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Oisd 149 PDF
Oisd 149 PDF
Oisd 149 PDF
Draft-III
FOR RESTRICTED
CIRCULATION ONLY
1
OISD - RP - 149
First Edition, February, 1996
Amended Edition, September 2001
Second Edition,----------, 2011
FOR RESTRICTED
CIRCULATION ONLY
Prepared by:
COMMITTEE ON “DESIGN ASPECTS FOR ELECTRICAL SAFETY”
2
NOTE
OISD publications are prepared for use in the oil and gas industry
under Ministry of Petroleum and Natural Gas. These are the property of
Ministry of Petroleum and Natural Gas and shall not be reproduced or
copied and loaned or exhibited to others without written consent from
OISD.
Though every effort has been made to assure the accuracy and
reliability of the data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or damage
resulting from their use.
3
FOREWORD
Oil Industry in India is nearly 100 years old. Due to various collaboration
agreements a variety of international codes, standards and practices are in vogue,
Standardisation in design philosophies, operating and maintenance practices at a national
level was hardly in existence. This lack of uniformity coupled with feedback from some
serious accidents that occurred in the recent past in India and abroad, emphasised the
need for the industry to review the existing state of art in designing, operating and
maintaining oil and gas installations.
With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a
Safety Council assisted by the Oil Industry Safety Directorate (OISD) staffed from within
the industry in formulating and implementing a series of self-regulatory measures aimed
at removing obsolescence, standardising and upgrading the existing standards to ensure
safer operations. Accordingly OISD constituted a number of functional committees
comprising of experts nominated from the industry to draw up standards and guidelines
on various subjects.
The present document on “Design Aspects for Safety in Electrical System” was
prepared by the Functional committee on “Design Aspects for Electrical Safety”. This
document is based on the accumulated knowledge and experience of industry members
and the various national and international codes and practices.
Suggestions are invited from the users after it is put into practice to improve the
document further. Suggestions for amendments, if any, to this standard should be
addressed to :
The Co-ordinator
Committee on “Design Aspects for Electrical Safety”
OIL INDUSTRY SAFETY DIRECTORATE
th
7 Floor, ‘New Delhi House’
27, Barakhamba Road
New Delhi – 110 001
4
COMMITTEE
ON
DESIGN ASPECTS FOR ELECTRICAL SAFETY
(First Edition – 1996)
---------------------------------------------------------------------------------------------------------------------------------
NAME ORGANISATION
---------------------------------------------------------------------------------------------------------------------------------
LEADER
MEMBERS
MEMBER CO-ORDINATORS
5
COMMITTEE
ON
DESIGN ASPECTS FOR ELECTRICAL SAFETY
(Second Edition – ------,2011)
---------------------------------------------------------------------------------------------------------------------------------
NAME ORGANISATION
---------------------------------------------------------------------------------------------------------------------------------
LEADER
MEMBERS
MEMBER CO-ORDINATORS
---------------------------------------------------------------------------------------------------------------------------------
In addition to the above, several other experts from Industry contributed in the preparation, review and
finalisation of this document.
6
DESIGN ASPECTS FOR SAFETY IN ELECTRICAL SYSTEM
CONTENTS
------------------------------------------------------------------------------
SECTION DESCRIPTION
-------------------------------------------------------------------------------
1.0 INTRODUCTION
2.0 SCOPE
3.0 DEFINITIONS
7.1 Characteristics
7.2.1 Transformers
7
------------------------------------------------------------------------------
SECTION DESCRIPTION
-------------------------------------------------------------------------------
7.2.9 Cables
12.6 Vehicles
13.0 REFERENCES
=====================================================================
8
DESIGN ASPECTS FOR SAFETY IN ELECTRICAL SYSTEM
9
vii) Voltage, Medium - (MV) xvi) Short-Circuit
10
xxii) Nominal Voltage (of an xxx) Flammable Material
Installation)
A flammable material is a gas, vapour,
Voltage for which an installation or part liquid, and/or mist which can react
of an installation is designated. continuously with atmospheric oxygen
and which may therefore, sustain a fire
xxiii) Highest System Voltage or explosion when such reaction is
initiated by a suitable spark, flame or
The highest R.M.S. phase to phase hot surface.
voltage, which occurs under normal
operating conditions at any time and at xxxi) Flammable Mixture
any point in the system. It excludes
voltage transients (such as those due A mixture of flammable gas, vapour, or
to system switching) and temporary mist with air under atmospheric
voltage variation due to abnormal conditions, in which after ignition,
system conditions (such as those due combustion spreads throughout the
to fault conditions on sudden unconsumed mixture.
disconnection of large loads).
xxxii) Hazard
xxiv) Lightning Protective System
The presence or the risk of presence,
The whole system of interconnected of a flammable mixture.
conductors used to protect a structure
from the effects of lightning. xxxiii) Hazardous (Flammable)
Atmosphere
xxv) Portable Equipment
In accordance with the Petroleum
Equipment which can be moved even Rules, an atmosphere containing any
while in operation or which can easily flammable gas or vapour in a
be moved from one place to another concentration capable of ignition.
while connected to the electric supply.
xxxiv) Non-hazardous (Safe) Area
xxvi) Hand-Held Equipment
An area, no part of which is within a
Portable equipment intended to be hazardous area.
held in the hand during normal use in
which the motor, if any, forms an xxxiv) Hazardous Area
integral part of the equipment. In accordance with the petroleum
rules, an area shall be deemed to be a
xxvii) Stationary Equipment hazardous area, where:
Either fixed equipment or equipment a) Petroleum having flash point
not provided with a carrying handle below 65°C or any flammable gas
and having such a mass that it cannot or vapour in a concentration
easily be moved. capable of ignition is likely to be
present;
xxviii) Fixed Equipment
b) Petroleum or any flammable
Equipment fastened to a support or liquid having flash point above
otherwise secured in a specific 65°C is likely to be refined,
location. blended, handled or stored at
or above its flash point.
xxix) Self Powered Vehicle
Zone 0 An area in which an
A vehicle used for the conveyance of explosive atmosphere is present
stationary equipment (e.g. continuously, or is present for long
compressors), personnel or goods in periods or frequently.
which petroleum or storage battery is
used to generate the motive power. Zone 1 An area in which an
explosive atmosphere is likely to
occur in normal operation
occasionally.
11
those non-countable faults which give
Zone 2 An area in which an the most onerous condition.
explosive atmosphere is not likely
to occur in normal operation but, if xxxviii) Flameproof Enclosure “d”
it does occur, will persist for a
short period only. Enclosure in which the parts which can
ignite an explosive gas atmosphere
xxxv) Non-hazardous (Safe) Area are placed and which can withstand
the pressure developed during an
An area, no part of which is within a internal explosion of an explosive
hazardous area. mixture, and which prevents the
transmission of the explosion to the
xxxvi) Electrical Apparatus for Hazardous explosive gas atmosphere surrounding
Areas the enclosure.
Type of protection based on the Air or inert gas used for purging and
restriction of electrical energy within maintaining an overpressure and, if
apparatus and of interconnecting required, dilution
wiring exposed to the potentially
explosive atmosphere to a level below NOTE For the purposes of this standard, inert
gas means nitrogen, carbon dioxide, argon or
that which can cause ignition by either
any gas which, when mixed with oxygen in the
sparking or heating effects. ratio 4 parts inert to 1 part oxygen as found in
air, does not make the ignition and flammability
An intrinsically safe apparatus is one in properties, such as explosive limits, more
onerous.
which all electrical circuits are
intrinsically safe. It is placed in one of
the following categories: xli) Powder filling “q”
12
xliii) Type of protection “n” 4.0 Power System Design
13
ii) While carrying out load analysis, vi) Details of protection relays
loads shall be characterised and their settings at sending
under different heads as under: end breaker side.
- Essential loads
(Emergency loads) vi) When capacitors are added to the
system for power factor
- Critical loads (e.g. improvement, necessary system
computer, fire water study should be carried out to
pumps, communication, decide measures for avoiding
instrumentation controls problems due to harmonics,
etc.) system resonance, oscillatory
torques in rotating equipment, in
iii) Required redundancy (based on rush current, increase in voltage
specific process/operating needs) across capacitors due to use of
shall be built in the substation series reactor, harmonic loading
which feeds power supply to the of capacitor, etc. The above
process units/important facilities assumes particular significance
so that in case of tripping of one where there is captive generation.
feeder, the unit/facility does not
get adversely affected.
