Electrical Design Basis_Rev 0

DOCUMENT No. 6556-00-16-50-DB-01 Rev.0

ENGINEERING DESIGN BASIS ELECTRICAL

Page 1 of 17

ENGINEERING DESIGN BASIS DESIGN PHILOSOPHY 5.7 ELECTRICAL

THIS DOCUMENT HAS BEEN APPROVED BY IOCL

0

10.02.05

IOCL Comments incorporated and issued for implementation

SA

RCS

AAN

A

02.11.04

Issued for client’s comments/Approval

SA

RCS

AAN

Rev. No

Date

Prepared by

Checked by

Approved by

Format No. EIL 1641-1924 Rev. 1

Purpose

Copyright EIL – All rights


DOCUMENT No. 6556-00-16-50-DB-01 Rev.0 Page 2 of 17

1.0

Site conditions

2.0

Power Source Details

3.0

Power Supply Distribution System

4.0

Protection - Metering – Control

5.0

Substation Design

6.0

Equipment Design

7.0

Cabling System

8.0

Earthing System

9.0

Lighting System

10.0

Electric Heat Tracing System

11.0

Electrical Equipment For Hazardous Areas

12.0

Statutory Approval

13.0

Cable Sizes for MV Motors

14.0

Specific requirements

15.0 Attachments 16.0

Deviation to design philosophy


Copyright EIL – All rights reserved



Page 3 of 17

The electrical design data defines the design requirements agreed by owner/clients in addition to Design philosophy for electrical facilities no: 6-51-0099 Rev 4 (Any additional deviation must be recorded as part of this document)

1.0

SITE CONDITIONS

A. B. C. D. E.

1

: 45°C

Soil Resistivity

: Later (after the soil Resistivity test)

Minimum temperature. for battery sizing

: 10°C

Equipment design temperature (IS 9676)

per IS-1893) Altitude above mean sea level

2.0

POWER SOURCE DETAILS

2.1

General

A. Independent system or existing system 2.2

: Independent system

Grid Supply

A. B. C. D. E. F. G. H. I. J. K. L. M. 2.3

: <1000 m

* Refer CPP design basis

Name of sub station / MW

: *

Number of feeders

: *

Length of feeder

:*

Type of conductor/ cable size

: *

mm²

Voltage

: *

kV±

%

Frequency

: *

Hz ±

%

Minimum/maximum fault level

: *

kA /

KA

Design fault level / Basic Insulation Level

: *

kA /

kV

System neutral earthing

: *

Minimum load power factor stipulated by

: *

Supply authority

:*

Parallel operation of incomers

: *

Yes/No

PLCC requirement

: *

Yes/No

CPP and its configuration

A. B. C. D. 2.4

* Refer CPP Design basis

Number / type of captive generators

: *

/Steam, Gas turbine

Generator rating/Voltage/Power factor

: *

MW/ kV/ 0.8

Parallel operation with grid

: *

Yes /No

Neutral earthing

:

High resistance earthed

Emergency generator

* Refer CPP design basis (Emergency power for lighting from existing PREP power plant)

A. B. C. D. E. 2.5

Number / type of emergency generator

:*

Generator rating/Voltage/Power factor

:*

kW/ V/ 0.8

Starting

:*

Auto / Manual

Short time para

:*

Yes/No

Paralleling with grid system

:*

Yes /No

Details of Existing System •

3.0

Refer CPP design basis

POWER SUPPLY DISTRIBUTION SYSTEM

1

Based on PREP-IOCL design basis and DFR





Page 4 of 17

3.1

Voltage and frequency variation AC System

i. ii.

Voltage Frequency

: :

+6% +3%

: :

+ 10% +%

Primary HV distribution voltage

:

33KV

Secondary HV distribution voltage

:

6.6 KV

Primary HV distribution system neutral earthing

:

Solidly earthed

Secondary HV distribution system Neutral

:

Resistance earthed

HV motor voltage

:

6.6KVabove 160KW &
MV motor voltage

:

415 VAC upto&including 160KW

Auto transfer at 6.6KV bus

:

Yes

Auto transfer at MV (At PCC Level)

:

Yes

Continuous Parallel operation of Incomers

:

B. DC System (at system output terminals) i. Electrical Control, Lighting etc. 2 ii. Instrumentation Power Supplies 3.2

Utilisation voltage and operating philosophy

A. B. C. D. E. F. G. H. I.

3

:

Yes /No ( 33KV-Yes, 6.6/11KV- No, 415V-No)

:

No

:

Yes/ No

Motors rated below 0.18 kW

:

240V AC, 1ph / 415V AC 3ph

Battery chargers incoming power supply

:

415V AC, 3ph

UPS System incoming power supply

:

415V AC, 3ph

AC Lighting/Power Panels and Auxiliary

:

415V AC, 3ph

Welding Receptacles

:

415V AC, 3ph

Bulk loads like Process Heaters etc.

