote IO Node, including VSD Valves Network Ethernet Ethernet Ethernet Ethernet, Discrete hardwire (also on Ethernet/IP) or ASI (applicable only for Egron)

3.1.4. PLC Software

Type ControlLogix programming SCADA programming Software and version RSLogix 5000, V17.0 Wonderware ArchestrA v3.1, InTouch V10.1/Factory Talk View Site Edition (SE) V6.00, V6.10, V7.10 Factory Talk View Studio Enterprise (for SE & ME) / Factory Talk View Studio ME

Panelview

3.2. Human Machine Interface (HMI) / SCADA Hardware Specification *)

PC Specification: Monitor Specification

HP Desktop DC8000SFF HP ZR22w LCD 21.5 Wide Screen 1680 x 1050 SNOW4 Windows Vista Business

Resolution Operating System

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Network Operator Interface (SCADA)

Ethernet 10/100 Base T Wonderware ArchestrA V3.1 (Intouch 10.1)

*) This specification to be validated with IT Department - HO

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