4.2 Neutral Earthing
iv) The power system design shall
Note-1
ensure system reliability. This 4.2.1 Earthed System
assumes particular significance
where in-plant generation i) Power system neutral shall be
supplements the external power earthed:
supply. For this, quick isolation of
in-plant system from faulty grid, a) To limit the difference of
in-plant load shedding etc. electric potential between all
requires detailed consideration. uninsulated conducting
objects in a local area.
v) Before carrying out system
design, it is recommended that b)To provide for isolation of
the following minimum faulty equipment and circuits
information/data be obtained, when a fault occurs.
from the power supply authorities:
c) To limit over voltages
i) Incoming grid voltage and appearing on the system
frequency, actual variation under various conditions.
limits, guaranteed power
availability. Note-1: In oil mines, fault currents shall be
limited to not more than 750 mA in MV
systems and 50 Amps in 3.3 kV / 6.6 kV by
ii) Existing fault level of feeding employing suitably designed restricted
bus and system expansion neutral system of power supply.
factor for fault level.
ii) The neutral earthing system
iii) Location of feeding substation employs one of the following
and routing of supply methods:
lines/feeder and the reliability
of power supply. a) Solid earthing for low,
medium voltage system
iv) Size of conductor and current (upto 650V) and for high
carrying capacity. voltage above 11 kV.
14
b) Resistance / Impedance delta potential transformers
earthing for 3.3 kV to 11 kV (PTs) under earth fault
system. conditions. Besides it is
recommended that provision of
iii) The values of neutral earthing ‘on line insulation monitoring
resistors normally applied in facilities’ may be considered.
industrial power system are
selected to meet the governing 4.3 Short Circuit Capacities
criteria for limiting transient over-
voltages, i.e. earth fault current i) Each short-circuit interrupting
should not be less than the device shall have fault duty
system charging current. higher than the maximum value
Besides, the value of neutral of short circuit current calculated
earthing resistor selected shall at its location. The related
limit the earth fault current to a switchgear and bus ducts shall
value, which shall be sufficient withstand the above maximum
for selective and reliable fault current (mechanical and
operation of earth fault thermal stresses) for a minimum
protection system. duration of one second.)
15
the system neutral earthing, and a. Transformers rated 5
the over-voltages resulting due MVA and above,
to system fault, switching or
lightning surges. The insulation b. Induction and
co-ordination between the synchronous motors
electrical equipment and the rated 1500 kW above,
protective devices shall be done
in line with IS: 3716 and IS: c. Generators rated 2 MVA
2165. and above.
16
Provided that the above shall having long length of control
not apply to overhead supply cables (more than 800 m or so)
lines having protective devices due consideration shall be given
which are effectively bonded to the effect of capacitance on
to the neutral of supply ON/OFF operations of contactor.
transformers and conforming
to Rule 91 of I.E. Rules, 1956. vii) Recommended relay protections
for Transformers, motors and
vi) Metering instruments shall be feeders which are generally
provided on plant Main Switch encountered in distributing
Board to monitor the power network are given below :
consumption and supervision of
all concerned parameters like
current, voltage, power,
frequency, power factor etc.
Ammeters in the field for
monitoring motor current shall
be provided as per process
requirements. Metering and
protection current transformers
shall be preferably kept
separate. However, numerical
relays may be fed from a single
set of CTs for both metering and
protection. In the case of
contactor controlled feeders
17
TABLE-I
Relay protection system
Protection devices for power distribution system shall be as indicated below
(Figure inside bracket refers to note below) √ Applicable
RELAY DESCRIPTION RELAY HV TRANSFORMER HV OUTGOING INCOMER
NUMBER MOTOR BREAKER
FEEDER
FEEDER FEEDER
(SECONDARY (SECONDARY HV MV HV MV
WINDING PLANT PCC/ PCC/
VOLTAGE WINDING FEEDER
PMCC PMCC
> 3.3 KV) VOLTAGE
18
TABLE -II
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 as follows
(Figure inside bracket refers to note below) √ Applicable
RELAY DESCRIPTION NEMA GENERATOR GENERATOR EHV EHV SYN MOTOR
TRANSFORMER INCOMER TRANSFO-
CODE
RMER
Distance protection 21 - - √ - -
Synchronous check 25 - √ √ - -
Under voltage with 27 √ - √ - √
timer
Reverse power 32 √ - - - √
Low power flow 37 √ - - - -
Loss of excitation 40 √ - - - √
Negative sequence 46 √ - - - √
Over current 50 - - - √ √
Earth fault relay 50N - - - √ √
Over current 51 - - √ √ -
Voltage restrained 51V √ √ √ -
Earth Fault back up 51G √ √ √ -
Over current E/F 51N - √ √ √ -
Over voltage with 59 √ - - - √
timer
VT failure 60 √ - - - √
Auxiliary relay for 63TX - √ - √ -
transformer
Transformer 64R √(26) √ - √ -
Restricted Earth Fault
Stator back up earth 64G √ - - - -
fault
Rotor Earth fault 64R √ - - - √
Directional O/C 67 - - √ - -
Directional E/F 67N - - √ - -
Under frequency/df/dt 81 √ - √ - √
Tripping relay 86 √ √ √ √ √
Gen differential 87G √ - - - -
Gen and Transformer 87GT - √ - - -
differential
Transformer 87T - √ - - -
différentiel
Feeder differential 87F - - - √ -
Bus bar differential 87B/ - √ - - -
and check 87C
H
Trip circuit 95 √ √ √ √ -
supervision
19
RELAY DESCRIPTION NEMA GENERATOR GENERATOR EHV EHV SYN MOTOR
TRANSFORMER INCOMER TRANSFO-
CODE
RMER
Notes:
20
22. Breaker control switch shall be hardwired type.
23. Stand by earth fault relay 51G shall be provided in the incomer of switchboard fed from
transformers and transformer and switchboard located remotely from HV substation.
24. Restricted earth fault relay 64R shall be provided in the incomer of switchboard fed from
transformers having secondary voltage greater than 3.3KV and secondary winding is star
connected.
25. Relay 51V voltage controlled over current relay shall be provided on specific requirement
considering the rating of the outgoing feeders with respect to the Incomer rating. Generally this
relay shall be provided wherever CT primary current of outgoing feeders is exceeding 40% of
the CT primary current of the Incomer.
26. 415V DG set rated above 500kVA shall be additionally provided with Restricted Earth Fault
protection, 64R.
21
viii) Medium Voltage Motor - Auxiliaries of emergency set as
Protection: applicable
ii) The emergency power supply system i) These systems shall have inherent
shall feed the following loads to enable independent battery backup to maintain
continuity of supply in the event of continuity of supply to critical loads (e.g.
failure of MAIN SUPPLY. process control, communication, fire
alarm systems etc.) in the event of
- Electrical loads essential for the normal/emergency supply failure.
safe shutdown of the plant.
4.7.1 Un-interrupted Power Supply
- Emergency lighting, security (UPS)
lighting, obstruction lights.
i) An un-interrupted power supply shall
- Process plant instruments as be provided, as required for meeting
required critical loads that cannot withstand a
momentary interruption/other A.C.
- Communication equipment, Fire mains disturbance in supply voltage. A
Alarm control panels. separate battery shall be provided for
UPS system.
- D.C. Supply system, UPS system
22
ii) UPS supply should be provided for v) DC supply for electrical controls,
control circuit of all the critical variable instrumentation, UPS etc. shall have
speed drives. separate independent battery banks.
The DC bus for electrical controls and
iii) It is desirable that a 2 x 50% battery DC lighting should preferably be
bank configuration be provided. distinct to avoid switchgear control
supply being affected by faults in DC
iv) Following loads shall be connected to lighting circuits.
the UPS system:
4.7.3 Battery Sizing for DC systems
- Critical instrumentation and process
control, i) Electrical Switchgear and Controls
- Critical communication equipment, Battery shall normally be sized for a load
cycle having a minimum duration of one
- Microprocessor based Digital hour. While deciding the load cycle,
Control System. consideration shall be given to the specific
operating/safety requirements of plant &
Incoming power to the UPS system
equipment e.g. lube oil pump of STG for
shall be fed from the emergency
bearing oil flushing. The duration for
system, wherever provided.
battery sizing hence shall vary accordingly
v) In case of total power failure, un- as per specific operational requirements.
interrupted power supply shall be
available for at least 30 minutes or as ii) DC Instrumentation Shutdown System
determined by the process
considerations. This shall in general be sized for 30
minutes, unless otherwise required.
vi) Each branch circuit of the UPS
distribution system shall have a fused iii) Fire Alarm System
disconnect switch. The fuse shall be
fast clearing type and the fuse rating The battery shall be sized for the
shall be coordinated with the rating of duration and load in line with the
the UPS system. guidelines given in IS 2189.
