Engg Design Basis (Electrical)_Job No. A324 (Rev 5)

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ENGINEERING DESIGN BASIS(ELECTRICAL)

PROJECT : EXPANSION OF DAHEJ LNGTERMINAL FROM 10 TO 15 MMTPA

CLIENT : PETRONET LNG LIMITED, DAHEJ

DOCUMENT No.

A324-000-16-50-EDB-01Rev. 5

Page 1 of 21

5 26.2.2013REVISED INCORPORATING CLIENT COMMENTS

DTD. 21.2.13 & ISSUED FOR ENGINEERINGPS MKS MKS

4 03.12.2012REVISED AS PER MOM DTD.30.11.2012 & ISSUED

FOR ENGINEERINGPS MKS MKS





1 14.08.2012REVISED INCORPORATING CLIENT COMMENTS &

ISSUED FOR ENGINEERINGPS MKS UAP

0 24.7.2012REVISED INCORPORATING CLIENT COMMENTS &

ISSUED FOR ENGINEERING PS MKS UAP

A 28.05.2012 ISSUED FOR CLIENT’S APPROVAL/COMMENTS PS MKS UAP

Rev.No

Date PurposePrepared

byChecked

byApproved

by

Format No. EIL 1650-1296P Rev. 2 Copyright EIL – All rights reserved

ENGINEERING DESIGN BASIS

(ELECTRICAL)

PROJECT : EXPANSON OF DAHEJ LNGTERMINAL FROM 10 TO 15 MMTPA

OWNER : PETRONET LNG LIMITED

PMC : ENGINEERS INDIA IMITED

JOB NO. : A324






DOCUMENT No.

A324-000-16-50-EDB-01Rev. 5

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CONTENTS

1. SITE CONDITIONS

2. POWER SOURCE DETAILS

3. POWER SUPPLY DISTRIBUTION SYSTEM

4. PROTECTION - METERING - CONTROL

5. SUBSTATION DESIGN

6. EQUIPMENT DESIGN

7. CABLING SYSTEM

8. EARTHING SYSTEM

9. LIGHTING SYSTEM

10. ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

11. STATUTORY APPROVAL

12. CABLE SIZES FOR MV MOTORS

13. ELECTRICAL CONTROL SYSTEM

14. SPECIFIC REQUIREMENTS






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The electrical design data defines the design requirements agreed by owner/clients inaddition to EIL standard design philosophy for electrical facilities no: 6-51-0099 Rev-5(Any additional deviation must be recorded as part of this document)

1.0 Site conditions

1.1 Design Ambient : 45°C (max), 10°C (min)

1.2 Equipment design temperature (IS-9676) : 40°C

1.3 Soil Resistivity : As per Soil investigation report

1.4 Minimum temperature. for battery sizing : 10°C

1.5 Altitude above mean sea level : 10m.

2.0 Power Source Details

2.1 General

Independent system or existing system : Independent system2.2 Grid Supply (Existing)

2.2.1 Name of sub station : GETCO

2.2.2 Number of feeders ; 11

2.2.3 Length of feeder : *

2.2.4 Type /size of conductor/ cable size : XLPE /7x3Cx300 mm² (min.)

2.2.5 Voltage : 220kV±10 %

2.2.6 Frequency : 50Hz ± 3%

2.2.7 Maximum fault level : 40kA

2.2.8 Minimum fault level : 2.5kA

2.2.9 Design fault level : 40kA

2.2.10 Basic Insulation Level : 1050kV

2.2.11 System neutral Earthing : Solid

2.2.12 Minimum load power factor stipulated bysupply authority

: 0.9

2.2.13 Parallel operation of incomers : Yes/No

2.2.14 PLCC requirement : Yes/No

2.3 CPP and its configuration

2.3.1 Number of captive generators : Three2.3.2 Type of captive generators : Steam/ Gas turbine

2.3.3 Generator rating/Voltage/Power factor : 7.2 MW (Min) / 11 kV/ 0.8pf

2.3.4 Parallel operation with other sources /Grid

: Yes /No

2.3.5 Type of Neutral Earthing : Resistance

‘$’: => To be decided by EPC contractor during detail engineering.

`*’ : => Data to be provided/ confirmed by Client.