:

415V AC, 3ph

Normal Lighting/Emergency Lighting

:

240V AC, 1ph

Power factor improvement capacitors

:

As required

Convenience outlets

:

240V AC, 1ph

DC Motor

:

Not envisaged

Motor operated valves

:

415V AC, 3ph

Normal Instrumentation power supply

:

V AC

Critical instrumentation power supply

:

V AC/ V DC

Shut-down system power supply

:

V AC/ V DC

Switchgear protection and Critical lighting

:

220V, DC

E. DC supply for instrumentation F. Plant communication system power supply

:

Independent system

:

415V, Normal, backup

G. Fire alarm system power supply

:

240V AC Normal

•

•

J. K. L. M. N.

HV PCC/PMCC 4

Load shedding

Boards incoming power supply

O. P. Q. R. S. T. U. 3.3

5

Utilization voltage for critical supplies

A. B. C. D.

power supply with

battery

(With battery back up) 2

Refer instrument design basis More than 6MW, the motor shall be connected on 11KV through dedicated transformers 4 Refer DB Document, section 11 of advanced E&I for load shedding 5 Refer instrument design basis for voltage choice for instrument loads 3





Page 5 of 17

H. Annunciation panel power supply6

:

4.0

PROTECTION - METERING – CONTROL

4.1

Metering for external power supply incomers

7

A. Summation metering B. Trivector meter 4.2

V AC Normal/AC UPS V DC (No separate Pnl)

Not applicable :

Yes/No

:

Yes/No

Protection relays for HV switchgear

:

On Switchgear panel

HV Switchgear control

:

Local/ Remote/ ECS

Control Philosophy

A. B. C. D.

Hard wired annunciation panel

:

No (Part of substation HMI)

: : : :

Yes / No (Not applicable) Yes Yes Yes

Numerical Protection/Monitoring system for

i. ii. iii. iv.

EHV system HV Switchboard 415V PMCC/PCC 415V MCC

E. Microprocessor based system for control interlocks :

Yes

and monitoring of electrical power system

i.

Human machine interface system-HMI : Yes Operator console : Yes Engineering console : No, use LAP TOP instead Data concentrator for each substation (Separate for HV and MV system) 8 : Yes / No Interface with higher level control system: Yes

• •

ii. iii.

F. Limiting Conditions for Motor start up (e.g. starting current limitation or method of Starting) 9

i. ii.

HV Motors MV Motors

iii.

Method of starting for large HV motors :

iv.

Method of starting for large MV motors :

: :

G. Type of power isolation for remote transformers10 i. Load break switch in switchgear room : ii. Push button in transformer bay for tripping:

550% (No tolerance allowed) 600% up to 75KW, 550% above 75KW Direct on line (refer foot note for F(i) Direct on line No for all transformers

Remote breaker

6

Hard wired annunciation panel is not proposed. Annunciation will be part of substation HMI No grid backup is envisaged as per CPP design basis. 8 Separate data concentrators for HV and MV are not required for same make and type of relays 9 For motors greater than 2.5MW, maximum starting current shall be based on motor startup study 10 As 33KV switchboards are of rating 31.5KA and available in GIS, instead of local isolating panel, it is suggested to provide push button station with lamp indication for trip of sending end breaker and requires approval with CEA for implementation. 7





Page 6 of 17

4.3

11

Relay protection system

Protection devices for power distribution system shall be as indicated below Relay number

51

Relay description

Feeder

IDMTL over-current relay

51N

Transformer

IDMTL earth-fault relay

(Secondary winding voltage

(Secondary winding voltage

> 3.3 KV)

< 0.433 KV)

Yes

Yes

Yes (7)

51G

51G backup earth-fault (secondary neutral)

relay Yes

99

Motor protection relay with locked rotor feature No (50, 50N,46, 49, 50L/R)

No

Motor feeder

Outgoing feeder

Incomer

HV

HV

HV

MV PCC/

MV PCC/ PMCC

PMCC -

Yes Yes

Yes

Yes

(4)

(13)

Yes

Yes

(4)

(13)

Yes (4) Yes

Yes

-

No

No

No

No

No

Yes

No

Yes (8)

No

No

64R

Instantaneous restricted earth-fault Yes relay (secondary side)

No

-

No

No

No

No

50

Instantaneous over-current relay

Yes

Yes

-

No

No

No

No

50N

Instantaneous earth-fault relay

Yes (6)

Yes

-

No

No

No

No

87

Differential protection relay

Yes (1)

No

Yes (2)

Yes (3)

No

No

No

86

High speed tripping relay

Yes

Yes

Yes

Yes

Yes

Yes

Yes

95

Trip circuit supervision relay

Yes

Yes

Yes

Yes

No

Yes

No

63

Transformer auxiliary relay

Yes

Yes

-

No

No

No

No

27/2

Under-voltage relay with timer

-

-

No

-

-

Yes (5)

Yes (5)

-

-

Yes

Yes(9)

(14) 25

Check synchronisation relay

-

-

-

(9)