23
ii) Following factors shall be considered for TABLE-III
proper selection of electrical apparatus TYPES OF PROTECTION
and equipment for areas where
flammable gas or vapour risks may arise: Area Description Symbol
Classification
a) Area classification, i.e. Zone 0, Zone 0 Intrinsic safety ‘ia’
1 or 2 category ‘ia’
Encapsulation ‘ma’
b) Gas group classification, i.e.
gas groups IIA, IIB or IIC.
Other electrical ‘s’
c) Temperature classification i.e. apparatus,
T-Rating. specifically
designed for
d) Environmental conditions in Zone 0. (See
which apparatus is to be Note 1)
installed.
Zone 1 Any type of
protection
Wherever practicable, electrical
adequate for
apparatus in general and switch and
Zone 0.
control apparatus in particular shall be
Intrinsic safety ‘ib’
installed in safe area. Substation and
category ‘ib’
control room shall be located in safe
Flame proof ‘d’
area. While deciding the route of
enclosure
overhead power lines, necessary
(See Note 6)
considerations shall be given to avoid
overhead lines passing through Intrinsic safety ‘ib’
hazardous areas. category ‘ib’
Pressurisation ‘p’, ‘px,
Electrical equipment intended for service (See Table IV) py’
in hazardous area shall be selected in Sand filling ‘q’
accordance with IS : 5571 and these Encapsulation ‘m’, ‘ma’,
shall be certified by recognised testing/ ‘mb’
certifying authorities of country of origin
Other electrical ‘s’
(e.g. CIMFR, LCIE, UL, FM, PTB,
apparatus
Baseefa etc.) and approving authorities
specifically
i.e. CCE or DGMS or DGFASLI as
designed for
applicable.
Zone 1
Zone 2 Any type of
For details on hazardous area
protection
classification, enclosure protection etc.
adequate for
OISD standard 113, National Electric
Zone 0 or Zone
Code IS 5571, 5572, IS 13408
1
Petroleum Rules and Oil Mines
Regulations shall be referred. Intrinsic safety ‘ic’
category ‘ic’
iii) General guidelines for type of protection Increased ‘e’
for electrical equipment in hazardous safety (See
areas are enumerated in Table-III. Note 2)
Non-sparking ‘n’
apparatus
(See Note 2)
Pressurisation ‘pz’
(See table IV)
Encapsulation ‘m’, ‘ma’,
‘mb’
Oil Immersion ‘o’
(see note 4)
24
permitted only when the use of such any other factor that might affect the safe
apparatus cannot be completely operation of the sub-station. (Refer also
excluded, whereas the Oil Mines OISD Standard 118 ‘Layout for Oil and
regulations prohibit use of any Gas Installations’)
electrical equipment in zone ‘0’ areas.
i) In large plants, the main sub-station floor
Note 2 The apparatus with type of protection shall be raised above grade level and the
‘e’ and type of protection ‘n’ when space below the sub-station floor shall be
installed outdoors shall have utilised for installation of cable trays. The
enclosures having the ingress substation cellar shall preferably have a
protection as recommended in IS clear height of at least 2 meters. The
469/2147. switchgear rooms shall preferably be
pressurised to prevent ingress of dust.
a. IP 55 where there are uninsulated Large substation shall have three entries,
conducting parts internally, and one for equipment entry, second for
normal entry and the third emergency exit.
b. IP 44 for insulated parts. Whereas required normal and equipment
entries can be combined.
Note 3 Name plate details of equipment
intended for use in hazardous area Pressurised substation shall have
shall include relevant marking of necessary Airlock lobby for the normal
hazardous protection as per applicable entry.
codes.
Small and medium size substations shall
Note 4 Oil-immersed apparatus may be used have one equipment cum normal entry and
only in case its security will not be the second for emergency exit. Emergency
impaired by tilting or vibration of the exit door in substation shall open
apparatus. outwards. The main entry for operating
personnel shall preferably be provided
Note 5 Flameproof enclosures are covered with double door system. Operator cabin
under compulsory certification. may be separately located to avoid
repeated opening of doors and dust entry
Note 6 : In Zone ‘1’ areas, Ex d/e equipment to substation. Pressurised substation
i.e. Ex ‘d’ equipment with Ex ‘e’ building shall have fixed glazing with
terminal boxes is also permissible. minimum number of openable windows. All
openings shall be kept properly closed to
maintain sufficient pressure inside to
TABLE-IV prevent dust entry.
MINIMUM ACTIONS ON FAILURE OF
PROTECTIVE GAS FOR TYPE OF ii) Non pressurised remote switch
PROTECTION ‘P’ room/offsite substation shall have fixed
glazing with suitable exhaust fans with
Area Enclosure Enclosure louvers to meet the ventilation
Classification does not Contains requirements. Proper maintenance and
contain ignition care shall be taken to keep the room free
ignition capable from dust.
capable apparatus
apparatus iii) The building shall be sized to take care of
present/future needs and to maintain
Zone 1 Alarm Alarm and adequate clearances between equipment,
switch off and equipment and wall for ease of
Zone 2 No action Alarm operation and maintenance. Small sub-
required stations shall be suitably elevated by
compacting the soil so that the bottom of
the cable trench within substation is above
the surrounding grade level.
6.0 SUBSTATION LOCATION / LAYOUT
iv) Normally transformers, reactors, neutral
The sub-station shall be located in a safe
earthing resistors etc. shall be installed
area. Consideration shall be given to
outdoor. Equipment like UPS system and
cooling tower sprays, vapours contributing
Variable frequency drives shall be installed
to insulation break down, vehicular traffic,
in a separate air-conditioned room. The
accessibility for installation of equipment or
25
battery banks shall be located in a Description Distance
separate, freely ventilated room in the a) At the rear of HV 1500mm
substation building along with the Switchboard
necessary fresh air inlet and exhaust
system and water connection. Battery b) At the front HV 2000mm
room door shall be provided with louvers at Switchboard
the bottom to aid cross-ventilation. Floor of
the battery room and the walls up to height
of one metre shall have acid resisting c) At the side of 1000mm
material/coating/be painted with acid/alkali various Switch
resistive paint or otherwise protected. boards and from
wall
v) Necessary space to keep equipment under
repair such as breakers, switch control d) At the front of 1500mm
gear items, spares/consumables like fuses various
etc. shall also be identified in building Switchboards
layout.
e) Between front to 2000 mm
vi) It is recommended to locate DG sets in a front of two
separate house/shed away from Switchboards.
Substation in a safe area to reduce noise (Say DRAWOUT
level in substation. If required DG set of MCCS) facing each
smaller rating can be located in substation other.
building provided the substation is located f) At the rear of MV 1000mm
in a safe area. However in such cases, the Switchboards
foundation of such D.G. sets shall be requiring rear
structurally delinked from the slab or floor access
of the rest of the substation building. g) Rear clearance in More than
Exhaust of Diesel Engine shall be kept other cases 750mm
away from Process/Hydrocarbon area. otherwise less
than 200mm.
vii) Transformer yard/bay shall be provided h) Transformers with As per IS
with fencing and gate and shall have fire wall on one side 10028
isolation walls for individual transformers.
i) Transformers with As per IS
Oil immersed equipment involving use of
walls on three sides 10028
large quantity of oil shall have oil soak pit
j) Clear height of bus- 2000mm
and drain arrangement as per Indian
duct from finished
Electricity Rules and regulations. Fire
floor level
fighting equipment, first-aid boxes, etc.
k) Clear space 1000mm
shall also be provided as required. (Further
between
guidelines on this can be had from OISD
Switchboard top
standard 116 - ‘Fire Protection facilities for
and beam soffit
Petroleum Refineries and Oil/Gas
Processing Plants’ and OISD standard 117
‘Fire Protection Facilities for Petroleum
Depots and Terminals.)
