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Electrical Design Basis Date: 11-Oct-23
Doc. No.GB1516-SAC-240-EL-DB-0001_Rev-1 Page: 1 of 36
DOCUMENT DETAILS
EMPLOYER CONTRACT NO. : 1516-23-BD-850-00
PROJECT TITLE : EPC for Installation of PWT, Republic of Iraq
EMPLOYER : Gazprom Neft Badra B.V.
EPC CONTRACTOR : Suhool Azmer Company Ltd.
ENGG CONTRACTOR : Petrochemical Engineering Consultants
CONTRACT JOB NO. : SAC
PROJECT DOCUMENT NO. : GB1516-SAC-240-EL-DB-0001
REVISION NO. : 1 No. of pages (incl. sheet) :36
DOCUMENT DESCRIPTION : Electrical Design Basis
Revision Details
1 Re-Issued for Design 11-Oct-23 HM SAR AJ
0 Issued for Design 02-Dec-19 ACR KKR DTS
H Revised & Reissued For Approval 13-Nov-19 ACR KKR DTS
G Revised & Reissued For Approval 22-Nov-19 ACR KKR DTS
F Revised & Reissued For Approval 22-Oct-19 ACR KKR DTS
E Revised & Reissued For Approval 27-Sept-19 ACR KKR DTS
D Revised & Reissued For Approval 26-Aug-19 ACR KKR DTS
C Revised & Reissued For Approval 16-Aug-19 SAR AJ
B Issued for Approval 1-Aug-19 SJB SAP DTS
A Issued for Review 22-Jul-19 SJB SAP DTS
Rev. Description Date PRPD CHKD APPD
GB1516-SAC-240-PI-DB-001_Rev-1 DOC PAGE SIZE: A4

REVISION DESCRIPTION SHEET
Rev. Para. Revision Description
A Issued for review
B Revised as per GPNB’s Comments
C Revised as per GPNB’s comments
D Revised as per GPNB’s comments
E 5 Revised as per GPNB’s comments
F 14, 15, 16, Revised as per GPNB’s Comments

17, 18, 21,
27, 30 &
34
G 17, 18 & Revised as per GPNB’s Comments

34
H 18 Tag No. of DB Revised as per GPNB’s Comments
0 19 UPS Power for Telecom/CCTV included as per GPNB’s Comments
1 Issued for Design

Hold
Para. Description of Hold
No.

TABLE OF CONTENTS
1. General ............................................................................................................. 5
2. Introduction....................................................................................................... 5
3. Definitions and Abbreviations......................................................................... 5
3.1. Definitions......................................................................................................... 5
3.2. Abbreviations ................................................................................................... 6
4. List of Applicable Codes and Standards....................................................... 9
4.1. British Standards – BS .................................................................................... 9
4.2. Engineering Equipment & Materials User’s Association – EEMUA ........... 9
4.3. International Electro-Technical Standards – IEC ......................................... 9
4.4. European & International Codes and Standards........................................ 11
5. Project Specifications & Documents............................................................ 12
6. Site Data & Service Conditions.................................................................... 12
6.1. System Voltage, Frequency and System Earthing .................................... 13
6.2. Utilization Voltages........................................................................................ 13
6.3. Voltage Drops ................................................................................................ 14
7. Objective ......................................................................................................... 15
8. Electrical Design ............................................................................................ 15
8.1. Power Supply Distribution and Modification ............................................... 16
8.2. Substation SS-000-04 ................................................................................... 16
8.3. Satellite Control Center SCC-05 .................................................................. 18
8.4. EMCS Interface ............................................................................................. 19
8.5. Tie-In Points ................................................................................................... 19
8.6. Instrumentation .............................................................................................. 19
9. Hazardous Area Classification and Equipment Selection ......................... 19
9.1. Electrical Equipment in Safe Area ............................................................... 20
9.2. Electrical Equipment in Hazardous Area .................................................... 20
10. Equipment and Material Selection............................................................... 20
11. Ingress Protection ......................................................................................... 21
12. Certification of Electrical equipment for installation in Hazardous Areas21
13. Distribution Boards ........................................................................................ 22
14. Lighting System ............................................................................................. 22
15. Electrical Calculations ................................................................................... 24
15.1. Electrical Load / Load Summary.................................................................. 24
15.2. Cable Sizing ................................................................................................... 25
15.3. Lighting System ............................................................................................. 25
16. Earthing and Lightning Protection ............................................................... 25
16.1. Earthing System ............................................................................................ 25
16.2. Lightning Protection System ......................................................................... 28

17. LV Motors ..................................................................................................... 29

18. Local Control Stations ................................................................................ 29
19. Welding Socket Outlet ................................................................................ 30
20. Convenience Socket Outlet ....................................................................... 30
21. Cables & Cable Laying ............................................................................... 31
21.1. Above Ground Installation ......................................................................... 33
21.2. Underground Installation ............................................................................ 34
22. Equipment Installation & Operation.......................................................... 35
23. Cathodic Protection (CP System) ............................................................. 35
24. Equipment Tagging ..................................................................................... 36

1. General
Gazprom Neft Badra B.V (EMPLOYER) is engaged in the development of the Badra Oilfield,
located in Republic of Iraq. The Badra Oilfield is situated in Wasit Governorate, 160km
southeast of Baghdad city.
The produced water treatment facility will be developed with a treatment target of 2500 m 3/day.
However, the treatment of produced water capacity shall be achieved by designing three
parallel trains (3 X 33%) with each capacity of 833 m 3/day. Gas resulting produced water
treatment will be flared.
Further, feasibility study for utilization of the treated water (2500 m 3/day) for beneficial use
shall be carried out.
The facility shall be equipped with surge drum to collect the incoming produced water from
existing CPF, produced water treatment packages and chemical injection packages.
2. Introduction
EMPLOYER has appointed SAC (EPC Contractor) to carry out the Detailed Engineering,
Procurement, Construction, the Pre-Commissioning, the Commissioning, the Start-Up and the
Performance Tests for Electrical System. It includes to develop & integrate new Electrical
System with the Existing Electrical System, further to carry out required modifications in the
existing Substation (SS-000-04) And Satellite Control Center (SCC05) along with any other
associated systems and facilities in the scope of the EPC contractor under this Project.
In pursuit of this objective, EMPLOYER / EPC CONTRACTOR has appointed Petrochemical
Engineering Consultants as ENGINEERING CONSULTANT to carry out the Detailed
Engineering for the Produced Water Treatment (PWT), Horizontal Combustion Unit (HCU)
and any other associated systems and facilities at Badra oil field.
3. Definitions and Abbreviations
3.1. Definitions
Throughout the document the following definitions shall apply:
EMPLOYER - Gazprom Neft Badra B.V.
(GPNB) EPC CONTRACTOR - SAC, IRAQ (SAC)
CONSULTANT - Petrochemical Engineering Consultants.
PROJECT - EPC for Installation of PWT,
Republic of IRAQ
SHALL - Indicates a mandatory requirement
SHOULD - Indicates that the requirement is
strongly recommended to be adhered
to

3.2. Abbreviations
AC - Alternating Current
ACB - Air Circuit Breaker
API - American Petroleum Institute
A.S.L - Above Sea Level
ATS - Automatic Transfer Switch
CCTV - Closed Circuit Television
CP - Cathodic Protection
DC - Direct Current
DCS - Distributed Control System
DG - Diesel Generator
DOL - Direct On Line
E&I - Electrical & Instrumentation
Ex ‘e’ - Increased Safety
Ex ‘ia’ - Intrinsically Safe
Ex ‘d’ - Explosion Proof
Ex ‘n’ - Non-Sparking
Ex’nR’ - Non-Restricted
EEMUA - Engineering Equipment & Materials

User’s Association
EMC - Electro Magnetic Compatibility
EPC - Engineering Procurement and Construction
ESD - Emergency Shutdown (System)
EMCS - Electrical Monitoring Control System
F&G - Fire & Gas
FAT - Factory Acceptance Test

Hz - Hertz

I/O - Input / Output
IEC - International Electro Technical Commission

IEEE - Institute of Electrical and Electronics Engineers
IP - Ingress Protection
IRP - Interposing Relay Panel
ISO - International Organization for Standardization
ITB - Information to Bidder
ITP - Inspection and Test Plan
JB - Junction Box
LAN - Local Area Network
LCP - Local Control Panel
LCS - Local Control Station
LED - Light Emitting Diode
LLI - Long Lead Items
LV - Low Voltage
MCB - Miniature Circuit Breaker
MCC - Motor Control Center
MCCB - Moulded Case Circuit Breaker
MOV - Motor Operated Valve
MTO - Material Take-Off
MCT - Multi Cable Transit
MOC - Material of construction
M - Meter
NACE - National Association of Corrosion Engineers
NEMA - National Electrical Manufacturers Association
NFPA - National Fire Protection Association

