EIL Electrical Design Philosophy

SECTION C-2.4.
2
ELECTRICAL DESIGN PHILOSOPHY DOCUMENT No.
(M205EIL-CPF-E-BD-0002) A358-CPF-16-50-BD-0002 Rev-A
Page 1 of 29
ELECTRICAL DESIGN PHILOSOPHY
UNIT : CENTRAL POLYMER FACILITY

PACKAGE : PACKAGE-1
A 20.11.2012 ISSUED WITH FEED PACKAGE VB RKS VKJ

Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL 1650-1296P Rev. 2 Copyright EIL – All rights reserved
DOCUMENT No.
(M205EIL-CPF-16-50-BD-0002) A358-CPF-16-50-BD-0002 Rev-A
Page 2 of 29
TABLE OF CONTENTS
1.0 SCOPE ....................................................................................................................................... 3
2.0 SPECIFICATIONS, ITP’S & DATASHEETS ............................................................................. 3
3.0 STANDARDS ............................................................................................................................. 3
4.0 STATUTORY REQUIREMNTS .................................................................................................. 4
5.0 SYSTEM DESIGN PHILOSOPHY ............................................................................................. 4
5.1 General ......................................................................................................................... 4
5.2 AREA CLASSIFICATION and EQUIPMENT SELECTION ......................................... 4
5.3 Power system Design ................................................................................................. 5
5.4 Capacity of Electrical system ..................................................................................... 5
5.5 System voltages .......................................................................................................... 6
5.6 Allowable Voltage Drop .............................................................................................. 7
5.7 System Earthing .......................................................................................................... 8
5.8 Short Circuit Capacities .............................................................................................. 8
5.9 Insulation system ........................................................................................................ 9
5.10 Protection and Metering schemes ............................................................................. 9
5.11 DC Power Supply ......................................................................................................... 9
5.12 Emergency Power supply ........................................................................................... 9
5.13 Uninterrupted Power Supply (UPS) ......................................................................... 10
5.14 Power Factor Improvement ...................................................................................... 10
5.15 Harmonics Elimination .............................................................................................. 10
6.0 EQUIPMENT DESIGN PHILOSOPHY ..................................................................................... 10
6.1 General ....................................................................................................................... 10
6.2 Transformers.............................................................................................................. 10
6.3 Switch Gear ................................................................................................................ 11
6.4 BUS DUCT .................................................................................................................. 14
6.5 Neutral Grounding Resistor ..................................................................................... 14
6.6 Electric Motors ........................................................................................................... 14
6.7 Control Station ........................................................................................................... 15
6.8 Black Start and Emergency Generators .................................................................. 15
6.9 Lighting Systems ....................................................................................................... 16
6.10 SOCKET OUTLETS .................................................................................................... 17
6.11 Earthing and Lightning Protection .......................................................................... 18
6.12 AC/DC Distribution Boards....................................................................................... 20
6.13 DC Power Supply Systems ....................................................................................... 20
6.14 Uninterruptible Power Supply (UPS) System ......................................................... 21
6.15 Batteries ..................................................................................................................... 22
6.16 Cables ......................................................................................................................... 22
6.17 Cable Tray .................................................................................................................. 23
6.18 Equipment Enclosures .............................................................................................. 25
6.19 Actuators for Motor Operated Value........................................................................ 25
6.20 ELECTRICAL SUBSTATION BUILDINGS ................................................................ 25
6.21 CATHODIC PROTECTION ......................................................................................... 28
6.22 Electric heat tracing (EHT) System .......................................................................... 29
7.0 33KV OVERHEAD POLE LINE ............................................................................................... 29
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1.0 SCOPE
This specification along with the applicable project design basis / data form the basis for developing
detailed design and engineering for electrical facilities including electrical power system , electrical
equipment , Electrical Installation etc .
2.0 SPECIFICATIONS, ITP’S & DATASHEETS

The following specifications shall be referred for additional information for procurement, installation
and pre-commissioning of electrical equipment and material.
CAIRN-TSG-E-SP-0001 Specification for Oil Type Transformers

CAIRN-TSG-E-SP-0002 Specification for Medium Voltage Induction Motors
CAIRN-TSG-E-SP-0004 Specification for Dry Type Lighting Transformers
CAIRN-TSG-E-SP-0005 Specification for Medium Voltage Switch Gears
CAIRN-TSG-E-SP-0006 Specification for High Voltage Switch Gears
CAIRN-TSG-E-SP-0007 Specification for Power and Control cables
CAIRN-TSG-E-SP-0008 Specification for Electrical Heat Tracing
CAIRN-TSG-E-SP-0009 Specification for Lighting Systems
CAIRN-TSG-E-SP-0010 Spec for FLP control stations
CAIRN-TSG-E-SP-0011 Spec for FLP Light fittings and JB's
CAIRN-TSG-E-SP-0012 Spec for hazardous Area Plugs , sockets and hand lamps
CAIRN-TSG-E-SP-0013 Spec for safe area industrial type control stations
CAIRN-TSG-E-SP-0015 Spec for Uninterruptable Power Supply ( AC )
CAIRN-TSG-E-SP-0016 Specification for DC Power supply system
CAIRN-TSG-E-SP-0017 Project General - AC-DC Distribution Boards
CAIRN-TSG-E-SP-0018 Electrical Cable Tray System
CAIRN-TSG-E-SP-0019 Cathodic Protection
CAIRN-TSG-E-SP-0020 Project General - Variable Frequency Drives - VFD / Soft Starters
CAIRN-TSG-E-SP-0021 Project General - Neutral Grounding Resistor
CAIRN-TSG-E-SP-0022 Motor Operated Valve (MOVs)
CAIRN-TSG-E-SP-0023 Specification for Packaged Substation
CAIRN-TSG-E-SP-0024 Electrical Specification For Construction Power Supply System
CAIRN-TSG-E-SP-0025 Electrical Specification for High Mast Lighting
3.0 STANDARDS
3.1 All electrical equipments shall be in conformance with Central Electrical Authority (CEA) Regulations
& Indian Electricity Rules 1956 (IER 1956) as applicable. Any other regulatory design requirements
and approvals needs to be followed where ever applicable.
3.2 Employ the standards, as applicable, in the design as per relevant specification
a. Oil Industries Safety Standards ( OISD )
b. Bureau of Indian Standards (BIS or IS)
c. International Electro-technical Commission (IEC) Standards ( wherever relevant IS standards

are not available )
d. IEEE standards (wherever IS / IEC standards are not available.
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e. National Association of Corrosion Engineers (NACE) Recommended Practice for Cathodic

Protection
f. NFPA standards as part of fire proofing and design of substation buildings
3.3 Metric SI system of units shall be applied to all dimensions and documents.
4.0 STATUTORY REQUIREMENTS

Indian electricity Act
Indian Electricity Rules
The Factory Act
Oil Mines Regulations
Requirements of other statutory bodies as applicable, e.g. Central Electricity Authority

(CEA)/State Electrical inspectorate, CCE, DGMS
5.0 SYSTEM DESIGN PHILOSOPHY

5.1 General
The Electrical system shall be designed to provide
a. safety to plant, personnel and equipment during operation and maintenance
b. Reliability of service
c. flexibility of operation and maintenance
d. Minimal fire risk
e. Reliable Protection system through selective relaying system.
f. Adequate provision for future extension and modification
g. Effective power management and load shedding
h. Low harmonics in the system as per standards
i. Rated performance at applicable environment factors ( Project specific )
5.2 AREA CLASSIFICATION and EQUIPMENT SELECTION
5.2.1 Hazardous classification of areas and installations shall be in accordance with IS 5572 ,
IS14154, OISD standards and Oil mines regulations act .All the area within the battery limits
shall be classified for the degree and the extent of hazard from flammable materials.
5.2.2 Following factors shall be considered for proper selection of electrical equipment for use in
hazardous area.
• Area classification as per Zone
• Gas classification as per Group – The characteristic of the gas or vapour involved in
relation to the ignition current or minimum ignition energy and safe gap data.
• Dust classification as per Group. – The Characteristic of the dust involved
• Temperature classification – The Ignition temperature of the gas, Vapour or dust involved
or the lowest of the ignition temperature if more than one combustible is present.
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• Environment condition in which apparatus is to be installed – the selected electrical