1 In existing, two nos. grid supplies are connected; one of them is to be relocated to Phase-IIIA.






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2.4 Emergency generator 2

2.4.1 Number of emergency generators : One

2.4.2 Type of emergency generators : Diesel Engine driven

2.4.3 Generator rating/Voltage/Power factor : `$’ MW / 0.415 KV / 0.8pf 2.4.4 Type of starting : Auto / Manual

2.4.5 Short time paralleling with Grid : Yes / No

3.0 Power Supply Distribution System

3.1 Voltage and frequency variation

3.1.1 AC System

Voltage : ±6 %

Frequency : ±3 %

(Refer cl. No.6.10 of this document for design voltage/frequency variation for

motors)3.1.2 DC System

Electrical protection and Control system. : ±10 %

DC critical Lighting system : ±10%

Instrumentation Power Supplies : ±10%

3.2 Utilisation voltage

3.2.1 Primary HV distribution voltage : 11KV

3.2.2 Secondary HV distribution voltage : 6.6KV

3.2.3 Primary HV distribution system neutral

Earthing

: Resistance earthed

3.2.4 Secondary HV distribution system NeutralEarthing

: Resistance earthed

3.2.5 HV motor voltage(KW more than 160KW)

(Except in tank pumps & inst air compressor)

: 6.6KV

3.2.6 MV motor voltage ( 0.18≤KW ≤160 )

(Except in tank pumps & inst air compressor)

: 415 V AC3

3.2.7 AC Motors rated below 0.18 Kw (except

MOVs)

: 240V AC

3.2.8 DC Motor : 110V/220V DC

3.2.9 Motor operated valves : 415V AC

3.2.10 Battery chargers incoming power supply : 415 V AC

3.2.11 UPS System incoming power supply : 415 V AC

3.2.12 AC Lighting/Power Panels : 415 V AC

3.2.13 Auxiliary Boards incoming power supply : 415 V AC

3.2.14 Welding Receptacles : 415 V AC

3.2.15 Bulk loads like Process Heaters etc : 415 V AC

2 Standby jetty total load to be considered as emergency load with Phase-IIIA emergency load.

3 Utilisation voltage shall be 415V for DOL motors of specified range. However, the KW-range will vary for

VFD driven motors as per process requirement.






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3.2.16 Normal Lighting/Emergency Lighting : 240V AC

3.2.17 Convenience outlets : 240V AC

3.3 Utilisation voltage for critical supplies

3.3.1 Switchgear protection control power supply

: 220V, DC

3.3.2 Critical lighting power supply : 220V, DC

3.3.3 Input power supply Plant communicationsystem

: 110V AC UPS

3.3.4 Input power supply Fire alarm systempower supply

: 110V AC UPS

3.3.5 Normal Instrumentation power supply :Refer Instrumentation design basis

3.3.6 Critical instrumentation power supply :Refer Instrumentation design basis

3.3.7 Instrumentation Shut-down system power supply

:Refer Instrumentation design basis

3.3.8 DC supply for instrumentation : Independent system

3.4 Operating philosophy

3.4.1 Auto/Manual transfer at primary HV distribution : Yes/ No (with Bus-coupler `ON’) voltage bus with momentary paralleling

3.4.2 Auto/Manual transfer at secondary HV : Yes/ No

Distribution voltage bus with momentary

Paralleling

3.4.3 Auto /Manual transfer at MV with momentary

parallelinga (At PCC/EPC/EPMCC Level) : Yes /No

b (At MCC/ASB/LDB Level) : Yes4 /No

3.4.4 Continuous Parallel operation of Incomers

a Primary HV voltage : Yes /No

b Secondary HV voltage : Yes /No

c PCC/PMCC : Yes /No

3.5 Power factor improvement capacitors : Required at Secondary HV bus

3.6 Load shedding : Yes /No

3.7 Load sharing : Yes /No4.0 Control -Protection - Metering

4.1 Control Philosophy

4.1.1 Location of Protection relays for HV switchgear

a Primary voltage HV switch gear : On switchgear/

Separate relay and control panel

b Secondary Voltage HV switchgear : On switchgear/

Separate relay and control panel

4.1.2 HV Switchgear control

a Primary voltage HV switch gear : On switchgear/Separate relay :

and control panel/ SCAP/ LMSSCADA

4 A/M Transfer will be limited to switchboards having incomers and bus-couplers equipped with ACB.






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b Secondary Voltage HV switchgear : On switchgear/Separate relay :and control panel

C Annunciation Panel : On Switchgear / SCADA (LMS)

4.1.3 Numerical Protection/Monitoringsystem for

a EHV system : N.A

b HV Switchboard : Yes / No

c 415V PMCC/PCC : Yes / No (For I/C, B/C, outgoing :breaker feeders)

d 415V MCC : Yes / No

4.1.4 Control and logic through numericalrelays

: Yes / No

4.1.5 HMI/Data concentrator panel5 :

a Human machine interface system-HMI : Yes / No

b Data concentrator panel for eachsubstation

: Yes/No

c Separate data concentrator panel for each HV/MV system

: Yes/No

d Operator cum engineering console : Yes/No

e Separate Operator console : Yes/No

f Separate Engineering console : Yes/No

g Interface with Electrical control system : Yes/No

h Location of HMI : Existing Engineering roomi Common HMI for HV /MV system : Yes/No

j Lap Top : Yes/No

4.1.6 Hardwired synchronization controlpanel

: Yes / No

4.1.7 Hard wired annunciation panel : Yes (part of LMS-SCADA) / No

Type of annunciation panel6 : Hard wired/HMI/Part of SCAP

4.1.8 Method of motor starting

a HV Motors : Direct on line

b MV Motors : DOL (VFD if required by Process)4.1.9 Starting MVA Limiting Conditions for

Motors

a HV Motors

Induction motor rated below 2MW

Induction motor rated 2MW & above

: 500% inclusive of positive tolerance

: To be decided during detail engineering

b MV Motors : 600% subject to IS/IEC tolerance

5 This panel is to be installed in existing Engineering room and to be integrated with existing system.

6Both synchronization control & annunciation to be done through LMS-SCADA.






