ELECTRICAL

GUIDELINES

COMPILED BY
ION EXCHANGE INDIA LTD
STANDARD SYSTEM DIVISION,
HOSUR
ELECTRICAL RECKONER

CONTENTS

1. UNIT OF MEASUREMENT

2. POWER RATING OF CENTRIFUGAL PUMP

3. COMMON SUPPLY VOLTAGES

4. ENERGY EFFICIENT PUMPS

5. DEGREE OF PROTECTION

6. CONVERSION TABLE FROM Kw to HP

7. MOTOR CONTROL CENTRE

8. CABLING AND EARTHING

9. PROGRAMMABLE LOGIC CONTROLLER

10. AIR FLOW CALCULATION CHART

11. ELECTRICAL AND CABLING SCHEDULE ILLUSTRATIONS

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1. Unit of Measurement

S No Quantity Unit Name Notation

standard
1. Pressure Kilogram per centimeter Kg/Cm2
Square(gauge)
Bar(gauge) bar(g)
Millimeter bar(gauge) mmbar(g)
2. Volume Cubic meter m3
Litre litre
Normal cubic meter Nm3
3. Temperature Degree Celsius ◦C
Fahrenheit F
4. Frequency Hertz Hz
5. Energy Joule J
6. Mass Kilogram kg
Tonne t
7. Length Inch Inch(“)
Milimeter mm
Meter mtr
8. Velocity Metre per second m/s
9. Concentration Milligram per litre mg/l
Parts per million ppm
10. Time Second s
Minute min
Hour hr
11. Force Newton N
12. Resistance ohm Ω
13. Area Square meter m2
Square cm cm2
Square mm mm2
14. Electrical potential kilovolt KV
Volt V
15. Power Watt W
16. Volumetric Flow Cubic meter / Hour m3/hr
Litre /minute l/min
17. Mass flow Kilogram per hour Kg/hr
18. Density Kilogram/Cubic meter Kg/m3
19. Differential pressure Milimetre water column mmwc
20. Conductivity Micro Siemens /Centimeter µS/Cm
21. Relative Humidity Percentage %
22. Current Ampere A
23. Viscosity Centipoise cP
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2. Power rating of Centrifugal pump :

Power (kW) = (Flow x Head x Specific gravity) / (367 x Efficiency)

Wherein flow is expressed as m3/hr
Head in Meter water column
Generally fluid handled is water, which is 1 for water.

For E.g. For given flow rate of 30 m3/hr with head of 35 MWC, efficiency (as provided
by the pump manufacturer) – 70%, then

Power rating (BKW) = (30 x 35 x 1)/ (367 x 0.70)

= 4.08 Kw
Considering losses and efficiency of the motor, the above rating is hiked by 15% to
arrive at motor rating.
Therefore for this case, motor rating will be = 4.08*1.15
= 4.692 Kw
From Table 2, Available motor rating nearest to the above to be selected, which is 5.5
Kw.

3. Common supply voltage :

S No Country frequency in Hertz 1Ø supply in 3Ø supply in

(Volts) (Volts )
1. India 50 230 415
2. South Africa 50 220/230 220/380;230/400
3. Afghanistan 50 220 220/380
4. USA 60 120/240 240/480
5. Malaysia 50 150/240,230 240/415;400/440
6. Bangladesh 50 230 230/400
Table 1: Supply voltage across different countries

4. Energy efficient motors:

Energy efficient motors also called as premium efficient motors saves power and are
used for longer insulation , bearing lives, lower heat output and less vibration. Generally
th motor we procure are EFF II motors, squirrel cage induction motors, foot mounted,
with Class F insulation , IP 55 Degree of protection, power 415 V ±10%,50 Hz ±5%.
Other commonly available motors are Eff I / IE2 or IE2 (premium efficiency motors).