equipments apparatus shall be adequately protected against corrosive and solvent
agencies, water ingress, thermal and mechanical stresses as determined by the
environmental conditions.
5.2.3 All the electrical Equipment installed in hazardous areas shall be selected as per IS-5571
and IS 14154 and shall meet the requiremnts of relevant IS and statutory regulations .
However , electrical equipments for Zone 2 areas as a minmum shall be EX(e) / EX (n)type
as per IS/ IEC codes . increased saftety type Ex(e) equipment shall not be used in zone 1
areas . Type of explosion protection to be used for individual equipment shall not be as
specfied in the job design data.
5.2.4 As far as possible Pressurised electrical equipments need to be avoided as along as other
alternative is available. In case using pressurised equipment (Type Ex (p) then on failure of
pressurisation system, the following minimum actions shall be provided.
1. For Zone 1 the equipment needs to switched off and alarm needs to be initiated.
2. For Zone 2 Alarm needs to be initiated
5.2.5 All electrical equipment to be used in classified areas shall be certified by CMRI /CPRI/ERTL
or equivalent recognized independent test house such as BASEEFA/LCIE/PTB/UL/FM. All
equivalent (Indigenous and imported) shall also have valid statutory approvals as applicable
for use in the specified hazardous area . The indigenous equipment shall confirm to Indian
standards and shall be approved by CCE/ DGMS as applicable based on mines non mines
application. All mines application shall be under DGMS jurisdiction and shall be defined
based on project condition in design basis.
5.2.6 All mines area electrical equipments to be used in hazardous area are type tested by other
reputed agencies outside India, the vendor shall approach applicable statutory bodies
specified above and get the equipment approved by them for use in the specified area of
utilization prior to energization.
5.2.7 The product transported along the pipe rack is heavy crude combined with water and is
deemed non-hazardous.
5.2.8 The well heads will be classified zones.
5.2.9 The hazardous area motors (Ex (e), or Ex (d) fed by variable frequency drive shall be
certified as a combination for the specified location by independent test house and shall
have valid statutory approvals. Non -sparking (Ex (n) motors shall not be used were solid
state starters/ VFD’s are used for separating purpose of the motor. In case of flame proof
motor and variable frequency drive combination may not be certified together if direct
temperature control by embedded temperature sensors are provided which will disconnect
the motors.
5.3 Power system Design
The power distribution shall be designed in accordance with project specification taking into account
all possible factors affecting the choice of the system to be adopted such us required continuity of
supply , flexibility of operation , operating cost , reliability of supply from available power sources ,
total load and the concentration of individual loads .
5.4 Capacity of Electrical system
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All the components of the electrical system shall be sized to suit the maximum load, under the most
severe operating conditions. Accordingly, the maximum simultaneous consumption of power,
required by continuously operating loads shall be considered and an additional margin shall be taken
into account for intermittent service loads, if any. The amount of electrical power consumed by each
process unit shall be calculated for its operation at the design capacity. System design shall permit
direct on line starting of all motors unless specified otherwise
5.5 System voltages
Power distribution between terminal to well 33KV + 10%, 3ph, 3W, 50 Hz + 3%, solidly
pads and remote areas outside the terminal grounded. ( To be referred with Design basis
of specific projects )
Power distribution 415V + 6%, 3ph, 3W, 50Hz + 3%.
240 V, +/- 6 %, 3 PH, 3 W system for Lighting

and Small power
( To be referred with Design basis / SLD of

specific projects )
Utilization voltage (Motors/Heaters > 160KW) 6.6KV + 6%, 3ph, 3W, 50 Hz + 3%, resistance
grounded
Utilization voltage (250W <=Motors/Heaters 415V + 6%, 3ph, 3W, 50 Hz+ 3%, resistance
<=160KW , Welding socket outlet) grounded
Motors < 250W, Lighting, Space Heaters, 240V + 6%, 2 ph, 2 W, 50 Hz+ 3%, solidly
Single phase socket outlet grounded
Protection, Control & Indication Supply for

33KV/6.6KV Switchboard and 415V 110V+ 10%, DC, 2W, Ungrounded
Breakers*
Charging of HV Switchgears and 415V 110V+ 10%, DC, 2W, Ungrounded

*
Breaker
415V contactor feeders control and indication 240V+ 6%, 2ph, 2W, 50 Hz+ 3%, solidly
supply grounded
UPS system 230 V+ 1%, 1ph, 50 Hz+ 1%
DC system 110 V + 10%, DC and 24V DC. 24V DC is

generated internally
Process Control & Instrumentation system 230V+ 1%, 1ph, 50 Hz + 1%, (from UPS
System)
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Communication System 230V+ 1%, 1ph, 50 Hz + 1%, (from UPS

System)
Instrument and Local Control panel (LCP) 24V DC generated within the instrument
panels (original source will be from 230V UPS
system).
* 415V switchgear control power supply can be 240V, 2ph, 50Hz, where 110V DC is unavailable. 240V, 2ph,
50Hz supply shall be derived from the Switchboard’s Control Power Transformer (CPT).
5.6 Allowable Voltage Drop

The maximum allowable voltage drops, as a percentage of the system During Normal Operating and
Start up
Sl. System Description Operating Maximum

No condition Permissible
voltage
drop
1 Main Bus Stabilized 0.5 %
2 Bus duct or cable between transformer Stabilized 0.5 %
secondary and HV switch board
3 Cable between PCC / MCC and MCC or auxiliary Stabilized
switch board 0.5 %
• MCC / Auxiliary switch board near PCC / 2 to 2.5 % (
Note 3
MCC
• Remotely located MCC / Auxiliary switch

board to PCC / PMCC
4 Cable between HV switch Board and HV Motor Stabilized 3%
5 Cable between PCC / PMCC and motor Stabilized 5%
6 Cable between MCC and motor ( distance Stabilized 5%
between Motor and MCC in different area / 100
meters away )
7 Cable between MCC and motor ( distance Stabilized 3%
between Motor and MCC in same area and
remote form PCC )
8 Cable between auxiliary switch board / LDB and Stabilized 1.5 % Note
lighting 2
9 Circuits between lighting panel and Lighting Stabilized 4%
points
10 DC supply circuits for electrical systems Stabilized 5%
10 From Main DCDB to DC Sub DB Stabilized 2%
11 From DC Sub DB to farthest consumer Stabilized 3%
12 From Main UPS DB to UPS Sub DB Stabilized 2 % Note 1
13 From UPS Sub DB to farthest consumer Stabilized 3 % Note 1
14 At the bus bar of the worst affected switch board Startup 15 %
(Start up of the large HV motors with other loads
on the bus or reacceleration of a group of motors
of HV motors ( Simultaneous start up or group
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reacceleration of HV motors is not envisaged )

15 At the bus bar of the worst affected MV switch Startup of 10 %
board ( PCC / PMCC / MCC ) large MV
motor with
other loads
on the bus ,
or
reacceleration
of a group of
MV motors
16 Cables between HV switch board and Motors Motor startup 5 % ( note
or 8)
reacceleration
17 Cables between MV switch board Motor startup 15 % (
or Note 8 )
reacceleration
18 33 KV OH line Stabilized 3%
Notes
1. Minimum voltage available across any instrument in the field shall be as per instrumentation design
basis. Distribution system for instrumentation supplies shall be designed accordingly. in case of any
conflict between electrical design basis and instrumentation design basis , the later shall govern
regarding instrumentation power supplies.
2. In case of difficulty in achieving specified voltage drops in cables up to lighting panel 5 % drop from
auxiliary switch board up to lighting points may be permitted.
3. Higher voltage drop may be permitted between PCC / PMCC and remote mounted MCC/ ACB; if
overall voltage drops up to motor (PCC to motor) is limited within 5.5 %.
4. The Voltage available at the motor terminals during startup must be sufficient to ensure positive
starting or reacceleration of the motor (even with the motor fully loaded, if required), without causing
any damage to the motor .
5. For medium voltage motors, the voltage available at the motor terminals must not be less than 75 % of
the rated value during startup or reacceleration.
6. For high voltage motors, the voltage available at the motor terminals must not be less than 80 % of the
rated value during startup or reacceleration.
7. Based on the sizing criteria as defined, including voltage drop criteria, cables for 415 V motors shall be
selected as per cable sizing table indicated in design data.
8. Higher voltage drop in motor cables may be permitted, in case the condition given in note 4, 5, 6 are
complied.
5.7 System Earthing
System earthing for incoming supply and primary / secondary HV distribution, LV distribution
system shall be as per design basis / SLD.
5.8 Short Circuit Capacities
Each short circuit interrupting device shall be designed to have rated service short circuit
breaking capacity (Ics) equal to or higher than the maximum value of short circuit current
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calculated, at its location. The related switchgear and bus – ducts shall withstand the above
maximum available fault current for a maximum period of one second. The sizing of high voltage
cables also be based on the short circuit withstand capacity for a minimum time period as
dictated by the protection system as defined in design basis, in addition to the maximum
anticipated load current .
5.9 Insulation system