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4.3 Relay protection system

4.3.1 Protection devices for power distribution system shall be as indicated below

(Figure inside bracket refers to note below) √ Applicable

RELAY DESCRIPTION RELAYNUMBER HV TRANSFORMERFEEDER

HVMOTORFEEDER

OUTGOINGBREAKERFEEDER

INCOMER

(SECONDARYWINDINGVOLTAGE

> 3.3 KV)

(SECONDARYWINDINGVOLTAGE

< 0.433 KV)

HVPLANT

FEEDER

MVPCC/

PMCC

HV MVPCC/

PMCC

IDMTL over-current relay 51 √ √ - √ √ √ (1) √

IDMTL earth-fault relay 51N √ (2) - - √ √ √ (1) √

51G backup earth-fault relay(secondary neutral)

51G √ √ - - - - -

Motor protection relay with

(50,50N,46,49, 50L/R, 86,95 )

99 - - √ - √ (3) - -

Instantaneous restrictedearth-fault relay (secondaryside)

64R √ √ - - - - -

Instantaneous over-currentrelay

50 √ √ - - - - -

Instantaneous earth-faultrelay

50N √ (2) √ - - - - -

Differential protection relay 87 √ (5) - √ (6) √(28) - - -

High speed tripping relay 86 √ √ √ √ √ √ √

Trip circuit supervision relay 95 √ √ √ √ - √ √

Transformer auxiliary relay 63 √ √ - - - - -

Under-voltage relay with timer 27/2 - - (13) - - √ (9) √ (9)

Check synchronisation relay 25 - - - - - √ (10) √(10)






DOCUMENT No.

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4.3.2 Power generation and External power supply

Minimum protection relays for Synchronous generator (GTG/STG), generator transformer National power supply incomer and Synchronous motors shall be asfollows √ Applicable

RELAYDESCRIPTION

NEMA

CODE

GENERATOR GENERATORTRANSFORMER

HV/EHVINCOMER

HV / EHVTRANSFO-

RMER

SYNMOTOR

Distance protection 21 NA NA NA

Synchronous check 25 NA NA NA

U/V with timer 27 NA NA NA

Reverse power 32 NA NA NA

Low power flow 37 NA NA NA

Loss of excitation 40 NA NA NA

Negative sequence 46 NA NA NAOver current 50 NA NA NA

Earth fault relay 50N NA NA NA

Over current 51 NA NA NA

Voltage restrained o/c 51V NA NA NA

Earth Fault back up 51G NA NA NA

Over current E/F 51N NA NA NA

Over voltage withtimer

59 NA NA NA

VT failure 60 NA NA NA

Auxiliary relay for transformer

63TX NA NA NA

Transformer Restricted Earth Fault

64R NA NA NA

Stator back up earthfault

64G NA NA NA

Rotor Earth fault 64R NA NA NA

Directional O/C 67 NA NA NA

Directional E/F 67N NA NA NA

Under frequency/df/dt 81 NA NA NA

Tripping relay 86 NA NA NA

Generator differential 87G NA NA NA

Gen. and Transformer differential

87GT NA NA NA

Transformer differential

87T NA NA NA

Feeder differential 87F NA NA NA

Bus bar differentialand check

87B/87CH

NA NA NA

Trip circuit supervision 95 NA NA NA

Dead bus chargingrelay

98 NA NA NA

Over fluxing 99 NA NA NA






DOCUMENT No.

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Notes:

1. In case of HV switchboards with continuous parallel operation of incomers, followingadditional relays shall be provided:

a. One set of 87B (Bus differential) and 95 B (Bus wire supervision) for each bussection & 86 (lockout) for ach bus section.

b. 67 and 67N (Directional IDMTL over current and earth fault) relays for theincomers.

2. Instantaneous earth fault (50N) shall be provided only for transformer with deltaprimary.

3. For motor feeders rated 75 kW & above. Relay 50 shall not be provided for contactor controlled feeders

4. Directional IDMTL earth fault (67N) shall be provided for transformer with star primary.

5. For transformers rated 5 MVA and above

6. For motors rated 1500 kW and above.7. Trip circuit supervision relay 95 shall be provided as part of the numerical relay for MV

feeders wherever numerical relays are provided

8. Wherever auto-transfer feature is provided

9. For switchgears where continuous or momentary paralleling of Incomers isenvisaged, check synchronising relay shall be integrated with overall parallelingscheme.