Note: The maximum length of switchgear line-
viii) The substation equipment layout and the up may preferably be limited to
clearances between different equipment 15-20 metres considering
shall be planned to ensure ease of operation and maintenance
operation and maintenance and meet all requirements.
requirements from the point of view of x) It is recommended that battery room,
safety of the operating personnel. UPS room, process shut-down DC
system room, operator’s room of large
ix) Clearance between various equipments sub stations, located close to process
shall also satisfy respective equipment units should have blast resistant walls.
manufacturer’s requirements and Indian This is to protect vital control power
Electricity Rules. Where these are not sources from any external damage,
specified the following minimum thus ensuring availability of control
clearances are recommended as general power for safe shutdown in disastrous
guidelines. conditions suitable for indoor use.
26
7.0 ELECTRICAL EQUIPMENT iv) Power
All electrical equipment shall be selected Internal and external parts of the
with respect to the maximum steady state casing and all metal parts likely to
current (rms value for AC) which it has to come in contact with the surrounding
carry in normal service, and with respect to air should be protected with epoxy
the currents (prospective, short circuit paint that will resist corrosion under
currents) likely to be carried under the particular atmospheric conditions.
abnormal conditions and the period (for
example, operating time of protective b) Switchgear panels and
devices, if any) during which it may be service boards
expected to flow.
Painting of the switch gear panels
iii) Frequency should be as per manufacturer’s
standard.
Electrical equipment shall be suitable for
continuous operation with respect to the All unpainted steel parts should be
system rated frequency with variation limits zinc passivated or suitably treated to
likely to occur. prevent corrosion. If these parts are
moving elements, then these should
be greased.
27
generally be as per Indian standards
c) Outdoor electrical equipment unless otherwise required. The rating
and the percentage impedance of
Painting of the outdoor equipment transformer shall be compatible to
should be as per manufacturer’s permit start of highest rated motor
standard. All metal parts likely to come while the transformer is preloaded with
in contact with the surrounding air maximum operating base load.
should be protected with epoxy paint
that will resist corrosion under the ii) Transformers connected to Grid
particular atmospheric conditions. supply / Generator transformer may
have ON LOAD TAP CHANGERS for
vii) Prevention of Harmful effects in-plant control of secondary voltage.
Plant distribution transformers may
a) All electrical equipment shall be have OFF CIRCUIT TAP changers.
selected so that it will not cause
harmful effects on other equipment or iii) In addition to standard accessories,
impair the supply during normal the transformer shall be provided with
service including switchgear auxiliary devices/ protective devices
operations. In this context, the factors such as Buchholz relay, oil level and
which may have an influence include: oil temperature indicator with alarm/
trip output contacts and current
* Power factor transformers for the secondary side
neutral for Protection. Transformers of
* Inrush current rating above 2000 kVA should have
winding temperature indicators with
* Asymmetrical load Alarm/ Trip provisions.
28
energised. The minimum clearances be preferably sleeved and joints shall
between live parts and between live be taped/shrouded. Minimum
parts to earth and neutral and clearances between live parts,
creepage distance of bus bars shall between live parts to Earth and Neutral
conform to IS 4237. shall conform to applicable IS code (IS
4237) Switchboards shall have
v) The drawout carriage on the additional safety features such as
switchboard shall have three positions falling tool shrouds for trapping of free
viz., ‘Service’, ‘Test’ and ‘drawn out’. fall of maintenance tools on live parts.
Automatic safety shutters shall be Busbar supports shall be of synthetic
provided to ensure the inaccessibility material with high tracking index. The
of all live parts after the breaker is switchboard shall have earth busbar of
drawn out. It shall not be possible to adequate size. The switchgear
drawout the carriage or rack it in with drawout trolley (in case of drawout
circuit breaker closed. The breaker/ design) shall have suitable scraping
contactor feeder trolley shall remain earth connection. Feeder tag plates
inside the cubicle even in the test shall be provided at both front and rear
position. There shall be distinct overall side of panels. Where required,
door for the breaker compartment and busbar routing shall be clearly marked
it should be lockable. All circuit on the back side of the H.V. Switch
breaker truck/trolley of the same rating board panels for easy identification
shall be interchangeable. during maintenance.
vi) Suitable interlocks shall be provided to ix) All non-current carrying metallic parts of
prevent faulty operation such as: mounted equipment/components shall be
- ‘Plugging in’ or ‘drawing out’ of a bonded to the earth bus.
closed breaker. x) Surge absorbers to limit the switching
- ‘Plugging in’ a breaker with earthing surges shall be provided as dictated by
isolator closed. the type of arc quenching media and
switching device.
- ‘Closing’ of earthing isolator with the xi) Starting of motors from substation shall
breaker ‘Plugged in’. not be allowed and switch boards shall
not have close push button at
- Pulling out of auxiliary circuit plug with switchboard for motor starting.
breaker in service position.
xii) In specific cases, motors requiring
- Pushing in breaker to service position frequent start/stop, (e.g. product, loading
with auxiliary circuit plug not in pumps etc.) shall be controlled by
position. contactor feeder appropriate to its rating.
- Opening of compartment door with xiii) Switch Boards shall have anti
isolating switch in ON position and condensation heaters.
vice-versa for Motor Control Centres.
xiv) All HV switch gears should have provision
The maximum height of operating of view glasses to take thermo graphic
handle/switches shall not exceed 1900 readings for predictive/ preventive
mm and the minimum height not below maintenance. It must be ensured that all
300 mm. such switch gears with view glasses
windows have been duly type tested and
- It shall not be possible to operate the certified for internal arc faults as per the
circuit-breaker unless it is fully in provisions envisaged in IEC:62271 or
service or Test or isolated position. other equivalent international standards.
vii) Suitable eye bolts for lifting of panels 7.2.3 MOTORS HIGH VOLTAGE (HV) &
shall be provided. On removing the MEDIUM VOLTAGE (MV)
eye bolts, no holes offering access to 7.2.3.1 General
panel shall be permitted.
i) Motors shall be totally enclosed, fan
viii) Busbars and supports shall withstand cooled type as far as practicable. As a
specified short circuit level without minimum, all HV motors shall have
permanent deformation. Busbars shall anti condensation heaters. The
29
minimum degree of enclosure shall be less than the hot withstand
protection for motor shall preferably be time of the motor.
IP 44 for indoor use and IP 55 for
outdoor duty motors. viii) MV Motors in general and HV Motors
where required shall be suitable for
ii) Generally Motors upto and including restarting under full load after a
160 kW shall be rated for medium momentary loss of voltage with the
voltage and motors of rating above possibility of application of 100 percent
160 kW shall be rated for high voltage. of the rated voltage, when the residual
If required, the rating of medium voltage has dropped down to 50
voltage motors may be extended up to percent and is in phase opposition to
and including 200 kW. Sleeve or anti the applied voltage.
friction type bearings shall be used.
Vertical motors shall have thrust ix) Medium voltage motors above 55 kW
bearings suitable for the load imposed rating and not requiring frequent starts;
by the driven machinery. Unless should be provided with suitable type
otherwise specified, all motors shall be of circuit breakers and composite
designed for ‘Direct ON line’ starting. motor protection relays.
iii) High voltage DOL starting motors shall x) Motor bearings shall be selected to
be suitable for starting under specified give a minimum L-10 life rating of 5
load conditions with 80% of the rated years (40,000 hours) at rated
voltage at the terminals and medium operating condition (the L-10 rating life
voltage DOL starting motors shall be is the number of hours at constant
suitable for starting under specified speed that 90% of a group of identical
load conditions with 75% of the rated bearings will complete or exceed
voltage at the terminals. before the first evidence of failure).
The bearings shall be adequate to
iv) The permissible noise level shall not absorb axial thrust in either direction
exceed the stipulations laid down in produced by the motor itself or due to
IEC 60034-9. shaft expansion. On line greasing
facility should be provided on motor for
v) Motor vibrations shall be within the all grease lubricated bearings (anti
limits of IS-4729 unless otherwise friction bearings). Wherever space
specified for the driven equipment. heaters are provided for motors, a
Motors with sleeve bearings may separate terminal box should be
require proximity probes to measure provided for termination of space
shaft vibration adjacent & relative to heater cables, as far as practicable.
the bearings.
xi) Considerations should be made at the
vi) Motors shall be required for design stage for the torque values of
continuous, satisfactory operation at all the Pumps / Fans requiring auto re-
rated output under the following acceleration with discharge valve
conditions : open.
