Design Basis

DOC NO.
1061-SMI-E-DB-1001
CLIENT: SAUDI MARJAN INDUSTRIES, JEDDAH, KSA PROJECT NO. 1061
SHEET NO. 1 of 30
PROJECT USED LUBE OIL RE-REFINING

EPC TITLE AND HYDROGENATION PLANT
CONTRACTOR: JEDDAH, KINGDOM OF SAUDI
CHEMIE - TECH DMCC LOCATION
ARABIA
ELECTRICAL DESIGN BASIS
REVISION
C 08-08-2018 Issued for Design A.J.D T.D S.S
B 20-09-2016 Issued for Approval H.N.P K.N.P D.P.B
A 04-04-2016 Issued for Review/Approval H.N.P D.P.B D.P.B

REVISION PREPARED CHECKED APPROVED
DATE DESCRIPTIONS
NO BY BY BY
SAUDI MARJAN INDUSTRIES,
JEDDAH, KSA ELECTRICAL DESIGN BASIS
Project No.: 1061 1061-SMI-E-DB-1001
Table of Contents
1. INTRODUCTION .................................................................................................................. 3
1.1. Project Summary ................................................................................................................ 3
1.2. Project Objective ................................................................................................................ 3
2. SCOPE OF WORK .............................................................................................................. 4
2.1. Definitions / Abbreviations ................................................................................................ 4
2.2. Statutory Requirements, Codes & Standards .................................................................. 5
3. SITE CONDITION ................................................................................................................ 7
4. ELECTRICAL SYSTEM DESIGN ........................................................................................ 8
4.1. Plant Power Source Details ............................................................................................... 8
4.2. Supply System Parameters ............................................................................................... 9
4.3. System Earthing Details .................................................................................................... 9
4.4. System Voltage and Circuit Parameters ........................................................................... 9
4.5. Permissible Voltage Drops ...............................................................................................10
4.6. Protection Philosophy ......................................................................................................11
5. AREA CLASSIFICATION ...................................................................................................13
6. EQUIPMENT DESIGN PHILOSOPHY ................................................................................13
6.1. Transformer .......................................................................................................................14
6.2. Emergency Diesel Generator ...........................................................................................14
6.3. MV and LV Switchgear ......................................................................................................14
6.4. Power Factor Improvement System .................................................................................16
6.5. Electric Motors ..................................................................................................................17
6.6. DC System .........................................................................................................................18
6.7. Uninterruptible Power Supply System .............................................................................18
6.8. Batteries.............................................................................................................................19
6.9. Lighting System ................................................................................................................19
6.10. Socket Outlets ...................................................................................................................22
6.11. Local Control Station ........................................................................................................22
6.12. Cable Glands .....................................................................................................................22
6.13. Earthing and Lightning Protection System .....................................................................23
6.14. Cables, Cable Tray and cable laying ................................................................................26
6.15. Neutral Grounding Resistor .............................................................................................28
6.16. Low Voltage Bus duct ......................................................................................................28
7. ELECTRICAL SUBSTATION BUILDING ...........................................................................29
8. INSTALLATION, TESTING AND COMMISSIONING ..........................................................29
ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_C Dt. 12/01/2018) Page 2 of 30

THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER
WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.
1. INTRODUCTION
Saudi Marjan Industries has planned to setup a Used Lube Oil Re Refining Plant at Jeddah,
K.S.A with Capacity of Flash Distillation Plant to process feed of 200 MT/day Used Lube Oil.
Flash Distillation output (From FFE / WFE) Capacity shall be 150 MT/day. The Output of
Hydro-treatment Unit is 147 MT/day of Base Oil with API Grade II or II+ quality.
Chemie Tech DMCC has been appointed as an EPC contractor for Basic & Detailed
Engineering, Procurement & Supply, Installation, Testing and Commissioning of 200 MT/Day
Capacity Used Lube Oil Re-refining Plant at Jeddah, K.S.A.
Chemie Tech DMCC, Dubai (EPC Contractor) has appointed M/s Green Industrial
Technologies (GIT-Greece) as a consultant for Basic Engineering of Hydro Treatment (HDT)
Plant.
1.1. Project Summary
Project Name Used Lube Oil Re-Refining Plant
Project Number 1061
Project Location Jeddah, K.S.A
Comapany Saudi Marjan Industries
EPC Contractor Chemie-Tech DMCC
1.2. Project Objective
This Electrical Design basis describes the Used Lube Oil Re-Refining design criteria
implanted to carry out Design Engineering for Used Lube oil Re-refining Plant. Also for the
development of Detailed Engineering specifications
The Re refining of Lube Oil shall be carried out by following Plants:
• Flash Distillation Plant

• Hydrotreatment Plant
The Process is intended to Recover Lube Oil as an intermediate product from the used
lubricating oil. The recovered Lube Oil will be sent to Hydrotreatment process to produce
lube oil base stock of API Grade - II or API Grade - II+.
The objective here is to resourcefully use the collected used lubricating oil for producing
base oil of API Gr-II Or API Gr-II+. Through various processes we will be removing

contaminants like free solids, water, light ends / Diesel (light Oil) in order to reclaim 70-75 %
lube oil base stock.
A further process of refining (Hydro-treatment & fractionation), finished products will be

produce and by-products obtained from the process are asphalt and Diesel (Light Oil) which
are also saleable products.
2. SCOPE OF WORK
The purpose of this document is to set out a Basis of Engineering & Design of electrical
system of the project in respect of:
▪ Design Philosophy
▪ Electrical Parameters
▪ Equipment Requirements
▪ Safety Considerations
This document is intended as a guide for design engineering and to specify the requirements
for this project.
2.1. Definitions / Abbreviations
AC : Alternating Current
C ACB : Air Circuit Breaker
APFC : Automatic Power Factor Correction
ASPB : Auxiliary Supply Panel Board

ATS : Automatic Transfer Switch
CR : Control Room
CT : Current Transformer
DC : Direct Current
DCDB : DC Distribution Board
DG : Emergency Diesel Generator
Hz : Hertz
FAT : Factory Acceptance Test
FR : Flame Retardant
IP : Ingress Protection
JB : Junction Box
LCS : Local Control Station

LDB : Lighting Distribution Board
LV : Low Voltage
C MCCB : Moulded Case Circuit Breaker
MCC : Motor Control Centre
MLDB : Main Lighting Distribution Board
MV : Medium Voltage
PDB : Power Distribution Board
PLC : Programmable Logic Controller
PT : Potential Transformer
PVC : Polyvinyl Chloride
SAT : Site Acceptance Test
SCADA : Supervisory Control and Data Acquisition System
SPN : Single Phase Neutral
SS : Substation
UPS : Uninterruptible Power Supply
VCB : Vacuum circuit breaker
XLPE : Cross (X) Linked Poly Ethylene
2.2. Statutory Requirements, Codes & Standards
The design and the installation shall be in accordance with established codes, good
engineering practices and shall confirm to the statutory regulations applicable in the country.
Latest IEC standards are to be followed for all electrical equipment/ component design.
The main codes, standards and statutory regulations considered as minimum requirements
are as given below. Latest version of these shall be followed:
▪ International Electro-technical Commission (IEC)