10. 51G and 64R relays shall not be provided for input transformer of VFD system.

11. The bus tie feeders in HV switchboards & MV PCC/PMCC shall be provided with 51,51N, 86, 95& 25 (Check synchronizing) relays & timer (5 min) for delayed closing.

12. HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage), 60

(Neutral displacement), 86 and 95 relays.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 capacitor feeders

b. HV and MV breaker controlled motor feeders

c. Contactor controlled motor feeders with DC control supply.

Numerical relays where ever provided for motor and capacitor feeders shall use inbuilt under voltage relay and timer for delayed tripping on bus under voltage.

14. One no. DC supply supervision relay (80) shall be provided for each incoming DCsupply to the switchboard.

15. 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 generationbuses

16. In case of numerical relays, all relays shall be comprehensive units including allprotection, metering and control unless other wise specified.

17. Under voltage and over voltage along with associated timer shall be part of thenumerical relays..

18. Auto changeover logic between Incomers and bus coupler shall be built in thenumerical relay.

19. Tripping relays (86) & Trip Circuit supervision relay (95) shall be part of numericalrelay.

20. 2Nos of 86 relays shall be considered for HV and MV motor rated 75KW & above and

it shall be part of the Numerical relays wherever provided.21. Breaker control switch shall be hardwired type.






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22. Stand by earth fault relay 51G shall be provided in the incomer of switchboard fedfrom transformers and transformer and switchboard located remotely from HVsubstation.

23. Restricted earth fault relay 64R shall be provided in the incomer of switchboard fedfrom transformers having secondary voltage greater than 3.3KV and secondarywinding is star connected.

24. Relay 51V voltage controlled over current relay shall be provided on specificrequirement considering the rating of the outgoing feeders with respect to the Incomer rating. Generally this relay shall be provided wherever CT primary current of outgoingfeeders is exceeding 40% of the CT primary current of the Incomer.

25. 415V DG set shall be provided with protection but not limited to51V,51G,40,46,86,95,80 , 64R etc for generator rated above 500KVA and Generator rated less than 500KVA shall have 51V,51G,40,46,86,95,80 unless other wise agreedwith the owner.

26. All the 415V outgoing feeders (switch fuse/ MCCB) rated 100A and above in all MV

switchboards shall be provided with CBCT & earth leakage protection.27. All relays shall be with IEC-61850 protocol (numerical relay).

28. 11KV plant feeders connected to CPP Bus (Future).

4.4 Metering

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

Type of metering : Digital/As part of the Numerical relay

FEEDER TYPE A V Hz PF MW MWH HM MVAR MVAH MVA

HV Incomer - (1)

HV Bus Tie - - - - - - - - -

HV Transformer -

HV Bus P.T. - - - - - - - - -

HV Plant Feeder -

HV Motor

HV Capacitor - - - - - - -

PCC/PMCC Incomer -

PCC/PMCC Bus Tie - - - - - - - - -

PCC Bus P.T. - - - - - - - - -

ACB Outgoing( Non motor)

-

MV Motor (>75kW)

MCC/ASB Incomer -

MCCB/SFUO/G(250A)

- - - - - - - -

MCCB/ ASB Bus tiefeeder

- - - - - - - - -

LDB Incomer - - - - - - -

DG Set-MV kW kWh - - -






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Metering for generator shall not be limited to following.

Meter HV Generator Generator

transformer Ammeter 3nos NA

Voltmeter with selector switch NA

MW meter NA

MVAR meter NA

MVA meter NA

MWH meter NA

MVARH meter NA

Power factor NA

Frequency meter NA

Notes:

1. MVA meter in grid incomers shall include maximum demand indication also.

2. Field Ammeters are to be provided for all motors rated above 5.5kW.

3. All metering shall be part of numerical relay in case of electrical system havingnumerical relays.

5.0 Substation Design

5.1 EHV Switchyard/Substation : Not Applicable (Existing)

5.4.1 Type :5.4.2 Type of bus :

5.4.3 Structure for outdoor ;

5.4.4 Bus material :

5.2 Substation feature

Description HV MV

5.2.1 Elevated with trays in cable cellar 7 Yes/No Yes/No

5.2.2 Raised with internal trenches Yes/No Yes/No

5.2.3 All top cable entry with trays belowceiling Yes/No Yes/No

5.2.4 Air-conditioning against ingress of dust

Yes/No Yes/No

5.2.5 Air-conditioned room for operator Yes/No Yes/No

5.2.6 Roof slab for

a Power transformer Yes/No N.A

b Distribution transformer Yes/No Yes/No

7 In cable cellar, the bottom most level of cable tray shall be minimum 2.5m.






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5.3 Specific Equipment Locations