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5. Degree of protection:

The IP codes are used to define protection against the ingress of solid foreign objects and
water with harmful effects. Commonly used degree of protection

S No Degree of protection Protection against

1. IP53 Access to hazardous parts with a wire. This is
the minimum IP code that should be used for
equipment installed outdoors. Numeral 3 means
protection against water coming from an angle
of 60°.
2. IP 54 Access to hazardous parts with a wire.
protection against water coming from all
directions
3. IP 64 Access to hazardous parts with a wire. Water
splashed against the enclosure from any
Direction shall have no harmful effects.
4. IP 65 Access to hazardous parts with a wire. Water
projected in jets against the enclosure from any
Direction shall have no harmful effects.

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6. Conversion Table from KW to HP

1 HP  0.745 KW

S No KW HP
1. 0.37 0.5
2. 0.55 0.75
3. 0.75 1
4. 1.1 1.5
5. 1.5 2
6. 2.2 3
7. 3.7 5
8. 5.5 7.5
9. 7.5 10
10. 11 15
11. 15 20
12. 18.5 25
13. 22 30
14. 30 40
15. 37 50
16. 45 60
17. 55 75
18. 75 100
19. 90 120
20. 110 150
21. 125 170
22. 132 180
23. 160 215
24. 200 270
25. 250 335
26. 315 425
Table 2: conversion table from KW to HP

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7. Motor Control Center :

A motor control center (MCC) is an assembly of one or more enclosed sections having a
common power bus and principally containing motor control units. Motor control
centers are in modern practice a factory assembly of several motor starters. A motor
control center can include variable frequency drives and metering and may also be the
electrical service entrance for the building. Motor control centers are usually used for
low voltage three-phase alternating current motors from 208 V to 600 V.

MCC are provided with main and feeder compartments. Control can be automatic or
manual for starting or stopping the motor, regulating the speed of motor with the aid of
VFD (Special requirement only), protecting against overload and faults. MCC are cubical
construction panel made of 2mm CRCA sheet. MCC panel are generally
compartmentalized. Each compartment is provided with hinged doors. Sheet metal is
provided between compartments, bus bar chamber and cable alley to make the panels
fully compartmentalized.

Each motor controller in an MCC can be specified with a range of options such as
common control transformers (Special requirements) or tapped from bus bar, pilot
lamps, control switches, extra control terminal blocks, various types of thermal or solid-
state overload protection relays, or various classes of power fuses or types of circuit
breakers. A motor control center can either be supplied ready for the customer to
connect all field wiring, or can be an engineered assembly with internal control and
interlocking wiring to a central control terminal panel board or programmable
controller.

Fig 1: MCC – Non Draw out type Fig 2: MCC – Draw out type

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7.1 Standard Specification of MCC

 Supply Voltage for MCC 415 V AC, 3 phases, 4 wires, 50 Hz.

 Non – draw out type.
 Construction will be indoor floor mounting, compartmentalized, single front& fixed
type.
 Shell: 2 mm (Mild Steel), doors: 2 mm (Mild Steel).
 Internal partition : 1.6 mm (ms)
 Mounting plate : 2 mm CRCA, glad plates : 3 mm
 The panel will rest on ISMC 100/75 mm channel (plinth) and will be painted in
black color.
 Protection will be IP54
 Frame & doors paint finish will be RAL 7032 ( Siemens)
 Cable entry from the top
 Bus bar support will be FRP
 Control wiring will be
a) 1.5 sq.mm MSCC for potential circuit – grey & white color
b) 2.5 sq.mm MSCC for current circuit - black color
c) 1.5 sq.mm MSCC for control circuit – grey & white color
 Bus bar sleeves will be heat sink sleeves (R, Y, B & N)
 Incomer and outgoing feeders will be controlled by SDF(Switch Disconnection Fuse) with
fuse of SFU ( switch fuse unit) , OLR & contactor as per TYPE II co-ordination chart selection
given below in Table
 Earth bus bar – copper
 All other RYBN bus bars will be aluminum
 MCC fault level will be 50 kA for 1 sec
 All switchgears protected selection type 2, IQ = 50 kA
 Power cable will be black in color with minimum size of 2.5 Sq.m.
 Control cable shall be 1.5 sq.m.
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 Ammeter & voltmeter will be analog type.

 All switchgears components will be of Siemens make.
 All lamp & push button will be of vaishno make.