▪ Atmospheres Explosives (ATEX)
▪ National Electrical Manufacturers Association (NEMA)
▪ Institute of electrical & electronics engineers (IEEE)
▪ National Fire Protection Association (NFPA)
The design and terminology shall comply as a minimum with the latest editions of the
engineering codes, standards and practices as below. However system/equipment design
shall be in line with latest of all applicable standards-

Codes Description
IEC 60027-1 Letter symbols to be used in electrical technology Part-1
IEC 60034 Rotating electrical machines (All Applicable Parts)
Standard voltages for use in low voltage and high voltage AC
IEC 60038
electricity supply systems.
IEC 60079 Electrical apparatus for Explosive gas atmospheres
IEC 60255 Electrical relays
IEC 60309 Plugs, socket-outlets and couplers for industrial
IEC 60364 Low-voltage electrical installations

IEC 60417 Graphical symbols for use on equipment
IEC 60598 Luminaires
Power cables with extruded insulation and their accessories for rated
IEC 60502-1/2/4
voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36kV)
IEC 60529 Degree of protection provided by enclosure
IEC 60662 High-Pressure Sodium Vapour Lamps

Low-Voltage Power Supply Devices, D.C. Output -Performance
IEC 61204
Characteristics
IEC 61439 Low Voltage Switchgear and Control gear Assemblies
Uninterruptible Power Systems (UPS) Part 1-1: General and Safety
IEC 62040-1
Requirements for UPS used in operator access areas
IEC 62305 Protection against lightning
Industrial systems, installation and equipment and industrial products
IEC 81346
– structuring principles and reference designations.
Stationary lead-acid batteries. General requirements and methods of
IEC 60896
test. Valve regulated types
Recommended Practice for the classification of Locations for Electrical
API RP-505 Installations at Petroleum facilities classified as Class-I, Zone-0, Zone-
1, & Zone-2.
Recommended practice for Sizing Lead-Acid Batteries for Stationary
IEEE 485
Applications
ATEX Directive Guidelines for equipment intended for use in potentially Explosive
94/9EC EN70079 Atmospheres (ATEX)
The System will be designed and built in accordance with the requirements of the all
applicable local codes and standards.
In case of any conflict / deviation amongst various documents the order of precedence shall
be as follows:

▪ Statutory Regulations
▪ Data Sheet
▪ Technical Specifications
▪ Electrical Design Basis
▪ Reference Codes & Standards
3. SITE CONDITION
Parameters Description Reference
Altitude from above Sea Level 17 Meter ( Note :1)

Average Ambient Temperature (Max./Min./
39/18.1 /28.3 °C ( Note :1)
Mean.)
Ambient Temperature (Min. / Max.) 48 / 9 °C ( Note :1)
Average Daily Max. Temp. (hottest month) 33 °C ( Note :1)
Monthly Normal Max. Temp. (hottest month) 39 °C ( Note :1)
Lowest Recorded Temperature 9 °C ( Note :1)
Highest Recorded Temperature 48 °C ( Note :1)
9 / 55 °C ( Note :1)
Design Ambient Temperature (Min. / Max.)
Ground Temperature at 1m below ground
40 °C
(Min. / Max.) C
Rainfall, Average Annual 57 mm
Rainfall Maximum in 24 hours 73 mm
Design Wind Velocity 151.2 KM/Hr. (42.2 m/s )
Seismic Risk Class ZONE 2A as per UBC 97
Minimum Temperature for Battery Sizing 9 °C Standard

Average Soil resistivity for Earthing & CP
150 Ω-M. At 1.5 Mt Depth
system
Relative Humidity (Max./Min./ Mean.) 100 / 3 / 60 %
Desert / Corrosive, salt

Environment
laden, marine environment
Note-1: Data has been considered from Meteorological and seismic design data
(SAESA-112)

4. ELECTRICAL SYSTEM DESIGN
4.1. Plant Power Source Details

➢ Grid Supply
It is assumed that the facilities installed within premises of Saudi Marjan Industries: Used Lube
Oil Re-Refining Plant – Jeddah, K.S.A will be powered entirely by Saudi Electricity Company
C (SEC)_Jeddah at a voltage and frequency level of 13.8kV, 3-Phase and 60Hz.
The site will normally be connected to Grid supplies of Saudi Electricity Company (SEC),
Jeddah to meet the normal power requirements of the facilities identified for Saudi Marjan
Industries: Used Lube Oil Re-Refining Plant – Jeddah, K.S.A.
Within the premises of the Saudi Marjan Industries: Used Lube Oil Re-Refining Plant, 13.8KV
Distribution Substation shall be constructed & shall comprise of below listed Equipment:
▪ 13.8KV MV Switchgear with VCB

▪ 33KV / 4.16KV Distribution Transformer
C
▪ 13.8KV / 0.380KV Distribution Transformer
▪ 4.16KV MV Switchgear with VCB
▪ 0.380KV Main LV Switchgear (PMCC)
▪ 0.380KV LV Busduct
▪ 380V DG. Set
▪ DG. Set AMF Panel
▪ Battery bank with charger & DC Distribution Board
▪ Auxiliary Distribution Boards
A separate Electrical Room within the premises of the Re-Refining Plant site shall be
constructed & shall comprise of below listed Equipment:
▪ 380V LV PMCC/MCC/ESWG
▪ VFD Panels / Packages Panel/ Heat Tracing Panel
C
▪ Auxiliary Distribution Boards
➢ Normal Operation
In normal operation, all loads will be catered by the Grid supplies of Saudi Electricity
Company (SEC), Jeddah.
➢ Emergency Operation
In the event of complete power failure from the grid supply, the Diesel Generator will be
started automatically and some emergency plant load i.e. Emergency lighting load, Fire
Fighting jockey motor load, AC & DC UPS system shall be transferred to D.G. Set through

ATS.
Generator breaker will close automatically with time delay after stabilization of DG voltage
and frequency to feed power to the emergency load, EDG shall start in maximum 15 second.
One number 380V Diesel Generator suitably rated for emergency power generation is
envisaged to maintain plant safety and security as required.
4.2. Supply System Parameters
: 13.8kV, 60Hz, 3-Phase, 3 wire (Saudi Electricity

Main Grid Supply
Company (SEC)
: 4.16 KV, 3-Phase / 3 wire
Distribution Supply 380V, 3-Phase / 4 wire,
220V, 1-Phase Supply
Voltage tolerance : ± 10%
System Frequency : 60Hz
Frequancy tolerance : ± 5%
System Power Factor : 0.95 (Assumed)
C Design Fault Level: 13.8kV System : 21kA for 1 Sec.
Design Fault Level: 4.16kV System : (HOLD)

Design Fault Level: 380V System : 65kA for 1 Sec
4.3. System Earthing Details
33KV / 4.16KV Transformer

: Neutral Grounded through resistor (NGR)
(Secondary)
13.8KV / 0.380KV Transformer
C : Solidly earthed Neutral
(Secondary)
380V Diesel Generator : Solidly earthed Neutral
DC System : Unearthed
4.4. System Voltage and Circuit Parameters
Sr.
System Description Voltage Level
No.
C 1 Grid Incoming Supply : 13.8KV ± 10% AC, 60Hz ± 5%, 3 Phase, 3 Wire
2 Power Factor for the Plant : 0.95

