I-2007-EE-A4-9060 (1)

Royal Commission for Jubail and Yanbu I-2007-EE-A4-9060 – Rev.
Basis of Design - Electrical
BASIS OF DESIGN - ELECTRICAL
CONTRACT: JCPDI I-2007

CONTRACT TITLE: DESIGN & CONSTRUCTION OF SEA
WATER COOLING (SWC) SYSTEM -
PHASE 1
CONTRACTOR NAME: CHINA HARBOUR ENGINEERING ARABIA
COMPANY LTD.
DATE 20-Jan-23 20-Jan-23 20-Jan-23

SIGNATURE
NAME Abhishek Kapoor / Sushant Gadewar Sajid Gul

Tanu M Tuli
POSITION Originator Design Manager Project Manager
I-2007-EE-A4-9060 Page 1 of 32 Rev. A

Contractor name: CHINA HARBOUR ENGINEERING ARABIA COMPANY LTD
Document no: I-2007-EE-A4-9060
Revision: A
Revision date: 20 January 2023
Project no: SA340WTD
Project manager: Sajid Gul
Prepared by: Tanu M Tuli
Approved by: Sushant Gadewar
File name: 773036816.docxBasis of Design - Electrical
Revision Date Description Author Reviewed Approved

A 20-Jan-23 Issued for Review AK/TMT SGR SG
Document history and status
I-2007-EE-A4-9060 Page 2 of 32 Rev. A

Royal Commission for Jubail and Yanbu I-2007-EE-A4-9060 – Rev. A
Contents
1. INTRODUCTION............................................................................................................................
1.1 Background..................................................................................................................................
1.2 Project Site...................................................................................................................................
1.3 Project Scope of Work...............................................................................................................
1.4 Purpose of this Report...............................................................................................................
1.5 Project Reference Documents...................................................................................................
1.6 Codes and Standards................................................................................................................
2. GENERAL DESIGN CRITERIA....................................................................................................
2.1 Design Scope.............................................................................................................................
2.2 Electrical Calculation Software...................................................................................................
2.3 Site Ambient Conditions.............................................................................................................
2.4 Design Life.................................................................................................................................
2.5 Protective Coating, Painting Requirement.................................................................................
2.6 Equipment Ingress Protection....................................................................................................
2.7 Power System Studies...............................................................................................................
2.8 System Description....................................................................................................................
2.9 Electrical Buildings.....................................................................................................................
2.9.1 GIS Building..................................................................................................................
2.9.2 MV Switchgear Building................................................................................................
2.9.3 Minimum Clearances.....................................................................................................
3. ELECTRICAL EQUIPMENT & SYSTEMS...................................................................................
3.1 GIS Switchgear..........................................................................................................................
3.2 MV Switchgear...........................................................................................................................
3.3 LV Switchgear............................................................................................................................
3.4 Power Transformer....................................................................................................................
3.5 Distribution Transformer.............................................................................................................
3.6 Neutral Grounding Resistor (NGR)............................................................................................
3.7 Automatic Power Factor Correction Panel (APFC)....................................................................
3.8 EDG Set.....................................................................................................................................
3.9 VFD Panel along with Transformer............................................................................................
3.10 Battery Charger and Battery.......................................................................................................
3.11 AC UPS with Battery Bank.........................................................................................................
3.12 Motors........................................................................................................................................
3.12.1 MV Motors.....................................................................................................................
3.12.2 LV Motors......................................................................................................................
3.13 Cables........................................................................................................................................
3.13.1 HV Cables.....................................................................................................................
3.13.2 MV Cables.....................................................................................................................
3.13.3 LV Cables......................................................................................................................
3.13.4 Permissible Voltage Drop in Power Cables...................................................................
3.14 Earthing/Grounding System.......................................................................................................
3.15 Lightning Protection System.......................................................................................................
3.16 Lighting and Small Power System..............................................................................................
3.17 Cable Installation Methodology..................................................................................................
I-2007-EE-A4-9060 Page 3 of 32 Rev. A

I-2007-EE-A4-9060 Page 4 of 32 Rev. A

Figures
Figure 1-1. Project location.................................................................................................................... 9
Figure 1-2. The Location of Existing Seawater Intake and Outfall.........................................................9
Figure 1-3. Onshore Supply and Return Pipeline Scope.....................................................................10
Tables
Table 1-1. Project Reference Documents............................................................................................ 11
Table 2-1. Software Program............................................................................................................... 13
Table 2-2. Site Conditions.................................................................................................................... 13
Table 2-3. Equipment Ingress Protection............................................................................................. 14
Table 2-4. Minimum Clearance for Equipment.....................................................................................16
Table 3-1. HV Switchgear Design Conditions......................................................................................18
Table 3-2. MV Switchgear Design Conditions......................................................................................19
Table 3-3. LV Switchgear Design Conditions.......................................................................................20
Table 3-4. Power Transformer Design Conditions...............................................................................21
Table 3-5. Grounding Resistor Characteristics....................................................................................22
Table 3-6. Current Transformer Characteristics...................................................................................23
Table 3-7. VFD System Design Conditions.......................................................................................... 24
Table 3-8. MV Motor Design Conditions.............................................................................................. 26
Table 3-9. HV Cables Design Conditions............................................................................................ 26
Table 3-10. MV Cables Design Conditions:......................................................................................... 27
Table 3-11. LV Cables Design Conditions...........................................................................................27
Table 3-12. Voltage Drop Criteria........................................................................................................ 28
Table 3-13. Lux Level.......................................................................................................................... 29
I-2007-EE-A4-9060 Page 5 of 32 Rev. A

Acronyms and Abbreviations

Abbreviation Description
A, amp Ampere
AC, a.c. Alternating Current
ACB Air Circuit Breaker
AHF Active Harmonic Filter
AIS Air Insulated Switchgear
ANSI American National Standard Institute
APFC Automatic Power Factor Controller
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
BS British Standards
B/C Bus-coupler
CB Circuit Breaker
CBCT Core Balance Current Transformer
CT Current Transformer
CP Cathodic Protection
DB Distribution Board
DC, d.c. Direct Current
DF Demand Factor
DOL Direct Online
DP Double Pole
EDG Emergency Diesel Generator
ELCB Earth Leakage Circuit Breaker
ELV Extra Low Voltage
EMC Electromagnetic Compatibility
EMI Electromagnetic Interference
EPC Engineering, Procurement and Construction
EI Energy Institute
ETAP Electrical Transient Analysis & Program
FAT Factory Acceptance Test
FEED Front End Engineering Design
FOC Fiber Optic Cable
FOS Factor of Safety
I-2007-EE-A4-9060 Page 6 of 32 Rev. A