The insulation of electrical facilities shall be designed considering the system voltage, the system
neutral earthing and the over voltages due to system fault, switching or lightning surges.
Lightning / Surge arrestors shall be provided wherever necessary
5.10 Protection and Metering schemes
5.10.1 The protective system shall be selected and coordinated to ensure the following
• Protection of equipment against damage , which occur due to internal or external short
circuits or atmospheric discharges
• Uninterrupted operation of those parts of the system , which are not affected by the fault
• Personnel safety
5.10.2 Protection relays shall be numerical based smart and communicable type relays. In
general, quick acting relays (with time delays, if necessary) shall be used and all the fault
tripping shall be done through high speed tripping relays. All the protection system
communication needs to be wired to central control system for monitoring and event
logging purpose. All the protection inputs commands and signals shall be hard wired. The
protective relays shall be compatible to time synchronization with GPS .
5.10.3 Metering shall be provided to keep record of power consumption and supervision of all
concerned parameters like current, voltage, frequency, power factor etc as specified. For
this dedicated data concentrator with HMI shall be considered. In addition to this metering
as per statutory requirement with relevant class of accuracy as per their guidelines and
approval needs to be provided.
5.10.4 The power system study Load flow , short circuit analysis , motor starting and re
acceleration analysis , harmonic study , relay coordination , DC load flow ,cable sizing
calculation needs to carried out by ETAP software .
5.11 DC Power Supply
Independent DC Power supply system shall be provided for the following
• Plant shutdown system including DC Instrumentation
• Electrical switch gear controls including critical lighting

Each DC power supply system shall include charger –cum- rectifier, batteries and DC distribution
board. Battery backup time shall be as specified in design data.
5.12 Emergency Power supply

The emergency power supply system, wherever envisaged, shall feed the following:
• Electrical loads essential for the safe shutdown of the plant
• Emergency lighting
• Process plant instruments as required
• Communication equipment
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• Fire detection and alarm system
• DC supply system
• Ups System
• Firefighting equipment excluding main firewater pump.
• Loads critical for process , plant and personnel safety
• Project specific loads other than above for commercial reasons.
• Emergency power could be from a different power source or Emergency generator as

per project design basis / SLD. Where emergency generator is envisaged emergency
power supply shall be made available within a time period of 30 seconds from the
instant of failure of normal supply / under voltage system activated. Manual start
provision shall be provided in the system .
5.13 Uninterrupted Power Supply (UPS)

Uninterrupted power supply system shall be provided for meeting critical loads that cannot
withstand a momentary interruption in voltage like critical instrumentation and control system
equipments like DCS , PLC etc . Separate battery bank shall be provided for UPS system.
Battery backup time shall be as specified in project design basis.
The UPS system shall be double redundant ( battery bank, charging and inverter units ) with a
single automatic regulated by pass arrangement
5.14 Power Factor Improvement

Capacitor banks shall be provided to improve the power factor in order to meet the minimum
stipulated power factor by the power supply authorities. Absence of regulation design
consideration needs to given to meet 0.9 lagging.
5.15 Harmonics Elimination

Design consideration and equipment selection needs to carried out to reduce the overall
harmonics within 5 % in the system by following ways
• Harmonics needs to reduced at the source of generation like VFD , UPS etc and all this
equipments needs to meet IEEE 519 compliance and within 5 % THD .
6.0 EQUIPMENT DESIGN PHILOSOPHY
6.1 General
The equipment shall in general confirm to CEIL standard specification. Equipments shall be
selected and sized as per philosophy given below
6.2 Transformers
6.2.1 All transformers except lighting transformers shall be three phase, oil immersed, double
wound type suitable for outdoor use, unless otherwise specified. Lighting transformers shall
be dry type unless otherwise specified
6.2.2 In general KVA rating and percentage impedance of each transformer shall be selected to
limit the rated current and short circuit current o values which are within the current rating
and interrupting capacity of switch gear available.
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Transformers rated more than 2500 KVA shall have provision for fan cooled rating unless
otherwise specified to increase the rating from the normal specified rating .
The KVA rating shall be decided on the following basis and should be as far as possible a
standard value. Sizing shall include 10 Percent margin for future growth.
• In systems having redundancy for transformers, with transformers without any forced
cooling, each transformer shall be rated to or equal to or greater than the 8 hr maximum
demand of the load plus 10 % margin for future growth.
• In systems having redundancy for transformers, with transformers having forced cooling ,
each transformer shall be rated equal to or greater than the 8 hrs maximum demand of the
load plus 10 % margin for future growth within 110 % of its self cooled ONAN rating and
shall be fitted with automatic forced air cooling fans .
• Where redundancy in number of transformers is not provided, rating shall be equal to