: 4.16 KV ± 10% AC, 60Hz ± 5%, 3 Phase + Earth

3 Utilization voltage 380 V ± 10% AC, 60Hz ± 5%, 3 Phase + Neutral +
Earth
Motors/Heaters <160 kW;
4 : 380 V ± 10% AC, 60Hz ± 5%, 3 Phase + Earth
Welding socket outlet
5 Motors/Heaters >160 kW : 4.16 KV ± 10% AC, 60Hz ± 5%, 3 Phase + Earth
6 Emergency Power Supply : Diesel Generator: 380V, 3Ph, 4 Wire, 60Hz ± 5%
7 Control Voltage : 220 V ± 10% AC, 60Hz ± 5%, 1 Phase, 3 Wire

UPS System
(for Process Control & : 220 V ± 10% AC, 60Hz ± 5%, 1 Phase, 3 Wire
Instrumentation system,
8
SCADA/PLC, F&G, ESD,
Fire alarm, Communication
System, etc)
9 DC System : 110 V ± 10% DC
10 Lighting : 220 V ± 10% AC, 60Hz ± 5%, 1 Phase, 3 Wire

Control Supply for LV &
11 : 220 V ± 10% AC, 60Hz ± 5%, 1 Phase, 3 Wire
MV Motor feeder
12 All Panel space heaters : 220 V ± 10% AC, 60Hz ± 5%, 1 Phase, 2 Wire
13 Motor space heater : 220 V ± 10% AC, 60Hz ± 5%, 1 Phase, 2 Wire
PMCC & MCC Indication
14 : 220 V ± 10% AC, 60Hz ± 5%, 1 Phase, 2 Wire
Lamp
MV Switchgear Indication
15 : 110 V ± 10% DC, 2 Wire
Lamp
Tripping coil Voltage for
16 : 110 V ± 10% DC, 2 Wire
Breakers
Spring Charging Motor of
17 MV & LV Switchgears : 110 V ± 10% DC, 2 Wire
Breakers for Incomers
All LV contactor controlled : 220 V ± 10% AC, 60Hz ± 5%, 1 Phase, 2 Wire
18 feeders control and
(via control transformer)
indication
19 All Numerical Relays : 110 V ± 10% DC, 2 Wire
All Panel Sockets & plugs
20 : 220 V ± 10% AC, 60Hz ± 5%, 1 Phase, 3 Wire
(Industrial type)
4.5. Permissible Voltage Drops
The maximum voltage drops in various sections of the electrical system under steady state
conditions at full load shall be within the limits stated in the following table:

Maximum
Sr. Permissible
System Description
No. Voltage
Drops
Cable between Grid Supply arrangement (Saudi Electricity Company
1 0.5%
C (SEC)) and 13.8KV VCB Panel
2 Cable between 33KV Panel and 4.16KV Transformer primary 0.5%
3 Cable between 4.16KV Transformer Secondary and 4.16KV Switchgear 0.5%
4 Cable between 13.8KV VCB Panel and 0.380KV Transformer primary 0.5%
5 Busduct between 0.380KV Transformer secondary and LV switchgear 0.5%
6 Cable between PMCC and MCC in Electrical Room 2-2.5%

7 Cable between MV switchgear and MV motor 5%
8 Cable between MCC and LV motor (situated near MCC) 3%
Cable between MCC and LV motor (situated at remote location from
9 5%
MCC)
Maximum voltage drop for cables between LV switchgear & LV motor
10 15%
during motor startup
11 Cable between LV Switchgear and Lighting panels 1.5%
12 Circuit between lighting panels and lighting points 3%
13 DC supply circuit (Electrical controls) 5%
14 UPS outgoing circuit 3%
4.6. Protection Philosophy
The protection system will be designed such that a faulty circuit is identified and disconnected
safely and quickly without adversely affecting the stable operation of other healthy circuits and
plant.
All the protection relays shall be numerical type (intelligent electronic devices).
Typical protection relay applications as minimum are tabulated as follows:
Feeder Description Type of Feeder Relay Description

▪ Instantaneous Over Current Relay - 50
▪ IDMT Over Current Relay -51
▪ IDMT Earth fault Relay -51N
▪ Directional Overcurrent Relay -67
13.8KV VCB Panel Incomer ▪ Directional Earth fault Relay -67N C
▪ Under voltage Relay with Timer -27
▪ Synchro check Relay -25
▪ Trip circuit supervision Relay -95
▪ Lock out relay - 86


▪ IDMT Over Current Relay - 51
▪ Instantaneous Earth fault Relay - 50G
▪ AC inverse time Earth Overcurrent Relay -51N
13.8KV VCB Panel Outgoing Feeder
▪ Phase-Balance Current Relay – 46
▪ Over Current Relay - 49
▪ Trip circuit supervision Relay -95 C
▪ Lock out relay - 86
▪ IDMT Earth fault Relay -51N & 51G
4.16KV Switchgear Incomer
▪ High speed tripping relay - 86
▪ IDMT Over Current Relay - 51
Outgoing Feeder ▪ Instantaneous Earth fault Relay - 50G
4.16KV Switchgear
(Breaker Feeder) ▪ Phase-Balance Current Relay – 46
▪ Over Current Relay - 49
Outgoing Feeder ▪ Motor Protection Relay with (50, 50G,
4.16KV Switchgear
(MV Motor Feeder) 46,48,49,49W,50L/R,86,95,27,59,38)
▪ Phase – Balance Current Relay -46
▪ Thermal Relay -49
▪ Instantaneous Over Current Relay – 50
▪ AC Over Voltage Relay -59 C
▪ Restricted Earth fault Relay -64R
380V Diesel Generator
▪ Lockout Relay -86
Generator Protection
▪ IDMT Over current Relay -51
▪ IDMT Earth fault Relay -51N
▪ Generator Protection Relay
▪ Reverse Power Relay -Anti motoring protection
-32
▪ Voltage restrained O/C relay-51V
▪ Instantaneous Over Current Relay -50
Incomer Feeder ▪ IDMT Earth fault Relay -51G & 51N
LV Switchgear (From Transformer ▪ Restricted Earth fault Relay -64R
▪ Under voltage Relay with Timer -27 C
secondary winding)
▪ High speed tripping relay – 86
▪ Instantaneous Over Current Relay -50
Outgoing Feeder ▪ IDMT Over Current Relay -51
LV Switchgear ▪ IDMT Earth fault Relay -51G
(Breaker Feeder)
▪ Lockout Relay -86
Outgoing Motor ▪ MPCB (Motor Protection Circuit Breaker) with,
Feeder over-current, Short-Circuit, Ground Fault
LV Switchgear
(Motor up to 30KW) Protection & single phasing protection