F&G Fire and Gas
GIS Gas Insulated Switchgear
HMI Human Machine Interface
HV High Voltage
HVAC Heating Ventilation and Air Conditioning
IAC Internal Arc Classification
I/C Incomer
IDMT Inverse Definite Minimum Time
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
IMD Individual Maximum Demands
I/O Input, Output
IP The Degree of Ingress Protection
ISO International Organization for Standardization
ITP Inspection & Test Plan
kA Kilo Ampere
kV Kilo Volt
kVA Kilo Volt Ampere
kVAr Kilo Volt Ampere Reactive
kW Kilo Watt
LCD Liquid Crystal Display
LED Light Emitting Diode
LV Low Voltage
MCC Motor Control Centre
MCB Miniature Circuit Breaker
MCCB Moulded Case Circuit Breaker
MD Maximum Demands
MTO Material Take Off
MSL Mean Sea Level
Modbus Modicon Bus
MOU Memorandum of Understanding
MOV Motor Operated Valve
NACE National Association of Corrosion Engineers
NEC National Electrical Code
NFPA National Fire Protection Association
OCTC Off Circuit Tap Changer
I-2007-EE-A4-9060 Page 7 of 32 Rev. A
OEM Original Equipment Manufacturer

OLTC On Load Tap Changer
ONAN Oil Natural Air Natural
O/G Outgoing
PC Personal Computer
PEC Parallel Earthing Conductor
PFC Power Factor Correction
PMS Power Management System
PVC Polyvinyl Chloride
QAQC Quality Assurance & Quality Control
RCC Reinforced Cement Concrete
REF Restricted Earth Fault
RF Radio Frequency
RMS Root Mean Square
SAT Site Acceptance Test
SCADA Supervisory Control and Data Acquisition
SI System de International
SFU Switch Fuse Unit
SLD Single Line Diagram
SPD Surge Protective Device
SS Soft Starter
TCL Total Connected Load
TCP/IP Transmission Control Protocol / Internet Protocol
TDL Total Demand Load
TEWAC Totally Enclosed Water to Air Cooled
TEFC Totally Enclosed Fan Cooled
THDv Total Voltage Harmonic Distortion
THDi Total Current Harmonic Distortion
TP Three Phase
TPN Three Phase Neutral
UPS Uninterrupted Power Supply
V Volt
VCB Vacuum Circuit Breaker
VC Vacuum Contactor
VFD Variable Frequency Drive
I-2007-EE-A4-9060 Page 8 of 32 Rev. A
VRLA Valve Regulated Lead Acid

VT Voltage Transformer
XLPE Cross-linked polyethylene
RC Royal Commission
JCPDI SWC Jazan City Primary and Downstream Industries Sea Water Cooling
I-2007-EE-A4-9060 Page 9 of 32 Rev. A

1. INTRODUCTION
1.1 Background
China Harbour Engineering Arabia Company (CHEAC) has been awarded the design and
construction, a phase 1 of sea water cooling project to service the Jazan City for Primary
and Downstream Industries (JCPDI), located in the South West in the Kingdom of Saudi
Arabia in the Province of Jazan.
The project for sea water cooling is part of the National Transformation Program (NTP)
initiative “Development of the Industrial Zone” that support the Economic Development by
providing the cooling capacity to heavy industries under Environmental Development
considerations in order to protect the coastal environment.
The project site located at Jazan Economic city, shown in (Figure 1-1).
Figure 1-1. Project location
1.2 Project Site

This project is located at north of Jazan Commercial Port and Jazan Refinery.
Existing RO Intake
and Outfall
Proposed JCPDI
Intake and Outfall
Existing JIGCC
Intake and Outfall
Figure 1-2. The Location of Existing Seawater Intake and Outfall

I-2007-EE-A4-9060 Page 10 of 32 Rev. A
At south of the proposed new SWC system, there is an existing seawater intake and outfall
system as part of Jazan Integrated Gasification Combined Cycle (JIGCC). At north, there is
another existing intake and outfall for the reverse osmosis (RO) plant. The location of the
existing intakes and outfalls is shown in (Figure 1-2).
1.3 Project Scope of Work

The project shall be designed to provide the Seawater flowrate of 96,000 m3/hr with 3 working & 1
standby pump configuration. The future provision of 2 pumps shall also be considered in the design
resulting in overall design capacity of the system as 160,000 m3/hr. The project scope of Seawater
Cooling System (SWC) includes the design and construction of:
• 2 no. of offshore intake pipes with a supply head at the shore end of each pipe and with the
other end connected with the onshore supply structure;
• An onshore supply structure from which the Seawater is convey to the supply pipes by
pumps;
• 2 no. of supply pipes to convey to the Seawater to the facilities to be served;
• 2 no. of return pipes to convey the Seawater which has been circulated through the plant to
an onshore return structure;
• 1 no. of spare pipe will also be provided. The spare pipe can be connected to supply as well
as return pipes;
• The return pipes will be connected to a return structure with a discharge channel to
discharge the return water through the shoreline.
Figure 1-3. Onshore Supply and Return Pipeline Scope
I-2007-EE-A4-9060 Page 11 of 32 Rev. A

1.4 Purpose of this Report
The scope of this document is to detail the minimum requirements for the Electrical System
and associated equipment forming part of the project.
Further, this document shall be read in conjunction with all specifications, datasheets,
standard installation drawing, code & standard, statutory requirement of the relevant local
authorities forming part of the project to ensure compliance with project requirements.
The electrical system shall be simple to operate and maintain with adequate back up
facilities. The removal of a single part of the system or item of electrical equipment, due
either to maintenance, failure or shutdown, shall not compromise safety or disrupt plant
operation.
1.5 Project Reference Documents
The following documents are referred while preparing the basis of design:
Table 1-1. Project Reference Documents