OSHA - Occupational Safety and Health Authority
PLC - Programmable Logic Controller
PVC - Poly Vinyl Chloride
PWT - Produced Water Treatment
QA - Quality Assurance
QC - Quality Control
RAM - Reliability, Availability, Maintainability
RFQ - Request for Quotation
ROI - Republic of Iraq
RTU - Remote Terminal Unit
SAT - Site Acceptance Test
SIL - Safety Integrity Level
SLD - Single Line Diagram
SPIR - Spare Parts Inter-Changeability Register
SOV - Solenoid Valve
SOW - Scope of Work
TBE - Technical Bid Evaluation
TPA - Third Party Agency
TRU - Transformer Rectifier Unit (CP System)
UG - Underground
UL - Underwriters Laboratories
UPS - Uninterrupted Power Supply
UT - Ultra-Sonic Testing
V - Volt
XLPE - Cross Link Poly Ethylene

4. List of Applicable Codes and Standards
4.1. British Standards – BS

BS 1449 - Galvanization after Manufacture
BS 278 - Methods of Testing Plastics (Note-1)
BS 6004 - Electric Cables - PVC Insulated and PVC Sheathed

Cables for Voltages up to and Including 300/500V,
for Electric Power and Lighting
BS 612 - Specification for metallic glands
4.2. Engineering Equipment & Materials User’s Association – EEMUA

EEMUA 133 - Underground Cable Protected against Solvent
Penetration and Corrosive Attack
4.3. International Electro-Technical Standards – IEC

IEC 60028 - International Standard of Resistance for
Copper IEC 60034 - Rotating Electrical Machines (Note-1)
IEC 60038 - IEC Standard Voltages
IEC 60044 - Instrument Transformers (Note-1)
IEC 60050 - International Electro-Technical Vocabulary (Note-1)
IEC 60051 - Direct Acting Indicating Analogue Electrical Measuring
Instruments and their Accessories (Note1)
IEC 60060 - High-Voltage Test Techniques (Note-)
IEC 60068 - Environmental Testing (Note-1)
IEC 60072 - Dimensions and Output Series for Rotating Electrical

Machines (Note-1)
IEC 60079 - Explosive Atmospheres (Note-1)
IEC 60085 - Electrical Insulation - Thermal Evaluation and

Designation
IEC 60204 - Safety of Machinery - Electrical Equipment of Machines
(Note-1)

IEC 60227 - Polyvinyl Chloride Insulated Cables of Rated Voltages

up to and Including 450 / 750 V (Note-
1) IEC 60228 - Conductors of Insulated Cables
IEC 60230 - Impulse Tests on Cables and Their Accessories
IEC 60255 - Measuring Relays and Protection Equipment (Note-1)
IEC 60287 - Electric Cables- Calculation of Current Rating (Note-
1) IEC 60304 - Standard Colours for Insulation for Low-Frequency

Cable and Wires
IEC 60309 - Plugs, Socket-Outlets and Couplers for Industrial

Proposes
IEC 60331 - Tests for Electric Cables under Fire Conditions - Circuit
Integrity (Note-1)
IEC 60332 - Test on Electric and Optical Fiber Cables under Fire
Conditions (Note-1)
IEC 60364 - Low Voltage Electrical Installations (Note-1)
IEC 60423 - Conduit Systems for Cable Management - Outside

Diameters of Conduits for Electrical Installations
and Threads for Conduits and Fittings
IEC 60502 - Power Cables with Extruded Insulation and Their

Accessories for Rated Voltages from 1 kV (Um =
1,2 kV) up to 30 kV (Um = 36 kV) (Note-1)
IEC 60529 - Degrees of Protection Provided by Enclosures (IP

Code)
IEC 60598 - Luminaries (Note-1)
IEC 60724 - Short-Circuit Temperature Limits of Electric Cables with

Rated Voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um
= 3,6 kV)
IEC 60754 - Test on Gases Evolved during Combustion of Materials

from Cables (Note-1)
IEC 60909 - Short-Circuit Currents in Three-Phase A.C. Systems
(Note-1)

IEC 60934 - Circuit Breaker for Equipment
IEC 60947 - Low-Voltage Switchgear and Control Gear (Note-
1) IEC 61000 - Electromagnetic Compatibility (EMC) (Note-1)
IEC 61140 - Protection against Electric Shock – Common Aspects

of Installation and Equipment
IEC 61200 - Electrical Installation Guide (Note-1)
IEC 61204 - Low Voltage Power Supply Devices, DC Output (Note-1)
IEC 61386 - Conduit Systems for Cable Management (Note-1)
IEC 61439 - Low-Voltage Switchgear and Control Gear Assemblies

(Note-1)
IEC 61641 - Enclosed Low-Voltage Switchgear and Control Gear

Assemblies - Guide for Testing under Conditions
of Arcing due to Internal Fault
IEC 61642 - Industrial A.C. Networks Affected by Harmonics -

Application of Filters and Shunt Capacitors
IEC 62040 - Uninterruptible Power Systems (UPS)(Note1)
IEC 62208 - Empty Enclosures for Low-Voltage Switchgear and

Control Gear Assemblies General Requirements
IEC 62305 - Protection against Lightning (Note-1)
Institute of Electrical and Electronics Engineers – IEEE
IEEE 80 - Guide for Safety in AC Substation Earthing
IEEE 142 - Recommended Practice for Grounding of Industrial
and Commercial Power Systems
4.4. European & International Codes and Standards

DIN E12954 - Cathodic Protection of Buried or immersed metallic
structure – General principles and application
for Pipelines
DIN E13509 - Cathodic Protection Measurement techniques

NACE SP 0286 - Electrical Isolation of Cathodically Protected Pipelines.

Note-1: Where the codes consist more than one part, all part shall apply with their
latest revision.
5. Project Specifications & Documents

CONSULTANT shall follow the various Project documents & Specifications of ITB to
develop the detailed Electrical Design of the PWT Area and HCU Area. Below
mentioned design documents / drawings, calculations and investigations reports shall
be re-validated during detail engineering phase and shall be revised, if needed.
a. GB547-WGK1-240-EL-DB-001 - Electrical Design Basis
b. GB547-WGK1-240-EL-EL-001 - Electrical Equipment List
c. GB547-WGK1-240-EL-GA-001 - Existing Substation Equipment Layout (SS-
00-04)
d. GB1516-SAC-240-EL-MR-0001 - MR for Substation Modification
e. GB1516-SAC-240-EL-RP-0001 - Study report for existing substation (SS-000-04)
and switch board (SCC-05)
f. GB1516-SAC-240-EL-SL-0001 - SLD – Packages and Existing
facility Interface
g. GB1516-SAC-240-EL-DL-0001 - Electrical Load List
h. GB1516-SAC-240-EL-SC-0004 - Electrical Tie-in List
i. GB090-2614-250-EL-SP-0013 - Specification for Electrical Cables
j. GB090-2614-250-EL-SP-0011 - Specification for LV Induction Motor
k. GB090-2614-250-EL-SP-0021 - Specification for Bulk Materials
l. GB090-2614-250-EL-DB-0002 - Design basis for electrical installation within
package equipment
m. GB547-WGK1-240-EL-SP-006 - Specification for Distribution Boards
n. GB1516-SAC-240-EL-DD-0001 - Typical Installation Details - Power, Lighting,
Earthing & Lightning Protection
o. GB547-WGK1-240-EL-SP-006 - Specification for Distribution Boards
p. GB090-2614-250-MT-SP-0001 - Specification for Cathodic Protection System
q. GB1516-SAC-240-EL-DL-0002 - LV Power & Control Cable Data Sheet
6. Site Data & Service Conditions

CONSULTANT shall carry out the design & engineering of the electrical system of project
using the following site data & environmental conditions:
Max design air temperature for outdoor installation : + 55 °C
Min design air temperature for outdoor installation : - 0.4 °C
Max design air temperature for indoor installation : + 40 °C
Min design air temperature for indoor installation : + 5 °C
Max relative humidity for outdoor installation : 81 % at 20 °C