30
withstand the specified fault level for a hot condition and four uniformly
minimum duration of 0.2 sec. distributed starts in one hour.
(Commensurate with instantaneous
short circuit protection). Winding ends ii) Winding insulation shall be class F and
shall be preferably brought out and temperature rise limited to that
star point made in a separate terminal specified in the applicable IS for class
box. Neutral terminal box shall have B insulation. The windings shall be
necessary space provision to mount tropicalised and adequately braced.
differential CTs for motors of rating The ends of the windings shall be
1500 kW & above. brought out in a terminal box with six
terminals with suitable links to connect
iv) Motors of rating above 1000 kW shall them in Delta. However, motors rated
be provided with RTDs, BTDs and up to 2.2 kW may be connected in star
scanners. Separate terminal boxes with three terminals.
shall be provided for space heater and
RTDs, BTDs. iii) The terminal box of motor controlled
by air circuit breaker shall be capable
v) Induced voltage at the shaft of the of withstanding the full internal short
motor having uninsulated bearing circuit conditions, with the specified
system shall not exceed 250 mV r.m.s. system fault level for a minimum
for roller and ball bearings and 400 mV duration of 0.2 second
r.m.s. for sleeve bearings with the (Commensurate with instantaneous
motor running at no load. Alternatively, short circuit protection). Where motor
the non driving end bearing shall be control is through contactor and
insulated from the motor frame to MCCB, or back up fuse, the terminal
avoid circulating current. box shall be able to withstand the let-
through energy of protective devices
vi) The insulated bearing end shield or corresponding to maximum system
pedestal shall bear a prominent fault level.
warning and manufacturer shall
provide detailed drawing showing iv) The terminal box shall be of sturdy
insulation arrangement. construction and large enough to
facilitate easy connection of required
vii) Motors shall be designed to withstand number of cable runs and size.
impulse voltage of at least (4Un+5) kV (Specifically Aluminium Conductor
with a wave front raise rise time of 1.2 Cables). Additional trifurcating boxes
microsecond and decay time of 50 may be considered for motors
microsecond to half the peak voltage. requiring termination of two or more
parallel runs of power cables.
viii) The inter-turn insulation of HV motors
shall be able to withstand a peak 7.2.4 Battery Charger and DC
voltage of at least 0.5 (4Un+5) kV with Distribution Board
a wave front rise time between 0.5 &
1.5 µs and a decay time to half the Charger and distribution board shall be
peak voltage of between 3 & 10 µs. floor mounted, free standing, metal
Un = rated line to line voltage. enclosed and vermin proof type having
front access hinged door and suitable
ix) Polarisation index for indoor use.
31
in the duty cycle. Accessories shall Automatic forward transfer, in case of
generally be as follows: inverter malfunction, shall be effected
with a break not exceeding 5 ms.
- Battery stand made of solid polymer or
epoxy/ powder coated mild steel (MS). 7.2.7 Capacitor Banks
- Inter-cell, inter row and inter bank i) The capacitor shall conform to IS 2834 -
connectors and end take offs. specifications for shunt capacitor for
power system.
- Porcelain cell insulators, stand
insulators. (As applicable) ii) H V capacitor shall comprise
appropriate numbers of basic single
- Hydrometers suitable for specific phase units (minimum 4Nos. basic units
gravity readings. (As applicable) in parallel per phase) which shall be
connected in star formation.
- Cell number plates as required.
iii) Capacitor banks shall be with necessary
- Thermometer with specific gravity discharge resistors to reduce the
correction scale. (As applicable) terminal voltage of each unit to a value
equal to or less than 50V in 5 minutes.
- Cell testing voltmeter (3V-0-3V)
complete with 1 m long leads. iv) Steel rack assembly suitable for outdoor
installations (where outdoor location is
- Rubber gloves required) to accommodate the basic
- Rubber aprons capacitor units with necessary post
- Spanner Set. insulators. Panel assembly (where
indoor location is required) to
ii) While sizing the battery following accommodate the basic capacitor units,
factors shall be taken into interconnecting busbars, insulators etc.
consideration, in addition to envisaged The panel shall have minimum IP-51
duty cycle: protection and shall be constructed with
sheet steel of minimum thickness 2.0
- Temperature correction factor. mm.
- Ageing factor as applicable.
v) Necessary series reactor to limit inrush
current and suppress harmonics (where
7.2.6 Equipment for Uninterrupted required)
Power Supply System
vi) The impregnant in the capacitors shall
i) This shall be of free-standing, floor be non-toxic.
mounted, metal enclosed and vermin
proof type having hinged door for front
access and suitable for indoor use. 7.2.8 Emergency Generator
ii) Under normal conditions, the rectifier- i) The emergency generating sets shall
cum-charger shall feed the inverter form a complete package and shall be
and charge the battery set. In case of designed to start automatically on
mains failure, the battery shall supply power failure and feed the selected
the necessary power to the inverter. loads. It shall be capable of taking
The inverter in turn feeds the load care of the load variations (e.g. the
through the static switch. If the inverter starting of largest rated motors on a
malfunctions or is overloaded, the load preloaded system). The unit shall be
shall be instantaneously transferred to complete with necessary starting
the by-pass line through the static equipment, associated control panel
switch. Normally the inverter shall be and shall be suitable for remote
operated in synchronised mode with starting.
the by-pass line, and manual forward ii) The regulation of generator voltage
transfer or manual reverse transfer shall be automatic and necessary
shall be effected without any break. instruments for metering viz. Ammeter,
Voltmeter, Frequency meter, kWh
meter, pf meter, Hour run counter etc.
shall be included in the control panel.
32
iii) The conductor screen, XLPE
iii) Warning of abnormal conditions shall insulation screen shall all be extruded
be incorporated prior to automatic trip in one operation by ‘Triple Extrusion’
to prevent unnecessary shutdown. process.
iv) All the six stator winding ends shall be iv) 1.1 kV grade cables may be
brought out to an externally mounted Aluminium/Copper Conductor PVC/
terminal box and shall be connected in XLPE insulated, PVC sheathed,
star. Necessary temperature detectors armoured type.
shall be provided for the stator
winding. The terminal box shall have v) All power and control cables shall
sufficient space to receive the cables preferably have extruded inner and
of specified size. outer sheaths.
v) Emergency DG set shall have Auto vi) Where single core cables are
starting arrangement but only with armoured and are meant for use on
manual switching off features. The AC circuits, armouring with non-
rating (Ampere Hours) of battery, for magnetic material (e.g. Aluminium)
cranking the engine shall be adequate shall be employed.
to make three attempts with an interval
of 5 to 10 seconds, if required. In case The communication cables shall
the engine fails to start ‘FAIL TO conform to DOT (Department of
START’ annunciation shall be Telecom) specification. For fire alarm
provided in substation or in control systems, PVC insulated, armoured
room. and overall PVC sheathed cable with
2
1.5 mm copper conductors may be
vi) The generator set shall be provided used.
with complete protection against
overloads, short circuits, ground faults, vii) The power and control cables shall
excitation failure, prime-mover failure have the following minimum cross
and shall include other connected sectional areas:
instrumentation interlocks.
Description Size
2
vii) The load shall be switched on to the a) Medium voltage 4mm Aluminium
2
generator only after the requisite power cable or 2.5 mm
voltage build-up. Copper
2
b) Control cables 2.5 mm (Copper)
viii) Diesel Engine installation, does not (See Note 1 below)
call for Area Classification, provided
the DG room is properly ventilated. c) Lighting
2
2.5 mm (Copper)/
Normally the ventilation provided to 2
4mm (Aluminium)
remove heat from the radiator is (See Note 2 below)
adequate to take care of the hazard
aspect. DG sets shall comply with the
Note 1 In case of difficulty in connecting the
latest guidelines of environment
cables to instrument relay terminals,
ministry with regard to noise levels.
the minimum cross section may be
2
7.2.9 Cables reduced to 1.5 mm copper.
i) In order to avoid spread of fire due to Note 2 For lighting inside the building copper
cables, it is recommended that the conductor cables shall be used.
outer PVC sheath of all cables used in Where conduit wiring is adopted,
2
industry shall be flame retardant type minimum 1.5 mm copper conductor
conforming to category AF as per IS: PVC insulated wire may be used.