Document Document No.
RCY-GDCTG 2018 4ED Rev.1.00 General Design Criteria and Technical Guidelines
30% FEED for JCPDI SWC System – Design Analysis
PB9055-RHD-ZZ-XX-RP-Z-9013
Report (DAR)
- Technical Specification Data (Royal Commission)
1.6 Codes and Standards
All electrical equipment shall follow IEC standards. Applicable Codes & Standards are indicated
below not limited to:
 IEC 62271 - High Voltage & Medium Voltage Switchgear Assembly
 IEC 61439 - Low Voltage Switchgear Assembly
 IEC 60076 - Power Transformers
 IEC 60502 - Power cables with extruded insulation and their accessories for rated
voltages from 1 kV up to 30 kV
 IEC 60840 - Power cables with extruded insulation and their accessories for rated
voltages above 30 kV up to 150 kV
 IEC 60034 - Rotating Electrical Machines
 IEC 61800 - Variable Frequency Drive System
 IEC 61869 - Instrument Transformer
 IEC 60529 - Degrees of Protection Provided by Enclosure (IP Code)
 IEC 62305 - Protection against lightning
 IEC 60364 - Earthing for General Building
 IEC 60909 - Short Circuit Currents and Calculations in Three Phase A.C. Systems
 IEEE 519 - Harmonics Control in Electrical Power System
 IEEE 80 - Earthing/Grounding System
I-2007-EE-A4-9060 Page 12 of 32 Rev. A

2. GENERAL DESIGN CRITERIA
Electrical Power distribution shall be provided to meet the electricity demands of the JCPDI
SWC system. The network will be developed based on the project requirements and the
international codes and standards.
The design of power distribution system and equipment shall meet the functional
requirements of the project. The objective of electrical design is to provide simplicity,
reliability and safety while ensuring cost effectiveness and low maintenance needs,
equipment interchangeability, easy inspection, cleaning, and repair. All required precautions
necessary to make the works safe, including safety of third parties shall be considered.
2.1 Design Scope

The scope of electrical infrastructure for this Project covers the following items:
a. 132KV GIS Switchgear

b. 132/13.8 KV Power Transformer
c. Neutral Grounding Resistor
d. 13.8 KV MV Switchgear
e. 13.8/0.4 KV Distribution Transformer
f. 400 V Emergency DG Set
g. LV Switchgear
h. VFD Panel along with 13.8/6.6KV Transformer
i. Control Station
j. MV Motors
k. Battery Charger & Battery bank
l. AC UPS & Battery bank
m. Capacitor Bank
n. HV Cable
o. MV Cable
p. LV Cable
q. Lighting and Small Power System
r. Lightning Protection System
s. Earthing/Grounding System
t. Cable Management System
u. System Studies
I-2007-EE-A4-9060 Page 13 of 32 Rev. A

2.2 Electrical Calculation Software

Table 2-1 lists the software that will be used for the various electrical calculations.
Table 2-2. Software Program
Electrical Calculation / Study Software Program
Transformer Sizing Calculation Microsoft Excel
Emergency DG Sizing Calculation Microsoft Excel
Electrical Load List Microsoft Excel
Earthing Calculation Microsoft Excel
Lightning Protection Calculation Microsoft Excel
Cable sizing Calculation Microsoft Excel
AC UPS sizing Calculation Microsoft Excel
Battery Charger sizing Calculation Microsoft Excel
Power System Study (Load Flow, Short Circuit, Motor ETAP as per IEC 60909
Starting & Relay Coordination)
Lighting Calculation DiaLux
Material Take Off Schedule Microsoft Excel
2.3 Site Ambient Conditions

All equipment, apparatus, materials and accessories used in the electrical installations shall be
suitable for the purpose intended and capable of operating with satisfactory performance in the
climatic conditions which are included in Table 2-2.
Table 2-3. Site Conditions
Parameter Value
Altitude Less than 1000 Mtr. Above sea level

Minimum/ Maximum ambient air temperature 0˚C / 50˚C
Design Temperature 50˚C
Surface temperature (Direct sun exposure) 80˚C
Indoor temperature in Air-Conditioned Spaces 30˚C
Relative humidity 10-100 %
Ground temperature 40˚C
Atmosphere humid, salty, dusty and sandy
atmosphere
I-2007-EE-A4-9060 Page 14 of 32 Rev. A
2.4 Design Life

All Electrical equipment shall have 30 years design life.
For VRLA battery, minimum design life shall be 10 years at 25°C.
2.5 Protective Coating, Painting Requirement

Paint System or other surface protection system shall be selected to be durable considering
the marine environment. Paint shade for all Electrical panels install indoor/outdoor shall be
RAL 7035. In case of any deviations by OEM, RFI shall be raised for Employer’s approval.
2.6 Equipment Ingress Protection

Ingress protection for Electrical Equipment shall be selected as per following criteria:
Table 2-4. Equipment Ingress Protection
Location Ingress Protection
Indoor Panels / DBs / Equipment IP 41 (min)
Outdoor Panels / DBs / Equipment IP 54 (min)
Inside Pit IP 67
Outdoor Socket Outlet & Switch IP 65
Luminaires (External) IP 65
AC UPS / DC UPS / Battery Charger IP 3X (min)
Battery Rack IP 2X (min)
2.7 Power System Studies

Followings power system studies shall be performed:
a) Load Flow Study

b) Short Circuit Study
c) Relay coordination
d) Motor starting
I-2007-EE-A4-9060 Page 15 of 32 Rev. A