C

Outgoing Motor
▪ Multifunction Motor Protection Relay with (46,
LV Switchgear Feeder
48, 49, 27, 50G, 86 Protection Relay)
(Motor up to160KW)
All numerical protection relays and other communicable meters shall have FO/RS485 port for
serial interface, the data of this relays shall be capable of transferring to SCADA/PLC via
Modbus communication or Ethernet.
5. AREA CLASSIFICATION
Hazardous areas shall be defined in accordance with API-RP-505: Recommended Practice for
the classification of Locations for Electrical Installations at Petroleum facilities classified as
Class-I, Zone-0, Zone-1, & Zone-2.
Electrical equipment installed in the classified area shall be suitable for the area and taken into
consideration, during design of the plant equipment, the gases and chemical substances,
which shall be handled, processed or stored in the plant. Selection of equipment shall be made
in compliance with IEC 60079 Standard.
Electrical apparatuses suitable for use in classified areas with test certificates by an official test
laboratory / Notified body such as CESI for Italy, PTB for Germany, BASEEFA for England,
LCIE or INERIS for France, FM or UL for US and ATEX etc. will be considered.
The equipment suitable for Zone 1 area will be deemed suitable for zone 2 area.
6. EQUIPMENT DESIGN PHILOSOPHY
➢ General Criteria
All equipment will comply with project specification, data sheets and relevant IEC code.
All equipment will be suitable for continuous operation at full load and will withstand the
thermal and electrodynamics stresses due to the specified abnormal conditions.
All ratings will be continuous at specified maximum ambient temperature.
Unless otherwise specified all components will have at least 20% extra capacity above the
expected load.
Insulation levels of the power system will be coordinated in accordance with IEC standard.
Rated short duration power frequency withstand voltage and switching/lightning impulse
withstand voltage will take into account of system voltages and type of Earthing.
➢ Design Life
The equipment will be designed for an operational design life of minimum 20 years.
➢ Weather Protection
For Indoor Installations : IP 42

For Outdoor Installations : IP 55
6.1. Transformer
Transformers shall be double wound; oil immersed conservator type suitable for outdoor
installation without additional weather protection.
Cooling shall be ONAN using oil. Forced cooling is not envisaged. Windings shall conform to
vector group Dyn 11, as defined in IEC 60076.
The KVA rating (1x100%) shall include minimum 20% margin for future growth and should be
as far as possible a standard value.
KVA rating and % impedance of each transformer shall be selected so as to limit the short
circuit current to values within the current rating and rupturing capacity of proprietary available
switchgear whilst also ensuring that the voltage drop in the system elements stays within
permissible limits. The transformer impedances shall comply with the applicable IEC
standards unless otherwise required.
Transformer shall be provided with off circuit tap changer (OCTC) on the primary (HV)
winding with tap selection for (-) 5% to (+) 5% of rated primary voltage in steps of 2.5%.
6.2. Emergency Diesel Generator
380V Diesel generator set is envisaged to back up the normal power. The unit will
automatically start and come into operation without manual intervention in the event of failure
of normal supply. Manual starting will be possible locally.
The DG set shall consist of a diesel engine directly coupled to an electric generator, complete
with all the required accessories and components including starting, cooling, lubricating,
combustion air intake, exhaust and fuel systems, control panel, battery, Generator Control
Panel, and diesel tank etc., along with electrical protection & metering system. The generator
shall have brushless excitation.
The generator set shall have at least 20% spare capacity for meeting future requirements.
It will be suitable for outdoor operation in a sound proof shelter Acoustic enclosure with
common base frame & Anti-vibration mounting pad suitable for assembly of engine, radiator
and alternator with their accessories.
6.3. MV and LV Switchgear
MV Switchgear
MV switch gear shall be air insulated type with VCB and draw out feature. Switchgear
enclosure shall be robust metal construction, vermin & dust proof and shall have minimum
degree of protection IP42 suitable for indoor installation. Each vertical section shall consist of
1 no. of circuit breaker only.
All switchgear shall have integral circuit earthing facilities suitably interlocked with the
switching mechanism.

Switchgear mechanisms shall be fully interlocked and provide shutters, door locks etc., to
prevent persons contacting live parts.
MV circuit breakers shall be of the trolley mounted withdrawal type assembled to make up a
switchboard. A test position shall be incorporated. The interrupting medium shall be vacuum
circuit breaker.
MV motor feeder shall have withdrawal type vacuum contactor with backup fuse & numerical
Motor protection relay.
All busbars and jumper connections shall be of electrolytic copper conforming to relevant IEC
standards. They shall be adequately supported on epoxy insulators to withstand electrical and
mechanical stresses due to specified short circuit currents. Busbar cross section shall be
uniforms, throughout the length of switch board.
Earth switch shall be provided for MV Switchgear. Necessary mechanical interlocks shall be
provided.
VCB feeder shall be provided with numerical relays and shall be with microprocessor based
adjustable type release for current and time for over current, short circuit, instantaneous and
earth fault release.
All cable connections and entries, including those of the low voltage cables, shall be made
from the bottom.
LV Switchgear:
Low voltage switchgear will consist of incoming circuit breakers, motor starters, lighting and
power distribution board feeder, APFC units grouped together to form appropriate cubicle
type LV Switchgear and construction shall conform to Form-3b, Type-2 Busbar separation as
defined in IEC 61439 Part 1 and Part 2.
LV Switchgear shall be metal enclosed, floor mounted, free standing type as per applicable
IEC standards with the following features: Incomer and bus-tie Circuit Breakers shall be ACB,
four poles, spring charged, horizontal draw out electrically operated type single front design.
➢ LV Switchgear shall be fully draw- out (withdraw-able) double front type. However, Air
Circuit Breaker shall be of single front design.
➢ Distribution boards (PDB) shall be fixed type with a single front design.
➢ All the switch boards shall be suitable for future expansion on both sides and all bus bars
for all the switch boards shall be of electrolytic grade copper and shall be fully insulated
unless otherwise specified.
➢ A minimum of 20% spare feeders or one no. of each rating and type on each side of the
bus section, whichever is the greater, shall be provided
➢ Circuit breakers / contactors controlling motor feeders shall have a rating of at least
125% of the maximum continuous rating of the connected motors.
➢ Motor starter and contactor components shall be selected to achieve type-2 co-

ordination.
➢ For feeders rated up to and including 630A, MCCBs shall be provided, and for feeders
rated above 630A, ACBs shall be provided.
➢ All incomer ACB feeder for LV switchboard shall be provided with numerical relays and
outgoing MCCB feeder in LV switchboard shall be with microprocessor based adjustable
type release for over current, short circuit, instantaneous and earth fault release. MCCBs
shall be provided tripping device with inverse time characteristic for overload protection
and instantaneous characteristics for short circuit & earth fault protection.
➢ The switch board components like circuit breakers, Main horizontal and vertical bus bars,
bus bar joints, bus bar supports etc. shall be designed to withstand the maximum
specified short circuit current for a minimum of 1 second, unless otherwise specified.
➢ Provision shall be made for space heater supply of motors rated 30kW and above.
➢ LV switch board shall have metal enclosed horizontal main bus bar compartment running
at the top.
➢ Zero Sequence ground fault protection shall be provided for motor above 30KW and for
C motors located in hazardous areas.
➢ Top entry bus duct as incomer for LV Switchgear fed from Transformer rated 1000kVA
and above shall be provided. Incomers for other boards shall be from Bottom entry. All
other cables shall be from Bottom entry. For lighting panels in Building, incoming power
cable entry shall be from bottom, however outgoing cable/wire entry shall be from top or
bottom to suit the installation.
➢ Control transformer of suitable rating shall be provided in each bus section in LV

switchgear for control supply.
➢ Thermostatically controlled space heater for each panels, maintenance sockets outlets,
panel illumination etc. shall be provided.
All switchgear, modules shall be designed to have all safety features, not to have access to
live terminals and interlocks to ensure to protection against accidental closing while racking in
and door opening while in service
6.4. Power Factor Improvement System
An automatic power factor improvement system shall be considered on Busbar of 13.8KV MV