10810. The cables shall have a low
smoke property. The minimum Note 3 Conductor size for wiring inside the
Oxygen Index shall be 29
Note 3
. panel for electronic
circuits/components shall be as per
ii) High voltage cables may be manufacturer’s standard.
Aluminium/Copper Conductor XLPE
insulated PVC sheathed, armoured viii) Cables shall be properly sized to carry
type. without undue temperature rise the
load current under site derated
conditions. The derating shall take into
33
account ambient air temperature,
ground/ duct temperature, grouping - Auto/ Manual selector switch
and proximity of cables with each and
other, thermal resistivity of soil etc.
Cables protected by fuses shall be - Cable glands.
2
able to withstand the maximum I t let
through energy of fuse. iv) Stop push button shall generally have
stay put feature except in the case of
In other cases, cables shall be able to critical drives such as lube oil pump
withstand the fault current for a etc.
duration as dictated by protective
disconnecting device. v) Control station shall have suitable
locking facility.
viii) The type of cable selected and the
insulation shall be compatible with 7.2.11 Convenience Receptacles
various chemicals encountered in the
plant and other environmental i) These shall have the necessary
conditions such as dampness highly mechanical interlocks and earthing
corrosive atmosphere, high/ low facilities. The enclosure shall have
temperature, radiation etc., bearing in suitable protection for site conditions
mind that certain chemicals (e.g. specified such as flameproof, weather-
Benzene, Ethylene Chloride) are proof, dust-proof, corrosion resistant,
known to be detrimental to PVC. etc.
ix) The selection of voltage rating of HV ii) Welding receptacles shall be provided
cables shall take into account the at suitable locations to ensure
system voltage, system earthing accessibility with a 50 meters length of
arrangements and type of earth fault trailing cable to any point in the
protection schemes. (Guidelines on process area. These shall be rated for
this can be had from IEC 60183). 63 A suitable for 415 V, 3-phase
system with a scraping earth
x) When feeders comprising of parallel connection.
runs of cables are envisaged, the size,
length and type of individual cable Adequate number of sockets for lamps and
shall be identical. portable tools shall be provided at suitable
locations to ensure accessibility with a 15
7.2.10 Control Station meters length of cable to any point in the
process area. These shall be rated for 15
i) Each Motor shall be provided with a A single phase supplied at 240 V. Hand
control station in the field. Motors lamps and portable tools shall be earthed
installed at elevated platforms (such through flexible cords. The flexible cable
as cooling tower fan, air fin cooler etc.) shall have 3 cores of multistrand copper
shall be provided with one stop push conductor of minimum size equivalent to
button at ground level in addition to the 1.5 Sq mm, with PVC insulation and metal
one provided near the motor braiding. In hazardous areas, hand lamps
shall be rated for 24 Volts. Accordingly
ii) The control station enclosure shall 240/24 V transformers shall be provided
have suitable protection for site either in the plug or in separate flameproof
conditions such as flameproof, enclosure.
weather-proof, dust-proof, corrosion
resistant, etc.. 7.2.12 Actuators for Motor Operated
Valves
iii) The control station shall include the
following equipment as per individual i) Valves with electrical actuators shall
requirements : generally be provided with integral
starters.
- Start/stop push button/ close,
neutral, Trip Switch ii) The necessary local/ remote selector
switch, start/ stop control switches or
- Ammeter, push button, torque limit switches etc.
shall be provided on actuator for
- Local/ Remote Selector Switch local/ remote control depending on
34
mode of selection. In case of failure considered e.g. ambient
of torque limit switches, the temperature, depth of laying etc.
mechanical design shall be adequate
to stall and trip the motor without iii) All trenches shall be sized
damage. depending upon the number of
cables, and their voltage grade. High
iii) The control circuits shall be AC voltage, medium voltage and other
operated for short distance or DC control cables shall be separated
operated for extended distance. The from each other by required spacing
actuator shall be provided with an anti or running through independent
condensation heater. pipes, trenches or cable trays as
applicable. Cable trenches inside
8.0 Plant Cabling substations shall be filled with sand,
pebbles or similar non-flammable,
i) Cables below ground shall be laid in materials or covered with
concrete trench/ tunnel or directly incombustible slabs. If a significant
buried. Cables above ground shall number of cables are taken on
be laid in cable trays/ cable racks. racks, adequate supports should be
provided on the side wall of trench.
However, cabling for fire water
system shall, as far as possible, be iv) RCC covers of trenches shall be
taken in exclusive route through effectively sealed to avoid ingress of
underground trench. chemicals and oils.
ii) While designing layout with single v) In unpaved areas, cables should be
core cable installations following directly buried in ground. Where
factors shall be considered : underground cables cross roadways
or pipe sleepers at grade etc., they
a) Cables are laid as a general shall be protected by being drawn
practice in trefoil formation through sleeves/ ducts to provide a
touching each other. permanent crossing. Sleeve/ duct
ends shall be effectively sealed
or thereafter.
b) Flat formation with spacing as vi) Concrete lined trenches shall have
per requirement. suitable drainage arrangement to
avoid water collection. Concrete
- When cables are laid in a flat lined cable trenches shall be sealed
formation, the individual cable fixing against ingress of liquid and gases
clamps and spacers shall be of non wherever the trenches leave a
magnetic material. hazardous area or enter control
room or substation. Pipes laid for
- As a general practice, the sheath of mechanical protection shall be
single core cables shall earthed to sealed at both ends.
keep sheath at earth potential.
However depending on the current vii) Above ground cable trays shall be
the cable has to carry, the feeder well supported suitably at every 2 to
length and permissible sheath 2.5 metres interval and protected
potential, various methods of against mechanical damage.
sheath bonding are employed, viz. Routing shall be decided to avoid
single point bonding, bonding at proximity to high temperature
middle, bonding at two ends, cross sources (steam drains, furnaces
bonding, sectionalised bonding etc., etc.), places subject to undue fire
for which cable manufacturers risk. Cable trays, racks and trenches
recommendations shall be shall be sized to allow for 10 to 20%
followed. future cables reserve. Each cable
tray tier shall accommodate the
- It should be noted here that the cables preferably in single layer.
current rating of cables will vary
depending upon laying formation, Instrument and communication
method of sheath bonding etc., apart cables shall not be laid in the same
from other derating factors normally trench/ tray along with electrical
35
cables. The overall cable layouts xvi) Besides each underground cable
shall be designed for minimum shall be provided with tags of
interference between signal and aluminium securely fastened at
power cables. every 30 metres of underground
length with at least one tag at each
Where ever there is a possibility of end before the cable enters the
electromagnetic interference, ground.
shielded twisted pair and/ or
screened and overall shielded For further details, on installation
cables should be used for control practices and requirements refer
cables/ signal cables. OISD-RP-147 on ‘Inspection and
Safe Practices during Electrical
viii) Cable cellars and important cable Installations’.
tunnels shall be provided with fire
detection and monitoring devices. 9.0 Plant Lighting
ix) Trailing cables for equipment such This can be broadly classified as
as cranes and excavators shall have under:
one additional core for earthing and
the cable shall be well protected i) Normal lighting
against mechanical damage.
ii) Emergency lighting
x) Cable straight through joints in
power and control cables shall be iii) Critical lighting
avoided as far as possible.
i) Normal and emergency lighting
xi) Only type tested termination kits system shall be on 415/240V AC
shall be used. While selecting the supply, whereas critical lighting will
type of cable kit, necessary be either on 220V or 110V DC. In
consideration should be given to the case of oil mines the maximum
additional safety measures needed voltage of the lighting system
for carrying out termination with kits should be 250 volts phase to phase
of type such as heat shrinkable type with midpoint grounded.