Highest wind speed : 31.9 m/s
Altitude : + 45 m A.S.L.
Atmosphere : Marine dusty and

corrosive
6.1. System Voltage, Frequency and System Earthing
Operation Voltage
Frequency System
Voltage variation Phase Frequency
variation Earthing
Level in %
400V +/- 10 % 3Ph 50 Hz +/- 5 % Solid

230V +/- 10 % 1Ph 50 Hz +/- 5 % Solid
400 / 230V
3Ph / Solid
AC UPS +/- 1 % 50 Hz +/- 1 %
1Ph Earthed
110V (DC Un-

+/- 1 % - 50 Hz -
UPS) Earhted
Electrical Equipments shall work satisfactorily with following system voltage & frequency
variations, which shall be result of momentary system disturbances, expected to occur
due to varying system conditions. The system parameters shall return to the steady state
conditions within 10 sec. System design shall be with:
• Voltages variations of ± 10 % of rated values,

• Frequency variations ranging within ± 5 % of rated frequency
. The Total Harmonic Distortion (THD) of the supply network shall not exceed 5%.
6.2. Utilization Voltages
Following voltage levels shall be applied for designing of electrical equipment &
Electrical Power System at rated frequency of 50 Hz.
Motors up to & Including 200 kW 400 V, 3 PH, 4 Wire, 50 Hz AC
Space Heater for motor or cubicle 230 V, 1 PH, 3 Wire, 50 Hz AC
Welding Socket Outlet 400 V, 3 PH, 5 Wire, 50 Hz AC
Convenience Socket Outlet 230 V, 1 PH, 3 Wire, 50 Hz AC
Lighting Fixtures 230 V, 1 PH, 3 Wire, 50 Hz AC
(Normal Lighting)

Lighting Fixtures 230 V, 1 PH, 4 Wire, 50 Hz AC

(Emergency
Lighting)
AC UPS (Package PLC /
System Control Panels – For 230 V, 1 PH, 3 Wire, 50 Hz AC
Instrumentation)
DC UPS 110 V, 2 Wire, DC
48 V, 2 wire, DC (refer note
Solenoids, Transmitters & Switches
below)
400 V switchgear - Outgoing non-
ACB feeders control circuit, 230V, 1PH, 3 wire, 50 Hz AC
space heater and internal lighting
Note: The UPS power supply available for various Instruments shall be 1PH 230V AC
UPS supply. In case, smaller voltages such as 48V DC or 24V DC, if required for
performance of some instrument, the same shall be derived internally by
instrumentation VENDOR.
6.3. Voltage Drops

The maximum voltage drop at various buses during start-up of large motor and
motor reacceleration conditions shall be within the limits stated below:
System Max. Permissible

S. Operating Condition
No. Element Voltage Drop
a) Motor Terminal Start-up of the motor (≤ 75kW) 15% or as per

with other loads on the bus Motor
(Simultaneous start-up or group manufacturer’s
reacceleration of LV motors is recommendation
not envisaged) (at Motor
Terminal)
b) Motor Terminal Start-up of the motor (≥75kW) 15% or as per

with other loads on the bus Motor
(Simultaneous start-up or group manufacturer’s
reacceleration of LV motors is recommendation
not envisaged) (at Motor
Terminal)

c) Motor Feeder Max. Voltage Drop when Motor

is Running at Full Load at rated 5%
speed
d) Power Feeder - 2%
e) Switchgear to • If MCC located at in

MCC / same building 1%
Switchboard • If MCC located at distant 2%
location
f) Lighting Circuit At the Last Lighting Fixture in

3%
the circuit.
Note: During motor start, a maximum voltage drops of 10% shall be permitted on
the switchgear bus.
7. Objective
This Electrical Design Basis is developed an objective to lay down various design conditions
and parameters and engineer the Electrical facilities to feed continuous & reliable power
supply to various electrical equipment which shall be installed in Produced Water (PWT) &
Horizontal Combustion System (HCU) Area.
The Electrical system shall:

• Meet the Codes and Standards
• Provide safety to operating and maintenance personnel.
• Provide safety to the connected equipment.
• Provide reliability of power supply to plant / facilities depending on criticality.
• Provide maximum security for power supply during emergencies.
• With minimal fire risk.
• Ease of operation and maintenance.
• Shall provide spare capacity of 25% for future expansion.
• Be Compatible with adequate power supply from the existing systems of the
project.
• Optimize operation and maintenance cost.
• Have provision (spare feeders) and flexibility for future expansion.
• Safe starting and shutdown of the plant under all conditions.

8. Electrical Design
In the Detailed Design and Engineering phase, CONSULTANT shall revalidate the project
documents related to GB874, GB875 and FEED projects and develop the detail design &
engineering documents, incorporate the various vendor inputs. CONSULTANT shall increase
/ Decrease and update the Scope of Work where deemed necessary to meet the Project
requirements. The detail design developed by CONSULTANT shall provide the required
design drawings, data & other relevant information, which shall be good for construction at
8.1. Power Supply Distribution and Modification
Existing power source in Substation SS-000-04 and Satellite Control Center SCC-05
shall be utilized to feed power to new loads in PWT and HCU facilities. CONSULTANT
shall revalidate the adequacy report during detail engineering stage, so as to ensure
that the adequate spare capacity is available in the upstream transformer & spare
feeders / vacant spaces are available in the 400V Swgr & MCC (274-EL-101) to feed
electrical power to Electrical Loads of PWT & HCU Areas.
Input Power Supply required for PWT Area
a) 400V, 3Ph 4W 50Hz Power supply for new electrical loads of “ProducedWater
Treatment (PWT)” and Horizontal Combustion Unit (HCU).
b) Emergency Lighting
c) UPS power supply for instrument loads,
a) Non-UPS power supply for instrument & other loads including anti-condensation
Heaters.
Modifications work required in Existing 400V, Swgr & MCC (274-EL-101)
CONSULTANT shall confirm the necessary modifications work required in Existing 400V
Swgr & MCC (274-EL-101). The details of Scope of Modification Works for Existing 400V
LV Switchgear & MCC are listed in doc. no. GB1516-SAC-240-EL-MR- 001.
Detailed description of power distribution is listed in section 8.2 & 8.3 below.
8.2. Substation SS-000-04

a) New Oil Recovery Pumps (240-P-24001A/B) and Feed Pumps (240-P-
24410A/B)
• Recovered Oil Pumps (240-P-00401A/B) shall be fed from 240-DB-001. The Rating
of the Recovered Oil Pump Motor is 22 KW. There are 2 incomer feeders in 240-
DB-001 rated for 250A, 400V, 3Ph. N+PE. This 240-DB-001 shall be fed from 274-
EL-101.
• Two number of 4P 250A MCCB, 250AF/250AT feeders shall be provided from 274-
EL-101 as per Single Line Diagram doc. no. GB1516-SAC-240-

EL-SL-001.
• The Water Feed Pumps (240-PM-24410A/B) shall be fed power from 274-EL-101.
b) The rating of the Feed Pump’s Motor is 18.5 Kw. One (1) No. DOL Starter feeder
is available (20R-D on Bus-B) and one (1) vacant or Spare feeder shall be modified.
It is indicated on the GA drawing of the OEM (L&T) and has been added in the Single
Line Diagram doc. no. GB1516-SAC-240-EL-SL-001. Based on new load distribution
and requirements, GPNB and CONSULTANT have envisaged to add one new Sub
Power Distribution Board (240-DB-002).
New Sub Power Distribution Board (240-DB-002): This will be newly designed. The
New Sub Power Distribution Board (240-DB-002) shall be located in PWT area
(near 240-DB-001). DB (240-DB-002) shall have 2 nos. Incomers and shall be fed
from Bus-A & B of Existing 400V Switchgear & MCC (274-EL- 101, located in
Substation- 4). This DB shall have ATS facility.
DB (240-DB-002) shall cater to Electrical Load of Train-B (U-24201) / Train-C (U-