Switchgear. The system shall have capability to improve the overall power factor of the grid
supply to above 0.95 lag.
The power factor improvement system shall consist of:
➢ Capacitor banks
➢ Series Reactors
➢ Power cabinets with MCCB, busbars, feeders comprising fuses/breakers and power

contactors, control transformers, etc.
➢ Power factor correction relay
6.5. Electric Motors
In general, three phase squirrel cage induction motors shall be totally enclosed, fan cooled
type and suitable for continuous outdoor use with protection IP 55. Wherever identified Motors
shall be suitable for direct on-line starting.
Motor construction shall be as per IEC 60034 and have efficiency class IE2 as indicated in
IEC 60034-30-1.
The type of enclosure for motors (i.e. weatherproof / flameproof) shall be adequate for the
application and area in which it is to be installed.
The terminal box of MV motors shall be designed to withstand the specified short circuit
current for 0.25 second without damage.
All MV motors shall be provided with 3 nos. duplex or 6 Nos. simplex RTDs (resistance
temperature detectors for winding temperature detection and 2 nos. for bearing temperature
detectors (for sleeve bearings) and connected to numerical relay for alarm/tripping and to
process PLC via serial link for temperature monitoring. Vendor will connect Instruments to
separate Junction box. Also a separate Junction box will be provided for space heater
connection.
➢ Hot & Cold Start
Motors shall be designed to allow the minimum number of consecutive starts indicated below:
Min. no. of consecutive

Condition
starts
With initial temp. of the motor as ambient temp. (cold) 3
With initial temp. of the motor as full load operating temp. (hot) 2
Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds under cold
conditions and 8 seconds under hot conditions. The hot thermal withstand time at 100%
voltage shall be at least 5 seconds more than the starting time at 75% voltage. The starting
time of the motor shall be less than the hot thermal withstand time (time te in case of
increased safety motors) to facilitate application of conventional bimetal relays or thermal
release against locked rotor and overload conditions.
➢ Insulation
All motors shall have class F insulation with temperature rise limit to class B on a maximum
ambient temperature measured by resistance, for all parts of the machine windings, adjusted
for ambient temperature in excess of maximum temperature in accordance with IEC.
Motors identified to be driven and controlled by a VFD shall be suitable for the required

variable speed range at a temperature rise within the permissible limits. All motors driven by
VFDs shall be suitable for inverter duty application and shall have embedded PTC thermistors
in the windings, when temperature of the winding exceeds the permissible limits, thermistor
trip relay in the VFD should operate. VFD shall be interface with SCADA/PLC through serial
link by either Modbus or Profibus protocol.
Starting current of All motors shall be limited to as per IEC 60034.
Provision shall be made for space heater supply of motors rated 30kW and above.
6.6. DC System
DC Power supply system comprises the converters, battery banks and the Main DC
Distribution Boards (Main DCDBs).
System shall supply continuous 110V DC power to MV and LV switchgear and relays. The
DC power supply system shall be a fully redundant system consisting of two units operating in
parallel.
The DC UPS system shall comply with IEC 60146 and IEC 61204.The DC UPS rectifier shall
be Thyristor based three phase full wave rectification.
Each unit shall consist of one 100% Float-cum-boost charger with 100% loading capability but
operating at 50% load. Batteries shall be one common 100% valve regulated lead acid battery
bank placed in a separate well ventilated room on racks.
In case of normal power failure to the float-cum-boost chargers, each battery unit shall have
C sufficient capacity to supply the total 110V DC system loads for 60 Minutes.
Under normal condition the Float-cum-boost charger will take care of all DC load connected to
its Main DCDB and keep the battery under charged condition. In case of failure of normal
supply, battery will feed the DC load requirement. Retransfer of load on resumption of normal
supply will be done without interruption of supply to loads.
AC input to the DC system shall be 380V ± 10%, 3 phase, and 60Hz ± 5% from the plant LV
Switchgear.
Each battery charger and DCDB shall be sized to cater to selected battery capacity.
Each DCDB shall have at least 10% spare for future loads. All the DB’s shall have cable entry
from bottom.
The battery chargers shall have intelligent monitoring / metering system and shall display the
capacity of the battery, battery voltage, rectifier voltage and current, events and alarms and
communicable for remote monitoring
6.7. Uninterruptible Power Supply System
Uninterruptible Power Supply system comprises the converters, static inverters, static
automatic transfer switch, battery banks, and Isolation transformer with voltage stabilizer in
C bypass with maintenance by pass switch along with AC distribution Board.

One complete Uninterruptible Power Supply System consisting of two parallel units (for
redundancy) shall be provided for powering the plant Process PLC, FGS, instrument package
equipment system, and local control panels.
The inverter shall be with the latest proven technology. All components shall be of a high
quality and reliability that satisfy the requirements of a secure AC power to vital equipment
with respect to performance.
Rectifier shall be Thyristor base three phase full wave rectification.
The system input shall be 3 phase, 380V ± 10%, 60Hz ± 5%; Output shall be 220V ± 10%
AC, 1 Phase, 60Hz ± 5%. Harmonic filters shall be considered at input side, if required.
System total harmonic distortion (THD) content shall not exceed 5%.
UPS system shall consist of two parallel units (each including a 100 % converter, a 100 %
solid state inverter,) with one common 100% Valve regulated lead acid battery bank, static
automatic transfer switch, and a constant voltage by-pass transformer with maintenance by
pass switch. Batteries to be placed in a separate well ventilated room on racks.
Both units shall operate in parallel, each shall provide 50% load but each shall have 100%
loading capability. Battery backup time shall be 30 Minutes for the complete system.
Under normal condition, the converter will feed the inverter load requirement through static
switch and keep the battery under charged condition. On failure of supply to converter, the
battery will start feeding the inverter load requirements automatically without interruption.
Reverse transfer on resumption of normal power will also be automatic.
Usually, the two UPS units will operate in parallel and share total load requirement equally.
On failure of inverter of one of the UPS the other UPS will start feeding 100 % of the load
automatically without any interruption. In case of failure of both the inverters, the bypass
mains will take care of 100 % of the load through static bypass switch automatically without
interruption. Forward and reverse transfer of load will be done automatically and without any
interruption of supply to loads.
Each UPS shall have at least 10% spare feeders and the UPS shall be designed to cater
additional 10 % for future loads.
6.8. Batteries
Valve regulated lead acid Batteries shall be of adequate capacity to meet the backup
requirements as envisaged in the duty cycle. While sizing the battery, temperature correction
factor, and ageing factor shall be considered in addition to the maintenance factor. Battery
backup time shall be 30 Minutes for complete system.
6.9. Lighting System
➢ General
Indoor Lighting System
Lighting system will consist of fluorescents lighting fixtures for indoor lighting of non-process