generated than 8 hr maximum demand plus 10 percent margin for future load growth. fan
cooled rating , where applicable , shall be reserved as spare capacity for further future load
growth .
6.2.3 100 % stand by transformers shall be provided in all unit offsite and utility substations unless
otherwise specified.
6.2.4 Unless otherwise specified dry type transformers shall be used for Heat tracing and lighting
transformers.
6.2.5 Heat tracing transformers shall be rated for 30 % spare capacity considering the unequal
loading.
6.2.6 Heat tracing transformers secondary side shall be protected with ELR and CBCT with CBCT
installed on the secondary side in the transformer itself.
6.3 Switch Gear
6.3.1 All switchgear and associated equipment fed from generators and transformers shall have
rating at least equal to the rating of respective generator and transformers feeding it, under
any circuit configuration. Generator incomer shall be rated to the maximum power output of
the generator set over entire operating temperature range. Transformer incomer shall be
rated equal to forced cooled rating of transformer or 110 % of ONAN rating as applicable.
6.3.2 Bus tie circuit breakers shall have rating higher of the following
• Largest incoming circuit breaker
• Maximum running load on either side of the bus section
6.3.3 All other switch gears not directly fed from generator and transformers shall have rating at
least to the maximum demand under any circuit configuration plus a provision for 10 % future
load growth. Incomers of these switch gears shall be designed to cater to the complete load
including 10 % margin for future load growth
6.3.4 All HV switch gear up to 33 KV shall be GIS and VCB / VC for individual feeders depending
upon the utility
6.3.5 All HV breakers above 33 KV shall be GIS switch gear with SF6 breakers for individual
feeders
6.3.6 Spare outgoing feeders shall be provided in all the switch gear. For HV switch boards the
number of spares shall be as indicated in SLD / Project specific Design basis.
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6.3.7 For other switch boards ( and where not specifically indicated in the SLD including HV switch
gear , at least one number of each type of outgoing feeders or 10 % of each out going feeder
whichever is more shall be provided as spare in switch boards
6.3.8 Separate feeders shall be provided in the switch board for each load / motor. However as an
exception maximum two numbers of welding receptacles may be connected to one power
feeders looped from the first to second receptacles
6.3.9 Circuit breakers / contactors controlling motor feeders shall have a rating of at least 125 % of
the maximum continuous rating of the connected motors.
6.3.10 All circuit breakers shall be of single break type having one pole per phase. Circuit breakers
for MV generator incomer shall be with four poles. Alternatively three phase breaker with
adequately rated air break contactor for neutral isolation may be provided where ever
applicable.
6.3.11 In case of HV vacuum circuit breaker, surge suppressors shall be provided for all out going
feeders .
6.3.12 All High voltage feeders and incomers shall have Numerical protection relays according to
their service like transformers, generators, motors
6.3.13 Rated service short circuit breaking capacities (Ics 0 for all breakers and MCCB‘s shall be
equal to or higher than the maximum specified value of short circuit current at the point of
installation . MCCB with backup fuses are not acceptable.
6.3.14 Air circuit breakers (ACB) shall be provided in MV ( 415 Volts and below ) switch boards for
all feeders rated from 400 A and MCCB ‘s shall be provided for all feeders rated below 400
Amps . Switch fuse unit is not acceptable
6.3.15 All MCCB’s, ACB’s for individual feeders, incomers shall be communicable type unless
otherwise specified.
6.3.16 Circuit breakers for capacitors shall have a current rating of at least 135 % of the capacitor
rated current. Circuit breakers capability to interrupt applicable capacitive current shall be
specifically verified.
6.3.17 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 .
6.3.18 For motors rated above 5 .5 KW, CT shall be provided in the switch gear for ammeter on the
local push button station.
6.3.19 The maximum rating of bus bar for MCC / ACB / LDB should preferably be limited to 800
amps. ACB shall be used for incomers and the tie breakers and these shall have suitable
mechanical interlocks.
6.3.20 Top entry bus duct as incomer for PMCC/PCC fed from Transformers rated 750kVA and
above and bottom entry cables as incomers for other boards. Bottom entry cables as feeders
for all boards or us specified during detailed engineering
6.3.21 Start / Stop control from DCS, emergency stop form ESD system, shall be hard wired Motor
ON / OFF status indication to DCS shall be soft communication however provision shall be
made in the system for hard communication as well
6.3.22 Other communication between the DCS and ACB incomers/ feeders, will be via TCP / IP
Mod bus protocol
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6.3.23 Control room to interface with Instrumentation via marshalling cabinet / data concentrator or
project specific.
6.3.24 All feeders for motor shall have motor control unit (MCU) and shall be microprocessor based
devise with integrated control , monitoring and protection functions with a communication
facility serving a single power module . The MCU shall be configured to suit the protection,
control and monitoring requirements for following motor starter functions .
• Non reversing direct Online
• Reversion Direct Online ( Rev – DOL )
• Star delta Motor ( SD )
MCU protection device are to include the following options as minimum .
• Thermal Over load
• Under load , stall protection under voltage detection
• Earth leakage
• Motor temperature protection by probes
• Phase Imbalance and loss protection
• Long start protection ( stall )
All MCU data shall be available via serial link via modbus TCP / IP to the central
communication system for Electrical system and DCS / ECS.
6.3.25 Similarly all Power feeders shall be fully self contained and draw out type fitted with MCCB
which shall be used as Isolator, short circuit protective device, Over current protection,
measuring units for current and voltage measurement for data logging.
6.3.26 All feeders shall include as a minimum on /off indicating lights and trip indication
6.3.27 All outgoing feeders will have earth fault protection
6.3.28 Tropical protection for PCC/PMCC/MCC
6.3.29 Thermostatically controlled space heater for panels
6.3.30 All the switch boards Suitable for future expansion on both sides
6.3.31 Bus bars for the switch boards shall be copper unless otherwise specified
6.3.32 The switch boards shall have centralized individual HMI Unit to monitor all feeders and
incomers of the particular switch board’s feeders. This unit shall have additional features to
interface with DCS, SCADA, Power management system etc based on overall system
philosophy of specified project.
6.3.33 All HV switchgears shall have IR windows installed as per OEM design
6.3.34 The vertical / horizontal / tap off bus bars shall be insulated and all joints shall be shrouded
with high thermal capability non flammable shrouds
6.3.35 The protective relays of switchgear shall have a dedicated control MCB
6.3.36 The short circuit capacity of current transformers shall be in accordance with the short circuit
capacity of the switchgear
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6.3.37 The switchgear control shall be designed for earthing through earthing truck and At least two
earthing truck per rating of switch gear shall be considered per switchboard
6.3.38 All switchgear, modules shall be suitable for applying Lockout procedure and shall be
designed to have all safety features not to have access to live terminals and interlocks to
ensure to protect accidental closing while racking in and door opening while in service
6.3.39 The transformer incomer feeders shall have NGR monitoring relay as well apart from other
protective relays as appropriate
6.4 BUS DUCT
6.4.1 LV bus ducts will be provided for interconnection of transformers rated 750kVA and above
from the transformer secondary to the 415V PMCC/PCCs.
6.4.2 Non-phase segregated, self cooled type, 3 phase, 3 wire.
6.4.3 Copper bus bars with heat shrinkable PVC Sleeves.
6.4.4 Enclosure will be fabricated from 3mm thick (min) aluminum sheets for ratings above 3000A
and 2mm thick (min) sheet steel otherwise.
6.4.5 Seal-off bushings with wall frame assembly wherever the bus duct crosses wall from outdoor
to indoor
6.4.6 All bus ducts shall have temperature monitoring system and connected to nearest data
concentrator or switch board HMI or DCS. If there is no provision to hookup to the nearest
system then standalone temperature indicator with alarm shall be provided
6.4.7 The Rating of the bus bar ducts connected to breakers shall have same continuous and
short circuit rating as that of breakers. Similarly bus ducts connecting to two bus sections
shall have same continuous and short circuit rating as that of main bus bars
6.4.8 Neoprene rubber bellows for enclosure wherever expansion joints are provided.
6.4.9 The outdoor portion of the bus bar shall be minimum IP 55
6.4.10 The adopter box on both ends of the bus duct shall be designed as part of the bus duct.
6.5 Neutral Grounding Resistor

The NGR shall be rated to withstand the fault current for 10 seconds and shall be out door type
with IP 55 enclosure. The NGR element shall be stainless steel / nichrome
6.6 Electric Motors
6.6.1 In general, three phase squirrel cage motors designed for direct online starting shall be used.
Motors shall be totally enclosed, fan cooled type and suitable for continuous outdoor use.
6.6.2 All motors shall be continuous maximum rated with possible exception of crane and hoist
motors, soot blowers, turbine starting motors etc., which may be rated for the envisaged duty
cycle
6.6.3 High voltage motors shall be suitable for starting under specified load condition with 80 % of
the rated at the terminal s and medium voltage motors shall be suitable for starting under
specified load condition with 75 % of the rated voltage at the terminals.
6.6.4 For heavy duty motors such us reciprocating compressor /agitator/crusher etc .high starting
torque motors shall be provided and starting time shall be limited to ensure adequate
protection by motor protection relays.
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6.6.5 Induced voltage across the shafts ends of motors shall not exceed 200 mv (rms) for ball and
roller bearings and 400 mV (rms ) for sleeve bearings . Wherever it exceeds specified limit,
the non driving end bearing shall be insulated from the motor frame to avoid circulating
current. The insulated bearing end shield or pedestal shall bear a prominent warning.
6.7 Control Station
6.7.1 Motors shall be controlled in the field at the motor location. Local control station shall have
Start / Stop pushbuttons and HOA selector switch. In ‘H’ position start control transfers to
only local, in ‘A’ position control transfers to DCS, while in ‘O’ position, the motor start is
disabled.
6.7.2 Circuit breakers shall be wired for both local and remote operations.
6.7.3 Local-Remote Selector Switch for contactor fed motor shall be located in the 415V
PMCC/PCC/MCC
6.7.4 DCS shall control and monitor motors through logic or by the control room operator. Each
starter shall have an ESD stop in the control circuit.
6.7.5 Each substation shall have two operator consoles (workstations) for monitoring and control
of protection relays.
6.8 Black Start and Emergency Generators
6.8.1 The Black Start and Emergency System shall consist of packaged diesel generators each
housed in a self container shipping enclosure complete with intake air louvers, exhaust,
silencer, controls, air start compressor, battery chargers and battery banks, etc. Quantities
and ratings of the packaged generators will be indicated on the single-line diagrams.
6.8.2 The Emergency generator set shall be designed to start automatically on power failure and
fee the selected loads. It shall be capable of taking care of the load variations like starting of
largest motor with specified base loads. Generator shall be designed to take care of
harmonics as per IEEE 519.
6.8.3 All the generators shall equip with Numerical Generator Protection system and
synchronizing panel and shall be capable for parallel operation with the main grid.
6.8.4 The Emergency generator set shall have at least 10 % spare capacity for meeting future
requirements
6.8.5 The Package shall be installed with fire suppression and F&G systems which are compatible
with the plant F&G system.
6.8.6 All emergency / backup generators shall have 1 + 1 redundant battery system with dedicated
battery charger and shall have provision for both trickle and boost charging
6.8.7 The exhaust of emergency / backup generators shall be designed to meet necessary
pollution control board regulations
6.8.8 All the engine parameters shall be monitored and shall be controlled with suitable PLC in
place.
6.8.9 The DG sets shall be preferably located in a separate building other than the E-house, in a
safe area to reduce noise level in substation. Exhaust of diesel engine shall be kept away
from the process/hydrocarbon handling areas and diesel day tanks shall be located outside
the DG room. Suitable ventilation system shall be provided to avoid heat accumulation in the
DG room.
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6.9 Lighting Systems
6.9.1 Plant lighting will be broadly classified into 3 categories
• Normal lighting
• Emergency lighting
• Critical lighting
Normal and emergency lighting will be on 240V AC (phase-phase) Supply whereas critical lighting
will be on 110V DC. In CPP and Mangala Process Terminal area, under normal conditions, both
emergency and normal lighting will be fed by normal power source. On failure of normal supply,
emergency lighting loads will be fed from emergency generator supply. Critical lighting shall be
automatically kept ON during normal/emergency power failure by 110V DC battery.
In the event of normal power failure, emergency lighting may be provided to facilitate safe shutdown
of the plant, access to fire fighting facilities and escape route for safe evacuation of plant operating
personnel. Emergency lighting will be 20-25% of normal lighting load. Probable areas for critical
lighting are Control Rooms, Substations, Central Fire Station, Emergency Escape Routes, critical
valves and devises identified for safe shutdown etc.
Well pads and remote area terminals will not have emergency lighting due to absence of emergency
power source. Instead critical lighting with self contained battery will perform the functions of
emergency lighting.
6.9.2 415/240V, 3ph, 50Hz lighting transformer of adequate capacity will be used to feed AC
lighting circuits. Lighting transformers shall be located inside floor/wall mounted Sub Lighting
Distribution Boards.
6.9.3 Lighting power distribution shall be through Main Lighting Distribution Boards (MLDBs), Sub
Power and Lighting Distribution Boards (SPLDBs) and Sub Lighting Distribution Boards
(SLDBs). MLDBs shall receive 415V, 3ph, 50Hz supply from PMCC/PCC/MCC and distribute
to SPLDBs in each building. SPLDBs apart from feeding HVAC and other three phase power
loads, shall also feed SLDBs. SLDBs shall have 415/240V, 3ph, 50Hz lighting transformer of
adequate capacity
6.9.4 Separate panel boards are provided for indoor and outdoor lighting. Enclosure of indoor
panel boards will have min IP 4X protection and outdoor panel boards will be housed
outdoors in an IPW 55 enclosure.
6.9.5 Lighting circuits will be R-Y, Y-B, B-R and emergency repeated in series.
6.9.6 Branch circuit protection shall be provided by miniature circuit breakers (MCBs). The total
estimated load of each circuit shall not exceed 80% of the branch circuit rating.
6.9.7 Lighting methods and material shall be suitable for the area classification in which they are to
be installed.
6.9.8 Indoor Lighting
a. Each lighting circuit load shall not exceed 2000VA (240V, 2ph).
b. 2 x 36 Watts, decorative, mirror optic, low glare, high power factor, surface mounted
fluorescent lamp fixture for Control Room and offices.
c. Industrial type, slotted reflector, open bottom in utility areas.
d. Lighting for Control Room will be two levels.