24301) and other Miscellaneous Loads of PWT.
Electrical loads of PWT Trains B & C shall be fed from 274-EL-101 with new 4P
250AF/250AT MCCB to make them suitable for 240-DB-002 (New DB) as per
Single Line Diagram doc. no. GB1516-SAC-240-EL-SL-001.
c) There are 5 Chemical Injection Packages (U-24001, U-24002, U-4003, U-24004 &
U-24005). All 10 Injection Pumps shall be fed from 240-DB-001 ofTrain A. 5 Nos.
Convenience Sockets shall be provided near the ChemicalInjection Skid to cater 5
Nos Unloading Pumps (portable type). All 5 Convenience Sockets shall be 230V
50Hz (1Ph+N+PE) and in the same circuit.
d) Welding Sockets (240-WSO-001) in PWT and (244-WSO-001) in HCU are loop

powered and shall be fed from the Sub Power DB (240-DB-001).
e) Welding Sockets for PWT Trains B & C (242-WSO-001) in PWT Area shallbe fed
from the New Sub Power DB (240-DB-002).
f) All the Pumps of PWT Trains B & C shall be fed from the New DB (240-DB- 002). The
new DB (240-DB-002) shall have DOL Starters for these pumps and they will not
be intelligent starters.

g) Normal Lighting:
Power supply to normal lighting fixtures in PWT area shall be fed from a new
Outdoor Normal Lighting Distribution Board 240-LDB-001 which shall be installed in
PWT Skid (as per PWT Vendor). Upstream power for 240-LDB-001 shall be fed
from new sub-sub–Distribution Board 240-ELDB-004 that shall be installed near to
240-DB-001. 240-ELDB-004 shall be power supplied from 240-DB- 001and 274-
EMDB-107 and shall have ATS facility between two sufficiently rated incomers. 240
cell. A separate feeder in sub-sub–Distribution Board 240- ELDB-004 shall be
allocated for Normal Lighting for HCU Area (connected to photo cell-controlled bus)
and single-phase socket outlets (connected to non-photo cell-controlled bus).
Single phase sockets shall be supplied from 240-ELDB-004 as 240-LDB-001 is
equipped with 10 Amp rated MCBs only.
h) Emergency Lighting:
Power supply for emergency lighting fixtures in PWT Area shall be fed from new
Outdoor Emergency Lighting Power Distribution Board (240-EDB-001), as per
PWT vendor. It shall also be installed in PWT area. This new Outdoor Emergency
Lighting Power Distribution Board (240-EDB-001) shall be installed on the Train- A
Skid. 240-EDB-001 shall be fed from new sub-sub–Distribution Board 240- ELDB-
004 from non-photo cell-controlled bus bar. 240-EDB-001 shall be controlled by
separate photo cell.
For Emergency lighting requirement for HCU Gas Valve Skid, a Separate Feeder
shall be taken from the new sub-sub–Distribution Board 240-ELDB-004 from non-
photo cell-controlled bus.
8.3. Satellite Control Center SCC-05

230V AC UPS power supply for new instrumentation loads and PLC Panels (Control
System) shall be fed from existing AC UPS DBs in SCC-05. The power requirement
shall be redundant OR No-redundant (as per vendor’s requirement).
Non-UPS power supply for new instrumentation loads (instruments) and Internal
Illumination & Anti-Condensation Heaters of PLC Panels shall be fed from existing Non-
UPS DB in SCC-05.
a) UPS Power (Train-A): New Package WTP PLC (installed in SCC-05), shall beprovided
with 2 nos. UPS power supply feeders from Existing Sub AC UPS Power Distribution
Board - 3 & 4 (225-DB-010& 11), both DBs are located in SCC-05. Existing equipped
spare feeder no. 10 (16A, 2P MCB) available in both 225-DB- 010and 225-DB-011
respectively shall be used for redundant power connection to PLC Panel.

UPS Power (Train-B & C): These will be Future Package WTP PLC (installedin SCC-
05), shall be provided with 2 nos. UPS power supply feeders from Existing Sub AC
UPS Power Distribution Board - 3 & 4 (225-DB-010& 11), both DBs are located in
SCC-05. Existing equipped spare feeder no. 11 (16A, 2P MCB) available in both
225
DB-010 and 225-DB-011 respectively shall be used for redundant power connection
to PLC Panel.
b) UPS Power (Flare Control Unit – HCU Area): This Panel shall be located in field in HCU
Area. UPS Power to this panel shall be non-Redundant and shall be provided with 1
no. existing spare feeder (16A, 2P MCB) from Existing Sub AC UPS Power Distribution
Board - 3 (225-DB-010),
c) UPS Power for Telecom/ CCTV: Redundant UPS power for the Telecom / CCTV shall be
drawn from UPS DBs 225-DB-010 & 225-DB-011 (both located in SCC05). These
redundant power supplies shall be fed to 240-EDB-004 through a ATS (240-ATS-001
(located in SCC05 adjacent to “UPS DBs 225-DB-010 &225-DB-011”).
d) Non-UPS Power: Non-UPS power supply (1 no.) for new Package PLCs for Train A
shall be fed from existing equipped spare feeder (10A, 2P MCB) in Non- UPS Power
Distribution Board (225-DB-009), located in SCC-05.
e) Non-UPS Power: Non-UPS power supply (1 no.) for new Package PLCs for Train B &
C shall be fed from existing equipped spare feeder (10A, 2P MCB) inNon-UPS Power
Distribution Board (225-DB-009), located in SCC-05.
8.4. EMCS Interface
Data / signal from new Feed Pump’s starters (240-PM-24410A/B) in existing 400V
Switchgear & MCC (274-EL-001) located in Substation no. SS-000-04 shall be
communicated to existing EMCS Cabinet (274-ECP-101A/B) in Substation no. SS-
000-04 as per existing interface’s philosophy.
Data Communication of all Pumps in PWT area (of Trains-A, B & C) shall be communicated
to the EMCS via their PLC Panels located in SCC 05.
8.5. Tie-In Points
CONSULTANT shall verify and update the Tie-in points document as per detail engineering
developments.
8.6. Instrumentation
Some requirements provided with this document are applicable for the Instrument
installation. If requirements are different for same subject in various projects documents,

the stronger shall be applicable.
9. Hazardous Area Classification and Equipment Selection

All the areas within the PWT Area shall be classified for the degree and the extent of hazard
from flammable materials. Classification of hazardous areas shall be done in accordance
Area Classification Code for Installation Handling Flammable Fluids IP: 15. The Electrical
Equipment installed in the Classified Hazardous Area of PWT & HCU shall be reviewed,
revised and accordingly included for procurement.
9.1. Electrical Equipment in Safe Area
Electrical equipment in safe area shall be weatherproof type with minimum ingress
protection for all outdoor equipment as IP 55 and for all indoor equipment IP 41.
9.2. Electrical Equipment in Hazardous Area
The equipment and material selection shall be in accordance the standard IEC 60079
and hazardous area classification layouts.
10. Equipment and Material Selection

Various Electrical Equipment for hazardous areas shall be suitable for the area classified.
Minimum requirements for Electrical Equipment located in Zone 1 & 2 are:
Zone 1 areas
Junction boxes, etc. - Increased Safety Ex (e) / Flameproof type Ex (d) Light
fittings - Increased Safety Ex (e)/ Flameproof type Ex (d) Plugs
and Sockets - Increased Safety Ex (e)/ Flame proof type Ex (d)
Arcing and sparking - Flameproof Type Ex

(d) equipment (switches, circuit
breakers, switchgear,
panel boards, control stations, etc.)
LV motors - Flameproof Type Ex (d)

Zone 2 areas
Junction boxes, etc. - Same as in Zone 1
Light fittings - Fame as in Zone 1
Plugs and Sockets - Same as in Zone 1
Arcing and sparking - Same as inZone 1
equipment (switches, circuit
breakers, switchgear, panel

boards, control stations etc.)

LV motors (Zone2, Gas Gr. IIB) - Ex (n) – Non-
Sparking LV motors (Zone2, Gas Gr. IIC) - Flameproof Type
Ex(D)
The equipment suitable for Zone 1 area are suitable for Zone 2 area.
The equipment selection shall be based on hazardous area classification in accordance with
IEC 60079-14.
1. Ingress Protection
Ingress Protection of electrical equipment shall be selected based on location of their
installation, environmental condition and application of equipment. Following is the guideline
for selection of ingress protection for electrical equipment.
Degree of Protection (IP)
S. No. Equipment Outdoor Indoor
1 Motor IP 55 NA
2 IP 55 or
Power Outlet NA
Better
3 IP 55 or
Convenience Outlet NA
Better
4 IP 55 or
Local Control Station NA
Better
5 IP 55 or
Junction Box NA
Better
6 IP 55 or
Lighting Fixture NA
Better
7 Lighting / Small Power Panel / IP 55 or
NA
Local Control Panel Better
8 400V Switchgear / MCC NA IP 41
9 IP 55 or
Distribution Boards NA
Better
10 UPS NA IP 41 OR IP42
NA - Not Applicable for PWT & HCU Area.