buildings, offices, substations, control and electrical rooms, warehouse, laboratories,
Battery room shall be provided with flameproof fluorescent lighting fixture, suitable to Zone-1,
Gas Group IIC, and Temp. Class T3. High-Pressure sodium Vapor (HPSV) lamp shall be
used for bay lighting in Process building/Shop floor.
Outdoor Lighting System
External area lighting will consist of High-Pressure Sodium Vapor (HPSV) lamps rapid re-
strike type. Telescopic tubular hot dip galvanized high masts shall be provided for illumination
of Tank Farm and wide open area. High pressure sodium vapour lamp with well glass fixture
shall be used for process area lighting.
Where feasible street lighting poles may be avoided where lighting high masts provide
adequate illumination, Street lighting will be standard luminaries, 220V±10%, on galvanized
steel pole.
For certain confined locations fluorescent surface mounting fittings can be considered.
All fittings to be installed outdoors shall have ingress protection of IP55 and shall be
weatherproof/Increased Safety/Flameproof type (depending on area of installation) and have
a guard. All Light Fittings, JBs shall be so located to have easy maintenance approach.
External lighting will be automatically controlled by Photoelectric cell or timer.
➢ Emergency
In addition to the normal lighting, 20-25% of the total lighting fixture shall be fed from
Emergency supply from DG Set & will be provided to give immediate light following a power
failure in the following building & process plant areas:
Control room, Sub-station, Fire Station, stairways, corridors, exits, and around all equipment
where personnel would otherwise be endangered in the event of a power failure.
Emergency lighting panel shall be connected to emergency power supply source.
Exit lights shall be provided at all exit doors in building.
Lighting installation will be designed to provide an average sustained illumination level not
less than the values tabulated below.
Location Lux (average)
Process & Utilities areas
Pumps, collectors, separators areas 70 to 85 at grade

Ladders and stairs 45 at floor level
Instruments, Local boards 150 at 1 m level
Storage area
Tanks (ladder, gauge area) 15 at grade

Manifold area 10 at grade

Loading area
C
General area 70 to 85 at grade
Tank loading point 150 at 1m level

Street & fence lighting
Main road 15 at grade
Secondary road 10 at grade

Fences 10 at grade
Car park 12 at grade
Buildings
Control rooms 500
Electrical rooms 200 C

Instrumentation rooms 400
First aid room 500
Lockers rooms – showers - toilets 150
Laboratories 500
Workshops 250 C
Fire station 150
Gate house 250
Stairs 150
Exits 100
Pantry 400
Fittings to be installed in hazardous area shall be suitable for the Zone specified and certified
by a notified body.
Wiring Type
Process plant/Shed & Outdoor area Armoured cable
Surface conduit wiring above false

Non plant building with/without false
ceiling & Canceled conduit wiring on wall below false
Ceiling / Control room
ceiling
Surface conduit / Armoured cable in G.I perforated
Substation (Switchgear Room)
trays

Wiring for lighting in outdoor area shall be done with armoured cable run along the columns/
Platform & structures.
6.10.Socket Outlets
220V, 15A receptacles shall be provided at selected location in plant. Enclosure of the
convenience receptacle shall be suitable for site conditions such as weather proof, dust proof,
flame proof, corrosion resistant etc. Necessary interlocks and earthing facilities shall be
provided as per safety requirements.
C For office buildings, 220V, 13A/15A twin socket outlet will be provided for PC, monitors and
printer from UPS supply. 220V, 13A/15A, socket outlets will be provided in each room from
normal supply for general purpose. In halls, one socket for each 10m of the hall periphery will
be provided.
Apart from the above power outlets will also be provided for Pantry appliances, water coolers,
refrigerators and Lab.
Welding outlets (380V-3ph-63A-4P+E) will be provided at suitable location near major

equipment like Pump house, Process area etc. to provide power for portable equipment at
inspection and maintenance point.
Substation will have industrial type receptacle while Control Room and Office rooms will have
decorative type receptacles, with ELCB (sensitivity range 30mA-300mA) controlled socket,
220V, 1 phase, Neutral & Earthing,13A/15A, 3Pin.
All receptacles shall have looping facility & shall have cable entry at the bottom.
6.11. Local Control Station
All motors will be provided with local control stations each having START (Green)/STOP
(Red) pushbuttons. The stop position is stay put type with pad lock facility.
The local control stations shall be of aluminium alloy (LM6) construction, Enclosure of the
control station shall be suitable for site conditions such as weather proof, dust proof, flame
proof (Ex-d), corrosion resistant etc. LCS located outside shall have minimum IP-65.
Local/Remote (Hand - Auto) selector switch with start stop indication lamp shall be provided
in LCS.
Ammeter shall be provided in LCS for motor rating above 5.5 KW.
6.12. Cable Glands
All cable glands shall be made of nickel chromium plated brass and shall have ISO metric
entry threads with 1.5mm pitch. The same type and make of cable glands shall be used
throughout the installation.
Cable glands shall be certified for EEx’d’ for installing in hazardous area and industrial type
weatherproof for installing in safe area. Glands shall be provided with an integral permanent

sealing device to prevent water ingress at the armour clamp. Each gland shall be supplied
complete with an IP66 entry thread seal and a brass locknut. Cable shrouds shall not be
required. Cable glands shall be double compression type.
6.13. Earthing and Lightning Protection System
Entire electrical system envisaged for the terminal, shall follow earthing installation practice in
accordance with the provisions of the relevant NFPA-70. For the Earthing calculation purpose
IEEE 80 shall be followed.
The earthing system will protect the electric network and assure personal safety in case of an
electric failure and against static charges.
Earthing system in general cover the various earthing system listed below.
▪ Cable armoring (multi-core power cables)

▪ Generator and Transformer neutral points.
▪ Substation building ground busbars.
▪ MV and LV Switchboard/PDB ground buses.
▪ All panel Enclosures
▪ High Mast, Street light and flood light pole
▪ Motor / generator machine frames.
▪ Transformer body
▪ Metallic structure of building and metallic reinforcement of concrete building Pipe rack
steel.
▪ Tanks, vessels, towers, stack, Reactor
▪ Lorry tanks during loading, if necessary
▪ Mounting Skid / Base plate of rotating machinery
▪ All non-current carrying metallic structures
▪ Metal fences, gates, side rails
▪ Separate clean earth system for Instrumentation. I.e. SCADA / PLC Panel as per
specified requirements.
Main earth grid will be provided around substation and main plant area. It will consist of buried
bare copper conductor connected to rods driven earth pits at several points.
Size of copper conductor shall be calculated based on the system fault level. Copper
conductor shall be laid at a depth of not less than 500 mm below ground level. Earth pit will
consist of 16 mm dia., 3m long copper clad steel rod. The main earthing ring shall be
extended to earth bus to connect parts of all electrical equipment and machinery at two
separate and distinct earth connectors.
All product and water tanks shall be adequately protected against lightning strokes, by
connecting them to the earth grid with adequate size of Cu earth continuity conductors.