7.2 Different type of starter:

Different starting methods are employed for starting induction motors because Induction
Motor draws more starting current during starting. To prevent damage to the windings
due to the high starting current flow, we employ different types of starters. Commonly
used starters are DOL and Star Delta starter.

DOL Starter:

Direct online starters are the simplest starter for induction motors. The Direct on Line
Motor Starter (DOL) consist a MCCB or Circuit Breaker, Contactor and an overload relay
for protection. Electromagnetic contactor which can be opened by the thermal overload
relay under fault conditions.

Star Delta starter:

This is commonly used for start of three phase motors. The motor windings are configured
in a star formation to the supply voltage.

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7.3 When and Where DOL and Star- Delta starters

Usage of starters depends on the power rating of the motor. Unless otherwise specified
DOL starter will be provided till 20HP above which will be Star- Delta starter.

7.4 Selection of Power components in MCC for Continuous duty cage motor
Drives.

7.4.1 SDF - DOL starters

S No Motor Rating Minimum rating of Minimum rating OLR rating in A

in Kw SDF in A of contactor in A
1. Up to 3.7 20 9 7 – 10
2. 5.5 32 12 9-12.5
3. 7.5 32 17 11-16
4. 11 63 25 20-25
5. 15 63 32 27-32
6. 18.5 63 40 28-40
7. 22 100 50 36-45
8. 30 100 65 45-63
9. 37 125 80 57-75
10. 45 125 95 70-90
11. 55 160 115 80-100
12. 75 200 150 85-135
13. 90 250 185 115-180
14. 110 250 225 160-250
15. 132 315 265 160-250
16. 160 400 300 200-320
17. 200 500 400 250-400
18. 250 500 500 320-500
Table3: MCC components selection using SDF for DOL starters

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7.4.2 SDF -Star Delta Starter

S No Motor Rating Minimum rating of Minimum rating OLR rating in A

in Kw SDF in A of contactor in A
1. 5.5 20 9 5.5-8
2. 7.5 20 9 7-10
3. 11 32 9 9-12.5
4. 15 32 17 14-20
5. 18.5 63 32 14-20
6. 22 63 32 18-25
7. 30 63 32 22-32
8. 37 100 32 28-40
9. 45 100 32 40-50
10. 55 100 32 45-63
11. 75 160 65 70-90
12. 90 160 65 80-100
13. 110 200 115 85-135
14. 132 250 115 115-180
15. 160 315 115 115-180
16. 200 400 185 160-250
17. 250 500 265 160-250
Table4: MCC components selection using SDF for Star Delta starters

7.4.3 MCCB - DOL starters

S No Motor Rating Minimum rating of Minimum rating OLR rating in A

in Kw SDF in A of contactor in A
1. 0.37 1.25 7 0.9-1.25
2. 0.55 1.6 7 1.1-1.6
3. 0.75 2 7 1.4-2
4. 1.1 3.2 7 2.2-3.2
5. 1.5 4 7 2.8-4
6. 2.2 6.3 12 4.5-6.3
7. 3 8 12 5.5-8
8. 4 10 12 7-10
9. 5.5 12.5 12 9-12.5
10. 7.5 16 25 11-16
11. 11 25 32 20-25
12. 15 32 32 27-32
13. 18.5 40 40 28-40
14. 22 50 50 40-50

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15. 30 63 65 45-63
16. 37 75 80 57-75
17. 45 90 95 70-90
18. 55 100 115 80-100
19. 75 1160 150 85-135
20. 90 250 185 115-180
21. 110 250 225 160-250
22. 132 250 265 160-250
23. 160 315 300 200-320
24. 200 500 500 250-400
25. 250 500 500 320-500
Table 5: MCC components selection using MCCB for DOL starters

7.4.4 MCCB - Star Delta Starter

S No Motor Rating Minimum rating of Minimum rating OLR rating in A

in Kw SDF in A of contactor in A
1. 5.5 16 7 5.5-8
2. 7.5 16 7 7-10
3. 11 25 12 11-16
4. 15 32 12 14-20
5. 18.5 40 12 18-25
6. 22 45 25 22-32
7. 30 63 25 28-40
8. 37 75 32 36-50
9. 45 90 32 45-63
10. 55 100 65 45-63
11. 75 160 65 70-90
12. 90 250 65 80-100
13. 110 250 115 85-135
14. 132 250 115 85-135
15. 160 315 115 115-180
16. 200 500 185 160-250
17. 250 500 265 160-250
Table 6: MCC components selection using MCCB for Star Delta starters

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7.4.5: Illustration for arriving at Incomer rating and MCC power rating.