2. Certification of Electrical equipment for installation in Hazardous Areas The Electrical
Equipment’s installed in classified areas shall be certified by test laboratory
/ Notified Bodies such as
• CESI for equipments manufactured in Italy,

• PTB for equipments manufactured in Germany,

• BASEEFA for equipments manufactured in England,
• LCIE or INERIS for equipments manufactured in France, OR
• Any other Certified laboratory.
11. Distribution Boards

For outdoor installation, Distribution Boards shall have degree of protection of IP55(min), free
standing on frame, constructed from sheet steel. Distribution Boards shall be designed &
manufactured in accordance with Specification for Distribution Boards.
Distribution Boards located inside any containerized package units supplied by package
VENDOR shall be type tested, metal enclosed type, Form 2b, wall mounted fixed type, single
front execution with a minimum degree of Protection of IP 41.
All outgoing feeders supplying power to lighting fixtures shall be provided with Residual
Current Device (RCD) with 100 milli-Ampere (mA) sensitivity for protection against ground
faults. While feeders supplying power to convenience sockets shall be provided with Residual
Current Device (RCD) with 30 milli-Ampere (mA) sensitivity for protection against ground
faults.
25% fully equipped, spare outgoing feeders shall be provided in each Distribution Board. The
feeders in lighting Distribution Boards shall not be intelligent type and shall have no link with
EMCS or DCS.
Lighting load in all the three phases shall be balanced in Normal / Emergency Lighting
Distribution Boards (as far as possible).
Outdoor Lighting shall be switched off by photocell control.
Any indoor lighting fixtures located inside any containerized package units supplied by
package VENDOR shall be switched on manually.
12. Lighting System

CONSULTANT shall design the lighting system to provide the illumination necessary for plant
operation and maintenance. It shall be designed to avoid any stroboscopic effect. The design
and installation of lighting system shall be performed in accordance to IEC Standards.
The lighting equipment located outdoors shall suitable for outdoor installation, capable to
withstand direct sunlight and shall be designed for a minimum ambient temperature of -
0.4 °C and maximum ambient temperature of +55 °C.
The outdoor single phase convenience outlets in Zone 1 or Zone 2 area and other hazardous
areas within process installations shall be fully weatherproof, dustproof (IP 55), corrosion
resistance with Ex-'d' execution, Gas Group IIB Temperature Class T3. For safe area,

industrial type, fully weatherproof, dustproof (IP 55), corrosion and UV resistant outlets shall
be used. All material shall be as per Specification for Electrical Bulk Materials.
Following design consideration shall be taken care while designing the lighting system for the
new facilities:
• Lighting DBs shall have required number of equipped lighting feeder MCBsalong
with 25% spare feeders.
• The total estimated load of each circuit shall not exceed 80% of the MCB rating.
• Lighting methods and material shall be suitable for the area classification inwhich
they are to be installed.
• Lighting system shall provide adequate light distribution in all outdoor areas of the
plants by the following categories of lighting systems.
• Normal Lighting
• Emergency Lighting
a) Open Area lighting: Open Are lighting shall cover outdoor open areas. Open area
lighting shall be designed by use of LED Flood Lighting Fixtures installed on 10M
high Lighting Poles. The Outdoor lighting shall be automatically controlled by
Photocell circuit. The Lighting fixture in open area shall be fed from both normal &
emergency circuit. The Flood Lighting Pole shall be hinged construction type to
raise OR Lower the Lighting fixtures for maintenance
b) Plant Lighting: Plant Lighting shall cover the lighting provided for platforms
/ staircases and walk-ways. The lighting Lux Levels shall be achieved by providing
linear LED Fixtures mounted on 2.5m high Platform poles or steel columns, as
applicable. The Outdoor plant lighting shall also be automatically controlled by
Photocell circuit. The plant lighting fixtures shall be fed from both normal &
emergency circuit.
c) Indoor Lighting: Indoor lighting envisaged is lighting in containerized package.
Indoor Lighting shall also be done using linear LED Lighting Fixtures and shall be
supplied by package supplier. The Lighting inside thepackage shall be fed from both
normal & emergency circuit. CONSULTANT shall provide the lighting feeder cabling
at the JB at the battery limit of Package.
Lighting Lux Levels
The illumination levels shall be in compliance with the following lux values:
Control Room
General, Including in Front of Panels :
300 Lux Control Room in Front of Desk :

500 Lux
Rear Of panels : 150 Lux
Auxiliary Rooms : 150 / 300 Lux
Plant Areas
Operating Areas requiring :
150 Lux Regular operator intervention (Pumps &
Valves etc.)
Local Control Stations & Monitoring Points :
75 Lux (Like Indicating Instruments, Gauges and
control devices)
Access ways (walk-ways & Platforms :

75 Lux stairways & ladders)
Non-Plant Areas
Switch Rooms, relay & Auxiliary Rooms : 150 Lux
Street Lighting & Fence Lighting : 5 Lux
(min) By LED Lighting Fixture On
On 10M / 12M high Poles at 25m Spacing
13. Electrical Calculations

CONSULTANT shall review / revalidated electrical calculations in line with
recommendations of IEC & IEEE standards. It includes the following:
a) Electrical Load List / Load summary

b) Cable sizing
c) Earthing calculation
d) Lightning Protection Calculation
e) Indoor/ Outdoor Lighting calculation
13.1. Electrical Load / Load Summary

CONSULTANT shall reproduce the electrical load schedule with updated loads provided in
PWT & HCU Areas. The Electrical Load List shall contain the following information as
minimum:
a. Electrical load items with brief description / tag numbers of the items.
b. Operation category of loads, such as continuous, intermittent, or standby
c. Power source identification (normal, essential, emergency) Type of loads,such
as motors and feeders as minimum
d. Rated active power in kW, voltage grade, full load current, frequency (if AC),
Ex non-Ex proof / weatherproof.
e. Load classification – normal, essential and vital

f. Classification of factors – Continuous (100%), Intermittent (30%) and

Standby (5%)
13.2. Cable Sizing

CONSULTANT shall size the cables according to requirements of IEC 60364 (Low
voltage electrical installations) by considerations of:
a) Full load current of equipment

b) Environmental & Site Ambient conditions. Soil temperature for cablesizing
shall be considered as 40°C.
c) Soil thermal resistivity.
d) Current carrying capacity after applying all de-rating factors based on method
of installation grouping factor, ambient temperature. The cableampacity
calculation is based on the value defined by the IEC standards.
e) Voltage drop in both normal operating and starting conditions.
f) Maximum short circuit conditions.
g) Specification for Electrical Cables.
Cables shall be rated suitably to withstand the short circuit with a coordinated short time
withstand to match the associated switchgear rating and short circuit let through current
of the associated protection.
13.3. Lighting System

The Lighting Calculations shall be carried out on the basis of Lighting Lumen
requirement specified in Cl. 14 Lighting System.
The lighting equipment located outdoors shall withstand direct sunlight and shall be
designed for a minimum ambient temperature of -0.4 °C and maximum ambient
temperature of +55 °C.
14.Earthing and Lightning Protection
14.1. Earthing System

CONSULTANT shall review / revalidated Earthing & Lightning Protection Calculations
in line with recommendations of IEEE standards. Installation of earthing system shall be
as per project Typical Installation Details drawing no. GB1516-SAC- 240-EL-DD-001.
The earthing system shall protect the electric network and assure personnel safety in
case of an electric failure and against static charges. It shall also protect equipment’s
against damage arising from earth fault currents, static discharge and lightning.
Earthing cables shall be yellow/green, 450V/750V grade and PVC insulated.
A general earthing system shall be provided within the fence limits. The general system
shall be designed in such a way that every electrical equipment shall be connected to the
earthing grid by at least two connections. The earth ring shall extend throughout the new
facilities of PWT & HCU with branch interconnections to the equipment’s to be earthed.