Storage Tanks shall be considered as self-protecting, Depending on the tank diameter

following number of cleats shall be welded on the tank body with application of bituminous
paint at welded joint.
Tank Diameter (D)

Earthing Connection
in meters
≤ 10 2 Nos. at 180°
10 ≤ D ≤ 20 3 Nos. at 120°
20 ≤ D ≤ 40 4 Nos. at 90°
Earthing resistance of the grid shall be measured after connecting all the earth electrodes to
the grid. Value of resistance of earth grid to the general mass of earth shall be as follows:
▪ For electrical system and equipment, a value that ensures operation of the protective
device in the electrical circuit but not in excess of 1 ohms.
▪ For lightning protection, value of resistance of 5 ohms as earth resistance shall be

desirable, but in no case it shall be more than 10 ohm.
▪ Overall grid resistance shall be less than 1 ohm.
Below ground earthing is carried out by Thermit welding and above ground earthing through
compression type lugs. Cadmium coated nuts and bolts are to be used at tapping points
where welding is not envisaged. Lighting fixtures and receptacles shall be earthed through the
extra core provided in the lighting circuit / cable for this purpose.
Recommended earthing Conductor sizes are indicated in the table below.
Size of Earthing copper

Equipment
cable
185 Sq.mm Multi-stranded
MV Switchgear Cu green/yellow flexible
PVC insulated cables
LV Switchgear Cu green/yellow flexible
Transformer & DG Set Cu green/yellow flexible
Auxiliary Power Distribution Board, HVAC MCC Cu green/yellow flexible
Lighting Panels, Welding Outlets Cu green/yellow flexible

LV motors Enclosure (For motor 30 KW & Above) Cu green/yellow flexible
LV motors Enclosure (For motor below 30 KW) Cu green/yellow flexible
PE conductor of electrical equipment having a supply Half of the phase
cable with cross section more than 35 sq.mm conductor
PE conductor of electrical equipment having a supply 16 Sq.mm Multi-stranded
cable with cross section more than 16 4 sq.mm and up Cu green/yellow flexible
to 35 sq.mm PVC insulated cables
PE conductor of electrical equipment having a supply
cable with cross section more than 4 sq.mm and up to same as phase conductor
16 sq.mm
Storage tanks, Pipe racks, Vessels & Heat Exchangers,
Cu green/yellow flexible
Building Reinforcement
Small equipment & instruments Cu green/yellow flexible
Push button station Cu green/yellow flexible
Lighting Poles Cu green/yellow flexible
Lightning Protection
Lightning protection will be provided to equipment, structure and buildings as per the risk
index analysis worked as per IEC 62305.
The Lightning Protection System shall be in accordance with IEC 62305 with supplementary
surge protective devices fitted.
All lightning protection systems shall be bonded to the building electrical earths. Test links
shall be provided.
The air termination system on the roof shall comprise of a number of copper cross tapes, and
a number of final rods/air conductors. The air termination system shall be connected at roof
level to the down conductor system.
At roof level and at ground level proprietary clamps shall be used to facilitate the tape to bar
connection.
The earth termination network shall consist of a number of earth rods installed within a
dedicated inspection pit.

6.14. Cables, Cable Tray and cable laying
Electrical Cables:
The cables shall be sized based on the maximum continuous load current, the voltage drop,
system voltage, system earthing and short circuit withstand criteria as applicable. The Laying
condition de rating due to ambient air temperature, ground temperature, grouping and
proximity of cables with each other, thermal resistivity of soil etc., shall be taken in to account.
MV power cables shall be made of stranded copper conductor, conductor screen, dry cured
XLPE insulation, insulation screen, PVC inner sheath, steel wire armoured, and FR PVC
outer sheath as per IEC 60502-2.
All LV power cables shall be with stranded copper conductor with XLPE insulation, PVC inner
sheathed, steel flat / round wire armoured, FR PVC outer sheath and construction as per IEC
60502-1. Power cables shall be minimum 4 mm2 sizes.
The control cables shall be PVC insulated, extruded PVC sheathed, steel round armored
type, outer FR sheathed with copper conductors. Special cables like twisted or shielded
control cables etc. shall be used as applicable for numerical relays, VFD etc. to suit selected
equipment as per equipment supplier’s recommendation. Cables used for CT connection shall
have minimum cross section area of 4 mm2.
All earthing cables shall be Multi-Stranded Copper conductor, flexible PVC insulated, colored
Yellow/Green, for above/underground use.
All power and control cables shall be in continuous lengths without any joints subject to
availability of drum length. The cables used for lighting and wires in conduits shall have
appropriate junction boxes with adequately sized terminals. Cable joints in hazardous areas
shall not be permitted.
Fire Resistant Power Cables shall be used for Fire-fighting system.
In case of difficulty in connecting the cables to instrument or relay terminals, minimum cross
section may be reduced to 1.5 mm2 copper.
For lighting inside the building, 3R x 1C 2.5 mm2 copper conductor, PVC insulated wire shall
be used in conduit system (for circuit and point wiring), with proper color coding.
The termination kit shall be suitable for termination of the cables to indoor switchgear or to a
weatherproof cable box of an outdoor mounted transformer / motor. For outdoor terminations,
weather shields / sealing ends and any other accessories required shall also form part of the
kit. The terminating kits shall be air insulated with terminal boxes sized suitably for heat shrink
or elastic connections.
Cable laying philosophy:
➢ General:
Cables will be in general laid above ground on cable trays and or directly buried as per the
convenience at each location.

Cable trays will be hot dip galvanized Iron, ladder type. Covers will be provided for protection
against direct sunlight, rain water and mechanical damage.
Electrical cables will not be laid in the same trench, tray or conduit with the instrument and
communication cables.
Cable trenches, Trays and PVC duct banks will have 20% of spare space for future cables.
Multi-core MV cables will be arranged in a single layer with one cable diameter spacing
between them. Single core MV cables shall be arranged in trefoil formation in single layer,
with one trefoil cable diameter spacing between them.
➢ Buildings:
For buildings like sub stations, control rooms, etc. cables will generally be laid on cable trays
supported on metal structures, trenches, or along building structures, walls, ceilings, etc.
In other non-plant buildings, power cables shall be laid in Hot Dip Galvanized GI cable
trays/PVC conduits. In the false ceiling area, above false ceiling cables shall be laid as
surface mounted in cable tray/Conduit. Vertical dropper below the false ceiling shall be
concealed in wall. In the non-false ceiling area vertical trays shall be provided with cover.
➢ Outdoor Underground Area:
In unpaved areas cables will be in general directly buried on a layer of sand and covered by
sand.
In paved areas cables will be laid in concrete trenches filled with sand and covered with
concrete slab.
For road crossing cables will be laid in PVC sleeves in concrete duct bank.
Cables will be identified with corrosion resistant cable strips, showing the cable numbers,
every 10m and at both side of road crossing, where ever transition from underground to
above ground and vice versa. A warning system of plastic strips will be provided above the
top level of all cables run in trenches. For unpaved areas cable trench markers will be
provided at grade over the cable trenches to show clearly the extent and the run of the
cables.
➢ Outdoor Aboveground Area:
Cables will be laid on hot-dip galvanized cable trays (ladder type) or in heavy duty PVC
conduits.
Cable trays will be bolted/welded to steel structures and walls or to adequately sized tray
supports and shall be routed on dedicated tiers of the pipe racks and on sleepers to
equipment.
➢ Cable Tray:
The trays shall not show deflection / bend / deformation after laying of cables.

