Design Basis EIL STD

DOCUMENT No.
ENGINEERING DESIGN BASIS

ELECTRICAL 6987-00-16-50-DB-01 Rev.0
Page 1 of 21
DESIGN PHILOSOPHY
6.7 ELECTRICAL
------------ ------------
OPaL EIL
OPaL comments incorporated & issued for

0 07.07.2009 RS PG/AK JMS
implementation
A 06.03.2009 Issued for clients comments/approval RS PG/AK JMS
Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL 1650-1296P Rev. 2 Copyright EIL – All rights reserved
DOCUMENT No.
Page 2 of 21
CONTENTS
1. SITE CONDITIONS
2. POWER SOURCE DETAILS
3. POWER SUPPLY DISTRIBUTION SYSTEM
4. PROTECTION - METERING - CONTROL
5. SUBSTATION DESIGN
6. EQUIPMENT DESIGN
7. CABLING SYSTEM
8. EARTHING SYSTEM
9. LIGHTING SYSTEM
10. ELECTRIC HEAT TRACING SYSTEM
11. ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS
12. STATUTORY APPROVAL
13. CABLE SIZES FOR MV MOTORS
14. ELECTRICAL CONTROL SYSTEM
15. SPECIFIC REQUIREMENTS
$-data to be provided /confirmed by client. Copyright EIL – All rights reserved

@-Details to be finalised during detail engineering
Format No. EIL 1650-1296P Rev. 2

DOCUMENT No.
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The electrical design data defines the design requirements agreed by owner/clients in addition to EIL standard
design philosophy for electrical facilities no: 6-51-0099 Rev-5 (Any additional deviation must be recorded as
part of this document)
In case of any conflict the following order of priority shall govern:

- Statutory requirements
- This design data document
- Standard Specification 6-51-0099 Rev 5
1.0 Site conditions

1.1 Equipment design temperature (IS-9676) : 45°C
1.2 Minimum /Maximum Ambient Temperature : 5.6°C/ 47°C
1.3 Relative Humidity : 89%
1.4 Soil Resistivity : As per Soil investigation report or 20 Ohm-m(min)
whichever is maximum
1.5 Minimum temperature for battery sizing : 10°C
1.6 Minimum Temperature for Electric heat tracing : 5.6°C
system design
1.7 Altitude above mean sea level : Less than 1000m above mean sea level
1.8 Seismic Zone :As per IS-1893-ZONE-III
2.0 Power Source Details
2.1 General
Independent system or existing system : Independent system
2.2 Grid Supply
2.2.1 Name of sub station : $
2.2.2 Number of feeders : 2
2.2.3 Length of feeder : $ 2km approx.
2.2.4 Type /size of conductor/ cable size : $/ mm², Zebra, ACSR
2.2.5 Voltage : 220kV (+)10% (-)12.5%
2.2.6 Frequency : 50Hz ± 3%
2.2.7 Maximum fault level : 40kA for 1sec
2.2.8 Minimum fault level : $
2.2.9 Design fault level : 40kA for 1sec
2.2.10 Basic Insulation Level : 1050kV
2.2.11 System neutral Earthing : Solidly Earthed
2.2.12 Minimum load power factor : $
2.2.13 Parallel operation of incomers : Yes/No
2.2.14 PLCC requirement : Yes/No
2.3 CPP and its configuration
2.3.1 Number of captive generators : Refer CPP design basis
2.3.2 Type of captive generators : Steam/ Gas turbine
2.3.3 Generator rating/Voltage/Power factor : @ MW/ 11 kV/ 0.8 (Refer CPP DB)
2.3.4 Parallel operation with other sources : Yes /No1
1
Parellel operation of CPP with grid shall be with confirmation from TEL. Exact requirements for parallel
operation shall be confirmed by OPaL.

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2.3.5 Type of Neutral Earthing : NGT

2.4 Emergency generator
2.4.1 Number of emergency generators : 1 (Central) + Local DG’s at remote
locations -@
2.4.2 Type of emergency generators : Diesel
2.4.3 Generator rating/Voltage/Power factor : @ KW/6.6kV/415V / 0.82
2.4.4 Parallel operation with other sources :Yes /No (except for transfer of power from
emergency to normal)
2.4.5 Type of starting : Auto / Manual
2.4.6 Centralised DG set : Yes /No2
2.4.7 Location of generator set : 1 No. at Centralised location & remote
location if required-@
2.5 Details of Existing System : Not applicable
3.0 Power Supply Distribution System

3.1 Voltage and frequency variation
3.1.1 AC System
Voltage : + 6%
Frequency : + 3%
(Refer clause no:6.10 of this document for design voltage/frequency variation for motors)
3.1.2 DC System (at system output terminal)
Electrical protection and Control system. : +10 %
DC critical Lighting system : +10 %
Instrumentation Power Supplies : +10 %
3.2 Utilisation voltage
3.2.1 Primary EHV distribution voltage : 66kV
3.2.2 Secondary HV distribution voltage : 6.6kV
3.2.3 Primary EHV distribution system neutral Earthing : Solidly earthed for 66kV
3.2.4 Secondary HV distribution system neutral Earthing : Resistance earthed for 6.6kV
3.2.5 HV motor voltage (KW more than 160KW) : 6.6kV3
3.2.6 MV motor voltage ( 0.18≤KW ≤160) : 415 V AC
3.2.7 AC Motors rated below 0.18 KW (except MOVs) : 240V AC 1Ph/415V 3Ph
3.2.8 DC Motor : As per manufacturer standard design
3.2.9 Motor operated valves : 415V AC, 3 Ph
3.2.10 Battery chargers incoming power supply : 415V AC, 3 Ph
3.2.11 UPS System incoming power supply : 415V AC, 3 Ph
3.2.12 AC Lighting/Power Panels : 415V AC, 3 Ph
3.2.13 Auxiliary Boards incoming power supply : 415V AC, 3 Ph
3.2.14 Welding Receptacles : 415V AC, 3 Ph
3.2.15 Bulk loads like Process Heaters etc. : 415V AC, 3 Ph
2
Emergency power distribution shall be on 6.6KV network with Centralised DG. However, smaller DG at 415V
can be implemented at remote locations
3
Large KW motors may be 11kV, fed through dedicated feeder with soft starter or DOL starter as per motor start
up studies -@

