Utilisation of Electrical Power in

LPG Department
Some relevant points
HAZARDS OF ELECTRICITY

ELECTRICAL FIRE
EXPLOSION
FLASH OVER
ELECTRICAL SHOCK
RADIATION ( Electro Magnetic )
INDIRECT EFFECTS
 EFFECTS OF CURRENT ON HUMAN
BODY

0 TO 5 MILLI AMPS -> PERCEPTUAL FEELING

5 TO 10 MILLI AMPS -> MUSCLE CONTRACTION

10 TO 15 MILLI AMPS -> MORE PAINFUL FEELING

15 TO 20 MILLI AMPS -> RESPIRATORY FAILURE

20 TO 30 MILLIAMPS -> VENTRICULAR FIBRILLATION

 Voltage Classification as per I E Rules
“Low” where the voltage does not exceed 250 volts.

“Medium” where the voltage does not exceed 650

volts.

“High” where the voltage exceeds 650 volts but up to

33KV.

“Extra high” where the voltage exceeds 33 KV.

Every Electrical Installation must follow :-

Indian Electricity Rules, 1956

Electricity Act, 2003(Indian Electricity Act, 1910 as amended)
Additionally in Oil & Gas Sector industry
to follow:-
Oil Mine Regulations
Electrical Safety as per OISD RP149
Section 54 of Electricity Act 2003
Section 30 of Electricity Act 1910
 In LPG Installations we must also
comply to
OISD STD 108
OISD STD 110
OISD STD 113
OISD STD 147
OISD RP-149- relates to Design Aspects of Safety
in Electrical systems.
OISD –Std 110- relates to Static Electricity
OISD-Std 113- Classification of Areas for
Electrical Installations in Petroleum Processing
and Handling Areas.
OISD Std 147 – relates to Electrical Installations
in hydrocarbons industries.
 Steps towards Electrical Safety
• Proper design of electrical installations
• Use of proper isolating device
• Provision of ELCB/RCCB
• Provision of ACB, OCB, MCCB
• Proper Earthing
• Use of Safety equipments
• Importance of two “I”s (Isolate & Inspect )
• Safe working on equipments, machinery etc
• Use of Standard wiring materials
• The Electrical Installation by LEC
• Testing & Certification
Electrical System Design
Capacitor Banks
Capacitor Banks assumes particular significance
when Captive Power Plant supplies Power. (in
our case technically we are getting power
from Captive Power Plant.)

The Capacitor bank may be useful incase of

Infinite Bus (i.e. numbers of Generators are
quite large and are connected in Grid )
Duliajan Power House (DPH) Alternators have
p.f. of 0.8 (lag) only whereas our HT motor p.f.
is 0.85(lag).
So p.f. at DPH presently is near about 0.83 (lag).
Anymore p.f. improvement in our MCC panel is
detrimental to the health of rotating
equipment (Motors) and other Electronic
components of our Plant.
Earthing
 Causes of Electrical Hazards
Bare conductors
Insulation failure
Equipment failure
Static electricity
Heating and overheating
 Single Line Diagrams
2 feeders 11KV from Power
House Feeder Panels

BUS COUPLER 11 kv Bus HT Sub Station

HT Motor
Starter
2 nos 1000 KVA Spare Panel
11/0.415 Dry type
Transformers
4500 hp
motor

BUS COUPLER MCC # 1B Panel 415 V BUS

MCC 1A Panel 415V BUS
 415 Volts Distribution Network
• MCC 1A 415Vac BUS at Recovery Plant Bus Coupler MCC 1B 415 Vac BUS at Recovery Plant

Loads like Motors,

Loads like Motors,
lights, AC, PCs etc.
lights, AC, PC etc.

MCC#3 for Air

Compressors

MCC# 2 Old BUS at Filling Plant MCC #2 New BUS at Filling Plant

Filling Plant
Filling Plant
Loads Loads
 2 nos 11 KV Feeders from Duliajan
Power House
Electrical Loads :- High Voltage
- one HT Motor- 3350 KW
Step Down to Low Voltage:-
- 2 nos 1000 KVA Dry Type Transformers
supplies 415 Vac Power thru MCC (Motor Control Center) Panels
Recovery Plant Load + Filling Plant Load (= MCC# 1 Panel Load)
RECOVERY PLANT LOAD
4 nos 30 KW CT fan = 120 KW
1 no 110 KW CW Pump = 110 KW
Other Process Pumps = 210 KW
3 nos 225 KW FW Pump = 675 KW
1 no 110 KW FW Pump = 110 KW
Control Room ac+ light =
Office / Workshop ac+ light
+ computers =
 Filling Plant Load
2 MCC Panels
• Air Compressors
• Tanker Evacuation
• Carousal
• Conveyors
• Cylinder Evacuation
• Office ac + lights + computers
 Addition of Load on Panel # 1 from Original design
due to Operational /Safety /Security reasons.