All cable trays and accessories shall be prefabricated, 2 mm thick hot dipped Galvanized Iron
ladder trays with rungs at 300 mm interval. Maximum width of trays will be 900mm. Collar
height will be 100 mm. The maximum length of single cable tray shall be 3000 mm.
For tray system design, in addition to self-load and wind forces, following guidelines for
design shall be considered.
Support span - 2000 mm for horizontal & 1500 mm for vertical tray supports. Nuts, bolts and
any other hardware to be used in cable trays shall be stainless steel/cadmium coated.
Fastening of cables in cable ways shall be done with UV resistant (Black) PVC cable ties.
Cable trays used in the outdoor areas shall be provided with covers on top layer, for
protection from rain water & mechanical damage.
A horizontal clearance of 300 mm shall be maintained between instrumentation, signal cable

and electrical power/control cables.
For all cable trays stacked vertically, there shall be a minimum vertical working clearance of
300 mm from the top of the lower tray to the bottom of the tray above.
The trays shall be supported at appropriate intervals both vertically and horizontally, as
required by the cable tray manufacturer’s design criteria.
For Lighting Perforated cable tray with maximum width of 300mm shall be used for above
ground cable laying.
6.15. Neutral Grounding Resistor

The Neutral Grounding Resistor (NGR) shall be rated to withstand the fault current and shall
be out door type with IP 55 enclosure. The NGR element shall be stainless steel / ni-chrome.
6.16. Low Voltage Bus duct

LV bus ducts will be provided for interconnection of 13.8/0.380kV transformer secondary to C
the 380V LV Switchgear.
Non-phase segregated, self-cooled type, 3 phase, 4 wires, copper bus bars with heat
shrinkable PVC Sleeves shall be used.
Enclosure will be fabricated from 3 mm thick aluminum sheets for ratings above 3000A and 2
mm thick sheet steel otherwise. The Indoor portion of the bus duct shall be minimum IP42
and the outdoor portion of the bus duct shall be minimum IP55. The adopter box with flexible
bus bars on both ends of the bus duct shall be designed as part of the bus duct.
Bus bar supporting insulator shall be made of SMC (Sheet molding compound). Bus bar shall
be supported at regular intervals on insulator made of high dielectric strength. Non
hygroscopic, non-inflammable material with tracking index equal to or more than that defined
in standard.
Both Bus bar and supports shall be adequately sized and braced to withstand dynamic and
thermal stress expected due to the specified short time rating. Seal-off bushings with wall
frame assembly wherever the Busduct crosses wall from outdoor to indoor.

The Rating of the bus ducts connected to breakers shall have same continuous and short
circuit rating as that of breakers.
Neoprene rubber bellows for enclosure wherever expansion joints, transformer end, panels
end are provided.
C
7. ELECTRICAL SUBSTATION BUILDING
➢ Substation building & Electrical room shall be in accordance with IEC Standards.
➢ The Electrical substation building shall have a minimum two access points, one entry
suitably sized to accommodate equipment / normal entry and the second for emergency
exit.
C
➢ The Electrical substation building shall be provided with portable fire extinguishers, safety
signs, First-aid box etc. in accordance with safety requirements as per Local regulation.
➢ The Electrical substation building shall be sized to accommodate all electrical loads
identified and to give adequate clearances between items of equipment for ease of
maintenance.
SUBSTATION BUILDING:
▪ The substation building will consist of switchgear room and transformer bay. The
switchgear room will house MV & LV Switchboard, LV MCC, Auxiliary switchboards, AC
C
& DC UPS, Battery banks and Distribution Boards.
▪ The sub-station shall be located in a safe area close to the load center. Proper access
shall be provided/ ensured for operation/ maintenance of indoor and outdoor equipment.
Layout of the substation shall comply with the requirements of the latest versions of
relevant standards.
▪ The Substation building floor will be elevated such that the floor level of the building will
C be 3 meter (Min.) above the site FGL (ground level) to allow trays & trenches below
switchboards for cabling.
▪ The Substation shall be designed for mounting on raised columns to provide access for
the installation of cables to the equipment. All switchgear panels shall be arranged to
permit all cables to enter from below.
▪ Transformer bay & neutral grounding resistor (if any) will be outdoor type separated from
substation building with firewalls Fence & gate. Gravel stone shall be provided in
transformer bay. Firewall shall be provided between Transformer Bays.
▪ Batteries of UPS and DC Power Supply System shall be located separately in well
ventilated room provided with an exhaust fan and heat detectors.
8. INSTALLATION, TESTING AND COMMISSIONING
Installation of all electrical equipment shall be carried out with high standard or workmanship,

neat routing/layouts, and clearances/access as per recommendations by the manufacturers,

standards and good engineering practices.
After installation the system equipment shall be tested for pre-commissioning test as
recommended by the manufacturers & established practices. Further, commissioning tests
shall be conducted to prove agreed performance within specified tolerance, temperature rise,
noise and vibration.


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DOC NO.

CLIENT: SAUDI MARJAN INDUSTRIES, JEDDAH, KSA PROJECT NO. 1061

PROJECT USED LUBE OIL RE-REFINING

ELECTRICAL DESIGN BASIS

C 08-08-2018 Issued for Design A.J.D T.D S.S

B 20-09-2016 Issued for Approval H.N.P K.N.P D.P.B

A 04-04-2016 Issued for Review/Approval H.N.P D.P.B D.P.B

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_C Dt. 12/01/2018) Page 2 of 30

1.1. Project Summary

Project Name Used Lube Oil Re-Refining Plant

Project Number 1061

Project Location Jeddah, K.S.A

Comapany Saudi Marjan Industries

EPC Contractor Chemie-Tech DMCC

1.2. Project Objective

The Re refining of Lube Oil shall be carried out by following Plants:

• Flash Distillation Plant

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_C Dt. 12/01/2018) Page 3 of 30

A further process of refining (Hydro-treatment & fractionation), finished products will be

2.1. Definitions / Abbreviations

C ACB : Air Circuit Breaker

APFC : Automatic Power Factor Correction

ASPB : Auxiliary Supply Panel Board

DCDB : DC Distribution Board

DG : Emergency Diesel Generator

FAT : Factory Acceptance Test

LCS : Local Control Station

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_C Dt. 12/01/2018) Page 4 of 30

LDB : Lighting Distribution Board

C MCCB : Moulded Case Circuit Breaker

MCC : Motor Control Centre

MLDB : Main Lighting Distribution Board

PDB : Power Distribution Board

PLC : Programmable Logic Controller

PVC : Polyvinyl Chloride

SAT : Site Acceptance Test

SCADA : Supervisory Control and Data Acquisition System

SPN : Single Phase Neutral

VCB : Vacuum circuit breaker

XLPE : Cross (X) Linked Poly Ethylene

2.2. Statutory Requirements, Codes & Standards

▪ International Electro-technical Commission (IEC)

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_C Dt. 12/01/2018) Page 5 of 30

IEC 60255 Electrical relays

IEC 60309 Plugs, socket-outlets and couplers for industrial

IEC 60364 Low-voltage electrical installations

IEC 60662 High-Pressure Sodium Vapour Lamps

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_C Dt. 12/01/2018) Page 6 of 30

Parameters Description Reference

Altitude from above Sea Level 17 Meter ( Note :1)

Monthly Normal Max. Temp. (hottest month) 39 °C ( Note :1)

Lowest Recorded Temperature 9 °C ( Note :1)

Highest Recorded Temperature 48 °C ( Note :1)

Rainfall Maximum in 24 hours 73 mm

Design Wind Velocity 151.2 KM/Hr. (42.2 m/s )

Seismic Risk Class ZONE 2A as per UBC 97

Minimum Temperature for Battery Sizing 9 °C Standard