For instance, let the scheme be MGF  SAC  ACF SACDGT SBAMB with Flow
rate of 30 m3/hr and pumps list as below,

S No. Description of Qty in Capacity Head in Motor Total Total

Drive Nos. in m3/hr mwc Rating connected connected
in (Kw ) Load in Load in
Kw Kw
1. Filter feed 2 30 35 5.5 = 5.5*2 Summing
pump = 11 all
2. Chlorine 2 4 25 0.04 = 0.04*2
dosing pump = 0.08
3. DG blower 2 600 0.5 0.375 = 0.375*2 = 27.23
= 0.75
4. SBA feed 2 30 35 5.5 = 5.5*2
pump = 11
5. MB blower 2 60 4 2.2 =2.2*2
= 4.4

From the total connected load in column 8 , Incomer to MCC can be decided based on
the table rating given below. Individual power rating of motor can be arrived (as
explained in point: 2), accordingly the feeder cost of MCC to be worked out.

S No Incomer range in A Corresponding KW rating

1. 32 7.5
2. 63 18.5
3. 100 30
4. 160 55
5. 200 75
6. 250 90

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7.8 Local Push button station

LPBS are provided for local on/off pump. The LPBS consist of a set of terminal block,
Set of push button and Actuators to start and stop. For each pump one LPBS is
provided.

8. Cabling:

Different types cabling considered:

1. Power cabling
2. Control cabling
3. Instrument cabling
4. Signal cabling

8.1 Power Cabling:

Cabling is provided to provide power for individual motors from MCC. Different MOC
(Copper and Aluminum) are used based on the Power rating of the motors. Generally
cable preferred are Copper or Aluminum, Armoured, PVC insulated, Heavy duty
electric cables. Working voltage of cable will be around – 1100 Volts confirming to
IS:7098 (part 1). Below table will let us know the cable size selection based on motor
rating. Cable preferred are Armoured and 3 Core.

Based on the motor rating, selection of starter, Core size , MOC and cross section of cable
can be selected from the below table. Generally if layout of plant is not provided, 40 m
per feeder is considered for power cabling.

EDITION 1 14
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S No Motor Rating Type of Core size of Cable cross MOC of cable

in Kw starter cable section in recommended
Sq.mm
1. 0.15 3 1.5
2. 0.37 3 2.5
3. 0.55 3 2.5
4. 0.75 3 2.5
5. 1.1 3 2.5
6. 1.5 3 2.5
7. 2.2 3 2.5
DOL Copper
8. 3 3 2.5
9. 4 3 2.5
10. 5.5 3 4
11. 7.5 3 4
12. 9.3 3 4
13. 11 3 6
14. 15 3 6
15. 18.5 3 10
16. 22 3 10
17. 30 3 25
18. 37 3 35
19. 45 3 50
20. 55 Star/Delta 3 70 Aluminum
21. 75 3 95
22. 90 3 120
23. 110 3 185
24. 132 3 240
25. 160 3 300
26. 200 3 300
27. 250 3 400
Table 6: Power Cable size selection

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8.2 Control Cabling :

These cables are provided for on/off of pump through LPBS on field .Generally cables
preferred are Copper with 4 core and 1.5 Sq.mm Cross sectional area. Generally if layout
of plant is not provided, 40 m per feeder is considered for both power cabling. Market
available sizes are indicated below.