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3.2.16 Normal Lighting/Emergency Lighting : 240V AC, 1 Ph

3.2.17 Convenience outlets : 240V AC, 1 Ph
3.3 Utilisation voltage for critical supplies
3.3.1 Switchgear protection control power supply : 110V, DC
3.3.2 Critical lighting power supply : 110V, DC
3.3.3 Input power supply for Plant communication system : 110VAC UPS
3.3.4 Input power supply for Fire alarm system : 415V/240VAC (with
dedicated battery backup)
3.3.5 Power supply for electrical annunciation panel : Not applicable
3.3.6 Normal Instrumentation power supply :Refer Instrumentation design basis
3.3.7 Critical instrumentation power supply :Refer Instrumentation design basis
3.3.8 Instrumentation Shut-down system power supply :Refer Instrumentation design basis
3.3.9 DC supply for instrumentation :Independent system
3.4 Operating philosophy
3.4.1 Auto/Manual transfer at 66kV voltage bus with :Yes /No
momentary paralleling
3.4.2 Auto/Manual transfer at 6.6kV voltage bus with :Yes /No-
momentary paralleling
3.4.3 Auto /Manual transfer at MV with momentary
paralleling
a (At PCC/PMCC Level) :Yes /No
b (At MCC/ASB/LDB Level) :Yes /No
3.4.4 Continuous Parallel operation of Incomers
a Primary EHV voltage (66kV) :Yes /No
b Secondary HV voltage (6.6kV ) :Yes /No
c PCC/PMCC : Yes /No
3.5 Power factor improvement capacitors :Secondary HV (6.6kV)
3.6 Load shedding : Yes /No
4.0 Control -Protection - Metering
4.1 Control Philosophy
4.1.1 Location of Protection relays for EHV/HV switchgear
a Primary voltage 66kV switch gear :On switchgear/Separate relay and control panel
for STG/GTG
b Secondary Voltage 6.6kV HV switchgear :On switchgear/Separate relay and control panel
4.1.2 EHV/HV Switchgear control
a Primary voltage 66kV switch gear :On switchgear/Separate relay and control panel
b Secondary Voltage 6.6kV HV switchgear :On switchgear/Separate relay and control panel -
4.1.3 Numerical Protection/Monitoring system for
a 220kV EHV system :Yes / No
b 66kV & 6.6kV Switchboard :Yes / No
c 415V PMCC/PCC :Yes / No( For incomers, bus coupler and outgoing
breaker feeders)
d 415V MCC :Yes / No
4.1.4 Control and logic through numerical relays :Yes / No


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4.1.5 HMI/Data concentrator panel :

a Human machine interface system-HMI :Yes / No
b Data concentrator panel for each substation :Yes/No
c Separate data concentrator panel for each :Yes/No
HV/MV system
d Operator cum engineering console :Yes/No
e Separate Operator console :Yes/No
f Separate Engineering console :Yes/No
g Interface with Electrical control system :Yes/No
h Location of HMI : Substation operator room
i Common HMI for HV /MV system :Yes/No (Separate HMI for HV& MV)
j Lap Top :Yes/No
4.1.6 Hardwired synchronization control panel- :Yes / No
SCAP
4.1.7 Hard wired annunciation panel :Yes / No
Type of annunciation panel :Hard wired/HMI/Part of SCAP
4.1.8 Load shedding panel : Part of ECS/Separate PLC/ Hardwired
4.1.9 Method of motor starting
a HV Motors :Direct on line4
c MV Motors :Direct on line (VFD if required by process)
4.1.10 Starting Current Limiting Conditions for
Motors
a HV motors
Induction Motor rated below 2 MW : 500% inclusive of positive tolerance
Induction Motor rated 2 MW and above : To be decided during detailed engg.5
b MV Motors : 600% with tolerance as per IEC /IS
4.2 Type of power isolation for transformers located remotely away from HV substation-
4.2.1 Push button in transformer bay for tripping breaker :Yes/No
4.2.2 Local Isolating load break switch panel in :Yes/No
switchgear room
4.2.3 Local Isolating breaker panel in switchgear room6 :Yes/No-
4.2.4 Local Isolating panel with protection relay and : Yes/No
metering
4.2.5 Local Isolating panel with out protection relay and : Yes/No
metering
4
Alternatively soft start may be considered for starting of large HV motors, if essential / unavoidable, as per
system design requirements / equipment design limitations.
5
Starting current for motors shall be further reduced from 500% as per motor startup study.
6
66kV GIS isolating breaker panel and 6.6kV isolating breaker panel shall be provided for isolation of
transformer located remotely from sending end substation

DOCUMENT No.
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4.3 Relay protection system

4.3.1 Protection devices for power distribution system shall be as indicated below
(Figure inside bracket refers to note below) √ Applicable
RELAY DESCRIPTION RELAY HV TRANSFORMER HV OUTGOING INCOMER
NUMBER FEEDER MOTOR BREAKER
FEEDER FEEDER
(SECONDARY (SECONDARY HV MV HV MV
WINDING WINDING PLANT PCC/ PCC/
VOLTAGE VOLTAGE FEEDER PMCC PMCC
> 3.3 KV) < 0.433 KV)
IDMTL over-current relay 51 √ √ - √ √ √ (1) √
IDMTL earth-fault relay 51N √ (2) √ - √ √ √ (1) √
51G backup earth-fault relay 51G √ √ - - - - -