2.8 System Description

2 Nos. 132kV redundant input power supply shall be provided to the new GIS substation
through HV cables which shall be supplied and terminated by others. Any one power source
should be made sufficient to feed the complete load of the plant.
This GIS switchgear shall have 2 Nos. I/C, 1 No. B/C and 3 Nos. O/G transformer feeders,
along with double bus bar arrangement. At any time, one I/C shall be connected to one bus
and other I/C shall be connected to the other bus with B/C open condition. In case there is
no power from one of the sources B/C shall be used to power the other bus. Isolators shall
only be used to switch from one bus to another bus in off-load condition. In no condition
paralleling of the incoming sources shall be permitted.
The 132kV voltage level is further transformed to 13.8kV voltage level with the help of 3 Nos.
(3x50%) 132kV/13.8kV Power Transformers (2 Working + 1 Standby). These Power
Transformers are sized in accordance with the Ultimate Demand Load of the sea water
cooling pumps and other auxiliaries power demand only for Phase-1. The 13.8kV MV
switchgear shall receive power from each Power Transformers making 3 bus system. Loads
shall be distributed in a balanced manner between the two buses and 3 rd bus shall be used
as reserve only. In case there is a fault on one of the buses the load shall be transferred to
the 3rd bus with the help of Switching Isolators. There is no B/C envisaged as each of the
transformers can feed maximum only 50% of the total demand load.
Alternatively, the 132kV voltage level can be transformed to 13.8kV voltage level with the
help of 2 Nos. (2x100%) 132kV/13.8kV Power Transformers. The 13.8kV MV switchgear
shall receive power from these Power Transformers making 2 I/C, 1B/C arrangement. Loads
shall be distributed in a balanced manner between the two buses however in the case where
either Transformer is not available the other Transformer can feed the complete plant load.
The advantage of this scheme is that there would be minimum operational equipment in this
scheme and thereby less complex in operation & maintenance. Also, it shall be noted that
the bus fault situation is very rare phenomenon and even in that case at least half of the
plant load shall be in working condition. Due to high-speed protection relays the faulty bus
might have very little or no destruction effect and can be made online in minimum possible
time.
This 13.8kV MV switchgear shall feed 4 Nos (3 working + 1 standby) of Sea Water Cooling
Pump Motors through Transformer & VFD arrangement, 2 Nos of 13.8kV/0.4kV Distribution
Transformers (2x100%) for LV auxiliary loads of the complete plant including Chlorination
Package and Electrolysis Transformers for Chlorination Package as per vendor design.
EDG will be sized to provide power supply to serve the essential and life safety equipment
(auxiliary loads in the pump station and building services) only in case of utility failure. EDG
shall be connected to the Main LV switchgear which shall have 3 I/C (2 Normal Grid supply
from 13.8kV MV switchgear and 1 from EDG) & 2 B/C. The complete LV bus (400V/230V,
three phase four wire, 60Hz) with 3 sections shall feed all the LV Auxiliary Loads of the plant
however the 3rd section (powered from EDG) shall feed only essential and life safety
equipment. In the normal scenario Bus-1 shall be powered through I/C-1 and Bus-2 & Bus-3
with B/C closed shall be powered from I/C-2. If any of the normal grid I/C is not available, the
complete bus shall be fed from the other I/C by closing the remaining B/C. In the case of
black-out both the B/C shall remain open and EDG I/C shall be closed.
Electric motors driving the sea water cooling pumps will have an operational voltage of 6.6kV
at 60Hz, powered by variable frequency drives with a primary operational voltage of 13.8kV
I-2007-EE-A4-9060 Page 16 of 32 Rev. A

and a secondary operational voltage of 6.6kV. The function of the variable frequency drives
will be to reduce the rotational speed of the pumps to suit the required pump duties. One
step down transformer (13.8kV/6.6kV) shall be provided along with each VFD panel to get
6.6kV power supply to feed VFD panel.
Motors rated ≤ 0.37kW shall be supplied at 1 Phase 230V, whereas Motors rated > 0.37kW
on valves, penstocks, screens shall be rated at 380V but supplied at 3 Phase 400V.
All lighting and socket outlets will be 230V, 60Hz except where lower voltages are required
for instrumentation or safety reasons.
AC UPS will be designed based on the load application and the backup time. Battery
charger shall be considered for requirement of HV/MV switchgears, control panels, relays
etc.
2.9 Electrical Buildings
2.9.1 GIS Building

The new GIS Building shall be Ground + Basement. The ground level is allocated for the
GIS switchgear, Local Control Cubicle, Protection Relay panel, PLC panel and Battery
charger/battery. Power Transformers shall be placed outside the building. The Basement is
for cable management system for GIS switchgear.
Substation shall be concrete/brick build substation. Incoming and outgoing cable routing
shall be underground.
2.9.2 MV Switchgear Building
The new MV switchgear Building shall be Ground + Basement. The ground level is allocated
for the MV switchgear, EDG set, PFC panel, PLC panel, LV switchgear and Battery
charger/battery. Distribution Transformers shall be placed outside the building. The
Basement is for cable management system.
Substation shall be concrete/brick build substation. Incoming and outgoing cable routing
shall be underground.
2.9.3 Minimum Clearances

Following are the minimum clearances shall be provided around various equipment in
compliance with safety regulations and for ease of maintenance:
Table 2-5. Minimum Clearance for Equipment

Equipment Description Minimum
Clearance
Front clearance for HV/MV switchgear 2000 mm
Front clearance for LV switchgear 1500 mm
Front clearance for two MV switchgear placed face to face 2000 mm
Front clearance for two LV switchgear placed face to face 1500 mm
Rear side of MV/LV switchgear required maintenance access from 750 mm

rear
I-2007-EE-A4-9060 Page 17 of 32 Rev. A

Equipment Description Minimum

Clearance
Rear side of MV/LV switchgear for which rear access is not required 200 mm
Side clearance between two switchgear or from nearest obstruction ≥750 mm or

(e.g., wall)
≤200mm
From highest point of equipment to underside of lowest roof beam / 500 mm

Duct
Between back of UPS, VFD and wall in case rear access required ≥750 mm or
in case rear access not required
≤200mm
Clearance between battery rack to rack and battery rack to wall in 750 mm
front side (double row, double tier arrangement)
Clearance between transformer and nearest wall/column 1000 mm
Front clearance for wall mounted equipment 750 mm
Around Diesel Generator 1000 mm

NOTE: Above mentioned clearances are minimum and shall be checked with Vendor
recommendation and higher among the two shall be considered.
I-2007-EE-A4-9060 Page 18 of 32 Rev. A