(particularly in hazardous areas).
ii) Sufficient lighting shall be provided
xii) Cable route markers shall be so as to enable plant operators to
installed at every 30 metres intervals move safely within the accessible
all along the cable routes and also at areas of plant and to perform
cable joints and locations where the routine operations. In the event of
direction of cable trench changes. normal power failure, emergency
Cable route markers shall extend lighting should be provided. Desired
600 mm above ground. lux level shall be achieved
considering that both the lighting
xiii) Cable installations shall provide for fixtures, normal as well as
minimum cable bending radii as emergency one are energised. In
recommended by manufacturer. the event of normal power failure,
emergency lighting shall remain
xiv) Cable trenches in hazardous area energised through emergency
shall be filled with sand and covered power source.
with RCC slabs to prevent
accumulation of flammable iii) Lighting requirements provided
gas/vapour inside the trench. during the failure of power supply
for Normal lighting are intended
xv) Cables shall be identified close to broadly,
their termination point by cable tag
numbers as per cable schedule. a) To facilitate carrying out of
Cable tag numbers shall be punched specified operations, for
on aluminium strap 2mm thick flat or safe shutdown of the plant.
circular, securely fastened to the
cable. b) To gain access and permit
ready identification of fire
fighting facilities such as fire
36
water pumps, fire alarm critical lighting system should take
stations etc. care of entire emergency lighting.
v) The recommended areas for AC ix) HPMV/ MLL / CFL / lamps shall
emergency lighting include : generally be used for outdoor plant
lighting. Keeping in view the re-strike
Control rooms (Process & utility) time lag and to avoid complete
darkness in case of a voltage dip/
brown out conditions, necessary
Fire water pump house, Fire stations incandescent / CFL lamps should be
judiciously distributed throughout the
Main sub stations plant area. Incandescent / CFL lamps
can be considered for emergency
Foot of stairs and ladder lighting to achieve this objective.
Fluorescent lamps may be used for
Platforms with ladders changing indoor lighting in non-process buildings
direction and control rooms. Safe area street
lighting and yard lighting may employ
sodium vapour lamps. Low pressure
Other changes of floor level that may sodium vapour lamps shall not be
constitute a hazard. installed in hazardous areas.
x) The illumination levels in different
Strategic locations in Process, utility areas shall be as per good engineering
areas where specific safety operations practice. Depending on the nature of
are to be carried out such as: job activities to be carried out the
- Areas near heat suggested minimum illumination
exchangers, condensers levels for various areas are as under:
- Barring gears of steam
turbine
- Some portions of roads
interconnecting
substations and process
plants.
vi) As a good engineering practice the
AC emergency load is generally
considered as 20-25% of Normal
Lighting load. However for small
plants, where AC emergency load
is not substantial/ where there is no
separate standby DG set, DC
37
TABLE-V TABLE-VI
38
10.0 Plant Earthing iv) All connections shall be carefully
made and adequately locked
i) Earthing system in general, shall against loosening. Normally
cover the following earthing system shall comprise of
GI strip as main earth grid along
with suitably located GI
Equipment earthing for disconnecting plates to provide
personnel safety, multiple earth connections
between earth grid and
System neutral earthing, and equipment and for connections
between main earth grid and
Static and lightning protection. electrodes. Alternatively, mild
steel strip can also be used for
ii) The earthing system envisages earth grid after providing
an earthing network with corrosion allowance.
designed number of earth
electrodes attached to it. The v) Connections between GI earth
following shall be earthed : electrode and the disconnecting
plates shall be done by GI strip.
- System Neutral For highly corrosive areas, PVC
insulated Aluminium Conductor
- Current and potential cable (un-armoured) can be
transformer secondary neutral used. Connections between the
disconnecting plate and various
- Metallic non-current carrying equipments shall be made by GI
parts of all electrical apparatus strip, GI wire or GI wire rope, size
such as transformers, as recommended in Table VII.
switchgears, motors, lighting/
power panels, terminal boxes, vi) In corrosive areas, aluminium
control stations, lighting fixtures, disconnecting plates along with
receptacles etc. suitably sized PVC insulated
aluminium conductor cables can
- Steel structures, loading platform be used for earthing grid/
etc. connections.
- Cable trays and racks, lighting vii) All utility, process pipelines and
mast and poles. flanges shall be earthed on
entering or leaving the hazardous
- Storage tanks, spheres, vessels, areas, except where conflicting
columns and all other process with the requirements of cathodic
equipments. protection. In addition, steel pipe
racks in the process units and
- Electrical equipment fencing offsite area shall be earthed at
(e.g. transformer, yard etc.) every 25 meters.
39
system at a minimum of two d. The roof shall have a minimum
points of the base. An thickness of 3/16 in. (4.8 mm).
independent earthing network
shall be provided for lightning
protection and this shall be x) The resistance value of an
bonded with the main earthing earthing system to the general
network below ground, minimum mass of earth shall be as follows
at two points. :
40
TABLE – VII
1. Earth connections to individual equipment from nearest earth plate/ grid may also be done
alternatively using Aluminium/ Copper conductor PVC insulated core of size not less than half
the cross-section of respective power cable to the equipment (Motor, Panel etc.). Connections
shall be made using crimped type of lugs.
2. Earth rods and conductors shall be designed to cope with the conditions imposed. The earth
conductor shall be adequately sized to carry the applicable maximum earth fault current
without undue temperature rise. All joints shall be protected against corrosion.
3. All the electrical equipment operating above 250 volts shall have two separate and distinct
connections to earth grid.
4. Lighting Fixtures shall be earthed through the extra core provided in the lighting cable.
11.0 Plant Safety and Security systems ii) Manned locations prone to fire hazard shall
have manual call points which on operation
This shall include the following systems: shall give audio-visual indication at the
control rooms and actuate the sirens. If
11.1 Plant Fire Detection and Alarm System there are many manual call points, these
should be conveniently grouped together to
i) The purpose of a fire detection and alarm form various zones and zone panels to be
system is to detect fire at the earliest and to installed in convenient places other than unit
give an alarm so that appropriate action can control rooms. Operation of each zone
be taken (e.g. evacuation of personnel panel should be indicated by audio-visual
summoning the fire fighting organisation, indication in the main control panel in the
triggering of extinguishing process etc.). An unit control room as well as in the other
alarm system can be activated by automatic zone panels with distinct colour indicating
detection devices viz. smoke detectors, heat the zone number.
detectors etc. and/or by manual operation of
manual call points i.e. break glass units. iii) Analogue addressable fire detection and
alarm systems may be considered for large
oil & gas installations due to their versatility.
41
iv) A fire detection and alarm system shall: Certain requirements for each facility are given
below as general recommendation.
a) Operate quickly enough to fulfil
its intended functions; 11.2.1 Telephone System
42
in colour and shall have ringing
c) Communication or call from indication lights.
master control station to any of 11.2.4 Radio Communication System
the field stations and
communication between field Portable Walkie-Talkie system.
stations at the discretion of
master station. i) A walkie-talkie system shall be
provided for radio
d) Communication between pre- communication within the plant
designated field stations as per area. The system shall operate
process operating requirements in the simplex mode on U.H.F.
without interference of the and the exact frequency shall be
operator manning the master decided in consultation with P &
station. T DOT authorities.
e) Operating an alarm call from ii) The system shall consist of base
master control station over all the station, monitoring receivers,
loud speakers during an portable stations, antennas and
emergency. associated accessories.
Adequate number of hand
ii) Paging speakers provided in areas
stations shall be provided.
having high ambient noise levels shall
produce a 6 dB paging sound level iii) The system shall enable
above anticipated ambient level for communication between
effective recognition of speaker’s voice portable station and the base
signals. station or between any of the two
portable stations. The system
Also the field stations shall be capable of
shall have a range of
operating in areas of high noise levels
approximately 6 km.
without any interference.
iv)The system shall provide
11.2.3 Emergency Communication System
excellent penetration in all
i) The ‘Hot line system’ shall be operating areas of the plant with
designed to provide a dependable no marginal locations and extend
communication link between pre- beyond the boundaries of the
designated points of operation. plant. The system shall operate
This system shall be completely above the man-made noise
isolated from the telephone system. spectrum to provide clear noise
free communication in all areas
ii) The emergency communication of high electrical noise.
system shall include a ‘Direct 11.2.4.1 VHF System
phone to phone hot line (H.L.)
system’ and a ‘Dedicated hot line Radio communication (VHF band) may
(D.H.L.) system’. be provided for communication between
the plant and pre-designated points
H. L. System outside the plant. The system shall
include necessary transmitter/ receivers
iii) By removing phone from cradle and associated antenna. The frequency
switch, the corresponding phone at of operation shall be decided in
opposite end will ring till answered consultation with statutory authorities
or until the phone is returned back (DOT).
to cradle disengaging the circuit
switch. 11.2.5 Fax System
D.H.L. System One fax machine shall be installed in the
administration building of the plant.
iv) A simplified selective dial scheme
shall be provided to give selective
12.0 MOBILE EQUIPMENT FOR
contact between all the extensions
HAZARDOUS AREAS
of this system. All the telephones
used for the emergency
12.1 PORTABLE HAND LAMPS
communication system shall be red
43
i) Hand lamps for use in b) Any other electrical equipment
hazardous area shall be associated with the engine shall
flameproof with an operating be flameproof. Electrical
voltage of 24 V. The hand lamp equipment shall be effectively
shall be connected to the source earthed and bonded.