NOTES: 1. For transformers rated 5 MVA and above. 2. For motors rated 1500 kW and above. 3. For critical/long feeders and plant feeders connected to main power generation and distribution bus. 4. These relay functions can be substituted by inherent releases. At remote substations where DC supply is not envisaged, 415V switchboard shall have inherent releases instead of relays. 5. Wherever auto-transfer feature is provided. 6. Instantaneous earth fault 50N shall be provided only for transformer with delta primary. 7. Directional IDMTL earth fault 67N shall be provided for transformer with star primary. 8. For motor feeders rated 55 kW and above. 9. For switchgears having bus transfer scheme, where continuous or momentary paralleling is envisaged, check synchronising relay shall be integrated with overall paralleling scheme. 10. The bus tie feeders in HV switchboards shall be provided with 51, 51N, 86 and 95 relays. However MV bus tie shall not have any protective relays. 11. HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage), 60 (Neutral displacement), 86 and 95 relays. 12. In case of HV switchboards with parallel operation of incomers, following additional relays shall be provided: a. One set of 87B (Bus differential) and 95 B (Bus wire supervision) for each bus section. b. 67 and 67N (Directional IDMTL over current & earth fault) relays for the incomers. 13. The following feeders shall be provided with timers for delayed tripping on bus under voltage while the under voltage relay shall be common for the bus a. HV and MV capacitor feeders

11

Generator protection requirement shall be covered separately in respective EPCC document.





Page 7 of 17

b.

14.

15. 16. 17.

4.4

HV and MV breaker controlled motor feeders or contactor feeders with DC control supply. c. One no. DC supply supervision relay (80) shall be provided for each incoming DC supply to the switchboard. One set of bus differential relays (87B) and bus wire supervision relay (95 B) for each bus section shall be provided for HV switchboards connected directly to generation buses and those used as extension buses at remote substation. In case of numerical relays, all relays shall be comprehensive units including all protection, metering and control unless other wise specified. Breaker control switch shall be hardwired type in addition to control switch as a part of numerical relay. Transformer trouble 63TX relay shall be provided for all transformers and relay shall be located on MV side in case of remotely located transformers. This function shall be realized part of numerical relays.

Metering The metering devices in EHV, HV and MV switchboards shall be as below :

Feeder Type

A

V

Hz

PF

MW

MWH

Hour Run

MVAR

MVAH

MVA

X

X

X

X

X

X

-

X

X

X

(2)

(2)

(1,2)

EHV Incomers EHV Bus Tie EHV Transformer EHV Bus P.T. HV Incomer

(2) HV Bus Tie

X

-

-

-

HV Transformer

X

-

-

-

HV Bus P.T.

-

X

-

-

HV Plant Feeder

X

-

-

HV Motor

X

-

-

-

-

-

-

-

-

X

-

-

-

-

-

-

-

-

-

-

-

-

X

-

-

-

-

-

-

X

X

-

-

-

-

-

kWh HV Capacitor

X

X

-

-

-

-

-

PCC/PMCC Incomer

X

X

-

X

-

X

-

-

-

-

kWh PCC/PMCC Bus Tie

X

-

-

-

-

-

-

-

-

-

PCC Bus P.T.

-

X

-

-

-

-

-

-

-

-

ACB Outgoing

X

-

-

-

-

X

-

-

-

-

kWh MV Motor (>55kW)

-

-

-

-

-

-

-

-

-

-

MCC/ASB Incomer

X

X

-

-

-

-

-

-

-

-

MCCB/SFU O/G(250A)

X

-

-

-

-

X

-

-

-

-

LDB Incomer

X

X

-

-

-

-

-

-

-

-

DG Set

X

X

X

X

X

X

X

-

-

-

kW

kWh

kWh

NOTE 1. 2. 3. 4.

: MVA meter in Grid Incomers shall include maximum demand indication also. MW, MVAR, MVA, MVAH meters shall be provided for only Grid Incomer feeders. Field Ammeters are to be provided for all motors rated above 3.7kW. All metering shall be part of numerical relay in case of electrical system having numerical relays. Energy meter where provided separately shall be digital type. 5. Indicating lamps in switchboards shall be cluster type LED lamps as per EIL specifications.





5.0

SUBSTATION DESIGN

5.1

EHV Switchyard

Not applicable

A. Type B. Structure C. Bus material 5.2

: String bus / Tubular bus : Galvanised / Painted / RCC : Aluminium / Copper

HV/MV Substation Description

HV *

MV

Elevated with trays in cable cellar

Yes

No 12

Raised with internal trenches

Yes

Yes

All top cable entry with trays below ceiling

No

No

Pressurisation against ingress of dust

Yes

Yes

Air-conditioned room for operator

Yes

No

13

Roof slab for

Note: 1. 2.

5.3

•

Power transformer

No

No

•

Distribution transformer

No

No

* Substation with long high voltage switchboards having substantial amount of cabling work Battery room shall be preferably located in corner side at first floor of the substation building.