C1, C2, C3 motors of Horton Despatch

CT fan motors
Jockey Pump Motor
Deluge Compressor
Vapour Expulsion Motors
Tanker Evacuation Pump Motor
Additional Conveyor Motors
Air Compressor at Filling Plant
Air Conditioners ( Split type- , Window Type )
Lighting Load ( Top Control Room/ Empty Cylinder Shed/ High Masts/ Structure / Flare
area/ Street Lights / Office/ Garage)
 Load on Bus Bar and Transformer
Starting current of DOL starter  7 times Full Load Current
Starting Current of Star Delta starter > 3.5 times Full Load Current.
full load current of one 225 Kw Fire Hydrant Pump motor = 380 amps
Starting current of this motor > 1330 amps
Aluminum Bus Bar needs more time to recover from Mechanical & Electrical
stresses created during heavy inrush of current.

Transformer Capacity 1000KVA

Bus Bar capacity of MCC panel-1600 amps (This
1982 vintage Bus Bar due to stress on the Bus-Bar while
starting big motors, may fail any moment at the present
loading pattern)
Impressed Current Cathodic Protection
The mounded Bullets are fed small DC potential through
Automatic Transformer Rectifier (ATR) to keep the bullets at a
negative potential w.r.t. Earth.

The feeding current is dependant on the potential maintained by

ATR on the feedback from the Reference Half-Cells.

Reference Half-cells are permanently buried near the Bullets.

As per NACE standard the Off PSP should be kept between

(-)0.85 to (-)1.2 DC Volt w.r.t. Cu-CuSO4 half-cell.
 CP System
Connections to
50Vdc, +ve AJB Anodeflex
50amp
23o Vac Supply ATR -ve
Make Raychem
RPG

Connections to Bullets
CJB
 AnodeFlex Cable strings gap 100mm vertical between strings,
separation 300 mm from Bullets.
TR unit Positive Terminal connected to Anodeflex Cable Strings and Negative Terminal connected to Bullets.

Anodeflex cables

6 m dia 6 m dia
6 m dia
Bullets Bullets
Bullets
 Minimum requirement for Electrical Power connection to
FLP motors

FLP Motor- Correct rating, correct Frame size

Spare Bus Bar Capacity of MCC Panel
Starter Panel – Isolator
Overload protector
Contactor
Timer
Earth leakage protector
Terminal Block
Cables- in case of DOL start motors - 1 power cable, 1 control cable Copper
in case of Star -Delta motors - 2 power cables, 1 control cable Copper

FLP Glands for Cable termination to Motors

Cable Tray or Trench
 I.E. Rules
Rule 61 A
Earth Leakage Protective Device

Provision of Earth Leakage Circuit Breaker

mandatory for loads > 5 Kw
 Rule 44 A
Intimation of Accident
• Telephonic intimation to Electrical
Inspector within 24 hrs

• Detailed report of incident

within 48 hrs
 Rule 44
Instructions for Restoration
• Instructions in English/Hindi and local language in
conspicuous place

• In accordance with Section 2 of

Factories Act, 1948

• Ensure acquaintance of employees

with above instructions
 Rule 3 - Authorisation

• Maintenance of list of authorised persons

• Authority to maintain loads in

excess of 250 KW
 Rule 45
Precautions by Consumers, Owners etc
• Only licensed electrical contractors to undertake
electrical installations

• Certificate of Competency to
supervisors and wiremen

• Submission of test report

 Rule 46
Periodical Inspection
• Intervals not exceeding 5 yrs

• Payment of fees

• Compliance of defects

• Disconnections
 Rule 48
Megger Tests
• Between each live conductor and earth

• Pressure of 1000 volts

• Period of 1 minute

• IR not less than 1 Mega Ohm

 Rule 49
Leakage on Consumers Premises

• Disconnection of dangerous
Installations

• 48 hrs notice
 Rule 61
Connection with Earth
• The frame of every generator, stationary motor,
portable motor, and the metallic parts ( not
intended as conductors) of all transformers and any
other apparatus used for regulating or controlling
energy all medium voltage energy consuming
apparatus shall be earthed by the
owner by two separate and distinct
connection with earth.
• Record of earth test to be maintained
by supplier/owner (earth test not more
than 1 Ohm)
 Rule 65
Testing, Operation and Maintenance

• Production of Manufacturers
test certificate, Insulation resistance
test, Earth resistance test,
Di-electric strength of oil,
etc mandatory prior to approval
by Inspector
IE Rules

Rules 109 to 132 : Additional Precautions to

be adopted in Mines and
Oilfields

Rule 118. Voltage Limits- Energy shall not be used

in any Mine at a voltage exceeding 6600 volts.

Rule 126 . Various Precautions where gas exists