S No No of cores Cross sectional area in Sq.mm

1. 2 1.5,2.5,4,6,10,25,35,50,70,95,120,150,185,240,300,400
2. 3 1.5,2.5,4,6,10,25,35,50,70,95,120,150,185,240,300,400
3. 4 1.5,2.5,4,6,10,25,35,50,70,95,120,150,185,240,300,400
4. 5 1.5,2.5
5. 6 1.5,2.5
6. 7 1.5,2.5
7. 8 1.5,2.5
8. 9 1.5,2.5
9. 10 1.5,2.5
10. 12 1.5,2.5
11. 14 1.5,2.5
12. 16 1.5,2.5
13. 24 1.5,2.5
14. 27 1.5,2.5
15. 30 1.5,2.5
16. 37 1.5,2.5
17. 44 1.5,2.5
18. 52 1.5,2.5
19. 61 1.5,2.5
Table 7: Commonly available sizes of cables

8.3 Instrument Cabling:

When PLC is provided the required power for instrument is supplied through this cable.
Instrument cabling can be further bifurcated as power cabling to instruments and Signal
cabling from instruments to PLC. Schedule of cable is illustrated in table7.

8.3.1 Junction Box:

Junction box are provided to decrease the cost of cables in and around the plant. Instead
of bringing all the cable signal and power to instruments and PLC directly, cable are
made to run till the junction box. From Junction Box multicore cables can be used to
transmit the power and signal to PLC. Separate junction boxes are provided for power
and signal cabling.

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8.3.2 Signal Cabling:

The single pair/triad and multi pair/triad cables will be of 1.0 Sq. mm conductor
size, made of electrolytic copper conductor of 7 strands with each strand of 0.43
mm diameter. All signal cables are shielded.

S No Instrument Cable size Cross sectional area

Sq.mm
Power cable (from Junction box to Instrument)
1. Pressure switch 2Core 1.5
Level switch
2. Level transmitter 3 core 1.5
Pressure transmitter
pH analyzer
Conductivity analyzer
Silica analyzer
Flow transmitter
3. Multicore cabling from No of Instruments x 2 1.5
junction box to PLC (Note nearest core
based on market
availability can be
chosen from table 7)
Signal Cables (from junction box to instruments)
1. Level transmitter 1Pair 1
Pressure transmitter
pH analyzer
Conductivity analyzer
Silica analyzer
Flow transmitter
2. Multicore cabling from 6pair 1
Junction to PLC
PLC - Solenoid Valve box On command cabling
1. MGF 16 Core 1.5
2. ACF 16 Core 1.5
3. SAC 30 Core 1.5
4. SBA 30 Core 1.5
5. MB 30 Core 1.5
6. SAC regeneration system 10 Core 1.5
7. SBA regeneration system 10 Core 1.5
8. MB regeneration system 30 Core 1.5
PLC - Solenoid valve feedback cabling

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1. MGF 30 Core 1.5

2. ACF 30 Core 1.5
3. SAC 30 Core 1.5
16 core 1.5
4. SBA 30 Core 1.5
16 Core 1.5
5. MB 30 Core 1.5
30 Core 1.5
Note :Since the valves in SAC and SBA are more we need to provide 30 and 16 core
cabling , for MB its 30 core 2 run
Limit switch feedback cabling
1. Per valve 4 Core 1.5
Table 8: Cable size for instruments cabling

8.4 Cable trays :

Perforated type Cable trays Ladder type Cable trays

Cable trays are provided to support the cables used for power, control and signal
transmission. Widely used type of cable tray are perforated and ladder type. MOC of
cable tray will be GI. Common available sizes in the market
1. 50 x 50 x 5 mm
2. 100 x 50 x 5 mm
3. 150 x 50 x 5 mm
4. 300 x 50 x 5 mm
5. 400 x 50 x 5 mm

For estimation Perimeter of the layout that is 2(L+B) is used for working out the main
cable tray. Apart from this a drop of 10m for each drive is additionally considered. FRP
cable trays can be provided if specifically asked by the client.

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8.5 Cable tray support:

Generally MOC of support will be GI.. For every 3m of cable tray , one support is
considered for estimation.

8.6 Cable glands:

Cable glands are provided to secure and attach the ends of a cable to the equipment. Per
cable two glands are provided. Cable glands are double compression type and MOC
will be Plastic.