Specific Equipment Locations

A. Batteries Electrical switchgear batteries UPS batteries

B. Battery charger for electrical system Battery charger for instrumentation

C. D. E. F.

: In Control room along with UPS.

UPS System

: Air conditioned room in control room

Lead-Acid and Nickel-Cadmium

: In separate rooms

Annunciation panel

:

Not envisaged/ HMI annunciation Operator substation

:

Single/Double

:

Minimum oil/SF6

EQUIPMENT DESIGN

6.1

EHV Switchyard

to have room in

NOT APPLICABLE

A. Bus bar system B. Circuit breaker type C. Isolator type

: Pantograph/ Semi pantograph/ Centre rotating/ Centre break

HV Switch-board

A. B. C. D. 6.3

: In substation air conditioned room

Variable speed drive panels/Thyristor control panel : Air-conditioned room in substation

6.0

6.2

: Separate room in sub-station : Separate room in control room

Execution

:

Drawout (Fixed for GIS-33KV)

Bus bar system

:

Single /(Double bus for GIS)

Circuit breaker typ

:

SF6 /Vacuum

Motor Control

:

Breaker/ Vacuum contactor

:

1/5A

Current Transformer (CT)/potential Transformer (PT)

A. CT Secondary •

14

Protection

12

HV cables in cable cellar shall be laid in trenches filled with sand Pressurization not required for remote MCC room located in safe area 14 1A Protection CT for differential, REF protection; Separate CT for differential/ REF protection 13





Page 9 of 17 •

Metering

:

B. PT Secondary 6.4

1A (No separate metering CT except Metering CT for motor PB stn :

110 V AC

15

Transformers (Power/distribution) Transformer

Vector group

Tap changer

Soak pit

Main power transformer

Yyo/Dy1

OLTC

Yes

Generator unit transformer

Ynd 11

Off-circuit

Yes

Intermediate power transformer

Dyn 11

OLTC/Off-circuit

Yes / No

Dedicated (e.g. for VFD)

As Reqd.

Off-circuit

Yes / No

Distribution transformer

Dyn 11

Off-circuit

No

16

Preferred (kVA)

rating

(< 2000 KVA)

6.5

MV Switchboard

A. Execution i. • •

ii. iii. iv. v. • •

vi.

PCC / PMCC Breaker panels Contactor feeders MCC ASB LDB Motors PMCC MCC 17 Type of switchboard for package

:Draw out/Single front :Drawout, single / Double front :Drawout, single / Double front :Drawout /Fixed, single/Double Front :Drawout /Fixed: single/Double Front : Above 55KW Upto&Including 160kW : Upto and including 55 kW : Compartmentalised/Fixed type

B. Motor Starter Type i. Contactor and switch fuse with overload relay: Up to 22 kW ii. Contactor, switch fuse and overload relay with: Above 22 up to 55 iii. iv. v. vi. vii.

KW

CBCT for earth fault protection Contactor and switch fuse with motor protection relay : Above 55 up to 160KW Air circuit breaker with motor protection : No Contactor and MCCB with overload relay: No Contactor, MCCB and overload relay with CBCT:No for earth fault protection CT for remote metering : Motor rated above 5.5KW

C. Motor Controls18 i. Auto / Manual switch : Near motor/Switchgear/control room ii. Local/remote switch : Near motor/Switchgear/control room iii. Normal / Standby switch : Near motor/Switchgear/control room iv. Process interlock : PLC /relay panel/switchgear v. Reacceleration equipment : PLC /relay panel /switchgear vi. Control voltage for Contactor Starter : 240V AC vii. Control supply for contactor starter : Control transformer. viii. Separate transformer for each bus section: Yes/No

15

Rating of Power and intermediate transformers, OLTC requirement including vector grouping of all transformers shall be decided during basic engineering based on KSLD attached with FEED. 16 To be finalized based on licensor’s recommendation 17 Package like AC plant MCC, Bagging plant MCC etc 18 6.5C(i to iv): Operating philosophy and location of controls shall be as per process and instrumentation design basis. Format No. EIL 1641-1924 Rev. 1




Page 10 of 17

6.6

Motors Motors

High voltage

415 volts

Indoor

IP55/IP54

IP55/IP54

Outdoor

IP55

IP55

Insulation class

F (Temp. Rise limited to B)

B

Terminal box

Phase segregated/ Phase separated / Phase insulated

Anti-condensation heater

Yes

Enclosure: • •

30 kW and Above

Additional canopy (outdoor motors) Yes

Yes

Design voltage variation

± 6 % / ±3%

/

frequency ±6 % / ±3%

Note: Motors for MOV actuator shall have F class of insulation with temperature rise limited to class-B.