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e. Switching will be local double pole toggle devices.
6.9.9 Outdoor Lighting
a. Each lighting circuit load shall not exceed 6000VA (240V, 3ph).
b. Control is photocell/timer switching with manual override of 3pole contactors fed from 32A.
c. 32 Amp, 3 pole outdoor panel board circuit breakers. Cable size for exterior lighting circuits
shall be a minimum of 3/C 6mm2. However, final lighting feeder sizes shall be determined
after all de-rating and voltage drop factors are considered, especially the extended distances
involved.
d. Aircraft warning lights shall be provided for structures of height 20 meters and above such as
communication tower and flare stack as per Directorate General of Civil Aviation (DGCA)
regulations.
e. Staircase and exterior lighting will be wall/back mounted compact with side hinged cover,
aluminum housing, epoxy finish, 240V ballast suitable for 100W metal halide (MH) lamp.
f. Flood lighting fixture will be die cast aluminum, multi-tap ballast; yoke mount with slip fitter
adapter 400W MH mounted on 12m galvanised steel poles, 2 per pole.
g. Flood lighting using adequate number of 400W die-cast aluminum metal halide fixtures
mounted on 25m, galvanised steel pole may also be used. In which case it will be possible to
lower / raise the fixtures manually and electrically for bulb replacement.
h. Street lighting will be standard cobra head luminaries, 240V ballast, 250W MH, on a 9m
galvanized steel pole
6.9.10 Levels of illumination for the design of lighting systems shall be based on the illumination
intensities as per OISD Recommended Practice 149. Some of the values are summarized
as given below:
Area Description Lux