8.7 Earthing:

Earthing simply means connecting to the Earth’s natural, negative surface

charge.Commonly preferred earthing strips MOC is GI. Main grid earthing and filling
of earth pit is always done by the client.

9. Programmable Logic Controller:

Its Simple computer with logic developed to control certain process and equipments.In
water treatment plant PLC is used to control critical operation like feed water quality,
control of flow rates, control of pumps, valves, instruments for critical parameters.

Following to be taken care while estimation

1. PLC whether its redundant or non redundant
2. IF redundant whether its Hot or cold redundant
3. SCADA/HMI required
4. Programming software required
5. Redundancy required for Processors/CPU/I/O’s
6. Third party communication(DCS/SCADA/Purchasers Master PLC) required or
not
7. If required type of communication port(RS 232/RS 485/Profibus/Ethernet)
8. Operating and engineering station required with PC and printers.

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Input and Output for PLC can be arrived with following table.

S No. Description Digital Input Digital Analog Analog

Output Input Output
1.Pump , Blowers, 3(on/off/trip) 1 - -
Dosing pump

2.Valves 2(open/close) 1 - -
3.Switches 1 - - -
4.Transmitter/analyzer - - 1 -

5.Auto dosing pump - - 1 1

6.VFD - - 1 1
Table 9: Input / Output for PLC

9.1 Automation:

Common requirements of Automation are mentioned below

1. Auto valves
2. Solenoid Valves
3. Solenoid Box
4. Pu/Copper tubing
5. Impulse tubing
6. Limit switches/Proximity switches

9.1.1 Auto valves:

Our normal butterfly and Diaphragm valves are auto operated with help of Pneumatic
actuator. Pneumatic actuator converts energy(compressed air) into motion.
Usually double acting actuator is provided for butterfly valves and single acting
actuator for Diaphragm valve. These valves can only work under two conditions on/off
valves. I.e. This shows only fully closed and opened condition.

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Butterfly Valve Diaphragm Valve

9.1.2 Solenoid Valves:

A solenoid valve is an electromechanical device used for controlling liquid or gas flow.
The solenid valve is controlled by electrical current, which is run through a coil. When
the coil is energized, a magnetic field is created, causing a plunger inside the coil to
move. Depending on the design of the valve, the plunger will either open or close the
valve. When electrical current is removed from the coil, the valve will return to its de-
energized state.

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For estimation, each pneumatically operated valve consider one solenoid valve.

9.1.3 Solenoid Box:

All solenoid valves are assembled in common panel which is called as Solenoid box.
Each unit one number solenoid valves are provided. Suppose if the scheme is MGF 
ACF SAC  DGT SBA MB , we will provide 5 nos of solenoid box.

9.1.4 Pu/Copper tubing:

This tubing are provided for each valve to supply air to solenoid valves. For estimation
we need to consider 20 m for butterfly valve and 10 M for Diaphragm valve. Size of
tubing will be around 6 mm.

9.1.5 Impulse tubing:

These tubing are provided to for instrument like ORP/pH/Conductivity/Differential
pressure switch/pressure switch(high and Low) . They are laid between main line to
sensor chamber of instrument and from chamber to drain. Size of tubing is ½ “ and
MOC - SS 316. This tubing is offered if asked by the client otherwise flexible hoses are
provided.

9.1.6 Limit Switches/Proximity switches:

These switches are provided when SCADA is provided in the auto plant. Individual
limit switches are provided for each valve. These valves are provided when SCAD is
provided so that the actual operating condition of valves are viewed and controlled
from a operators room.

10.0 Air flow calculation chart

S No Size in NB Air flow per valve in CFM

Butterfly Diaphragm
1. 25 2 2
2. 40 2 2
3. 50 4 4
4. 80 4 4
5. 100 4 5
6. 150 4 5
7. 200 4 5
8. 250 4 5
9. 300 4 5
Table 10: Air Flow calculation chart.