(secondary neutral)
Motor protection relay with 99 - - √ - √ (3) - -
(50, 50N,46, 49, 50L/R,86,95 )
Instantaneous restricted earth- 64R - - - - - √ √
fault relay (secondary side)
Instantaneous over-current relay 50 √ √ - - - - -
Instantaneous earth-fault relay 50N √ (4) √ - - - - -
Differential protection relay 87 √ (5) - √ (6) √ (7) - - -
High speed tripping relay 86 √ √ √ √ √ √ √
Trip circuit supervision relay 95 √ √ √ √ - √ √(8)
Transformer auxiliary relay 63 √ √ - - - - -
Under-voltage relay with timer 27/2 - - - - - √ (9) √ (9)
Check synchronisation relay 25 - - - - - √ (10) √(10)
4.3.2 Power generation and External power supply

Minimum protection relays for Synchronous generator (GTG/STG), generator transformer, Grid
power supply incomer and Synchronous motors shall be as follows √ Applicable
RELAY DESCRIPTION NEMA GENERATOR GENERATOR HV/EHV HV /EHV SYN
CODE TRANSFORMER INCOMER TRANSFO- MOTOR
RMER
Distance protection 21 √
Synchronous check 25 √ √
Under voltage with timer 27 √ √ √
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 √ √ √


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RELAY DESCRIPTION NEMA GENERATOR GENERATOR HV/EHV HV /EHV SYN

CODE TRANSFORMER INCOMER TRANSFO- MOTOR
RMER
Over voltage with timer 59 √ √
VT failure 60 √ √
Auxiliary relay for 63TX √ √
transformer
Transformer Restricted 64R √ √
Earth Fault
Stator back up earth fault 64G √
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 différentiel 87T √
Feeder differential 87F √
Bus bar differential and 87B/ √
check 87CH
Trip circuit supervision 95 √ √ √ √
Dead bus charging relay 98 √
Over fluxing 99 √
Notes:
1. In case of HV switchboards with continuous parallel operation of incomers, following additional relays
shall be provided:
a. One set of 87B (Bus differential) and 95 B (Bus wire supervision) for each bus section.
b. 67 and 67N (Directional IDMTL over current and earth fault) relays for the incomers.
2. Instantaneous earth fault (50N) shall be provided only for transformer with delta primary.
3. For motor feeders rated above 55 kW. Relay 50 shall not be provided for contactor controlled feeders.
4. Directional IDMTL earth fault (67N) shall be provided for transformer with star primary.
5. For transformers rated 5 MVA and above.
6. For motors rated 1500 kW and above.
7. For critical/long feeders and plant feeders connected to main power generation and distribution bus. A
plant feeder implies outgoing feeders from one switchboard to another switchboard of same voltage
level.
8. Trip circuit supervision relay 95 shall be provided as part of the numerical relay for MV feeders
wherever numerical relays are provided.
9. Wherever auto-transfer feature is provided.
10. For switchgears where continuous or momentary paralleling of Incomers is envisaged, check
synchronising relay shall be provided.
11. 51G and 64R relays shall not be provided for input transformer of VFD system.
12. The bus tie feeders in HV switchboards shall be provided with 51, 51N, 86 and 95 relays.
13. HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage), 60 (Neutral
displacement), 86 and 95 relays.


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14. The following feeders shall be provided with timers for delayed tripping on bus under voltage while the
under voltage relay shall be common for the bus
a. HV and MV capacitor feeders
b. HV and MV breaker controlled motor feeders
c. Contactor controlled motor feeders with DC control supply.
Numerical relays where ever provided for motor and capacitor feeders shall use in built under voltage
relay and timer for delayed tripping on bus under voltage.
15. One no. DC supply supervision relay (80) shall be provided for each incoming DC supply to the
switchboard.
16. One set of bus differential relays (87B) and bus wire supervision relay (95 B) for each bus section shall
be provided for HV switchboards connected directly to generation buses
17. In case of numerical relays, all relays shall be comprehensive units including all protection, metering
and control unless other wise specified.
18. Under voltage and over voltage along with associated timer shall be part of the numerical relays.
19. Auto changeover logic between Incomers and bus coupler shall be built in the numerical relay.
20. Tripping relays (86) & Trip Circuit supervision relay (95) shall be part of numerical relay.
21. 2 Nos. of 86 relays shall be considered for HV and MV motor rated more than 55KW.
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/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. DG set shall be provided with protection but not limited to 51V,51G,40,46,86,95,80 , 64R etc for
generator rated above 500KVA and Generator rated less than 500KVA shall have
51V,51G,40,46,86,95,80 unless other wise agreed with the owner. The protective relay shall be
numerical type.
27. Required GPS hardware and software to achieve time synchronisation with various clocks in data
concentrator/ ECS system at each substation shall be provided.
4.4 Metering
The metering devices in EHV, HV and MV switchboards shall be as below:
Type of metering : Analogue/As part of the Numerical relay
FEEDER TYPE A V Hz PF MW MWH HM MVAR MVAH MVA
EHV Incomers √ √ √ √ √ √ - √ √ √
EHV Bus Tie √
EHV Transformer √ √ √
EHV Bus P.T. √
HV Incomer √ √ √ √ √(2) √ - √(2) √(2) √(1,2)
HV Bus Tie √ - - - - - - - - -
HV Transformer √ - - - √ √ - - - -
HV Bus P.T. - √ - - - - - - - -
HV Plant Feeder √ - - - - √ - - - -
HV Motor √ - - - - √ kWh √ - - -
HV Capacitor √ √ - - - - - √ - -
PCC/PMCC Incomer √ √ - √ - √ kWh - - - -


DOCUMENT No.
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FEEDER TYPE A V Hz PF MW MWH HM MVAR MVAH MVA