3. ELECTRICAL EQUIPMENT & SYSTEMS
3.1 GIS Switchgear
132kV switchgear shall be Gas Insulated, indoor type, 3-phase double busbar configuration,
complying with the IEC 62271 Standards. Equipment Type/Routine testing requirements
shall satisfy IEC. Insulating gas shall be Sulphur hexafluoride (SF6). The switchgears shall
consist of a row of freestanding floor mounted panels that are of a single front, single tier
type.
Control supply for Switching Devices and Relays shall be 110V DC. Circuit breakers shall be
operated remotely, not from the front of the breaker unless in the TEST position which is
isolated from both live busbars and outgoing cables.
All the live parts including the CB, Disconnector, and main busbar shall be encapsulated in
Aluminium Alloy enclosure as per manufacturer design filled with SF6 gas. GIS switchgear
Incoming/outgoing cable chamber shall be designed to receive single run of 132kV power
cable per phase.
The HV switchgear (GIS) design conditions are summarized as below-
Table 3-6. HV Switchgear Design Conditions
Parameter Value
Nominal Voltage Level (KV) 132
Rated Equipment Ampacity (A) 3150
RMS 1-Second Withstand Rating (KA) 40
Momentary Peak Withstand Rating (KA) 104
BIL (KV Peak) 650
Power Frequency Withstand Voltage (KV RMS) 275
Substation Configuration Double Bus Single Breaker
Power / Control Cable Entry Bottom
3.2 MV Switchgear
13.8kV switchgear shall be air insulated, indoor type, free-standing, dead-front, floor
mounted, 3-phase, 3-wire, double busbar, type tested assemblies of metal-enclosed
withdrawable type switchgear and control gear, comprising of withdrawable VCB, all
necessary safety interlocks, earth-switch, protection relays, measurement instruments,
current and voltage transformers, surge arresters & other essential component parts for
installation within fully ventilated switch room. If to satisfy double bus configuration, OEM has
only standard & proven product in Back-to-back configuration, then the same shall be
informed to EMPLOYER for further discussion and approval.
The switchgear shall be designed in accordance with IEC 62271 & its parts, as minimum
requirements. Equipment Type/Routine testing requirements shall satisfy IEC.
I-2007-EE-A4-9060 Page 19 of 32 Rev. A

Minimum 2.0mm thick steel construction shall be used for panel manufacturing, with hinged
front doors and rear access panels of sufficient size to give full access to all components.
Multi-function digital communicable meters shall be provided for metering purpose for
switchgear Incomers & Outgoing Feeders. Analog devices shall not be used. VT circuits &
control wiring shall be done with flexible, 600V/650V grade wires with stranded copper
conductors of minimum 1.5 mm2 and for CT the minimum cross section shall be 2.5mm2.
Control supply for Switching Devices and Relays shall be 110V DC.
MV switchboards shall have at least one spare outgoing cubicle on each busbar section. The
type and rating of the spare cubicles shall be based upon the type and rating of feeders
provided in the MV switchgear. The switchgear shall be extensible on both sides.
The MV switchgear design conditions are summarized as below:
Table 3-7. MV Switchgear Design Conditions
Parameter Value
Nominal Voltage Level (KV) 13.8
Rated Equipment Ampacity (A) 1250
Momentary Peak Withstand Rating (KA) 65
BIL (KV Peak) 95
Power Frequency Withstand Voltage (KV RMS) 38
Substation Configuration Double-Bus-Single-Breaker
Power / Control Cable Entry Bottom
3.3 LV Switchgear
Air insulated LV switchgear shall be designed and manufactured in accordance with IEC
61439. Equipment Type/Routine testing requirements shall satisfy IEC. The switchgear shall
be designed to operate on 400 volt, 3 phase, 4 wire 60Hz AC with neutral solidly earthed.
The switchgear shall be free standing, totally enclosed metal switchgears incorporating
withdrawable ACB for I/C & B/C and MCCBs for outgoing feeders. 1000A and above shall be
ACB. Form 3b Type 2 segregation.
Bus bar will be of copper. The Panel shall be fabricated from steel sheet. Control voltage
shall be 230 V AC which shall be derived through control transformer.
Multi-function digital communicable meters shall be provided for metering purpose for
switchgear Incomers. Analog devices shall not be used. VT circuits & control wiring shall be
done with flexible, 600V/650V grade wires with stranded copper conductors of minimum 1.5
mm2 and for CT the minimum cross section shall be 2.5mm2.
Each distribution board/panel shall have a minimum of 10% spare capacity. For future
expansion, space for 2 verticals on each side shall be provided in the switchgear room.
The LV switchgear design conditions are summarized as below:
I-2007-EE-A4-9060 Page 20 of 32 Rev. A

Table 3-8. LV Switchgear Design Conditions
Parameter Value
Nominal Voltage Level (KV) 0.4
Rated Equipment Ampacity (A) Various
Substation Configuration Single-Bus-Single-Breaker
Power / Control Cable Entry Bottom / Top
3.4 Power Transformer
Power Transformer shall be liquid filled, outdoor type with copper windings, complying with
IEC 60076. Equipment Type/Routine testing requirements shall satisfy IEC. The average
temperature rise of the transformer windings shall not exceed 80 °C when the transformer is
operated at full name plate rating. Transformers shall be capable of carrying 100% of name
plate KVA rating at ambient temperature. Transformers shall have a minimum of 10% spare
capacity.
The transformer shall have the following-
a. Weather- proof enclosure for control equipment
b. Secondary voltage neutral terminal
c. Accessible grounding pads
d. Winding temperature gauge
e. Buchholz Relay
f. Air Breather
g. Dial type liquid thermometer
h. Magnetic liquid level gauge
i. Pressure vacuum gauge
j. Drain valve/liquid sampling valve
k. Valve for top filter pressure connection
l. Oil preservation device
m. Radiator valves and detachable radiator
n. Pressure relief device
o. Pulling eyes, jacking provisions, instruction name plates and lifting lugs
The power transformer design conditions are summarized as below-
I-2007-EE-A4-9060 Page 21 of 32 Rev. A