5.3.1 Batteries in substation and controlRooms

: Separate room

5.3.2 Battery charger in substation : Air conditioned /non air conditioned room5.3.3 Battery charger in control room :Air conditioned /non air conditioned room

5.3.4 Variable speed drive panels :Air-conditioned room in substation

5.3.5 Thyristor controlled panels :Air-conditioned room in substation

5.3.6 UPS System :Air conditioned room in control room

5.3.7 Lead-Acid and Nickel- Cadmium

:Separate room/common room

5.3.8 Location of VRLA battery : Air conditioned room

6.0 Equipment Design

6.1 EHV Outdoor Switchyard Not Applicable (Existing)

6.2 HV Switchboard

6.2.1 Execution : Draw out/Fixed

6.2.2 Type of switchgear : Gas insulated/Air insulated

6.2.3 Bus bar : Single bus/Double bus

6.2.4 Circuit breaker type : SF6 /Vacuum

6.2.5 Motor Control : Breaker/Vacuum contactor

6.3 Current Transformer (CT)/Potential Transformer (PT)

6.3.1 CT Secondary

a General Protection : 1A

b Metering : 1A

6.3.2 PT Secondary : 110 V AC

6.4 Transformers (Power/distribution)

Transformer Vector group

Tapchanger

Soak pit Preferredrating (KVA)

6.4.1 Power transformer Dyn 11 Off-circuit/

OLTC

See Note

Below

As per IS

6.4.2 Dedicated (e.g. for VFD) As Reqd. Off-circuit As per IS

6.4.3 Distribution transformer

(≤ 2500 KVA)

Dyn 11 Off-circuit See NoteBelow

As per IS

Note: Soak pit shall be provided as per the following condition:

a). Oil quantity<2000 lit : Not required

b). 2000lit<Oil qty<9000 lit : Soak pit

c). Oil qty>9000lit : Soak pit + Collection pit

6.5 MV Switchboard

6.5.1 Execution

6.5.1.1 PCC / PMCC

a Breaker panels :Draw out, Single front

b Contactor feeders :Draw out, single / Double front






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6.5.1.2 MCC :Draw out , single/Double Front

6.5.1.3 ASB Draw out /Fixed , single /Double Front

6.5.1.4 LDB Fixed: single front

6.5.1.5 Motors

PMCC :Above 55kW

MCC : Up to 55 kW

6.5.1.6 Type of switchboard for small package

(HVAC, Pressurisation system etc.)

:Compartmentalised and Fixed type / NonCompartmentalised and Fixed type

6.6 Medium voltage Motor Starter type

6.6.1 Contactor and switch fuse withoverload relay

: Up to 22 kW

6.6.2 Contactor, switch fuse and overload

relay with CBCT for earth faultprotection

: > 22KW up to 55KW8

6.6.3 Contactor and switch fuse with motor protection relay

: Not Applicable

6.6.4 Air circuit breaker with motor protection relay

: ≥75 KW

6.6.5 Contactor and MCCB with overloadrelay

: Not applicable

6.6.6 Contactor, MCCB and overload relaywith CBCT for earth fault protection

: Not applicable

6.7 Medium voltage Outgoing feeder Type

6.7.1 Switch fuse : Up to 63A

6.7.2 Switch fuse with Contactor and CBCTfor earth fault protection

: More than 63A and up to 400A

6.7.3 MCCB with Contactor and CBCT for earth fault protection

: Not applicable

6.7.4 MCCB : Not applicable

6.8 Motor Controls : As per process package and

operating philosophy

6.8.1 Auto / Manual switch :Near motor/Switchgear/control room (#)6.8.2 Local/remote switch :Near motor/Switchgear/control room (#)

6.8.3 Normal / Standby switch :Near motor/Switchgear/control room (#)

6.8.4 Process interlock :PLC /relay panel/ switchgear (#)

6.8.5 Reacceleration equipment :PLC /relay panel/ switchgear (#)

(#) As per process requirement

6.9 Control supply voltage

6.9.1 Breaker control : 220V DC

6.9.2 Breaker spring charging : 240V AC for VCB

240 V AC for ACB (415 V Swbd)

6.9.3 Contactor feeder 240V AC

8 However, Motor starter shall be with numerical type motor protection relay for all Air Heater Fan motors.






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6.9.4 Control supply for earth fault relay incontactor feeder