PCC/PMCC Bus Tie √ - - - - - - - - -
PCC Bus P.T. - √ - - - - - - - -
ACB Outgoing √ - - - - √ kWh - - - -
( Non motor)
MV Motor (>55kW) √ - - - - - - - - -
MCC/ASB Incomer √ √ - - - - - - - -
MCCB/SFU O/G(250A) √ - - - - √ kWh - - - -
LDB Incomer √ √ - - - √ kWh - - - -
DG Set √ √ √ √ √ kW √ kWh √ √ - -
4.5 Metering for generator and Generator transformer shall not be limited to following.
Meter HV Generator
Generator transformer
Ammeter 3nos √ √
Voltmeter with selector switch √ √
MW meter √ √
MVAR meter √
MVA meter √
MWH meter √ √
MVARH meter √
Power factor √ √
Frequency meter √
Notes:
1. MVA meter in EHV external power supply Incomers shall include maximum demand indication also.
2. MW, MVAR, MVA, MVAH meters shall be provided for EHV external power supply Incomers only.
3. Field Ammeters are to be provided for all motors rated above 5.5kW.
4. All metering shall be part of numerical relay in case of electrical system is having numerical relays.
Energy meters where provided separately shall be digital type.
5.0 Substation Design

5.1 EHV Switchyard/Substation
5.1.1 Type : Conventional open bus/GIS
5.1.2 Type of bus : String bus / Tubular bus-@
5.1.3 Structure for outdoor ; Galvanised / Painted/Not applicable
5.1.4 Bus material : Aluminium / Copper ACSR
5.2 Substation feature
Description HV MV MCC /Elect Room
5.2.1 Elevated with trays in cable cellar Yes/No Yes/No No
5.2.2 Raised with internal trenches Yes/No Yes/No Yes
5.2.3 All top cable entry with trays below ceiling Yes/No Yes/No No
5.2.4 Pressurisation against ingress of dust Yes/No Yes/No No
5.2.5 Air-conditioned room for operator Yes/No Yes/No No


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5.2.6 Roof slab for

a Power transformer Yes/No N.A -
b Distribution transformer Yes/No Yes/No -
5.3 Specific Equipment Locations
5.3.1 Batteries in substation and control Rooms : Separate room
5.3.2 Battery charger in substation : Air conditioned /non air conditioned room
5.3.3 Battery charger in control room :Air conditioned /non air conditioned room
5.3.4 Variable speed drive panels :Air-conditioned room in substation
5.3.5 Thyristor controlled panels :Air-conditioned room in substation
5.3.6 UPS System :Air conditioned room in control room
5.3.7 Lead-Acid and Nickel- Cadmium :Separate room/common room
5.3.8 Location of VRLA battery : Air conditioned room
5.3.9 Annunciation panel : Not envisaged, HMI in operator room to have
annunciation.
Note:1. Battery room shall be preferably located in corner side at switchgear floor of the substation building
6.0 Equipment Design
6.1 EHV Outdoor Switchyard
6.1.1 Bus bar system :Single/Double
6.1.2 Circuit breaker type :SF6
6.1.3 Isolator type :Pantograph/Semi pantograph/ Centre rotating/ Centre
break@
6.2 EHV/HV Switchboard
6.2.1 Execution :Draw out for 11 &6.6kV /Fixed for GIS-66 kV
6.2.2 Type of switchgear :Gas insulated for 66 kV /Air insulated for 11 & 6.6kV
6.2.3 Bus bar :Single bus for 11 &6.6kV/Double bus for GIS-66 kV 7
6.2.4 Circuit breaker type :SF6/Vacuum for 66 kV GIS, 11 & 6.6kV
6.2.5 Motor Control :Breaker/Vacuum contactor
6.3 Current Transformer (CT)/potential Transformer (PT)
6.3.1 CT Secondary
a General Protection :5A
b Special protection(87,64R ,51G etc) :1A
c Metering :1A for conventional and remote metering
6.3.2 PT Secondary :110 V AC
6.4 Transformers (Power/distribution)
Transformer Voltage ratio Vector group Soak pit Tap changer
6.4.1 Grid power transformer 220/66kV YNyno/Dy1 See Note-1 OLTC
6.4.2 Generator unit transformer 11/69 kV Ynd 11 See Note-1 Off-circuit

6.4.3 Main power transformer 66/6.9kV Dyn 1 See Note-1 Off-circuit/ OLTC
6.4.3 Intermediate power transformer As required Dyn 1 See Note-1 Off-circuit/ OLTC
6.4.4 Dedicated (e.g. for VFD) As required As Reqd. See Note-1 Off-circuit
6.4.5 Distribution transformer (< 2000 KVA) 6.6/.433kV Dyn 11 See Note-1 Off-circuit
7
Single bus shall be provided for 66 kV GIS isolating breaker panel.

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Note-1 : Soak pit shall be provided as per following condition:

a) Oil qty< 2000 lit : Not Reqd
b) 2000lit<Oil qty<9000 lit : Soak pit
c) Oil qty> 9000 lit : Soak pit + Collection pit
6.5 MV Switchboard
6.5.1 Execution
6.5.1.1 PCC / PMCC
a Breaker panels :Draw out, Single front
b Contactor feeders :Draw out, single / Double front
6.5.1.2 MCC :Draw out , single/Double Front
6.5.1.3 ASB :Draw out /Fixed , single /Double Front
6.5.1.4 LDB :Draw out /Fixed, single /Double Front
6.5.1.5 Motors
PCC :Above 55 kW Up to160 kW
MCC :Up to 55 kW
6.5.1.6 Type of switchboard for small package :Compartmentalised and Fixed type / Non
(AC system, Pressurisation system ,Bagging Compartmentalised and Fixed type
plant etc)
6.6 Medium voltage Motor Starter Type