Table 3-9. Power Transformer Design Conditions
Parameter Value
Primary Nominal Voltage Level (KV) 132
Secondary Nominal Voltage Level (KV) 13.8
Nominal Power Rating at Ambient (MVA) 20/25
Primary Connection Delta
Secondary Connection Resistive Grounded- Wye
Vector Group Dyn1
Minimum Transformer Impedance (%) 10
Cooling Arrangement ONAN/ONAF
Grounding Configuration Neutral Grounding Resistor
Nominal Grounding Impedance at Ambient (Ohm) 26.56
Nominal Earth Fault Current at Ambient (A) 300
Tap Changer OCTC (+/-5% in steps of 2.5%)
3.5 Distribution Transformer
Distribution Transformer shall be liquid filled, outdoor type with copper windings, complying
with IEC 60076. Equipment Type/Routine testing requirements shall satisfy IEC. At the rated
power, the maximum temperature rise of the transformer shall not exceed 45°C for the Top
Oil & 50°C for the Winding. Maximum hot sport temperature should not be more than 98°C
during normal operations and average temperature due to short circuit should not exceed
250°C. Transformers shall be capable of carrying 100% of name plate KVA rating at ambient
temperature. Transformers shall have a minimum of 10% spare capacity.
The transformer shall have the following-

a. Temperature indicators
b. Dial type liquid thermometer
c. Sight glass/dial type level gauge
d. Pressure Relief Device
e. Earthing Terminals on Tank
f. Oil Drain valve
g. Buchholz Relay
I-2007-EE-A4-9060 Page 22 of 32 Rev. A

h. Air Breather
i. Lifting lugs
j. Rollers
k. Cable clamps
The distribution transformer design conditions are summarized as below:
Table 3-6. Distribution Transformer Design Conditions
Parameter Value
Primary Nominal Voltage Level (KV) 13.8
Nominal Power Rating at Ambient (KVA) 1600/2000
Primary Connection Delta
Secondary Connection Grounded- Wye
Vector Group Dyn 1
Maximum Transformer Impedance (%) 6
Cooling Arrangement ONAN
Grounding Configuration Solid
Tap Changer OCTC (+/-5% in steps of 2.5%)
3.6 Neutral Grounding Resistor (NGR)

An outdoor type NGR shall be provided to ground the secondary winding neutral of the
Power Transformer. The NGR assembly shall consist of a grounding resistor, a current
transformer, base insulators, line-side terminal to receive an insulated cable, station ground
side terminal and a freestanding screened enclosure. Resistor support frame shall be
supported by post type stand-off insulators. Grounding resistors shall have the following
characteristic-
Table 3-10. Grounding Resistor Characteristics
Parameter Rating
Current rating 300 A
Voltage rating 12 kV
BIL 95 kV
Frequency 60 Hz
Time rating 10 sec

I-2007-EE-A4-9060 Page 23 of 32 Rev. A
Resistance at 20 deg C 26.56 ohms
Current transformer shall have the following characteristic-
Table 3-11. Current Transformer Characteristics
Parameter Rating
Rated frequency 60 Hz
Current transformation ratio 300:1 A
Accuracy class 5P20
3.7 Automatic Power Factor Correction Panel (APFC)
APFC Panels shall be provided to ensure that the power factor is within the range 0.9
lagging to unity. One number of such panel shall be connected to each of the MV switchgear
bus. Panel shall operate at 13.8 KV, 60 Hz power supply. The equipment shall comply with
IEC 60871. Equipment Type/Routine testing requirements shall satisfy IEC.
The panel shall be indoor, front accessible, free standing with necessary provisions for
ventilation and handling and cable entry shall be from bottom side. Copper bus bar shall be
sized to handle continuous current rating of capacitor bank as well as a minimum of 20%
future expansion. Thermostatically controlled forced air ventilation shall be provided as per
the manufacturer standard to control the temperature within permissible limit. Panel shall
consist of a bolted steel frame with formed steel doors and side sheets.
3.8 EDG Set
An EDG Set shall be provided to feed power to essential and life safety equipment in case of
main power supply failure and shall be mounted inside the room. DG Set shall be suitable for
standby operation having 400V, 60 Hz, 3 phase 4 wire power supply output complying with
IEC 60034. Equipment Type/Routine testing requirements shall satisfy IEC. The equipment
package shall include in general and as applicable, engine and generator on a common
vibration isolating base, with auxiliaries, accessories and controls, including intake filters,
discharge silencer, turbocharger, heat exchanger, foundation bolts, isolators, piping, flexible
couplings, supports, complete exhaust piping, silencer, insulation, control panels, lubrication
system, water jacket heaters, cooling system, fuel tank, batteries and battery rack, battery
charger, spare parts and all material necessary to permit installation, testing and placing the
system in successful operation. The Circuit breaker shall be provided inside the generator
enclosure.
Only diesel day tank (8 hours) shall be provided for EDG. Additional diesel storage facility is
not considered as part of this project scope. Diesel requirement for the EDG shall be fulfilled
from outside and not part of this project scope.
The generator set, enclosure, base-mounted fuel tank and accessories shall be assembled
and shipped to the Site as a complete, coordinated package, ready for installation.
I-2007-EE-A4-9060 Page 24 of 32 Rev. A

DG Set shall start/stop in auto mode as well as in manual mode through diesel engine
control panel.
3.9 VFD Panel along with Transformer

The transformer shall comply with IEC 60076 and the VSD shall comply with IEC 61800.
Equipment Type/Routine testing requirements shall satisfy IEC.
An appropriately sized 13.8/6.6 KV, dry type transformer shall be used to transform the
primary operational voltage to the desired secondary operational voltage.
The VFD shall be capable of operation without damage and without interruption under the
specified power supply distortions and interruptions. The speed of the variable drive shall
vary continuously between the lower and upper speed limits. The drive system shall also
have the facility to inhibit operation at pre-determined speeds to prevent system resonance.
The VFD shall be equipped with a protection relay to protect the VFD, transformer and
motor. When specified in the applicable Datasheet, the VFD shall be equipped with Profibus
RTU interface protocol with facilities to report all fault conditions on a first in first out basis as
well as control functions and the parameters during normal running condition. Protection
devices in the VFD shall be hardwired to ensure that an electrical fault within the controller
trips the transformer feeder circuit breaker. Power rating of the VFD will be sized based on
flow rate and ratings of the pump.
All semiconductor devices, power transformers, chokes and other components forming
necessary parts of the drive equipment shall be suitable for the application with respect to
their rated voltages, rated currents, temperature rise and service life. Cable-entry should be
from top.
The VFD System design conditions are summarized as below:
Table 3-12. VFD System Design Conditions
Parameter Value
Primary Nominal Voltage Level (KV) 13.8
Drive Concept Variable Torque
Drive Type IGBT Cell Based
Power Rating (KW) 6000
Front End Passive
Cooling Totally Enclosed Water Cooled / Air Cooled
I-2007-EE-A4-9060 Page 25 of 32 Rev. A