Existing philosophy for Instrumentation earthing shall be followed for earthing of new
Instrumentation panels as per Typical Installation Details doc. no. GB1516-SAC-240- EL-
DD-001 and Typical installation Drawings for Instruments doc. no. GB1516-SAC- 240-
IN-DD-001.
New earthing grid shall be provided around Produced Water Treatment area, and shall
be interconnected to the existing main plant earth grid at two diagonal points. New
lighting poles and fence shall be interconnected to the nearest plant earth grid.
Separate earthing system shall be provided for earthing of instrumentation systems.
This shall be designated as "Instruments earth" and used for earthing instrument, signal
cable screens and other electronic systems associated with instrumentation as per
Typical Installation Details doc. no. GB1516-SAC-240-EL-DD-001 and relevant
standards.
The main instrument earth grid shall be connected directly to the main electrical earth
grid by a single secure low impedance copper connection. This shall be the only point of
interconnection (intentional or unintentional) between these two earthing systems.
All underground earthing connections shall be made using exothermic bonding such as
thermite weld. Above ground earthing can be made using compression connectors
/ Bolted connections.
Earthing conductors shall be run underground at a minimum depth of 600 mm below

grade in unpaved areas. In paved areas, conductors shall run on rough grade under
paving. Where possible, earthing conductors shall run in cable trenches.
Earthing and Lightning system shall be designed conforming to the IEC Standards to
reduce control voltages to an acceptable low level to protect electrical network and
personnel safety in case of any electrical fault and static electricity discharge. In
general, following design criteria shall be followed:
• A single integrated earth system shall be installed. In the new PWT Area, earth
system shall be connected to the existing plant earth system to make integrated
earthing network.
• A separate ground system for the Instrumentation, DCS etc shall be established as
specified requirement as per Typical Installation Details doc.no. GB1516-SAC- 240-
EL-DD-001 and relevant standards.
• Earthing system shall consist of earth electrode and earth grid. Earth resistance of
each earth electrode shall be as low as possible; however

electrical resistance between earth grid and general mass of earth shall notexceed
1 ohm in any case at any point of measurement in dry and hot weatherseason.
• All skids and all other process equipment shall be effectively earthed to mainearthing
grid. Two (2) earthing bosses shall be welded at diagonally opposite corners of any
package units.
• Steel structures, Pipe Rack columns, fence, pipe supports etc., shall also beproperly
earthed. Maximum Resistance measure / allowed for Lightning protection system
shall be 10 Ohms.
• All material used for earthing shall be of corrosion resistant tinned copper.
• PVC insulated copper cables shall be used for all earth connections of individual
equipment’s. The Earthing Cables shall have Yellow & Green colored PCV
Insulation.
• The Earthing System shall be designed in such a way the potential of the earthing
system of the areas shall be affected by earth connections consisting of one or more
electrodes driven into the ground. In areas of high soil resistivity, deep well
electrodes shall be installed. Earth pit shall consist of 20 mm dia, 3m long solid
copper bar. Deep well earth electrodes shall consist of 150 mm dia Mild Steel Pipe
of required length. Earth electrode sections shall be coupled together such that the
electrode penetrates summer water table by at least two meters. The resistance of
each earthing system i.e., electrical earthing system and instrument earthing
system, to earth shall not exceed one Ohm at any point of measurement in dry and
hot weather season.
The earth grid shall be connected to at least two earth electrodes. The minimum
size of earth conductors shall be:
a) For main earthing loop of the plant 120 mm2
b) Metallic enclosures of LV electrical equipment,

having a supply cable cross-sectional area ≥ 35 mm2 70mm2
c) Metallic enclosures of LV electrical equipment,

having a supply cable cross-sectional area ≤ 35 mm2 35mm2
d) To Control Panels 35 mm2

The electrodes may be installed in parts with length of 1.2 m. The total earth loop
impedance shall not exceed 1 ohm for system earthing.
Earthing installation details shall be as per as per Typical Installation Details doc.
no. GB1516-SAC-240-EL-DD-001.

Earthing calculations that shall be performed based on above criteria and as per
IEEE-80 (doc. No. GB1082-SAC-240-EL-RP-002).
14.2. Lightning Protection System
Lightning protection risk assessment shall be carried out during detail engineering stage
for tall structures / pipe rack outside the package. Risk Factors such as number of
lightning strikes per year, collection area, correction factors, probabilities of damage
etc. shall be considered to arrive at the overall risk factor.
If the building / structure’s overall risk factor is greater than acceptable risk factor (1X10-
5), then the structure qualifies for provision of Lightning protection system. Lighting
protection system shall be complete with air terminals, down conductors, couplers,
clamps, earth electrodes and other accessories in accordance with IEC 62305.
Lightning protection system shall be provided to all structures that need protection in
accordance with IEC 62305.
Each down conductor shall be connected to one earth electrode via test / junction
clamp. Required connections and arrangements shall be as per typical installation
drawings. For each area, respective Lightning protection layouts shall be prepared to
help construction at site.
Lightning protection system comprises of air termination rods, roof conductors, down
conductors, test points, etc.
The whole of the earth termination network shall develop to have a combined
resistance to earth not exceeding 10 ohms for Lightning protection system without
taking account of any bonding to other services. In case the resistance exceeds the
limit then additional protection air terminal / roof conductors OR down conductor shall be
provided to reduce the earth resistance limited to 10 Ohms for Lightning protection
system.
Installation of lightning protection system shall be as per project Typical Installation
Details drawing no. GB1516-SAC-240-EL-DD-001.
The lightning protection conductor shall be bare stranded copper conductor. Lightning
Protection System shall be provided with dedicated earthing inspection rod/ pit which in
its turn shall be connected to the main electrical earthing grid.
All vessels, tall or short, shall be bonded to the plant earthing system using two numbers
independent earth conductors. These bindings shall provide effective protection against
static electricity including protection against lightning.
The metallic supporting structures of flares, communication towers, lighting masts
which are prone to lightning strikes because of their height shall be connected at
structure legs to earth at the base.

Metallic structures like pipe rack columns, shelter columns shall be connected at the base
with earth grid.
Any small structure, which falls within the conical zone of a tall structure having the
lightning protection and whose conical zone radius shall be equal to the height of that
structure with 45-degree zone angle, shall be automatically protected against lightning
strikes.
Lightning Protection calculation shall be presented in doc. no. GB1516-SAC-240-

EL-RP-003.
15. LV Motors
Low voltage motors shall be selected & supplied as per the specification of LV Induction
motor.
Motors shall generally be 3 phase squirrel cage induction type totally enclosed, adequately
rated for their duty and suitable for direct online starting. Motors shall be suitable to start and
accelerate the load at 80% nameplate voltage at its terminals.
LV Motors shall be Continuous duty, squirrel cage induction type. The Motors shall be
designed to start against rated load.
Motor service factor shall be S1. The motors paired for “duty” or “standby” operation shall be
interchangeable and shall be fed from bus bars separated by a sectionalized unit to optimize
supply continuity.
a) All LV motors above 1.5kW rating shall be Star & delta-connected in line with
specification for LV Motors.
b) All LV motors shall be suitable for DOL starting arrangement.
c) Motor rating > 30kW shall be fitted with anti-condensation heaters.
d) LV motors shall be class F insulated with a temperature rise limited to class B.
e) Degree of protection for outdoor duty motors shall be IP 55.
16. Local Control Stations

CONSULTANT shall select the design of the Local Control Stations (LCS), which shall be
suitable for outdoor installation & in Hazardous area. Local Control Stations (LCS) shall be
located close to the motor so that the operator is not in line of hazard & safe. LCS shall have
following facilities,

a) Local manual Start-Stop. Stop push button shall be Mushroom Head, StayPut Type
with padlock facility – for pump motors of PWT Unit and shall be part of design.
b) Local & Remote Selector Switch (Lockable) to control the motor of PWT Area from
DCS, as required by the process requirements.
c) Local Control Station for HCU Feed Pump shall have Start & Stop Push Buttons
with ON/OFF Indication Lamps (as per design and as provided byvendor).
17. Welding Socket Outlet

The Welding socket outlets shall be suitable for 63A, 400V, 3 Phase, 3Ph+N+PE, 50Hz. The
Welding Socket shall be located strategically inside the plant area. In case number of Welding
socket required are more than 1 (one), the maximum 3 welding socket outlets shall be
connected in one circuit and feeder shall be sized for the 100% loading of one welding outlet
at a time.
The feeders shall be provided with Residual Current Device (RCD) with 100 milli-ampere
(mA) sensitivity for protection against ground faults.
Welding Socket shall be suitable for installation in Zone 2, Gas Gr IIB, temp. Cl. T3 (as
minimum). The degree of protection for outdoor welding socket outlet shall be IP 55 (as
minimum).
18. Convenience Socket Outlet