: 220V DC

6.9.5 Control supply for contactor motor

starter

:Control transformer/Tapping of P-N of

respective feeders

6.10 Motors

Motors High voltage 415 volts

6.10.1 Enclosure

Indoor IP55/IP54 IP55/IP54

Outdoor IP55 IP55

6.10.2 Insulation class F (Temp. Rise limited to B) F (Temp. Rise limited to B)

6.10.3 Anti-condensation heater Yes Above 22KW

6.10.4 Additional canopy – FRPtype (outdoor motors)

Yes Yes

6.10.5 Design voltage variation ±6 % / ±10% ±6 % / ±10%

6.10.6 Design frequency variation ±3 % / ±5% ± 3 % / ±5%

6.10.7 Combined voltage /frequency variation (Design)

±10 %

Any combination of above

±10 %

Any combination of above

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

6.11 UPS System

6.11.1 Redundancy :50% /100%

6.11.2 Type of redundancy :Parallel redundant/Hot standby

6.11.3 Back-up time :240minutes

6.11.4 Inverter bypass transformer : server controlled/ Static

6.11.5 Bypass transfer control :Auto / Manual

6.11.6 Separate fault diagnostic unit :Yes / No

6.11.7 Battery type :Lead acid/Ni-Cd/VRLA

6.11.8 Type of UPS :IGBT/Transistorised

6.11.9 Battery execution : Single up to 600Ah.Parallel bank above 600Ah

(Redundant battery bank)

6.12 Communication System

6.12.1 Plant Communication System : Yes/No

6.12.2 Telephone System : Yes/No

6.12.3 Telephone system and plantCommunication system

:Separate/Integrated

6.12.4 No. of intercom & external P&T lines :60/10 (Minimum)6.12.5 No. of field call stations/ master call

stations:30/1 (Minimum)

6.12.6 Battery type : Lead acid/ Ni-Cd/ Sealedmaintenance free






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6.12.7 Battery backup time for telephone system :6 hours

6.12.8 Battery backup time for plantcommunication system

:30 minutes

6.13 Fire Detection and Alarm System9

6.13.1 Type : Analogue Addressable

6.13.2 Name of buildings to be provided with Automatic detectors

: Substation, control room,other buildings as required

6.13.3 Battery type10 : Lead acid/ Ni-Cd/ SealedMaintenance type

6.13.4 Battery backup time (Alarm) : 4 hours

6.13.5 Detection System : Break Glass, Smoke and

heat Detector

6.14 DC System

6.14.1 Battery type

a Switchgear Protection Control and criticallighting

: Lead acid/Ni-Cd/VRLA

b Instrumentation System : Lead acid/Ni-Cd/VRLA

c Diesel Engine Starting : Lead acid/ Ni-Cd/VRLA

d DC Motors : Lead acid/Ni-Cd/VRLA

e Telephone system : Lead acid/Ni-Cd/VRLA

6.14.2 Battery back up time

a Switchgear Protection and Control : 30/60/120 minute

b DC Critical lighting : 30/60/120 minute

c Instrumentation : 240 minutes

d Diesel Engine Starting : 10 starts (FW pumps) & 6

starts (others)

e DC Motors for emergency lube oil pumpsetc

: As per equipment supplier

recommendation.

6.15 Cables

The power and control cables shall have the following minimum cross sectionalareas:

6.15.1 Medium voltage power cable : 35mm² (Al.) / 2.5 mm² (Cu)

6.15.2 Control cables : 2.5 mm² (Copper)

6.15.3 Lighting : 2.5 mm² (Copper)

6.15.4 Communication system : 0.9 mm dia (Copper)

6.15.5 Fire alarm system : 1.5 mm² (Copper)

Notes:

9Fire Detection and alarm system of all buildings shall be integrated with plant FGS system through

TCP/IP modbus communication.10

Input power supply for Fire Alarm system shall be obtained from the 110V AC UPS (2-U-10-3001)

having Ni-Cd battery back up of 4 hours.






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1. For lighting inside the building, minimum 1.5 mm² copper conductor, PVC Insulatedwire shall be used in conduit system (for circuit and point wiring), with proper colour coding.

2. Special cable type and size shall be decided on specific requirement.

3. All power cables upto 16mm² shall be of copper conductor.

7.0 Cabling System

7.1 Cable details

Design Criteria High voltage 415 volts

Loads located beyond 1 km Cable -

Loads located 200-1000 m 1-core cable/ 3-core cable 1-core / 3½-corecable

Load located up to 200 m Cable Cable / Bus

trunkingLoads beyond 1000A rating andlocated near the transformer.

Bus duct /1 core cable Bus duct /1 corecable

Recommended limiting size of multi-core cable (mm²)

300 300

Short-circuit withstand time(seconds)

Incomer from transformer :1

Incomer from other swboard:0.6 Plant feeder:0.6

Motor/Transformer feeder:0.2

Not Applicable

Insulation voltage grade Earthed/Unearthed EarthedType of cable insulation XLPE XLPE