3.10 Battery Charger and Battery
The 110V DC system for electrical equipment shall include, but not necessarily be limited to
the following:
a. 2 x 100% rated Rectifier units with input supply from essential 400 VAC bus.
b. 2 x 50% rated Battery banks (VRLA Battery with 30 Minutes back up)
c. Battery circuit breaker, interconnecting cables and cable containment
d. 110V DC distribution board.
DC system shall be utilized for following purposes:
a. Control, protection, tripping, indication in 132kV & 13.8kV switchgear.
DC Distribution boards shall be provided with all hardware required for reliable operation and
safe isolation as well as with the protection against short-circuit incidents, with at least 10%
equipped spare. Distribution boards shall be 2-wire fitted with double pole miniature circuit-
breakers.
3.11 AC UPS with Battery Bank
A fully dedicated 230 V AC UPS system, required to feed auxiliary services in the substation,
the substation control and monitoring system plus all equipment necessary for the local and
remote monitoring installed in the substation.
230 VAC uninterruptible power supplies shall be provided for essential no-break power
supplies. The AC UPS shall be continuous duty, solid state, or modular type able to operate
in single and parallel mode and shall comprise the following points as minimum:
a. 1 x 100% rated battery chargers / rectifiers with input supply from essential 400 VAC
bus.
b. 1 x 100% rated battery bank (VRLA Battery with 30 Minutes back up)
c. 1 x 100% rated inverters with 230 VAC, 60 Hz, 1-Phase+N output. Inverters shall be
transistorized PWM type with microprocessor-based protection, control & metering
system with communication capability necessary to interface the UPS with monitoring
system.
d. UPS unit will be equipped with 1 x 100% bypass static transfer switch.
3.12 Motors
3.12.1 MV Motors
MV Motor shall be provided for sea water cooling pump. Motor shall be designed in
accordance with IEC 60034 for continuous duty application (S1). Equipment Type/Routine
testing requirements shall satisfy IEC. Motor insulation shall be class F with temperature rise
limited to class B. Motor shall operate at 6.6 KV, 60 Hz power supply.
Vertical shafts shall have thrust and guide bearings. Motors shall be provided with platinum
resistance detectors (RTDs) of type PT 100 - two per winding and one per bearing. Vibration
sensors shall be fitted to the motor bearing housings. Anticondensation heaters in the
I-2007-EE-A4-9060 Page 26 of 32 Rev. A

motors shall be built into the stator and rated for a single-phase power supply 230V AC, 60
Hz.
The terminal box for the main supply cables shall be adequately sized for the cables and
shall have a removable cover and gland plate. Phase segregation shall be provided inside
the terminal box to prevent flash over, if the air and creepage distances between phases,
and phase to earth are not adequate.
The MV Motor design conditions are summarized as below:
Table 3-13. MV Motor Design Conditions
Parameter Value
Nominal Voltage Rating (KV) 6.6
Power Rating (KW) 6000
Speed Pole Count to Match Pump Speed Requirement
Cooling TEWAC / TEFC
3.12.2 LV Motors
LV Motor shall be squirrel cage induction type. Motor shall be designed in accordance with
IEC 60034 for continuous duty application (S1) and enclosure TEFC. Equipment
Type/Routine testing requirements shall satisfy IEC. Motor insulation shall be class F with
temperature rise limited to class B.
The terminal box for the main supply cables shall be adequately sized for the cables and
shall have a removable cover and gland plate.
3.13 Cables
3.13.1 HV Cables
HV cables shall be used between GIS switchgear and power transformer. Cable voltage
grade shall be 76/132 KV and maximum voltage shall be 145 KV. HV cables shall be single
core copper conductor, XLPE insulation, copper wire screened, Aluminium laminated
sheath, HDPE outer sheathed cable.
The HV cables design conditions are summarized as below:
Table 3-14. HV Cables Design Conditions
Parameter Value
Nominal Voltage Level (KV) 76/132 (145 KV)
Insulation Type XLPE
Core Count Single Core
Conductor Type Copper Stranded
Screen Type Copper Wire
Sheath Type Aluminium Laminated
Outer Sheath Type HDPE
I-2007-EE-A4-9060 Page 27 of 32 Rev. A

I-2007-EE-A4-9060 Page 28 of 32 Rev. A

3.13.2 MV Cables
13.8 KV MV cables shall be provided from Power Transformer to MV switchgear, from MV
switchgear to Distribution Transformer, Electrolysis Transformer and VFD Panel (VFD
Transformer primary winding). Voltage grade of cable shall be 12/20 KV.
6.6 KV MV cables shall be provided from VFD Panel to SWC pump motor. The voltage
grade of this cable shall be 6/10 KV.
MV cables shall be single core/three core annealed stranded copper conductor, TR-XLPE
insulation, copper tape screened, Aluminium wire armored, PVC outer sheathed cable.
The MV cables design conditions are summarized as below:
Table 3-15. MV Cables Design Conditions:
Parameter Value
Insulation Type TR-XLPE
Core Count Single Core, Three Core
Screen Type Copper Tape
Armoring Type Aluminium Wired
Outer Sheath Type PVC
3.13.3 LV Cables
LV cables shall be multi core copper conductor, XLPE insulated, steel wire armored and
PVC Sheathed cable. Minimum size of LV power cable shall be 4 sqmm.
Control cables shall be PVC insulated. Minimum size of control cable shall be 1.5 sqmm.
The LV cables design conditions are summarized as below:
Table 3-16. LV Cables Design Conditions
Parameter Value
Nominal Voltage Level (KV) 0.6/1
Insulation Type XLPE
Core Count Multi Core
Armoring Type Steel Wired
Outer Sheath Type PVC
I-2007-EE-A4-9060 Page 29 of 32 Rev. A

3.13.4 Permissible Voltage Drop in Power Cables

In addition to the current carrying capacity and short-circuit level, the cable sizing shall be
done considering the following voltage drop criteria:
Table 3-17. Voltage Drop Criteria
Branch Permissible Voltage Drop
GIS switchgear to Power Transformer 1%
Power Transformer to MV switchgear 1%
MV switchgear to Distribution Transformer/VFD Panel 1%
Distribution Transformer to Load 5%
AC UPS to final load 5%
Battery Charger to final load 2%
3.14 Earthing/Grounding System