EDITION 1 22
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Thilagavathi.O Raj Kumar Datta Veerabhadra swamy
 ELECTRICAL RECKONER

11.0 Electrical and cabling schedule illustrations

Scheme of the Plant: MGF – ACF – SAC – DGT – SBA – MB

Flow rate – 1 x 25 m3/hr

11.1 List of Drives:

S No Description Quantity in Nos. Power rating in Kw

1. NaOCl dosing pump 2 0.1
2. MGF feed pump 2 9.3
3. DG blower 2 0.75
4. SBA feed pump 2 9.3
5. Agitator for CDT – MB and SBA 2 0.75
6. MB air blower 2 2.2
7. pH correction pump 2 0.1

11.2 List of instruments:

S No Instruments Quantity
1. Conductivity analyser 2
2. pH analyzer 2
3. FIT 2
4. DPS 2
5. LS 5

11.3 Power cabling for Drives:

S No Description Quantity Power Core Size of MOC Len of Total

in Nos. rating size the of cable cable Len in
in Kw cable Sq in mtrs
mm mtrs
1. NaOCl dosing 2 0.1 1.5 40 80
pump
2. MGF feed pump 2 9.3 4 40 80
3. DG blower 2 0.75 2.5 40 80
4. SBA feed pump 2 9.3 3 Core 4 Copper 40 80
5. Agitator for CDT 2 0.75 2.5 40 80
– MB and SBA
6. MB air blower 2 2.2 2.5 40 80
7. pH correction 2 0.1 1.5 40 80
pump
EDITION 1 23
Prepared by, Checked by, Approved by,
Thilagavathi.O Raj Kumar Datta Veerabhadra swamy
 ELECTRICAL RECKONER

11.4 Control cabling for Drives

S No Description Quantity Power Core Size of MOC Len of Total

in Nos. rating size the of cable cable Len in
in Kw cable Sq in mtrs
mm mtrs
1. MGF feed pump 2 9.3 40 80
2. DG blower 2 0.75 40 80
3. SBA feed pump 2 9.3 4 core 1.5 Cu 40 80
4. Agitator for CDT 2 0.75 40 80
– MB and SBA
5. MB air blower 2 2.2 40 80

Note : Control cabling are not required for dosing pumps

11.5 MCC to PLC – Control cables:

S No Description Quantity Power Core Size of MOC Len of Total

in Nos. rating in size the cable cable Len in
Kw Sq mm in mtrs
mtrs
1.MGF feed pump – 2 9.3
run
2.MGF feed pump – 2 9.3
trip 10 10
3.MGF feed pump – 2 9.3 30 1.5
Auto/Manual
4.DG blower - run 2 0.75
5.DG blower - Trip 2 0.75
6.DG blower - 2 0.75
Auto/Manual
7.SBA feed pump - 2 9.3
run Cu
8.SBA feed pump – 2 9.3
trip
9.SBA feed pump – 2 9.3
Auto / manual 30 1.5
10.
Agitator for CDT – 2 0.75 10 10
MB and SBA - run
11.
Agitator for CDT – 2 0.75
MB and SBA - trip
EDITION 1 24
Prepared by, Checked by, Approved by,
Thilagavathi.O Raj Kumar Datta Veerabhadra swamy
 ELECTRICAL RECKONER

12.
Agitator for CDT – 2 0.75
MB and SBA –
auto/manual
13.
MB air blower – run 2 2.2
14.
MB air blower - trip 2 2.2 10 10
15.
MB air blower – 2 2.2 30 1.5
auto/manual

Note: Multicore cables to be used. Length of this cabling is the distance

between PLC and MCC. Since the PLC and MCC shall be located very near ,
we have considered 10 mtrs.