6.7

UPS System

A. B. C. D. E. F. G. H. I. 6.8

: 50% /100%

Type of redundancy

: Parallel redundant/Hot standby

Back-up time

: 120 minutes

Inverter bypass transformer

: Static

Bypass transfer control

: Auto / Manual

Separate fault diagnostic unit

: Yes/No

Battery type

: Lead acid/ Ni-Cd / VRLA

Type of UPS

: IGBT/Transistorised

Battery execution

/servo controlled

: Single bank up to 600 Ah/Parallel bank above 600 Ah

Communication System

A. B. C. D. E. F. G. H. I. J. 6.9

Redundancy

Plant Communication System Telephone System

19

:

Yes

:

Yes

Telephone system and plant communication system :

Separate/Integrated

No. of intercom and external P&T lines

:

Later By IOCL

Battery type for telephone system

:

Sealed Lead acid (SMF) / VRLA

Battery type for plant communication system

:

Sealed Lead acid battery / VRLA

Battery backup time

:

120 min for both systems

Interface of Communication system with fire alarm system:

Yes

Interface of PA and telephone system

:

Yes

Type of communication system

:

Digital microprocessor based

Fire Detection and Alarm System

A. B. C. D. E. F. G.

Type

: Conventional/Analogue addressable

Name of buildings to be provided with detectors

: All buildings except watch tower

Battery type

:Sealed Lead acid (SMF) /Ni-Cd/VRLA

Battery backup time

:48hrs. (Normal) + 120 minutes. (Alarm)

Detection System

: Break Glass/ Smoke, Heat, linear beam

Type of manual call point

: With/Without call back facility

Number of Sirens and location

20

: 1 Number at Main control room

19

Plant wide Telephone and LAN system shall be common. Refer design basis for LAN system for details. Siren shall be electronic type with 5 tones (as per IOCL comment clause 2.3.10 (9) on fire and safety document no. 6556-00-16-47-DB-01), Number and range shall be modified as per the availability. 20





Page 11 of 17

H. Power supply for Siren I. Any specific requirement of range

: 415 V AC/DC normal supply : 10 Km diametrical

6.10 DC System A. Battery type i. Switchgear Protection, control Control and critical lighting Instrumentation System Diesel Engine Starting 21 DC Motors

ii. iii. iv.

: Lead acid/ Ni-Cd /VRLA : Lead acid/ Ni-Cd/VRLA(automotive type) : Lead acid/ Ni-Cd /VRLA

B. Battery back up time i. Switchgear Protection

:120 minute when no DG back up and 30 minutes where DG set is available : 30 /60 /120minutes : 10Starts (FW pumps)& 6 Starts others : refer foot note

Control, Lighting Instrumentation Diesel Engine Starting DC Motors

ii. iii. iv.

: Lead acid/ Ni-Cd / VRLA

6.11 Variable frequency drive 22 i. Type of inverter 23 ii. Number of pulse iii. By pass feature required iv. VFD rated output voltage

: : : :

See foot note 6/12 Yes As per licensor/FEED reqt.

6.12 Cables The power and control cables shall have the following minimum cross sectional areas:

A. B. C. D. E.

24

Medium voltage power cable

:

25mm² (Al)/2.5 mm² (Cu)

Control cables

:

2.5 mm² (Cu)

:

2.5 mm² (Cu)

:

0.9 mm dia (Cu)

:

1.5 mm² (Cu)

25

Lighting

Communication system

26

Fire alarm system

7.0

CABLING SYSTEM

7.1

Cable details 27

Design Criteria

High voltage

415 volts

Loads located beyond 1 km

1Core/ 3 Core Cable

Cable

Loads located 200-1000 m

1-Core/ 3 Core cable

1-core cable/ 3½-core cable

Load located up to 200 m

3 Core Cable

Cable / Bus trunking

Loads beyond 1 kA rating

Bus duct / cable

Bus duct /1 core cable

Recommended limiting size of multi-core cable (mm²)

300

300

Short-circuit withstand time (seconds)

0.2 (Outgoing)/0.60 (Plant)/1.0 (Incomer)

N.A.

Insulation voltage grade

Earthed for both 33KV and 6.6KV system

Earthed

Type of cable insulation

XLPE

PVC

21

DC motor application is not envisaged Licensor’s recommendation/ EIL equipment specification shall apply 23 6 or 12 pulse rectifier as per manufacturer’s standard and as required for meeting EIL equipment specification requirement. 24 Cable for motor above 110KW shall be sized considering copper cable. 25 1.5 mm² Cu conductor PVC Insulated wire shall be used in conduit with proper colour coding for building lighting. 26 Cable sizes for PA and FA systems are indicative. These shall be finalised later as per the manufacturer’s recommendation 27 1Core or 3 Core HV cable shall be decided during basic engineering based on load and distance 22