The outdoor single phase convenience outlets in Zone 1 or Zone 2 area and hazardous areas
within process installations shall be fully weatherproof, dustproof (IP 55), corrosion resistance
with Ex-'d' or Ex’de” execution, Gas Group IIB Temperature Class T3. For safe area, industrial
type, fully weatherproof, dustproof (IP 55), corrosion and UV resistant outlets shall be used.
All material shall be as per Specification for Electrical Bulk Materials.
The Convenience Socket Outlets shall be suitable for 16A, 230V, 1 Phase, 3Pin, 50Hz supply
and Hazardous area.
The Convenience Socket Outlets shall be located strategically inside the plant area & shall be
provided with flexible cables about 15 m in length so as to reach every operating point of the
plant area i.e. it shall be able to cover 30 m dia. of the plant area.
Maximum 8 Convenience socket outlets shall be connected in one circuit and feeder shall be
sized for the 100% loading of one convenience outlet at a time.
Convenience Socket Outlet shall be suitable for installation in Zone 2, Gas Gr IIB, temp. Cl.
T3 (as min.). The degree of protection for outdoor welding socket outlet shall be IP 55
minimum. Convenience socket outlets located inside any containerized package units,
supplied by package vendor, and classified as safe area inside. The Safe Area Convenience
Socket
Outlet shall be non-industrial type, suitable for 16A, 230V, 1-Ph, 3 Pin, 50Hz AC, with degree

of protection IP41 (minimum).
The feeders supplying power to the Convenience Socket Outlet Circuit shall be provided with
Residual Current Device (RCD) with 30 milli-Ampere (mA) sensitivity for protection against
ground faults.
1 no. Convenience Socket Outlet (OR 10% of total qty.) of socket outlets in Package Unit
shall be fed from emergency power source.
19. Cables & Cable Laying
The Cables sized & selected according to the load / motor rating and laying conditions. All
electrical cables selected for the project shall be in accordance with Data Sheet for Electrical
Cables doc. no. GB1516-SAC-240-EL-DL-002. The major constructional features of the
Power & Control cables shall be:
• The LV power cables shall be with copper conductor, XLPE insulated, PVC
inner sheath, armored, PVC outer sheath.
• The Conductor shall be plain annealed stranded high conductivity copper
(purity – 99.5%) as per IEC 60228.
• Insulation on the Conductor shall be XLPE, meeting the requirements as per
IEC 60502.
• Non-hygroscopic fillers, compatible with insulation material, shall be used to
ensure robustness and help circular shape of cable.
• Inner & Outer sheath shall be extruded PVC type. Outer sheath PVC shall have
flame retardant properties conforming with IEC 60332
• Armor of the cables shall be galvanized round steel wire or flat steel type for
multi- core cable and for single core cable the armor shall be of aluminum.
• Ground wire shall be single core copper conductor with heat resistant PVC
sheath. Outer sheath color shall be green and yellow stripes.
• No. Of cores for the Control cables shall be selected in such a way that the
Control cables shall at-least 20% spare cores.
All power cables shall have following voltage grades:
S. No. System Voltage Cable Voltage Grade
1 400V and lower 0.6/1kV
• Minimum and maximum cable sizes for LV and MV system shall generally
be as follows:

S. No. Cable Type Minimum Size Maximum Size
Lighting Cables & **

1 2.5 sq. mm.
Control Circuits
185 sq. mm. for Motors
4 sq. mm. for 240 sq. mm. for Distribution

LV System Power
2 Power & Motor feeders.
Cables
feeders
630 sq. mm. (Single Core)
Outer sheath for lighting cables routed & laid inside buildings shall be provided with LSZH -
PVC insulation (Low Smoke Zero Halogen).
Single core cables shall be aluminium wire armoured and multi core cables shall be
galvanized steel armoured. Single core cables shall be installed in trefoil formation.
The colour of outer PVC sheath of the Power and Control cables shall have black colour. The
conductor insulation shall be coloured in accordance with BS 6346 for 2, 3, 4 and 5 core
cables, as follows:
• Brown, Blue Colour for 2 Conductor Cables

• Brown, Black, Grey Colour for 3 Conductor Cables
• Brown, Black, Grey, Blue Colour for 4 Conductor Cables
• Brown, Black, Grey, Blue, Green-yellow Colour for 5 Conductor Cables
Earthing Cables shall be single core, stranded high conductivity copper conductor, with
green/ yellow PVC sheathing. The outer green / yellow PVC sheath shall be extruded with
450/ 750 Volt grade.
The power & Control Cables laid in-between the source & the Load (i.e. in-between MCC
/ DB / Motor and LCS etc.) shall be continuous in single length, without any joint. GAZPROM’s
(GPNB’s) approval shall be taken for Joints in Power Cables if the cable length is too large &
not available in single drum length from manufacturer.
Cable glands shall be standardized as Exd, for all cabled equipment certified for use in a
Zone 1 or 2 hazardous areas. All cable glands shall be double compression type and
corrosive resistive.
Cable glands used for cabling to equipment in other areas shall be selected as per the IP
rating requirement as per Cl. 11Ingress protection, as follows:

• Switchgear / MCC End in Substation - IP66, Double Compression & Weather

Proof.
• Control Panel in SCC 05 - IP66, Double Compression & Weather
Proof.
• DB located indoor in SS 04 & SCC 05 - IP66, Double Compression & Weather
Proof.
• DB located outdoor in field - IP66, Double Compression & Weather
Proof.
• Motor located outdoor - IP66, Double Compression & Weather
Proof.
• Motor located outdoor in Haz. Area - IP66, Ex’d’, Double Compression &
Weather Proof.
• DB, LCPs, LCSs located outdoor - IP66, Ex’d’, Double
Compression & Located in Haz area Weather Proof
Cable Glands shall be manufacture from Brass and shall be nickel plated.
19.1. Above Ground Installation

The cables inside cable cellar of Existing Substation no. SS-000-04 shall be laid in the
existing cable trays, wherever possible. The adequacy of space in the existing cable
trays shall be checked and if required new cable trays shall be laid on the existing / new
supports.
The new Cable Trays shall be bolted to steel structures and walls or to adequately sized
tray supports, by means of cable tray clamp. Cable trays shall be provided with covers
where subject to direct sunlight or where there is a high risk of mechanical damage
during normal operation or maintenance periods.
Cable ties of appropriate size shall be used to fix the cables on trays. Cables ties shall
be of UV PVC coated stainless steel material. Cable ties shall be provided at an interval,
not exceed one meter for horizontal runs and 500 mm for vertical runs. Single core cables
shall be installed in trefoil formation. Non-magnetic clamps or ties shall be provided to
single-core cables.
Cables leaving trays to reach equipment shall be individually protected by open conduit
system or telex rail.
A single layer of power cables shall be laid on trays, the relevant control cables shall be
laid in the second layer.
LV power cable and its associated control cable shall be allowed to run in the same
conduit. Lighting branch circuits shall run in common conduit.
Control, metering, interlocking, and signal circuits shall be grouped in common conduits
provided all cables are insulated for 500 V or more, otherwise the separate conduit OR

Tray shall be used for cable below 500V & above 500V grade insulation.
DC circuits from Substation SS04 to field are not envisages. In case required during
detail engineering stage, then DC circuit cables shall not run in the same conduit along
with AC circuits.
Electrical & Instrument cables shall not run in the same conduit.
Cables shall be marked with corrosion and UV resistant cable strips, every 30 - 40 m,
showing cable item. New Cable Trays shall be sized with at least 10 % of spare space
for future cable additions.
For PWT & HCU Area, Cable trays / ladders/ covers / fittings shall be heavy duty, hot dip
galvanized after fabrication to 85 microns Zinc coating. GAZPROM’s (GPNB) approval
shall be sought for Painted cable trays of proven type, painting suitable for the
galvanized surface and subjected to employer’s approval. Colour shade of the Painted
Galvanized cable trays for cable trays / ladders / covers shall be WHITE RAL 9010.
19.2. Underground Installation

In general, cable shall be laid below the ground in field in PWT & HCU Areas in concrete
trenches or in cable trays (above ground) along the cable route (as designed). The
cables shall be laid in Cable Trays inside the skid of PWT Train-A, as designed & provided
by the Skid Vendor to reach up to the electrical equipment (motor
/ LCS / Lighting JB & fixtures etc.) on the skid.
New cables from Substation no. SS-000-04 to PWT area and within PWT area shall be
routed in partly concrete trenches & partly in Underground direct buried cable trench. A
maximum of 2 layers of cables shall be laid in a trench.
Where underground cable route pass below access areas with heavy vehicle
movement or roads, cables shall be taken through duct banks. The underground cables
shall be laid in minimum 150mm dia, PVC, schedule 80 U.V resistant PVC pipe,
encased in concrete, buried at least 700 mm below finished level of the road / below
grade level and in process area, minimum 450 mm below grade level. Duct banks shall
be provided with at least 10% spare pipes, subject to a minimum of two, sealed at both
ends, to cater future requirements. Bell mouths shall be installed on ends of each pipe.
The cables shall be protected from mechanical damage by using 150mm galvanized
steel conduit for stub-up from the cable trenches. The Stub-ups shall be at least 150mm
above the grade level.
In paved areas, concrete shall be colored red over electric cable trenches.
Cable shall be marked with tag numbers along their routes and at both termination
points. The spacing between cable tag markers along the route shall not exceed 10m in
straight length and at every branch out, where there is a change in direction of cable
route.