2
of supply by a flexible 3x1.5 mm
copper conductor PVC insulated c) Cooling fan blades shall be made
metal braided cable. Glanding of from non-metallic materials which
these cables shall be specially do not accumulate electro-static
addressed to ensure proper charge.
integrity of flameproof enclosure.
d) All belts shall be of anti-static,
This cable should be protected by fire-resistant type.
PVC/ tough rubber sheath or
similar covering. The metallic e) In order to contain discharge of
body or any other exposed metal sparks or flames from the
part of the hand lamp shall be exhaust system, a gas
connected to earthing system. conditioner box and a flame trap
shall be installed. Alternatively,
ii) The source of supply shall be the exhaust should be designed
located as near as possible to to discharge to a location within a
the points to be illuminated. safe area.
Automatic protection employing
earth leakage detection scheme f) To prevent flashback through
(e.g. using ELCB with current induction system, wherever
sensitivity of 30 mA) shall be possible, air intakes for engines
provided to disconnect supply on shall be located in safe area.
occurrence of an earth fault. Alternatively a flame trap should
Hand lamps with self contained be installed.
batteries shall have type of g) The surface temperature of the
protection appropriate to the engine and exhaust system shall
applicable hazardous zone. not exceed 250°C when tested
12.2 DIESEL ENGINES under full load conditions. In
some situations cooling of the
i) The use of permanently installed exhaust manifold and piping may
diesel engines in Zone-0 and be necessary; using water
zone-1 areas is unacceptable jacketing or finned coolers and/
and the use of permanently or high temperature cut-outs or
installed diesel engines in Zone- alarms should be provided.
2 area should be avoided
wherever possible. h) However when either the free
movement of air is restricted by
ii) In the event of use of a thermal or acoustic shielding or
permanently installed diesel the ignition temperature of the
engine, being necessary in surrounding flammable
Zone-2 it is recommended that it atmosphere is below 200°C, no
should have the following engine exposed surface
minimum protections to ensure temperature shall exceed the
safety : minimum ignition temperature of
the gases involved.
a) The starter shall be either of a
flameproof electrical type (usually i) To prevent over-speeding of the
operated from the mains supply engine due to induction of
or battery) or of the following non- flammable gases or vapours,
electric types : means shall be provided to stop
the engine. It can be either :
i) Pneumatic A valve to close the air intake,
ii) Hydraulic Or
iii) Spring recoil A system to inject carbon
iv) Inertia, or dioxide into the air intake.
v) Hand start
44
j) Audio visual alarm for o) The fuel injection pump and
automatic shutdown of the governor where fitted should be
engine in the event of so designed that reverse
excessive cooling water running of the engine is not
temperature and/ or low lube oil possible.
pressure shall be provided.
12.3 STORAGE BATTERIES
k) A system using an alarm or trip
device to protect the engine i) Storage batteries shall not be
from excessive vibration should installed in Zone 1 locations,
be considered. except those used in portable
lamps where the enclosure
l) An engine having a crank case housing bulb, switch and battery
3
volume of over 0.5 m shall be shall be flameproof type.
provided with relief devices.
Relief valves or breathers on ii) As far as practicable use of
engines shall be fitted with storage batteries in Zone 2 areas
flame traps or discharge into shall be avoided. However where
the induction system unavoidable, storage batteries
downstream of the flame trap, if for use in Zone 2 areas shall be
fitted and upstream of the shut- “Increased Safety” type. These
off valve, if fitted. Dipsticks and/ shall meet the following
or filler caps should be screwed requirements :
or effectively secured by other
means. a) Celluloid and similar
combustibles shall not be
m) Intake and exhaust system used as constructional
design shall meet the following materials.
minimum requirements:
b) Battery containers as well as
• The length of the flame path fittings and insulating parts
through or across any joint outside the enclosed cells
shall be not less than 13 shall not consist of porous
mm. materials e.g. wood or other
flammable materials and shall
• Suitable metal-clad or other be resistant to flame and the
acceptable jointing material action of electrolytes.
shall be interposed between
all joint faces to ensure that c) Openings of cells necessary
leakage does not occur. for the escape of the gases
given off shall be so
• Where valve spindles pass constructed as to prevent
through the walls of any splashing of the electrolyte.
component of the induction
system, the diametrical d) The exterior of the cells shall
clearance shall not exceed be so constructed as to resist
0.13 mm, unless end caps impact, and the cell cases
are fitted. shall be firmly fixed.
45
voltage exceeds 24 volts, the c. Terminals shall be provided with
creepage distance shall be rubber covers.
correspondingly increased by
1mm per 2 volts. d. Enclosure and other
constructional features shall be
g) Where voltage of batteries is suitable as per the area
not less than 50 volts, either requirement.
the battery case shall be
subdivided by partitions or the 12.5 MISCELLANEOUS REQUIREMENTS
batteries shall be grouped into
containers; such that in no a. The electrical equipment and the
grouping does a voltage system as a part of mobile
exceeding 50 volts occur. In equipment shall be of intrinsically
these cases, the partitions or safe/ flame proof design, if
the containers shall have required to be taken in classified
heights of at least half that of hazardous areas.
the battery case.
b. The mobile apparatus shall be
h) The battery case shall be so used for temporary purpose only
constructed as to ensure under competent supervision.
sufficient ventilation in order
to prevent accumulation of c. No uninsulated current carrying
gases given off from the part shall be exposed.
battery, and the free space
within the case shall be as d. All components shall be
small as possible. accessible for maintenance/
repairs.
i) The metallic cover of the
battery case shall be lined e. All remote control or interlock
with materials resistant to circuits associated with
electrolyte. restrained plug and socket
coupling should be intrinsically
j) The cover of the battery case safe.
shall have special fastenings.
f. All electrical circuits shall be cut
k) Exposed live parts of battery off automatically in the event of :
contained in a case shall be
protected with rubber or • The current in any circuit
equivalent insulated materials. exceeding more than the
However, the openings for rated value in any circuit.
checking voltage may be • A leakage current to earth/
provided. earth fault.
46
13.0 REFERENCES
The following codes, standards and publications have either been referred to or used in the
preparation of this document and the same shall be read in conjunction with this document:
IS 1646 Code of practice for fire safety of buildings (General) Electrical Installations.
IS 2189 Code of practice for selection, installation and maintenance of Automatic Fire
Detection and Alarm System.
IS 3034 Code practice for fire safety of industrial buildings, electrical generating and
distributing stations.
IS 5572 Classification of hazardous areas (other than mines) for electrical installations.
Areas having flammable gases and vapour.
IS 10028 (Part 1, 2 & 3) code of practice for selection, installation and maintenance
of transformers.
IS 13408 Code of Practice for the selection, installation and maintenance of Electrical
Apparatus for use in potentially explosive atmospheres (other than mining applications or
explosives processing and manufacture)
IS 13346/ IEC 60079-0 General requirements for electrical apparatus for explosive gas
atmosphere.
47
IS/IEC 60079-7) Explosive atmospheres – Part 7: Equipment protection by increased
safety "e"
IS/IEC 60079-11) Explosive atmospheres – Part 11: Equipment protection by intrinsic
safety "i"
IEC 60947-1(1988), Low-voltage switchgear and controlgear: Part 1 General rules
IS 8289 IS/IEC 60079-15) Explosive atmospheres – Part 15: Equipment protection by type
of protection "n"
ii) C.B.I.P. (Central Board of Irrigation & Power) Technical Report No. 3 ‘Manual on Layout of
Substations’.
iv) Indian Electricity Act & Rules 1956 (Ministry of Irrigation & Power, Govt. of India)
vi) NFPA 780 Standard for the Installation of Lightning Protection Systems
b) OISD STD - 116 – Fire Protection Facilities for Petroleum Refineries & Oil/Gas Processing
Plants
c) OISD –STD- 117 – Fire Protection Facilities for Petroleum Depots, Terminals, Pipeline
Installations & Lube Oil Installations.
f) OISD –RP- 147 – Inspection, and safe practices during Electrical Installation
48