Page 12 of 17 27

Design Criteria

High voltage

415 volts

Fire pump

Yes /No

Yes/No

Plant communication

-

Yes/No

Armour for cables inside the substation

Yes/No

Yes/No

Fire survival (Resistant) cable

7.2

28

Cable laying philosophy

A. Process area29 B. Offsite paved area30 C. Offsite unpaved area

:Overhead cable tray /RCC trench-sand filled

D. Type of cable trays E. Special requirements

:Galvanized prefabricated / Site fabricated and painted

:Above Ground cable tray on sleeper/overhead rack/ RCC trench :Above Ground cable tray (on sleeper/ overhead rack) / directly buried. (see footnote against point 7.2 above) :Cables for fire water system shall be taken on exclusive route through underground trench starting from main substation in case applicable

F. Road Crossings for under ground cables31 G. Road Crossings for above ground cables 8.0

:Overhead cable bridge/culvert/ERC

EARTHING SYSTEM

A. B. C. D. E.

Earth electrode

: GI pipe

Main earth loop material

: GI strip

Substation earth loop

: GI strip

EHV switchyard earth grid

: Not applicable

Lightning system

: As per IS2309

9.0

LIGHTING SYSTEM

9.1

Supply System

A. Centralised with separate transformer32 B. At each substation with separate transformer C. Separate metering required 9.2

:PVC Pipes /Cable culvert

: Yes/No : Yes /No : Yes/No

Control Philosophy

A. B. C. D. E. F.

Outdoor yard

: Auto /Manual/centralised (ECS) /Local 33

Street lighting

: Auto /Manual/centralised(ECS) /Local

Outdoor process area

: Auto /Manual/Centralised (ECS) / Local

Process building

: Auto/Manual/centralised/Local

Auto control

: Yes-Synchronous timer/photocell / No

Lamp type for outdoor lighting

: HPMV-Process area /HPSV-Street light, FLM/ (Incandescent type for DC/emergency Critical lighting)

G. Panel execution

34

: Lighting transformer fed LDB with OG feeders for lighting panels

28

Where fire proof MOVs are provided cables shall be fire survival type as per IEC331 or mica insulated Cables for FA/PA shall be laid in instrument duct where available and shall be in separate trays where ducts are not available in ISBL. 30 FA and PA cables in offsite area shall be laid in road berm (opposite to berm used for lighting cable). Where chemical handled are hazardous for PVC insulation, cables shall be laid above ground.In such cases. Cables shall be laid overhead on pipe rack or above ground on sleeper level depending on availability of pipe rack/ sleeper. Where there is no rack/ sleeper, cable shall be laid in trenches if cables are large and directly buried if cables are few. 31 Road crossing through PVC pipe or culvert shall be decided based on number of cables. 32 The secondary voltage for lighting transformer shall be 380V. 33 Lighting shall normally be done using 30m flood light mast as per IOCL philosophy. Street light shall be considered only where considered absolutely necessary. 34 Local control shall be through FLP lighting panel in process area. 29





Page 13 of 17

H. ELCB at Incomer of lighting and Power panels35 9.3

AC Emergency Lighting

A. Name of process plants B. Name of buildings C. Power supply 9.4

: All process Unit except U&O Pump stn : All buildings- Plant and non plant : As per CPP design basis

DC Critical Lighting For Escape

A. B. C. D. 9.5

: Yes/No

Name of process units Name of building

36

: All process units : All buildings (see footnote)

Power supply

: 220V DC

DC lighting for remote substation

: (See foot note)

Wiring Type

A. Process plant / Building / Shed B. Large service building C. Buildings with false ceiling

: Armoured cable : Concealed/ surface conduit : cables/Surface conduit above false Ceiling

D. Substation (Switchgear Room) E. Substation (Cable Cellar) F. Other buildings

9.6

: METSEC channel : Surface Conduit /armoured cable : Concealed/Surface, conduit/ cable(armoured/ unarmoured).

Specific Lighting Requirements

A. B. C. D. E. F.

Aviation lighting

:

Yes /No

Navigation lighting

:

Yes/No

Security lighting for peripheral road at boundary wall :

37

Yes/ No

Type of control gear for HPMV/HPSV Lamps

:

Separate/ Integral

Control gear box location

:

Accessible level if separate

Type of flood light mast

:

30 m Telescopic fitted tubular

10.0 ELECTRIC HEAT TRACING SYSTEM A. System Design Basis

: Product Classification /System approach

35

ELCB shall be provided at sub distribution feeder at LDB for lighting panels for AC as well as DC lighting. All buildings except remote buildings not having DC supply shall be provided with DC lighting for escape. For buildings where DC supply is not available, portable DC light for escape to be provided. 37 To be provided on watch towers through search light 36





11.0 ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS The electrical equipment for hazardous areas shall be selected as per IS-5571 and petroleum rules The minimum requirement is summarised below: Equipment

Zone-1

Zone-2

Gas Group IIA, IIB

Gas Group IIC

Gas Group IIA, IIB

Gas Group IIC

MV Motors

Ex-d

Ex-d

Ex-e/Ex-n

Ex-e/Ex-n

HV Motors

Ex-d / Ex-p

Ex-d/ Ex-p

Ex-p/Ex-e/Ex-n/

Ex-e/Ex-n

Push Button Station

Ex-d

Ex-d

Ex-d

Ex-d

Motor Starters

Ex-d

Ex-d

Ex-d

Ex-d

Plug & Socket

Ex-d

Ex-d

Ex-d

Ex-d

Welding Receptacle

Ex-d

Ex-d

Ex-d

Ex-d

Lighting Fixtures

Ex-d

Ex-d

Div.2 Ltg.