For underground cables laid in unpaved areas, cable route markers shall be provided at
every 30-40 m along the route (to indicate cable route above ground), at change of
direction in the routing and at both sides of road or pipeline crossings, except when cable
routing is already indicated by coloured concrete pavement. In paved areas, cable route
markers shall be provided at every 15 meters.
Spacing between instrumentation and low voltage electrical cables center shall be
1000mm. If cables are crossing at 90o, than the required spacing shall be a minimum of
300 mm. Wherever the LV Cable passes along the HV Cable, a spacing of 300mm shall
be provided between LV cables and existing HV cables.
20. Equipment Installation & Operation

The front & rear spaces shall be maintained for any new panel installation inside Substation
no. SS-000-04 and SCC-05 for easy operation & maintenance. The spaces for minimum
working clearances shall be provided as below:
• From the Front of LV Switchgear - 1500mm.

• From the Rear of LV Switchgear - 1000mm.
• From the each side of LV Switchgear - 1000mm.
• From the Front of Aux. Panel / Small Power DB etc. - 1000mm.
• From the Rear of Aux. Panel / Small Power DB etc. - 150mm.
21. Cathodic Protection (CP System)

Cathodic Protection shall be designed, developed & provided to protect the external surfaces
of the pipeline from PWT to Evaporation Pond and HCU underground part. It shall protect
UG piping / structure, pipe casings, underground metallic equipment. CP System shall be
designed as per GB090-2614-250-MT-SP-0001 (Specification for Cathodic Protection
System). Cathodic protection system shall be provided for underground pipelines / piping laid
in accordance to NACE codes & standards. Sacrificial OR Impressed current cathodic system
shall be designed for the Underground Lines as required.
CP System shall be designed by the CP System specialist. The CP System shall be

provided by a specialized agency with proven track record of not less than 10years
(minimum).
CP System supplier shall conduct the Soil Resistivity survey to proceed with CP System design.
CP System supplier shall specify temporary protection, calculations of CP, output
voltage of cathodic station, produce anode size calculations, studies, schedules and
drawings to enable site installation in accordance with specifications and National /
International standards.
The CP System shall be designed for plant life of 25 years. During laying and construction of
the permanent CP system, the CP System supplier shall provide a temporary CP system with

sacrificial anodes of lifetime no less than 3 years. The sacrificial anodes shall be of
magnesium/zinc and high potential type. The Permanent CP System shall be Sacrificial OR
impressed current type with TRU, to be located in the field. The number of AC-DC
Transformers-rectifiers (TRUs) shall be designed & deployed based soil resistivity survey
report. TRU shall be fed from 240-DB-001.
a) The CP System’s input transformer, bridge and rectifiers, assembled in enclosure made of
stainless steel suitable for outdoor installation. The enclosure shall be weather proof /
water-proof and dustproof design in IP66/67 under standard IEC or NEMA type 4X;
b) CP System design shall ensure that Transformer-rectifier and cathodic protection stations
are:
1. working free of damage at ambient temperature -0.4°C to +55°C;

2. DC or AC input voltage, DC output voltage 0-18V;
3. Isolation impedance ≥ 2MOhms;
4. Air-type cooling;
5. on-off synchronously;
6. Sized to allow temporary installation of a data logger for collection of long term
data, to facilitate automated data collection;
7. The rectifier unit shall have spare capacity of 25% of rated power.
c) CONSULTANT shall provide the specification for CP system required to protect the
external metallic surfaces of the underground piping system, pipeline casings& supports
belonging to UG pipeline in the PWT & HCU area as required by process group.
d) CP System vendor shall prepare & furnish Pre-commissioning and Commissioning

procedures of Cathodic protection system, equipment, devices.
e) TRU for the CP System shall be installed in the safe Area.
22. Equipment Tagging

All electrical equipment shall be tagged as per the guidelines given in the project

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Electrical Design Basis Date: 11-Oct-23

Doc. No.GB1516-SAC-240-EL-DB-0001_Rev-1 Page: 1 of 36

EMPLOYER CONTRACT NO. : 1516-23-BD-850-00

PROJECT TITLE : EPC for Installation of PWT, Republic of Iraq

EMPLOYER : Gazprom Neft Badra B.V.

EPC CONTRACTOR : Suhool Azmer Company Ltd.

ENGG CONTRACTOR : Petrochemical Engineering Consultants

CONTRACT JOB NO. : SAC

PROJECT DOCUMENT NO. : GB1516-SAC-240-EL-DB-0001

REVISION NO. : 1 No. of pages (incl. sheet) :36

DOCUMENT DESCRIPTION : Electrical Design Basis

1 Re-Issued for Design 11-Oct-23 HM SAR AJ

0 Issued for Design 02-Dec-19 ACR KKR DTS

H Revised & Reissued For Approval 13-Nov-19 ACR KKR DTS

G Revised & Reissued For Approval 22-Nov-19 ACR KKR DTS

F Revised & Reissued For Approval 22-Oct-19 ACR KKR DTS

E Revised & Reissued For Approval 27-Sept-19 ACR KKR DTS

D Revised & Reissued For Approval 26-Aug-19 ACR KKR DTS

C Revised & Reissued For Approval 16-Aug-19 SAR AJ

B Issued for Approval 1-Aug-19 SJB SAP DTS

A Issued for Review 22-Jul-19 SJB SAP DTS

Rev. Description Date PRPD CHKD APPD

GB1516-SAC-240-PI-DB-001_Rev-1 DOC PAGE SIZE: A4

Doc. No.GB1516-SAC-240-EL-DB-0001_Rev-1 Page: 2 of 36

REVISION DESCRIPTION SHEET

Rev. Para. Revision Description

A Issued for review

B Revised as per GPNB’s Comments

C Revised as per GPNB’s comments

D Revised as per GPNB’s comments

E 5 Revised as per GPNB’s comments

F 14, 15, 16, Revised as per GPNB’s Comments

G 17, 18 & Revised as per GPNB’s Comments

0 19 UPS Power for Telecom/CCTV included as per GPNB’s Comments

1 Issued for Design

GB1516-SAC-240-PI-DB-001_Rev-1 DOC PAGE SIZE: A4

Doc. No.GB1516-SAC-240-EL-DB-0001_Rev-1 Page: 3 of 36

GB1516-SAC-240-PI-DB-001_Rev-1 DOC PAGE SIZE: A4

Doc. No.GB1516-SAC-240-EL-DB-0001_Rev-1 Page: 4 of 36

17. LV Motors ..................................................................................................... 29

GB1516-SAC-240-PI-DB-001_Rev-1 DOC PAGE SIZE: A4

Doc. No.GB1516-SAC-240-EL-DB-0001_Rev-1 Page: 5 of 36

3. Definitions and Abbreviations

GB1516-SAC-240-PI-DB-001_Rev-1 DOC PAGE SIZE: A4

Doc. No.GB1516-SAC-240-EL-DB-0001_Rev-1 Page: 6 of 36

ACB - Air Circuit Breaker

API - American Petroleum Institute

A.S.L - Above Sea Level

ATS - Automatic Transfer Switch

CCTV - Closed Circuit Television

DCS - Distributed Control System

DOL - Direct On Line

E&I - Electrical & Instrumentation

Ex ‘e’ - Increased Safety

Ex ‘ia’ - Intrinsically Safe

Ex ‘d’ - Explosion Proof

EEMUA - Engineering Equipment & Materials

EMC - Electro Magnetic Compatibility

EPC - Engineering Procurement and Construction