Control Room 500/250 lux 2 level
Inst, Equipment room/Offices/Laboratory 300 lux
Substation/Switchgear Room/UPS Room 200 lux
Kitchen/Mess/Prayer Room/Guard Room 300 lux
Shelter for other skids 150 lux
Outdoor Areas and Roads 10 lux
Outdoor Operational areas/Platforms 50 lux
Walkways/Staircases 50 lux
Change Room Toilet 100 lux
These are in-service values after applying a maintenance factor of 0.7 and a utilization factor
depending on the type of the fixture. These figures are the minimum vertical component values
for the locations described on a horizontal plane being 0.75m from the floor levels in buildings
and the ground or platform levels in other areas
Solar Power: All the building shall have roof mounted solar PV modules and associated
systems to cater the power required from Normal and emergency power DB’s during day hours.
6.10 SOCKET OUTLETS
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6.10.1 Single phase socket outlets shall be fed at 240(ph-ph) from Sub Lighting Distribution Boards.
Three phase socket outlets / welding receptacles shall be fed from SPLDBs located in
Substation / Facility buildings
6.10.2 Receptacles will have necessary mechanical interlocks, suitable protections for site
conditions and earthing facilities. All receptacles will have looping facility.
6.10.3 Substation, Control Room and Office Rooms will have decorative type receptacles, with
ELCB (100mA sensitivity) controlled socket, 240V, 1 phase 15 A, 3 pin at 10 meter interval.
Not more than four socket outlets shall be supplied by one circuit.
6.10.4 In plant area 240 V, 2 phase, 15 A, 3 pin ELCB (100mA sensitivity) controlled industrial type
receptacles will be provided at 15m spacing.
6.10.5 In outdoor area, 415 V, 63 A, ELCB (100mA) controlled TPNE welding socket spaced 50m
apart.
6.10.6 A maximum of two welding receptacles will be connected in one circuit.
6.10.7 All outdoor socket outlet/ receptacles will be of flameproof (Ex ‘d’) construction and rated for
temperature class T3, gas group IIA/B.
6.10.8 One outdoor 415V, 3 Phase+ E, 200A socket outlet shall be installed for each group (every
2) of power transformers, for oil treatment purposes.
6.10.9 All receptacles specified above shall have interlocked type and provided with one matching
plug.
6.10.10 All receptacles shall have looping facility
6.10.11 All the sockets shall have cable entry at the bottom.
6.10.12 Each branch circuit shall be protected with EL+MCBs and the main incomer shall have ELCB
in addition to the MCB / MCCB
6.10.13 Each branch circuit shall be double pole unless otherwise specified
6.10.14 The control rooms shall be provided with critical lighting fed from utility UPS supply.
6.11 Earthing and Lightning Protection
6.11.1 Earthing systems power system neutral earthing and plant earthing.
Power system neutral earthing employs following methods:
a. Solid earthing for 33kV system
b. High resistance earthing for 415V system
6.11.2 Plant earthing design will generally be carried out in accordance with the requirements of
Indian Electricity Rules and Code of Practice for Earthing BIS 3043.
6.11.3 Earth fault protection relays shall be provided for HV/LV distribution systems to limit the fault
current to a maximum of 750 milliamps for 415V systems and 100 Amps for 33kV system.
6.11.4 The resistance value of plant earthing system will not be more than 1 Ohm.
6.11.5 Main earth grid of 70mm2 bare copper conductor will be used below ground. Above ground
green / yellow PVC insulated copper conductors shall be used.
6.11.6 Earth rod of 20 mm diameter 3m copper clad steel rods shall be used
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6.11.7 Earthing of HV motors will be provided by connection to the main earth grid with 70mm2
PVC insulated copper conductors. LV motors, cable trays, metallic equipment, enclosures
and other items listed in paragraphs 6.11.10 and 6.11.11 below will be connected to the
main earth grid with 35mm2 PVC insulated copper conductors.
6.11.8 A separate ground system for the Instrumentation , DCS , ECWS etc shall be established as
specified requirements . The UPS shall be grounded to this system ground bus. The
resistance of this grounding system shall not exceed 1 ohm.
6.11.9 The step and touch potential calculations will be based on a soil resistivity report.
6.11.10 The following shall be connected to ground system at one location
a. Cable armoring (single core power cables)
b. Metallic enclosures of electric equipment including cable boxes, local control stations
etc
c. Lighting poles
d. Lighting fittings and control panels
e. Lightning protection ground rods
6.11.11 The following shall be connected to ground system at two locations:
a. Cable armoring (multi-core power cables)
b. Generator and Transformer neutral points
c. Transformer tank bodies
d. Substation building ground bus bars
e. High Voltage Switchboards and PMCC/MCC/PCC ground buses
f. Motor / generator machine frames
g. Buildings (metallic parts / piles, 1 per corner)
h. Pipe rack steel
i. Frames of skids
j. Tanks, vessels, towers, stacks
k. Base plate of rotating machinery
l. All non-current carrying metallic structures
m. All metallic structure / units
n. Metal fences, gates, side rails etc ( Shall be earthed at every 3 meters and wherever the
fence direction changes )
o. All metallic structure / units including permanent access ladders
6.11.12 Grounding cable joints shall be:
• Compression type below grade
• Bolted or compression type joints (above ground).
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6.11.13 Lightning protection will be provided to equipment, structure and buildings which are higher
than 20 meters or as per the risk index analysis worked as per IS 2309 / BS 6651. For
lightning protection, the value of 5 Ohms as earth resistance will be desirable.
6.11.14 Lightning protection system shall consist of air rods, down conductors and ground rods. Air
rods shall be of fully stainless steel (316). Installed as follows:
a. Drive a 3m long ground rod 1m from the structure; connect the rod to the unit with
minimum 70mm2 green/yellow insulated copper conductor.
2
b. Connect the rod to the plant system ground grid with a 70mm bare copper conductor
routed below grade.
c. Repeat this procedure at each unit.
6.11.15 All earth pits shall be chemically treated type
6.12 AC/DC Distribution Boards
6.12.1 This section covers main and sub distribution boards required for distribution of 415V for non
motor loads, 240V/230V (UPS)/110V DC power for loads and lighting
6.12.2 Indoor use, metal clad, vertical self-standing or wall mounting type, with min. IP 4X enclosure
in Substation/PMCC room and for other places min. IPW 55
6.12.3 Generally single incomer with associated protection and control logic
6.12.4 Generally for incomers and feeders MCCBs will be used.
6.12.5 Single front, fixed-out type construction.
6.12.6 Copper bus bars with heat shrinkable PVC Sleeves.
6.12.7 Identical breaker/contactor will be interchangeable.
6.12.8 Top or bottom entry cables as incomers and feeders
6.12.9 Tropical protection for AC/DC Distribution Boards
6.12.10 Thermostatically controlled space heater for panels
6.12.11 10 % spare feeders shall be provided in DB’s
6.12.12 All the DB’s shall have cable entry at the bottom.
6.13 DC Power Supply Systems
6.13.1 DC Power supply system comprises the converters, battery banks and the Main DC
Distribution Boards (Main DCDBs).
6.13.2 System shall supply continuous 110V dc power to HV and LV switchgear, relays and critical
lighting.
6.13.3 The dc power supply system shall be a fully redundant system consisting of two units
operating in parallel.
6.13.4 Each unit shall consists of one 100% nickel cadmium battery bank, one 100% Float-cum-
boost charger with 100% loading capability but operating at 50% load. Batteries shall be
placed in a separate well ventilated room on racks.
6.13.5 In case of normal power failure to the float-cum-boost chargers, each battery unit shall have
sufficient capacity to supply the total 110V DC system loads for 1 hour. Each battery unit
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shall cater to 50% of the loads (ie., connected only to the respective Main DCDB) for 2
hours.
6.13.6 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.
6.13.7 AC input to the DC system shall be 415V± 6%, 3 phase, 50Hz+ 3% from the plant 415V CPP
Emergency Power and Motor Control Center.
6.13.8 Ingress protection of panels shall be IP41.
6.13.9 A relay shall be connected to the DC busbars in the DC Power System to detect the
presence of earth leakage current flowing due to a fault somewhere in the outgoing sub-
circuits. This relay shall be sensitive to a low level of current (in the order of milli-amps), and
shall raise an alarm when the current exceeds a pre-set level.
6.13.10 The battery charger / rectifier shall feed the load and keep the batteries under fully charged
condition. Provision shall also be made for necessary boost charging / initial charging of
battery
6.13.11 Each battery charger and DCDB shall be sized to cater to selected battery capacity
6.13.12 Each DCDB shall have at least 10 % spare for future loads
6.13.13 All the DB’s shall have cable entry at the bottom.
6.13.14 The battery chargers shall have intelligent monitoring / metering system and shall display the
capacity of the battery, battery voltage, rectifier voltage and current and events and alarms
and communicable for remote monitoring
6.14 Uninterruptible Power Supply (UPS) System
6.14.1 Uninterruptible Power Supply system comprises the converters, inverters, static automatic
transfer switch, battery banks, constant voltage by-pass transformer with maintenance by
pass switch and Main UPS Distribution Board
6.14.2 One complete Uninterruptible Power Supply (UPS) system consisting of two parallel units
(for redundancy) shall be provided for powering the plant DCS, FGS, SIS and I/Os.
6.14.3 The system input shall be 3 phase, 415V± 6%, 50Hz+ 3% , Output shall be 230V ± 1%, 1ph,
50Hz ± 1%.
6.14.4 UPS system shall consist of two parallel units (each including a 100% converter, a 100%
solid state inverter, 100% nickel cadmium 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.
6.14.5 Both units shall operate in parallel, each shall provide 50% load but each shall have 100%
loading capability. Battery backup time shall be at least 2 hours for each battery unit and
total of 4 hours for the complete system.
6.14.6 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. The inverter will be
operating in synchronization with the bypass mains within specified voltage and frequency
limits.
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6.14.7 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.
6.14.8 UPS shall be fed from 415V Emergency PMCC. Out of three inputs one input can be fed
from Normal power supply also.
6.14.9 Ingress protection of panels shall be IP41.
6.14.10 A relay shall be connected to the AC bus bars in the UPS to detect the presence of earth
leakage current flowing due to a fault somewhere in the outgoing sub-circuits. This relay
shall be sensitive to a low level of current (in the order of milli-amps), and shall raise an
alarm when the current exceeds a pre-set level.
6.14.11 UPS system shall be sized to take care of the crest factor of the load current.
6.14.12 Each branch circuit of the UPS distribution system shall have a fast acting MCB with
auxiliary contact for alarm in each circuit of distribution . The MCB shall be fast clearing type
and the MCB rating shall be coordinated with the rating of the UPS system . Normally the
largest branch circuit shall not exceed 25 % of the UPS system rating.
6.14.13 Each UPS shall have at least 20 % spare feeders and the UPS shall be designed to cater
additional 20 % for future loads
6.15 Batteries
Batteries shall be of adequate capacity to meet the backup requirements as envisaged in the
duty cycle as well as to take care of future load growth of 10 %. While sizing the battery,
temperature correction factor, and ageing factor shall be considered in addition to the
maintenance factor. Batteries shall be complete will battery rack and shall be maintenance free.
6.16 Cables
6.16.1 Hv cables shall be dry cured XLPE insulated, extruded PVC sheathed, armored type with
copper conductors. All cables rated for 3.8/ 6.6 KV above shall be provided with both
conductor screening and insulation screening
6.16.2 MV power cables shall be XLPE insulated, extruded PVC sheathed, armored type with
copper conductors.
6.16.3 The control cables shall be PVC insulated, extruded PVC sheathed, armored type with
copper conductors. Special cables like twisted or shielded control cables etc shall be used
as applicable for numerical relays, VSD etc to suit selected equipment as per equipment
supplier’s recommendation.
6.16.4 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 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.
6.16.5 Cables connected in parallel shall be of the same type, cross section and termination.
6.16.6 As an exception within substation areas, un-armored cables may be used if specified and
agreed upon
6.16.7 All power and control cables shall be in continuous lengths (unless otherwise agreed upon)
without any splices or intermediate joints. The cables used for lighting and wires in conduits
DOCUMENT No.
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shall have appropriate junction boxes with adequately sized terminals. Unless otherwise
agreed, cable joints in hazardous area shall not be permitted.
6.16.8 Outer PVC sheath of all cables used shall be flame retardant type conforming to category AF
as per IS: 10810.
6.16.9 The cable shall have a low smoke or zero halogen property. The minimum Oxygen Index
shall be 29
6.16.10 All incoming cables to switch gear / UPS/ DC system / DB’s and other equipment shall be
sized for maximum load including 10 % future load growth. Cable for capacitor banks shall
be sized for 135 % of the rated capacitor current.
6.16.11 Maximum cross section area for multi core cables is 300mm2 and 630mm2 for single core
unless otherwise agreed upon.
6.16.12 All control cables shall have minimum 10 % spare cores, except that control cable having
seven cores may have one core as spare.
6.16.13 Cables shall be designed to Bureau of Indian Standards (BIS)
6.16.14 The armor for single core cables shall be of non magnetic material.
6.16.15 Fire resistance cables shall be used for ESD, telecom and other critical systems
6.16.16 Conductors of all sizes of cables shall be stranded and shall not be solid copper .
6.16.17 6.6KV and 11KV cables shall be Unearthed UE grade where as the 33KV and 415 V cable
shall be Earthed (E) grade.
6.16.18 The cable outer sheath shall have special coating / treatment for UV protection
6.17 Cable Tray
6.17.1 Cable tray will be manufactured as galvanized steel ladder type, H style, with 157mm (6”)
side rails and 129mm (5”) loading depth, using standard widths of 900 mm (36”), 600mm
(24”), 300 mm (12”), or 150mm (6”). Ladder rung spacing shall be 225mm (9”) on centers.
6.17.2 Cable tray shall have 1.5 safety factor and be capable of bearing149kg/m (100lb/ft) load for
900mm width, be supported at 6m span intervals, and same equivalent for other sizes.
Actual cable tray length must be equal to or exceed the supporting span interval.
6.17.3 Cable trays shall be routed on dedicated tiers of the pipe racks and on sleepers to
equipment. When required, inverted “V” type cable tray covers shall be used.
6.17.4 A separate tray system will be utilized for each voltage level as indicated in the Cable Tray
Voltage Separation Matrix below:
Cable Tray Voltage Separation Matrix
Cable Tray Voltage/Type Separation of Cable Trays (mm)
(see legend below) A B C D E F
A 150 150 150 150 600 600
B 150 150 150 150 600 600
C 150 150 150 150 600 600
D 150 150 150 150 150 150