Div.2 Ltg.

(IS-8224)

(IS-8224)

i. Lighting fitting ii. Control Gear Box

Ex-d

Ex-d

Ex-e/Ex-d

Ex-e /Ex-d

Junction Boxes

Ex-d

Ex-d

Ex-e/Ex-n

Ex-e/Ex-n

i. Light fitting

Ex-d

Ex-d

Ex-d

Ex-d

ii. Transformer Unit

Ex-d

Ex-d

Ex-d

Ex-d

iii. Plug & Socket

Ex-d

Ex-d

Ex-d

Ex-d

Break Glass Unit

Ex-d

Ex-d

Ex-d

Ex-d

Ex-d

Ex-d

Ex-d

Ex-d

Hand Lamps

(Fire Alarm System) Lighting Panel/Power Panel Transformers

Hermetically sealed with surface temperature not exceeding 200°C

Notes: 1. The electrical equipment for hazardous areas shall generally be suitable for gas group IIB and temperature classification T3 as applicable to the selected type of explosion protection. In case of hydrogen or hydrocarbon mixtures having more than 30% hydrogen, the gas group to be considered shall be IIC. 2. As additional safety features, the following requirements for electrical equipment shall be followed a. All electric motors for vertical oil sump pumps including ETP area shall be flameproof type. b. Irrespective of the area classification (whether zone-1 or zone-2), all lighting fixtures within the storage areas shall be flameproof type. c. All emergency/critical lighting fixtures and associated junction boxes in hazardous areas (whether zone-1 & zone-2) shall be flameproof type. 3. Even though fired heaters in process units are not considered for area classification, all electrical equipments associated with fired heaters in process units shall as a minimum be suitable for installation in Zone-2 area. 4. Where air conditioning system is designed considering ammonia as refrigerant, the room housing air conditioning equipment shall be adequately ventilated to classify it as safe area. For additional safety the following shall be considered: a. 100% standby system for ventilation b. Location of MCC/local panels in adjacent separate room. c. Instrumentation to be flameproofs type or hermetically sealed. d. AC plant room motors with type`e' protection. e. Lighting in AC plant room suitable for zone-2 area. 5. Compressor sheds in hazardous area shall be designed to allow adequate ventilation to allow area classification as Zone-2 Lighting equipment, EOT crane etc. in the shed shall be flameproof type. All other electrical equipment shall be suitable for Zone-1 or Zone-2 area depending on extent of hazard. 6. Motors fed from variable frequency drive in hazardous area application shall be type tested as unit with the VFD panel in case of Ex(e) type of motors and provision for tripping the motor in case temperature rise exceeds the permissible limits ,shall be considered for flameproof motors as per relevant standards.





12.0 STATUTORY APPROVAL • •

Statutory Authority for Electrical Installation Hazardous area equipment

: :

Central Electrical Inspectorate CCE

13.0 CABLE SIZES FOR MV MOTORS i. Direct on line (D.O.L) start motors (2/4 pole motors)38 Motor Rating

Cable Details Number of runs

No. of cores per run

Conductor material

Conductor mm²

Below 3.7 KW

1

3

Cu

2.5

3.7 KW

1

3

Cu

4

5.5 KW

1

3

Cu

6

7.5 KW

1

3

Cu

10

9.3 KW

1

3

Cu

16

11 KW

1

3

Cu

16

15 KW

1

3

Cu

16

18.5KW

1

3

Al

35

22 KW

1

3

Al

35

30 KW

1

3

Al

50

37 KW

1

3

Al

70

45 KW

1

3

Al

95

55 KW

1

3

Al

120

75 KW

1

3

Al

185

90 KW

2

3

Al

95

110 KW

2

3

Al

120

125/132 KW

2

3

Cu

120

160 KW

2

3

Cu

120

size

ii. Cable sizes for motors not confirming to above table e.g. for 2/4 poles motors, extended distance, reduced voltage starting, low speed motors, shall be worked out on case to case basis. iii. Cables sizes as indicated above are applicable for a distance up to 350m maximum and for 2/4 poles motors fed from MCCs located near PCCs and PMCCs. iv. Cables for lighting shall be used to allow the following voltage dips •

Street lighting

:10%

•

DC critical lighting

:5%

14.0 SPECIFIC REQUIREMENTS i. Canopy shall be provided for all out door equipment. ii. Substation shall be sized to ensure 2 nos panel extension on each bus section iii. iv.

v.

vi. vii.

for all HV/ MV switchboards except GIS. Dummy panel shall be provided in switchboards wherever there is expansion joint in the building. If signal cables for DCS interface with substations are envisaged, these shall be laid in separate trays/ trench. However in exceptional cases signal cables may be laid in electrical trench, properly cleated on trench wall allowing 300mm gap with other power cables in the trench. For building engineering, each office room, in addition to switch/ socket for lighting design, shall be provided with minimum 2 nos telephone sockets and 2 number LAN socket at two different location as duly approved during detailed engineering. Modular type switches/sockets in main control room and all non plant buildings shall be modular type. Lamps shall be standardized for the purpose of inventory in hazardous area lighting as below.