6.6.1 Contactor and switch fuse with overload :Up to 22 kW
relay
6.6.2 Contactor, switch fuse and overload relay :Above 22 up to 55 KW
with CBCT for earth fault protection
6.6.3 Contactor and switch fuse with motor : Not applicable
protection relay
6.6.4 Air circuit breaker with motor protection :Above 55 kW up to 160 kW
relay
6.6.5 Contactor and MCCB with overload relay : Not applicable
6.6.6 Contactor, MCCB and overload relay with : Not applicable
CBCT for earth fault protection
6.7 Medium voltage Outgoing feeder Type
6.7.1 Switch fuse :Up to 100A
6.7.2 Switch fuse with Contactor and CBCT for :More than 100A and up to 400A
earth fault protection
6.7.3 MCCB with Contactor and CBCT for earth : Not applicable
fault protection
6.7.4 MCCB : Not applicable
6.8 Motor Controls : As per process package operating philosophy,
process and inst. Design basis-
6.8.1 Auto / Manual switch :Near motor/Switchgear/control room-@
6.8.2 Local/remote switch :Near motor/Switchgear/control room-@
6.8.3 Normal / Standby switch :Near motor/Switchgear/control room-@
6.8.4 Process interlock :DCS/PLC /switchgear
6.8.5 Reacceleration equipment :PLC /switchgear


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6.9 Control supply voltage

6.9.1 Breaker control : 110V DC
6.9.2 Breaker spring charging : 110V DC
6.9.3 Contactor feeder : 240V AC
6.9.4 Control supply for earth fault relay in : 110V DC
contactor feeder
6.9.5 Control supply for contactor motor starter :Control transformer/Tapping of P-N of respective
feeders
6.9.6 Control transformer for each bus section :Yes/No/Not applicable
6.10 Motors
Motors High voltage 415 volts
6.10.1 Enclosure
Indoor IP55/IP54 IP55/IP54
Outdoor IP55 IP55
6.10.2 Insulation class F F
(Temp. Rise limited to B) (Temp. Rise limited to B)
6.10.3 Anti-condensation heater Yes 30 kW and Above
6.10.4 Additional canopy Yes Yes
(outdoor motors)
6.10.5 Design voltage variation ±6 % ±6%
6.10.6 Design frequency variation ±3 % ±3%
6.10.7 Combined voltage / frequency
variation (Design) Any combination of above Any combination of above
6.11 UPS System

6.11.1 Redundancy :50% /100%
6.11.2 Type of redundancy :Parallel redundant/Hot standby
6.11.3 Back-up time :30/60/120 minutes
6.11.4 Bypass transfer control :Auto / Manual
6.11.5 Separate fault diagnostic unit :Yes/No8
6.11.6 Battery type :Lead acid/Ni-Cd/VRLA
Note- UPS for data communication system, CFAP of FA system and substation HMI shall be non-redundant with
bypass type and with VRLA battery.
6.12 Communication System
6.12.1 Plant Communication System : Yes/No
6.12.2 Telephone System : Yes/No
6.12.3 Telephone system and plant Communication system :Separate/Integrated
6.12.4 Telephone system and Data communication LAN :Separate/Integrated
system
6.12.5 No. of external lines : $,@
6.12.6 No. of Intercom lines : @
8
Separate FDU is not required in case UPS system is serial connected to HMI and fault diagnosis can be done
from HMI.

DOCUMENT No.
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6.12.7 Interface of Communication system

a With fire alarm system :Yes/No
b With telephone system :Yes/No
6.13 Fire Detection and Alarm System
6.13.1 Type :Conventional/Analogue addressable
6.13.2 Name of buildings to be provided with Detectors : Sub-Stations, Control Rooms, SRR’s, DG
room and other buildings as required
6.13.3 Detection System :Break Glass, multi sensor detector and linear
beam Detector
6.13.4 Type of manual call point :With/Without call back facility
6.13.5 Qty of Siren and location : Adequate to cover the entire complex@
6.13.6 Power supply for Siren : AC/DC-@
6.13.7 Siren range : @(Diametrically)
6.13.8 Response indicator for rooms and concealed area for :Not applicable
conventional Fire alarm system
6.14 DC System
6.14.1 Battery type
a Switchgear Protection Control and critical lighting :Lead acid/Ni-Cd/VRLA
b Instrumentation System :Lead acid/Ni-Cd/VRLA
c Diesel Engine Starting :Lead acid
d DC Motors :As per equipment supplier recommendation
e Fire alarm system :VRLA
f Plant communication system :VRLA/Not applicable
g Telephone system :VRLA
h Data communication LAN system :VRLA
6.14.2 Battery back up time
a Switchgear Protection and Control :30/60/120 minute
b DC Critical lighting :30/60/120 minute
c Instrumentation :30 /60/120 minutes
d Diesel Engine Starting :10 starts (FW pumps) & 6 starts (others)
e DC Motors : As per equipment supplier recommendation
6.15 Variable frequency drive
6.15.1 By pass feature required :Yes/No9
6.15.2 VFD selection
a VFD motor with MV power supply :Motor rating up to & including 300KW@
b VFD motor with HV power supply :Motor rating more than 300KW @
6.16 Cables
The power and control cables shall have the following minimum cross sectional areas:
6.16.1 Medium voltage power cable : From 2.5 mm² up to 16 mm² -Copper,
Above 16 mm² -Aluminium
6.16.2 Control cables :2.5 mm² (Copper)
6.16.3 Lighting :2.5 mm² (Copper)
9
Bypass for VFD shall be provided as a standard practice unless not recommended by process licensor/driven
equipment supplier.