DOCUMENT No.
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E 600 600 600 150 150 150
F 600 600 600 150 150 150
Cable Tray Voltage/Type Legend
A. 33kV
B. 11kV / 6.6 kV
C. Low Voltage Power (415V / 240V Lighting / 230V UPS / 110VDC)
D. Control (240V Motor Control / 240V Lighting)
E. Instruments / Fire and Gas / Fiber Optic
F. Paging and Alarm
Note: For all cable trays stacked vertically, there shall be a minimum vertical working clearance of
300mm from the top of the lower tray to the bottom of the tray above.
6.17.5 Multi-core HV cables will be arranged in a single layer with one cable diameter spacing
between them. Single core HV cables shall be arranged in trefoil formation in single layer,
with one trefoil cable diameter spacing between them.
6.17.6 Low voltage power cables will be arranged in single layer with no spacing between them in
single layer.
6.17.7 Motor control cables will be laid with no spacing between them horizontally and vertically in
two layers.
6.17.8 In case separate trays are not practical for power and control cables, barriers shall be used
in same cable tray.
6.17.9 Instrument cable trays will be loaded to 50% of the total available cross sectional area of a
given cable tray. This area is determined by multiplying the inside width by the allowable
loading depth, times 50%.
6.17.10 If required, two optical fiber cables shall run for redundancy, in different trays / routes.
However, lengths must be the same within ±10m.
6.17.11 Trays will be connected by expansion splice plates between their sections and fitted with
expansion guide clamps at every 36 to 40m intervals. Tray will be connected at other
junctions by standard splice plate and fitted with hold-on clamps.
6.17.12 The trays shall be supported at appropriate intervals both vertically and horizontally, as
required by the cable tray manufacturer’s design criteria.
6.17.13 The maximum length of single cable tray shall be 3 Meters.
6.17.14 Ladder type cable trays shall be manufactured and installed in accordance with the
following:
NEMA VE-1 Metallic Cable Tray Systems

NEMA VE-2 Metallic Cable Tray Installation Guidelines
IEC 61537 Cable Tray Systems and Cable Ladder Systems
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6.18 Equipment Enclosures
6.18.1 All equipment shall be entirely suitable for the site service conditions as specified in
specifications and shall be protected against dust, humidity, sulfurous and atmosphere and
designed to obviate the entry of vermin and insects.
6.18.2 The degree of protection for enclosures shall be according to IEC 60529 and IEC 60144 as
follows:
• Indoor equipment : IP 4X
• Outdoor Equipment : IP 55
6.19 Actuators for Motor Operated Value
MOV‘s shall be provided with integral starters. the necessary local / remote selector switch , start
/ stop control switches or push button s , torque limit switches etc shall be provided on actuator
for local / remote control depending on the mode of selection . In case of failure of torque limit
switches, the mechanical design shall be adequate to stall and trip the motor without any
damage. The control circuit may AC operated for short distance and DC operated for extended
distances where required. MOV‘s with 2 wire control shall comply to job specification and control
supply shall be supplied therein.
6.20 E–HOUSE SUBSTATION BUILDING
E-house Sub station shall be Modular type E-House will be under CPF Contractor’s scope and shall
comply with Specification for Packaged substation, CAIRN-TSG-E-SP-0023..
6.20.1 Sub-station shall have fire extinguishers, first aid boxes and other safety equipment as Per
statutory requirements. Insulating mats shall be of synthetic rubber and required voltage rating
shall be provided in front of switchboards.
6.20.2 Separation walls between transformers in all substations and safe inter transformer distances
for switchyard transformers shall be as per clause 5.3.11 & 5.3.12 of OISD Std- 173.
6.20.3 Equipment like transformers, neutral grounding resistors, reactors and HV capacitor Banks shall
be located in bays adjacent to the sub-station building. All bays shall have well drained floor,
surfaced with gravel or other suitable material.
6.20.4 In order to prevent oil, whether from a small leakage or outflow from transformer tank, from
reaching and polluting the water bearing stratum, transformers shall have the following
provisions, depending on the oil capacity of the transformer.
6.20.5 Oil Capacity up to 2,000 liters:
Transformers installed adjacent to sub-station/buildings or in Switchyards shall be provided with

a layer of 100 mm deep stones of about 40 mm granulation, all around the Transformer, for a
width of 20 % of the transformer height or with a minimum width of about 800 mm.
6.20.6 Oil Capacity exceeding 2,000 liters:
Transformers installed adjacent to sub-station/building or in Switchyards shall be Provided

with oil containing pits.
DOCUMENT No.
Page 26 of 29
The oil containing pit may be shaped as per OISD standard 173. The pit shall extend all around
the transformer for a width of 20 % of the transformer height, with a minimum width of about
800 mm. In case oil capacity exceeds 9,000 liters, in any chamber, provision shall be made for
draining away of any oil, which may escape or leak from the tanks, to a waste oil tank.
6.20.7 The following clearances will be maintained around equipment as minimum, unless specified
otherwise:
Sl. NO Description Clearance

1 Front clearance for HV Switchboard 2500mm
2 Front clearance for other switch boards 2000mm
3 Rear Clearance for HV switch board 1500 mm
4 Rear clearance for other switchboard which requires 1000 MM
Maintenance switch board
5 Rear clearance for MV switchboard and other panels 200 mm or more than 1000mm.
which requires no Maintenance on the rear side and the
panels rear is not having any openings
6 Side clearance between switch boards or from nearest 1000 mm after considering
obstruction space for future panels as
specified .
7 Clear height of bus-duct from FFL 3000mm
8 Head clearance 2000mm
9 Battery rack to wall for clearance for -

Single row / double tier 100mm
Double row , single tier 100mm
Double row , double tier 750mm
10 Front clearance for wall mounted equipment 1000mm
11 Front clearance for operation station annunciation / 2500mm
control panel
12 Front-Front of 2 switchboards facing each other 2000 mm
6.20.8 Electrical equipment installed in battery room such as exhaust fan, lighting and circuit breakers /
receptacles shall be of flameproof and corrosion proof construction and certified for gas group
IIC classified locations. This particular clause may be deviated based on vendor
recommendation.
6.20.9 The switches, lighting, sockets, and equipment in substation buildings and battery rooms shall
be as per drawings, specifications, and IS/IEC standards.
6.20.10 Battery room and ventilation arrangement and approved by CEIL
DOCUMENT No.
Page 27 of 29
6.21 HIGH VOLTAGE SWITCHBOARD
Only major relays, meters and controls are indicated in the hardware data sheets. Any auxillary
relays, timers, switches etc as required while developing the control schematic and felt necessary for
safe operation, even if these are not specifically included, shall be supplied by the Contractor.
All relays, metering and control components shall be mounted on the panel front only.
All dummy panels and rear extensions required for bus trunking, cable terminations, mounting of
relays, metering and control components etc shall be supplied by the Contractor.
The following change over scheme shall be provided in 6.6kV Air insulated switchgear.
a. Change over scheme for two incomers and one bus –coupler
Auto manual change over scheme for switchboard with two incomers and one bus coupler breakers
shall comply with the logic described briefly as follows. Safety interlocks as deemed necessary shall
however be considered during detailed engineering.
b. Auto Change over:
Auto / Manual change over between the two incomers and one bus coupler shall be in such a way
that those two incomer breakers are ON at a time and bus-coupler breaker is normally open.
Bus coupler breaker is made ON automatically in case the incoming supply at incomer breaker no.1
or 2 fails and respective breaker trips on under voltage.
Blocking of auto transfer (i.e closing of bus-coupler) if any incomer breaker trips due to a fault.
c. Manual Change over:
Incomer no.1 and 2 breakers are ON, Bus-coupler breaker is OFF. Manual closing of bus coupler
with momentary paralleling (interlocked with check synchronizing relay) of the incoming supplies to
facilitate taking out any of the incomer breakers for maintenance.
Trip incomer 1 or 2 (preselected) after closing of incomer 1 or 2 or coupler to avoid continuous