38

Cable sizes given in the table are indicative and standardized for inventory and are the minimum sizes. The cable size as required to meet voltage drop criteria shall be provided. Format No. EIL 1641-1924 Rev. 1




Well glass normal Lighting : 70W HPMV lamps for well glass fittings Flood Lighting : 250W HPMV lamps for flood lighting Critical lighting : 100W GLS lamps

15.0 ATTACHMENTS Design philosophy for Electrical Facilities

6-51-0099

Rev 4

16.0 DEVIATION TO DESIGN PHILOSOPHY Document number 6-51-0099 rev 4 The requirement given under engineering design basis document shall be overriding. However following job specific requirement are highlighted as deviation to ‘Design Philosophy of Electrical facilities’ document number 6-51-0099.

16.1 Clause 4.6.1 Voltage drop i. b(ii) –MCC/Aux switchboard situated remote from PCC/PMCC – 2% ii. d - Cable between PCC/PMCC to motor- 5% during normal running 16.2 Clause 4.11 DC Power supply i. DC power supply system for electrical controls and for critical lighting shall be separate. For electrical controls and instrumentation, DC system shall be dual redundant with single set of battery and for critical lighting, DC system shall be non redundant.

16.3 Clause 4.15.3 Plant communication system-capacity for future expansion i. Exchange supplied shall be fully wired for hardware, power supply, software etc ii.

for the capacity as required with spare capacity of 20% field call stations with no future modification in exchange hardware/ software. Exchange shall have required hardware for communication between two exchange of the same make

16.4 Clause 4.16 Fire detection and alarm system i. Cl 4.16.5 : Spare fire alarm loop for future shall be 20% or 1number whichever is ii.

maximum. Each loop shall be engineered to provide the flexibility to add 20% additional detectors in future, if required. Cl 4.16.6 : The status for actuation of fire suppression system shall also be wired to fire alarm panel to annunciate at central fire alarm monitor.

16.5 Clause 5.3 Switchgear i. Cl 5.3.4 : Each HV Switchboard (above 415V and except 33KV) shall have ii.

minimum 2 numbers spares of each type. (i.e. type like transformer feeder, motor feeder, plant feeders etc) Cl 5.3.4 : Each MV Switchboard (Up to 415V) shall have 20% spares of each type ( Spares in each MCC shall however be 20% subject to 1 number of each motor feeder module )

16.6 Clause 5.7 Battery charger and Distribution board i. Cl 5.7.3 : Each DCDB shall have 20% spare feeder for future use. ii. DCDB outgoing feeders for critical lighting shall be provided with ELCB. 16.7 Clause 5.8 Uninterrupted power supply system i. Cl 5.8.4: Spare feeders in ACDB shall be 20% for future use with minimum of 1 ii.

number of each rating. Cl 5.8.5 : UPS shall be sized to have 20% spare capacity on calculated load for future loads.

16.8 Clause 5.13 Cable and Wires i. Cl 5.13.6 : No unarmored cable shall be used. ii. Cl 5.13.10 : Control cables shall have 1core spare upto 6core requirement and 20% or 2 core whichever is maximum for cables having requirement above 6 cores. Format No. EIL 1641-1924 Rev. 1




iii. iv.

For 4-20mA signal interface between switchboards and DCS, screened cable shall be used. Cl 5.13.7 : Cables laid for hazardous area shall not have any joints.

16.9 Clause 5.14 Control stations i. Cl 5.14.1 : Each motor shall be provided with local control station. If specified per process or equipment control requirement, local control station can be part of local control panel.

16.10 Clause 5.16 Actuators for motor operated valves i. MOV shall have separately mounted actuator in area of high vibrations. In particular the MOVs for Cooling water application shall have separate actuator located near the valve for local actuation.

16.11 Clause 7.2 Cabling System i. Clause 7.2.5: Cable trays shall be sized to allow 20% additional space for future ii.

cables. Clause 7.2.14: MCTs shall be provided wherever the entry is above ground. And where entry is below ground, sleeves (Laid in outward slope to avoid water entry) shall be provided for electrical cables.

16.12 Clause 7.4 Lighting system i. Non-plant buildings such as administrative building, gatehouses etc should be ii.

provided with energy efficient CFL lamp fixtures. In plant buildings, control rooms should be provided with energy efficient CFL lamp fixtures.



Electrical Design Basis_Rev 0

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