DOCUMENT No.
Page 15 of 21
6.16.4 Communication system :0.9 mm dia (Copper)

6.16.5 Telephone system :0.9 mm dia (Copper)
6.16.6 Fire alarm system :1.5 mm² (Copper)
Notes:
1. For lighting inside the building, minimum 1.5 mm² copper conductor, PVC Insulated wire shall be used
in conduit system (for circuit and point wiring), with proper colour coding.
2. Communication system, Telephone system and Fire alarm System cable sizes are indicative only and
these shall be finalised as per the recommendations of equipment manufacturers. However minimum
conductor size shall be as mentioned above.
3. Special cable type and size shall be decided on specific requirement.
7.0 Cabling System

7.1 Cable details
Design Criteria High voltage 415 volts
Loads located beyond 1 km Cable -
Loads located 200-1000 m 1-core cable/ 3-core cable 1-core / 3½-core cable
Load located up to 200 m Cable Cable / Bus trunking
Loads beyond 1000A rating and located Bus duct /1 core cable Bus duct /1 core cable
near the transformer.
Recommended limiting size of single- 300 (66KV)@ 630
core cable (mm²) 630 (6.6KV)
Recommended limiting size of multi- 300 (for 3 core cable) 300(for 3/3.5 core
core cable (mm²) cable)
Short-circuit withstand time (seconds) - Incomer from transformer :1 Not Applicable
- Incomer from other switchboard: 0.6
- Plant feeder:0.6
- Motor/Transformer feeder:0.2
Insulation voltage grade Earthed for 66kV Earthed
Earthed/Unearthed for 11 & 6.6kV
Type of cable insulation XLPE PVC
Conductor Cu/Al for 66 KV As per cl. No. 6.16.1
Cu/Al for 6.6KV
No. of cores for motor cables 3 (6.6 kV &11 kV) 3
Fire survival (Resistant) cable for
-Fire pump No No
-Plant communication - No
-MOVs (J.B. box to MOV) for product - Yes
tank isolation and fire proof MOV as
per process requirement
7.2 Cable laying philosophy
7.2.1 Process area :Overhead cable tray /RCC trench
7.2.2 Offsite paved area :Above Ground cable tray on sleeper/ Overhead
rack/RCC trench
7.2.3 Offsite unpaved area : Above Ground cable tray (on sleeper/ Overhead
rack) /directly buried.
7.2.4 Type of cable trays :Galvanized prefabricated /Site fabricated and
painted/FRP type
7.2.5 Road Crossings for underground cables :PVC Pipes /Cable culvert

DOCUMENT No.
Page 16 of 21
7.2.6 Road Crossings for Above ground cables :Overhead cable bridge/culvert
7.2.7 Walkways for overhead cable trays on pipe rack
a) Process areas :Required/Not required
b) Offsite areas :Required/Not required
Note: Plant communication, fire alarm and telephone cables shall be laid in overhead cable trays /
instrumentation trenches as far possible. In case these are not available. Cable shall be laid along
berm of the roads.
8.0 Earthing System

8.1 Earth electrode :GI pipe
8.2 Main earth loop material :GI strip
8.3 Substation earth loop :GI strip
8.4 EHV switchyard earth grid :GI strip/rod
9.0 Lighting System

9.1 Supply System
9.1.1 Centralised with Lighting distribution board-LDB :Yes/No
9.1.2 LDB at each substation :Yes /No
9.1.3 Lighting transformer required :Yes /No
9.1.4 100% Standby transformer for normal lighting system :Yes /No
9.1.5 100% Standby transformer for emergency lighting :Yes /No
system
9.1.6 Lighting transformer voltage ratio :415/415V
9.2 Control Philosophy
9.2.1 Outdoor yard :Auto/Manual/centralised/Local@
9.2.2 Street lighting :Auto/Manual/centralised/Local@
9.2.3 Outdoor process area :Auto /Manual; Centralised /Local
9.2.4 Process building :Auto/Manual/centralised/Local
9.2.5 Auto control :Intelligent type Synchronous
timer/photocell/ECS
9.2.6 Lamp type for outdoor lighting :HPMV for hazardous area, HPSV for safe
areas outside unit only
9.2.7 Lamp wattage :70/125/150/250/400W
9.2.8 Lamp type for DC critical lighting :100W Incandescent/Fluorescent type
9.2.9 ELCB for lighting circuits and lighting and Power :Yes/No (in LDB /ASB Outgoing feeders)
Panels
9.3 AC Emergency Lighting
9.3.1 Name of process plants : 20-25% of normal lighting in all process
units , O&U
9.3.2 Name of buildings : 20-25% of normal lighting in all
buildings( Control room, SRR,
Substations, DG room, pump houses,
compressor houses, fire station, Plant/Non
plant buildings)
9.3.3 Power supply source :Diesel Generator


DOCUMENT No.
Page 17 of 21
9.4 DC Critical Lighting for Escape

9.4.1 Name of process units : All (at escape route)
9.4.2 Name of building :Control room, SRR, Substations, DG
room, fire station, FWPH
9.4.3 Power supply : 110V DC
9.4.4 DC lighting for remote buildings : Lighting fixture with built in battery
9.5 Wiring Type
9.5.1 Process plant / Building / Shed :Armoured cable
9.5.2 Large service building :Surface conduit/Concealed conduit in
office building
9.5.3 Buildings with false ceiling : Armoured cables/Surface conduit above
false Ceiling
9.5.4 Substation (Switchgear Room) :METSEC channel/Concealed conduit
9.5.5 Substation (Cable Cellar) :Surface Conduit/armoured cable
9.5.6 Other buildings in safe area : Black enamelled surface conduit/PVC
concealed conduit
9.6 Specific Lighting Requirements
9.6.1 Aviation lighting :Yes /No
9.6.2 Security lighting for peripheral road boundary wall :Required/Not Required
9.6.3 Type of control gear for HPMV/HPSV lamps :Separate/Integral
9.6.4 Control gear box location :Accessible level
9.6.5 Type of high mast flood light :30 meters Telescopic tubular /
Lattice structural mast
10.0 Electric Heat Tracing System
System Design Basis : Product Classification /System approach
11.0 Electrical Equipment for Hazardous Areas
11.1 The electrical equipment for hazardous areas shall be selected as per IS-5571 and petroleum rules and Gas
group shall be selected based on the hazardous area classification. The minimum requirement is summarised
below:
Equipment Zone-1 Zone-2
MV Motors Ex-d Ex-n (Refer note-2.10 &
2.11)
HV Motors Ex-d / Ex-p (Refer note-2.9 & 2.12) Ex-d/Ex-p/Ex-n (Refer
note-2.10 & 2.11)
Push Button Station Ex-d Ex-d
Motor Starters Ex-d Ex-d
Plug & Socket Ex-d Ex-d
Welding Receptacle Ex-d Ex-d
Lighting fixtures
i) Lighting fitting Ex-d Ex-d / Ex-nR
ii) Control Gear Box Ex-d Ex-d
Junction Boxes Ex-d Ex-d/Ex-n
Hand lamps
i) Light fitting Ex-d Ex-d
ii) Transformer Unit Ex-d Ex-d
iii) Plug & Socket Ex-d Ex-d