paralleling of incomers)
d. Initiation of Auto changeover:
When the incoming supply to breaker no.1 or 2 fails, the respective incomer is tripped through under
voltage relays and a timer. The time delay is in the range of 0.5 to 5 sec. Breaker trip on under
voltage is blocked in case of the power failure on both the incomers.
The voltage on healthy bus section has been above the set value of normal voltage for a specified
duration (settable through an Off delay timer0.5-5 secs) and the incomer breaker of healthy bus is
closed in service position.
Bus-coupler is open and in service position
Auto/ Manual switch is set for “Auto” operation.
e. Closing of bus coupler breaker under auto operation:
One of the incomer breaker has tripped on under voltage.
The residual voltage on the bus that has lost supply is less than 40% of normal voltage.
Incoming voltage of healthy incomer has been above 80% of normal voltage for a specific duration
(Through timer 0.5 sec-5 sec)
Auto/Manual switch is set for AUTO operation.
DOCUMENT No.
Page 28 of 29
f. Manual transfer after auto changeover
When supply is again available at incomer breaker after the Auto changeover has already taken
place, it is possible to restore the system to normal operation condition by operating selector switch
(meant for tripping incomer no.1 or 2 or bus-coupler and by setting auto/manual switch in Manual
mode.
In manual transfer the closing circuit shall be interlocked through check synchronizing relay.
6.21.1 MEDIUM VOLTAGE SWITCHBOARD
Rating of Power cum motor control centre (PMCC) shall be decided Contractor and same shall be
suitable for a minimum fault level of 50kA for one sec.
The connection from Transformer secondary to PMCC incomer shall be through Bus-duct.
No. of outgoing feeders shall be decided based on system requirement. Feeders as required, based
on final approved single line diagram shall be provided with no cost and time implication to the
Company.
All protective relays in PMCC for incomers and outgoing breaker feeders shall be numerical type
(digital microprocessor based and communicable type). Only major relays, meters amd controls are
indicated in data sheets. Any auxillary relays, timers, switches etc as required while developing the
control schematic and felt necessary for safe operation even if these are not specifically included
shall be supplied by the Contractor. All relays, metering and control components shall mounted on
the panel front only.
All dummy panels and rear extensions required for bus trunking, cable terminations,mounting of
relays, metering and control components etc shall be supplied by Contractor
All hardware signals ( with minimum requirement specified below) from various motor feeders for
DCS/LCS interface shall be wired and terminated in the respective feeder module:
• Breaker/contactor ON indication in service position

• Breaker/contactor OFF indication in service position
• Breaker/contactor Tripped due to electrical fault
• Process start command (Auto)
• Process STOP command
• Process TRIP command
• Interface for auto manual selector switch
• Remote Start command (manual)
• Remote Stop command
• Emergency Stop command
• Ammeter
Current rating for these DCS/ Other location contacts shall be0.5A,110VDC or 240 V AC
The change over scheme as mentioned in Cl 6.21 for 6.6kV switchboard shall be provided in PMCCs
also. Contractor shall develop scheme for automatic start-up of Emergency Diesel generator in case
of power failure.
Shutdown of Emergency Diesel generator after power restoration shall also be done automatically.
Provision shall also be provided to start the emergency diesel generator in Test mode and load the
generator for some time without the need to disturb the electrical system while in operation.
All individual feeders in MV switchboard shall be provided with ELR and CBCT to trip the feder
incase of earth fault (sensitivity setting range shall be 30mA to 300mA)
6.22 CATHODIC PROTECTION
DOCUMENT No.
Page 29 of 29
6.22.1 A cathodic protection system for the protection of underground pipelines and underground steel
structures shall be provided utilizing impressed current with manual control and designed in
accordance with the National Association of Corrosion Engineers (NACE) and BS 7361.
6.22.2 Transformers shall be oil immersed and rectifiers shall be SCR type. They shall be operated on
415V, 3 phases, 50Hz and installed in non-hazardous areas preferably.
6.22.3 The anode(s) shall be high silicon cast iron with coke breeze backfill, suitable for burial and with
sufficient quantity and size to have a minimum life expectancy of 20 years. Anodes shall be
buried to a depth sufficient to provide adequate protection.
6.22.4 Necessary test posts shall be installed along the protected underground pipelines for periodic
measurements of the metal to soil potential.
6.22.5 The protective potential along the underground pipelines / structures shall not be less than 1.0
volt negative with respect to copper / copper sulphate electrode cell, neither shall be more than
1.5 volt negative.
6.23 Electric heat tracing (EHT) System

6.23.1 Individual EHT circuit design calculation shall be performed utilizing an industry accepted
software program.
6.23.2 Self regulating (SR) type cables may be utilized for field applications as deemed necessary.
6.23.3 For the most part, mineral insulated (MI) heating cables, shall be determined from circuit
calculations and factory fabricated. A skin effect current tracing (SECT) system may be
considered for lines longer than 1000 m and intermediate powering station is available
6.23.4 Heat tracing system is project specific and passed on process parameters
7.0 33KV OVERHEAD POLE LINE
Over head lines needs to be considered for transfer of power from terminal which has power
generation facilities to other remote area location if generation of power is not possible in remote
area other than emergency power generation.

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SECTION C-2.4.

ELECTRICAL DESIGN PHILOSOPHY

UNIT : CENTRAL POLYMER FACILITY

A 20.11.2012 ISSUED WITH FEED PACKAGE VB RKS VKJ

2.0 SPECIFICATIONS, ITP’S & DATASHEETS

CAIRN-TSG-E-SP-0001 Specification for Oil Type Transformers

a. Oil Industries Safety Standards ( OISD )

b. Bureau of Indian Standards (BIS or IS)

c. International Electro-technical Commission (IEC) Standards ( wherever relevant IS standards

d. IEEE standards (wherever IS / IEC standards are not available.

e. National Association of Corrosion Engineers (NACE) Recommended Practice for Cathodic

f. NFPA standards as part of fire proofing and design of substation buildings

4.0 STATUTORY REQUIREMENTS

Indian Electricity Rules

The Factory Act

Oil Mines Regulations

Requirements of other statutory bodies as applicable, e.g. Central Electricity Authority

5.0 SYSTEM DESIGN PHILOSOPHY

a. safety to plant, personnel and equipment during operation and maintenance

c. flexibility of operation and maintenance

d. Minimal fire risk

e. Reliable Protection system through selective relaying system.

f. Adequate provision for future extension and modification

g. Effective power management and load shedding

h. Low harmonics in the system as per standards

i. Rated performance at applicable environment factors ( Project specific )

5.2 AREA CLASSIFICATION and EQUIPMENT SELECTION

• Area classification as per Zone

• Dust classification as per Group. – The Characteristic of the dust involved

• Environment condition in which apparatus is to be installed – the selected electrical

2. For Zone 2 Alarm needs to be initiated

5.2.8 The well heads will be classified zones.

5.3 Power system Design

5.4 Capacity of Electrical system

5.5 System voltages

Power distribution 415V + 6%, 3ph, 3W, 50Hz + 3%.

240 V, +/- 6 %, 3 PH, 3 W system for Lighting

( To be referred with Design basis / SLD of

Protection, Control & Indication Supply for

Charging of HV Switchgears and 415V 110V+ 10%, DC, 2W, Ungrounded

UPS system 230 V+ 1%, 1ph, 50 Hz+ 1%

DC system 110 V + 10%, DC and 24V DC. 24V DC is

Communication System 230V+ 1%, 1ph, 50 Hz + 1%, (from UPS

5.6 Allowable Voltage Drop

Sl. System Description Operating Maximum

• Remotely located MCC / Auxiliary switch

reacceleration of HV motors is not envisaged )

5.7 System Earthing

5.8 Short Circuit Capacities

5.9 Insulation system

5.10 Protection and Metering schemes

5.11 DC Power Supply

Independent DC Power supply system shall be provided for the following

• Plant shutdown system including DC Instrumentation

• Electrical switch gear controls including critical lighting

5.12 Emergency Power supply

• Electrical loads essential for the safe shutdown of the plant

• Process plant instruments as required

• Fire detection and alarm system