11.6 PLC to MCC – On command

S No Description Quantity Power Core Size of MOC Len of Total

in Nos. rating size the of cable cable Len in
in Kw cable Sq in mtrs
mm mtrs
1. MGF feed pump 2 9.3 40 80
2. DG blower 2 0.75 40 80
3. SBA feed pump 2 9.3 4 core 1.5 Cu 40 80
4. Agitator for CDT – 2 0.75 40 80
MB and SBA
5. MB air blower 2 2.2 40 80

11.7 Instrument Power cables from Junction box to Instruments

S No Instruments Quantity Core Size Size of MOC of Len of cable Total Len
of cable the cable cables in mtrs in mtrs
Sq mm
1. Power cable to 2 16 1.5 Cu 40 80
Junction box
from PLC
2. Conductivity 2 20 40
analyzer
3. pH analyzer 2 3 core 1.5 20 40
4. FIT 2 Cu 20 40
5. DPS 2 20 40
6. LS 5 20 100
Note: Actual distance can be decided based on instrument and junction box
location in the layout.
EDITION 1 25
Prepared by, Checked by, Approved by,
Thilagavathi.O Raj Kumar Datta Veerabhadra swamy
 ELECTRICAL RECKONER

11.8 Instrument Control cables from PLC to Instruments

S No Instruments Quantity Core Size Size of MOC of Len of cable Total Len
of cable the cable cables in mtrs in mtrs
Sq mm
1. control cable 2 10 1.5 Cu 30 60
from PLC to
Junction box
2. Conductivity 2 20 40
analyzer
3. pH analyzer 2 20 40
4. FIT 2 2 core 1.5 Cu 20 40
5. DPS 2 20 40
6. LS 5 20 100

Note: Actual distance can be decided based on instrument and junction box
location in the layout

11.9 Instrument Signal cabling

S No Instruments Quantity Core Size Size of MOC of Len of cable Total Len
of cable the cable cables in mtrs in mtrs
Sq mm
1. Signal cable from 1 6 Pair 1.0 Cu 30 30
PLC to Junction
box
2. Conductivity 2 20 40
analyzer
3. pH analyzer 2 20 40
4. FIT 2 1 Pair 1.0 Cu 20 40
5. DPS 2 20 40
6. LS 5 20 100

11.10 PLC - Solenoid Valve box on command cabling

S No Instruments Quantity Core Size Size of MOC of Len of Total Len

of cable the cable cables cable in in mtrs
Sq mm mtrs
1. MGF 1 16 core 40 40
2. ACF 1 16 core 40 40
3. SAC 1 30 core 40 40
4. SBA 1 30 core 40 40
EDITION 1 26
Prepared by, Checked by, Approved by,
Thilagavathi.O Raj Kumar Datta Veerabhadra swamy
 ELECTRICAL RECKONER

5. MB 1 30 core 40 40
6. SAC regeneration 1 10 Core 1.5 Cu 40 40
system
7. SBA regeneration 1 10 Core 40 40
system
8. MB regeneration 1 30 core 40 40
system

11.11 PLC - Solenoid Valve feedback cabling

S No Instruments No of Core Size of Size of MOC of Len of Total Len

valves cable the cable cables cable in in mtrs
Sq mm mtrs
1. MGF 6 30 core 40 240
2. ACF 6 30 core 40 240
3. SAC 15 30 core – 1 run 40 600
16 core - 1 run 40 600
4. SBA 15 30 core – 1 run 40 600
16 core - 1 run 1.5 Cu 40 600
5. MB 20 30 core – 2 40 800
runs 40 800

6. SAC regeneration 4 16 Core 40 160

system
7. SBA regeneration 4 16 Core 40 160
system
8. MB regeneration 4 30 core 40 160
system

EDITION 1 27
Prepared by, Checked by, Approved by,
Thilagavathi.O Raj Kumar Datta Veerabhadra swamy
 ELECTRICAL RECKONER

11.12 Limit switches feedback cabling (from Solenoid valve box to valves)

S No Instruments No of No of Core Size of MOC of Len of Total Len

valves limit Size the cables cable in in mtrs
switches of cable Sq mtrs
cable mm
1. MGF 6 12 10 120
2. ACF 6 12 10 120
3. SAC 11 22 10 220
4. SBA 11 22 10 220
5. MB 11 22 10 220
6. SAC regeneration 4 8 4 core 1.5 Cu 10 80
system
7. SBA regeneration 4 8 10 80
system
8. MB regeneration 4 8 10 80
system

EDITION 1 28
Prepared by, Checked by, Approved by,
Thilagavathi.O Raj Kumar Datta Veerabhadra swamy