DOCUMENT No.
Page 18 of 21
Break Glass Unit Ex-d Ex-d

(Fire Alarm System)
Lighting Panel/Power Panel Ex-d Ex-d
Transformers Hermetically sealed with surface temperature not exceeding 200ºC
Notes:
1.0 The electrical equipment for hazardous areas shall generally be suitable for gas group IIB and temp
classification T3 as applicable to the selected type of explosion protection. In case of hydrogen or
hydrocarbon mixtures having more than 30% hydrogen, the gas group to be considered shall be IIC.
2.0 As additional safety features, the following requirements for electrical equipment shall be followed:
2.1 All electric motors for agitators/mixers and metering pumps handling flammable material shall be
flameproof type irrespective of the area being classified as zone-2 or zone-1.
2.2 All electric motors for vertical sump pumps handling flammable material shall be flameproof type.
2.3 Irrespective of the area classification (whether zone-1 or zone-2), all lighting fixtures within the storage
areas shall be flameproof type.
2.4 Irrespective of the area classification (whether zone-1 or zone-2), all motors and lighting fittings within
the pump house near the offsite tank farm and within the loading/unloading gantries shall be of
flameproof type.
2.5 All emergency/critical lighting fixtures and associated junction boxes in hazardous areas (whether zone-1
and zone-2) shall be flameproof type.
2.6 Even though fired heaters in process units are not considered for area classification, all electrical
equipments associated with fired heaters in process units shall as a minimum be suitable for installation in
Zone-2 area.
2.7 Where air conditioning system is designed considering ammonia as refrigerant, the room housing air
conditioning equipment shall be adequately ventilated to classify it as safe area. For additional safety the
following shall be considered:
- 100% standby system for ventilation
- Location of MCC/local panels in adjacent separate room.
- Instrumentation to be flameproof type or hermetically sealed.
- AC plant room motors with type`n' protection.
- Lighting in AC plant room suitable for zone-2 area.
2.8 Building such as Compressor sheds inside the process area shall be designed to allow adequate ventilation
to allow area classification as Zone-2. Lighting equipment, EOT crane etc. in the shed shall be flameproof
type. All other electrical equipment shall be suitable for Zone-1 or Zone-2 area depending on extent of
hazard.
2.9 All motors for hazardous area Zone-1 shall preferably be flameproof type. Pressurised motors may be
provided in exceptional cases.
2.10 Ex-n motors shall be without prestart ventilation as permitted by Indian Standard unless any other type is
specified by Process Licensor except for following cases as listed below:
¾ Ex-d motors shall be used in Zone-2 areas for HV motors for centrifugal compressors.
¾ Ex-d motors shall be used in Zone-2 areas for motors having frequent start/stop requirements e.g.
EOT cranes, Elevators, MOV actuators etc.
2.11 Ex-n motors with prestart ventilation provision or Ex-d or Ex-p motors shall be used in Zone-2 areas for
application having average starting frequency more than 1 per week, where rating of motor is more than
100KW.
2.12 Ex-p motors shall be used for large rating motors where either Ex-n or Ex-d motors are not available.
2.13 For Ex-n motors, the appropriate risk assessment factors shall be worked out taking operational and
maintenance considerations.
12.0 Statutory Approval
Statutory Authority for Electrical Installation: State Electrical Inspectorate/CEA
Statutory authority for hazardous area : CCOE/CIMFR


DOCUMENT No.
Page 19 of 21
13.0 CABLE SIZES FOR 415V MOTORS

13.1 Direct on line (D.O.L) start motors (2/4 pole motors)
MOTOR RATING CABLE DETAILS
NUMBER OF RUNS NO. OF CORES CONDUCTOR CONDUCTOR
PER RUN MATERIAL SIZE ( MM²)
Below 3.7 KW 1 3 Cu 4
3.7 KW 1 3 Cu 4
5.5 KW 1 3 Cu 6
7.5 KW 1 3 Cu 10
9.3 KW 1 3 Cu 16
11 KW 1 3 Cu 16
15 KW 1 3 Cu 16
18.5KW 1 3 Al 35
22 KW 1 3 Al 50
30 KW 1 3 Al 70
37 KW 1 3 Al 70
45 KW 1 3 Al 95
55 KW 1 3 Al 120
75 KW 1 3 Al 185
90 KW 2 3 Al 95
110 KW 2 3 Al 120
125 KW 2 3 Al 150
132 KW 2 3 Al 150
160 KW 2 3 Al 185
13.2 Cables sizes as indicated above are applicable for a distance of 350m maximum and for 2/4 poles
motors fed from MCCs located near PCCs and PMCCs.
13.3 Cable sizes for motors not confirming to above table (e.g. for 2/4 poles motors rated up to 160kw),
extended distance, reduced voltage starting ,low speed motors, VFD driven etc. shall be worked out on
case to case basis.
13.4 The cable sizes mentioned above are minimum sizes. Actual cable sizes shall be finalised during detail
engineering considering meet specification and cable laying requirements.
13.5 Cables for lighting shall be sized to allow the following voltage drops:
- Street Lighting : 10%
- DC Critical Lighting : 5%