Conductor Copper or Aluminium Copper up to 10sqmm & Aluminium

above 16 sqmm

Fire survival (Resistant) cable

Fire pump

Plant communication

MOV (J.B box to MOV) for crude/product tank isolation and as per

process requirement

Yes

-

-

Yes

Yes

Yes

7.2 Cable laying philosophy

7.2.1 Process area :Overhead cable tray /RCC trench

7.2.2 Offsite paved area :Above Ground cable tray on sleeper/Overhead rack/RCC trench

7.2.3 Offsite unpaved area : Overhead cable tray/lined trench/ RCCTrench.

7.2.4 Offsite lighting, FA & communication : Directly buried in road berm.

cables

7.2.5 Cables for non hazardous area : Armoured/ Un armoured

7.2.6 Type of cable trays :Galvanized prefabricated /Sitefabricated and painted/FRP type / SS

7.2.7 Road Crossings for undergroundcables

:PVC Pipes /Cable culvert/ undergroundcable duct






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7.2.8 Road Crossings for Above groundcables

:Overhead cable bridge/culvert

Note: Plant communication, fire alarm and telephone cables shall be laid in overhead

cable trays / instrumentation trenches as far possible. In case these are notavailable. Cable shall be laid along berm of the roads.

8.0 Earthing System

8.1 Earth electrode : GI pipe

8.2 Main earth loop material : GI strip

8.3 Substation earth loop : GI strip

8.4 EHV switchyard earth grid : Not Applicable

8.5 Above ground equipment earth : PVC insulated (green) copper

cable connections

8.6 Lightning conductor : As per IS:2309

9.0 Lighting System

9.1 Supply System

9.1.1 Centralised with separate transformer : No

9.1.2 At each substation with separate transformer : Yes

9.1.3 Separate metering required : Yes

9.2 Control Philosophy

9.2.1 Outdoor yard :Auto/Manual/centralised/Local

9.2.2 Street lighting :Auto/Manual/centralised/Local

9.2.3 Outdoor process area :Auto/Manual/centralised/Local9.2.4 Process building :Manual/centralised/Local

9.2.5 Auto control :Synchronous timer/photocell/ECS

9.2.6 Lamp type for outdoor lighting :HPMV/HPSV

9.2.7 ELCB at Incomer of lighting and Power Panels

:Yes/No

9.2.8 Panel execution : ASB fed fuse board/ ASB for MCBpanels/ Lighting transformer fedLDB connected to MCB panels

9.2.9 ELCB at each street lighting pole : Yes

9.3 AC Emergency Lighting

9.3.1 Name of process plants :25% of all process area

9.3.2 Name of buildings :25% of all buildings

9.3.3 Power supply source :Captive Generator/ DieselGenerator/ External

9.4 DC Critical Lighting for Escape

9.4.1 Name of process units :Nil

9.4.2 Name of building :Substation, control room, FW

pump house, fire station, GTGbuilding, DG room

9.4.3 Power supply :220V DC






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9.5 Wiring Type

9.5.1 Process plant / Building / Shed :Armoured cable

9.5.2 Large service building :Concealed conduit

9.5.3 Buildings with false ceiling :Cables/GI conduit above falseceiling & concealed conduit belowfalse ceiling

9.5.4 Substation (Switchgear Room) :METSEC channel/Concealedconduit (as applicable)

9.5.5 Substation (Cable Cellar) :Surface Conduit/armoured cable

9.5.6 Other buildings in safe area : Surface cable (armoured)/Surface conduit/ concealed conduit

9.6 Specific Lighting Requirements

9.6.1 Aviation lighting : Yes /No9.6.2 Navigation lighting : Yes /No

9.6.3 Security lighting for peripheral road boundarywall

:Required/Not Required

(with Metal halide lamps)

9.6.4 Type of control gear for HPMV/HPSV lamps :Separate/Integral

9.6.5 Control gear box location :Near fixture/Accessible level

9.6.6 Type of high mast flood light :30 meters Telescopic tubular /

Lattice structural mast






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10.0 Electrical Equipment for Hazardous Areas

10.1 The electrical equipments for Hazardous areas shall be selected as per electricalspecification that are part of the bid package

10.2 The electrical equipment for hazardous areas shall be selected as per IS-5571 andpetroleum rules and Gas group shall be selected based on the hazardous areaclassification. The minimum requirement is summarised below:

Equipment Zone-1 Zone-2

MV Motors Ex-d Ex-n

HV Motors Ex-d / Ex-p Ex-n

Push Button Station Ex-d Ex-d

Motor Starters Ex-d Ex-d

Plug & Socket Ex-d Ex-d

Welding Receptacle Ex-d Ex-d

Lighting fitting Ex-d Ex-e/ Ex-nR

Control Gear Box Ex-d Ex-d/Ex-e/ Ex-nR

Junction Boxes Ex-d Ex-n

Hand lamps

i). Light fitting

ii). Transformer Unit

iii). Plug & Socket

Ex-d

Ex-d

Ex-d

Ex-d

Ex-d

Ex-d

Break Glass Unit

(Fire Alarm System)

Ex-d Ex-d

Lighting Panel/Power Panel

Ex-d Ex-d

Transformers Hermetically sealed with surface temperature notexceeding 200ºC

Notes:

1.0 The electrical equipment for hazardous areas shall generally be suitable for gas groupIIB and temp classification T3 as applicable to the selected type of explosion protection.In case of hydrogen or hydrocarbon mixtures having more than 30% hydrogen, the gasgroup to be considered shall be IIC, besides IIA & IIB.