The following equipment shall be grounded: -
a. Motors
b. Panels
c. Switchgear
d. Transformer
e. Cable tray
f. Lighting/power panels
g. Lighting fixtures
h. All other equipment as required by local codes/standards
Grounding conductors shall be bare soft-drawn copper wire. Exposed or above grade
grounding cables shall be green PVC insulated.
Connect copper-clad steel ground rods only to copper ground conductor and weld the
connection. Insulate the entire area of the rod in the vicinity of the weld and the connecting
wire and seal against moisture penetration.
Ground rod will be 19mm diameter by 3000mm long copper-clad steel.
Predrilled rectangular bus bar shall be used for equipment earthing which shall be supported
on stand-off insulators. IEEE 80, IEEE 81 and IEC 60364 shall be referred for grounding
purpose.
I-2007-EE-A4-9060 Page 30 of 32 Rev. A

3.15 Lightning Protection System

Lightning protection system shall be designed as per IEC 62305 & include following:
a. Air termination(s)
b. Mechanical support(s)
c. Low impedance insulated down conductor(s)
d. Performance recording equipment
e. Low impedance grounding system
3.16 Lighting and Small Power System
Distribution boards shall be used for lighting & small power system & shall be supplied
complete with all necessary circuit protective devices as necessary to provide a complete
installation in accordance with IEC 60364. All distribution boards shall be provided with
printed DB circuit schedules provided in a laminated form permanently fixed to the inside of
distribution board door.
LED lights shall be used for internal and external lighting which shall operate at 230V AC, 60
Hz power supply. Outdoor lights shall be controlled automatically through photocell. Outdoor
lights shall be installed on lighting poles of suitable height as per lighting calculation, else on
structures, if available. Outdoor lights may be flood light / streetlight as per area requirement.
Indoor lights may be surface mounted/pendant type / square fitting as per requirement.
The lighting levels for the different areas of the plant shall be as indicated below:
Table 3-18. Lux Level
Area Average Lighting Level (Lux)
Walkway Area (Indoor) 100
Staircase (Indoor) 150
Store Room 100
Washroom/toilet 100
Electrical and ICA Equipment Room 200
Control Room 500
Office Room/Meeting Room 300
Plant operation Area (Indoor) 200
Walkway Area (Outdoor) 10
Plant operation Area (Outdoor) 150
Road/Street 10
I-2007-EE-A4-9060 Page 31 of 32 Rev. A

Entry/exit 50
3.17 Cable Installation Methodology
Power cable between GIS switchgear & power transformer and between power transformer
& MV switchgear will be laid in cable trays within the basement used for cables and while
coming out it will be underground ducts / cable trays in transformer area.
The MV cables between MV switchgear and VFD panels shall be laid underground in the
field area and cable trays in the building area.
Power cable between VFD panels and SWC motors shall be laid on cable trays / conduits.
Power cable between main LV distribution board and pump station motor control centres will
be laid underground in the field area and on cable tray in the building area.
All other MV/LV cables shall be laid direct buried in the field and through cable trays inside
the building.
I-2007-EE-A4-9060 Page 32 of 32 Rev. A

I-2007-EE-A4-9060 (1)

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

I-2007-EE-A4-9060 (1)

Uploaded by

Copyright:

Available Formats

Royal Commission for Jubail and Yanbu I-2007-EE-A4-9060 – Rev.

Basis of Design - Electrical

BASIS OF DESIGN - ELECTRICAL

CONTRACT: JCPDI I-2007

DATE 20-Jan-23 20-Jan-23 20-Jan-23

NAME Abhishek Kapoor / Sushant Gadewar Sajid Gul

I-2007-EE-A4-9060 Page 1 of 32 Rev. A

Document no: I-2007-EE-A4-9060

Revision date: 20 January 2023

Project no: SA340WTD

Project manager: Sajid Gul

Prepared by: Tanu M Tuli

Approved by: Sushant Gadewar

File name: 773036816.docxBasis of Design - Electrical

Revision Date Description Author Reviewed Approved

Document history and status

I-2007-EE-A4-9060 Page 2 of 32 Rev. A

Basis of Design - Electrical

I-2007-EE-A4-9060 Page 3 of 32 Rev. A

Basis of Design - Electrical

I-2007-EE-A4-9060 Page 4 of 32 Rev. A

Basis of Design - Electrical

I-2007-EE-A4-9060 Page 5 of 32 Rev. A

Basis of Design - Electrical

Acronyms and Abbreviations

I-2007-EE-A4-9060 Page 6 of 32 Rev. A

Basis of Design - Electrical

Basis of Design - Electrical

OEM Original Equipment Manufacturer

Basis of Design - Electrical

VRLA Valve Regulated Lead Acid

I-2007-EE-A4-9060 Page 9 of 32 Rev. A

Basis of Design - Electrical

Figure 1-1. Project location

1.2 Project Site

Figure 1-2. The Location of Existing Seawater Intake and Outfall

Basis of Design - Electrical

1.3 Project Scope of Work

• 2 no. of supply pipes to convey to the Seawater to the facilities to be served;

Figure 1-3. Onshore Supply and Return Pipeline Scope

I-2007-EE-A4-9060 Page 11 of 32 Rev. A

Basis of Design - Electrical

1.4 Purpose of this Report

1.5 Project Reference Documents

Table 1-1. Project Reference Documents

1.6 Codes and Standards

I-2007-EE-A4-9060 Page 12 of 32 Rev. A

Basis of Design - Electrical

2. GENERAL DESIGN CRITERIA

2.1 Design Scope

a. 132KV GIS Switchgear

I-2007-EE-A4-9060 Page 13 of 32 Rev. A

Basis of Design - Electrical

2.2 Electrical Calculation Software

Table 2-2. Software Program

Electrical Calculation / Study Software Program

Transformer Sizing Calculation Microsoft Excel

Emergency DG Sizing Calculation Microsoft Excel

Electrical Load List Microsoft Excel

Earthing Calculation Microsoft Excel

Lightning Protection Calculation Microsoft Excel

Cable sizing Calculation Microsoft Excel

AC UPS sizing Calculation Microsoft Excel

Battery Charger sizing Calculation Microsoft Excel