DOCUMENT No.
Page 20 of 21
14.0 Electrical Control System-ECS

14.1 Electrical control system :Yes/No
14.2 Extent of coverage :
14.2.1 No of substations : All substations
14.2.2 High voltage switchboard
Incomers/Bus coupler/Outgoing feeders :Yes/No
14.2.3 415V switchboard
a Incomers/Bus couplers :Yes/No
b Outgoing breaker feeders :Yes/No
14.2.4 Emergency DG set :Yes/No
14.3 Control function
14.3.1 ON/OFF control of breaker
a HV switchboard except motor feeder :Yes/No
b ON/OFF control of capacitor feeder :Yes/No
c OFF control of all breaker feeder :Yes/No
d ON/OFF control of area lighting :Yes/No
e Raise/Lower control of transformer OLTC :Yes/No
f Excitation Raise/Lower control of synchronous motors :Yes/No-@
g Remote set point control of excitation of all HV synchronous :Yes/No -@
motors
h Frequency/Speed control of all generators except DG set :Yes/No
i Remote set point control of load MW of all generators except :Yes/No
DG set
j Load shedding operated annunciation and inhibiting circuit :Yes/No
breaker closing after load shedding
14.4 Monitoring
14.4.1 Electrical plant data acquisition and display :Yes/No
a Routine log report generation and energy balance reports :Yes/No
b Detection and reporting of alarms :Yes/No
c Sequence of event recording of some selective contacts :Yes/No
14.4.2 Sequence of event recording
a Protective relay trips of generators :Yes/No
b Lock out realy-86 contact of all HV feeders :Yes/No
c Lock out realy-86 contact of all MV Incomers and bus couplers :Yes/No
feeders
14.5 Advance functionalities of ECS system
a Load shedding including maximum demand limit control :Yes/No
b Load control and tie line control including contract demand :Yes/No
control
c Synchronisation :Yes/No
d Capacitor feeders Switching for power factor improvement :Yes/No
e Data validation and data reconciliation :Yes/No
f Voltage and reactive power control :Yes/No


DOCUMENT No.
Page 21 of 21
g Performance monitoring : Yes/No

14.6 Communication with other system
14.6.1 Communication with DCS system for exchange of data :Yes/No
14.6.2 Interface with data concentrator of electrical system :Yes/No
15.0 Specific requirements
15.1 Canopy shall be provided for all outdoor equipment.

15.2 Dummy panel shall be provided in switchboards where switchboard is located over the expansion joint
in substation building.
15.3 No unarmoured cable shall be used.
15.4 All power cables in racks/trays shall be laid in single layer only. Further 20% spare space shall be
provided in cable trays/trenches for future use.
15.5 Heat shrinkable type EHV/HV cable end termination kits and straight through jointing kits shall be
used.
15.6 All MV switchboards (i.e. PCC, PMCC, MCC, ASB, LDB etc.) in one substation shall be of one make
only.
15.7 Spare feeders in UPS ACDB and DCDB shall be 20% for future use with minimum of 1 no. of each
rating.
15.8 Flameproof telephones connected to telephone exchange shall be provided in unit areas as per area
classification.
15.9 Substation shall be sized to ensure 1 no. panel extensions on each bus section for all HV/MV
switchboards for switchboard length up to 10 meters and 2 nos. of panel extensions on each bus section
for all HV/MV switchboards for switchboard length more than 10 meters.


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DOCUMENT No.

ENGINEERING DESIGN BASIS

ENGINEERING DESIGN BASIS

OPaL comments incorporated & issued for

2. POWER SOURCE DETAILS

3. POWER SUPPLY DISTRIBUTION SYSTEM

4. PROTECTION - METERING - CONTROL

10. ELECTRIC HEAT TRACING SYSTEM

11. ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

12. STATUTORY APPROVAL

13. CABLE SIZES FOR MV MOTORS

14. ELECTRICAL CONTROL SYSTEM

15. SPECIFIC REQUIREMENTS

$-data to be provided /confirmed by client. Copyright EIL – All rights reserved

Format No. EIL 1650-1296P Rev. 2

In case of any conflict the following order of priority shall govern:

1.0 Site conditions

Format No. EIL 1650-1296P Rev. 2

2.3.5 Type of Neutral Earthing : NGT

3.0 Power Supply Distribution System

Format No. EIL 1650-1296P Rev. 2

3.2.16 Normal Lighting/Emergency Lighting : 240V AC, 1 Ph

$-data to be provided /confirmed by client. Copyright EIL – All rights reserved

Format No. EIL 1650-1296P Rev. 2

4.1.5 HMI/Data concentrator panel :

Format No. EIL 1650-1296P Rev. 2

4.3 Relay protection system

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

51G backup earth-fault relay 51G √ √ - - - - -

Instantaneous earth-fault relay 50N √ (4) √ - - - - -

Differential protection relay 87 √ (5) - √ (6) √ (7) - - -

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

Trip circuit supervision relay 95 √ √ √ √ - √ √(8)

Transformer auxiliary relay 63 √ √ - - - - -

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

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

4.3.2 Power generation and External power supply

$-data to be provided /confirmed by client. Copyright EIL – All rights reserved

Format No. EIL 1650-1296P Rev. 2

RELAY DESCRIPTION NEMA GENERATOR GENERATOR HV/EHV HV /EHV SYN

$-data to be provided /confirmed by client. Copyright EIL – All rights reserved

Format No. EIL 1650-1296P Rev. 2

$-data to be provided /confirmed by client. Copyright EIL – All rights reserved

Format No. EIL 1650-1296P Rev. 2

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

5.0 Substation Design

$-data to be provided /confirmed by client. Copyright EIL – All rights reserved

Format No. EIL 1650-1296P Rev. 2

5.2.6 Roof slab for

6.4.2 Generator unit transformer 11/69 kV Ynd 11 See Note-1 Off-circuit

Format No. EIL 1650-1296P Rev. 2

Note-1 : Soak pit shall be provided as per following condition:

6.6 Medium voltage Motor Starter Type

$-data to be provided /confirmed by client. Copyright EIL – All rights reserved

Format No. EIL 1650-1296P Rev. 2

6.9 Control supply voltage

6.11 UPS System

Format No. EIL 1650-1296P Rev. 2