2.0 As additional safety features, the following requirements for electrical equipment shallbe followed

2.1 All electric motors for agitators/mixers and metering pumps handling flammablematerial shall be flameproof type irrespective of the area being classified as zone-2 or zone-1.

2.2 All electric motors for vertical sump pumps handling flammable material shall beflameproof type.

2.3 Irrespective of the area classification (whether zone-1 or zone-2), all lighting fixtures

within the storage areas shall be flameproof type.2.4 Irrespective of the area classification (whether zone-1 or zone-2), all motors and

lighting fittings within the pump house / station associated with storage area and withinthe loading/unloading gantries shall be of flameproof type.






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2.5 All emergency/critical lighting fixtures and associated junction boxes in hazardousareas (whether zone-1 and zone-2) shall be flameproof type.

2.6 All portable equipments to be used in zone-1 & zone-2 shall be ‘Ex-d’ type. 2.7 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 minimumbe suitable for installation in Zone-2 area. In furnace area, the gas group shall beconsidered as IIC apart from IIA, IIB and temperature class shall be T3.

2.8 Where air conditioning system is designed considering ammonia as refrigerant, theroom housing air conditioning equipment shall be adequately ventilated to classify it assafe area. For additional safety the following shall be considered:

- 100% standby system for ventilation

- Location of MCC/local panels in adjacent separate room.

- Instrumentation to be flameproof type or hermetically sealed.

- AC plant room motors with type`e' protection.

- Lighting in AC plant room suitable for zone-2 area.2.10 Building such as Compressor sheds inside the process area shall be designed to allow

adequate ventilation to allow area classification as Zone-2.Lighting equipment, EOTcrane etc. in the shed shall be flameproof type. All other electrical equipment shall besuitable for Zone-1 or Zone-2 area depending on extent of hazard.

2.11 All motors for hazardous area Zone-1 shall preferably be flameproof type. Pressurisedmotors may be provided in exceptional cases.

2.12 Ex-n motors shall be without prestart ventilation as permitted by Indian Standard unlessany other type is specified by Process Licensor except for following cases as listedbelow:

Ex-d motors shall be used in Zone-2 areas for HV motors for centrifugal

compressors. Ex-d motors shall be used in Zone-2 areas for motors having frequent start/stop

requirements e.g. EOT cranes, Elevators, MOV actuators etc.

2.13 Ex-n motors with prestart ventilation provision or Ex-d or Ex-p motors shall be used inZone-2 areas for application having average starting frequency more than 1 per week,where rating of motor is more than 100KW.

2.14 Imported electrical equipment for Zone-2 areas may be either be increased safety typeor flameproof type.

11.0 Statutory Approval

Statutory Authority for Electrical Installation: State Electrical Inspectorate/CEA

Statutory authority for hazardous area : PESO/CIMFR






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12.0 CABLE SIZES FOR 415V MOTORS

12.1 Direct on line (D.O.L) start motors (2/4 pole motors)

MOTOR

RATING

CABLE DETAILS

NUMBER OFRUNS

NO. OFCORES

PER RUN

CONDUCTORMATERIAL

CONDUCTOR SIZE (

MM²)

Below 3.7 KW 1 3 Cu 4

3.7 KW 1 3 Cu 6

5.5 KW 1 3 Cu 10

7.5 KW 1 3 Cu 10

9.3 KW 1 3 Al 25

11 KW 1 3 Al 25

15 KW 1 3 Al 2518.5KW 1 3 Al 35

22 KW 1 3 Al 50

30 KW 1 3 Al 70

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 KW 2 3 Al 150

132/160 KW 2 3 Al 185

12.2 Cables sizes as indicated above are applicable for a distance of 350m maximum andfor 2/4 poles motors fed from MCCs located near PCCs and PMCCs.

12.3 Cable sizes for motors not confirming to above table (e.g. for 2/4 poles motors ratedup to 160kw), extended distance, reduced voltage starting ,low speed motors, VFDdriven etc. shall be worked out on case to case basis.

12.4 The cable sizes mentioned above are minimum sizes. Actual sizes shall be finalisedduring detail engineering considering meet specification & cable laying requirements.

13.0 Electrical Control System-ECS: Not Applicable

14.0 Specific requirements

14.1 Cables for lighting shall be sized to allow the following voltage drops:

-Street Lighting:5%

- DC Critical Lighting: 5%

14.2 Philosophy of provision of spare feeders in HV/MV switchboards shall be 20% subjectto minimum of 1 of each type. However, in the main 11KV switchboard, besidesnormal spares, additionally 2 nos. (1L + 1R) outgoing plant feeders shall be provided.

Documents

Engg Design Basis (Electrical)_Job No. A324 (Rev 5)